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FILE DETAILS:
Bobcat Toolcat™ 5600 Service Manual SN 520511001 & Above – PDF DOWNLOAD
Language : English
Pages : 602
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat Toolcat™ 5600 Service Manual SN 520511001 & Above – PDF DOWNLOAD
FOREWORD
This manual is for the Toolcat Utility Work Machine mechanic. It provides necessary servicing and adjustment procedures for the Toolcat Utility Work Machine and its component parts and systems. Refer to the for operating instructions, starting procedure, daily checks, etc.
SAFETY INSTRUCTIONS
Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Bobcat Toolcat™ 5600 Service Manual SN 520511001 & Above – PDF DOWNLOAD
MAINTENANCE SAFETY.............................................................................. 3 ALPHABETICAL INDEX.............................................................................. 5 CONTENTS........................................................................................ 7 FOREWORD.................................................................................... 8 SAFETY INSTRUCTIONS......................................................................... 11 FIRE PREVENTION............................................................................. 13 Maintenance............................................................................. 13 Operation............................................................................... 13 Electrical.............................................................................. 13 Hydraulic System........................................................................ 13 Fueling................................................................................. 13 Starting................................................................................ 13 Spark Arrestor Exhaust System........................................................... 13 Welding And Grinding.................................................................... 14 Fire Extinguishers...................................................................... 14 SERIAL NUMBER LOCATIONS..................................................................... 15 Work Machine Serial Number.............................................................. 15 Engine Serial Number.................................................................... 15 DELIVERY REPORT............................................................................. 15 BOBCAT UTILITY WORK MACHINE IDENTIFICAITON.................................................. 16 SAFETY AND MAINTENANCE.......................................................................... 17 LIFTING AND BLOCKING THE MACHINE............................................................ 19 Procedure For Jackstand Placement On The Axle........................................... 19 Procedure For Jackstand Placement On The Frame.......................................... 20 LIFT ARM SUPPORT DEVICE..................................................................... 23 Installing The Lift Arm Support Device.................................................. 23 Removing the Lift Arm Support Device.................................................... 23 CARGO BOX SUPPORT DEVICE.................................................................... 25 Installing The Cargo Box Support Device................................................. 25 Removing the Cargo Box Support Device................................................... 25 OPERATOR CAB................................................................................ 27 Description............................................................................. 27 TRANSPORTING THE TOOLCAT.................................................................... 29 Loading Onto Transport Vehicle.......................................................... 29 Fastening To Transport Vehicle.......................................................... 29 TOWING THE MACHINE.......................................................................... 31 Procedure............................................................................... 31 REMOTE START................................................................................ 35 Procedure............................................................................... 35 SERVICE SCHEDULE............................................................................ 37 Chart................................................................................... 37 AIR CLEANER SERVICE......................................................................... 39 Replacing Filter Elements............................................................... 39 ENGINE COOLING SYSTEM....................................................................... 41 Checking The Coolant Level.............................................................. 41 Cleaning The Cooling System............................................................. 41 Removing & Replacing Coolant............................................................ 42 FUEL SYSTEM................................................................................. 43 Fuel Specifications..................................................................... 43 Filling The Fuel Tank................................................................... 43 Fuel Filter............................................................................. 43 Removing Air From The Fuel System....................................................... 44 ENGINE LUBRICATION SYSTEM................................................................... 45 Checking Engine Oil..................................................................... 45 Oil Chart............................................................................... 45 Replacing The Oil And Filter............................................................ 46 HYDRAULIC / HYDROSTATIC SYSTEM.............................................................. 47 Checking And Adding Fluid............................................................... 47 Replacing Hydraulic/Hydrostatic Filter.................................................. 47 Replacing Hydraulic Fluid............................................................... 48 Hydraulic Fluid Chart................................................................... 48 Reservoir Breather...................................................................... 48 AXLE/DIFFERENTIAL (FRONT & REAR)............................................................ 49 Checking And Adding Lubricant........................................................... 49 Replacing Lubricant..................................................................... 49 BOB-TACH.................................................................................... 51 Inspection And Maintenance.............................................................. 51 LUBRICATION................................................................................. 53 Lubrication Locations................................................................... 53 TIRE MAINTENANCE............................................................................ 55 Wheel Nuts.............................................................................. 55 Tire Rotation........................................................................... 55 Mounting................................................................................ 55 SPARK ARRESTOR MUFFLER...................................................................... 57 Maintenance............................................................................. 57 HYDRAULIC SYSTEM................................................................................ 59 HYDRAULIC / HYDROSTATIC SCHEMATICS.......................................................... 61 HYDRAULIC SYSTEM INFORMATION................................................................ 63 Glossary................................................................................ 