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Bobcat Toolcat™ 5600 Utility Work Machine Service Manual SN A94Y11001 & Above – PDF DOWNLOAD
Bobcat Toolcat™ 5600 Utility Work Machine Service Manual SN A94Y11001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat Toolcat™ 5600 Utility Work Machine Service Manual SN A94Y11001 & Above – PDF DOWNLOAD
Language : English
Pages : 816
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat Toolcat™ 5600 Utility Work Machine Service Manual SN A94Y11001 & 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:
- The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
- The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
- Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
- An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
- The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
- The Utility Work Machine Operator Training Course is available through your local dealer or at www.training.bobcat.com or www.bobcat.com. This course is intended to provide rules and practices of correct operation of the Utility Work Machine. The course is available in English and Spanish versions
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Bobcat Toolcat™ 5600 Utility Work Machine Service Manual SN A94Y11001 & Above – PDF DOWNLOAD
MAINTENANCE SAFETY.................................................................... 3 CONTENTS.............................................................................. 5 FOREWORD.............................................................................. 7 FOREWORD.......................................................................... 9 SAFETY INSTRUCTIONS............................................................... 11 FIRE PREVENTION................................................................... 13 Maintenance................................................................... 13 Operation..................................................................... 13 Electrical.................................................................... 13 Hydraulic System.............................................................. 13 Fueling....................................................................... 13 Starting...................................................................... 13 Spark Arrester Exhaust System................................................. 13 Welding And Grinding.......................................................... 14 Fire Extinguishers............................................................ 14 SERIAL NUMBER LOCATIONS........................................................... 15 Utility Work Machine Serial Number............................................ 15 Engine Serial Number.......................................................... 15 DELIVERY REPORT................................................................... 16 UTILITY WORK MACHINE IDENTIFICATION............................................... 17 SAFETY AND MAINTENANCE................................................................ 19 LIFTING AND BLOCKING THE UTILITY WORK MACHINE..................................... 23 Procedure For Jackstand Placement On The Control Arms......................... 23 Procedure For Jackstand Placement On The Frame................................ 24 LIFT ARM SUPPORT DEVICE........................................................... 25 Installing.................................................................... 25 Removing...................................................................... 26 CARGO BOX SUPPORT DEVICE.......................................................... 27 Installing.................................................................... 27 Removing...................................................................... 27 Raising The Cargo Box When Engine Is Not Running.............................. 28 OPERATOR CAB...................................................................... 29 Description................................................................... 29 TRANSPORTING THE UTILITY WORK MACHINE ON A TRAILER................................ 31 Loading And Unloading......................................................... 31 Fastening..................................................................... 31 TOWING THE UTILITY WORK MACHINE................................................... 33 Procedure..................................................................... 33 REMOTE START TOOL KIT - MEL1563................................................... 35 Remote Start Tool - MEL1563................................................... 35 Service Tool Harness Control - MEL1565........................................ 36 Service Tool Harness Communicator - MEL1566................................... 37 Remote Start Procedure........................................................ 38 REMOTE START TOOL (SERVICE TOOL) KIT - 7217666.................................... 41 Description................................................................... 41 Remote Start Tool (Service Tool) - 7022042.................................... 42 Service Tool Harness - 6689747................................................ 43 Computer Service Tool Harness - 6689746....................................... 44 Remote Start Procedure........................................................ 45 SERVICE SCHEDULE.................................................................. 49 Chart......................................................................... 49 AIR CLEANER SERVICE............................................................... 51 Replacing Filter Elements..................................................... 51 ENGINE COOLING SYSTEM............................................................. 53 Checking Level................................................................ 53 Cleaning...................................................................... 54 Removing And Replacing Coolant................................................ 54 FUEL SYSTEM....................................................................... 55 Fuel Specifications........................................................... 55 Biodiesel Blend Fuel.......................................................... 55 Filling The Fuel Tank......................................................... 56 Fuel Filter................................................................... 56 Removing Air From The Fuel System............................................. 57 Filling A Portable Fuel Container............................................. 57 ENGINE LUBRICATION SYSTEM......................................................... 59 Checking And Adding Engine Oil................................................ 59 Engine Oil Chart.............................................................. 59 Removing And Replacing Oil And Filter......................................... 60 HYDRAULIC / HYDROSTATIC SYSTEM.................................................... 61 Checking Fluid................................................................ 61 Hydraulic / Hydrostatic Fluid Chart........................................... 61 Adding Fluid.................................................................. 61 Alternate Fill Procedure...................................................... 62 Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters......... 63 Removing And Replacing Hydraulic Fluid........................................ 65 Breather Cap.................................................................. 66 TRANSAXLE (FRONT AND REAR)........................................................ 67 Checking And Adding Lubricant................................................. 67 Removing And Replacing Lubricant.............................................. 68 BOB-TACH (HAND LEVER)............................................................. 