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Bobcat Toolcat™ 5600 Utility Work Machine Service Manual- PDF DOWNLOAD
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Description
Bobcat Toolcat™ 5600 Utility Work Machine Service Manual- PDF DOWNLOAD
FILE DETAILS:
Bobcat Toolcat™ 5600 Utility Work Machine Service Manual- PDF DOWNLOAD
Language : English
Pages : 743
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat Toolcat™ 5600 Utility Work Machine Service Manual- PDF DOWNLOAD
FOREWORD
This manual is for the Toolcat Utility Work Machine mechanic. It provides necessary servicing and adjustment procedures for the Toolcat Utility Work Machine and its component parts and systems. Refer to the for operating instructions, starting procedure, daily checks, etc.
SAFETY INSTRUCTIONS
Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:
- The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
- The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
- Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
- An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
- The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
- The Utility Work Machine Operator Training Course is available through your local dealer or at www.training.bobcat.com or www.bobcat.com. This course is intended to provide rules and practices of correct operation of the Utility Work Machine. The course is available in English and Spanish versions.
TABLE OF CONTENTS:
Bobcat Toolcat™ 5600 Utility Work Machine Service Manual- PDF DOWNLOAD
CONTENTS........................................................................................ 5 FOREWORD........................................................................................ 7 FOREWORD.................................................................................... 9 SAFETY INSTRUCTIONS......................................................................... 12 FIRE PREVENTION............................................................................. 14 Maintenance............................................................................. 14 Operation............................................................................... 14 Electrical.............................................................................. 14 Hydraulic System........................................................................ 14 Fueling................................................................................. 14 Starting................................................................................ 14 Spark Arrestor Exhaust System........................................................... 14 Welding And Grinding.................................................................... 15 Fire Extinguishers...................................................................... 15 SERIAL NUMBER LOCATIONS..................................................................... 16 Utility Work Machine Serial Number...................................................... 16 Engine Serial Number.................................................................... 16 DELIVERY REPORT............................................................................. 17 TOOLCAT UTILITY WORK MACHINE IDENTIFICATION................................................. 18 SAFETY & MAINTENANCE............................................................................ 19 LIFTING AND BLOCKING THE UTILITY WORK MACHINE............................................... 21 Procedure For Jackstand Placement On The Axle........................................... 21 Procedure For Jackstand Placement On The Frame.......................................... 22 LIFT ARM SUPPORT DEVICE..................................................................... 25 Installing.............................................................................. 25 Removing................................................................................ 25 CARGO BOX SUPPORT DEVICE.................................................................... 27 Installing.............................................................................. 27 Removing................................................................................ 27 Raising The Cargo Box When Engine Is Not Running........................................ 27 OPERATOR CAB................................................................................ 29 Description............................................................................. 29 TRANSPORTING THE UTILITY WORK MACHINE ON A TRAILER.......................................... 31 Loading And Unloading................................................................... 31 Fastening............................................................................... 31 TOWING THE UTILITY WORK MACHINE............................................................. 33 Procedure............................................................................... 33 REMOTE START................................................................................ 37 Procedure............................................................................... 37 SERVICE SCHEDULE............................................................................ 39 Chart................................................................................... 39 AIR CLEANER SERVICE......................................................................... 41 Replacing Filter Elements............................................................... 41 ENGINE COOLING SYSTEM....................................................................... 43 Cleaning................................................................................ 43 Checking................................................................................ 44 Removing And Replacing Coolant.......................................................... 44 FUEL SYSTEM................................................................................. 45 Fuel Specifications..................................................................... 45 Filling The Fuel Tank................................................................... 45 Fuel Filter............................................................................. 45 Removing Air From The Fuel System....................................................... 46 Filling A Portable Fuel Container....................................................... 47 ENGINE LUBRICATION SYSTEM................................................................... 49 Checking And Adding Engine Oil.......................................................... 49 Engine Oil Chart........................................................................ 49 Removing And Replacing Oil And Filter................................................... 50 HYDRAULIC / HYDROSTATIC SYSTEM.............................................................. 51 Checking And Adding Fluid............................................................... 51 Hydraulic / Hydrostatic Fluid Chart..................................................... 51 Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters................... 52 Removing And Replacing Hydraulic Fluid.................................................. 53 Breather Cap............................................................................ 53 AXLE / DIFFERENTIAL (FRONT AND REAR)........................................................ 55 Checking And Adding Lubricant........................................................... 55 Removing And Replacing Lubricant........................................................ 55 BOB-TACH.................................................................................... 57 Inspection And Maintenance.............................................................. 57 LUBRICATING THE UTILITY WORK MACHINE........................................................ 