Bobcat Toolcat 5600 Utility Work Machine Workshop Repair Service Manual – 6990050

(S/N: A94Y11001 & 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: A94Y11001 & 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 : 6990050 (3-11)
Total Pages : 739

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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MAINTENANCE SAFETY
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
UTILITY WORK MACHINE IDENTIFICATION

SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE UTILITY WORK MACHINE
Procedure For Jackstand Placement On The Control Arms
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 TOOL KIT – MEL1563
Remote Start Tool – MEL1563
Service Tool Harness Control – MEL1565
Service Tool Harness Communicator – MEL1566
Remote Start Procedure
REMOTE START TOOL (SERVICE TOOL) KIT – 6689779
Description
Remote Start Tool (Service Tool) – 6689778
Service Tool Harness – 6689747
Computer Service Tool Harness – 6689746
Remote Start Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Elements
ENGINE COOLING SYSTEM
Checking Level
Cleaning
Removing And Replacing Coolant
FUEL SYSTEM
Fuel Specifications
Biodiesel Blend Fuel
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 Fluid
Hydraulic / Hydrostatic Fluid Chart
Adding Fluid
Alternate Fill Procedure
Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters
Removing And Replacing Hydraulic Fluid
Breather Cap
TRANS AXLE (FRONT AND REAR)
Checking And Adding Lubricant
Removing And Replacing Lubricant
BOB-TACH (HAND LEVER)
Inspection And Maintenance
BOB-TACH (POWER)
Inspection And Maintenance
LUBRICATING THE UTILITY WORK MACHINE
Lubrication Locations
TIRE MAINTENANCE
Wheel Nuts
Rotating
Mounting
SPARK ARRESTER 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 (When Equipped With Cab)
SEAT BELT
Inspection And Maintenance

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
Removal And Installation (Left Side)
Removal And Installation (Right Side)
Parts Identification
Disassembly
Assembly
CYLINDER (STEERING)
Testing (Rear)
Testing (Front)
Removal And Installation (Rear)
Removal And Installation (Front)
Parts Identification
Disassembly And Assembly
CYLINDER (BOB-TACH)
Testing
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 (Base End)
Lift Port Relief Valve Testing (Rod End)
Tilt Port Relief Valve Testing
HYDRAULIC CONTROL VALVE
Description
Removal And Installation
Identification Chart
Disassembly
End Valve Section Disassembly And Assembly
Box Valve Section Disassembly And Assembly
Lift Valve Section Disassembly And Assembly
Tilt Valve Section Disassembly And Assembly
Mid Inlet / 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
Parts Identification
Disassembly And Assembly
LIFT ARM (BYPASS)
Description
Testing
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
HYDRAULIC FLUID RESERVOIR
Description
Removal And Installation
Hydraulic Fluid Screen
OIL COOLER
Description
Removal And Installation
AUXILIARY HYDRAULIC COUPLER BLOCK
Description
Removal And Installation
Disassembly And Assembly
REMOTE HYDRAULICS DIVERTER VALVE
Description
Removal And Installation
Disassembly And Assembly
POWER BOB-TACH BLOCK
Description
Removal And Installation
Disassembly And Assembly
DIVERTER VALVE (REAR AUXILIARY)
Description
Solenoid Testing
Removal And Installation
Disassembly And Assembly

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting
Description
HYDROSTATIC MOTOR
Description
Removal And Installation (Front)
Removal And Installation (Rear)
Parts Identification
Disassembly
Assembly
CHARGE PRESSURE
Description
Testing
HYDROSTATIC PUMP
Description
Removal And Installation
Control Module Removal And Installation
Replenishing / High Pressure Relief Valve Removal And Installation
Charge Relief Valve Removal And Installation
Parts Identification
Disassembly And Assembly
Mechanical Neutral Adjustment
Hydraulic Controller Neutral Adjustment
DRIVE BELT
Description
Shield Removal And Installation
Adjusting
Belt Replacement
Tensioner Pulley Removal And Installation
Tensioner Pulley Disassembly

DRIVE SYSTEM
BRAKE
Description
Disassembly And Assembly (Front Trans Axle)
Disassembly And Assembly (Rear Trans Axle)
TRANS AXLE
Description
Removal And Installation (Front)
Removal And Installation (Rear)
Brake Housing Disassembly And Assembly
Primary Housing Disassembly And Assembly
HUB
Description
Removal And Installation
CV SHAFT
Description
Removal And Installation (Front)
Removal And Installation (Rear)
Inner Boot Removal And Installation
Outer Boot Removal And Installation

