Complete repair service manual with electrical wiring diagrams for Bobcat 2100, 2100S, 2200, 2300, 3200, 3400, 3400XL, 3450, 3650, 5600, 5610, with all the workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Bobcat 2100, 2100S, 2200, 2300, 3200, 3400, 3400XL, 3450, 3650, 5600, 5610 Utility Vehicles workshop service manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

6901891 (6-08) - Toolcat 5600 Operation & Maintenance Manual.pdf
6901892 (5-09) - Toolcat 5600 Service Manual.pdf
6901987 (05-09) - 2100, 2100S Utility Vehicle Service Manual.pdf
6902777 (6-08) - Toolcat 5600 (B Series) Operation & Maintenance Manual.pdf
6902819 (8-09) - Toolcat 5600 Service Manual.pdf
6903129 (12-09) - 2200 Utility Vehicle Service Manual.pdf
6904207 (6-08) - Toolcat 5600 Utility Work Machine Operation & Maintenance Manual.pdf
6904209 (2-10) - Toolcat 5600 Utility Work Machine Service Manual.pdf
6904791 (1-11) - Toolcat 5600 Utility Work Machine Operation & Maintenance Manual.pdf
6904792 (3-11) - Toolcat 5600 Utility Work Machine Service Manual.pdf
6904792 (6-12) - Toolcat 5600 Utility Work Machine Service Manual.pdf
6904893 (12-09) - 2200, 2200S, 2300 Utility Vehicle Service Manual.pdf
6986803 (3-11) - Toolcat 5610 Utility Work Machine Operation & Maintenance Manual.pdf
6986804 (3-11) - Toolcat 5610 Utility Work Machine Service Manual.pdf
6986804 (6-12) - Toolcat 5610 Utility Work Machine Service Manual.pdf
6989597 (2-11) - 3200 Utility Vehicle Operation & Maintenance Manual.pdf
6989598 (9-10) - 3200 Utility Vehicle Service Manual.pdf
6989598 (9-11) - 3200 Utility Vehicle Service Manual.pdf
6989601 (2-11) - 3400, 3400XL Utility Vehicle Operation & Maintenance Manual.pdf
6989602 (9-10) - 3400, 3400XL Utility Vehicle Service Manual.pdf
6989602 (9-11) - 3400, 3400XL Utility Vehicle Service Manual.pdf
6989605 (4-11) - 3400, 3400XL Utility Vehicle Operation & Maintenance Manual.pdf
6989606 (4-11) - 3400, 3400XL Utility Vehicle Service Manual.pdf
6989606 (08-11) - 3400, 3400XL Utility Vehicle Service Manual.pdf
6989609 (4-11) - 3450 Utility Vehicle Operation & Maintenance Manual.pdf
6989610 (4-11) - 3450 Utility Vehicle Service Manual.pdf
6989610 (8-11) - 3450 Utility Vehicle Service Manual.pdf
6990049 (12-10) - Toolcat 5600 Utility Work Machine Operation & Maintenance Manual.pdf
6990050 (3-11) - Toolcat 5600 Utility Work Machine Service Manual.pdf
6990050 (12-13) - Toolcat 5600 Utility Work Machine Service Manual.pdf
6990053 (3-11) - Toolcat 5610 Utility Work Machine Operation & Maintenance Manual.pdf
6990054 (3-11) - Toolcat 5610 Utility Work Machine Service Manual.pdf
6990054 (12-13) - Toolcat 5610 Utility Work Machine Service Manual.pdf
6990367 (04-14) - 3650 Utility Vehicle Service Manual.pdf
6990371 (04-14) - 3600 Utility Vehicle Service Manual.pdf
6990860 (07-14) - Toolcat 5600 Utility Work Machine Service Manual.pdf
6990864 (07-14) - Toolcat 5610 Utility Work Machine Service Manual.pdf

Total Pages: 10,032 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

CONTENTS

6901891 (6-08) - Toolcat 5600 Operation & Maintenance Manual...1
  OPERATOR SAFETY WARNINGS...3
  CONTENTS...5
  FOREWORD...7
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...9
    REGULAR MAINTENANCE ITEMS...9
    MOTOR OIL...9
    SERIAL NUMBER LOCATIONS...10
      Work Machine Serial Number...10
      Engine Serial Number...10
    DELIVERY REPORT...10
    MACHINE IDENTIFICATION...11
    FEATURES AND ACCESSORIES...12
      Standard Items...12
      Options And Field Accessories...12
      Attachments...12
  SAFETY...13
    SAFETY INSTRUCTIONS...15
      Before Operation...15
      Safe Operation Is The Operator’s Responsibility...16
      Safe Operation Needs A Qualified Operator...16
      Avoid Silica Dust...17
    FIRE PREVENTION...17
      Maintenance...17
      Operation...17
      Electrical...17
      Hydraulic System...18
      Fueling...18
      Starting...18
      Spark Arrestor Exhaust System...18
      Welding And Grinding...18
      Fire Extinguishers...18
    MACHINE SIGNS (DECALS)...19
  OPERATING INSTRUCTIONS...21
    OPERATOR CONTROLS AND INSTRUMENTATION...23
      Overview...23
      Switch Panel...23
      Display Controller Panel...24
      Indicator Icons...24
      Center Console...25
    TOOLCAT™ INTERLOCK CONTROL SYSTEM (Tics)...25
      TICS Operation...25
    TRAVEL DIRECTION CONTROL LEVER...26
      Operation...26
      Two Speed Control...26
    DRIVE PEDAL...26
      Operation...26
    BRAKE PEDAL...26
      Operation...26
    ENGINE SPEED CONTROL...27
      Operation...27
    PARKING BRAKE...27
      Operation...27
    STEERING...28
      Operation...28
      Steering Mode Selection...28
    WHEEL ALIGNMENT...29
      Procedure...29
    STOPPING THE WORK MACHINE...29
      Procedure...29
    DIFFERENTIAL LOCK...30
      Engaging the Differential Lock...30
    HYDRAULIC CONTROLS...31
      Joystick...31
      Lift Arm Operation...31
      Lift Arm Float Position...31
      Tilt Operation...31
      Auxiliary Hydraulics...31
      Quick Couplers...31
      Relieving Hydraulic Pressure (Work Machine and Attachment)...32
      Auxiliary Hydraulics Operation...32
      Auxiliary Hydraulics Continuous Operation...32
    DAILY INSPECTION...33
      Daily Inspection and Maintenance...33
    GETTING READY FOR OPERATION...34
    PRE STARTING PROCEDURE...35
    STARTING THE ENGINE...36
      Normal Starting...36
      Keyless Start...36
      Cold Temperature Starting...37
      Warming The Hydraulic/Hydrostatic System...37
    LEAVING THE WORK MACHINE...38
      Procedure...38
    MACHINE LOAD CAPACITIES...39
      Loader Rated Operating Capacity (ROC)...39
      Maximum Cargo Box Load...39
      Machine Rated Capacity...39
      Maximum Trailer Hitch Tongue Weight...39
      Total Rated Capacity...39
    ATTACHMENTS AND BUCKETS...40
      Choosing The Correct Bucket...40
      Pallet Forks...41
      Using Grapples...41
      Installing The Bucket or Attachment...42
      Removing The Bucket Or Attachment...43
    OPERATING PROCEDURE...44
      Operating With A Loaded Bucket & Empty Cargo Box...44
      Operating With An Empty Bucket & Loaded Cargo Box...44
      Filling The Bucket...45
      Emptying the Bucket...45
      Leveling The Ground...45
      Opening The Tailgate...46
      Raising And Lowering The Cargo Box...46
      Hauling Loads In The Cargo Box...46
      Towing Equipment With The Work Machine...46
    WORK MODE...47
      Operation...47
    PARKING THE WORK MACHINE...47
    TOWING THE WORK MACHINE...48
    TRANSPORTING THE WORK MACHINE...48
      Loading Onto Transport Vehicle...48
      Fastening To Transport Vehicle...48
  PREVENTIVE MAINTENANCE...49
    MAINTENANCE SAFETY...51
    SERVICE SCHEDULE...53
      Chart...53
    LIFT ARM SUPPORT DEVICE...54
      Installing The Lift Arm Support Device...54
      Removing the Lift Arm Support Device...54
    CARGO BOX SUPPORT DEVICE...55
      Installing The Cargo Box Support Device...55
      Removing The Cargo Box Support Device...55
      Raising The Cargo Box When Engine Is Not Running...55
    OPERATOR CAB...56
      Description...56
      Emergency Exit...56
    CAB AIR FILTER...57
      Cleaning And Maintenance...57
      Primary Filters...57
      Secondary Filters...57
    TOOLCAT™ INTERLOCK CONTROL SYSTEM (TICS)...58
      Inspecting The TICS...58
      Maintaining The TICS...58
      Inspecting The Lift Arm By-Pass Control...59
    NEUTRAL START SYSTEM...59
      Inspecting...59
      Maintaining...59
    PARKING BRAKE SYSTEM...60
      Inspecting...60
      Maintaining...60
    SUPPORTING THE MACHINE ON JACKSTANDS...60
    AIR CLEANER SERVICE...61
      Replacing Filter Elements...61
    FUEL SYSTEM...62
      Fuel Specifications...62
      Filling The Fuel Tank...62
      Fuel Filter...62
      Removing Air From The Fuel System...63
      Filling A Portable Fuel Container...63
    ENGINE LUBRICATION SYSTEM...64
      Checking Engine Oil...64
      Replacing The Oil And Filter...64
    ENGINE COOLING SYSTEM...65
      Checking The Coolant Level...65
      Cleaning The Cooling System...66
      Removing And Replacing Coolant...66
    ALTERNATOR BELT...67
      Adjusting The Alternator Belt...67
    ELECTRICAL SYSTEM...68
      Description...68
      Fuse Location & Identification...68
      Using A Booster Battery (Jump Starting)...69
      Removing And Installing The Battery...70
    HYDRAULIC / HYDROSTATIC SYSTEM...71
      Checking And Adding Fluid...71
      Replacing Hydraulic/Hydrostatic Filter...71
      Replacing Hydraulic Fluid...72
      Reservoir Breather...72
    SPARK ARRESTOR MUFFLER...73
      Maintenance...73
    TIRE MAINTENANCE...74
      Wheel Nuts...74
      Tire Rotation...74
      Mounting...74
    AXLE / DIFFERENTIAL (FRONT AND REAR)...75
      Checking And Adding Lubricant...75
      Replacing Lubricant...75
    LUBRICATION...75
      Lubrication Locations...75
    PIVOT PINS...77
      Inspection And Maintenance...77
    BOB-TACH...78
      Inspection And Maintenance...78
  SYSTEM SETUP & ANALYSIS...79
    DIAGNOSTICS SERVICE CODES...81
      Display...81
      Number Codes List...82
    DISPLAY SETUP...84
      Display Selection...84
      Passwords...84
      Password Entry (For Starting And Operating The Machine)...84
      Changing The Operator Password...84
      Password Lockout Feature...85
      Job Clock...85
      RPM...85
  MACHINE SIGN TRANSLATIONS...87
    SERVICE SCHEDULE (6814569)...89
    WARNING (6814304)...91
    WARNING (6814300)...92
    WARNING (6814305)...92
    WARNING (6814301)...93
    WARNING (6815053)...93
    WARNING (6814310)...94
    WARNING (6814307)...94
    WARNING (6814302)...94
  SPECIFICATIONS...95
    WORK MACHINE SPECIFICATIONS...97
      Dimensional Specifications...97
      Performance...98
      Controls...98
      Engine...98
      Hydraulic System...99
      Electrical...99
      Drive System...100
      Capacities...100
      Tires...100
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS...101
  WARRANTY...103
6901892 (5-09) - Toolcat 5600 Service Manual...105
  MAINTENANCE SAFETY...107
  ALPHABETICAL INDEX...109
  CONTENTS...111
    FOREWORD...112
    SAFETY INSTRUCTIONS...115
    FIRE PREVENTION...117
      Maintenance...117
      Operation...117
      Electrical...117
      Hydraulic System...117
      Fueling...117
      Starting...117
      Spark Arrestor Exhaust System...117
      Welding And Grinding...118
      Fire Extinguishers...118
    SERIAL NUMBER LOCATIONS...119
      Work Machine Serial Number...119
      Engine Serial Number...119
    DELIVERY REPORT...119
    BOBCAT UTILITY WORK MACHINE IDENTIFICAITON...120
  SAFETY AND MAINTENANCE...121
    LIFTING AND BLOCKING THE MACHINE...123
      Procedure For Jackstand Placement On The Axle...123
      Procedure For Jackstand Placement On The Frame...124
    LIFT ARM SUPPORT DEVICE...127
      Installing The Lift Arm Support Device...127
      Removing the Lift Arm Support Device...127
    CARGO BOX SUPPORT DEVICE...129
      Installing The Cargo Box Support Device...129
      Removing the Cargo Box Support Device...129
    OPERATOR CAB...131
      Description...131
    TRANSPORTING THE TOOLCAT...133
      Loading Onto Transport Vehicle...133
      Fastening To Transport Vehicle...133
    TOWING THE MACHINE...135
      Procedure...135
    REMOTE START...139
      Procedure...139
    SERVICE SCHEDULE...141
      Chart...141
    AIR CLEANER SERVICE...143
      Replacing Filter Elements...143
    ENGINE COOLING SYSTEM...145
      Checking The Coolant Level...145
      Cleaning The Cooling System...145
      Removing & Replacing Coolant...146
    FUEL SYSTEM...147
      Fuel Specifications...147
      Filling The Fuel Tank...147
      Fuel Filter...147
      Removing Air From The Fuel System...148
    ENGINE LUBRICATION SYSTEM...149
      Checking Engine Oil...149
      Oil Chart...149
      Replacing The Oil And Filter...150
    HYDRAULIC / HYDROSTATIC SYSTEM...151
      Checking And Adding Fluid...151
      Replacing Hydraulic/Hydrostatic Filter...151
      Replacing Hydraulic Fluid...152
      Hydraulic Fluid Chart...152
      Reservoir Breather...152
    AXLE/DIFFERENTIAL (FRONT & REAR)...153
      Checking And Adding Lubricant...153
      Replacing Lubricant...153
    BOB-TACH...155
      Inspection And Maintenance...155
    LUBRICATION...157
      Lubrication Locations...157
    TIRE MAINTENANCE...159
      Wheel Nuts...159
      Tire Rotation...159
      Mounting...159
    SPARK ARRESTOR MUFFLER...161
      Maintenance...161
  HYDRAULIC SYSTEM...163
    HYDRAULIC / HYDROSTATIC SCHEMATICS...165
    HYDRAULIC SYSTEM INFORMATION...167
      Glossary...167
      Tighten Procedures...171
      Troubleshooting Chart...172
    CYLINDER (LIFT)...173
      Checking...173
      Removal And Installation...174
      Parts Identification...176
      Disassembly...177
      Assembly...178
    CYLINDER (TILT)...181
      Checking...181
      Removal And Installation...182
      Parts Identification...184
      Disassembly...185
      Assembly...186
    CYLINDER (CARGO BOX)...189
      Checking (Left Side Cylinder)...189
      Checking (Right Side Cylinder)...190
      Removal And Installation...191
      Parts Identification...192
      Disassembly...193
      Assembly...194
    MAIN RELIEF VALVE...197
      Checking...197
      Adjustment...198
      Removal And Installation...198
    PORT RELIEFS...199
      Checking The Port Relief Valve (Lift)...199
      Checking The Port Relief Valves (Tilt)...200
    WORK VALVE...203
      Removal And Installation...203
      Disassembly and Assembly...205
    STEERING AND CARGO BOX VALVE...211
      Removal And Installation...211
      Disassembly and Assembly...213
    AUXILIARY HYDRAULIC VALVE...219
      Removal And Installation...219
      Disassembly And Assembly...221
    POWER STEERING PUMP...225
      Removal And Installation...225
      Disassembly And Assembly...226
    PILOT VALVE...231
      Removal And Installation...231
      Disassembly And Assembly...233
    LIFT ARM BY-PASS CONTROL VALVE...235
      Inspecting...235
      Removal And Installation...235
      Disassembly And Assembly...236
    HYDRAULIC PUMP...237
      Checking The Auxiliary Section Of The Hydraulic Pump...237
      Checking The Work Group Section Of The Hydraulic Pump...238
      Checking The Steering And Cargo Box Section Of The Hydraulic Pump...239
      Removal And Installation...240
      Disassembly And Assembly...242
    HYDRAULIC/HYDROSTATIC FILTER...247
      Housing Removal And Installation...247
    CONTROL LEVER (JOYSTICK)...249
      Joystick Handle Removal And Installation...249
      Joystick Removal And Installation...252
      Joystick Disassembly and Assembly...254
    HYDRAULIC FLUID RESERVOIR...257
      Removal And Installation...257
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK...259
      Removal And Installation...259
      Disassembly And Assembly...259
    REMOTE HYDRAULICS DIVERTER VALVE...261
      Removal And Installation...261
      Disassembly And Assembly...262
  HYDROSTATIC SYSTEM...263
    HYDROSTATIC SYSTEM INFORMATION...265
      Troubleshooting Chart...265
      Replenishing Valve Function...266
    HYDROSTATIC MOTOR...267
      Removal and Installation (Front Axle)...267
      Removal and Installation (Rear Axle)...269
      Disassembly...271
      Assembly...278
    CHARGE PRESSURE...283
      Checking Charge Pressure...283
    HYDROSTATIC PUMP...285
      Removal and Installation...285
      Directional Control Valve Removal and Installation...287
      PWM Control Valve Removal and Installation...288
      Replenishing/High Pressure Relief Valve...289
      Charge Relief Valve...289
      Disassembly...290
      Inspection...298
      Assembly...300
      Hydrostatic Pump Start-Up...309
      Neutral Adjustment...310
    DRIVE BELT...315
      Shield Removal And Installation...315
      Adjusting...316
      Drive Belt Replacement...317
      Tensioner Pulley Removal And Installation...318
      Tensioner Pulley Parts Identification...319
      Tensioner Pulley Disassembly...320
      Tensioner Pulley Assembly...321
    OIL COOLER...323
      Removal and Installation...323
  DRIVE SYSTEM...325
    BRAKE...327
      Disassembly & Assembly (Front Axle)...327
      Disassembly & Assembly (Rear Axle)...327
    AXLE...329
      Front Axle Brush Guard Removal And Installation (S/N 520511246 & Below)...329
      Front Axle Brush Guard Removal And Installation (S/N 520511247 & Above)...330
      Front Axle Removal And Installation...331
      Rear Axle Removal And Installation...335
      Disconnecting The Axle Housings...339
      Primary Housing Disassembly...342
      Steering Cylinder Disassembly...344
      Brake Disassembly...347
      Secondary Housing And Differential Lock Disassembly...349
      Secondary Housing And Differential Lock Assembly...351
      Steering Cylinder Assembly...352
      Primary Housing Assembly...355
      Brake Assembly...356
      Connecting The Axle Housings...358
    AXLE HUB WITH AXLE SHAFT...361
      Removal And Installation (Without Wheel Position Sensor)...361
      Removal (With Wheel Position Sensor)...364
      Inspection...366
      Installation (With Wheel Position Sensor)...368
    AXLE HUB WITHOUT AXLE SHAFT...371
      Removal And Installation (Without Wheel Position Sensor)...371
      Removal (With Wheel Position Sensor)...376
      Bearing Pivot Inspection...379
      Installation (With Wheel Position Sensor)...381
      Disassembly...386
      Axle Hub Inspection...387
      Assembly...388
      Torque Check Procedure...391
    TIE ROD...393
      Removal And Installation (Front Axle)...393
      Removal And Installation (Rear Axle)...395
      Adjusting...397
    AXLE SHAFT...399
      Removal and Installation...399
  MAIN FRAME...401
    OPERATOR CAB...403
      Removal And Installation...403
    OPERATOR SEAT...409
      Removal And Installation...409
      Seat Belt Removal And Installation...410
      Seat Pan Removal And Installation...411
      Slide Rail Removal And Installation...412
      Cushion Removal And Installation...412
      Back Removal And Installation...413
      Arm Rest Bracket Removal And Installation...413
      Arm Rest Removal And Installation...414
      Shock Removal And Installation...414
    PASSENGER SEAT...415
      Removal And Installation...415
      Seat Belt Removal And Installation...415
      Seat Pan Removal And Installation...416
      Arm Rest Removal And Installation...417
    BOB-TACH...419
      Removal and Installation...419
      Bob-Tach Lever and Wedge...420
    LIFT ARM...421
      Removal and Installation...421
    CARGO BOX...423
      Removal and Installation...423
    STEERING COLUMN...425
      Removal And Installation...425
    FUEL TANK...427
      Removal and Installation...427
    TRAVEL AND BRAKE PEDALS...429
      Removal And Installation...429
      Travel Speed Pedal Disassembly and Assembly...430
    SHOCKS...431
      Removal And Installation...431
    TRAILING ARMS...433
      Removal And Installation (Upper Arm)...433
      Removal And Installation (Lower Arm)...434
    LEAF SPRINGS...435
      Removal And Installation (Left Side)...435
      Removal and Installation (Right Side)...437
    HITCH...439
      Removal And Installation...439
    FLOOR CONSOLE...441
      Removal And Installation...441
    CENTER CONSOLE...443
      Removal And Installation...443
    FENDER (FRONT LEFT)...445
      Removal And Installation...445
    FENDER (FRONT RIGHT)...447
      Removal And Installation...447
    FENDER (REAR LEFT)...449
      Removal And Installation...449
    FENDER (REAR RIGHT)...451
      Removal And Installation...451
  ELECTRICAL SYSTEM & ANALYSIS...453
    ELECTRICAL SCHEMATICS...455
    ELECTRICAL SYSTEM INFORMATION...459
      Troubleshooting Chart...461
      Description...462
      Fuse Location...462
      Solenoid Test...464
    BATTERY...465
      Removal And Installation...465
      Servicing...466
      Using A Booster Battery (Jump Starting)...467
    ALTERNATOR (90 AMP)...469
      Adjusting The Alternator Belt...469
      Alternator Identification...469
      Charging System Check...470
      Alternator Voltage Test...471
      Low Voltage Test...472
      High Voltage Test...472
      Removal And Installation...473
      Rectifier Continuity (Diode) Test...475
      Alternator Regulator Test...476
      Disassembly...477
      Stator Continuity Test...477
      Stator Ground Test...478
      Rotor Continuity Test...478
      Rotor Ground Test...478
      Assembly...478
    STARTER...479
      Checking...479
      Removal And Installation...480
      Parts Identification...481
      Disassembly and Assembly...482
      Inspection And Repair...485
      No Load Test...487
    INSTRUMENT PANEL...489
      Display Controller Panel...489
      Switch Panel...490
      Center Console...490
      Display Controller Panel Removal And Installation...491
      Center Console Removal And Installation...492
      Light Bulb Removal And Installation...493
    LIGHTS...495
      Front Removal And Installation...495
    DISPLAY CONTROLLER...497
      Identification Chart...497
      Removal And Installation...498
    DRIVE CONTROLLER...499
      Identification Chart...499
      Removal And Installation...500
    DIAGNOSTICS...501
      Service Codes...501
    TICS SYSTEM...505
      Inspecting the TICS System (Engine STOPPED - Key ON)...505
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...505
      Inspecting The Arm Rest Sensor (Engine RUNNING)...505
      Inspecting The Traction Lock (Engine RUNNING)...505
      Inspecting The Lift Arm By-Pass Control...505
    ARM REST SENSOR...507
      Removal And Installation...507
    WHEEL SPEED SENSOR...509
      Removal and Installation (Front Axle)...509
      Removal and Installation (Rear Axle)...511
    WHEEL POSITION SENSOR...513
      Removal and Installation (Front Axle)...513
      Removal and Installation (Rear Axle)...518
    CALIBRATION...523
      Travel Pedal...523
      Brake Pedal...523
      Calibration for the brake pedal is complete...524
      Pump...524
      Wheel Alignment Calibration...525
    SERVICE PC (LAPTOP COMPUTER)...527
      Connecting The Service PC To Remote Start Tool...527
    TRAVEL DIRECTION CONTROL LEVER...529
      Removal And Installation...529
  ENGINE SERVICE...531
    TROUBLESHOOTING...533
      Chart...533
    ENGINE SPEED CONTROL...535
      Removal And Installation...535
    MUFFLER...537
      Removal and Installation...537
    AIR CLEANER...539
      Removal and Installation...539
    RADIATOR...541
      Removal And Installation...541
    COOLING FAN...545
      Removal And Installation...545
      Fan Motor Disassembly and Assembly...548
    ENGINE COMPONENTS AND TESTING...551
      Compression Checking...551
      Glow Plugs Checking...552
      Glow Plugs Removal And Installation...553
      Fuel Shut-Off Solenoid Checking...554
      Fuel Shut-Off Solenoid Adjusting...554
      Fuel Shut-Off Solenoid Removal And Installation...554
      Checking...555
      Fuel Injection Pump Removal And Installation...556
      Timing The Injection Pump...559
      Fuel Injector Removal And Installation...561
      Fuel Injector Checking...562
      Fuel Injector Disassembly...563
      Fuel Injector Assembly...563
      Valve Clearance Adjustment...564
      Rocker Arm And Shaft Checking...565
      Valve Timing Checking...565
    ENGINE...567
      Removal And Installation...567
      Engine Mount Replacement...577
    FLYWHEEL AND HOUSING...579
      Flywheel Removal And Installation...579
      Ring Gear Removal And Installation...579
      Housing Removal And Installation...580
    RPM SENSOR...581
      Adjustment...581
    RECONDITIONING THE ENGINE...583
      Cylinder Head Removal And Installation...583
      Cylinder Head Disassembly And Assembly...584
      Cylinder Head Servicing...585
      Cylinder Head Top Clearance...585
      Checking The Valve Guide...586
      Reconditioning The Valve And Valve Seat...587
      Valve Spring...588
      Rocker Arm And Shaft Checking...589
      Timing Gearcase Cover Removal And Installation...589
      Idler Gear And Camshaft Removal And Installation...592
      Servicing The Camshaft...593
      Servicing The Idler Gear And Shaft...594
      Timing Gears Checking Backlash...595
      Fuel Camshaft Removal And Installation...596
      Fuel Camshaft Governor...596
      Crankshaft Gear Removal And Installation...597
      Oil Pump Removal And Installation...597
      Oil Pump Service...598
      Checking Engine Oil Pressure...599
      Relief Valve...599
      Piston And Connecting Rod Removal And Installation...600
      Servicing The Piston And Connecting Rod...601