63 Tighten Procedures...................................................................... 67 Troubleshooting Chart................................................................... 68 CYLINDER (LIFT)............................................................................. 69 Checking................................................................................ 69 Removal And Installation................................................................ 70 Parts Identification.................................................................... 72 Disassembly............................................................................. 73 Assembly................................................................................ 74 CYLINDER (TILT)............................................................................. 77 Checking................................................................................ 77 Removal And Installation................................................................ 78 Parts Identification.................................................................... 80 Disassembly............................................................................. 81 Assembly................................................................................ 82 CYLINDER (CARGO BOX)........................................................................ 85 Checking (Left Side Cylinder)........................................................... 85 Checking (Right Side Cylinder).......................................................... 86 Removal And Installation................................................................ 87 Parts Identification.................................................................... 88 Disassembly............................................................................. 89 Assembly................................................................................ 90 MAIN RELIEF VALVE........................................................................... 93 Checking................................................................................ 93 Adjustment.............................................................................. 94 Removal And Installation................................................................ 94 PORT RELIEFS................................................................................ 95 Checking The Port Relief Valve (Lift)................................................... 95 Checking The Port Relief Valves (Tilt).................................................. 96 WORK VALVE.................................................................................. 99 Removal And Installation................................................................ 99 Disassembly and Assembly................................................................101 STEERING AND CARGO BOX VALVE................................................................107 Removal And Installation................................................................107 Disassembly and Assembly................................................................109 AUXILIARY HYDRAULIC VALVE...................................................................115 Removal And Installation................................................................115 Disassembly And Assembly................................................................117 POWER STEERING PUMP.........................................................................121 Removal And Installation................................................................121 Disassembly And Assembly................................................................122 PILOT VALVE.................................................................................127 Removal And Installation................................................................127 Disassembly And Assembly................................................................129 LIFT ARM BY-PASS CONTROL VALVE..............................................................131 Inspecting..............................................................................131 Removal And Installation................................................................131 Disassembly And Assembly................................................................132 HYDRAULIC PUMP..............................................................................133 Checking The Auxiliary Section Of The Hydraulic Pump....................................133 Checking The Work Group Section Of The Hydraulic Pump...................................134 Checking The Steering And Cargo Box Section Of The Hydraulic Pump.......................135 Removal And Installation................................................................136 Disassembly And Assembly................................................................138 HYDRAULIC/HYDROSTATIC FILTER................................................................143 Housing Removal And Installation........................................................143 CONTROL LEVER (JOYSTICK)....................................................................145 Joystick Handle Removal And Installation................................................145 Joystick Removal And Installation.......................................................148 Joystick Disassembly and Assembly.......................................................150 HYDRAULIC FLUID RESERVOIR...................................................................153 Removal And Installation................................................................153 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.....................................................155 Removal And Installation................................................................155 Disassembly And Assembly................................................................155 REMOTE HYDRAULICS DIVERTER VALVE............................................................157 Removal And Installation................................................................157 Disassembly And Assembly................................................................158 HYDROSTATIC SYSTEM..............................................................................159 HYDROSTATIC SYSTEM INFORMATION..............................................................161 Troubleshooting Chart...................................................................161 Replenishing Valve Function.............................................................162 HYDROSTATIC MOTOR...........................................................................163 Removal and Installation (Front Axle)...................................................163 Removal and Installation (Rear Axle)....................................................165 Disassembly.............................................................................167 Assembly................................................................................174 CHARGE PRESSURE.............................................................................179 Checking Charge Pressure................................................................179 HYDROSTATIC PUMP............................................................................181 Removal and Installation................................................................181 Directional Control Valve Removal and Installation......................................183 PWM Control Valve Removal and Installation..............................................184 Replenishing/High Pressure Relief Valve.................................................185 Charge Relief Valve.....................................................................185 Disassembly.............................................................................186 Inspection..............................................................................194 Assembly................................................................................196 Hydrostatic Pump