59 Lubrication Locations................................................................... 59 TIRE MAINTENANCE............................................................................ 63 Wheel Nuts.............................................................................. 63 Rotating................................................................................ 63 Mounting................................................................................ 63 SPARK ARRESTOR MUFFLER...................................................................... 65 Cleaning Procedure...................................................................... 65 PIVOT PINS.................................................................................. 67 Inspection And Maintenance.............................................................. 67 UTILITY WORK MACHINE STORAGE AND RETURN TO SERVICE.......................................... 69 Storage................................................................................. 69 Return To Service....................................................................... 69 STOPPING THE ENGINE AND LEAVING THE UTILITY WORK MACHINE.................................... 71 Procedure............................................................................... 71 Emergency Exit.......................................................................... 71 HYDRAULIC SYSTEM................................................................................ 73 HYDRAULIC / HYDROSTATIC SCHEMATICS.......................................................... 77 HYDRAULIC SYSTEM INFORMATION................................................................ 81 Glossary Of Hydraulic / Hydrostatic Symbols............................................. 81 Troubleshooting......................................................................... 85 CYLINDER (LIFT)............................................................................. 87 Testing................................................................................. 87 Removal And Installation................................................................ 88 Parts Identification.................................................................... 91 Disassembly............................................................................. 92 Assembly................................................................................ 93 CYLINDER (TILT)............................................................................. 97 Testing................................................................................. 97 Removal And Installation................................................................ 98 Parts Identification....................................................................100 Disassembly.............................................................................101 Assembly................................................................................102 CYLINDER (CARGO BOX)........................................................................105 Testing (Left Side Cylinder)............................................................105 Testing (Right Side Cylinder)...........................................................106 Removal And Installation................................................................107 Parts Identification....................................................................109 Disassembly.............................................................................110 Assembly................................................................................111 MAIN RELIEF VALVE...........................................................................115 Description.............................................................................115 Auxiliary Main Relief Valve Testing.....................................................115 Auxiliary Main Relief Valve Removal And Installation....................................116 Lift, Tilt And Cargo Box Main Relief Valve Testing......................................117 Lift, Tilt And Cargo Box Main Relief Valve Removal And Installation.....................118 PORT RELIEF VALVES..........................................................................119 Description.............................................................................119 Lift Port Relief Valve Testing..........................................................119 Tilt Port Relief Valve Testing..........................................................120 HYDRAULIC CONTROL VALVE.....................................................................123 Description.............................................................................123 Removal And Installation................................................................124 Identification Chart....................................................................127 Disassembly.............................................................................128 End Valve Section Disassembly And Assembly..............................................129 Lift Valve Section Disassembly And Assembly.............................................131 Tilt Valve Section Disassembly And Assembly.............................................135 Box Valve Section Disassembly And Assembly..............................................139 High Flow Valve Section Disassembly And Assembly........................................143 Auxiliary Valve Section Disassembly And Assembly........................................147 Assembly................................................................................152 STEERING SELECTOR VALVE.....................................................................155 Description.............................................................................155 Removal And Installation................................................................155 Disassembly And Assembly................................................................157 PILOT MANIFOLD..............................................................................159 Description.............................................................................159 Removal And Installation................................................................159 Disassembly And Assembly................................................................161 LIFT ARM BYPASS CONTROL VALVE...............................................................163 Description.............................................................................163 Testing.................................................................................163 Removal And Installation................................................................163 Disassembly And Assembly................................................................164 HYDRAULIC PUMP..............................................................................165 Description.............................................................................165 Auxiliary Section Testing...............................................................166 Lift, Tilt And Cargo Box Section Testing................................................168 Steering And Cooling Fan Section Testing................................................170 Removal And Installation................................................................172 Parts Identification....................................................................176 Disassembly And Assembly................................................................177 POWER STEERING PUMP.........................................................................189 Description.............................................................................189 Removal And Installation................................................................189 Disassembly And Assembly................................................................190 