Bobcat Toolcat 5600 Utility Work Machine Workshop Repair Service Manual – 6902819

(S/N: 424711001 & Above – S/N: 424811001 & 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: 424711001 & Above
S/N: 424811001 & Above

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
BOBCAT UTILITY WORK MACHINE IDENTIFICAITON
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
HEATING, VENTILATION, AIR CONDITIONING
SPECIFICATIONS
SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6902819 (8-09)
Total Pages : 643

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

SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE MACHINE
Procedure For Jackstand Placement On The Axle
Procedure For Jackstand Placement On The Frame
LIFT ARM SUPPORT DEVICE
Installing The Lift Arm Support Device
Removing the Lift Arm Support Device
CARGO BOX SUPPORT DEVICE
Installing The Cargo Box Support Device
Removing the Cargo Box Support Device
OPERATOR CAB
Description
TRANSPORTING THE TOOLCAT
Loading Onto Transport Vehicle
Fastening To Transport Vehicle
TOWING THE Machine
Procedure
REMOTE START
Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Elements
ENGINE COOLING SYSTEM
Checking The Coolant Level
Cleaning The Cooling System
Removing & Replacing Coolant
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Fuel Filter
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Oil Chart
Replacing The Oil And Filter
HYDRAULIC / HYDROSTATIC SYSTEM
Checking And Adding Fluid
Replacing Hydraulic/Hydrostatic Filter
Replacing Hydraulic Fluid
Hydraulic Fluid Chart
Reservoir Breather
AXLE/DIFFERENTIAL (FRONT & REAR)
Checking And Adding Lubricant
Replacing Lubricant
BOB-TACH
Inspection And Maintenance
LUBRICATION
Lubrication Locations
TIRE MAINTENANCE
Wheel Nuts
Tire Rotation
Mounting
SPARK ARRESTOR MUFFLER
Maintenance

HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary
Tighten Procedures
Troubleshooting Chart
CYLINDER (LIFT)
Checking
Removal And Installation
Identification
Disassembly
Assembly
CYLINDER (TILT)
Checking
Removal And Installation
Identification
Disassembly
Assembly
CYLINDER (CARGO BOX)
Checking (Left Side Cylinder)
Checking (Right Side Cylinder)
Removal And Installation
Identification
Disassembly
Assembly
MAIN RELIEF VALVE
Auxiliary Main Relief Valve Checking
Auxiliary Main Relief Valve Removal And Installation
Lift, Tilt And Cargo Box Main Relief Valve Checking
Lift, Tilt And Cargo Box Main Relief Valve Removal And Installation
PORT RELIEFS
Checking The Port Relief Valve (Lift)
Checking The Port Relief Valves (Tilt)
CONTROL VALVE
Removal And Installation
Identification Chart
Main Relief Valve Removal And Installation
Lift Section Disassembly And Assembly
Tilt Section Disassembly And Assembly
Box Section Disassembly And Assembly
High Flow Section Main Relief Valve Disassembly And Assembly
High Flow Manual Override Button
High Flow Solenoid Removal And Installation
Auxiliary Section Disassembly And Assembly
Load Check Valve Removal And Installation
Control Valve Disassembly And Assembly
STEERING SELECTOR VALVE
Removal And Installation
Disassembly and Assembly
POWER STEERING PUMP
Removal and Installation
Disassembly and Assembly
PILOT VALVE
Removal And Installation
Disassembly And Assembly
LIFT ARM BYPASS CONTROL VALVE
Inspecting
Removal And Installation
Disassembly And Assembly
HYDRAULIC PUMP
Checking The Auxiliary Section Of The Hydraulic Pump
Checking the Lift, Tilt And Cargo Box Section Of The Hydraulic Pump
Checking The Steering And Cooling Fan Section Of The Hydraulic Pump
Removal And Installation
Load Sense Disassembly And Assembly
Disassembly And Assembly
HYDRAULIC/HYDROSTATIC FILTER
Housing Removal and Installation
CONTROL LEVER (JOYSTICK)
Joystick Handle Removal And Installation
Joystick Removal And Installation
Joystick Disassembly and Assembly
HYDRAULIC FLUID RESERVOIR
Removal and Installation
AUXILIARY HYDRAULIC COUPLER BLOCK
Removal And Installation (Front)
Removal And Installation (Rear)
Disassembly And Assembly
REMOTE HYDRAULICS DIVERTER VALVE
Removal And Installation
Disassembly And Assembly
PTO HYDRAULIC MOTOR
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
REAR AUXILIARY DIVERTER VALVE
Removal And Installation
Disassembly And Assembly