Start-Up...............................................................205 Neutral Adjustment......................................................................206 DRIVE BELT..................................................................................211 Shield Removal And Installation.........................................................211 Adjusting...............................................................................212 Drive Belt Replacement..................................................................213 Tensioner Pulley Removal And Installation...............................................214 Tensioner Pulley Parts Identification...................................................215 Tensioner Pulley Disassembly............................................................216 Tensioner Pulley Assembly...............................................................217 OIL COOLER..................................................................................219 Removal and Installation................................................................219 DRIVE SYSTEM....................................................................................221 BRAKE.......................................................................................223 Disassembly & Assembly (Front Axle).....................................................223 Disassembly & Assembly (Rear Axle)......................................................223 AXLE........................................................................................225 Front Axle Brush Guard Removal And Installation (S/N 520511246 & Below).................225 Front Axle Brush Guard Removal And Installation (S/N 520511247 & Above).................226 Front Axle Removal And Installation.....................................................227 Rear Axle Removal And Installation......................................................231 Disconnecting The Axle Housings.........................................................235 Primary Housing Disassembly.............................................................238 Steering Cylinder Disassembly...........................................................240 Brake Disassembly.......................................................................243 Secondary Housing And Differential Lock Disassembly.....................................245 Secondary Housing And Differential Lock Assembly........................................247 Steering Cylinder Assembly..............................................................248 Primary Housing Assembly................................................................251 Brake Assembly..........................................................................252 Connecting The Axle Housings............................................................254 AXLE HUB WITH AXLE SHAFT....................................................................257 Removal And Installation (Without Wheel Position Sensor)................................257 Removal (With Wheel Position Sensor)....................................................260 Inspection..............................................................................262 Installation (With Wheel Position Sensor)...............................................264 AXLE HUB WITHOUT AXLE SHAFT.................................................................267 Removal And Installation (Without Wheel Position Sensor)................................267 Removal (With Wheel Position Sensor)....................................................272 Bearing Pivot Inspection................................................................275 Installation (With Wheel Position Sensor)...............................................277 Disassembly.............................................................................282 Axle Hub Inspection.....................................................................283 Assembly................................................................................284 Torque Check Procedure..................................................................287 TIE ROD.....................................................................................289 Removal And Installation (Front Axle)...................................................289 Removal And Installation (Rear Axle)....................................................291 Adjusting...............................................................................293 AXLE SHAFT..................................................................................295 Removal and Installation................................................................295 MAIN FRAME......................................................................................297 OPERATOR CAB................................................................................299 Removal And Installation................................................................299 OPERATOR SEAT...............................................................................305 Removal And Installation................................................................305 Seat Belt Removal And Installation......................................................306 Seat Pan Removal And Installation.......................................................307 Slide Rail Removal And Installation.....................................................308 Cushion Removal And Installation........................................................308 Back Removal And Installation...........................................................309 Arm Rest Bracket Removal And Installation...............................................309 Arm Rest Removal And Installation.......................................................310 Shock Removal And Installation..........................................................310 PASSENGER SEAT..............................................................................311 Removal And Installation................................................................311 Seat Belt Removal And Installation......................................................311 Seat Pan Removal And Installation.......................................................312 Arm Rest Removal And Installation.......................................................313 BOB-TACH....................................................................................315 Removal and Installation................................................................315 Bob-Tach Lever and Wedge................................................................316 LIFT ARM....................................................................................317 Removal and Installation................................................................317 CARGO BOX...................................................................................319 Removal and Installation................................................................319 STEERING COLUMN.............................................................................321 Removal And Installation................................................................321 FUEL TANK...................................................................................323 Removal and Installation................................................................323 TRAVEL AND BRAKE PEDALS.....................................................................325 Removal And Installation................................................................325 Travel Speed Pedal Disassembly and Assembly.............................................326 SHOCKS......................................................................................327 Removal And Installation................................................................327 TRAILING ARMS...............................................................................329 Removal And Installation (Upper Arm)....................................................329 Removal And Installation (Lower Arm)....................................................330 