HYDRAULIC / HYDROSTATIC FILTER..............................................................195 Description.............................................................................195 Housing Removal And Installation........................................................195 Case Drain Housing Removal And Installation.............................................196 CONTROL JOYSTICK............................................................................197 Description.............................................................................197 Handle Removal And Installation.........................................................197 Removal And Installation................................................................200 Disassembly And Assembly................................................................202 HYDRAULIC FLUID RESERVOIR...................................................................205 Description.............................................................................205 Removal And Installation................................................................205 Hydraulic Fluid Screen..................................................................208 OIL COOLER..................................................................................211 Description.............................................................................211 Removal And Installation................................................................211 AUXILIARY HYDRAULIC COUPLER BLOCK...........................................................213 Description.............................................................................213 Removal And Installation (Front)........................................................213 Removal And Installation (Rear).........................................................214 Disassembly And Assembly................................................................214 REMOTE HYDRAULICS DIVERTER VALVE............................................................217 Description.............................................................................217 Removal And Installation................................................................217 Disassembly And Assembly................................................................219 PTO HYDRAULIC MOTOR.........................................................................221 Description.............................................................................221 Removal And Installation................................................................221 Parts Identification....................................................................223 Disassembly.............................................................................224 Assembly................................................................................226 REAR AUXILIARY DIVERTER VALVE...............................................................231 Description.............................................................................231 Solenoid Testing........................................................................231 Removal And Installation................................................................231 Disassembly And Assembly................................................................238 HYDROSTATIC SYSTEM..............................................................................259 HYDROSTATIC SYSTEM INFORMATION..............................................................261 Troubleshooting.........................................................................261 Description.............................................................................262 HYDROSTATIC DRIVE MOTOR.....................................................................263 Description.............................................................................263 Removal And Installation (Front Axle)...................................................263 Removal And Installation (Rear Axle)....................................................265 Parts Identification....................................................................267 Disassembly.............................................................................268 Assembly................................................................................275 CHARGE PRESSURE.............................................................................279 Description.............................................................................279 Testing.................................................................................279 HYDROSTATIC PUMP............................................................................281 Description.............................................................................281 Removal And Installation................................................................281 Directional Control Valve Removal And Installation......................................283 PWM Control Valve Removal And Installation..............................................284 Replenishing / High Pressure Relief Valve Removal And Installation......................285 Charge Relief Valve Removal And Installation............................................285 Parts Identification (Left Half)........................................................286 Parts Identification (Right Half).......................................................288 Disassembly.............................................................................290 Assembly................................................................................299 Hydrostatic Pump Start-Up...............................................................309 Pump Neutral Adjustment.................................................................309 DRIVE BELT..................................................................................313 Description.............................................................................313 Shield Removal And Installation.........................................................313 Adjusting...............................................................................314 Belt Removal And Installation...........................................................315 Tensioner Pulley Removal And Installation...............................................316 Tensioner Pulley Parts Identification...................................................317 Tensioner Pulley Disassembly............................................................318 Tensioner Pulley Assembly...............................................................319 DRIVE SYSTEM....................................................................................321 BRAKE.......................................................................................323 Description.............................................................................323 Disassembly And Assembly (Front Axle)...................................................323 Disassembly And Assembly (Rear Axle)....................................................324 AXLE........................................................................................325 Description.............................................................................325 Front Axle Brush Guard Removal And Installation.........................................325 Front Axle Removal And Installation.....................................................326 Rear Axle Removal And Installation......................................................330 Separate The Axle Housings..............................................................334 Primary Housing Disassembly.............................................................337 Steering Cylinder Disassembly...........................................................339 Brake