69 Inspection And Maintenance.................................................... 69 BOB-TACH (POWER).................................................................. 71 Inspection And Maintenance.................................................... 71 LUBRICATING THE UTILITY WORK MACHINE.............................................. 73 Lubrication Locations......................................................... 73 TIRE MAINTENANCE.................................................................. 75 Wheel Nuts.................................................................... 75 Rotating...................................................................... 75 Mounting...................................................................... 75 SPARK ARRESTER MUFFLER............................................................ 77 Cleaning Procedure............................................................ 77 PIVOT PINS........................................................................ 79 Inspection And Maintenance.................................................... 79 UTILITY WORK MACHINE STORAGE AND RETURN TO SERVICE................................ 81 Storage....................................................................... 81 Return To Service............................................................. 81 STOPPING THE ENGINE AND LEAVING THE UTILITY WORK MACHINE.......................... 83 Procedure..................................................................... 83 Emergency Exit (When Equipped With Cab)....................................... 83 SEAT BELT......................................................................... 85 Inspection And Maintenance.................................................... 85 HYDRAULIC SYSTEM...................................................................... 87 HYDRAULIC / HYDROSTATIC SCHEMATICS................................................ 91 HYDRAULIC SYSTEM INFORMATION...................................................... 99 Glossary Of Hydraulic / Hydrostatic Symbols................................... 99 Troubleshooting...............................................................103 CYLINDER (LIFT)...................................................................105 Testing.......................................................................105 Removal And Installation......................................................106 Parts Identification..........................................................109 Disassembly...................................................................110 Assembly......................................................................111 CYLINDER (TILT)...................................................................115 Testing.......................................................................115 Removal And Installation......................................................116 Parts Identification..........................................................118 Disassembly...................................................................119 Assembly......................................................................120 CYLINDER (CARGO BOX)..............................................................123 Testing.......................................................................123 Removal And Installation (Left Side)..........................................124 Removal And Installation (Right Side).........................................126 Parts Identification..........................................................127 Disassembly...................................................................128 Assembly......................................................................129 CYLINDER (STEERING)...............................................................133 Testing (Rear)................................................................133 Testing (Front)...............................................................134 Removal And Installation (Rear)...............................................135 Removal And Installation (Front)..............................................138 Parts Identification..........................................................141 Disassembly And Assembly......................................................142 CYLINDER (BOB-TACH)...............................................................147 Testing.......................................................................147 Removal And Installation......................................................148 Parts Identification..........................................................149 Disassembly...................................................................150 Assembly......................................................................151 MAIN RELIEF VALVE.................................................................155 Description...................................................................155 Auxiliary Main Relief Valve Testing...........................................155 Auxiliary Main Relief Valve Removal And Installation..........................156 Lift, Tilt And Cargo Box Main Relief Valve Testing............................157 Lift, Tilt And Cargo Box Main Relief Valve Removal And Installation...........158 PORT RELIEF VALVES................................................................159 Description...................................................................159 Lift Port Relief Valve Testing (Base End).....................................159 Lift Port Relief Valve Testing (Rod End)......................................160 Tilt Port Relief Valve Testing................................................161 HYDRAULIC CONTROL VALVE...........................................................163 Description...................................................................163 Removal And Installation......................................................163 Identification Chart..........................................................166 Disassembly...................................................................167 End Valve Section Disassembly And Assembly....................................170 Box Valve Section Disassembly And Assembly....................................172 Lift Valve Section Disassembly And Assembly...................................176 Tilt Valve Section Disassembly And Assembly...................................181 Mid Inlet / High flow Valve Section Disassembly And Assembly..................185 Auxiliary Valve Section Disassembly And Assembly..............................189 Assembly......................................................................194 STEERING SELECTOR VALVE...........................................................199 Description...................................................................199 Removal And Installation......................................................199 Disassembly And Assembly......................................................201 PILOT MANIFOLD W/O TRACTION CONTROL...............................................203 Description...................................................................203 Removal And Installation (Early Models).......................................203 Parts Identification (Early Models)...........................................205 Disassembly And Assembly (Early Models).......................................206 Removal And Installation (Later Models).......................................210 Parts Identification (Later Models)...........................................212 Disassembly And Assembly (Later Models).......................................213 PILOT MANIFOLD WITH TRACTION CONTROL..............................................217 Description...................................................................217 Removal And