Bobcat Toolcat 5600 Utility work machine Service Manual
643 pages · Publication 6902819_8_09
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- Models
- Toolcat 5600
- Serial coverage
- SN 424711001 & above, SN 424811001 & above
- Manual type
- Service Manual
- Pages
- 643
- Publication
- 6902819_8_09
- Condition
- Brand new
What's inside
From the manual's own table of contents: 22 sections, 543 entries. See sample pages (PDF, 421 KB)
MAINTENANCE SAFETY
ALPHABETICAL INDEX
FOREWORD16 topics
- 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 MACHINE53 topics
- 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 SCHEMATICS88 topics
- 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 INFORMATION30 topics
- 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
BRAKE36 topics
- 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 CAB52 topics
- 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
- 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 SCHEMATICS74 topics
- 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
TROUBLESHOOTING66 topics
- 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 FLOW44 topics
- 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 SPECIFICATIONS62 topics
- 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
Inside this manual
Real pages from this service manual (643 pages). Open the sample pages (PDF, 420 KB)
- Troubleshooting, page 199: HYDROSTATIC SYSTEM INFORMATION
- Diagram, page 460: SERVICE PC (LAPTOP COMPUTER)
- Specifications, page 613: ENGINE SPECIFICATIONS-KUBOTA V2203-M-DI
- Foldout diagram: BATTERY FEED 1000-1999 RED, RED/WHT, RNG
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the Toolcat 5600 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 6902819_8_09$69.87
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 643 pages
Quantity one is the manual described above.
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Other editions and similar models
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