Disassembly.......................................................................342 Secondary Housing And Differential Lock Disassembly.....................................344 Secondary Housing And Differential Lock Assembly........................................346 Steering Cylinder Assembly..............................................................347 Primary Housing Assembly................................................................350 Brake Assembly..........................................................................351 Join The Axle Housings..................................................................353 AXLE HUB WITH AXLE SHAFT....................................................................355 Description.............................................................................355 Removal And Installation (Without Wheel Position Sensor)................................355 Removal (With Wheel Position Sensor)....................................................358 Installation (With Wheel Position Sensor)...............................................362 AXLE HUB WITHOUT AXLE SHAFT.................................................................365 Description.............................................................................365 Removal And Installation (Without Wheel Position Sensor)................................365 Removal (With Wheel Position Sensor)....................................................369 Installation (With Wheel Position Sensor)...............................................373 Disassembly.............................................................................377 Assembly................................................................................379 Torque Check Procedure..................................................................382 AXLE SHAFT..................................................................................385 Description.............................................................................385 Removal And Installation................................................................385 TIE ROD.....................................................................................387 Description.............................................................................387 Removal And Installation (Front Axle)...................................................387 Removal And Installation (Rear Axle)....................................................389 Adjusting...............................................................................391 MAINFRAME.......................................................................................393 OPERATOR CAB................................................................................395 Removal And Installation................................................................395 OPERATOR SEAT...............................................................................401 Removal And Installation................................................................401 Seat Belt Removal And Installation......................................................402 Seat Pan Removal And Installation.......................................................403 Slide Rail Removal And Installation.....................................................403 Lower Cushion Removal And Installation..................................................404 Back Cushion Removal And Installation...................................................404 Arm Rest Bracket Removal And Installation...............................................405 Arm Rest Removal And Installation.......................................................405 Shock Removal And Installation..........................................................406 PASSENGER SEAT..............................................................................407 Removal And Installation................................................................407 Seat Belt Removal And Installation......................................................407 Seat Pan Removal And Installation.......................................................408 Arm Rest Removal And Installation.......................................................409 BOB-TACH....................................................................................411 Description.............................................................................411 Removal And Installation................................................................411 Lever And Wedge Disassembly And Assembly................................................412 LIFT ARM....................................................................................413 Removal And Installation................................................................413 CARGO BOX...................................................................................415 Removal And Installation................................................................415 STEERING COLUMN.............................................................................417 Removal And Installation................................................................417 FUEL TANK...................................................................................419 Main Tank Removal And Installation......................................................419 Auxiliary Tank Removal And Installation.................................................421 Fuel Level Sender Removal And Installation..............................................422 DRIVE AND BRAKE PEDALS......................................................................423 Description.............................................................................423 Removal And Installation................................................................423 Drive Pedal Disassembly And Assembly....................................................424 SHOCKS......................................................................................425 Removal And Installation................................................................425 TRAILING ARMS...............................................................................427 Description.............................................................................427 Removal And Installation (Upper Arm)....................................................427 Removal And Installation (Lower Arm)....................................................428 LEAF SPRINGS................................................................................429 Removal And Installation (Left Side)....................................................429 Removal And Installation (Right Side)...................................................431 HITCH.......................................................................................433 Removal And Installation................................................................433 FLOOR CONSOLE...............................................................................435 Access Cover Removal And Installation...................................................435 CENTER CONSOLE..............................................................................437 Removal And Installation................................................................437 FENDER (FRONT LEFT).........................................................................439 Removal And Installation................................................................439 FENDER (FRONT RIGHT)........................................................................441 Removal And Installation................................................................441 FENDER (REAR LEFT)..........................................................................443 Removal And Installation................................................................443 FENDER (REAR RIGHT).........................................................................445 Removal