Installation......................................................217 Parts Identification..........................................................219 Disassembly And Assembly......................................................220 LIFT ARM (BYPASS).................................................................225 Description...................................................................225 Testing.......................................................................225 HYDRAULIC PUMP....................................................................227 Description...................................................................227 Auxiliary Section Testing.....................................................228 Lift, Tilt And Cargo Box Section Testing......................................230 Steering And Cooling Fan Section Testing......................................232 Removal And Installation......................................................234 Parts Identification..........................................................236 Disassembly And Assembly......................................................237 POWER STEERING PUMP...............................................................247 Description...................................................................247 Removal And Installation......................................................247 Disassembly And Assembly......................................................248 HYDRAULIC / HYDROSTATIC FILTER....................................................253 Description...................................................................253 Housing Removal And Installation..............................................253 Case Drain Housing Removal And Installation...................................254 CONTROL JOYSTICK S/N A94Y11001 - A94Y12003 AND S/N A94Y12005 - A94Y12034..........255 Description...................................................................255 Handle Removal And Installation...............................................255 CONTROL JOYSTICK S/N A94Y12004 & ABOVE AND S/N A94Y12035 & ABOVE..................257 Description...................................................................257 Handle Removal And Installation...............................................257 HYDRAULIC FLUID RESERVOIR.........................................................259 Description...................................................................259 Removal And Installation......................................................259 Hydraulic Fluid Screen........................................................262 OIL COOLER........................................................................263 Description...................................................................263 Removal And Installation......................................................263 AUXILIARY HYDRAULIC COUPLER BLOCK.................................................269 Description...................................................................269 Removal And Installation......................................................269 Disassembly And Assembly......................................................270 REMOTE HYDRAULICS DIVERTER VALVE..................................................273 Description...................................................................273 Removal And Installation......................................................273 Disassembly And Assembly......................................................274 POWER BOB-TACH BLOCK S/N A94Y11001 - A94Y12393....................................275 Description...................................................................275 Removal And Installation......................................................275 Disassembly And Assembly......................................................277 POWER BOB-TACH BLOCK S/N A94Y12394 & ABOVE........................................283 Description...................................................................283 Removal And Installation......................................................283 Disassembly And Assembly......................................................285 DIVERTER VALVE (REAR AUXILIARY)...................................................291 Description...................................................................291 Solenoid Testing..............................................................291 Removal And Installation......................................................291 Disassembly And Assembly......................................................294 HYDROSTATIC SYSTEM....................................................................303 HYDROSTATIC SYSTEM INFORMATION....................................................305 Troubleshooting...............................................................305 Description...................................................................306 HYDROSTATIC MOTOR.................................................................307 Description...................................................................307 Removal And Installation (Front)..............................................307 Removal And Installation (Rear)...............................................310 Parts Identification..........................................................314 Disassembly...................................................................315 Assembly......................................................................325 CHARGE PRESSURE...................................................................331 Description...................................................................331 Testing.......................................................................331 HYDROSTATIC PUMP..................................................................333 Description...................................................................333 Removal And Installation......................................................333 Control Module Removal And Installation.......................................336 Replenishing / High Pressure Relief Valve Removal And Installation............338 Charge Relief Valve Removal And Installation..................................338 Parts Identification..........................................................339 Disassembly And Assembly......................................................341 Mechanical Neutral Adjustment.................................................355 Hydraulic Controller Neutral Adjustment.......................................360 DRIVE BELT........................................................................365 Description...................................................................365 Shield Removal And Installation...............................................365 Adjusting.....................................................................366 Belt Replacement..............................................................367 Tensioner Pulley Removal And Installation.....................................369 Tensioner Pulley Disassembly..................................................370 DRIVE SYSTEM..........................................................................371 BRAKE.............................................................................373 Description...................................................................373 Disassembly And Assembly (Front Trans Axle)...................................373 Disassembly And Assembly (Rear Trans Axle)....................................373 TRANS AXLE........................................................................375 Description...................................................................375 Removal And Installation (Front)..............................................375 Removal And Installation (Rear)...............................................379 Brake