LEAF SPRINGS................................................................................331 Removal And Installation (Left Side)....................................................331 Removal and Installation (Right Side)...................................................333 HITCH.......................................................................................335 Removal And Installation................................................................335 FLOOR CONSOLE...............................................................................337 Removal And Installation................................................................337 CENTER CONSOLE..............................................................................339 Removal And Installation................................................................339 FENDER (FRONT LEFT).........................................................................341 Removal And Installation................................................................341 FENDER (FRONT RIGHT)........................................................................343 Removal And Installation................................................................343 FENDER (REAR LEFT)..........................................................................345 Removal And Installation................................................................345 FENDER (REAR RIGHT).........................................................................347 Removal And Installation................................................................347 ELECTRICAL SYSTEM & ANALYSIS....................................................................349 ELECTRICAL SCHEMATICS.......................................................................351 ELECTRICAL SYSTEM INFORMATION...............................................................355 Troubleshooting Chart...................................................................357 Description.............................................................................358 Fuse Location...........................................................................358 Solenoid Test...........................................................................360 BATTERY.....................................................................................361 Removal And Installation................................................................361 Servicing...............................................................................362 Using A Booster Battery (Jump Starting).................................................363 ALTERNATOR (90 AMP).........................................................................365 Adjusting The Alternator Belt...........................................................365 Alternator Identification...............................................................365 Charging System Check...................................................................366 Alternator Voltage Test.................................................................367 Low Voltage Test........................................................................368 High Voltage Test.......................................................................368 Removal And Installation................................................................369 Rectifier Continuity (Diode) Test.......................................................371 Alternator Regulator Test...............................................................372 Disassembly.............................................................................373 Stator Continuity Test..................................................................373 Stator Ground Test......................................................................374 Rotor Continuity Test...................................................................374 Rotor Ground Test.......................................................................374 Assembly................................................................................374 STARTER.....................................................................................375 Checking................................................................................375 Removal And Installation................................................................376 Parts Identification....................................................................377 Disassembly and Assembly................................................................378 Inspection And Repair...................................................................381 No Load Test............................................................................383 INSTRUMENT PANEL............................................................................385 Display Controller Panel................................................................385 Switch Panel............................................................................386 Center Console..........................................................................386 Display Controller Panel Removal And Installation.......................................387 Center Console Removal And Installation.................................................388 Light Bulb Removal And Installation.....................................................389 LIGHTS......................................................................................391 Front Removal And Installation..........................................................391 DISPLAY CONTROLLER..........................................................................393 Identification Chart....................................................................393 Removal And Installation................................................................394 DRIVE CONTROLLER............................................................................395 Identification Chart....................................................................395 Removal And Installation................................................................396 DIAGNOSTICS.................................................................................397 Service Codes...........................................................................397 TICS SYSTEM.................................................................................401 Inspecting the TICS System (Engine STOPPED - Key ON)....................................401 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....401 Inspecting The Arm Rest Sensor (Engine RUNNING).........................................401 Inspecting The Traction Lock (Engine RUNNING)...........................................401 Inspecting The Lift Arm By-Pass Control.................................................401 ARM REST SENSOR.............................................................................403 Removal And Installation................................................................403 WHEEL SPEED SENSOR..........................................................................405 Removal and Installation (Front Axle)...................................................405 Removal and Installation (Rear Axle)....................................................407 WHEEL POSITION SENSOR.......................................................................409 Removal and Installation (Front Axle)...................................................409 Removal and Installation (Rear Axle)....................................................414 CALIBRATION.................................................................................419 Travel Pedal............................................................................419 Brake Pedal.............................................................................419 Calibration for the brake pedal is complete.............................................420 Pump....................................................................................420 Wheel Alignment