Bobcat Toolcat 5600 Utility Work Machine Workshop Repair Service Manual – 6904209

(S/N: A00211001 & Above – S/N: A00311001 & Above)
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This workshop repair service manual PDF download for the Toolcat™ 5600 Bobcat Utility Work Machine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

Bobcat Utility Work Machine Toolcat™ 5600
S/N: A00211001 & Above
S/N: A00311001 & Above

TABLE OF CONTENTS :

SAFETY & MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAINFRAME
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
HEATING, VENTILATION, AIR CONDITIONING
SPECIFICATIONS
ALPHABETICAL INDEX
SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6904209 (2-10)
Total Pages : 745

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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CONTENTS
FOREWORD
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrestor Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATIONS
Utility Work Machine Serial Number
Engine Serial Number
DELIVERY REPORT
TOOLCAT UTILITY WORK MACHINE IDENTIFICATION

SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE UTILITY WORK MACHINE
Procedure For Jackstand Placement On The Axle
Procedure For Jackstand Placement On The Frame
LIFT ARM SUPPORT DEVICE
Installing
Removing
CARGO BOX SUPPORT DEVICE
Installing
Removing
Raising The Cargo Box When Engine Is Not Running
OPERATOR CAB
Description
TRANSPORTING THE UTILITY WORK MACHINE ON A TRAILER
Loading And Unloading
Fastening
TOWING THE UTILITY WORK MACHINE
Procedure
REMOTE START
Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Elements
ENGINE COOLING SYSTEM
Cleaning
Checking
Removing And Replacing Coolant
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Fuel Filter
Removing Air From The Fuel System
Filling A Portable Fuel Container
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil Chart
Removing And Replacing Oil And Filter
HYDRAULIC / HYDROSTATIC SYSTEM
Checking And Adding Fluid
Hydraulic / Hydrostatic Fluid Chart
Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters
Removing And Replacing Hydraulic Fluid
Breather Cap
AXLE / DIFFERENTIAL (FRONT AND REAR)
Checking And Adding Lubricant
Removing And Replacing Lubricant
BOB-TACH
Inspection And Maintenance
LUBRICATING THE UTILITY WORK MACHINE
Lubrication Locations
TIRE MAINTENANCE
Wheel Nuts
Rotating
Mounting
SPARK ARRESTOR MUFFLER
Cleaning Procedure
PIVOT PINS
Inspection And Maintenance
UTILITY WORK MACHINE STORAGE AND RETURN TO SERVICE
Storage
Return To Service
STOPPING THE ENGINE AND LEAVING THE UTILITY WORK MACHINE
Procedure
Emergency Exit

HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
Troubleshooting
CYLINDER (LIFT)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (TILT)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (CARGO BOX)
Testing (Left Side Cylinder)
Testing (Right Side Cylinder)
Removal And Installation
Parts Identification
Disassembly
Assembly
MAIN RELIEF VALVE
Description
Auxiliary Main Relief Valve Testing
Auxiliary Main Relief Valve Removal And Installation
Lift, Tilt And Cargo Box Main Relief Valve Testing
Lift, Tilt And Cargo Box Main Relief Valve Removal And Installation
PORT RELIEF VALVES
Description
Lift Port Relief Valve Testing
Tilt Port Relief Valve Testing
HYDRAULIC CONTROL VALVE
Description
Removal And Installation
Identification Chart
Disassembly
End Valve Section Disassembly And Assembly
Lift Valve Section Disassembly And Assembly
Tilt Valve Section Disassembly And Assembly
Box Valve Section Disassembly And Assembly
High Flow Valve Section Disassembly And Assembly
Auxiliary Valve Section Disassembly And Assembly
Assembly
STEERING SELECTOR VALVE
Description
Removal And Installation
Disassembly And Assembly
PILOT MANIFOLD
Description
Removal And Installation
Disassembly And Assembly
LIFT ARM BYPASS CONTROL VALVE
Description
Testing
Removal And Installation
Disassembly And Assembly
HYDRAULIC PUMP
Description
Auxiliary Section Testing
Lift, Tilt And Cargo Box Section Testing
Steering And Cooling Fan Section Testing
Removal And Installation
Parts Identification
Disassembly And Assembly
POWER STEERING PUMP
Description
Removal And Installation
Disassembly And Assembly
HYDRAULIC / HYDROSTATIC FILTER
Description
Housing Removal And Installation
Case Drain Housing Removal And Installation
CONTROL JOYSTICK
Description
Handle Removal And Installation
Removal And Installation
Disassembly And Assembly
HYDRAULIC FLUID RESERVOIR
Description
Removal And Installation
Hydraulic Fluid Screen
OIL COOLER
Description
Removal And Installation
AUXILIARY HYDRAULIC COUPLER BLOCK
Description
Removal And Installation (Front)
Removal And Installation (Rear)
Disassembly And Assembly
REMOTE HYDRAULICS DIVERTER VALVE
Description
Removal And Installation
Disassembly And Assembly
PTO HYDRAULIC MOTOR
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
REAR AUXILIARY DIVERTER VALVE
Description
Solenoid Testing
Removal And Installation
Disassembly And Assembly