Housing Disassembly And Assembly........................................383 Primary Housing Disassembly And Assembly......................................386 HUB...............................................................................393 Description...................................................................393 Removal And Installation......................................................393 CV SHAFT..........................................................................395 Description...................................................................395 Removal And Installation (Front)..............................................395 Removal And Installation (Rear)...............................................398 Inner Boot Removal And Installation...........................................401 Outer Boot Removal And Installation...........................................403 MAINFRAME.............................................................................407 OPERATOR CAB......................................................................409 Removal And Installation......................................................409 OPERATOR SEAT.....................................................................419 Removal And Installation......................................................419 Seat Belt Removal And Installation............................................420 Seat Pan Removal And Installation.............................................421 Slide Rail Removal And Installation...........................................421 Arm Rest Bracket Removal And Installation.....................................422 Arm Rest Removal And Installation.............................................422 PASSENGER SEAT....................................................................423 Removal And Installation......................................................423 Seat Belt Removal And Installation............................................424 Seat Pan Removal And Installation.............................................425 Arm Rest Removal And Installation.............................................425 BOB-TACH (HAND LEVER).............................................................427 Description...................................................................427 Removal And Installation......................................................427 Lever And Wedge Disassembly And Assembly......................................428 BOB-TACH (POWER)..................................................................429 Description...................................................................429 Removal And Installation......................................................429 Lever And Wedge Disassembly And Assembly......................................431 LIFT ARM..........................................................................433 Removal And Installation......................................................433 CARGO BOX.........................................................................435 Removal And Installation......................................................435 STEERING COLUMN...................................................................437 Removal And Installation......................................................437 FUEL TANK.........................................................................439 Removal And Installation......................................................439 Fuel Level Sender Removal And Installation....................................441 DRIVE AND BRAKE PEDALS............................................................443 Description...................................................................443 Removal And Installation......................................................443 Drive Pedal Disassembly And Assembly..........................................444 SHOCKS............................................................................445 Removal And Installation......................................................445 CONTROL ARMS......................................................................447 Removal And Installation (Lower Arm)..........................................447 Removal And Installation (Upper Arm)..........................................448 Inspection....................................................................449 Ball Joint Removal And Installation...........................................450 SPINDLE...........................................................................451 Removal And Installation......................................................451 TIE ROD...........................................................................453 Description...................................................................453 Removal And Installation......................................................453 Toe Adjustment Procedure......................................................454 FLOOR CONSOLE.....................................................................457 Access Cover Removal And Installation (Side)..................................457 Access Cover Removal And Installation (Top)...................................457 CENTER CONSOLE S/N A94Y11001 - A94Y12003, S/N A94Y12005 - A94Y12034...............459 Removal And Installation......................................................459 CENTER CONSOLE S/N A94Y12004, S/N A94Y12035 & ABOVE...............................461 Removal And Installation......................................................461 FENDER............................................................................465 Removal And Installation (Front)..............................................465 Removal And Installation (Left Rear)..........................................466 Removal And Installation (Right Rear).........................................467 WINDOWS...........................................................................469 Front, Rear And Lower Door Removal And Installation...........................469 Upper Door Removal And Installation...........................................472 HEADLINER.........................................................................475 Removal And Installation......................................................475 ELECTRICAL SYSTEM AND ANALYSIS........................................................477 ELECTRICAL SCHEMATICS.............................................................481 ELECTRICAL SYSTEM INFORMATION.....................................................507 Glossary Of Electrical Symbols................................................507 Cab Harness Connectors........................................................510 Mainframe / Engine Harness Connectors.........................................511 Description...................................................................512 Troubleshooting...............................................................513 Fuse And Relay Location - Cab Panel...........................................514 Fuse And Relay Location - Frame Panel.........................................515 Solenoid Testing..............................................................516 BATTERY...........................................................................517 Removal And Installation......................................................517 Servicing.....................................................................519 Using A Booster Battery (Jump Starting).......................................520 ALTERNATOR........................................................................521 Belt Adjustment...............................................................521 Belt Replacement..............................................................521 Charging System Inspection....................................................522 Alternator Voltage