      Connecting Rod Alignment...604
      Crankshaft And Bearings Removal And Installation...604
      Servicing The Crankshaft And Bearings...606
      Checking The Cylinder Bore...609
      Water Pump Disassembly And Assembly...610
  HEATING, VENTILATION, AIR CONDITIONING...611
    AIR CONDITIONING SYSTEM FLOW...614
      Principals...614
      Chart...615
    COMPONENTS...617
      Identification...617
    SAFETY...621
      Safety Equipment...621
    REGULAR MAINTENANCE...623
      Filter Elements Removal And Installation...623
      Cleaning The Condenser...624
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...625
      Compressor Oil...625
      Compressor Oil Check...626
      Component Replacement And Refrigeration Leaks...627
    SYSTEM TROUBLESHOOTING...629
      Checking A/C Performance...629
      Gauge Pressure Related Troubleshooting...631
      Troubleshooting Tree...633
    TEMPERATURE/PRESSURE...637
      Chart...637
    AIR CONDITIONING SERVICE...639
      Chart...639
    SYSTEM CHARGING AND RECLAMATION...641
      Reclamation Procedure...641
      Charging Procedure With A Manifold Gauge Set...644
    COMPRESSOR...647
      Removal And Installation...647
      Compressor Clutch Disassembly...648
    CONDENSER...653
      Removal And Installation...653
    RECEIVER/DRIER...655
      Removal And Installation...655
      Pressure Switch Removal And Installation...655
      Pressure Relief Valve Removal And Installation...656
    EVAPORATOR/HEATER UNIT...657
      Removal And Installation...657
    THERMOSTAT...659
      Removal And Installation...659
    EXPANSION VALVE...661
      Removal And Installation...661
    HEATER/AC FAN...663
      Removal And Installation...663
    HEATER VALVE...665
      Removal And Installation...665
      Disassembly And Assembly...665
  SPECIFICATIONS...667
    UTILITY WORK MACHINE SPECIFICATIONS...669
      Dimensional Specifications...669
      Performance...670
      Controls...670
      Engine...670
      Hydraulic System...671
      Electrical...671
      Drive System...672
      Capacities...672
      Tires...672
    ENGINE SPECIFICATIONS...673
      Fuel Injection Nozzles...673
      Fuel Injection Pump...673
      Cylinder Head...673
      Valves...673
      Valve Springs...673
      Valve Timing...674
      Rocker Arms...674
      Camshaft...674
      Tappet...674
      Cylinders...674
      Piston Rings...675
      Pistons...675
      Connecting Rod...675
      Oil Pump...675
      Crankshaft...676
      Timing Gear...676
      Thermostat...676
      Crankshaft Re-Grind Data...677
    TORQUE SPECIFICATIONS FOR BOLTS...679
      Torque For General SAE Bolts...679
      Torque For General Metric Bolts...680
      Torque For Kubota Metric Bolts...680
    HYDRAULIC CONNECTION SPECIFICATIONS...681
      O-ring Face Seal Connection...681
      Straight Thread O-ring Fitting...682
      Tubelines And Hoses...682
      Flare Fitting...682
      O-ring Flare Fitting...683
      Port Seal Fitting...685
      Quick-Lok™ Fitting...686
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...687
      Specifications...687
    CONVERSIONS...689
      Decimal And Millimeter Equivalents...689
      U.S. To Metric Conversion...690
  SERVICE MANUAL REVISION...691
    Revision No: 5600 - 1...691
    Revision No: 5600 - 2...693
    Revision No: 5600 - 3...695
    Revision No: 5600 - 4...697
    Revision No: 5600 - 5...699
    Revision No: 5600 - 6...701
    Revision No: 5600 - 7...703
    Revision No: 5600 - 8...705
6901987 (05-09) - 2100, 2100S Utility Vehicle Service Manual...707
  Section 1 - Safety...721
  General Warning...721
  Section 2 - Vehicle Specifications...725
  Section 3 - General Information...727
  General Information...727
  Serial Number Identification...727
  Storage...728
    Preparing the Vehicle for Extended Storage...728
    To Return Vehicle to Service...728
  Section 4 - Body and Trim...731
  Cleaning the Vehicle...731
  Front Body Repair...731
    Abrasions and Haze...731
    Light Scratches...732
    Large Scratches and Abrasions...732
  Front Body Components...732
    Dashboard Removal...732
    Dashboard Installation...732
    Front Body Removal...733
    Front Fender Removal...733
    Front Fender Installation...734
    Front Body Installation...734
  Seat...734
    Seat Adjustment...734
  Front Seat Support...736
    Front Seat Support Removal...736
    Front Seat Support Installation...737
  Rear Seat Support...737
    Rear Seat Support Removal...737
    Rear Seat Support Installation...737
  Cargo Bed...739
    Cargo Bed Removal...739
    Cargo Bed Installation...739
    Bed Stop Bumper Adjustment...741
  Rear Fender...742
    Rear Fender Removal...742
    Rear Fender Installation...742
  Tailskirt...742
    Tailskirt Removal...742
    Tailskirt Installation...742
  Receiver Hitch...742
    Receiver Hitch Removal...742
    Receiver Hitch Installation...743
  Floor Mat...744
    Floor Mat Removal...744
    Floor Mat Installation...744
  Section 5 - Accelerator and Brake Pedal Assemblies...745
  Brake Pedal...745
    Brake Pedal Removal...745
    Brake Pedal Installation...745
  Brake Pedal Adjustment...746
  Accelerator Pedal...748
    Accelerator Pedal Removal...748
    Accelerator Pedal Installation...749
  Accelerator Pedal Adjustment...749
  Section 6 - MC012C-AS00 Transaxle: Hydraulic and Park Brake Systems...753
  Brake System Inspection...753
  Brake System Troubleshooting...755
  Brake Drum Removal...758
    Front Wheel Brake Drum Removal...758
    Rear Wheel Brake Drum Removal...760
  Brake Shoe Removal...760
    Front Brake Shoe Removal...760
    Rear Brake Shoe Removal...761
  Brake Cluster Inspection and Cleaning...762
  Brake Shoe Installation...763
    Front Brake Shoe Installation...764
    Rear Brake Shoe Installation...764
  Brake Drum Installation...766
    Front Wheel Brake Drum Installation...766
    Rear Wheel Brake Drum Installation...768
  Brake Cluster Assembly Replacement...769
    Front Brake Cluster Assembly Removal...769
    Front Brake Cluster Assembly Installation...769
    Rear Brake Cluster Assembly Removal...770
    Rear Brake Cluster Assembly Installation...771
  Wheel Cylinder Replacement...771
    Front Wheel Cylinder Removal...771
    Front Wheel Cylinder Installation...772
    Rear Wheel Cylinder Removal...772
    Rear Wheel Cylinder Installation...772
  Brake Shoe Adjuster Replacement...773
    Front Brake Shoe Adjuster Removal...774
    Front Brake Shoe Adjuster Installation...774
    Rear Brake Shoe Adjuster Removal...774
    Rear Brake Shoe Adjuster Installation...774
  Hydraulic Line and Hose Replacement...775
    Front Brake Line Removal...775
    Front Brake Line Installation...775
    Front Brake Hose Assembly Removal...776
    Front Brake Hose Assembly Installation...776
    Rear Brake Line Removal...776
    Rear Brake Line Installation...778
    Rear Brake Hose Removal...778
    Rear Brake Hose Installation...779
  Master Cylinder And Bell Crank Replacement...779
    Bell Crank Removal...779
    Bell Crank Installation...779
    Master Cylinder Removal...781
    Master Cylinder Installation...781
  Bleeding the Hydraulic Brake System...783
    Purging the Hydraulic System...784
    Filling the Hydraulic System...784
  Park Brake System...785
    Park Brake Cable Removal...785
    Park Brake Cable Installation...786
    Park Brake Handle Removal...787
    Park Brake Handle Installation...787
    Park Brake Adjustment...787
  Section 7 - Steering and Front Suspension...791
  Steering Wheel...791
    Steering Wheel Removal...791
    Steering Wheel Installation...793
  Steering Column...793
    Steering Column Removal...793
    Steering Column Disassembly...793
    Steering Column Assembly...794
    Steering Column Installation...794
  Rack and Pinion...795
    Rack and Pinion Removal...795
    Rack and Pinion Disassembly...796
    Rack and Pinion Assembly...799
    Rack and Pinion Installation...800
  Front Suspension...802
    Lubrication...802
    Wheel Alignment...802
  Front Suspension Components...804
    Kingpin and Steering Spindle Removal...804
    Kingpin and Steering Spindle Installation...804
    A-Arm Removal...805
    A-Arm Installation...807
    Shock Absorber Removal...807
    Shock Absorber Installation...808
  Front Wheel Bearings and Hubs...808
    Front Wheel Free Play Inspection...808
    Front Wheel Bearings and Hub Removal...809
    Front Wheel Bearings and Hub Installation...809
  Section 8 - Wheels and Tires...811
  General Information...811
  Section 9 - Rear Suspension...813
  Shock Absorbers...813
    Shock Absorber Removal and Inspection...813
    Shock Absorber Installation...813
  Multi-Leaf Springs...813
    Multi-Leaf Spring Removal...813
    Multi-Leaf Spring Installation...815
  Snubber...816
    Snubber Removal...816
    Snubber Installation...816
  Section 10 - Periodic Maintenance...817
  Periodic Service Schedule...817
  Periodic Lubrication Schedule...818
  Master Cylinder...819
    Brake Fluid...820
  Engine Oil...820
    Engine Oil Level Check...820
    Engine Oil and Filter Change...821
    Oil Viscosity...823
  Fueling Instructions...823
  Battery...824
  Section 11 - Troubleshooting and Electrical System: FE400 Engine...827
  Troubleshooting Guide...827
  Electrical System...831
  Wiring Diagram...832
  Electrical Circuits...834
    Starter Circuit...834
    Generator Circuit...834
    Engine Ignition Circuit...835
    Engine Kill Circuit...835
    Reverse Buzzer Circuit...836
    Low Oil Warning Circuit...836
    Lockout Cam Circuit...838
    Fuel Gauge and Sending Unit Circuit...839
    Hour Meter Circuit...840
    Lighting Circuit...840
  Circuit Testing...840
    Testing the Starter Circuit and Generator Circuit...841
    Testing the Engine Ignition Circuit...842
    Testing the Engine Kill Circuit...842
    Testing the Reverse Buzzer Circuit...843
    Testing the Low Oil Warning Circuit...844
    Testing the Lockout Cam Circuit...845
    Testing the Fuel Gauge and Sending Unit Circuit...845
    Testing the Lighting Circuit...846
  Test Procedures...846
    Index of Test Procedures...846
  Section 12 - Electrical Components: FE400 Engine...875
  Starter/Generator...875
  Voltage Regulator...885
  Diode...886
  Key Switch...888
  Solenoid...889
  Fuse...889
  Lockout Cam Limit Switch...891
  Lockout Cam...891
  Reverse Warning Buzzer...892
  Reverse Buzzer Limit Switch...893
  Low Oil Warning Light...894
  Fuel Gauge/Hour Meter...895
  Fuel Level Sending Unit...896
  RPM Limiter...896
  Ignition Coil...897
  Oil Level Sensor...900
  Headlights...900
  Headlight Diode...901
  Light Switch...902
    Testing the Light Switch...902
  Battery...902
    General Information...903
  Ground Straps...907
  Section 13 - FE400 Engine...909
  General Information...909
    Before Servicing...909
    Lubrication System...909
    Spark Plug...909
  Cylinder...911
    Breather Valve (Reed Valve)...911
    Valve Clearance Check and Adjustment...911
  Crankcase...911
    Engine Removal...911
    Crankcase Cover Removal...912
    Oil Level Sensor...913
  Ignition Coil and Flywheel...914
    Crankcase Cover Installation...915
  Flywheel Installation...915
  Engine Installation...916
    Torque Specifications...917
    Adjustment and Settings...917
  Section 14 - Fuel System...919
  General Information...919
  Carburetor...919
    Main Jet Elevation/Size Chart...919
    Changing the Main Jet...920
  Engine Control Linkage...923
    General Information...923
    Accelerator Rod...924
    Governor Cable...925
    Accelerator Cable...926
    Closed Throttle or Idle Adjustment...928
    Engine RPM Adjustment...928
  Choke and Air Intake System...929
    Choke Cable Removal...929
    Choke Cable Installation...929
    Air Box Removal...929
    Air Box Installation...930
    Intake Duct Repair...931
    Intake Duct Removal...931
    Intake Duct Installation...933
    Air Filter...934
  Fuel Filters...935
    Fuel Filter Removal...935
    Fuel Filter Installation...935
  Fuel Pump...935
    General Information...935
    Fuel Pump Removal...938
    Fuel Pump Disassembly...938
    Fuel Pump Cleaning and Inspection...938
    Fuel Pump Assembly...939
    Fuel Pump Installation...939
  Fuel Tank...940
    Fuel Tank Removal...940
    Fuel Tank Storage or Disposal...944
    Fuel Tank Installation...944
  Fuel Lines...945
  Fuel Shut-Off Valve...946
  Section 15 - Exhaust System...949
  Muffler...949
    Muffler Removal...949
    Muffler Installation...949
  Section 16 - MC012C-AS00 Unitized Transaxle with Differential Lock...951
  General Information...951
    Lubrication...952
  Axle Shaft...953
    Axle Shaft, Bearing, and Oil Seal Removal...953
    Axle Bearing Removal...955
    Axle Shaft, Bearing, and Oil Seal Installation...955
  Unitized Transaxle Removal...956
  Unitized Transaxle Installation...966
  Forward/Reverse Shifter Cable...974
    Forward/Reverse Shifter Cable Removal...974
    Forward/Reverse Shifter Cable Installation...974
    Forward/Reverse Shifter Cable Adjustment...975
  Differential Lock System...976
    Differential Lock System Inspection...976
    Differential Lock Cable Removal...976
    Differential Lock Cable Installation...977
  Section 17 - Torque Converter...979
  General Information...979
  Troubleshooting...981
  Drive Belt...981
    Drive Belt Removal...981
    Drive Belt Installation...982
  Drive Clutch...982
    Drive Clutch Removal...982
    Drive Clutch Cleaning and Inspection...983
    Drive Clutch Disassembly...984
    Inspection of Drive Clutch Parts...985
    Drive Clutch Assembly...987
    Drive Clutch Installation...990
  Driven Clutch...991
    Driven Clutch Removal...991
    Driven Clutch Disassembly...991
    Driven Clutch Inspection...991
    Driven Clutch Assembly...993
    Driven Clutch Installation...995
  Section 18 - Reconditioning the FE400 Engine...997
  General Information...997
  Special Engine Service Tools Available...997
    Recommended Replacement Parts For Engine Teardown...998
    Before Servicing...998
    Mechanical Systems...998
  Cylinder Components...1000
    Cylinder Head...1000
    General Information...1000
    Cylinder Shroud Removal...1001
    Rocker Arm and Push Rod Removal...1003
    Cylinder Head Removal...1004
    Valve Removal...1004
    Breather Valve (Reed Valve)...1005
    Cylinder Head Cleaning and Inspection...1005
    Valve Guides...1006
    Valve Seats...1007
    Valves...1009
    Rocker Arm and Rocker Shaft inspection...1011
    Push Rod Inspection...1012
    Cylinder Head Installation...1012
    Valve Clearance Check and Adjustment...1013
    Breather Valve (Reed Valve)...1013
    Installation of Remaining Engine Components...1014
  Crankcase Components...1016
    Crankcase Cover Removal...1016
    Camshaft and Hydraulic Lifters...1018
  Piston and Connecting Rod...1020
  Cylinder Block...1022
  Ignition Coil and Flywheel...1024
  Oil Pump...1025
    Oil Pressure Relief Valve...1027
  Crankshaft and Counterbalance...1028
    Counterbalance Weight...1031
    Oil Screen...1034
    Ball Bearing...1034
    Oil Seals...1035
  Crankshaft Axial Play Adjustment...1038
    Crankcase Cover Installation...1040
  Engine Assembly...1041
  Engine Installation...1042
  Service Specifications...1043
    Specifications for Resizing Cylinder Bore...1044
    Torque Specifications...1044
    Adjustment and Settings...1045
  Section 19 - Reconditioning the MC012C- AS00 Unitized Transaxle with Differential Lock...1047
  General Information...1047
  Transaxle Model and Identification...1047
    Lubrication...1048
  Axle Shaft...1049
  Unitized Transaxle Removal...1049
  Unitized Transaxle Disassembly...1051
  Component Disassembly...1053
    Differential Gear Lock Housing Disassembly...1053
    Governor Gear Disassembly...1055
    Differential Gear Case Disassembly...1055
    Shifter Fork Disassembly...1058
    Synchronizer Gear Disassembly...1058
    Intermediate Gear Disassembly...1059
    Idler Shaft Disassembly...1060
  Unitized Transaxle Component Inspection...1061
  Component Assembly...1061
    Idler Shaft Assembly...1061
    Intermediate Gear Assembly...1062
    Synchronizer Gear Assembly...1062
    Shifter Fork Assembly...1064
    Differential Gear Case Assembly...1065
    Governor Gear Assembly...1067
    Differential Gear Lock Housing Assembly...1067
  Unitized Transaxle Assembly...1068
  Unitized Transaxle Installation...1075
    A...1077
      accelerator...1077
      air box...1077
      air filter 14-1...1077
      armature...1077
      axle...1077
    B...1077
      ball bearing...1077
      battery 12-28...1077
      bed, cargo...1077
      belt, drive...1077
      body, front...1077
      brakes...1077
      breather valve (reed valve) 18-9...1078
    C...1078
      camshaft...1078
      camshaft and hydraulic lifter...1078
      carburetor...1078
      cargo bed...1078
      CAUTION...1078
      choke 14-1...1078
      cleaning...1078
      clutch (torque converter) troubleshooting 17-3...1078
      clutch, drive...1078
      clutch, driven...1078
      column, steering...1078
      commutator...1078
      connecting rod...1078
      counterbalance...1078
      counterbalance guide shaft...1078
      counterbalance weight...1078
      crankcase 18-20...1078
      crankshaft...1078
      cylinder block 18-26...1078
      cylinder head 18-4...1078
      cylinder shroud...1078
    D...1078
      DANGER...1078
      dashboard...1078
      differential gear case...1078
      differential lock...1079
      differential lock housing...1079
      diode...1079
      diode, headlight...1079
      drive belt...1079
      drive clutch...1079
      driven clutch...1079
    E...1079
      electrical system...1079
      engine...1079
      engine oil 10-4...1079
      exhaust system 14-1...1079
    F...1079
      fender, front...1079
      fender, rear...1079
      field coil...1079
      fluid, brake 10-4...1079
      flywheel...1079
      forward/reverse...1079
      front body...1079
      fuel filter 14-1...1079
      fuel gauge...1079
      fuel gauge sending unit circuit...1079
      fuel gauge/hour meter...1079
      fuel level sending unit 12-22...1080
      fuel lines 14-1...1080
      fuel pump 14-1, 14-17...1080
      fuel shut-off valve 14-28...1080
      fuel tank...1080
      fueling instructions 10-7...1080
      fuse...1080
    G...1080
      generator circuit...1080
      governor cable...1080
      governor gear...1080
      governor system 16-3, 19-3...1080
      ground straps...1080
    H...1080
      headlight bulb...1080
      headlight diode...1080
      headlight switch...1080
      headlights...1080
      hour meter...1080
      hydraulic lifter...1080
      hydrometer test 11-21...1080
    I...1080
      idler shaft...1080
      ignition...1080
      ignition coil...1080
      inspection...1080
      intake duct...1081
      intermediate gear...1081
    K...1081
      key switch...1081
      kill circuit, engine...1081
      kill wire, engine...1081
    L...1081
      leaf springs, multi 9-1...1081
      lighting circuit...1081
      link rod...1081
      lockout cam...1081
      lockout cam circuit...1081
      low oil warning circuit...1081
      low oil warning light...1081
      lubrication...1081
    M...1081
      maintenance...1081
      master cylinder...1081
      muffler...1081
    N...1081
      neutral lockout 16-3...1081
    O...1081
      oil level sensor...1081
      oil light...1081
      oil pressure relief valve...1081
      oil pump...1081
      oil screen...1081
      oil seal...1081
      oil viscosity 10-7...1081
      oil, engine 10-4...1081
    P...1081
      park brake...1081
      pedal, accelerator...1082
      pedal, brake...1082
      periodic lubrication schedule 10-2...1082
      periodic service schedule 10-1...1082
      piston...1082
      piston and connecting rod...1082
      piston pin...1082
      piston ring...1082
      push rod...1082
    R...1082
      rack and pinion...1082
      receiver hitch...1082
      reed valve...1082
      reverse buzzer...1082
      reverse buzzer circuit...1082
      rocker arm...1082
      rocker arm and push rod...1082
      rocker shaft...1082
      RPM adjustment 14-10...1082
      RPM limiter...1082
    S...1082
      safety...1082
      seat...1082
      serial number, vehicle 3-1...1082
      service schedule...1082
      shifter fork...1082
      shock absorber...1082
      snubber...1082
      solenoid...1082
      spark plug 13-1, 14-1...1082
      specifications...1082
      starter/generator...1082
      starter/generator circuit...1083
      steering...1083
      steering column...1083
      steering wheel...1083
      storage...1083
      suspension, front...1083
      suspension, rear...1083
      synchronizer gear...1083
    T...1083
      test procedure...1083
      test procedures, index of 11-19...1083
      testing...1083
      tire...1084
      torque converter...1084
      torque specifications 18-48...1084
      trailer hitch...1084
      transaxle...1084
      troubleshooting...1084
    U...1084
      unitized transaxle 19-1...1084
    V...1084
      valve (cylinder)...1084
      valve guide...1084
      valve seat...1084
      valves (engine)...1084
      voltage limiter...1084
      voltage regulator...1084
    W...1085
      WARNING...1085
      wheel...1085
      wheel cylinder...1085
      wire continuity testing 11-29...1085
      wiring diagram 11-5...1085
6902777 (6-08) - Toolcat 5600 (B Series) Operation & Maintenance Manual...1089
  OPERATOR SAFETY WARNINGS...1091
  CONTENTS...1093
  FOREWORD...1095
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...1097
    REGULAR MAINTENANCE ITEMS...1097
    MOTOR OIL...1097
    SERIAL NUMBER LOCATIONS...1098
      Work Machine Serial Number...1098
      Engine Serial Number...1098
    DELIVERY REPORT...1098
    MACHINE IDENTIFICATION...1099
    FEATURES AND ACCESSORIES...1100
      Standard Items...1100
      Options And Field Accessories...1100
      Attachments...1100
  SAFETY...1101
    SAFETY INSTRUCTIONS...1103
      Before Operation...1103
      Safe Operation Is The Operator’s Responsibility...1104
      Safe Operation Needs A Qualified Operator...1104
      Avoid Silica Dust...1105
    FIRE PREVENTION...1105
      Maintenance...1105
      Operation...1105
      Electrical...1105
      Hydraulic System...1106
      Fueling...1106
      Starting...1106
      Spark Arrestor Exhaust System...1106
      Welding And Grinding...1106
      Fire Extinguishers...1106
    MACHINE SIGNS (DECALS)...1107
  OPERATING INSTRUCTIONS...1109
    OPERATOR CONTROLS AND INSTRUMENTation...1113
      Overview...1113
      Switch Panel...1113
      Display Controller Panel...1114
      Indicator Icons...1115
      WARNING and SHUTDOWN...1115
      Center Console...1115
    TOOLCAT™ INTERLOCK CONTROL SYSTEM (Tics)...1116
      TICS Operation...1116
    TRAVEL DIRECTION CONTROL LEVER...1116
      Operation...1116
      Two-Speed Control...1116
    DRIVE PEDAL...1117
      Operation...1117
    BRAKE PEDAL...1117
      Operation...1117
    ENGINE SPEED CONTROL...1117
      Operation...1117
    PARKING BRAKE...1117
      Operation...1117
    STEERING...1118
      Operation...1118
      Steering Mode Selection...1118
    WHEEL ALIGNMENT...1119
      Procedure...1119
    STOPPING THE Work Machine...1119
      Procedure...1119
    DIFFERENTIAL LOCK...1119
      Engaging the Differential Lock...1119
    HYDRAULIC CONTROLS...1120
      Joystick...1120
      Lift Arm Operation...1120
      Lift Arm Float Position...1120
      Tilt Operation...1120
      Quick Couplers...1121
      Relieving Hydraulic Pressure (Work Machine and Attachment)...1121
      High Flow Operation (If Equipped)...1121
      Front Auxiliary Hydraulics Operation...1122
      Front Auxiliary Hydraulics Continuous Operation...1122
    REAR AUXILIARY HYDRAULICS (If Equipped)...1123
      Description...1123
      Quick Couplers...1123
      Relieving Hydraulic Pressure (Work Machine and Attachment)...1123
      Operating The Rear Auxiliary Hydraulics...1124
    POWER TAKE-OFF (PTO) (If Equipped)...1125
      PTO Description...1125
      Safety Rules For PTO...1125
      Connecting The PTO Motor...1126
      Connecting The Attachment...1126
      Operating The PTO...1128
      Disconnecting The Attachment...1130
    REMOTE HYDRAULICS (If Equipped)...1131
      Description...1131
      Quick Couplers And Hoses...1131
      Operating the Remote Hydraulics...1133
    DAILY INSPECTION...1134
      Daily Inspection and Maintenance...1134
    GETTING READY FOR OPERATION...1135
    PRE STARTING PROCEDURE...1136
    STARTING THE ENGINE...1136
      Normal Starting...1136
      Keyless Start...1136
    STARTING THE ENGINE (CONT’D)...1137