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
Replenishing Valve Function
HYDROSTATIC MOTOR
Removal And Installation (Front Axle)
Removal And Installation (Rear Axle)
Disassembly
Assembly
CHARGE PRESSURE
Checking Charge Pressure
HYDROSTATIC PUMP
Removal and Installation
Directional Control Valve Removal and Installation
PWM Control Valve Removal and Installation
Replenishing/High Pressure Relief Valve
Charge Relief Valve
Disassembly
Inspection
Assembly
Hydrostatic Pump Start-Up
Neutral Adjustment
DRIVE BELT
Shield Removal And Installation
Adjusting
Drive Belt Replacement
Tensioner Pulley Removal And Installation
Tensioner Pulley Parts Identification
Tensioner Pulley Disassembly
Tensioner Pulley Assembly
OIL COOLER
Removal And Installation

DRIVE SYSTEM
BRAKE
Disassembly & Assembly (Front Axle)
Disassembly & Assembly (Rear Axle)
AXLE
Front Axle Brush Guard Removal And Installation
Front Axle Removal And Installation
Rear Axle Removal And Installation
Disconnecting 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
Connecting The Axle Housings
AXLE HUB WITH AXLE SHAFT
Removal And Installation (Without Wheel Position Sensor)
Removal (With Wheel Position Sensor)
Inspection
Installation (With Wheel Position Sensor)
AXLE HUB WITHOUT AXLE SHAFT
Removal And Installation (Without Wheel Position Sensor)
Removal (With Wheel Position Sensor)
Bearing Pivot Inspection
Installation (With Wheel Position Sensor)
Disassembly
Axle Hub Inspection
Assembly
Torque Check Procedure
TIE ROD
Removal And Installation (Front Axle)
Removal And Installation (Rear Axle)
Adjusting
AXLE SHAFT
Removal and Installation

MAIN FRAME
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
Cushion Removal And Installation
Back 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
Removal and Installation
Bob-Tach Lever and Wedge
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
TRAVEL AND BRAKE PEDALS
Removal And Installation
Travel Speed Pedal Disassembly and Assembly
SHOCKS
Removal And Installation
TRAILING ARMS
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
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

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
Description
Fuse Location
Solenoid Test
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
ALTERNATOR (90 AMP)
Adjusting The Alternator Belt
Alternator Identification
Charging System Check
Alternator Voltage Test
Low Voltage Test
High Voltage Test
Removal And Installation
Rectifier Continuity (Diode) Test
Alternator Regulator Test
Disassembly
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Assembly
STARTER
Checking
Removal And Installation
Parts Identification
Disassembly and Assembly
Inspection And Repair
No Load Test
INSTRUMENT PANEL
Display Controller Panel
Switch Panel
Center Console
Display Controller Panel Removal And Installation
Light Bulb Removal And Installation
LIGHTS
Front Removal And Installation
DISPLAY CONTROLLER
Identification Chart
Removal And Installation
DRIVE CONTROLLER
Identification Chart
Removal And Installation
DIAGNOSTICS SERVICE CODES
Display
Number Codes List
TICS SYSTEM
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
Removal And Installation
WHEEL SPEED SENSOR
Removal and Installation (Front Axle)
Removal and Installation (Rear Axle)
WHEEL POSITION SENSOR
Removal and Installation (Front Axle)
Removal and Installation (Rear Axle)
CALIBRATION
Travel Pedal
Brake Pedal
Pump
Wheel Alignment Calibration
SERVICE PC (LAPTOP COMPUTER)
Connecting The Service PC To Remote Start Tool
TRAVEL DIRECTION CONTROL LEVER
Removal And Installation
RPM SENSOR
Adjustment