Testing....................................................523 Low Voltage Testing...........................................................524 High Voltage Testing..........................................................524 Removal And Installation......................................................525 Parts Identification..........................................................527 STARTER...........................................................................529 Testing.......................................................................529 Removal And Installation......................................................530 Parts Identification..........................................................531 INSTRUMENT PANELS.................................................................533 Display Controller Panel......................................................533 Switch Panel..................................................................534 Floor Console.................................................................535 Center Console (With Early Model Joystick)....................................535 Center Console (With Later Model Joystick)....................................536 Radio.........................................................................537 LIGHTS............................................................................539 Front Removal And Installation................................................539 BOBCAT CONTROLLER (DISPLAY).......................................................541 Description...................................................................541 Connector Identification......................................................542 Removal And Installation......................................................543 BOBCAT CONTROLLER (DRIVE).........................................................545 Description...................................................................545 Connector Identification......................................................546 Removal And Installation......................................................547 DIAGNOSTIC SERVICE CODES..........................................................549 Description...................................................................549 Service Codes List............................................................550 CONTROL PANEL SETUP...............................................................553 Enter Setup...................................................................553 Two-Speed.....................................................................553 High Flow.....................................................................553 Horsepower Management.........................................................553 Tire Size.....................................................................553 Save Setup....................................................................553 Exit Setup....................................................................553 PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START)...................................555 Password Description..........................................................555 Changing The Owner And Operator Passwords.....................................555 Password Lockout Feature......................................................556 TOOLCAT INTERLOCK CONTROL SYSTEM (TICS™)..........................................557 Description...................................................................557 Inspecting The TICS™..........................................................557 Maintaining The TICS™.........................................................557 Lift Arm Bypass Procedure.....................................................558 Testing The Lift Arm Bypass Procedure.........................................558 ARM REST SENSOR...................................................................559 Description...................................................................559 Removal And Installation......................................................559 SPEED SENSORS.....................................................................561 Description...................................................................561 Removal And Installation (Front Trans Axle)...................................561 WHEEL POSITION SENSORS............................................................563 Description...................................................................563 Removal And Installation (Front)..............................................563 Removal And Installation (Rear)...............................................564 Adjusting (In The Machine)....................................................565 Adjusting (Out Of The Machine)................................................566 SERVICE PC (LAPTOP COMPUTER)......................................................567 Connecting Remote Start Tool..................................................567 Connecting Remote Start Tool (Service Tool)...................................567 CALIBRATION.......................................................................569 Description...................................................................569 Throttle Position Sensor Calibration..........................................569 Drive System Calibration......................................................570 Brake Pedal Calibration.......................................................571 Travel Pedal Calibration......................................................572 TRAVEL DIRECTION CONTROL LEVER....................................................573 Description...................................................................573 Removal And Installation......................................................573 FLYWHEEL RPM SENSOR...............................................................575 Description...................................................................575 Adjusting.....................................................................575 ELECTRIC COOLING FAN..............................................................577 Description...................................................................577 Removal And Installation......................................................577 MAINTENANCE CLOCK.................................................................579 Description...................................................................579 Setup.........................................................................579 Reset.........................................................................581 BACK-UP ALARM SYSTEM..............................................................583 Description...................................................................583 Inspecting....................................................................583 FRONT HORN........................................................................585 Description...................................................................585 Removal And Installation......................................................585 Troubleshooting...............................................................586 TRACTION CONTROL..................................................................587 Description...................................................................587 Operation.....................................................................587 Removal And Installation......................................................588 ENGINE SERVICE........................................................................591 ENGINE INFORMATION................................................................595 Description...................................................................595 Specifications................................................................596 