Calibration.............................................................421 SERVICE PC (LAPTOP COMPUTER)................................................................423 Connecting The Service PC To Remote Start Tool..........................................423 TRAVEL DIRECTION CONTROL LEVER..............................................................425 Removal And Installation................................................................425 ENGINE SERVICE..................................................................................427 TROUBLESHOOTING.............................................................................429 Chart...................................................................................429 ENGINE SPEED CONTROL........................................................................431 Removal And Installation................................................................431 MUFFLER.....................................................................................433 Removal and Installation................................................................433 AIR CLEANER.................................................................................435 Removal and Installation................................................................435 RADIATOR....................................................................................437 Removal And Installation................................................................437 COOLING FAN.................................................................................441 Removal And Installation................................................................441 Fan Motor Disassembly and Assembly......................................................444 ENGINE COMPONENTS AND TESTING...............................................................447 Compression Checking....................................................................447 Glow Plugs Checking.....................................................................448 Glow Plugs Removal And Installation.....................................................449 Fuel Shut-Off Solenoid Checking.........................................................450 Fuel Shut-Off Solenoid Adjusting........................................................450 Fuel Shut-Off Solenoid Removal And Installation.........................................450 Checking................................................................................451 Fuel Injection Pump Removal And Installation............................................452 Timing The Injection Pump...............................................................455 Fuel Injector Removal And Installation..................................................457 Fuel Injector Checking..................................................................458 Fuel Injector Disassembly...............................................................459 Fuel Injector Assembly..................................................................459 Valve Clearance Adjustment..............................................................460 Rocker Arm And Shaft Checking...........................................................461 Valve Timing Checking...................................................................461 ENGINE......................................................................................463 Removal And Installation................................................................463 Engine Mount Replacement................................................................473 FLYWHEEL AND HOUSING........................................................................475 Flywheel Removal And Installation.......................................................475 Ring Gear Removal And Installation......................................................475 Housing Removal And Installation........................................................476 RPM SENSOR..................................................................................477 Adjustment..............................................................................477 RECONDITIONING THE ENGINE...................................................................479 Cylinder Head Removal And Installation..................................................479 Cylinder Head Disassembly And Assembly..................................................480 Cylinder Head Servicing.................................................................481 Cylinder Head Top Clearance.............................................................481 Checking The Valve Guide................................................................482 Reconditioning The Valve And Valve Seat.................................................483 Valve Spring............................................................................484 Rocker Arm And Shaft Checking...........................................................485 Timing Gearcase Cover Removal And Installation..........................................485 Idler Gear And Camshaft Removal And Installation........................................488 Servicing The Camshaft..................................................................489 Servicing The Idler Gear And Shaft......................................................490 Timing Gears Checking Backlash..........................................................491 Fuel Camshaft Removal And Installation..................................................492 Fuel Camshaft Governor..................................................................492 Crankshaft Gear Removal And Installation................................................493 Oil Pump Removal And Installation.......................................................493 Oil Pump Service........................................................................494 Checking Engine Oil Pressure............................................................495 Relief Valve............................................................................495 Piston And Connecting Rod Removal And Installation......................................496 Servicing The Piston And Connecting Rod.................................................497 Connecting Rod Alignment................................................................500 Crankshaft And Bearings Removal And Installation........................................500 Servicing The Crankshaft And Bearings...................................................502 Checking The Cylinder Bore..............................................................505 Water Pump Disassembly And Assembly.....................................................506 HEATING, VENTILATION, AIR CONDITIONING..........................................................507 AIR CONDITIONING SYSTEM FLOW................................................................510 Principals..............................................................................510 Chart...................................................................................511 COMPONENTS..................................................................................513 Identification..........................................................................513 SAFETY......................................................................................517 Safety Equipment........................................................................517 REGULAR MAINTENANCE.........................................................................519 Filter Elements Removal And Installation................................................519 Cleaning The Condenser..................................................................520 GENERAL AIR CONDITIONING SERVICE GUIDELINES.................................................521 Compressor Oil..........................................................................521 Compressor Oil Check....................................................................522 Component Replacement And Refrigeration Leaks...........................................523 