      Cold Temperature Starting...1137
      Warming The Hydraulic/Hydrostatic System...1137
    LEAVING THE WORK MACHINE...1137
      Procedure...1137
    MACHINE Load CAPACITIES...1138
      Loader Rated Operating Capacity (ROC)...1138
      Maximum Cargo Box Load...1138
      Machine Rated Capacity...1138
      Maximum Trailer Hitch Tongue Weight...1138
      Total Rated Capacity...1138
    ATTACHMENTS AND BUCKETS...1139
      Choosing The Correct Bucket...1139
      Pallet Forks...1139
      Installing The Bucket or Attachment...1140
      Removing The Bucket Or Attachment...1141
    OPERATING PROCEDURE...1142
      Operating With A Loaded Bucket & Empty Cargo Box...1142
      Operating With An Empty Bucket & Loaded Cargo Box...1142
      Filling The Bucket...1143
      Emptying the Bucket...1143
      Leveling The Ground...1143
      Opening The Tailgate...1144
      Raising And Lowering The Cargo Box...1144
      Hauling Loads In The Cargo Box...1144
      Towing Equipment With The Work Machine...1144
    WORK MODE...1145
      Operation...1145
    PARKING THE WORK MACHINE...1145
    tOWING THE WORK MACHINE...1145
    TRANSPORTING THE WORK MACHINE...1146
      Loading Onto Transport Vehicle...1146
      Fastening To Transport Vehicle...1146
  PREVENTIVE MAINTENANCE...1147
    MAINTENANCE SAFETY...1149
    SERVICE SCHEDULE...1151
      Chart...1151
    LIFT ARM SUPPORT DEVICE...1152
      Installing The Lift Arm Support Device...1152
      Removing the Lift Arm Support Device...1152
    CARGO BOX SUPPORT DEVICE...1153
      Installing The Cargo Box Support Device...1153
      Removing The Cargo Box Support Device...1153
      Raising The Cargo Box When Engine Is Not Running...1153
    OPERATOR CAB...1154
      Description...1154
      Emergency Exit...1154
    CAB AIR FILTER...1155
      Cleaning And Maintenance...1155
      Primary Filters...1155
      Secondary Filters...1155
    TOOLCAT™ INTERLOCK CONTROL SYSTEM (TICS)...1156
      Inspecting The TICS...1156
      Maintaining The TICS...1156
      Inspecting The Lift Arm By-Pass Control...1157
    NEUTRAL START SYSTEM...1157
      Inspecting...1157
      Maintaining...1157
    SEAT BELT...1158
      Inspection and Maintenance...1158
    PARKING BRAKE SYSTEM...1159
      Inspecting...1159
      Maintaining...1159
    SUPPORTING THE MACHINE ON JACKSTANDS...1160
    SEATS...1160
      Removal...1160
      Installation...1160
    AIR CLEANER SERVICE...1161
      Replacing Filter Elements...1161
    FUEL SYSTEM...1162
      Fuel Specifications...1162
      Filling The Fuel Tank...1162
      Fuel Filter...1162
      Removing Air From The Fuel System...1163
      Filling A Portable Fuel Container...1164
    ENGINE LUBRICATION SYSTEM...1165
      Checking Engine Oil...1165
      Replacing The Oil And Filter...1165
    ENGINE COOLING SYSTEM...1166
      Checking The Coolant Level...1166
      Cleaning The Cooling System...1167
      Removing And Replacing Coolant...1167
    ALTERNATOR BELT...1168
      Adjusting The Alternator Belt...1168
    ELECTRICAL SYSTEM...1169
      Description...1169
      Fuse Location & Identification...1169
      Using A Booster Battery (Jump Starting)...1170
      Removing And Installing The Battery...1171
    HYDRAULIC / HYDROSTATIC SYSTEM...1172
      Checking And Adding Fluid...1172
      Replacing Hydraulic/Hydrostatic Filters...1172
      Replacing Hydraulic Fluid...1173
      Reservoir Breather...1173
    SPARK ARRESTOR MUFFLER...1174
      Maintenance...1174
    TIRE MAINTENANCE...1175
      Wheel Nuts...1175
      Tire Rotation...1175
      Mounting...1175
    AXLE / DIFFERENTIAL (FRONT AND REAR)...1176
      Checking And Adding Lubricant...1176
      Replacing Lubricant...1176
    LUBRICATION...1177
      Lubrication Locations...1177
    PIVOT PINS...1179
      Inspection And Maintenance...1179
    BOB-TACH...1179
      Inspection And Maintenance...1179
  SYSTEM SETUP & ANALYSIS...1181
    DIAGNOSTICS SERVICE CODES...1183
      Display...1183
      Number Codes List...1184
    DISPLAY SETUP...1186
      Display Selection...1186
      Passwords...1186
      Password Entry (For Starting And Operating The Machine)...1186
      Changing The Operator Password...1186
      Password Lockout Feature...1187
      Job Clock...1187
      RPM...1187
  MACHINE SIGN TRANSLATIONS...1189
    SERVICE SCHEDULE (6814569)...1191
    MACHINE LOAD CAPACITIES (6814303)...1193
    CARGO BOX SUPPORT (6814308)...1193
    OPERATION INSTRUCTION (6814309)...1194
    WARNING (6814304)...1195
    LIFT ARM SUPPORT (6814306)...1196
    LIFT ARM SUPPORT LOCATION (6815099)...1196
    WARNING (6814300)...1197
    DANGER / WARNING (6814305)...1197
    WARNING (6814301)...1198
    WARNING (7102877)...1198
    WARNING (6814310)...1198
    WARNING (6814302)...1198
    DANGER (6814307)...1199
    WARNING (7108176) (Remote Hydraulics Only) (Option)...1199
    IMPORTANT (7109316) (Power Take-Off Only) (Option)...1199
    WARNING (7107447) (Power Take-Off Only) (Option)...1199
  SPECIFICATIONS...1201
    WORK MACHINE SPECIFICATIONS...1203
      Dimensional Specifications...1203
      Performance...1204
      Controls...1204
      Engine...1204
      Hydraulic System...1205
      Electrical...1205
      Power Take-Off (PTO) System (Option)...1206
      Drive System...1206
      Capacities...1206
      Tires...1206
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS...1207
  WARRANTY...1209
6902819 (8-09) - Toolcat 5600 Service Manual...1211
  MAINTENANCE SAFETY...1213
  ALPHABETICAL INDEX...1215
  CONTENTS...1217
    FOREWORD...1218
    SAFETY INSTRUCTIONS...1221
    FIRE PREVENTION...1223
      Maintenance...1223
      Operation...1223
      Electrical...1223
      Hydraulic System...1223
      Fueling...1223
      Starting...1223
      Spark Arrestor Exhaust System...1223
      Welding And Grinding...1224
      Fire Extinguishers...1224
    SERIAL NUMBER LOCATIONS...1225
      Work Machine Serial Number...1225
      Engine Serial Number...1225
    DELIVERY REPORT...1226
    BOBCAT UTILITY WORK MACHINE IDENTIFICATION...1227
  SAFETY AND MAINTENANCE...1229
    LIFTING AND BLOCKING THE MACHINE...1231
      Procedure For Jackstand Placement On The Axle...1231
      Procedure For Jackstand Placement On The Frame...1232
    LIFT ARM SUPPORT DEVICE...1235
      Installing The Lift Arm Support Device...1235
      Removing the Lift Arm Support Device...1235
    CARGO BOX SUPPORT DEVICE...1237
      Installing The Cargo Box Support Device...1237
      Removing the Cargo Box Support Device...1237
    OPERATOR CAB...1239
      Description...1239
    TRANSPORTING THE TOOLCAT...1241
      Loading Onto Transport Vehicle...1241
      Fastening To Transport Vehicle...1241
    TOWING THE Machine...1243
      Procedure...1243
    REMOTE START...1247
      Procedure...1247
    SERVICE SCHEDULE...1249
      Chart...1249
    AIR CLEANER SERVICE...1251
      Replacing Filter Elements...1251
    ENGINE COOLING SYSTEM...1253
      Checking The Coolant Level...1253
      Cleaning The Cooling System...1253
      Removing & Replacing Coolant...1254
    FUEL SYSTEM...1255
      Fuel Specifications...1255
      Filling The Fuel Tank...1255
      Fuel Filter...1255
      Removing Air From The Fuel System...1256
    ENGINE LUBRICATION SYSTEM...1257
      Checking Engine Oil...1257
      Oil Chart...1257
      Replacing The Oil And Filter...1258
    HYDRAULIC / HYDROSTATIC SYSTEM...1259
      Checking And Adding Fluid...1259
      Replacing Hydraulic/Hydrostatic Filter...1259
      Replacing Hydraulic Fluid...1260
      Hydraulic Fluid Chart...1260
      Reservoir Breather...1260
    AXLE/DIFFERENTIAL (FRONT & REAR)...1261
      Checking And Adding Lubricant...1261
      Replacing Lubricant...1261
    BOB-TACH...1263
      Inspection And Maintenance...1263
    LUBRICATION...1265
      Lubrication Locations...1265
    TIRE MAINTENANCE...1267
      Wheel Nuts...1267
      Tire Rotation...1267
      Mounting...1267
    SPARK ARRESTOR MUFFLER...1269
      Maintenance...1269
  HYDRAULIC SYSTEM...1271
    HYDRAULIC / HYDROSTATIC SCHEMATICS...1275
    HYDRAULIC SYSTEM INFORMATION...1279
      Glossary...1279
      Tighten Procedures...1283
      Troubleshooting Chart...1284
    CYLINDER (LIFT)...1285
      Checking...1285
      Removal And Installation...1286
      Identification...1288
      Disassembly...1289
      Assembly...1290
    CYLINDER (TILT)...1293
      Checking...1293
      Removal And Installation...1294
      Identification...1296
      Disassembly...1297
      Assembly...1298
    CYLINDER (CARGO BOX)...1301
      Checking (Left Side Cylinder)...1301
      Checking (Right Side Cylinder)...1302
      Removal And Installation...1303
      Identification...1304
      Disassembly...1305
      Assembly...1306
    MAIN RELIEF VALVE...1309
      Auxiliary Main Relief Valve Checking...1309
      Auxiliary Main Relief Valve Removal And Installation...1310
      Lift, Tilt And Cargo Box Main Relief Valve Checking...1311
      Lift, Tilt And Cargo Box Main Relief Valve Removal And Installation...1312
    PORT RELIEFS...1313
      Checking The Port Relief Valve (Lift)...1313
      Checking The Port Relief Valves (Tilt)...1314
    CONTROL VALVE...1317
      Removal And Installation...1317
      Identification Chart...1320
      Main Relief Valve Removal And Installation...1321
      Lift Section Disassembly And Assembly...1321
      Tilt Section Disassembly And Assembly...1324
      Box Section Disassembly And Assembly...1326
      High Flow Section Main Relief Valve Disassembly And Assembly...1328
      High Flow Manual Override Button...1329
      High Flow Solenoid Removal And Installation...1329
      Auxiliary Section Disassembly And Assembly...1330
      Load Check Valve Removal And Installation...1333
      Control Valve Disassembly And Assembly...1335
    STEERING SELECTOR VALVE...1337
      Removal And Installation...1337
      Disassembly and Assembly...1339
    POWER STEERING PUMP...1341
      Removal and Installation...1341
      Disassembly and Assembly...1342
    PILOT VALVE...1347
      Removal And Installation...1347
      Disassembly And Assembly...1349
    LIFT ARM BYPASS CONTROL VALVE...1351
      Inspecting...1351
      Removal And Installation...1351
      Disassembly And Assembly...1352
    HYDRAULIC PUMP...1353
      Checking The Auxiliary Section Of The Hydraulic Pump...1353
      Checking the Lift, Tilt And Cargo Box Section Of The Hydraulic Pump...1355
      Checking The Steering And Cooling Fan Section Of The Hydraulic Pump...1357
      Removal And Installation...1358
      Load Sense Disassembly And Assembly...1361
      Disassembly And Assembly...1362
    HYDRAULIC/HYDROSTATIC FILTER...1367
      Housing Removal and Installation...1367
    CONTROL LEVER (JOYSTICK)...1369
      Joystick Handle Removal And Installation...1369
      Joystick Removal And Installation...1372
      Joystick Disassembly and Assembly...1374
    HYDRAULIC FLUID RESERVOIR...1377
      Removal and Installation...1377
    AUXILIARY HYDRAULIC COUPLER BLOCK...1379
      Removal And Installation (Front)...1379
      Removal And Installation (Rear)...1379
      Disassembly And Assembly...1380
    REMOTE HYDRAULICS DIVERTER VALVE...1383
      Removal And Installation...1383
      Disassembly And Assembly...1384
    PTO HYDRAULIC MOTOR...1385
      Removal And Installation...1385
      Parts Identification...1387
      Disassembly...1388
      Inspection...1390
      Assembly...1390
    REAR AUXILIARY DIVERTER VALVE...1395
      Removal And Installation...1395
      Disassembly And Assembly...1398
  HYDROSTATIC SYSTEM...1407
    HYDROSTATIC SYSTEM INFORMATION...1409
      Troubleshooting Chart...1409
      Replenishing Valve Function...1410
    HYDROSTATIC MOTOR...1411
      Removal And Installation (Front Axle)...1411
      Removal And Installation (Rear Axle)...1413
      Disassembly...1415
      Assembly...1422
    CHARGE PRESSURE...1427
      Checking Charge Pressure...1427
    HYDROSTATIC PUMP...1429
      Removal and Installation...1429
      Directional Control Valve Removal and Installation...1431
      PWM Control Valve Removal and Installation...1432
      Replenishing/High Pressure Relief Valve...1433
      Charge Relief Valve...1433
      Disassembly...1434
      Inspection...1442
      Assembly...1444
      Hydrostatic Pump Start-Up...1453
      Neutral Adjustment...1454
    DRIVE BELT...1459
      Shield Removal And Installation...1459
      Adjusting...1460
      Drive Belt Replacement...1461
      Tensioner Pulley Removal And Installation...1462
      Tensioner Pulley Parts Identification...1463
      Tensioner Pulley Disassembly...1464
      Tensioner Pulley Assembly...1465
    OIL COOLER...1467
      Removal And Installation...1467
  DRIVE SYSTEM...1471
    BRAKE...1473
      Disassembly & Assembly (Front Axle)...1473
      Disassembly & Assembly (Rear Axle)...1474
    AXLE...1475
      Front Axle Brush Guard Removal And Installation...1475
      Front Axle Removal And Installation...1476
      Rear Axle Removal And Installation...1480
      Disconnecting The Axle Housings...1484
      Primary Housing Disassembly...1487
      Steering Cylinder Disassembly...1489
      Brake Disassembly...1492
      Secondary Housing And Differential Lock Disassembly...1494
      Secondary Housing And Differential Lock Assembly...1496
      Steering Cylinder Assembly...1497
      Primary Housing Assembly...1500
      Brake Assembly...1501
      Connecting The Axle Housings...1503
    AXLE HUB WITH AXLE SHAFT...1505
      Removal And Installation (Without Wheel Position Sensor)...1505
      Removal (With Wheel Position Sensor)...1508
      Inspection...1510
      Installation (With Wheel Position Sensor)...1512
    AXLE HUB WITHOUT AXLE SHAFT...1515
      Removal And Installation (Without Wheel Position Sensor)...1515
      Removal (With Wheel Position Sensor)...1519
      Bearing Pivot Inspection...1522
      Installation (With Wheel Position Sensor)...1524
      Disassembly...1528
      Axle Hub Inspection...1529
      Assembly...1530
      Torque Check Procedure...1533
    TIE ROD...1535
      Removal And Installation (Front Axle)...1535
      Removal And Installation (Rear Axle)...1537
      Adjusting...1539
    AXLE SHAFT...1541
      Removal and Installation...1541
  MAIN FRAME...1543
    OPERATOR CAB...1545
      Removal And Installation...1545
    OPERATOR SEAT...1551
      Removal And Installation...1551
      Seat Belt Removal And Installation...1552
      Seat Pan Removal And Installation...1553
      Slide Rail Removal And Installation...1553
      Cushion Removal And Installation...1554
      Back Removal And Installation...1554
      Arm Rest Bracket Removal And Installation...1555
      Arm Rest Removal And Installation...1555
      Shock Removal And Installation...1556
    PASSENGER SEAT...1557
      Removal And Installation...1557
      Seat Belt Removal And Installation...1557
      Seat Pan Removal And Installation...1558
      Arm Rest Removal And Installation...1559
    BOB-TACH...1561
      Removal and Installation...1561
      Bob-Tach Lever and Wedge...1562
    LIFT ARM...1563
      Removal and Installation...1563
    CARGO BOX...1565
      Removal and Installation...1565
    STEERING COLUMN...1567
      Removal And Installation...1567
    FUEL TANK...1569
      Main Tank Removal and Installation...1569
      Auxiliary Tank Removal and Installation...1572
    TRAVEL AND BRAKE PEDALS...1573
      Removal And Installation...1573
      Travel Speed Pedal Disassembly and Assembly...1574
    SHOCKS...1575
      Removal And Installation...1575
    TRAILING ARMS...1577
      Removal And Installation (Upper Arm)...1577
      Removal And Installation (Lower Arm)...1578
    LEAF SPRINGS...1579
      Removal And Installation (Left Side)...1579
      Removal and Installation (Right Side)...1581
    HITCH...1583
      Removal And Installation...1583
    FLOOR CONSOLE...1585
      Removal And Installation...1585
    CENTER CONSOLE...1587
      Removal And Installation...1587
    FENDER (FRONT LEFT)...1589
      Removal And Installation...1589
    FENDER (FRONT RIGHT)...1591
      Removal And Installation...1591
    FENDER (REAR LEFT)...1593
      Removal And Installation...1593
    FENDER (REAR RIGHT)...1595
      Removal And Installation...1595
  ELECTRICAL SYSTEM & ANALYSIS...1597
    ELECTRICAL SCHEMATICS...1599
    ELECTRICAL SYSTEM INFORMATION...1602
      Troubleshooting Chart...1604
      Description...1605
      Fuse Location...1605
      Solenoid Test...1607
    BATTERY...1608
      Removal And Installation...1608
      Servicing...1609
      Using A Booster Battery (Jump Starting)...1610
    ALTERNATOR (90 AMP)...1612
      Adjusting The Alternator Belt...1612
      Alternator Identification...1613
      Charging System Check...1614
      Alternator Voltage Test...1615
      Low Voltage Test...1616
      High Voltage Test...1616
      Removal And Installation...1617
      Rectifier Continuity (Diode) Test...1619
      Alternator Regulator Test...1620
      Disassembly...1621
      Stator Continuity Test...1621
      Stator Ground Test...1622
      Rotor Continuity Test...1622
      Rotor Ground Test...1622
      Assembly...1622
    STARTER...1624
      Checking...1624
      Removal And Installation...1625
      Parts Identification...1626
      Disassembly and Assembly...1627
      Inspection And Repair...1630
      No Load Test...1632
    INSTRUMENT PANEL...1634
      Display Controller Panel...1634
      Switch Panel...1635
      Center Console...1636
      Display Controller Panel Removal And Installation...1637
      Light Bulb Removal And Installation...1637
    LIGHTS...1638
      Front Removal And Installation...1638
    DISPLAY CONTROLLER...1640
      Identification Chart...1640
      Removal And Installation...1641
    DRIVE CONTROLLER...1642
      Identification Chart...1642
      Removal And Installation...1643
    DIAGNOSTICS SERVICE CODES...1644
      Display...1644
      Number Codes List...1645
    TICS SYSTEM...1648
      Inspecting the TICS System (Engine STOPPED - Key ON)...1648
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...1648
      Inspecting The Arm Rest Sensor (Engine RUNNING)...1648
      Inspecting The Traction Lock (Engine RUNNING)...1648
      Inspecting The Lift Arm Bypass Control...1648
    ARM REST SENSOR...1650
      Removal And Installation...1650
    WHEEL SPEED SENSOR...1652
      Removal and Installation (Front Axle)...1652
      Removal and Installation (Rear Axle)...1654
    WHEEL POSITION SENSOR...1656
      Removal and Installation (Front Axle)...1656
      Removal and Installation (Rear Axle)...1661
    CALIBRATION...1666
      Travel Pedal...1666
      Brake Pedal...1666
      Pump...1667
      Wheel Alignment Calibration...1668
    SERVICE PC (LAPTOP COMPUTER)...1670
      Connecting The Service PC To Remote Start Tool...1670
    TRAVEL DIRECTION CONTROL LEVER...1672
      Removal And Installation...1672
    RPM SENSOR...1674
      Adjustment...1674
  ENGINE SERVICE...1676
    TROUBLESHOOTING...1678
      Chart...1678
    ENGINE SPEED CONTROL...1680
      Removal And Installation...1680
    MUFFLER...1682
      Removal and Installation...1682
    AIR CLEANER...1684
      Removal and Installation...1684
    RADIATOR...1686
      Removal And Installation...1686
    COOLING FAN...1690
      Removal And Installation...1690
      Proportional Valve Disassembly and Assembly...1693
    ENGINE COMPONENTS AND TESTING...1696
      Compression Checking...1696
      Glow Plugs Checking...1697
      Glow Plugs Removal And Installation...1698
      Fuel Shut-Off Solenoid, Checking...1699
      Fuel Shut-Off Solenoid Removal And Installation...1699
      Fuel Injection Pump Removal And Installation...1700
      Timing The Injection Pump...1703
      Fuel Injector Removal And Installation...1705
      Checking Nozzle Injection Pressure...1706
      Nozzle Spraying Condition...1707
      Valve Seat Tightness...1707
      Valve Clearance Adjustment...1708
      Valve Timing, Checking...1709
    ENGINE...1710
      Removal And Installation...1710
      Engine Mount Replacement...1721
    FLYWHEEL AND HOUSING...1722
      Flywheel Removal And Installation...1722
      Ring Gear Removal And Installation...1722
      Housing Removal And Installation...1723
    RECONDITIONING THE ENGINE-V2203-M-DI AND V2003-M-DI-T (TURBO)...1724
      Cylinder Head Removal And Installation...1724
      Cylinder Head Disassembly And Assembly...1727
      Cylinder Head Servicing...1728
      Cylinder Head Top Clearance...1728
      Valve Guide Checking...1729
      Reconditioning The Valve And Valve Seat...1731
      Valve Spring...1732
      Rocker Arm And Shaft Checking...1733
      Timing Gearcase Cover Removal And Installation...1733
      Idler Gear And Camshaft Removal And Installation...1736
      Camshaft Servicing...1737
      Idler Gear And Shaft Servicing...1738
      Timing Gears Checking Backlash...1739
      Fuel Camshaft Removal And Installation...1739
      Fuel Camshaft Governor...1740
      Crankshaft Gear Removal And Installation...1740
      Oil Pump Removal And Installation...1741
      Oil Pump Service...1741
      Checking Engine Oil Pressure...1742
      Valve Tappets...1743
      Piston And Connecting Rod Removal And Installation...1743
      Piston And Connecting Rod Servicing...1745
      Connecting Rod Alignment...1748
      Crankshaft And Bearings Removal And Installation...1748
      Crankshaft And Bearings, Servicing...1750
      Cylinder Bore, Checking...1754
      Water Pump Removal And Installation...1755
      Water Pump Disassembly And Assembly...1755
    TURBOCHARGER...1756
      Checking...1756
      Description...1756
      Removal And Installation...1757
  HEATING, VENTILATION, AIR CONDITIONING...1760
    AIR CONDITIONING SYSTEM FLOW...1763
      Principals...1763
      Chart...1764
    COMPONENTS...1766
      Identification...1766
    SAFETY...1770
      Safety Equipment...1770
    REGULAR MAINTENANCE...1772
      Filter Elements Removal And Installation...1772
      Cleaning The Condenser...1773
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...1774
      Compressor Oil...1774
      Compressor Oil Check...1775
      Component Replacement And Refrigeration Leaks...1776
    SYSTEM TROUBLESHOOTING...1778
      Checking A/C Performance...1778
      Gauge Pressure Related Troubleshooting...1780
      Troubleshooting Tree...1782
    TEMPERATURE / PRESSURE...1786
      Chart...1786
    AIR CONDITIONING SERVICE...1788
      Chart...1788
    SYSTEM CHARGING AND RECLAMATION...1790
      Reclamation Procedure...1790
      Charging Procedure With A Manifold Gauge Set...1793
    COMPRESSOR...1796
      Removal And Installation...1796
      Compressor Clutch Disassembly...1797
    CONDENSER...1802
      Removal And Installation...1802
    RECEIVER/DRIER...1804
      Removal And Installation...1804
      Pressure Switch Removal And Installation...1804
      Pressure Relief Valve Removal And Installation...1805
    EVAPORATOR/HEATER UNIT...1806
      Removal And Installation...1806
    THERMOSTAT...1808
      Removal And Installation...1808
    EXPANSION VALVE...1810
      Removal And Installation...1810
    HEATER/AC FAN...1812
      Removal And Installation...1812
    HEATER VALVE...1814
      Removal And Installation...1814
      Disassembly And Assembly...1814
  SPECIFICATIONS...1816
    UTILITY WORK MACHINE SPECIFICATIONS...1818
      Dimensional Specifications...1818
      Performance...1819
      Controls...1819
      Engine...1819
      Hydraulic System...1820
      Electrical...1820
      Drive System...1821
      Capacities...1821
      Tires...1821
    ENGINE SPECIFICATIONS-KUBOTA V2203-M-DI...1822
      Fuel Injection Nozzles...1822
      Fuel Injection Pump...1822
      Cylinder Head...1822
      Valves...1822
      Valve Springs...1823
      Valve Timing...1823
      Rocker Arms...1823
      Camshaft...1823
      Tappet...1823
      Cylinders...1824
      Piston Rings...1824
      Pistons...1824
      Connecting Rod...1824
      Oil Pump...1824
      Crankshaft...1825
      Timing Gear...1825
      Thermostat...1825
    ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO)...1826
      Fuel Injection Nozzles...1826
      Fuel Injection Pump...1826
      Cylinder Head...1826
      Valves...1826
      Valve Springs...1827
      Valve Timing...1827
      Rocker Arms...1827
      Camshaft...1827
      Tappet...1827
      Cylinder Liner...1828
      Piston Rings...1828
      Pistons...1828
      Connecting Rod...1828
      Oil Pump...1828
      Crankshaft...1829
      Timing Gear...1829
      Thermostat...1829
    TORQUE SPECIFICATIONS FOR BOLTS...1830
    ...