Torque Values.................................................................600 Troubleshooting...............................................................600 Engine Removal And Installation...............................................602 Engine Mount Replacement......................................................609 Compression - Checking........................................................610 ENGINE SPEED CONTROL..............................................................611 Removal And Installation (Position Sensing)...................................611 Removal And Installation (Non Position Sensing)...............................611 Speed Control Cable Removal And Installation..................................612 MUFFLER...........................................................................615 Removal And Installation......................................................615 AIR CLEANER.......................................................................617 Housing Removal And Installation..............................................617 ENGINE COOLING SYSTEM.............................................................619 Radiator Removal And Installation.............................................619 Hydraulic Fan Removal And Installation........................................621 Hydraulic Fan Disassembly And Assembly........................................624 Water Pump Removal And Installation...........................................627 Water Pump Disassembly And Assembly...........................................627 Thermostat Housing Removal And Installation...................................628 Thermostat - Checking.........................................................629 LUBRICATION SYSTEM................................................................631 Oil Pan Removal And Installation..............................................631 Oil Pump Removal And Installation.............................................631 Front Cover / Oil Pump Oil Seal Removal And Installation......................632 Relief Valve - Testing........................................................633 Oil Pump Inspection...........................................................633 Oil Filter Cooler Removal And Installation....................................635 Engine Oil Pressure - Testing.................................................635 FUEL SYSTEM.......................................................................637 Fuel Shutoff Solenoid - Checking..............................................637 Fuel Shutoff Solenoid Removal And Installation................................637 Fuel Injection Pump - Checking................................................638 Fuel Injection Pump Assembly Removal And Installation.........................639 Governor Housing Disassembly And Assembly.....................................642 Governor Disassembly And Assembly.............................................644 Fuel Camshaft Removal And Installation........................................646 Fuel Injection Pump Removal And Installation..................................649 Fuel Injection Pump - Timing..................................................651 Fuel Injector Removal And Installation........................................653 Fuel Injector Nozzle Pressure - Checking......................................654 Nozzle Spray Condition........................................................655 Valve Seat Tightness..........................................................655 CYLINDER HEAD.....................................................................657 Glow Plugs - Testing..........................................................657 Glow Plugs Removal And Installation...........................................657 Valve Clearance Adjustment....................................................658 Valve Timing - Checking.......................................................659 Cylinder Head Removal And Installation........................................660 Cylinder Head Disassembly And Assembly........................................663 Cylinder Head - Servicing.....................................................663 Cylinder Head Top Clearance...................................................664 Valve Guide - Checking........................................................665 Valve Guide Removal And Installation..........................................665 Reconditioning The Valve And Valve Seat.......................................666 Valve Spring..................................................................668 Valve Tappets.................................................................669 Rocker Arm And Shaft - Checking...............................................670 Bridge Arm And Bridge Arm Shaft - Checking....................................670 Bridge Arm Shaft Removal And Installation.....................................671 Push Rod Alignment - Checking.................................................672 CRANKSHAFT AND PISTONS............................................................673 Piston And Connecting Rod Removal And Installation............................673 Piston And Connecting Rod - Servicing.........................................674 Cylinder Bore - Checking......................................................678 Connecting Rod Alignment......................................................679 Crankshaft Gear Removal And Installation......................................679 Crankshaft And Bearings Removal And Installation..............................680 Crankshaft And Bearings - Servicing...........................................683 CAMSHAFT AND TIMING GEARS.........................................................687 Timing Gearcase Cover Removal.................................................687 Timing Gearcase Cover Installation............................................688 Timing Gears Backlash - Checking..............................................691 Idler Gear And Camshaft Removal And Installation..............................691 Camshaft - Servicing..........................................................692 Idler Gear And Shaft - Servicing..............................................693 TURBOCHARGER......................................................................695 Description...................................................................695 Testing.......................................................................695 Removal And Installation......................................................696 FLYWHEEL AND HOUSING..............................................................699 Flywheel Removal And Installation.............................................699 Ring Gear Removal And Installation............................................700 Housing Removal And Installation..............................................701 EXHAUST GAS RECIRCULATION (EGR) SYSTEM............................................705 Description...................................................................705 Testing.......................................................................706 Removal And Installation......................................................709 Disassembly And Assembly......................................................710 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)......................................711 AIR CONDITIONING SYSTEM FLOW......................................................713 Description...................................................................713 Chart.........................................................................714 Components....................................................................715 Safety Equipment..............................................................718 REGULAR MAINTENANCE...............................................................719 