SYSTEM TROUBLESHOOTING......................................................................525 Checking A/C Performance................................................................525 Gauge Pressure Related Troubleshooting..................................................527 Troubleshooting Tree....................................................................529 TEMPERATURE/PRESSURE........................................................................533 Chart...................................................................................533 AIR CONDITIONING SERVICE....................................................................535 Chart...................................................................................535 SYSTEM CHARGING AND RECLAMATION.............................................................537 Reclamation Procedure...................................................................537 Charging Procedure With A Manifold Gauge Set............................................540 COMPRESSOR..................................................................................543 Removal And Installation................................................................543 Compressor Clutch Disassembly...........................................................544 CONDENSER...................................................................................549 Removal And Installation................................................................549 RECEIVER/DRIER..............................................................................551 Removal And Installation................................................................551 Pressure Switch Removal And Installation................................................551 Pressure Relief Valve Removal And Installation..........................................552 EVAPORATOR/HEATER UNIT......................................................................553 Removal And Installation................................................................553 THERMOSTAT..................................................................................555 Removal And Installation................................................................555 EXPANSION VALVE.............................................................................557 Removal And Installation................................................................557 HEATER/AC FAN...............................................................................559 Removal And Installation................................................................559 HEATER VALVE................................................................................561 Removal And Installation................................................................561 Disassembly And Assembly................................................................561 SPECIFICATIONS..................................................................................563 UTILITY WORK MACHINE SPECIFICATIONS.........................................................565 Dimensional Specifications..............................................................565 Performance.............................................................................566 Controls................................................................................566 Engine..................................................................................566 Hydraulic System........................................................................567 Electrical..............................................................................567 Drive System............................................................................568 Capacities..............................................................................568 Tires...................................................................................568 ENGINE SPECIFICATIONS.......................................................................569 Fuel Injection Nozzles..................................................................569 Fuel Injection Pump.....................................................................569 Cylinder Head...........................................................................569 Valves..................................................................................569 Valve Springs...........................................................................569 Valve Timing............................................................................570 Rocker Arms.............................................................................570 Camshaft................................................................................570 Tappet..................................................................................570 Cylinders...............................................................................570 Piston Rings............................................................................571 Pistons.................................................................................571 Connecting Rod..........................................................................571 Oil Pump................................................................................571 Crankshaft..............................................................................572 Timing Gear.............................................................................572 Thermostat..............................................................................572 Crankshaft Re-Grind Data................................................................573 TORQUE SPECIFICATIONS FOR BOLTS.............................................................575 Torque For General SAE Bolts............................................................575 Torque For General Metric Bolts.........................................................576 Torque For Kubota Metric Bolts..........................................................576 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................577 O-ring Face Seal Connection.............................................................577 Straight Thread O-ring Fitting..........................................................578 Tubelines And Hoses.....................................................................578 Flare Fitting...........................................................................578 O-ring Flare Fitting....................................................................579 Port Seal Fitting.......................................................................581 Quick-Lok™ Fitting......................................................................582 HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS..................................................583 Specifications..........................................................................583 CONVERSIONS.................................................................................585 Decimal And Millimeter Equivalents......................................................585 U.S. To Metric Conversion...............................................................586 SERVICE MANUAL REVISION.........................................................................587 Revision No: 5600 - 1.......................................................................587 Revision No: 5600 - 2.......................................................................589 Revision No: 5600 - 3.......................................................................591 Revision No: 5600 - 4.......................................................................593 Revision No: 5600 - 5.......................................................................595 Revision No: 5600 - 6.......................................................................597 Revision No: 5600 - 7.......................................................................599 Revision No: 5600 - 8.......................................................................601