      Operation...2468
    ENGINE SPEED CONTROL...2469
      Operation...2469
    PARKING BRAKE...2469
      Operation...2469
    STEERING MODE SELECTION...2470
      Operation...2470
    TRAVEL DIRECTION CONTROL LEVER...2471
      Operation...2471
      Two-Speed Control...2471
    DRIVE PEDAL...2471
      Operation...2471
    BRAKE PEDAL...2471
      Operation...2471
    STOPPING THE UTILITY WORK MACHINE...2471
      Procedure...2471
    WHEEL ALIGNMENT...2472
      Procedure...2472
    DIFFERENTIAL LOCK...2472
      Engaging...2472
    HYDRAULIC CONTROLS...2473
      Description...2473
      Lift Arm Operation...2473
      Lift Arm Float Position...2473
      Tilt Operation...2473
      Front Auxiliary Hydraulics Operation...2474
      Front Auxiliary Hydraulics Operation (CONTINUOUS FLOW)...2474
      Quick Couplers...2474
      Relieve Hydraulic Pressure (Utility Work Machine and Attachment)...2475
      High Flow Hydraulics Operation (If Equipped)...2475
    REAR AUXILIARY HYDRAULICS (If Equipped)...2476
      Description...2476
      Rear Auxiliary Hydraulics Operation...2476
      Rear Auxiliary Hydraulics Operation (CONTINUOUS FLOW)...2477
      Quick Couplers...2477
      Relieve Hydraulic Pressure (Utility Work Machine and Attachment)...2477
    POWER TAKE-OFF (PTO) (If Equipped)...2478
      Description...2478
      Safety Rules For PTO...2478
      Connecting The Motor...2479
      Connecting The Attachment...2479
      Operation...2481
      Disconnecting The Attachment...2483
    REMOTE HYDRAULICS (If Equipped)...2484
      Description...2484
      Remote Hydraulics Operation...2484
      Function Chart [Figure OI-43] and [Figure OI-44]...2484
      Quick Couplers And Hoses...2485
    DAILY INSPECTION...2486
      Daily Inspection and Maintenance...2487
    PRE-STARTING PROCEDURE...2488
      Entering The Utility Work Machine...2488
      Seat And Steering Wheel Adjustment...2488
      Seat Belt Adjustment And Arm Rest...2489
    STARTING THE ENGINE...2490
      Key Switch...2490
      Keyless...2491
      Cold Temperature Starting...2491
      Warming The Hydraulic / Hydrostatic System...2491
    MONITORING THE DISPLAY PANEL...2492
      Key Switch And Keyless...2492
      Warning And Shutdown...2492
    STOPPING THE ENGINE AND LEAVING THE UTILITY WORK MACHINE...2493
      Procedure...2493
      Emergency Exit...2493
    MACHINE Load CAPACITIES...2494
      Loader Rated Operating Capacity (ROC)...2494
      Maximum Cargo Box Load...2494
      Machine Rated Capacity...2494
      Maximum Trailer Hitch Tongue Weight...2494
      Total Rated Capacity...2494
    ATTACHMENTS...2495
      Choosing The Correct Bucket...2495
      Pallet Fork...2495
      Installing And Removing The Attachment...2496
    OPERATING PROCEDURE...2498
      Inspect The Work Area...2498
      Operating With A Full Bucket & Empty Cargo Box...2498
      Operating With An Empty Bucket & Loaded Cargo Box...2498
      Filling And Emptying The Bucket...2499
      Leveling The Ground Using Float...2500
      Backfilling...2500
      Work Mode Operation...2500
      Opening And Closing The Tailgate...2501
      Raising And Lowering The Cargo Box...2501
      Hauling Loads In The Cargo Box...2501
      Towing Equipment With The Utility Work Machine...2501
    TOWING THE UTILITY WORK MACHINE...2501
      Procedure...2501
    TRANSPORTING THE UTILITY WORK MACHINE ON A TRAILER...2502
      Loading And Unloading...2502
      Fastening...2502
  PREVENTIVE MAINTENANCE...2504
    MAINTENANCE SAFETY...2508
    SERVICE SCHEDULE...2510
      Chart...2510
    TOOLCAT INTERLOCK CONTROL SYSTEM (TICS)...2511
      Inspecting The TICS...2511
      Maintaining The TICS...2511
      Inspecting The Lift Arm By-Pass Control...2512
    SEAT BELT...2513
      Inspection and Maintenance...2513
    NEUTRAL START SYSTEM...2514
      Inspection And Maintenance...2514
    LIFT ARM SUPPORT DEVICE...2515
      Installing...2515
      Removing...2515
    CARGO BOX SUPPORT DEVICE...2516
      Installing...2516
      Removing...2516
      Raising The Cargo Box When Engine Is Not Running...2516
    PARKING BRAKE SYSTEM...2517
      Inspection And Maintenance...2517
    OPERATOR CAB...2518
      Description...2518
    HEATING AND AIR CONDITIONING...2518
      Cleaning and Maintenance...2518
      Filters...2518
      Evaporator Coil...2518
      Air Conditioning Lubrication...2518
      Troubleshooting...2518
    CAB AIR FILTER...2519
      Cleaning And Maintenance...2519
      Fresh Air Filter...2519
      Recirculating Air Filter...2519
    AIR CLEANER SERVICE...2520
      Replacing Filter Elements...2520
    SEATS...2521
      Removal...2521
      Installation...2521
    FUEL SYSTEM...2522
      Fuel Specifications...2522
      Filling The Fuel Tank...2522
      Fuel Filter...2522
      Removing Air From The Fuel System...2523
      Filling A Portable Fuel Container...2524
    ENGINE LUBRICATION SYSTEM...2525
      Checking And Adding Engine Oil...2525
      Engine Oil Chart...2525
      Removing And Replacing Oil And Filter...2525
    ENGINE COOLING SYSTEM...2526
      Checking...2526
      Cleaning...2527
      Removing And Replacing Coolant...2528
    ELECTRICAL SYSTEM...2529
      Description...2529
      Fuse And Relay Location / Identification...2529
      Battery And Battery Terminal Maintenance...2530
      Using A Booster Battery (Jump Starting)...2530
      Removing And Installing Battery...2532
    HYDRAULIC / HYDROSTATIC SYSTEM...2533
      Checking And Adding Fluid...2533
      Hydraulic / Hydrostatic Fluid Chart...2533
      Removing And Replacing Hydraulic/Hydrostatic And Case Drain Filters...2533
      Removing And Replacing Hydraulic Fluid...2534
      Breather Cap...2534
    SPARK ARRESTOR MUFFLER...2535
      Cleaning Procedure...2535
    SUPPORTING THE MACHINE ON JACKSTANDS...2536
      Procedure...2536
    TIRE MAINTENANCE...2537
      Wheel Nuts...2537
      Rotating...2537
      Mounting...2537
    AXLE / DIFFERENTIAL (FRONT AND REAR)...2538
      Checking And Adding Lubricant...2538
      Removing And Replacing Lubricant...2538
    ALTERNATOR BELT...2539
      Belt Adjustment...2539
      Belt Replacement...2539
    AIR CONDITIONER BELT...2540
      Belt Adjustment...2540
      Belt Replacement...2540
    DRIVE BELT...2541
      Belt Adjustment...2541
      Drive Belt Replacement...2542
    LUBRICATING THE UTILITY WORK MACHINE...2543
      Lubrication Locations...2543
    PIVOT PINS...2545
      Inspection And Maintenance...2545
    BOB-TACH...2546
      Inspection And Maintenance...2546
    MACHINE STORAGE AND RETURN TO SERVICE...2547
      Storage...2547
      Return To Service...2547
  SYSTEM SETUP & ANALYSIS...2548
    DIAGNOSTIC SERVICE CODES...2550
      Viewing Service Codes...2550
      Service Codes List...2551
    DISPLAY CONTROLLER PANEL SETUP...2553
      Display Selection...2553
      Passwords...2553
      Password Entry (For Starting And Operating The Machine)...2553
      Changing The Operator Password...2553
      Password Lockout Feature...2554
      Job Clock...2554
      RPM...2554
  MACHINE SIGN TRANSLATIONS...2556
    SERVICE SCHEDULE (7120002)...2558
    MACHINE LOAD CAPACITIES (6814303)...2560
    CARGO BOX SUPPORT (6814308)...2560
    OPERATION INSTRUCTION (6814309)...2561
    DANGER / WARNING (6814305)...2561
    WARNING (7114129)...2562
    WARNING (6814300)...2562
    LIFT ARM SUPPORT (6814306)...2563
    LIFT ARM SUPPORT LOCATION (6815099)...2563
    WARNING (6814301)...2564
    WARNING (7102877)...2564
    WARNING (6814310)...2564
    WARNING (6814302)...2564
    DANGER (6814307)...2565
    WARNING (7108176) (Remote Hydraulics Only) (Option)...2565
    IMPORTANT (7109316) (Power Take-Off Only) (Option)...2565
    WARNING (7107447) (Power Take-Off Only) (Option)...2565
  SPECIFICATIONS...2566
    TOOLCAT 5600 UTILITY WORK MACHINE SPECIFICATIONS...2568
      Dimensions...2568
      Performance...2569
      Controls...2569
      Engine...2569
      Hydraulic System...2570
      Electrical...2570
      Power Take-Off (PTO) System (Option)...2571
      Drive System...2571
      Capacities...2571
      Tires...2571
  WARRANTY...2572
  ALPHABETICAL INDEX...2576
6904209 (2-10) - Toolcat 5600 Utility Work Machine Service Manual...2578
  CONTENTS...2582
  FOREWORD...2584
    FOREWORD...2586
    SAFETY INSTRUCTIONS...2589
    FIRE PREVENTION...2591
      Maintenance...2591
      Operation...2591
      Electrical...2591
      Hydraulic System...2591
      Fueling...2591
      Starting...2591
      Spark Arrestor Exhaust System...2591
      Welding And Grinding...2592
      Fire Extinguishers...2592
    SERIAL NUMBER LOCATIONS...2593
      Utility Work Machine Serial Number...2593
      Engine Serial Number...2593
    DELIVERY REPORT...2594
    TOOLCAT UTILITY WORK MACHINE IDENTIFICATION...2595
  SAFETY & MAINTENANCE...2596
    LIFTING AND BLOCKING THE UTILITY WORK MACHINE...2598
      Procedure For Jackstand Placement On The Axle...2598
      Procedure For Jackstand Placement On The Frame...2599
    LIFT ARM SUPPORT DEVICE...2602
      Installing...2602
      Removing...2602
    CARGO BOX SUPPORT DEVICE...2604
      Installing...2604
      Removing...2604
      Raising The Cargo Box When Engine Is Not Running...2604
    OPERATOR CAB...2606
      Description...2606
    TRANSPORTING THE UTILITY WORK MACHINE ON A TRAILER...2608
      Loading And Unloading...2608
      Fastening...2608
    TOWING THE UTILITY WORK MACHINE...2610
      Procedure...2610
    REMOTE START...2614
      Procedure...2614
    SERVICE SCHEDULE...2616
      Chart...2616
    AIR CLEANER SERVICE...2618
      Replacing Filter Elements...2618
    ENGINE COOLING SYSTEM...2620
      Cleaning...2620
      Checking...2621
      Removing And Replacing Coolant...2621
    FUEL SYSTEM...2622
      Fuel Specifications...2622
      Filling The Fuel Tank...2622
      Fuel Filter...2622
      Removing Air From The Fuel System...2623
      Filling A Portable Fuel Container...2624
    ENGINE LUBRICATION SYSTEM...2626
      Checking And Adding Engine Oil...2626
      Engine Oil Chart...2626
      Removing And Replacing Oil And Filter...2627
    HYDRAULIC / HYDROSTATIC SYSTEM...2628
      Checking And Adding Fluid...2628
      Hydraulic / Hydrostatic Fluid Chart...2628
      Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters...2629
      Removing And Replacing Hydraulic Fluid...2630
      Breather Cap...2630
    AXLE / DIFFERENTIAL (FRONT AND REAR)...2632
      Checking And Adding Lubricant...2632
      Removing And Replacing Lubricant...2632
    BOB-TACH...2634
      Inspection And Maintenance...2634
    LUBRICATING THE UTILITY WORK MACHINE...2636
      Lubrication Locations...2636
    TIRE MAINTENANCE...2640
      Wheel Nuts...2640
      Rotating...2640
      Mounting...2640
    SPARK ARRESTOR MUFFLER...2642
      Cleaning Procedure...2642
    PIVOT PINS...2644
      Inspection And Maintenance...2644
    UTILITY WORK MACHINE STORAGE AND RETURN TO SERVICE...2646
      Storage...2646
      Return To Service...2646
    STOPPING THE ENGINE AND LEAVING THE UTILITY WORK MACHINE...2648
      Procedure...2648
      Emergency Exit...2648
  HYDRAULIC SYSTEM...2650
    HYDRAULIC / HYDROSTATIC SCHEMATICS...2654
    HYDRAULIC SYSTEM INFORMATION...2658
      Glossary Of Hydraulic / Hydrostatic Symbols...2658
      Troubleshooting...2662
    CYLINDER (LIFT)...2664
      Testing...2664
      Removal And Installation...2665
      Parts Identification...2668
      Disassembly...2669
      Assembly...2670
    CYLINDER (TILT)...2674
      Testing...2674
      Removal And Installation...2675
      Parts Identification...2677
      Disassembly...2678
      Assembly...2679
    CYLINDER (CARGO BOX)...2682
      Testing (Left Side Cylinder)...2682
      Testing (Right Side Cylinder)...2683
      Removal And Installation...2684
      Parts Identification...2686
      Disassembly...2687
      Assembly...2688
    MAIN RELIEF VALVE...2692
      Description...2692
      Auxiliary Main Relief Valve Testing...2692
      Auxiliary Main Relief Valve Removal And Installation...2693
      Lift, Tilt And Cargo Box Main Relief Valve Testing...2694
      Lift, Tilt And Cargo Box Main Relief Valve Removal And Installation...2695
    PORT RELIEF VALVES...2696
      Description...2696
      Lift Port Relief Valve Testing...2696
      Tilt Port Relief Valve Testing...2697
    HYDRAULIC CONTROL VALVE...2700
      Description...2700
      Removal And Installation...2701
      Identification Chart...2704
      Disassembly...2705
      End Valve Section Disassembly And Assembly...2706
      Lift Valve Section Disassembly And Assembly...2708
      Tilt Valve Section Disassembly And Assembly...2712
      Box Valve Section Disassembly And Assembly...2716
      High Flow Valve Section Disassembly And Assembly...2720
      Auxiliary Valve Section Disassembly And Assembly...2724
      Assembly...2729
    STEERING SELECTOR VALVE...2732
      Description...2732
      Removal And Installation...2732
      Disassembly And Assembly...2734
    PILOT MANIFOLD...2736
      Description...2736
      Removal And Installation...2736
      Disassembly And Assembly...2738
    LIFT ARM BYPASS CONTROL VALVE...2740
      Description...2740
      Testing...2740
      Removal And Installation...2740
      Disassembly And Assembly...2741
    HYDRAULIC PUMP...2742
      Description...2742
      Auxiliary Section Testing...2743
      Lift, Tilt And Cargo Box Section Testing...2745
      Steering And Cooling Fan Section Testing...2747
      Removal And Installation...2749
      Parts Identification...2753
      Disassembly And Assembly...2754
    POWER STEERING PUMP...2766
      Description...2766
      Removal And Installation...2766
      Disassembly And Assembly...2767
    HYDRAULIC / HYDROSTATIC FILTER...2772
      Description...2772
      Housing Removal And Installation...2772
      Case Drain Housing Removal And Installation...2773
    CONTROL JOYSTICK...2774
      Description...2774
      Handle Removal And Installation...2774
      Removal And Installation...2777
      Disassembly And Assembly...2779
    HYDRAULIC FLUID RESERVOIR...2782
      Description...2782
      Removal And Installation...2782
      Hydraulic Fluid Screen...2785
    OIL COOLER...2788
      Description...2788
      Removal And Installation...2788
    AUXILIARY HYDRAULIC COUPLER BLOCK...2790
      Description...2790
      Removal And Installation (Front)...2790
      Removal And Installation (Rear)...2791
      Disassembly And Assembly...2791
    REMOTE HYDRAULICS DIVERTER VALVE...2794
      Description...2794
      Removal And Installation...2794
      Disassembly And Assembly...2796
    PTO HYDRAULIC MOTOR...2798
      Description...2798
      Removal And Installation...2798
      Parts Identification...2800
      Disassembly...2801
      Assembly...2803
    REAR AUXILIARY DIVERTER VALVE...2808
      Description...2808
      Solenoid Testing...2808
      Removal And Installation...2808
      Disassembly And Assembly...2815
  HYDROSTATIC SYSTEM...2836
    HYDROSTATIC SYSTEM INFORMATION...2838
      Troubleshooting...2838
      Description...2839
    HYDROSTATIC DRIVE MOTOR...2840
      Description...2840
      Removal And Installation (Front Axle)...2840
      Removal And Installation (Rear Axle)...2842
      Parts Identification...2844
      Disassembly...2845
      Assembly...2852
    CHARGE PRESSURE...2856
      Description...2856
      Testing...2856
    HYDROSTATIC PUMP...2858
      Description...2858
      Removal And Installation...2858
      Directional Control Valve Removal And Installation...2860
      PWM Control Valve Removal And Installation...2861
      Replenishing / High Pressure Relief Valve Removal And Installation...2862
      Charge Relief Valve Removal And Installation...2862
      Parts Identification (Left Half)...2863
      Parts Identification (Right Half)...2865
      Disassembly...2867
      Assembly...2876
      Hydrostatic Pump Start-Up...2886
      Pump Neutral Adjustment...2886
    DRIVE BELT...2890
      Description...2890
      Shield Removal And Installation...2890
      Adjusting...2891
      Belt Removal And Installation...2892
      Tensioner Pulley Removal And Installation...2893
      Tensioner Pulley Parts Identification...2894
      Tensioner Pulley Disassembly...2895
      Tensioner Pulley Assembly...2896
  DRIVE SYSTEM...2898
    BRAKE...2900
      Description...2900
      Disassembly And Assembly (Front Axle)...2900
      Disassembly And Assembly (Rear Axle)...2901
    AXLE...2902
      Description...2902
      Front Axle Brush Guard Removal And Installation...2902
      Front Axle Removal And Installation...2903
      Rear Axle Removal And Installation...2907
      Separate The Axle Housings...2911
      Primary Housing Disassembly...2914
      Steering Cylinder Disassembly...2916
      Brake Disassembly...2919
      Secondary Housing And Differential Lock Disassembly...2921
      Secondary Housing And Differential Lock Assembly...2923
      Steering Cylinder Assembly...2924
      Primary Housing Assembly...2927
      Brake Assembly...2928
      Join The Axle Housings...2930
    AXLE HUB WITH AXLE SHAFT...2932
      Description...2932
      Removal And Installation (Without Wheel Position Sensor)...2932
      Removal (With Wheel Position Sensor)...2935
      Installation (With Wheel Position Sensor)...2939
    AXLE HUB WITHOUT AXLE SHAFT...2942
      Description...2942
      Removal And Installation (Without Wheel Position Sensor)...2942
      Removal (With Wheel Position Sensor)...2946
      Installation (With Wheel Position Sensor)...2950
      Disassembly...2954
      Assembly...2956
      Torque Check Procedure...2959
    AXLE SHAFT...2962
      Description...2962
      Removal And Installation...2962
    TIE ROD...2964
      Description...2964
      Removal And Installation (Front Axle)...2964
      Removal And Installation (Rear Axle)...2966
      Adjusting...2968
  MAINFRAME...2970
    OPERATOR CAB...2972
      Removal And Installation...2972
    OPERATOR SEAT...2978
      Removal And Installation...2978
      Seat Belt Removal And Installation...2979
      Seat Pan Removal And Installation...2980
      Slide Rail Removal And Installation...2980
      Lower Cushion Removal And Installation...2981
      Back Cushion Removal And Installation...2981
      Arm Rest Bracket Removal And Installation...2982
      Arm Rest Removal And Installation...2982
      Shock Removal And Installation...2983
    PASSENGER SEAT...2984
      Removal And Installation...2984
      Seat Belt Removal And Installation...2984
      Seat Pan Removal And Installation...2985
      Arm Rest Removal And Installation...2986
    BOB-TACH...2988
      Description...2988
      Removal And Installation...2988
      Lever And Wedge Disassembly And Assembly...2989
    LIFT ARM...2990
      Removal And Installation...2990
    CARGO BOX...2992
      Removal And Installation...2992
    STEERING COLUMN...2994
      Removal And Installation...2994
    FUEL TANK...2996
      Main Tank Removal And Installation...2996
      Auxiliary Tank Removal And Installation...2998
      Fuel Level Sender Removal And Installation...2999
    DRIVE AND BRAKE PEDALS...3000
      Description...3000
      Removal And Installation...3000
      Drive Pedal Disassembly And Assembly...3001
    SHOCKS...3002
      Removal And Installation...3002
    TRAILING ARMS...3004
      Description...3004
      Removal And Installation (Upper Arm)...3004
      Removal And Installation (Lower Arm)...3005
    LEAF SPRINGS...3006
      Removal And Installation (Left Side)...3006
      Removal And Installation (Right Side)...3008
    HITCH...3010
      Removal And Installation...3010
    FLOOR CONSOLE...3012
      Access Cover Removal And Installation...3012
    CENTER CONSOLE...3014
      Removal And Installation...3014
    FENDER (FRONT LEFT)...3016
      Removal And Installation...3016
    FENDER (FRONT RIGHT)...3018
      Removal And Installation...3018
    FENDER (REAR LEFT)...3020
      Removal And Installation...3020
    FENDER (REAR RIGHT)...3022
      Removal And Installation...3022
    WINDOWS...3024
      Front, Rear And Lower Door Removal And Installation...3024
      Upper Door Removal And Installation...3025
  ELECTRICAL SYSTEM & ANALYSIS...3028
    ELECTRICAL SCHEMATICS...3032
    ELECTRICAL SYSTEM INFORMATION...3045
      Glossary Of Electrical Symbols...3045
      Description...3049
      Troubleshooting...3050
      Fuse And Relay Location / Identification...3051
      Solenoid Testing...3052
    BATTERY...3053
      Removal And Installation...3053
      Servicing...3054
      Using A Booster Battery (Jump Starting)...3054
    ALTERNATOR...3057
      Belt Adjustment...3057
      Charging System Inspection...3058
      Alternator Voltage Testing...3059
      Low Voltage Testing...3060
      High Voltage Testing...3060
      Removal And Installation...3061
      Parts Identification...3062
    STARTER...3063
      Testing...3063
      Removal And Installation...3064
      Parts Identification...3065
    INSTRUMENT PANELS...3067
      Display Controller Panel...3067
      Switch Panel...3068
      Floor Console...3069
      Center Console...3069
      Display Controller Panel Removal And Installation...3070
      Light Bulb Removal And Installation...3070
    LIGHTS...3071
      Front Removal And Installation...3071
    BOBCAT CONTROLLER (DISPLAY)...3073
      Description...3073
      Connector Identification...3074
      Removal And Installation...3075
    BOBCAT CONTROLLER (DRIVE)...3077
      Description...3077
      Connector Identification...3078
      Removal And Installation...3079
    DIAGNOSTIC SERVICE CODES...3081
      Description...3081
      Service Codes List...3082
    DISPLAY CONTROLLER PANEL SETUP...3085
      Display Selection...3085
      Passwords...3085
      Password Entry (For Starting And Operating The Machine)...3085
      Changing The Owner And Operator Password...3085
      Password Lockout Feature...3086
      Job Clock...3086
      RPM...3086
    TOOLCAT INTERLOCK CONTROL SYSTEM (TICS)...3087
      Description...3087
      Inspecting The TICS System (Engine STOPPED - Key ON)...3087
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...3087
      Inspecting The Arm Rest Sensor (Engine RUNNING)...3087
      Inspecting The Traction Lock (Engine RUNNING)...3087
      Inspecting The Lift Arm Bypass Control...3087
    ARM REST SENSOR...3089
      Description...3089
      Removal And Installation...3089
    SPEED SENSORS...3091
      Description...3091
      Removal And Installation (Front Axle)...3091
      Removal And Installation (Rear Axle)...3093
    WHEEL POSITION SENSORS...3095
      Description...3095
      Removal And Installation (Front Axle)...3095
      Removal And Installation (Rear Axle)...3100
    SERVICE PC (LAPTOP COMPUTER)...3105
      Connecting Remote Start Tool...3105
    CALIBRATION...3107
      Description...3107
      Drive Pedal Calibration...3107
      Brake Pedal Calibration...3108
      Hydrostatic Pump Calibration...3109
      Wheel Alignment Calibration...3110
    TRAVEL DIRECTION CONTROL LEVER...3111
      Description...3111
      Removal And Installation...3111
    FLYWHEEL RPM SENSOR...3113
      Description...3113
      Adjusting...3113
    ELECTRIC COOLING FAN...3115
      Description...3115
      Removal And Installation...3115
  ENGINE SERVICE...3117
    ENGINE INFORMATION...3121
      Description...3121
      Engine Specifications-Kubota V2203-M-DI...3122
      Engine Specifications-Kubota V2003-M-DI-T (Turbo)...3126
      Engine Torque Values...3131
      Troubleshooting...3132
      Engine Removal And Installation...3134
      Engine Mount Replacement...3145
      Compression - Checking...3146
    ENGINE SPEED CONTROL...3147
      Removal And Installation...3147
      Speed Control Cable Removal And Installation...3147
    MUFFLER...3149
      Removal And Installation...3149
    AIR CLEANER...3151
      Housing Removal And Installation...3151
    ENGINE COOLING SYSTEM...3153
      Radiator Removal And Installation...3153
      Radiator Mount Removal And Installation...3155
      Hydraulic Fan Removal And Installation...3156
      Hydraulic Fan Disassembly And Assembly...3158
      Water Pump Removal And Installation...3160
      Water Pump Disassembly And Assembly...3160
      Thermostat Housing Removal And Installation...3161
    LUBRICATION SYSTEM...3163
      Oil Pan Removal And Installation...3163
      Oil Pump Removal And Installation...3164
      Oil Pump Inspection...3165
      Engine Oil Pressure - Testing...3166
    FUEL SYSTEM...3167
      Fuel Camshaft Removal And Installation...3167
      Fuel Camshaft Governor Disassembly And Assembly...3168
      Fuel Shutoff Solenoid - Checking...3169
      Fuel Shutoff Solenoid Removal And Installation...3169
      Fuel Injection Pump Removal And Installation (Turbo)...3170
      Fuel Injection Pump Removal And Installation (Non- Turbo)...3173
      Injection Pump - Timing...3177
      Fuel Injector Removal And Installation...3179
      Fuel Injector Nozzle Pressure - Checking...3181
      Nozzle Spray Condition...3181
      Valve Seat Tightness...3182
    CYLINDER HEAD...3183
      Glow Plugs - Testing...3183
      Glow Plugs Removal And Installation...3184
      Valve Clearance Adjustment...3185
      Valve Timing - Checking...3186
      Cylinder Head Removal And Installation...3186
      Cylinder Head Disassembly And Assembly...3189
      Cylinder Head - Servicing...3190
      Cylinder Head Top Clearance...3190
      Valve Guide - Checking...3191
      Reconditioning The Valve And Valve Seat...3193
      Valve Spring...3194
      Valve Tappets...3195
      Rocker Arm And Shaft - Checking...3195
    CRANKSHAFT AND PISTONS...3197
      Piston And Connecting Rod Removal And Installation...3197
      Piston And Connecting Rod - Servicing...3198
      Cylinder Bore - Checking...3201
      Connecting Rod Alignment...3201