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting
Description
HYDROSTATIC DRIVE MOTOR
Description
Removal And Installation (Front Axle)
Removal And Installation (Rear Axle)
Parts Identification
Disassembly
Assembly
CHARGE PRESSURE
Description
Testing
HYDROSTATIC PUMP
Description
Removal And Installation
Directional Control Valve Removal And Installation
PWM Control Valve Removal And Installation
Replenishing / High Pressure Relief Valve Removal And Installation
Charge Relief Valve Removal And Installation
Parts Identification (Left Half)
Parts Identification (Right Half)
Disassembly
Assembly
Hydrostatic Pump Start-Up
Pump Neutral Adjustment
DRIVE BELT
Description
Shield Removal And Installation
Adjusting
Belt Removal And Installation
Tensioner Pulley Removal And Installation
Tensioner Pulley Parts Identification
Tensioner Pulley Disassembly
Tensioner Pulley Assembly

DRIVE SYSTEM
BRAKE
Description
Disassembly And Assembly (Front Axle)
Disassembly And Assembly (Rear Axle)
AXLE
Description
Front Axle Brush Guard Removal And Installation
Front Axle Removal And Installation
Rear Axle Removal And Installation
Separate The Axle Housings
Primary Housing Disassembly
Steering Cylinder Disassembly
Brake Disassembly
Secondary Housing And Differential Lock Disassembly
Secondary Housing And Differential Lock Assembly
Steering Cylinder Assembly
Primary Housing Assembly
Brake Assembly
Join The Axle Housings
AXLE HUB WITH AXLE SHAFT
Description
Removal And Installation (Without Wheel Position Sensor)
Removal (With Wheel Position Sensor)
Installation (With Wheel Position Sensor)
AXLE HUB WITHOUT AXLE SHAFT
Description
Removal And Installation (Without Wheel Position Sensor)
Removal (With Wheel Position Sensor)
Installation (With Wheel Position Sensor)
Disassembly
Assembly
Torque Check Procedure
AXLE SHAFT
Description
Removal And Installation
TIE ROD
Description
Removal And Installation (Front Axle)
Removal And Installation (Rear Axle)
Adjusting