ENGINE SERVICE
TROUBLESHOOTING
Chart
ENGINE SPEED CONTROL
Removal And Installation
MUFFLER
Removal and Installation
AIR CLEANER
Removal and Installation
RADIATOR
Removal And Installation
COOLING FAN
Removal And Installation
Proportional Valve Disassembly and Assembly
ENGINE COMPONENTS AND TESTING
Compression Checking
Glow Plugs Checking
Glow Plugs Removal And Installation
Fuel Shut-Off Solenoid, Checking
Fuel Shut-Off Solenoid Removal And Installation
Fuel Injection Pump Removal And Installation
Timing The Injection Pump
Fuel Injector Removal And Installation
Checking Nozzle Injection Pressure
Nozzle Spraying Condition
Valve Seat Tightness
Valve Clearance Adjustment
Valve Timing, Checking
ENGINE
Removal And Installation
Engine Mount Replacement
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Housing Removal And Installation
RECONDITIONING THE ENGINE-V2203-M-DI AND V2003-M-DI-T (TURBO)
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
Rocker Arm And Shaft Checking
Timing Gearcase Cover Removal And Installation
Idler Gear And Camshaft Removal And Installation
Camshaft Servicing
Idler Gear And Shaft Servicing
Timing Gears Checking Backlash
Fuel Camshaft Removal And Installation
Fuel Camshaft Governor
Crankshaft Gear Removal And Installation
Oil Pump Removal And Installation
Oil Pump Service
Checking Engine Oil Pressure
Valve Tappets
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod Servicing
Connecting Rod Alignment
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings, Servicing
Cylinder Bore, Checking
Water Pump Removal And Installation
Water Pump Disassembly And Assembly
TURBOCHARGER
Checking
Description
Removal And Installation

HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW
Principals
Chart
COMPONENTS
Identification
SAFETY
Safety Equipment
REGULAR MAINTENANCE
Filter Elements Removal And Installation
Cleaning The Condenser
GENERAL AIR CONDITIONING SERVICE GUIDELINES
Compressor Oil
Compressor Oil Check
Component Replacement And Refrigeration Leaks
SYSTEM TROUBLESHOOTING
Checking A/C Performance
Gauge Pressure Related Troubleshooting
Troubleshooting Tree
TEMPERATURE / PRESSURE
Chart
AIR CONDITIONING SERVICE
Chart
SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
Charging Procedure With A Manifold Gauge Set
COMPRESSOR
Removal And Installation
Compressor Clutch Disassembly
CONDENSER
Removal And Installation
RECEIVER/DRIER
Removal And Installation
Pressure Switch Removal And Installation
Pressure Relief Valve Removal And Installation
EVAPORATOR/HEATER UNIT
Removal And Installation
THERMOSTAT
Removal And Installation
EXPANSION VALVE
Removal And Installation
HEATER/AC FAN
Removal And Installation
HEATER VALVE
Removal And Installation
Disassembly And Assembly

SPECIFICATIONS
UTILITY WORK MACHINE SPECIFICATIONS
Dimensional Specifications
Performance
Controls
Engine
Hydraulic System
Electrical
Drive System
Capacities
Tires
ENGINE SPECIFICATIONS-KUBOTA V2203-M-DI
Fuel Injection Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Valve Timing
Rocker Arms
Camshaft
Tappet
Cylinders
Piston Rings
Pistons
Connecting Rod
Oil Pump
Crankshaft
Timing Gear
Thermostat
ENGINE SPECIFICATIONS – KUBOTA V2003-M-DI-T (TURBO)
Fuel Injection Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Valve Timing
Rocker Arms
Camshaft
Tappet
Cylinder Liner
Piston Rings
Pistons
Connecting Rod
Oil Pump
Crankshaft
Timing Gear
Thermostat
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
Torque For Kubota 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 Equivalents
U.S. To Metric Conversion

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

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