      Crankshaft Gear Removal And Installation...3202
      Crankshaft And Bearings Removal And Installation...3202
      Crankshaft And Bearings - Servicing...3204
    CAMSHAFT AND TIMING GEARS...3209
      Timing Gearcase Cover Removal And Installation...3209
      Timing Gears Backlash - Checking...3211
      Idler Gear And Camshaft Removal And Installation...3212
      Camshaft - Servicing...3213
      Idler Gear And Shaft - Servicing...3214
    TURBOCHARGER...3217
      Description...3217
      Testing...3217
      Removal And Installation...3218
    FLYWHEEL AND HOUSING...3221
      Flywheel Removal And Installation...3221
      Ring Gear Removal And Installation...3221
      Housing Removal And Installation...3222
  HEATING, VENTILATION, AIR CONDITIONING...3223
    AIR CONDITIONING SYSTEM FLOW...3226
      Description...3226
      Chart...3227
      Components...3228
      Safety Equipment...3231
    REGULAR MAINTENANCE...3233
      Filter Elements Removal And Installation...3233
      Compressor Drive Belt Inspection...3234
      Condenser...3234
      Air Conditioning Service Chart...3235
      A/C Evaporator Coil...3236
    TROUBLESHOOTING...3237
      Blower Motor Does Not Operate...3237
      Blower Motor Operates Normally But Air Flow Is Insufficient...3237
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...3237
      The Compressor Does Not Operate At All Or Operates Improperly...3238
      Gauge Pressure Related Troubleshooting...3239
      Temperature / Pressure Chart...3241
      Poor A/C Performance...3242
      HVAC Repair And Leaks...3242
      Electrical System...3243
      Engine Coolant Bypassing The Heater Valve...3250
      Heater Valve Not Opening Or Closing...3251
    SYSTEM CHARGING AND RECLAMATION...3253
      Refrigerant Identification...3253
      Reclamation And Charging With Recovery / Charging Unit...3254
      Charging With A Manifold Gauge Set...3256
    COMPRESSOR...3259
      Belt Adjusting...3259
      Removal And Installation...3259
      Oil...3260
      Oil Check...3261
      Clutch Disassembly And Assembly...3263
    CONDENSER...3267
      Removal And Installation...3267
    RECEIVER / DRIER...3269
      Receiver / Drier Removal And Installation...3269
      Pressure Relief Valve Removal And Installation...3270
      Pressure Switch Removal And Installation...3271
    EVAPORATOR / HEATER UNIT...3273
      Removal And Installation...3273
    THERMOSTAT...3277
      Removal And Installation...3277
    EXPANSION VALVE...3279
      Removal And Installation...3279
    EVAPORATOR COIL...3281
      Removal And Installation...3281
    HEATER COIL...3283
      Removal And Installation With A/C...3283
    BLOWER FAN...3285
      Removal And Installation...3285
    HEATER VALVE...3287
      Removal And Installation...3287
      Disassembly And Assembly...3287
  SPECIFICATIONS...3289
    TOOLCAT 5600 UTILITY WORK MACHINE SPECIFICATIONS...3291
      Dimensions...3291
      Performance...3292
      Controls...3292
      Engine...3292
      Hydraulic System...3293
      Electrical...3293
      Power Take-Off (PTO) System (Option)...3294
      Drive System...3294
      Capacities...3294
      Tires...3294
    TORQUE SPECIFICATIONS FOR BOLTS...3295
      Torque For General SAE Bolts...3295
      Torque For General Metric Bolts...3296
    HYDRAULIC CONNECTION SPECIFICATIONS...3297
      O-ring Face Seal Connection...3297
      Straight Thread O-ring Fitting...3298
      Tubelines And Hoses...3298
      Flare Fitting...3298
      O-ring Flare Fitting...3299
      Port Seal Fitting...3301
      Quick-Lok™ Fitting...3302
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...3303
      Specifications...3303
    CONVERSIONS...3305
      Decimal And Millimeter Equivalent Chart...3305
      U.S. To Metric Conversion Chart...3306
  ALPHABETICAL INDEX...3307
  SERVICE MANUAL REVISION...3309
    Revision No: 5600 - 1...3309
    Revision No: 5600 - 2...3311
    Revision No: 5600 - 3...3313
    Revision No: 5600 - 4...3315
    Revision No: 5600 - 5...3317
    Revision No: 5600 - 6...3319
    Revision No: 5600 - 7...3321
6904791 (1-11) - Toolcat 5600 Utility Work Machine Operation & Maintenance Manual...3323
  OPERATOR SAFETY WARNINGS...3325
  CONTENTS...3327
  FOREWORD...3329
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...3331
    REGULAR MAINTENANCE ITEMS...3331
    SERIAL NUMBER LOCATIONS...3332
      Utility Work Machine Serial Number...3332
      Engine Serial Number...3332
    DELIVERY REPORT...3332
    UTILITY WORK MACHINE IDENTIFICATION...3333
    FEATURES, ACCESSORIES AND ATTACHMENTS...3334
      Standard Items...3334
      Options And Accessories...3334
      Buckets Available...3334
      Attachments...3334
  SAFETY & TRAINING RESOURCES...3335
    SAFETY INSTRUCTIONS...3337
      Before Operation...3337
      Safe Operation Is The Operator’s Responsibility...3338
      Safe Operation Needs A Qualified Operator...3338
      Avoid Silica Dust...3339
    FIRE PREVENTION...3339
      Maintenance...3339
      Operation...3339
      Electrical...3339
      Hydraulic System...3340
      Fueling...3340
      Starting...3340
      Spark Arrestor Exhaust System...3340
      Welding And Grinding...3340
      Fire Extinguishers...3340
    MACHINE SIGNS (DECALS)...3341
    PUBLICATIONS AND TRAINING RESOURCES...3343
  OPERATING INSTRUCTIONS...3345
    OPERATOR CONTROLS AND INSTRUMENT PANELS...3349
      Overview...3349
      Switch Panel...3349
      Control Panel...3350
      Indicator Icons...3351
      Floor Console...3352
      Center Console...3352
    TOOLCAT INTERLOCK CONTROL SYSTEM (TICS)...3353
      TICS And Arm Rest Operation...3353
    ENGINE SPEED CONTROL...3353
      Operation...3353
    PARKING BRAKE...3354
      Operation...3354
    BACK-UP ALARM SYSTEM (IF EQUIPPED)...3355
      Description...3355
      Operation...3355
    STEERING MODE SELECTION...3356
      Operation...3356
    TRAVEL DIRECTION CONTROL LEVER...3357
      Operation...3357
      Two-Speed Control...3357
    DRIVE PEDAL...3357
      Operation...3357
    BRAKE PEDAL...3357
      Operation...3357
    STOPPING THE UTILITY WORK MACHINE...3358
      Procedure...3358
    WHEEL ALIGNMENT...3358
      Procedure...3358
    LIFT ARM BYPASS...3359
      Operation...3359
    HYDRAULIC CONTROLS...3360
      Description...3360
      Lift Arm Operation...3360
      Lift Arm Float Position...3360
      Tilt Operation...3360
      Front Auxiliary Hydraulics Operation...3361
      Front Auxiliary Hydraulics Operation (CONTINUOUS FLOW)...3361
      Quick Couplers...3361
      Relieve Hydraulic Pressure (Utility Work Machine And Attachment)...3362
      High-Flow Hydraulics Operation (If Equipped)...3362
    REMOTE HYDRAULICS (OPTION)...3363
      Description...3363
      Quick Couplers And Hoses...3363
      Operating The Remote Hydraulics...3365
    ATTACHMENT CONTROL DEVICE (ACD) (IF EQUIPPED)...3366
      Description...3366
    DAILY INSPECTION...3367
      Daily Inspection And Maintenance...3368
    PRE-STARTING PROCEDURE...3369
      Entering The Utility Work Machine...3369
      Seat And Steering Wheel Adjustment...3369
      Seat Belt Adjustment And Arm Rest...3370
    STARTING THE ENGINE...3370
      Key Switch...3370
      Keyless...3371
      Cold Temperature Starting...3371
      Warming The Hydraulic / Hydrostatic System...3371
    MONITORING THE CONTROL PANEL...3372
      Key Switch And Keyless...3372
      Warning And Shutdown...3372
    STOPPING THE ENGINE AND LEAVING THE UTILITY WORK MACHINE...3373
      Procedure...3373
      Emergency Exit (When Equipped With Cab)...3373
    MACHINE LOAD CAPACITIES...3374
      Loader Rated Operating Capacity (ROC)...3374
      Maximum Cargo Box Load...3374
      Machine Rated Capacity...3374
      Maximum Trailer Hitch Tongue Weight...3374
      Total Rated Capacity...3374
    ATTACHMENTS...3375
      Choosing The Correct Bucket...3375
      Pallet Fork...3375
      Installing And Removing The Attachment (Hand Lever Bob-Tach)...3376
      Installing And Removing The Attachment (Power Bob-Tach)...3378
    OPERATING PROCEDURE...3381
      Inspect The Work Area...3381
      Basic Operating Instructions...3381
      Operating With A Full Bucket And Empty Cargo Box...3381
      Operating With An Empty Bucket And Loaded Cargo Box...3381
      Filling And Emptying The Bucket...3382
      Leveling The Ground Using Float...3383
      Backfilling...3383
      Work Mode Operation...3383
      Opening And Closing The Tailgate...3384
      Raising And Lowering The Cargo Box...3384
      Hauling Loads In The Cargo Box...3384
      Towing Equipment With The Utility Work Machine...3384
    TOWING THE UTILITY WORK MACHINE...3384
      Procedure...3384
    TRANSPORTING THE UTILITY WORK MACHINE ON A TRAILER...3385
      Loading And Unloading...3385
      Fastening...3385
  PREVENTIVE MAINTENANCE...3387
    MAINTENANCE SAFETY...3391
    SERVICE SCHEDULE...3393
      Chart...3393
    TOOLCAT INTERLOCK CONTROL SYSTEM (TICS)...3394
      Description...3394
      Inspecting The TICS...3394
      Maintaining The TICS...3394
    LIFT ARM BYPASS...3395
      Inspecting...3395
    SEAT BELT...3396
      Inspection And Maintenance...3396
    BACK-UP ALARM SYSTEM (IF EQUIPPED)...3397
      Description...3397
      Inspecting...3397
    NEUTRAL START SYSTEM...3398
      Inspecting...3398
    LIFT ARM SUPPORT DEVICE...3399
      Installing...3399
      Removing...3399
    CARGO BOX SUPPORT DEVICE...3400
      Installing...3400
      Removing...3400
      Raising The Cargo Box When Engine Is Not Running...3401
    PARKING BRAKE SYSTEM...3401
      Inspection And Maintenance...3401
    OPERATOR CAB...3401
      Description...3401
    CAB FILTERS...3402
      Cleaning And Maintenance...3402
      Fresh Air Filter...3402
      Recirculating Air Filter...3402
    HEATING AND AIR CONDITIONING...3403
      Cleaning And Maintenance...3403
      Filters...3403
      Evaporator...3403
      Air Conditioning Lubrication...3403
      Troubleshooting...3403
    AIR CLEANER SERVICE...3404
      Replacing Filter Elements...3404
    OPERATOR SEAT...3405
      Removal And Installation...3405
    PASSENGER SEAT...3406
      Removal And Installation...3406
    FUEL SYSTEM...3407
      Fuel Specifications...3407
      Biodiesel Blend Fuel...3407
      Filling The Fuel Tank...3408
      Fuel Filter...3408
      Removing Air From The Fuel System...3409
      Filling A Portable Fuel Container...3409
    ENGINE LUBRICATION SYSTEM...3410
      Checking And Adding Engine Oil...3410
      Engine Oil Chart...3410
      Removing And Replacing Oil And Filter...3410
    ENGINE COOLING SYSTEM...3412
      Checking Level...3412
      Cleaning...3413
      Removing And Replacing Coolant...3413
    ELECTRICAL SYSTEM...3414
      Description...3414
      Fuse And Relay Location - Cab Panel...3414
      Fuse And Relay Location - Frame Panel...3415
      Battery Maintenance...3416
      Using A Booster Battery (Jump Starting)...3417
      Removing And Installing Battery...3418
    HYDRAULIC / HYDROSTATIC SYSTEM...3419
      Checking Fluid...3419
      Hydraulic / Hydrostatic Fluid Chart...3419
      Adding Fluid...3419
      Alternate Fill Procedure...3420
      Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters...3421
      Removing And Replacing Hydraulic Fluid...3423
      Breather Cap...3424
    SPARK ARRESTOR MUFFLER...3425
      Cleaning Procedure...3425
    SUPPORTING THE MACHINE ON JACKSTANDS...3426
      Procedure...3426
    TIRE MAINTENANCE...3427
      Wheel Nuts...3427
      Rotating...3427
      Mounting...3427
    TRANS AXLE (FRONT AND REAR)...3428
      Checking And Adding Lubricant...3428
      Removing And Replacing Lubricant...3429
    ALTERNATOR BELT...3430
      Belt Adjustment...3430
      Belt Replacement...3430
    AIR CONDITIONING BELT...3430
      Belt Adjustment...3430
      Belt Replacement...3431
    DRIVE BELT...3432
      Belt Adjustment...3432
      Belt Replacement...3434
    LUBRICATING THE UTILITY WORK MACHINE...3436
      Lubrication Locations...3436
    PIVOT PINS...3438
      Inspection And Maintenance...3438
    BOB-TACH (HAND LEVER)...3439
      Inspection And Maintenance...3439
    BOB-TACH (POWER OPTION)...3440
      Inspection And Maintenance...3440
    UTILITY WORK MACHINE STORAGE AND RETURN TO SERVICE...3441
      Storage...3441
      Return To Service...3441
  SYSTEM SETUP & ANALYSIS...3443
    DIAGNOSTIC SERVICE CODES...3445
      Viewing Service Codes...3445
      Service Codes List...3446
    CONTROL PANEL SETUP...3448
      Enter Setup...3448
      Two-Speed...3448
      High Flow...3448
      Horsepower Management...3448
      Tire Size...3448
      Save Setup...3448
      Exit Setup...3448
    PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START)...3449
      Password Description...3449
      Changing The Owner And Operator Passwords...3449
      Password Lockout Feature...3450
  MACHINE SIGN TRANSLATIONS...3451
    MACHINE SIGN TRANSLATIONS...3453
      Service Schedule (7134482)...3453
      Machine Load Capacities (6814303)...3456
      Cargo Box Support (7128961)...3456
      Operation Instruction (6814309)...3457
      Danger (7114128)...3457
      Wheel Alignment (6814813)...3457
      Warning (7114129)...3458
      Warning (6814300)...3458
      Lift Arm Support (7128957)...3459
      Warning (6814301)...3460
      Coolant (6708929)...3460
      Warning (6814310)...3460
      Warning (6814302)...3460
      Danger (6814307)...3461
      Bob-Tach (6561383)...3461
      Auxiliary Coupler (6731757)...3461
      Joystick (6814312)...3462
      Warning (6737189)...3462
      Warning (6804233)...3462
      Warning (7146237) (Remote Hydraulics Option Only)...3463
  SPECIFICATIONS...3465
    (5600) UTILITY WORK MACHINE SPECIFICATIONS...3467
      Dimensions (With 27 Inch Tires)...3467
      Dimensions (With 29 Inch Tires)...3468
      Performance...3469
      Controls...3469
      Engine...3469
      Hydraulic System...3470
      Electrical...3470
      Drive System...3471
      Capacities...3471
      Tires...3471
  WARRANTY...3473
    WARRANTY...3475
  ALPHABETICAL INDEX...3477
6904792 (3-11) - Toolcat 5600 Utility Work Machine Service Manual...3479
  MAINTENANCE SAFETY...3481
  CONTENTS...3483
  FOREWORD...3485
    FOREWORD...3487
    SAFETY INSTRUCTIONS...3490
    FIRE PREVENTION...3492
      Maintenance...3492
      Operation...3492
      Electrical...3492
      Hydraulic System...3492
      Fueling...3492
      Starting...3492
      Spark Arrestor Exhaust System...3492
      Welding And Grinding...3493
      Fire Extinguishers...3493
    SERIAL NUMBER LOCATIONS...3494
      Utility Work Machine Serial Number...3494
      Engine Serial Number...3494
    DELIVERY REPORT...3495
    UTILITY WORK MACHINE IDENTIFICATION...3496
  SAFETY & MAINTENANCE...3497
    LIFTING AND BLOCKING THE UTILITY WORK MACHINE...3501
      Procedure For Jackstand Placement On The Control Arms...3501
      Procedure For Jackstand Placement On The Frame...3502
    LIFT ARM SUPPORT DEVICE...3503
      Installing...3503
      Removing...3503
    CARGO BOX SUPPORT DEVICE...3505
      Installing...3505
      Removing...3505
      Raising The Cargo Box When Engine Is Not Running...3506
    OPERATOR CAB...3507
      Description...3507
    TRANSPORTING THE UTILITY WORK MACHINE ON A TRAILER...3509
      Loading And Unloading...3509
      Fastening...3509
    TOWING THE UTILITY WORK MACHINE...3511
      Procedure...3511
    REMOTE START TOOL KIT - MEL1563...3513
      Remote Start Tool - MEL1563...3513
      Service Tool Harness Control - MEL1565...3514
      Service Tool Harness Communicator - MEL1566...3515
      Remote Start Procedure...3516
    REMOTE START TOOL (SERVICE TOOL) KIT - 6689779...3519
      Description...3519
      Remote Start Tool (Service Tool) - 6689778...3520
      Service Tool Harness - 6689747...3521
      Computer Service Tool Harness - 6689746...3522
      Remote Start Procedure...3523
    SERVICE SCHEDULE...3527
      Chart...3527
    AIR CLEANER SERVICE...3529
      Replacing Filter Elements...3529
    ENGINE COOLING SYSTEM...3531
      Cleaning...3531
      Checking Level...3532
      Removing And Replacing Coolant...3533
    FUEL SYSTEM...3535
      Fuel Specifications...3535
      Filling The Fuel Tank...3535
      Fuel Filter...3535
      Removing Air From The Fuel System...3536
      Filling A Portable Fuel Container...3536
    ENGINE LUBRICATION SYSTEM...3537
      Checking And Adding Engine Oil...3537
      Engine Oil Chart...3537
      Removing And Replacing Oil And Filter...3538
    HYDRAULIC / HYDROSTATIC SYSTEM...3539
      Checking Fluid...3539
      Hydraulic / Hydrostatic Fluid Chart...3539
      Adding Fluid...3539
      Alternate Fill Procedure...3540
      Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters...3541
      Removing And Replacing Hydraulic Fluid...3542
      Breather Cap...3544
    TRANS AXLE (FRONT AND REAR)...3545
      Checking And Adding Lubricant...3545
      Removing And Replacing Lubricant...3546
    BOB-TACH (HAND LEVER)...3547
      Inspection And Maintenance...3547
    BOB-TACH (POWER)...3549
      Inspection And Maintenance...3549
    LUBRICATING THE UTILITY WORK MACHINE...3551
      Lubrication Locations...3551
    TIRE MAINTENANCE...3553
      Wheel Nuts...3553
      Rotating...3553
      Mounting...3553
    SPARK ARRESTER MUFFLER...3555
      Cleaning Procedure...3555
    UTILITY WORK MACHINE STORAGE AND RETURN TO SERVICE...3557
      Storage...3557
      Return To Service...3557
    PIVOT PINS...3559
      Inspection And Maintenance...3559
    STOPPING THE ENGINE AND LEAViNG THE UTILITY WORK MACHINE...3561
      Procedure...3561
      Emergency Exit (When Equipped With Cab)...3561
    SEAT BELT...3563
      Inspection And Maintenance...3563
  HYDRAULIC SYSTEM...3565
    HYDRAULIC / HYDROSTATIC SCHEMATICS...3569
    HYDRAULIC SYSTEM INFORMATION...3573
      Glossary Of Hydraulic / Hydrostatic Symbols...3573
      Troubleshooting...3577
    CYLINDER (LIFT)...3579
      Testing...3579
      Removal And Installation...3580
      Parts Identification...3583
      Disassembly...3584
      Assembly...3585
    CYLINDER (TILT)...3589
      Testing...3589
      Removal And Installation...3590
      Parts Identification...3592
      Disassembly...3593
      Assembly...3594
    CYLINDER (CARGO BOX)...3597
      Testing...3597
      Removal And Installation (Left Side)...3598
      Removal And Installation (Right Side)...3600
      Parts Identification...3601
      Disassembly...3602
      Assembly...3603
    CYLINDER (STEERING)...3607
      Testing (Rear)...3607
      Testing (Front)...3608
      Removal And Installation (Rear)...3609
      Removal And Installation (Front)...3612
      Parts Identification...3615
      Disassembly And Assembly...3616
    CYLINDER (BOB-TACH)...3621
      Testing...3621
      Removal And Installation...3622
      Parts Identification...3623
      Disassembly...3624
      Assembly...3625
    MAIN RELIEF VALVE...3629
      Description...3629
      Auxiliary Main Relief Valve Testing...3629
      Auxiliary Main Relief Valve Removal And Installation...3630
      Lift, Tilt And Cargo Box Main Relief Valve Testing...3631
      Lift, Tilt And Cargo Box Main Relief Valve Removal And Installation...3632
    PORT RELIEF VALVES...3633
      Description...3633
      Lift Port Relief Valve Testing (Base End)...3633
      Lift Port Relief Valve Testing (Rod End)...3634
      Tilt Port Relief Valve Testing...3635
    HYDRAULIC CONTROL VALVE...3637
      Description...3637
      Removal And Installation...3637
      Identification Chart...3640
      Disassembly...3641
      End Valve Section Disassembly And Assembly...3644
      Box Valve Section Disassembly And Assembly...3646
      Lift Valve Section Disassembly And Assembly...3650
      Tilt Valve Section Disassembly And Assembly...3655
      Mid Inlet / High flow Valve Section Disassembly And Assembly...3659
      Auxiliary Valve Section Disassembly And Assembly...3663
      Assembly...3668
    STEERING SELECTOR VALVE...3673
      Description...3673
      Removal And Installation...3673
      Disassembly And Assembly...3675
    PILOT MANIFOLD...3677
      Description...3677
      Removal And Installation...3677
      Parts Identification...3679
      Disassembly And Assembly...3680
    LIFT ARM (BYPASS)...3685
      Description...3685
      Testing...3685
    HYDRAULIC PUMP...3687
      Description...3687
      Auxiliary Section Testing...3688
      Lift, Tilt And Cargo Box Section Testing...3690
      Steering And Cooling Fan Section Testing...3692
      Removal And Installation...3694
      Parts Identification...3696
      Disassembly And Assembly...3697
    POWER STEERING PUMP...3707
      Description...3707
      Removal And Installation...3707
      Disassembly And Assembly...3708
    HYDRAULIC / HYDROSTATIC FILTER...3713
      Description...3713
      Housing Removal And Installation...3713
      Case Drain Housing Removal And Installation...3714
    CONTROL JOYSTICK...3715
      Description...3715
      Handle Removal And Installation...3715
    HYDRAULIC FLUID RESERVOIR...3717
      Description...3717
      Removal And Installation...3717
      Hydraulic Fluid Screen...3720
    OIL COOLER...3721
      Description...3721
      Removal And Installation...3721
    AUXILIARY HYDRAULIC COUPLER BLOCK...3727
      Description...3727
      Removal And Installation...3727
      Disassembly And Assembly...3728
    REMOTE HYDRAULICS DIVERTER VALVE...3731
      Description...3731
      Removal And Installation...3731
      Disassembly And Assembly...3732
    POWER BOB-TACH BLOCK...3733
      Description...3733
      Removal And Installation...3733
      Disassembly And Assembly...3735
    DIVERTER VALVE (REAR AUXILIARY)...3741
      Description...3741
      Solenoid Testing...3741
      Removal And Installation...3741
      Disassembly And Assembly...3744
  HYDROSTATIC SYSTEM...3753
    HYDROSTATIC SYSTEM INFORMATION...3755
      Troubleshooting...3755
      Description...3756
    HYDROSTATIC MOTOR...3757
      Description...3757
      Removal And Installation (Front)...3757
      Removal And Installation (Rear)...3760
      Parts Identification...3764
      Disassembly...3765
      Assembly...3775
    CHARGE PRESSURE...3781
      Description...3781
      Testing...3781
    HYDROSTATIC PUMP...3783
      Description...3783
      Removal And Installation...3783
      Control Module Removal And Installation...3787
      Replenishing / High Pressure Relief Valve Removal And Installation...3789
      Charge Relief Valve Removal And Installation...3789
      Parts Identification...3790
      Disassembly And Assembly...3792
      Mechanical Neutral Adjustment...3806
      Hydraulic Controller Neutral Adjustment...3811
    DRIVE BELT...3815
      Description...3815
      Shield Removal And Installation...3815
      Adjusting...3816
      Belt Removal And Installation...3818
      Tensioner Pulley Removal And Installation...3819
      Tensioner Pulley Parts Identification...3820
      Tensioner Pulley Disassembly...3821
      Tensioner Pulley Assembly...3822
  DRIVE SYSTEM...3825
    BRAKE...3827
      Description...3827
      Disassembly And Assembly (Front Trans Axle)...3827
      Disassembly And Assembly (Rear Trans Axle)...3827
    TRANS AXLE...3829
      Description...3829
      Removal And Installation (Front)...3829
      Removal And Installation (Rear)...3833
      Brake Housing Disassembly And Assembly...3837
      Primary Housing Disassembly And Assembly...3840
    HUB...3847
      Description...3847
      Removal And Installation...3847
    CV SHAFT...3849
      Description...3849
      Removal And Installation (Front)...3849
      Removal And Installation (Rear)...3852
      Inner Boot Removal And Installation...3855
      Outer Boot Removal And Installation...3857
  MAINFRAME...3861
    OPERATOR CAB...3863
      Removal And Installation...3863
    OPERATOR SEAT...3873
      Removal And Installation...3873
      Seat Belt Removal And Installation...3874
      Seat Pan Removal And Installation...3875
      Slide Rail Removal And Installation...3875
      Arm Rest Bracket Removal And Installation...3876
      Arm Rest Removal And Installation...3876
    PASSENGER SEAT...3877
      Removal And Installation...3877
      Seat Belt Removal And Installation...3878
      Seat Pan Removal And Installation...3879
      Arm Rest Removal And Installation...3879
    BOB-TACH (HAND LEVER)...3881
      Description...3881
      Removal And Installation...3881
      Lever And Wedge Disassembly And Assembly...3882
    BOB-TACH (POWER)...3883
      Description...3883
      Removal And Installation...3883
      Lever And Wedge Disassembly And Assembly...3885
    LIFT ARM...3887
      Removal And Installation...3887
    CARGO BOX...3889
      Removal And Installation...3889
    STEERING COLUMN...3891
      Removal And Installation...3891
    FUEL TANK...3893
      Removal And Installation...3893
      Fuel Level Sender Removal And Installation...3895
    DRIVE AND BRAKE PEDALS...3897
      Description...3897
      Removal And Installation...3897
      Drive Pedal Disassembly And Assembly...3898
    SHOCKS...3899
      Removal And Installation...3899
    CONTROL ARMS...3901
      Removal And Installation (Lower Arm)...3901
      Removal And Installation (Upper Arm)...3902
      Inspection...3903
      Ball Joint Removal And Installation...3904
    SPINDLE...3905
      Removal And Installation...3905
    TIE ROD...3907
      Description...3907
      Removal And Installation...3907
      Toe Adjustment Procedure...3908
    FLOOR CONSOLE...3911
      Access Cover Removal And Installation (Side)...3911
      Access Cover Removal And Installation (Top)...3911
    CENTER CONSOLE...3913
      Removal And Installation...3913
    FENDER...3915
      Removal And Installation (Front)...3915
      Removal And Installation (Left Rear)...3916