MAINFRAME
OPERATOR CAB
Removal And Installation
OPERATOR SEAT
Removal And Installation
Seat Belt Removal And Installation
Seat Pan Removal And Installation
Slide Rail Removal And Installation
Lower Cushion Removal And Installation
Back Cushion Removal And Installation
Arm Rest Bracket Removal And Installation
Arm Rest Removal And Installation
Shock Removal And Installation
PASSENGER SEAT
Removal And Installation
Seat Belt Removal And Installation
Seat Pan Removal And Installation
Arm Rest Removal And Installation
BOB-TACH
Description
Removal And Installation
Lever And Wedge Disassembly And Assembly
LIFT ARM
Removal And Installation
CARGO BOX
Removal And Installation
STEERING COLUMN
Removal And Installation
FUEL TANK
Main Tank Removal And Installation
Auxiliary Tank Removal And Installation
Fuel Level Sender Removal And Installation
DRIVE AND BRAKE PEDALS
Description
Removal And Installation
Drive Pedal Disassembly And Assembly
SHOCKS
Removal And Installation
TRAILING ARMS
Description
Removal And Installation (Upper Arm)
Removal And Installation (Lower Arm)
LEAF SPRINGS
Removal And Installation (Left Side)
Removal And Installation (Right Side)
HITCH
Removal And Installation
FLOOR CONSOLE
Access Cover Removal And Installation
CENTER CONSOLE
Removal And Installation
FENDER (FRONT LEFT)
Removal And Installation
FENDER (FRONT RIGHT)
Removal And Installation
FENDER (REAR LEFT)
Removal And Installation
FENDER (REAR RIGHT)
Removal And Installation
WINDOWS
Front, Rear And Lower Door Removal And Installation
Upper Door Removal And Installation

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Description
Troubleshooting
Fuse And Relay Location / Identification
Solenoid Testing
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
ALTERNATOR
Belt Adjustment
Charging System Inspection
Alternator Voltage Testing
Low Voltage Testing
High Voltage Testing
Removal And Installation
Parts Identification
STARTER
Testing
Removal And Installation
Parts Identification
INSTRUMENT PANELS
Display Controller Panel
Switch Panel
Floor Console
Center Console
Display Controller Panel Removal And Installation
Light Bulb Removal And Installation
LIGHTS
Front Removal And Installation
BOBCAT CONTROLLER (DISPLAY)
Description
Connector Identification
Removal And Installation
BOBCAT CONTROLLER (DRIVE)
Description
Connector Identification
Removal And Installation
DIAGNOSTIC SERVICE CODES
Description
Service Codes List
DISPLAY CONTROLLER PANEL SETUP
Display Selection
Passwords
Password Entry (For Starting And Operating The Machine)
Changing The Owner And Operator Password
Password Lockout Feature
Job Clock
RPM
TOOLCAT INTERLOCK CONTROL SYSTEM (TICS)
Description
Inspecting The TICS System (Engine STOPPED – Key ON)
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
Inspecting The Arm Rest Sensor (Engine RUNNING)
Inspecting The Traction Lock (Engine RUNNING)
Inspecting The Lift Arm Bypass Control
ARM REST SENSOR
Description
Removal And Installation
SPEED SENSORS
Description
Removal And Installation (Front Axle)
Removal And Installation (Rear Axle)
WHEEL POSITION SENSORS
Description
Removal And Installation (Front Axle)
Removal And Installation (Rear Axle)
SERVICE PC (LAPTOP COMPUTER)
Connecting Remote Start Tool
CALIBRATION
Description
Drive Pedal Calibration
Brake Pedal Calibration
Hydrostatic Pump Calibration
Wheel Alignment Calibration
TRAVEL DIRECTION CONTROL LEVER
Description
Removal And Installation
FLYWHEEL RPM SENSOR
Description
Adjusting
ELECTRIC COOLING FAN
Description
Removal And Installation