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
Arm Rest Bracket Removal And Installation
Arm Rest 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 (HAND LEVER)
Description
Removal And Installation
Lever And Wedge Disassembly And Assembly
BOB-TACH (POWER)
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
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
CONTROL ARMS
Removal And Installation (Lower Arm)
Removal And Installation (Upper Arm)
Inspection
Ball Joint Removal And Installation
SPINDLE
Removal And Installation
TIE ROD
Description
Removal And Installation
Toe Adjustment Procedure
FLOOR CONSOLE
Access Cover Removal And Installation (Side)
Access Cover Removal And Installation (Top)
CENTER CONSOLE
Removal And Installation
FENDER
Removal And Installation (Front)
Removal And Installation (Left Rear)
Removal And Installation (Right Rear)
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
Cab Harness Connectors
Mainframe / Engine Harness Connectors
Description
Troubleshooting
Fuse And Relay Location – Cab Panel
Fuse And Relay Location – Frame Panel
Solenoid Testing
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
ALTERNATOR BELT
Belt Adjustment
Belt Replacement
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
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
CONTROL PANEL SETUP
Enter Setup
Two-Speed
High Flow
Horsepower Management
Tire Size
Save Setup
Exit Setup
PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START)
Password Description
Changing The Owner And Operator Passwords
Password Lockout Feature
TOOLCAT INTERLOCK CONTROL SYSTEM (TICS)
Description
Inspecting The TICS
Maintaining The TICS
Lift Arm Bypass Procedure
Testing The Lift Arm Bypass Procedure
ARM REST SENSOR
Description
Removal And Installation
SPEED SENSORS
Description
Removal And Installation (Front Trans Axle)
WHEEL POSITION SENSORS
Description
Removal And Installation (Front)
Removal And Installation (Rear)
Adjusting (In The Machine)
Adjusting (Out Of The Machine)
SERVICE PC (LAPTOP COMPUTER)
Connecting Remote Start Tool
Connecting Remote Start Tool (Service Tool)
CALIBRATION
Description
Throttle Position Sensor Calibration
Drive System Calibration
Brake Pedal Calibration
Travel Pedal Calibration
TRAVEL DIRECTION CONTROL LEVER
Description
Removal And Installation
FLYWHEEL RPM SENSOR
Description
Adjusting
ELECTRIC COOLING FAN
Description
Removal And Installation
MAINTENANCE CLOCK
Description
Setup
Reset
BACK-UP ALARM SYSTEM (IF EQUIPPED)
Description
Inspecting

ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Torque Values
Troubleshooting
Engine Removal And Installation
Engine Mount Replacement
Compression – Checking
ENGINE SPEED CONTROL
Removal And Installation (Position Sensing)
Removal And Installation (Non Position Sensing)
Speed Control Cable Removal And Installation
MUFFLER
Removal And Installation
AIR CLEANER
Housing Removal And Installation
ENGINE COOLING SYSTEM
Radiator 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
Thermostat – Checking
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Front Cover / Oil Pump Oil Seal Removal And Installation
Relief Valve – Testing
Oil Pump Inspection
Oil Filter Cooler Removal And Installation
Engine Oil Pressure – Testing
FUEL SYSTEM
Fuel Shutoff Solenoid – Checking
Fuel Shutoff Solenoid Removal And Installation
Fuel Injection Pump – Checking
Fuel Injection Pump Assembly Removal And Installation
Governor Housing Disassembly And Assembly
Governor Disassembly And Assembly
Fuel Camshaft Removal And Installation
Fuel Injection Pump Removal And Installation
Fuel 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
Valve Guide Removal And Installation
Reconditioning The Valve And Valve Seat
Valve Spring
Valve Tappets
Rocker Arm And Shaft – Checking
Bridge Arm And Bridge Arm Shaft – Checking
Bridge Arm Shaft Removal And Installation
Push Rod Alignment – 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
Timing Gearcase Cover 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 Adjustment
Belt Replacement
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
(5600) UTILITY WORK MACHINE SPECIFICATIONS
Dimensions (With 27 Inch Tires)
Dimensions (With 29 Inch Tires)
Performance
Controls
Engine
Hydraulic System
Electrical
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

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