      Removal And Installation (Right Rear)...3917
    WINDOWS...3919
      Front, Rear And Lower Door Removal And Installation...3919
      Upper Door Removal And Installation...3920
  ELECTRICAL SYSTEM & ANALYSIS...3923
    ELECTRICAL SCHEMATICS...3927
    ELECTRICAL SYSTEM INFORMATION...3940
      Glossary Of Electrical Symbols...3940
      Cab Harness Connectors...3943
      Mainframe / Engine Harness Connectors...3944
      Description...3945
      Troubleshooting...3946
      Fuse And Relay Location - Cab Panel...3947
      Fuse And Relay Location - Frame Panel...3948
      Solenoid Testing...3949
    BATTERY...3950
      Removal And Installation...3950
      Servicing...3951
      Using A Booster Battery (Jump Starting)...3952
    ALTERNATOR...3954
      Belt Adjustment...3954
      Charging System Inspection...3955
      Alternator Voltage Testing...3956
      Low Voltage Testing...3957
      High Voltage Testing...3957
      Removal And Installation...3958
      Parts Identification...3959
    STARTER...3960
      Testing...3960
      Removal And Installation...3961
      Parts Identification...3962
    INSTRUMENT PANELS...3964
      Display Controller Panel...3964
      Switch Panel...3965
      Floor Console...3966
      Center Console...3966
      Display Controller Panel Removal And Installation...3967
      Light Bulb Removal And Installation (S/N A0W111001 - A0W111722)...3968
      Light Bulb Removal And Installation (S/N A0W111723 & Above)...3968
    LIGHTS...3970
      Front Removal And Installation...3970
    BOBCAT CONTROLLER (DISPLAY)...3972
      Description...3972
      Connector Identification...3973
      Removal And Installation...3974
    BOBCAT CONTROLLER (DRIVE)...3976
      Description...3976
      Connector Identification...3977
      Removal And Installation...3978
    DIAGNOSTIC SERVICE CODES...3980
      Description...3980
      Service Codes List...3981
    DISPLAY CONTROLLER PANEL SETUP...3984
      Display Screen Selection...3984
      Job Clock...3984
      RPM...3984
      Password Description...3985
      Password Entry (For Starting And Operating The Machine)...3985
      Changing The Owner And Operator Passwords...3985
      Password Lockout Feature...3986
    TOOLCAT INTERLOCK CONTROL SYSTEM (TICS)...3988
      Description...3988
      Inspecting The TICS...3988
      Maintaining The TICS...3988
      Lift Arm Bypass Procedure...3989
      Testing The Lift Arm Bypass Procedure...3989
    ARM REST SENSOR...3990
      Description...3990
      Removal And Installation...3990
    SPEED SENSORS...3992
      Description...3992
      Removal And Installation (Front Trans Axle)...3992
    WHEEL POSITION SENSORS...3994
      Description...3994
      Removal And Installation (Front)...3994
      Removal And Installation (Rear)...3995
      Adjusting (In The Machine)...3996
      Adjusting (Out Of The Machine)...3997
    SERVICE PC (LAPTOP COMPUTER)...3998
      Connecting Remote Start Tool...3998
      Connecting Remote Start Tool (Service Tool)...3998
    CALIBRATION...4000
      Description...4000
      Throttle Position Sensor Calibration...4000
      Drive System Calibration...4001
      Brake Pedal Calibration...4002
      Travel Pedal Calibration...4003
    TRAVEL DIRECTION CONTROL LEVER...4004
      Description...4004
      Removal And Installation...4004
    FLYWHEEL RPM SENSOR...4006
      Description...4006
      Adjusting...4006
    ELECTRIC COOLING FAN...4008
      Description...4008
      Removal And Installation...4008
    MAINTENANCE CLOCK...4010
      Description...4010
      Setup...4010
      Reset...4012
    BACK-UP ALARM SYSTEM (IF EQUIPPED)...4014
      Description...4014
      Inspecting...4014
  ENGINE SERVICE...4016
    ENGINE INFORMATION...4018
      Description...4018
      Specifications-Kubota V2003-M-DI-T (Turbo)...4019
      Engine Torque Values...4024
      Troubleshooting...4025
      Engine Removal And Installation...4027
      Engine Mount Replacement...4033
      Compression - Checking...4034
    ENGINE SPEED CONTROL...4036
      Removal And Installation (Position Sensing)...4036
      Removal And Installation (Non Position Sensing)...4036
      Speed Control Cable Removal And Installation...4037
    MUFFLER...4040
      Removal And Installation...4040
    AIR CLEANER...4042
      Housing Removal And Installation...4042
    ENGINE COOLING SYSTEM...4044
      Radiator Removal And Installation...4044
      Hydraulic Fan Removal And Installation...4047
      Hydraulic Fan Disassembly And Assembly...4049
      Water Pump Removal And Installation...4052
      Water Pump Disassembly And Assembly...4052
      Thermostat Housing Removal And Installation...4053
    LUBRICATION SYSTEM...4054
      Oil Pan Removal And Installation...4054
      Oil Pump Removal And Installation...4056
      Oil Pump Inspection...4057
      Engine Oil Pressure - Testing...4058
    FUEL SYSTEM...4060
      Fuel Camshaft Removal And Installation...4060
      Fuel Camshaft Governor Disassembly And Assembly...4061
      Fuel ShutOff Solenoid - Checking...4062
      Fuel ShutOff Solenoid Removal And Installation...4062
      Fuel Injection Pump Removal And Installation...4063
      Injection Pump - Timing...4066
      Fuel Injector Removal And Installation...4068
      Fuel Injector Nozzle Pressure - Checking...4070
      Nozzle Spray Condition...4070
      Valve Seat Tightness...4071
    CYLINDER HEAD...4072
      Glow Plugs - Testing...4072
      Glow Plugs Removal And Installation...4072
      Valve Clearance Adjustment...4074
      Valve Timing - Checking...4075
      Cylinder Head Removal And Installation...4075
      Cylinder Head Disassembly And Assembly...4078
      Cylinder Head - Servicing...4079
      Cylinder Head Top Clearance...4079
      Valve Guide - Checking...4080
      Reconditioning The Valve And Valve Seat...4082
      Valve Spring...4083
      Valve Tappets...4084
      Rocker Arm And Shaft - Checking...4084
    CRANKSHAFT AND PISTONS...4086
      Piston And Connecting Rod Removal And Installation...4086
      Piston And Connecting Rod - Servicing...4087
      Cylinder Bore - Checking...4090
      Connecting Rod Alignment...4090
      Crankshaft Gear Removal And Installation...4091
      Crankshaft And Bearings Removal And Installation...4091
      Crankshaft And Bearings - Servicing...4093
    CAMSHAFT AND TIMING GEARS...4098
      Timing Gearcase Cover Removal And Installation...4098
      Timing Gears Backlash - Checking...4100
      Idler Gear And Camshaft Removal And Installation...4101
      Camshaft - Servicing...4102
      Idler Gear And Shaft - Servicing...4103
    TURBOCHARGER...4104
      Description...4104
      Testing...4104
      Removal And Installation...4105
    FLYWHEEL AND HOUSING...4108
      Flywheel Removal And Installation...4108
      Ring Gear Removal And Installation...4108
      Housing Removal And Installation...4109
  HEATING, VENTILATION, AIR CONDITIONING...4114
    AIR CONDITIONING SYSTEM FLOW...4117
      Description...4117
      Chart...4118
      Components...4119
      Safety Equipment...4122
    REGULAR MAINTENANCE...4124
      Filter Elements Removal And Installation...4124
      Compressor Drive Belt Inspection...4125
      Condenser...4125
      Air Conditioning Service Chart...4126
      A/C Evaporator Coil...4127
    TROUBLESHOOTING...4128
      Blower Motor Does Not Operate...4128
      Blower Motor Operates Normally But Air Flow Is Insufficient...4128
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...4128
      The Compressor Does Not Operate At All Or Operates Improperly...4129
      Gauge Pressure Related Troubleshooting...4130
      Temperature / Pressure Chart...4132
      Poor A/C Performance...4133
      HVAC Repair And Leaks...4133
      Electrical System...4134
      Engine Coolant Bypassing The Heater Valve...4143
      Heater Valve Not Opening Or Closing...4144
    SYSTEM CHARGING AND RECLAMATION...4146
      Refrigerant Identification...4146
      Reclamation And Charging With Recovery / Charging Unit...4147
      Charging With A Manifold Gauge Set...4149
    COMPRESSOR...4152
      Belt Adjusting...4152
      Removal And Installation...4152
      Oil...4153
      Oil Check...4154
      Clutch Disassembly And Assembly...4156
    CONDENSER...4160
      Removal And Installation...4160
    RECEIVER / DRIER...4162
      Receiver / Drier Removal And Installation...4162
      Pressure Relief Valve Removal And Installation...4163
      Pressure Switch Removal And Installation...4164
    EVAPORATOR / HEATER UNIT...4166
      Removal And Installation...4166
    THERMOSTAT...4168
      Removal And Installation...4168
    EXPANSION VALVE...4170
      Removal And Installation...4170
    EVAPORATOR COIL...4172
      Removal And Installation...4172
    HEATER COIL...4174
      Removal And Installation With A/C...4174
    BLOWER FAN...4176
      Removal And Installation...4176
    HEATER VALVE (S/N A0W111001 - A0W111373)...4178
      Removal And Installation...4178
      Disassembly And Assembly...4178
    HEATER VALVE (S/N A0W111374 & ABOVE)...4180
      Removal And Installation...4180
      Disassembly And Assembly...4180
  SPECIFICATIONS...4182
    (5600) UTILITY WORK MACHINE SPECIFICATIONS...4184
      Dimensions (With 27 Inch Tires)...4184
      Dimensions (With 29 Inch Tires)...4185
      Performance...4186
      Controls...4186
      Engine...4186
      Hydraulic System...4187
      Electrical...4187
      Drive System...4188
      Capacities...4188
      Tires...4188
    TORQUE SPECIFICATIONS FOR BOLTS...4190
      Torque For General SAE Bolts...4190
      Torque For General Metric Bolts...4191
    HYDRAULIC CONNECTION SPECIFICATIONS...4192
      O-ring Face Seal Connection...4192
      Straight Thread O-ring Fitting...4193
      Tubelines And Hoses...4193
      Flare Fitting...4193
      O-ring Flare Fitting...4194
      Port Seal Fitting...4196
      Quick-Lok™ Fitting...4197
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...4198
      Specifications...4198
    CONVERSIONS...4200
      Decimal And Millimeter Equivalent Chart...4200
      U.S. To Metric Conversion Chart...4201
  ALPHABETICAL INDEX...4202
  SERVICE MANUAL REVISION...4204
    Revision No: 5600 - 1...4204
    Revision No: 5600 - 2...4206
    Revision No: 5600 - 3...4208
    Revision No: 5600 - 4...4210
    Revision No: 5600 - 5...4212
    Revision No: 5600 - 6...4214
    Revision No: 5600 - 7...4216
    Revision No: 5600 - 8...4218
    Revision No: 5600 - 9...4220
    Revision No: 5600 - 10...4222
    Revision No: 5600 - 11...4224
6904792 (6-12) - Toolcat 5600 Utility Work Machine Service Manual...4226
  MAINTENANCE SAFETY...4228
  CONTENTS...4230
  FOREWORD...4232
    FOREWORD...4234
    SAFETY INSTRUCTIONS...4237
    FIRE PREVENTION...4239
      Maintenance...4239
      Operation...4239
      Electrical...4239
      Hydraulic System...4239
      Fueling...4239
      Starting...4239
      Spark Arrester Exhaust System...4239
      Welding And Grinding...4240
      Fire Extinguishers...4240
    SERIAL NUMBER LOCATIONS...4241
      Utility Work Machine Serial Number...4241
      Engine Serial Number...4241
    DELIVERY REPORT...4242
    UTILITY WORK MACHINE IDENTIFICATION...4243
  SAFETY & MAINTENANCE...4244
    LIFTING AND BLOCKING THE UTILITY WORK MACHINE...4248
      Procedure For Jackstand Placement On The Control Arms...4248
      Procedure For Jackstand Placement On The Frame...4249
    LIFT ARM SUPPORT DEVICE...4250
      Installing...4250
      Removing...4250
    CARGO BOX SUPPORT DEVICE...4252
      Installing...4252
      Removing...4252
      Raising The Cargo Box When Engine Is Not Running...4253
    OPERATOR CAB...4254
      Description...4254
    TRANSPORTING THE UTILITY WORK MACHINE ON A TRAILER...4256
      Loading And Unloading...4256
      Fastening...4256
    TOWING THE UTILITY WORK MACHINE...4258
      Procedure...4258
    REMOTE START TOOL KIT - MEL1563...4260
      Remote Start Tool - MEL1563...4260
      Service Tool Harness Control - MEL1565...4261
      Service Tool Harness Communicator - MEL1566...4262
      Remote Start Procedure...4263
    REMOTE START TOOL (SERVICE TOOL) KIT - 6689779...4266
      Description...4266
      Remote Start Tool (Service Tool) - 6689778...4267
      Service Tool Harness - 6689747...4268
      Computer Service Tool Harness - 6689746...4269
      Remote Start Procedure...4270
    SERVICE SCHEDULE...4274
      Chart...4274
    AIR CLEANER SERVICE...4276
      Replacing Filter Elements...4276
    ENGINE COOLING SYSTEM...4278
      Checking Level...4278
      Cleaning...4279
      Removing And Replacing Coolant...4279
    FUEL SYSTEM...4280
      Fuel Specifications...4280
      Biodiesel Blend Fuel...4280
      Filling The Fuel Tank...4281
      Fuel Filter...4281
      Removing Air From The Fuel System...4282
      Filling A Portable Fuel Container...4282
    ENGINE LUBRICATION SYSTEM...4284
      Checking And Adding Engine Oil...4284
      Engine Oil Chart...4284
      Removing And Replacing Oil And Filter...4285
    HYDRAULIC / HYDROSTATIC SYSTEM...4286
      Checking Fluid...4286
      Hydraulic / Hydrostatic Fluid Chart...4286
      Adding Fluid...4286
      Alternate Fill Procedure...4287
      Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters...4288
      Removing And Replacing Hydraulic Fluid...4289
      Breather Cap...4291
    TRANS AXLE (FRONT AND REAR)...4292
      Checking And Adding Lubricant...4292
      Removing And Replacing Lubricant...4293
    BOB-TACH (HAND LEVER)...4294
      Inspection And Maintenance...4294
    BOB-TACH (POWER)...4296
      Inspection And Maintenance...4296
    LUBRICATING THE UTILITY WORK MACHINE...4298
      Lubrication Locations...4298
    TIRE MAINTENANCE...4300
      Wheel Nuts...4300
      Rotating...4300
      Mounting...4300
    SPARK ARRESTER MUFFLER...4302
      Cleaning Procedure...4302
    PIVOT PINS...4304
      Inspection And Maintenance...4304
    UTILITY WORK MACHINE STORAGE AND RETURN TO SERVICE...4306
      Storage...4306
      Return To Service...4306
    STOPPING THE ENGINE AND LEAViNG THE UTILITY WORK MACHINE...4308
      Procedure...4308
      Emergency Exit (When Equipped With Cab)...4308
    SEAT BELT...4310
      Inspection And Maintenance...4310
  HYDRAULIC SYSTEM...4312
    HYDRAULIC / HYDROSTATIC SCHEMATICS...4316
    HYDRAULIC SYSTEM INFORMATION...4320
      Glossary Of Hydraulic / Hydrostatic Symbols...4320
      Troubleshooting...4324
    CYLINDER (LIFT)...4326
      Testing...4326
      Removal And Installation...4327
      Parts Identification...4330
      Disassembly...4331
      Assembly...4332
    CYLINDER (TILT)...4336
      Testing...4336
      Removal And Installation...4337
      Parts Identification...4339
      Disassembly...4340
      Assembly...4341
    CYLINDER (CARGO BOX)...4344
      Testing...4344
      Removal And Installation (Left Side)...4345
      Removal And Installation (Right Side)...4347
      Parts Identification...4348
      Disassembly...4349
      Assembly...4350
    CYLINDER (STEERING)...4354
      Testing (Rear)...4354
      Testing (Front)...4355
      Removal And Installation (Rear)...4356
      Removal And Installation (Front)...4359
      Parts Identification...4362
      Disassembly And Assembly...4363
    CYLINDER (BOB-TACH)...4368
      Testing...4368
      Removal And Installation...4369
      Parts Identification...4370
      Disassembly...4371
      Assembly...4372
    MAIN RELIEF VALVE...4376
      Description...4376
      Auxiliary Main Relief Valve Testing...4376
      Auxiliary Main Relief Valve Removal And Installation...4377
      Lift, Tilt And Cargo Box Main Relief Valve Testing...4378
      Lift, Tilt And Cargo Box Main Relief Valve Removal And Installation...4379
    PORT RELIEF VALVES...4380
      Description...4380
      Lift Port Relief Valve Testing (Base End)...4380
      Lift Port Relief Valve Testing (Rod End)...4381
      Tilt Port Relief Valve Testing...4382
    HYDRAULIC CONTROL VALVE...4384
      Description...4384
      Removal And Installation...4384
      Identification Chart...4387
      Disassembly...4388
      End Valve Section Disassembly And Assembly...4391
      Box Valve Section Disassembly And Assembly...4393
      Lift Valve Section Disassembly And Assembly...4397
      Tilt Valve Section Disassembly And Assembly...4402
      Mid Inlet / High flow Valve Section Disassembly And Assembly...4406
      Auxiliary Valve Section Disassembly And Assembly...4410
      Assembly...4415
    STEERING SELECTOR VALVE...4420
      Description...4420
      Removal And Installation...4420
      Disassembly And Assembly...4422
    PILOT MANIFOLD...4424
      Description...4424
      Removal And Installation...4424
      Parts Identification...4426
      Disassembly And Assembly...4427
    LIFT ARM (BYPASS)...4432
      Description...4432
      Testing...4432
    HYDRAULIC PUMP...4434
      Description...4434
      Auxiliary Section Testing...4435
      Lift, Tilt And Cargo Box Section Testing...4437
      Steering And Cooling Fan Section Testing...4439
      Removal And Installation...4441
      Parts Identification...4443
      Disassembly And Assembly...4444
    POWER STEERING PUMP...4454
      Description...4454
      Removal And Installation...4454
      Disassembly And Assembly...4455
    HYDRAULIC / HYDROSTATIC FILTER...4460
      Description...4460
      Housing Removal And Installation...4460
      Case Drain Housing Removal And Installation...4461
    CONTROL JOYSTICK S/N A94Y11001- A94Y12003, S/ N A94Y12005 - A94Y12034...4462
      Description...4462
      Handle Removal And Installation...4462
    CONTROL JOYSTICK S/N A94Y12004, S/N A94Y12035 & ABOVE...4464
      Description...4464
      Handle Removal And Installation...4464
    HYDRAULIC FLUID RESERVOIR...4466
      Description...4466
      Removal And Installation...4466
      Hydraulic Fluid Screen...4469
    OIL COOLER...4470
      Description...4470
      Removal And Installation...4470
    AUXILIARY HYDRAULIC COUPLER BLOCK...4476
      Description...4476
      Removal And Installation...4476
      Disassembly And Assembly...4477
    REMOTE HYDRAULICS DIVERTER VALVE...4480
      Description...4480
      Removal And Installation...4480
      Disassembly And Assembly...4481
    POWER BOB-TACH BLOCK...4482
      Description...4482
      Removal And Installation...4482
      Disassembly And Assembly...4484
    DIVERTER VALVE (REAR AUXILIARY)...4490
      Description...4490
      Solenoid Testing...4490
      Removal And Installation...4490
      Disassembly And Assembly...4493
  HYDROSTATIC SYSTEM...4502
    HYDROSTATIC SYSTEM INFORMATION...4504
      Troubleshooting...4504
      Description...4505
    HYDROSTATIC MOTOR...4506
      Description...4506
      Removal And Installation (Front)...4506
      Removal And Installation (Rear)...4509
      Parts Identification...4513
      Disassembly...4514
      Assembly...4524
    CHARGE PRESSURE...4530
      Description...4530
      Testing...4530
    HYDROSTATIC PUMP...4532
      Description...4532
      Removal And Installation...4532
      Control Module Removal And Installation...4536
      Replenishing / High Pressure Relief Valve Removal And Installation...4538
      Charge Relief Valve Removal And Installation...4538
      Parts Identification...4539
      Disassembly And Assembly...4541
      Mechanical Neutral Adjustment...4555
      Hydraulic Controller Neutral Adjustment...4560
    DRIVE BELT...4564
      Description...4564
      Shield Removal And Installation...4564
      Adjusting...4565
      Belt Replacement...4567
      Tensioner Pulley Removal And Installation...4569
      Tensioner Pulley Parts Identification...4570
      Tensioner Pulley Disassembly...4571
      Tensioner Pulley Assembly...4572
  DRIVE SYSTEM...4574
    BRAKE...4576
      Description...4576
      Disassembly And Assembly (Front Trans Axle)...4576
      Disassembly And Assembly (Rear Trans Axle)...4576
    TRANS AXLE...4578
      Description...4578
      Removal And Installation (Front)...4578
      Removal And Installation (Rear)...4582
      Brake Housing Disassembly And Assembly...4586
      Primary Housing Disassembly And Assembly...4589
    HUB...4596
      Description...4596
      Removal And Installation...4596
    CV SHAFT...4598
      Description...4598
      Removal And Installation (Front)...4598
      Removal And Installation (Rear)...4601
      Inner Boot Removal And Installation...4604
      Outer Boot Removal And Installation...4606
  MAINFRAME...4610
    OPERATOR CAB...4612
      Removal And Installation...4612
    OPERATOR SEAT...4622
      Removal And Installation...4622
      Seat Belt Removal And Installation...4623
      Seat Pan Removal And Installation...4624
      Slide Rail Removal And Installation...4624
      Arm Rest Bracket Removal And Installation...4625
      Arm Rest Removal And Installation...4625
    PASSENGER SEAT...4626
      Removal And Installation...4626
      Seat Belt Removal And Installation...4627
      Seat Pan Removal And Installation...4628
      Arm Rest Removal And Installation...4628
    BOB-TACH (HAND LEVER)...4630
      Description...4630
      Removal And Installation...4630
      Lever And Wedge Disassembly And Assembly...4631
    BOB-TACH (POWER)...4632
      Description...4632
      Removal And Installation...4632
      Lever And Wedge Disassembly And Assembly...4634
    LIFT ARM...4636
      Removal And Installation...4636
    CARGO BOX...4638
      Removal And Installation...4638
    STEERING COLUMN...4640
      Removal And Installation...4640
    FUEL TANK...4642
      Removal And Installation...4642
      Fuel Level Sender Removal And Installation...4644
    DRIVE AND BRAKE PEDALS...4646
      Description...4646
      Removal And Installation...4646
      Drive Pedal Disassembly And Assembly...4647
    SHOCKS...4648
      Removal And Installation...4648
    CONTROL ARMS...4650
      Removal And Installation (Lower Arm)...4650
      Removal And Installation (Upper Arm)...4651
      Inspection...4652
      Ball Joint Removal And Installation...4653
    SPINDLE...4654
      Removal And Installation...4654
    TIE ROD...4656
      Description...4656
      Removal And Installation...4656
      Toe Adjustment Procedure...4657
    FLOOR CONSOLE...4660
      Access Cover Removal And Installation (Side)...4660
      Access Cover Removal And Installation (Top)...4660
    CENTER CONSOLE S/N A94Y11001 - A94Y12003, S/N A94Y12005 - A94Y12034...4662
      Removal And Installation...4662
    CENTER CONSOLE S/N A94Y12004, S/N A94Y12035 & ABOVE...4664
      Removal And Installation...4664
    FENDER...4668
      Removal And Installation (Front)...4668
      Removal And Installation (Left Rear)...4669
      Removal And Installation (Right Rear)...4670
    WINDOWS...4672
      Front, Rear And Lower Door Removal And Installation...4672
      Upper Door Removal And Installation...4673
  ELECTRICAL SYSTEM & ANALYSIS...4676
    ELECTRICAL SCHEMATICS...4680
    ELECTRICAL SYSTEM INFORMATION...4693
      Glossary Of Electrical Symbols...4693
      Cab Harness Connectors...4696
      Mainframe / Engine Harness Connectors...4697
      Description...4698
      Troubleshooting...4699
      Fuse And Relay Location - Cab Panel...4700
      Fuse And Relay Location - Frame Panel...4701
      Solenoid Testing...4702
    BATTERY...4703
      Removal And Installation...4703
      Servicing...4704
      Using A Booster Battery (Jump Starting)...4705
    ALTERNATOR...4707
      Belt Adjustment...4707
      Belt Replacement...4707
      Charging System Inspection...4708
      Alternator Voltage Testing...4709
      Low Voltage Testing...4710
      High Voltage Testing...4710
      Removal And Installation...4711
      Parts Identification...4712
    STARTER...4713
      Testing...4713
      Removal And Installation...4714
      Parts Identification...4715
    INSTRUMENT PANELS...4717
      Display Controller Panel...4717
      Switch Panel...4718
      Floor Console...4719
      Center Console (With Early Model Joystick)...4719
      Center Console (With Later Model Joystick)...4720
      Display Controller Panel Removal And Installation...4721
      Light Bulb Removal And Installation (S/N A0W111001 - A0W111722)...4722
      Light Bulb Removal And Installation (S/N A0W111723 & Above)...4722
    LIGHTS...4723
      Front Removal And Installation...4723
    BOBCAT CONTROLLER (DISPLAY)...4725
      Description...4725
      Connector Identification...4726
      Removal And Installation...4727
    BOBCAT CONTROLLER (DRIVE)...4729
      Description...4729
      Connector Identification...4730
      Removal And Installation...4731
    DIAGNOSTIC SERVICE CODES...4733
      Description...4733
      Service Codes List...4734
    DISPLAY CONTROLLER PANEL SETUP...4737
      Display Screen Selection...4737
      Two-Speed...4737
      High Flow...4737
      Horsepower Management...4737
      Tire Size...4737
      Save Setup...4737
      Exit Setup...4737
      Password Description...4738
      Password Entry (For Starting And Operating The Machine)...4738
      Changing The Owner And Operator Passwords...4738
      Password Lockout Feature...4739
    TOOLCAT INTERLOCK CONTROL SYSTEM (TICS)...4741
      Description...4741
      Inspecting The TICS...4741
      Maintaining The TICS...4741
      Lift Arm Bypass Procedure...4742
      Testing The Lift Arm Bypass Procedure...4742
    ARM REST SENSOR...4743
      Description...4743
      Removal And Installation...4743
    SPEED SENSORS...4745
      Description...4745
      Removal And Installation (Front Trans Axle)...4745
    WHEEL POSITION SENSORS...4747
      Description...4747
      Removal And Installation (Front)...4747
      Removal And Installation (Rear)...4748
      Adjusting (In The Machine)...4749
      Adjusting (Out Of The Machine)...4750
    SERVICE PC (LAPTOP COMPUTER)...4751
      Connecting Remote Start Tool...4751
      Connecting Remote Start Tool (Service Tool)...4751