ENGINE SERVICE
ENGINE INFORMATION
Description
Engine Specifications-Kubota V2203-M-DI
Engine Specifications-Kubota V2003-M-DI-T (Turbo)
Engine Torque Values
Troubleshooting
Engine Removal And Installation
Engine Mount Replacement
Compression – Checking
ENGINE SPEED CONTROL
Removal And Installation
Speed Control Cable Removal And Installation
MUFFLER
Removal And Installation
AIR CLEANER
Housing Removal And Installation
ENGINE COOLING SYSTEM
Radiator Removal And Installation
Radiator Mount Removal And Installation
Hydraulic Fan Removal And Installation
Hydraulic Fan Disassembly And Assembly
Water Pump Removal And Installation
Water Pump Disassembly And Assembly
Thermostat Housing Removal And Installation
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Inspection
Engine Oil Pressure – Testing
FUEL SYSTEM
Fuel Camshaft Removal And Installation
Fuel Camshaft Governor Disassembly And Assembly
Fuel Shutoff Solenoid – Checking
Fuel Shutoff Solenoid Removal And Installation
Fuel Injection Pump Removal And Installation (Turbo)
Fuel Injection Pump Removal And Installation (Non- Turbo)
Injection Pump – Timing
Fuel Injector Removal And Installation
Fuel Injector Nozzle Pressure – Checking
Nozzle Spray Condition
Valve Seat Tightness
CYLINDER HEAD
Glow Plugs – Testing
Glow Plugs Removal And Installation
Valve Clearance Adjustment
Valve Timing – Checking
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head – Servicing
Cylinder Head Top Clearance
Valve Guide – Checking
Reconditioning The Valve And Valve Seat
Valve Spring
Valve Tappets
Rocker Arm And Shaft – Checking
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod – Servicing
Cylinder Bore – Checking
Connecting Rod Alignment
Crankshaft Gear Removal And Installation
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings – Servicing
CAMSHAFT AND TIMING GEARS
Timing Gearcase Cover Removal And Installation
Timing Gears Backlash – Checking
Idler Gear And Camshaft Removal And Installation
Camshaft – Servicing
Idler Gear And Shaft – Servicing
TURBOCHARGER
Description
Testing
Removal And Installation
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Housing Removal And Installation

HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW
Description
Chart
Components
Safety Equipment
REGULAR MAINTENANCE
Filter Elements Removal And Installation
Compressor Drive Belt Inspection
Condenser
Air Conditioning Service Chart
A/C Evaporator Coil
TROUBLESHOOTING
Blower Motor Does Not Operate
Blower Motor Operates Normally But Air Flow Is Insufficient
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
The Compressor Does Not Operate At All Or Operates Improperly
Gauge Pressure Related Troubleshooting
Temperature / Pressure Chart
Poor A/C Performance
HVAC Repair And Leaks
Electrical System
Engine Coolant Bypassing The Heater Valve
Heater Valve Not Opening Or Closing
SYSTEM CHARGING AND RECLAMATION
Refrigerant Identification
Reclamation And Charging With Recovery / Charging Unit
Charging With A Manifold Gauge Set
COMPRESSOR
Belt Adjusting
Removal And Installation
Oil
Oil Check
Clutch Disassembly And Assembly
CONDENSER
Removal And Installation
RECEIVER / DRIER
Receiver / Drier Removal And Installation
Pressure Relief Valve Removal And Installation
Pressure Switch Removal And Installation
EVAPORATOR / HEATER UNIT
Removal And Installation
THERMOSTAT
Removal And Installation
EXPANSION VALVE
Removal And Installation
EVAPORATOR COIL
Removal And Installation
HEATER COIL
Removal And Installation With A/C
BLOWER FAN
Removal And Installation
HEATER VALVE
Removal And Installation
Disassembly And Assembly

SPECIFICATIONS
TOOLCAT 5600 UTILITY WORK MACHINE SPECIFICATIONS
Dimensions
Performance
Controls
Engine
Hydraulic System
Electrical
Power Take-Off (PTO) System (Option)
Drive System
Capacities
Tires
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
O-ring Face Seal Connection
Straight Thread O-ring Fitting
Tubelines And Hoses
Flare Fitting
O-ring Flare Fitting
Port Seal Fitting
Quick-Lok™ Fitting
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalent Chart
U.S. To Metric Conversion Chart

ALPHABETICAL INDEX

SERVICE MANUAL REVISION
Revision No: 5600 – 1
Revision No: 5600 – 2
Revision No: 5600 – 3
Revision No: 5600 – 4
Revision No: 5600 – 5
Revision No: 5600 – 6
Revision No: 5600 – 7

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