Filter Elements Removal And Installation......................................719 Compressor Drive Belt Inspection..............................................720 Condenser.....................................................................720 Air Conditioning Service Chart................................................721 A/C Evaporator Coil...........................................................722 TROUBLESHOOTING...................................................................723 Blower Motor Does Not Operate.................................................723 Blower Motor Operates Normally But Air Flow Is Insufficient...................723 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....723 The Compressor Does Not Operate At All Or Operates Improperly.................724 Gauge Pressure Related Troubleshooting........................................725 Temperature / Pressure Chart..................................................727 Poor A/C Performance..........................................................728 HVAC Repair And Leaks.........................................................728 Electrical System.............................................................729 Engine Coolant Bypassing The Heater Valve.....................................738 Heater Valve Not Opening Or Closing...........................................739 SYSTEM CHARGING AND RECLAMATION...................................................741 Refrigerant Identification....................................................741 Reclamation And Charging With Recovery / Charging Unit........................742 Charging With A Manifold Gauge Set............................................744 COMPRESSOR........................................................................747 Belt Adjustment...............................................................747 Belt Replacement..............................................................747 Removal And Installation......................................................748 Oil...........................................................................749 Oil Check.....................................................................749 Clutch Disassembly And Assembly...............................................751 CONDENSER.........................................................................755 Removal And Installation......................................................755 RECEIVER / DRIER..................................................................757 Receiver / Drier Removal And Installation.....................................757 Pressure Relief Valve Removal And Installation................................758 Pressure Switch Removal And Installation......................................759 EVAPORATOR / HEATER UNIT..........................................................761 Removal And Installation......................................................761 THERMOSTAT S/N A94Y11001 - A94Y12367..............................................765 Removal And Installation......................................................765 THERMOSTAT S/N A94Y12368 & ABOVE..................................................767 Description...................................................................767 Removal And Installation......................................................768 EXPANSION VALVE...................................................................771 Removal And Installation......................................................771 EVAPORATOR COIL...................................................................773 Removal And Installation......................................................773 HEATER COIL.......................................................................775 Removal And Installation With A/C.............................................775 BLOWER FAN........................................................................777 Removal And Installation......................................................777 HEATER VALVE......................................................................779 Removal And Installation......................................................779 Disassembly And Assembly......................................................779 SPECIFICATIONS........................................................................781 (5600) UTILITY WORK MACHINE SPECIFICATIONS........................................783 Dimensions (With 27 Inch Tires)...............................................783 Dimensions (With 29 Inch Tires)...............................................784 Performance...................................................................785 Controls......................................................................785 Engine........................................................................785 Hydraulic System..............................................................786 Electrical....................................................................786 Drive System..................................................................787 Capacities....................................................................787 Tires.........................................................................787 TECHNICAL SERVICE GUIDE SPECIFICATIONS............................................789 Engine........................................................................789 Engine Torques................................................................789 Cooling System................................................................789 Loader Torques................................................................790 Hydraulic / Hydrostatic System................................................790 Fuel Consumption..............................................................790 TORQUE SPECIFICATIONS FOR BOLTS...................................................791 Torque For General SAE Bolts..................................................791 Torque For General Metric Bolts...............................................792 HYDRAULIC CONNECTION SPECIFICATIONS...............................................793 O-ring Face Seal Connection...................................................793 Straight Thread O-ring Fitting................................................794 Tubelines And Hoses...........................................................794 Flare Fitting.................................................................794 O-ring Flare Fitting..........................................................795 Port Seal Fitting.............................................................797 Quick-Lok™ Fitting............................................................798 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS......................................799 Specifications................................................................799 CONVERSIONS.......................................................................801 Decimal And Millimeter Equivalent Chart.......................................801 U.S. To Metric Conversion Chart...............................................802 SERVICE TOOLS REQUIRED............................................................803 Remote Start Tools............................................................803 Hydraulic Tools...............................................................804 Mainframe And Drive Tools.....................................................806 Electrical Tools..............................................................806 Engine Tools..................................................................806 HVAC Tools....................................................................809 ALPHABETICAL INDEX....................................................................811
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