    CALIBRATION...4753
      Description...4753
      Throttle Position Sensor Calibration...4753
      Drive System Calibration...4754
      Brake Pedal Calibration...4755
      Travel Pedal Calibration...4756
    TRAVEL DIRECTION CONTROL LEVER...4757
      Description...4757
      Removal And Installation...4757
    FLYWHEEL RPM SENSOR...4759
      Description...4759
      Adjusting...4759
    ELECTRIC COOLING FAN...4761
      Description...4761
      Removal And Installation...4761
    MAINTENANCE CLOCK...4763
      Description...4763
      Setup...4763
      Reset...4765
    BACK-UP ALARM SYSTEM...4767
      Description...4767
      Inspecting...4767
  ENGINE SERVICE...4769
    ENGINE INFORMATION...4771
      Description...4771
      Specifications...4772
      Torque Values...4777
      Troubleshooting...4778
      Engine Removal And Installation...4780
      Engine Mount Replacement...4786
      Compression - Checking...4787
    ENGINE SPEED CONTROL...4789
      Removal And Installation (Position Sensing)...4789
      Removal And Installation (Non Position Sensing)...4789
      Speed Control Cable Removal And Installation...4790
    MUFFLER...4793
      Removal And Installation...4793
    AIR CLEANER...4795
      Housing Removal And Installation...4795
    ENGINE COOLING SYSTEM...4797
      Radiator Removal And Installation...4797
      Hydraulic Fan Removal And Installation...4800
      Hydraulic Fan Disassembly And Assembly...4802
      Water Pump Removal And Installation...4805
      Water Pump Disassembly And Assembly...4805
      Thermostat Housing Removal And Installation...4806
    LUBRICATION SYSTEM...4807
      Oil Pan Removal And Installation...4807
      Oil Pump Removal And Installation...4809
      Oil Pump Inspection...4810
      Engine Oil Pressure - Testing...4811
    FUEL SYSTEM...4813
      Fuel Camshaft Removal And Installation...4813
      Fuel Camshaft Governor Disassembly And Assembly...4814
      Fuel ShutOff Solenoid - Checking...4815
      Fuel ShutOff Solenoid Removal And Installation...4815
      Fuel Injection Pump Removal And Installation...4816
      Injection Pump - Timing...4819
      Fuel Injector Removal And Installation...4821
      Fuel Injector Nozzle Pressure - Checking...4823
      Nozzle Spray Condition...4823
      Valve Seat Tightness...4824
    CYLINDER HEAD...4825
      Glow Plugs - Testing...4825
      Glow Plugs Removal And Installation...4825
      Valve Clearance Adjustment...4827
      Valve Timing - Checking...4828
      Cylinder Head Removal And Installation...4828
      Cylinder Head Disassembly And Assembly...4831
      Cylinder Head - Servicing...4832
      Cylinder Head Top Clearance...4832
      Valve Guide - Checking...4833
      Reconditioning The Valve And Valve Seat...4835
      Valve Spring...4836
      Valve Tappets...4837
      Rocker Arm And Shaft - Checking...4837
    CRANKSHAFT AND PISTONS...4839
      Piston And Connecting Rod Removal And Installation...4839
      Piston And Connecting Rod - Servicing...4840
      Cylinder Bore - Checking...4843
      Connecting Rod Alignment...4843
      Crankshaft Gear Removal And Installation...4844
      Crankshaft And Bearings Removal And Installation...4844
      Crankshaft And Bearings - Servicing...4846
    CAMSHAFT AND TIMING GEARS...4851
      Timing Gearcase Cover Removal And Installation...4851
      Timing Gears Backlash - Checking...4853
      Idler Gear And Camshaft Removal And Installation...4854
      Camshaft - Servicing...4855
      Idler Gear And Shaft - Servicing...4856
    TURBOCHARGER...4857
      Description...4857
      Testing...4857
      Removal And Installation...4858
    FLYWHEEL AND HOUSING...4861
      Flywheel Removal And Installation...4861
      Ring Gear Removal And Installation...4861
      Housing Removal And Installation...4862
  HEATING, VENTILATION AND AIR CONDITIONING (HVAC)...4867
    AIR CONDITIONING SYSTEM FLOW...4870
      Description...4870
      Chart...4871
      Components...4872
      Safety Equipment...4875
    REGULAR MAINTENANCE...4877
      Filter Elements Removal And Installation...4877
      Compressor Drive Belt Inspection...4878
      Condenser...4878
      Air Conditioning Service Chart...4879
      A/C Evaporator Coil...4880
    TROUBLESHOOTING...4881
      Blower Motor Does Not Operate...4881
      Blower Motor Operates Normally But Air Flow Is Insufficient...4881
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...4881
      The Compressor Does Not Operate At All Or Operates Improperly...4882
      Gauge Pressure Related Troubleshooting...4883
      Temperature / Pressure Chart...4885
      Poor A/C Performance...4886
      HVAC Repair And Leaks...4886
      Electrical System...4887
      Engine Coolant Bypassing The Heater Valve...4896
      Heater Valve Not Opening Or Closing...4897
    SYSTEM CHARGING AND RECLAMATION...4899
      Refrigerant Identification...4899
      Reclamation And Charging With Recovery / Charging Unit...4900
      Charging With A Manifold Gauge Set...4902
    COMPRESSOR...4905
      Belt Adjusting...4905
      Removal And Installation...4905
      Oil...4906
      Oil Check...4907
      Clutch Disassembly And Assembly...4909
    CONDENSER...4913
      Removal And Installation...4913
    RECEIVER / DRIER...4915
      Receiver / Drier Removal And Installation...4915
      Pressure Relief Valve Removal And Installation...4916
      Pressure Switch Removal And Installation...4917
    EVAPORATOR / HEATER UNIT...4919
      Removal And Installation...4919
    THERMOSTAT...4921
      Removal And Installation...4921
    EXPANSION VALVE...4923
      Removal And Installation...4923
    EVAPORATOR COIL...4925
      Removal And Installation...4925
    HEATER COIL...4927
      Removal And Installation With A/C...4927
    BLOWER FAN...4929
      Removal And Installation...4929
    HEATER VALVE (S/N A0W111001 - A0W111373)...4931
      Removal And Installation...4931
      Disassembly And Assembly...4931
    HEATER VALVE (S/N A0W111374 & ABOVE)...4933
      Removal And Installation...4933
      Disassembly And Assembly...4933
  SPECIFICATIONS...4935
    (5600) UTILITY WORK MACHINE SPECIFICATIONS...4937
      Dimensions (With 27 Inch Tires)...4937
      Dimensions (With 29 Inch Tires)...4938
      Performance...4939
      Controls...4939
      Engine...4939
      Hydraulic System...4940
      Electrical...4940
      Drive System...4941
      Capacities...4941
      Tires...4941
    TORQUE SPECIFICATIONS FOR BOLTS...4943
      Torque For General SAE Bolts...4943
      Torque For General Metric Bolts...4944
    HYDRAULIC CONNECTION SPECIFICATIONS...4945
      O-ring Face Seal Connection...4945
      Straight Thread O-ring Fitting...4946
      Tubelines And Hoses...4946
      Flare Fitting...4946
      O-ring Flare Fitting...4947
      Port Seal Fitting...4949
      Quick-Lok™ Fitting...4950
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...4951
      Specifications...4951
    CONVERSIONS...4953
      Decimal And Millimeter Equivalent Chart...4953
      U.S. To Metric Conversion Chart...4954
    SERVICE TOOLS REQUIRED...4955
      Remote Start Tools...4955
      Hydraulic Tools...4956
      Mainframe And Drive Tools...4958
      Electrical Tools...4958
      Engine Tools...4958
      HVAC Tools...4960
  ALPHABETICAL INDEX...4961
  SERVICE MANUAL REVISION...4963
    Revision No: 5600 - 1...4963
    Revision No: 5600 - 2...4965
    Revision No: 5600 - 3...4967
    Revision No: 5600 - 4...4969
    Revision No: 5600 - 5...4971
    Revision No: 5600 - 6...4973
    Revision No: 5600 - 7...4975
    Revision No: 5600 - 8...4977
    Revision No: 5600 - 9...4979
    Revision No: 5600 - 10...4981
    Revision No: 5600 - 11...4983
    Revision No: 5600 - 12...4985
    Revision No: 5600 - 13...4987
6904893 (12-09) - 2200, 2200S, 2300 Utility Vehicle Service Manual...4989
  Section 1 - Safety...5009
    General Warning...5009
  Section 2a - Vehicle Specifications: Honda Gas & Kubota Diesel Powered...5013
    2200 and 2200S Specifications...5013
    2300 Specifications...5015
  Section 2b - Vehicle Specifications: Kawasaki Gas & Kubota Diesel Powered...5017
    2200 and 2200S Specifications...5017
    2200 Homologated Specifications...5019
    2300 Specifications...5021
  Section 3 - General Information...5023
    General Information...5023
    Model Identification...5023
    Engine Serial Number Locations...5024
      Gasoline EngineS...5024
      Diesel Engine...5024
    Storage...5024
      Preparing the Vehicle for Extended Storage...5025
      Returning the Stored Vehicle to Service...5026
    Using A Booster Battery (Jump Starting)...5027
  Section 4 - Body and Trim...5029
    Cleaning the Vehicle...5029
      Seat Cleaning...5029
    Front Body Repair...5030
      Light Scratches...5030
      Abrasions and Haze...5030
      Large Scratches and Abrasions...5030
    Front Body Components...5031
      Instrument Panel Removal...5031
      Instrument Panel Installation...5031
      Front Fascia Removal...5032
      Front Fascia Installation...5032
      Hood Removal...5032
      Hood Installation...5032
      Center Cowl Panel Removal...5032
      Center Cowl Panel Installation...5033
      Side Cowl Panel (Fender) Removal...5033
      Side Cowl Panel (Fender) Installation...5033
      Front Fender Flare Removal...5034
      Front Fender Flare Installation...5034
    Roll-Over Protective Structure (ROPS)...5034
      ROPS Removal...5035
      ROPS Installation...5036
    Seat...5037
      Seat Removal...5037
      Seat Adjustment...5037
      Seat Installation...5037
      Seat Support Removal...5038
      Seat Support Installation...5038
    Safety Belts...5038
      Safety Belt Removal...5038
      Safety Belt Installation...5039
    Cargo Bed - Electric Lift...5039
      Testing the Bed Lift Motor...5039
      Bed Lift Motor Removal...5039
      Bed Lift Motor Installation...5040
      Cargo Bed Removal...5040
      Cargo Bed Installation...5040
    Cargo Bed - Manual Lift...5041
      Cargo Bed Removal...5041
      Cargo Bed Installation...5041
    Rear Fender...5043
      Rear Fender Removal...5043
      Rear Fender Installation...5043
    Floor Mat...5043
      Floor Mat Removal...5043
      Floor Mat Installation...5043
  Section 5 - Accelerator and Brake Pedal Assemblies...5045
    Accelerator Pedal...5045
      Accelerator Pedal Removal...5045
      Accelerator Pedal Installation...5046
      Accelerator Pedal and RPM Adjustment...5046
    Brake Pedal...5047
      Brake Pedal Removal...5047
      Brake Pedal Installation...5047
      Brake Pedal Adjustment...5048
    Park Brake Pedal...5048
      Park Brake Pedal Assembly Removal...5048
      Park Brake Pedal Assembly Installation...5048
  Section 6 - Hydraulic and Park Brake Systems...5051
    Brake System Inspection...5051
    Brake System Troubleshooting...5053
    Brake Pads and Caliper...5055
      Front Brake Pad and Caliper Removal...5055
      Front Brake Pad and Caliper Installation...5057
      Rear Brake Pad and Caliper Removal...5058
      Rear Brake Pad and Caliper Installation...5059
    Brake Disc and Hub...5060
      Front Wheel Disc and Hub Removal...5060
      Front Wheel Disc and Hub Installation...5064
      Rear Wheel Disc Removal...5065
      Rear Wheel Disc Installation...5066
    Hydraulic Line Replacement...5067
      Front Brake Line Removal...5067
      Front Brake Line Installation...5067
      Rear Brake Line Removal...5068
      Rear Brake Line Installation...5069
    Master Cylinder and Reservoir...5070
      Filling the Hydraulic System...5070
      Reservoir Removal...5070
      Reservoir Installation...5070
      Master Cylinder Removal...5071
      Master Cylinder Installation...5071
    Bleeding the Hydraulic Brake System...5072
      Bleeding Brakes on a DOT 5 Fluid Filled System...5072
      Purging the Hydraulic System...5074
    Park Brake System...5075
      Park Brake Adjustment...5075
      Park Brake Cable Adjustment...5075
      Park Brake Wheel Cables...5076
      Front Park Brake Cable Removal...5077
      Front Park Brake Cable Installation...5078
      Park Brake Equalizer Removal...5078
      Park Brake Equalizer Installation...5078
  Section 7 - Steering and Front Suspension...5081
    Steering Wheel...5081
      Steering Wheel Removal...5081
      Steering Wheel Installation...5082
    Steering Column...5082
      Steering Column Removal...5082
      Steering Column Installation...5083
    Rack and Pinion...5083
      Rack and Pinion Removal...5083
      Rack and Pinion Installation...5084
      Rack and Pinion Disassembly...5085
      Rack and Pinion Assembly...5089
    Front Suspension...5091
      Wheel Alignment...5091
    Front Suspension Components...5093
      Steering Upright Removal...5093
      Upper A-Arm Removal...5094
      Upper A-Arm Installation...5096
      Lower A-Arm Removal...5096
      Lower A-Arm Installation...5097
      Front Coil-Over Shock Absorber Removal...5098
      Front Coil-Over Shock Absorber Installation...5099
      Steering Upright Installation...5099
  Section 8 - Wheels and Tires...5101
    General Information...5101
    Wheels...5102
      Wheel Removal...5102
      Wheel Installation...5102
    Tires...5102
      Tire Removal...5102
      Tire Installation...5103
  Section 9 - Rear Suspension...5105
    Rear Coil-Over Shock Absorber...5105
    Swing Arms...5106
      Swing Arm Removal...5106
      Swing Arm Installation...5107
  Section 10a - Periodic Maintenance: Honda Gasoline & Kubota Diesel Vehicles...5109
    Periodic Service Schedule...5109
    Periodic Lubrication Schedule - 2200...5112
    Periodic Lubrication Schedule - 2300...5114
    Lubricating The Attachment Arm And Interface...5115
    Brake Fluid Reservoir...5116
      Brake Fluid...5116
    Engine Oil...5116
      Oil Pressure - Gasoline Engine...5117
      Engine Oil Level Check...5117
      Engine Oil and Filter Change...5118
      Oil Viscosity...5121
    Gearcase Lubrication...5122
      Lubrication Level Check for Front Differential, Transmission, and Rear Differential...5122
      Lubrication Change for Front Differential, Transmission, and Rear Differential...5122
    Hydraulic System - 2300 Vehicle...5124
    Engine Coolant - Diesel Vehicles...5125
      Engine Coolant Level Check...5125
    Fueling Instructions...5125
      Draining Water from Fuel Filter...5126
    Battery...5127
  Section 10b - Periodic Maintenance: Kawasaki Gasoline & Kubota Diesel Powered Vehicles...5129
    Periodic Service Schedule...5129
    Periodic Lubrication Schedule - 2200...5132
    Lubricating The Attachment Arm And Interface...5134
    Brake Fluid Reservoir...5135
      Brake Fluid...5135
    Engine Oil...5135
      Oil Pressure - Gasoline Engine...5136
      Engine Oil Level Check...5136
      Engine Oil and Filter Change...5136
      Oil Viscosity...5139
    Spark Plugs...5140
      Spark Plug Cleaning And Inspection...5140
      Spark Plug Gap Inspection...5140
    Gearcase Lubrication...5141
      Lubrication Level Check for Front Differential, Transmission, and Rear Differential...5141
      Lubrication Change for Front Differential, Transmission, and Rear Differential...5141
    Hydraulic System - 2300 Vehicle...5143
    Engine Coolant - Diesel Vehicles...5144
      Engine Coolant Level Check...5144
    Fueling Instructions...5144
      Draining Water from Fuel Filter...5145
    Battery...5146
  Section 11a - Troubleshooting and Electrical System: Kawasaki Powered Gasoline Vehicles...5147
    Troubleshooting Guide...5147
    Wiring Diagram...5152
    Test Procedures...5154
      Index of Test Procedures...5154
  Section 11b - Troubleshooting and Electrical System: Honda Powered Gasoline Vehicles...5189
    Troubleshooting Guide...5189
    Wiring Diagram...5194
    Test Procedures...5196
      Index of Test Procedures...5196
  Section 11c - Troubleshooting and Electrical System: Diesel Vehicles...5229
    Troubleshooting Guide...5229
    Wiring Diagram...5234
    Test Procedures...5240
      Index of Test Procedures...5240
  Section 12a - Electrical Components: Kawasaki Powered Gasoline Vehicles...5283
    Starter and Starter Solenoid...5283
    Relays...5283
    Neutral Switch...5284
    Carburetor Solenoid...5284
    Carburetor Heater...5285
    Voltage Regulator...5286
    Warning Lights...5287
    Fuel Gauge/Hour Meter...5288
    Key Switch...5289
    12-Volt Accessory Receptacle...5290
    Bed Lift Switch...5291
    Bed Lift Circuit Breaker...5291
    Light Switch...5292
    Fuse...5292
    Reverse Warning Buzzer (If Equipped)...5293
    Reverse Warning Buzzer Limit Switch (If Equipped)...5294
    Front Differential Switch...5295
    Fuel Level Sending Unit...5296
    Ignition Coil and Charge Coil...5297
    Oil Pressure Sensor...5297
    Headlights...5297
    Wire Harness Diodes...5298
    Battery...5299
      General Information...5299
  Section 12b - Electrical Components: Honda Powered Gasoline Vehicles...5303
    Starter and Starter Solenoid...5303
    Relays...5303
    Neutral Switch...5304
    Carburetor Solenoid...5304
    Voltage Regulator...5305
    Warning Lights...5306
    Fuel Gauge/Hour Meter...5307
    Key Switch...5308
    12-Volt Accessory Receptacle...5309
    Bed Lift Switch...5310
    Bed Lift Circuit Breaker...5310
    Light Switch...5311
    Fuse...5311
    Reverse Warning Buzzer...5312
    Reverse Warning Buzzer Limit Switch...5313
    Fuel Level Sending Unit...5314
    Ignition Coil and Charge Coil...5314
    Charge Coil...5315
    Oil Pressure Sensor...5315
    Headlights...5315
    Wire Harness Diodes...5316
    Battery...5317
      General Information...5317
  Section 12c - Electrical Components: Diesel Vehicles...5321
    Starter and Starter Solenoid...5321
    Relays...5321
    Neutral Switch...5322
    Fuel Solenoid...5322
    60-Amp Fusible Link...5323
    Warning Lights...5324
    Fuel Gauge/Hour Meter...5326
    Key Switch...5327
    12-Volt Accessory Receptacle...5327
    Bed Lift Switch...5328
    Bed Lift Circuit Breaker...5328
    Light Switch...5329
    Fuse...5329
    Reverse Warning Buzzer (If Equipped)...5330
    Reverse Warning Buzzer Limit Switch (If Equipped)...5331
    Electric Fuel Pump...5332
    Fuel Level Sending Unit...5332
    Alternator...5333
    Oil Pressure Sensor...5335
    Headlights...5335
    Thermostat Switch...5336
    Fan...5337
    Wire Harness Diodes...5338
    Battery...5339
      General Information...5339
  Section 13a - Kawasaki Gasoline Engine, Muffler, Fuel System, and Clutches...5343
    Gasoline Engine...5343
      Engine Removal...5343
      Engine Installation...5345
      Oil Filter Hoses...5347
    Exhaust System...5348
      Muffler Removal...5348
      Intermediate Pipe Removal...5349
      Intermediate Pipe Installation...5349
      Muffler Installation...5350
    Fuel System...5351
      Fuel Lines...5352
      Fuel Filter...5352
      Fuel Pump...5352
      Carburetor...5352
      Fuel Level Sending Unit...5355
      Fuel Tank...5358
      Fuel Shut-Off Valve...5361
    Engine Control Linkages...5362
      Accelerator Cable...5362
      Choke Cable...5364
      Engine Governor Arm...5366
      Engine RPM Adjustment...5366
    Air Intake System...5367
      Air Filter Replacement...5367
      Air Canister Removal...5368
      Air Canister Installation...5368
      Air Filter Intake Hose Removal...5369
      Air Filter Intake Hose Installation...5369
      Air Filter Outlet Hose Removal...5370
      Air Filter Outlet Hose Installation...5370
    Clutches...5371
      Clutch Troubleshooting...5371
      Drive Belt...5372
      Drive Clutch...5373
      Driven Clutch...5378
      Clutch Cover...5381
  Section 13b - Honda Gasoline Engine, Muffler, Fuel System, and Clutches...5383
    Gasoline Engine...5383
      Engine Removal...5383
      Engine Installation...5385
    Exhaust System...5387
      Muffler Removal...5387
      Intermediate Pipe Removal...5387
      Intermediate Pipe Installation...5388
      Muffler Installation...5388
    Fuel System...5389
      Fuel Lines...5390
      Fuel Filter...5390
      Fuel Pump...5390
      Carburetor...5390
      Fuel Level Sending Unit...5391
      Fuel Tank...5394
      Fuel Shut-Off Valve...5397
      Oil Filter Hoses...5398
    Engine Control Linkages...5398
      Accelerator Cable...5398
      Governor Guard...5401
      Governor Cable...5401
      Accelerator Cable Retention Clip Adjustment...5402
      Ground Speed (Transmission) Governor Arm Adjustment...5403
      Engine Governor Arm...5405
      Engine RPM Adjustment...5405
    Choke and Air Intake System...5406
      Air Filter Replacement...5406
      Choke Cable Removal...5407
      Choke Cable Installation...5408
      Air Canister Removal...5408
      Air Canister Installation...5409
      Air Filter Intake Hose Removal...5409
      Air Filter Intake Hose Installation...5410
      Air Filter Outlet Hose Removal...5410
      Air Filter Outlet Hose Installation...5411
    Clutches...5411
      Clutch Troubleshooting...5412
      Drive Belt...5412
      Drive Clutch...5413
      Driven Clutch...5418
      Clutch Cover...5421
  Section 13c - Diesel Engine, Muffler, Fuel System, and Clutches...5423
    Diesel Engine...5423
      Engine Removal...5423
      Engine Installation...5425
    Exhaust System...5427
      Muffler Removal...5427
      Intermediate Pipe Removal...5427
      Manifold Pipe Removal...5428
      Manifold Pipe Installation...5428
      Intermediate Pipe Installation...5428
      Muffler Installation...5429
    Fuel System...5430
      Fuel Lines...5431
      Fuel Filter Replacement...5431
      Draining Water from the Secondary Fuel Filter...5431
      Electric Fuel Pump...5433
      Fuel Level Sending Unit...5434
      Fuel Tank...5438
    Engine Control Linkages...5441
      Accelerator Cable...5441
      Engine RPM Adjustment...5442
    Air Intake System...5445
      Air Filter Replacement...5445
      Air Canister Removal...5445
      Air Canister Installation...5446
      Air Filter Intake Hose Removal...5446
      Air Filter Intake Hose Installation...5447
      Air Filter Outlet Hose Removal...5448
      Air Filter Outlet Hose Installation...5448
    Clutches...5449
      Clutch Troubleshooting...5449
      Drive Belt...5450
      Drive Clutch...5451
      Driven Clutch...5455
      Clutch Cover...5457
  Section 14 - Drivetrain Components...5461
    Half Shafts...5461
      Half Shaft Removal...5461
      Half Shaft Installation...5463
    Front Differential...5464
      Front Differential Removal...5464
      Front Differential Installation...5466
    Front Driveshaft...5466
      Front Driveshaft Removal...5466
      Front Driveshaft Installation...5467
    Rear Receiver Hitch...5467
      Rear Receiver Hitch Removal...5467
      Rear Receiver Hitch Installation...5467
    Rear Axle...5468
      Rear Axle Removal...5468
      Rear Axle Installation...5470
    Rear Driveshaft...5471
      Rear Driveshaft Removal...5471
      Rear Driveshaft Installation...5472
    Transmission...5472
      Transmission Removal...5472
      Transmission Installation...5474
      Forward/Reverse Shifter Cable...5475
      Forward/Reverse Shifter Handle...5478
    Rear Differential and Axle Shafts...5478
      Rear Differential and Axle Shaft Removal...5478
      Rear Differential and Axle Shaft Installation...5480
      Rear Wheel Bearings...5480
  Section 15 - Radiator and Coolant System (Diesel)...5483
    General Information...5483
      Engine Coolant Level Check...5483
      Engine Coolant Change...5483
    Coolant Reservoir...5485
      Coolant Reservoir Removal...5485
      Coolant Reservoir Installation...5486
    Radiator...5486
      Radiator Removal...5486
      Radiator Installation...5487
    Coolant Pipe Weldment...5488
      Coolant Pipe Weldment Removal...5488
      Coolant Pipe Weldment Installation...5488
    Fan...5489
      Fan Removal...5489
      Fan Installation...5489
  Section 16 - Transmission Models 421274 and 421275...5491
    General Information...5491
    Model Identification...5491
    Service Fixture...5492
    Transmission Removal...5492
    Transmission Disassembly...5493
      Input Shaft Disassembly...5498
      Input Shaft Assembly...5498
      Intermediate Shaft Disassembly...5498
      Output Shaft Disassembly...5502
      Shifter Shaft Removal...5503
      Shifter Shaft Installation...5504
      Case Inspection...5504
      Shaft Seal Removal...5505
      Shaft Seal Installation...5505
      Output Shaft Assembly...5505
      Intermediate Shaft Assembly...5508
      Intermediate and Output Shaft Assembly...5512
    Transmission Assembly...5513
    Transmission Installation...5517
  Section 17 - Front Differential Models 6203-01-139-S and 6203-01-189-S...5519
    General Information...5519
    Axle Half Shaft Removal...5519
    Front Differential Removal...5520
      Tools Required For This Section...5521
    Front Differential Coil And Output Cover...5521
      Coil and Output Cover Removal...5521
      Coil and Output Cover Installation...5524
    Front Differential...5526
      Front Differential Disassembly...5526
      Front Differential Assembly...5532
    Front Differential Installation...5536
    Axle Half Shaft Installation...5536
  Section 18 - Rear Differential Models 420366 and 420851...5537
    General Information...5537
    Axle Shafts and Differential Removal...5538
    Rear Differential Disassembly...5538
      Pinion Gear Removal...5540
      Ring Gear Removal...5542
      Clutch Carrier Assembly...5543
      Ring Gear Installation...5544
      Pinion Gear Installation...5545
      Rear Differential Assembly...5545
    Axle Shafts and Differential Installation...5547
  Section 19 - Kubota D722 Diesel Engine Manual...5549
  Section 20a - Kawasaki FH680D Gasoline Engine Manual...5603
  Section 20b - Honda GX 620 Gasoline Engine Manual...5717
  Section 21 - Hydraulic Attachment System...5817
    Model Identification...5817
    ...
    LIFT ARM...6503
      Removal And Installation...6503
    REAR COVER...6505
      Opening And Closing...6505
      Removal And Installation...6506
      Latch Removal And Installation...6507
      Latch Adjusting...6508
      Rubber Bumper Adjusting...6509
    STEERING COLUMN...6511
      Removal And Installation...6511
    FUEL TANK...6513
      Removal And Installation...6513
      Fuel Level Sender Removal And Installation...6515
    DRIVE AND BRAKE PEDALS...6517
      Description...6517
      ...
  SPECIFICATIONS...8188
    (3200) UTILITY VEHICLE SPECIFICATIONS...8190
      Utility Vehicle Dimensions...8190
      Performance...8191
      Controls...8191
      Engine...8191
      Electrical...8192
      Drive System...8192
      Fluid And Capacities...8192
      Tires...8193
    TORQUE SPECIFICATIONS FOR BOLTS...8194
      Torque For General SAE Bolts...8194
      Torque For General Metric Bolts...8195
    CONVERSIONS...8196
      Decimal And Millimeter Equivalent Chart...8196
      U.S. To Metric Conversion Chart...8197
  ALPHABETICAL INDEX...8198
  SERVICE MANUAL REVISION...8200
    Revision No: 3200 - 1...8200
6989598 (9-11) - 3200 Utility Vehicle Service Manual...8202
  MAINTENANCE SAFETY...8204
  CONTENTS...8206
  FOREWORD...8208
    FOREWORD...8210
    ...
      Front Gearcase Fluid...9321
      Adding Front Gearcase Fluid...9321
      Removing And Replacing Front Gearcase Fluid...9321
    GEARCASE (S/N AJNT20001 & ABOVE AND AJNV20001 & ABOVE)...9322
      Checking Transmission Fluid...9322
      Transmission Fluid...9322
      Adding Transmission Fluid...9322
      Removing And Replacing Transmission Fluid...9322
      Checking Front Gear Case Fluid...9323
      Front Gear Case Fluid...9323
      Adding Front Gear Case Fluid...9323
      Removing And Replacing Front Gear Case Fluid...9323
    TIRE MAINTENANCE...9324
      Tires...9324
      Tire Tread Depth...9324
      Axle And Wheel Nut Torque...9324
      Wheel Removal And Installation...9324
      Mounting...9325
      Tire Pressure...9325
    SPARK ARRESTER MUFFLER...9326
      Cleaning Procedure...9326
    UTILITY VEHICLE STORAGE AND RETURN TO SERVICE...9328
      Storage...9328
      Return To Service...9328
    STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE...9330
      Procedure...9330
  DRIVE SYSTEM...9332
    BRAKE...9336
      General Specifications...9336
      Torque Specifications...9336
      System Service Notes...9337
      Noise Troubleshooting...9338
      System Troubleshooting...9339
      Hydraulic Brake System Operation...9340
      System Parts Identification...9341
      Master Cylinder Removal And Installation...9342
      Foot Brake Pedal Removal And Installation...9343
      Bleeding / Fluid Removal And Installation...9344
      Brake Inspection...9346
      Brake Pad Inspection...9346
      Burnishing...9346
    BRAKE (FRONT)...9348
      Pad Removal...9348
      Pad Installation...9349
      Caliper Removal...9350
      Caliper Parts Identification...9351
      Caliper Disassembly...9352
      Caliper Inspection...9353
      Caliper Assembly...9354
      Caliper Installation...9354
      Disc Inspection...9355
      Disc Removal And Installation...9356
    BRAKE (REAR) (S/N AJNT11001 & ABOVE)...9358
      Pad Removal...9358
      Pad Installation...9359
      Caliper Removal...9360
      Caliper Parts Identification...9361
      Caliper Disassembly...9362
      Caliper Inspection...9363
      Caliper Assembly...9364
      Caliper Installation...9364
      Disc Inspection...9365
      Disc Removal And Installation...9366
    BRAKE (REAR) (S/N AJNV11001 & ABOVE)...9368
      Pad Removal...9368
      Pad Installation...9369
      Caliper Removal...9370
      Caliper Parts Identification...9371
      Caliper Disassembly...9372
      Caliper Inspection...9373
      Caliper Assembly...9374
      Caliper Installation...9374
      Disc Inspection...9375
      Disc Removal And Installation...9376
    BRAKE (PARK)...9378
      Inspection And Maintenance...9378
      Parts Identification...9379
      Lever Removal And Installation...9380
      Cable Tension Inspection...9381
      Cable Adjustment...9381
      Caliper Removal...9382
      Caliper Parts Identification...9383
      Caliper Disassembly...9384
      Caliper Inspection...9384
      Pad Installation...9385
      Caliper Assembly...9385
      Disc Inspection...9386
      Disc Removal And Installation...9387
      Caliper Installation...9388
    GEARCASE (TRANSMISSION)...9390
      General Operation...9390
      System Troubleshooting...9391
      Shift Lever Removal And Installation...9392
      Shift Cable Inspecting...9393
      Shift Cable Adjustment...9393
      Removal And Installation...9394
      Parts Identification...9401
      Disassembly...9403
      Gear Cluster Disassembly...9407
      Snorkel Shaft Removal / Disassembly...9409
      Snorkel / Output Gear Backlash Procedure...9411
      Assembly...9414
    DRIVE BELT...9422
      Removal...9422
      Installation...9423
      Belt Inspection...9423
    CONTINUOUS VARIABLE TRANSMISSION (CVT)...9424
      CVT System Overview...9424
      ...
      Password Description...12287
      Changing The Owner And Operator Passwords...12287
      Password Lockout Feature...12288
  MACHINE SIGN TRANSLATIONS...12289
    MACHINE SIGN TRANSLATIONS...12291
      Service Schedule (7200952)...12291
      Machine Load Capacities (6814303)...12294
      Cargo Box Support (7128961)...12294
      Operation Instruction (6814309)...12295
      Danger (7114128)...12295
      Wheel Alignment (6814813)...12295
      Warning (7114129)...12296
      Warning (6814300)...12296
      Lift Arm Support (7128957)...12297
      Warning (6814301)...12298
      Coolant (6708929)...12298
      Warning (6814310)...12298
      Warning (7183987)...12298
      Danger (6814307)...12299
      Bob-Tach (6561383)...12299
      Auxiliary Coupler (6731757)...12299
      Joystick (6814312)...12300
      Warning (6737189)...12300
      Warning (7146237) (Remote Hydraulics Option Only)...12300
  SPECIFICATIONS...12301
    MACHINE LOAD CAPACITIES...12303
      Loader Rated Operating Capacity (ROC)...12303
      Maximum Cargo Box Load...12303
      Machine Rated Capacity...12303
      Maximum Trailer Hitch Tongue Weight...12303
      Total Rated Capacity...12303
    (5600) UTILITY WORK MACHINE SPECIFICATIONS...12304
      Dimensions (With 27 Inch Tires)...12304
      Dimensions (With 29 Inch Tires)...12305
      Performance...12306
      Controls...12306
      Engine...12306
      Hydraulic System...12307
      Electrical...12307
      Drive System...12308
      Capacities...12308
      Tires...12308
  WARRANTY...12309
    WARRANTY...12311
  ALPHABETICAL INDEX...12313
6990050 (12-13) - Toolcat 5600 Utility Work Machine Service Manual...12315
  MAINTENANCE SAFETY...12317
  CONTENTS...12319
  FOREWORD...12321
    FOREWORD...12323
    SAFETY INSTRUCTIONS...12326
    FIRE PREVENTION...12328
      Maintenance...12328
      Operation...12328
      Electrical...12328
      Hydraulic System...12328
      Fueling...12328
      Starting...12328
      Spark Arrester Exhaust System...12328
      Welding And Grinding...12329
      Fire Extinguishers...12329
    SERIAL NUMBER LOCATIONS...12330
      Utility Work Machine Serial Number...12330
      ...
      Torque For General Metric Bolts...15754
    HYDRAULIC CONNECTION SPECIFICATIONS...15755
      O-ring Face Seal Connection...15755
      Straight Thread O-ring Fitting...15756
      Tubelines And Hoses...15756
      Flare Fitting...15756
      O-ring Flare Fitting...15757
      Port Seal Fitting...15759
      Quick-Lok™ Fitting...15760
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...15761
      Specifications...15761
    CONVERSIONS...15763
      Decimal And Millimeter Equivalent Chart...15763
      U.S. To Metric Conversion Chart...15764
  ALPHABETICAL INDEX...15765
  SERVICE MANUAL REVISION...15767
    Revision No: 5610 - 1...15767
    Revision No: 5610 - 2...15769
6990367 (04-14) - 3650 Utility Vehicle Service Manual...15771
  MAINTENANCE SAFETY...15773
  CONTENTS...15775
  FOREWORD...15777
    FOREWORD...15779
      SAFETY INSTRUCTIONS...15781
      FIRE PREVENTION...15783
        Maintenance...15783
        Operation...15783
        Electrical...15783
        Fueling...15783
        Starting...15783
        Spark Arrester Exhaust System...15783
        Welding And Grinding...15783
        Fire Extinguishers...15784
      SERIAL NUMBER LOCATIONS...15785
        Utility Vehicle Serial Number...15785
        Engine Serial Number...15785
      DELIVERY REPORT...15786
      UTILITY VEHICLE IDENTIFICATION...15787
  SAFETY AND MAINTENANCE...15789
    LIFTING AND BLOCKING THE UTILITY VEHICLE...15791
      Procedure...15791
    ROLL-OVER PROTECTIVE STRUCTURE (ROPS) / OCCUPANT PROTECTIVE STRUCTURE (OPS)...15793
      Description...15793
    TRANSPORTING THE UTILITY VEHICLE ON A TRAILER...15795
      Loading And Unloading...15795
      Fastening...15795
    TOWING THE UTILITY VEHICLE...15797
      Procedure...15797
    SERVICE SCHEDULE...15799
      Chart...15799
    AIR CLEANER SERVICE...15801
      Pre-Filter Element...15801
      Replacing Filter Element...15802
    ENGINE COOLING SYSTEM...15803
      Checking Level...15803
      Cleaning...15804
      Removing And Replacing Coolant...15805
    FUEL SYSTEM...15807
      Fuel Specifications...15807
      Biodiesel Blend Fuel...15807
      Filling The Fuel Tank...15808
      Fuel Filter...15808
      Removing Air From The Fuel System...15809
      Filling A Portable Fuel Container...15809
    ENGINE LUBRICATION SYSTEM...15811
      Checking And Adding Engine Oil...15811
      Engine Oil Chart...15811
      Removing And Replacing Oil And Filter...15812
    HYDRAULIC / HYDROSTATIC SYSTEM...15815
      Checking Fluid...15815
      Hydraulic Fluid...15815
      Adding Fluid...15815
      Removing And Replacing Hydraulic / Hydrostatic Filter...15816
      Removing And Replacing Hydraulic / Hydrostatic Fluid...15817
    GEARCASE...15819
      Checking Transmission Fluid...15819
      Transmission Fluid...15819
      Adding Transmission Fluid...15819
      Removing And Replacing Transmission Fluid...15820
      Checking Front Gearcase Fluid...15820
      Front Gearcase Fluid...15821
      Adding Front Gearcase Fluid...15821
      Removing And Replacing Front Gearcase Fluid...15821
    TIRE MAINTENANCE...15823
      Tires...15823
      Tire Tread Depth...15823
      Axle And Wheel Nut Torque...15823
      Wheel Removal And Installation...15823
      Mounting...15824
      Tire Pressure...15824
    SPARK ARRESTER MUFFLER...15825
      Cleaning Procedure...15825
    UTILITY VEHICLE STORAGE AND RETURN TO SERVICE...15827
      Storage...15827
      Return To Service...15827
    STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE...15829
      Procedure...15829
      Emergency Exit (When Equipped With Cab)...15830
    RELIEVING HYDRAULIC PRESSURE...15831
      Procedure...15831
  DRIVE SYSTEM...15833
  ...
      Fuel Filter...17203
      Removing Air From The Fuel System...17204
      Filling A Portable Fuel Container...17204
    ENGINE LUBRICATION SYSTEM...17205
      Checking And Adding Engine Oil...17205
      Engine Oil Chart...17205
      Removing And Replacing Oil And Filter...17206
    HYDRAULIC / HYDROSTATIC SYSTEM...17207
      Checking Fluid...17207
      Hydraulic / Hydrostatic Fluid Chart...17207
      Adding Fluid...17208
      Alternate Fill Procedure...17208
      Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters...17209
      Removing And Replacing Hydraulic Fluid...17211
      Breather Cap...17212
    TRANSAXLE (FRONT AND REAR)...17213
      Checking And Adding Lubricant...17213
      Removing And Replacing Lubricant...17214
    BOB-TACH (HAND LEVER)...17215
      Inspection And Maintenance...17215
    BOB-TACH (POWER)...17217
      Inspection And Maintenance...17217
    LUBRICATING THE UTILITY WORK MACHINE...17219
      Lubrication Locations...17219
    TIRE MAINTENANCE...17221
      Wheel Nuts...17221
      Rotating...17221
      Mounting...17221
    PIVOT PINS...17223
      Inspection And Maintenance...17223
    UTILITY WORK MACHINE STORAGE AND RETURN TO SERVICE...17225
      Storage...17225
      Return To Service...17225
    STOPPING THE ENGINE AND LEAVING THE UTILITY WORK MACHINE...17227
      Procedure...17227
      Emergency Exit (When Equipped With Cab)...17227
    SEAT BELT...17229
      Inspection And Maintenance...17229
  HYDRAULIC SYSTEM...17231
    HYDRAULIC/HYDROSTATIC SCHEMATICS...17235
    HYDRAULIC SYSTEM INFORMATION...17239
      Glossary Of Hydraulic / Hydrostatic Symbols...17239
      Troubleshooting...17243
    CYLINDER (LIFT)...17245
      Testing...17245
      Removal And Installation...17246
      Parts Identification...17249
      Disassembly...17250
      Assembly...17251
    CYLINDER (TILT)...17255
      Testing...17255
      Removal And Installation...17256
      Parts Identification...17258
      Disassembly...17259
      Assembly...17260
    CYLINDER (CARGO BOX)...17263
      Testing...17263
      Removal And Installation (Left Side)...17264
      Removal And Installation (Right Side)...17266
      Parts Identification...17267
      Disassembly...17268
      Assembly...17269
    CYLINDER (STEERING)...17273
      Testing (Rear)...17273
      Testing (Front)...17274
      Removal And Installation (Rear)...17275
      Removal And Installation (Front)...17278
      Parts Identification...17281
      Disassembly And Assembly...17282
    CYLINDER (BOB-TACH)...17287
      Testing...17287
      Removal And Installation...17288
      Parts Identification...17289
      Disassembly...17290
      Assembly...17291
    MAIN RELIEF VALVE...17295
      Description...17295
      Auxiliary Main Relief Valve Testing...17295
      Auxiliary Main Relief Valve Removal And Installation...17296
      Lift, Tilt And Cargo Box Main Relief Valve Testing...17297
      Lift, Tilt And Cargo Box Main Relief Valve Removal And Installation...17298
    PORT RELIEF VALVES...17299
      Description...17299
      Lift Port Relief Valve Testing (Base End)...17299
      Lift Port Relief Valve Testing (Rod End)...17300
      Tilt Port Relief Valve Testing...17301
    HYDRAULIC CONTROL VALVE...17303
      Description...17303
      Removal And Installation...17303
      Identification Chart...17306
      Disassembly...17307
      End Valve Section Disassembly And Assembly...17310
      Box Valve Section Disassembly And Assembly...17312
      Lift Valve Section Disassembly And Assembly...17316
      Tilt Valve Section Disassembly And Assembly...17321
      Mid Inlet / High flow Valve Section Disassembly And Assembly...17325
      Auxiliary Valve Section Disassembly And Assembly...17329
      Assembly...17334
    STEERING SELECTOR VALVE...17339
      Description...17339
      Removal And Installation...17339
      Disassembly And Assembly...17341
    PILOT MANIFOLD W/O TRACTION CONTROL...17343
      Description...17343
      Removal And Installation...17343
      Parts Identification...17345
      Disassembly And Assembly...17346
    PILOT MANIFOLD WITH TRACTION CONTROL...17351
      Description...17351
      Removal And Installation...17351
      Parts Identification...17353
      Disassembly And Assembly...17354
    LIFT ARM (BYPASS)...17359
      Description...17359
      Testing...17359
    HYDRAULIC PUMP...17361
      Description...17361
      Auxiliary Section Testing...17362
      Lift, Tilt And Cargo Box Section Testing...17364
      Steering And Cooling Fan Section Testing...17366
      Removal And Installation...17368
      Parts Identification...17371
      Disassembly And Assembly...17372
    POWER STEERING PUMP...17381
      Description...17381
      Removal And Installation...17381
      Disassembly And Assembly...17382
    HYDRAULIC / HYDROSTATIC FILTER...17387
      Description...17387
      Housing Removal And Installation...17387
      Case Drain Housing Removal And Installation...17388
    CONTROL JOYSTICK...17389
      Description...17389
      Handle Removal And Installation...17389
    HYDRAULIC FLUID RESERVOIR...17391
      Description...17391
      Removal And Installation...17391
      Hydraulic Fluid Screen...17394
    OIL COOLER / RADIATOR...17395
      Description...17395
      Removal And Installation...17395
    AUXILIARY HYDRAULIC COUPLER BLOCK...17397
      Description...17397
      Removal And Installation...17398
      Disassembly And Assembly (FFI/FI)...17399
      Disassembly And Assembly (FFH/FH)...17401
    REMOTE HYDRAULICS DIVERTER VALVE...17403
      Description...17403
      Removal And Installation...17403
      Disassembly And Assembly...17404
    POWER BOB-TACH BLOCK...17405
      Description...17405
      Removal And Installation...17405
      Disassembly And Assembly...17407
    DIVERTER VALVE (REAR AUXILIARY)...17413
      Description...17413
      Solenoid Testing...17413
      Removal And Installation...17413
      Disassembly And Assembly...17416
  HYDROSTATIC SYSTEM...17425
    HYDROSTATIC SYSTEM INFORMATION...17427
    ...
      Blower Motor Does Not Operate...18643
      Blower Motor Operates Normally But Air Flow Is Insufficient...18643
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...18643
      The Compressor Does Not Operate At All Or Operates Improperly...18644
      Gauge Pressure Related Troubleshooting...18645
      Temperature / Pressure Chart...18647
      Poor A/C Performance...18648
      HVAC Repair And Leaks...18648
      Electrical System...18649
      Engine Coolant Bypassing The Heater Valve...18658
      Heater Valve Not Opening Or Closing...18659
    SYSTEM CHARGING AND RECLAMATION...18661
      Refrigerant Identification...18661
      Reclamation And Charging With Recovery / Charging Unit...18662
      Charging With A Manifold Gauge Set...18664
    COMPRESSOR...18667
      Belt Adjustment...18667
      Belt Replacement...18667
      Removal And Installation...18668
      Oil...18669
      Oil Check...18670
    CONDENSER...18671
      Removal And Installation...18671
    RECEIVER / DRIER...18673
      Receiver / Drier Removal And Installation...18673
      Pressure Relief Valve Removal And Installation...18674
      Pressure Switch Removal And Installation...18675
    EVAPORATOR / HEATER UNIT...18677
      Removal And Installation...18677
    THERMOSTAT...18681
      Description...18681
      Removal And Installation...18682
    EXPANSION VALVE...18685
      Removal And Installation...18685
    EVAPORATOR COIL...18687
      Removal And Installation...18687
    HEATER COIL...18689
      Removal And Installation With A/C...18689
    BLOWER FAN...18691
      Removal And Installation...18691
    HEATER VALVE...18693
      Removal And Installation...18693
      Disassembly And Assembly...18693
  SPECIFICATIONS...18695
    (5610) UTILITY WORK MACHINE SPECIFICATIONS...18697
      Dimensions (With 27 Inch Tires And Without Three-Point Hitch Option)...18697
      Dimensions (With 27 Inch Tires And With Three-Point Hitch Option)...18698
      Dimensions (With 29 Inch Tires And Without Three-Point Hitch Option)...18699
      Dimensions (With 29 Inch Tires And With Three-Point Hitch Option)...18700
      Performance...18701
      Controls...18701
      Engine...18702
      Hydraulic System...18703
      Electrical...18703
      Power Take-Off (PTO) System...18704
      Drive System...18704
      Capacities...18704
      Tires...18704
    TECHNICAL SERVICE GUIDE SPECIFICATIONS...18705
      Engine...18705
      Engine Torques...18705
      Cooling System...18705
      Loader Torques...18706
      Hydraulic / Hydrostatic System...18706
      Fuel Consumption...18706
    TORQUE SPECIFICATIONS FOR BOLTS...18707
      Torque For General SAE Bolts...18707
      Torque For General Metric Bolts...18708
    HYDRAULIC CONNECTION SPECIFICATIONS...18709
      O-ring Face Seal Connection...18709
      Straight Thread O-ring Fitting...18710
      Tubelines And Hoses...18710
      Flare Fitting...18710
      O-ring Flare Fitting...18711
      Port Seal Fitting...18713
      Quick-Lok™ Fitting...18714
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...18715
      Specifications...18715
    CONVERSIONS...18717
      Decimal And Millimeter Equivalent Chart...18717
      U.S. To Metric Conversion Chart...18718
    SERVICE TOOLS REQUIRED...18719
      Remote Start Tools...18719
      Hydraulic Tools...18720
      Mainframe And Drive Tools...18722
      Electrical Tools...18722
      Engine Tools...18722
      HVAC Tools...18724
  ALPHABETICAL INDEX...18725

Bobcat Utility Vehicles 2100, 2100S, 2200, 2300, 3200, 3400, 3400XL, 3450, 3650, 5600, 5610 Repair Service Manual + Operation & Maintenance Manual