And Installation................................................................445 WINDOWS.....................................................................................447 Front, Rear And Lower Door Removal And Installation.....................................447 Upper Door Removal And Installation.....................................................448 ELECTRICAL SYSTEM & ANALYSIS....................................................................451 ELECTRICAL SCHEMATICS.......................................................................455 ELECTRICAL SYSTEM INFORMATION...............................................................468 Glossary Of Electrical Symbols..........................................................468 Description.............................................................................472 Troubleshooting.........................................................................473 Fuse And Relay Location / Identification................................................474 Solenoid Testing........................................................................475 BATTERY.....................................................................................476 Removal And Installation................................................................476 Servicing...............................................................................477 Using A Booster Battery (Jump Starting).................................................477 ALTERNATOR..................................................................................480 Belt Adjustment.........................................................................480 Charging System Inspection..............................................................481 Alternator Voltage Testing..............................................................482 Low Voltage Testing.....................................................................483 High Voltage Testing....................................................................483 Removal And Installation................................................................484 Parts Identification....................................................................485 STARTER.....................................................................................486 Testing.................................................................................486 Removal And Installation................................................................487 Parts Identification....................................................................488 INSTRUMENT PANELS...........................................................................490 Display Controller Panel................................................................490 Switch Panel............................................................................491 Floor Console...........................................................................492 Center Console..........................................................................492 Display Controller Panel Removal And Installation.......................................493 Light Bulb Removal And Installation.....................................................493 LIGHTS......................................................................................494 Front Removal And Installation..........................................................494 BOBCAT CONTROLLER (DISPLAY).................................................................496 Description.............................................................................496 Connector Identification................................................................497 Removal And Installation................................................................498 BOBCAT CONTROLLER (DRIVE)...................................................................500 Description.............................................................................500 Connector Identification................................................................501 Removal And Installation................................................................502 DIAGNOSTIC SERVICE CODES....................................................................504 Description.............................................................................504 Service Codes List......................................................................505 DISPLAY CONTROLLER PANEL SETUP..............................................................508 Display Selection.......................................................................508 Passwords...............................................................................508 Password Entry (For Starting And Operating The Machine).................................508 Changing The Owner And Operator Password................................................508 Password Lockout Feature................................................................509 Job Clock...............................................................................509 RPM.....................................................................................509 TOOLCAT INTERLOCK CONTROL SYSTEM (TICS).....................................................510 Description.............................................................................510 Inspecting The TICS System (Engine STOPPED - Key ON)....................................510 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....510 Inspecting The Arm Rest Sensor (Engine RUNNING).........................................510 Inspecting The Traction Lock (Engine RUNNING)...........................................510 Inspecting The Lift Arm Bypass Control..................................................510 ARM REST SENSOR.............................................................................512 Description.............................................................................512 Removal And Installation................................................................512 SPEED SENSORS...............................................................................514 Description.............................................................................514 Removal And Installation (Front Axle)...................................................514 Removal And Installation (Rear Axle)....................................................516 WHEEL POSITION SENSORS......................................................................518 Description.............................................................................518 Removal And Installation (Front Axle)...................................................518 Removal And Installation (Rear Axle)....................................................523 SERVICE PC (LAPTOP COMPUTER)................................................................528 Connecting Remote Start Tool............................................................528 CALIBRATION.................................................................................530 Description.............................................................................530 Drive Pedal Calibration.................................................................530 Brake Pedal Calibration.................................................................531 Hydrostatic Pump Calibration............................................................532 Wheel Alignment Calibration.............................................................533 TRAVEL DIRECTION CONTROL LEVER..............................................................534 Description.............................................................................534 Removal And Installation................................................................534 FLYWHEEL RPM SENSOR.........................................................................536 Description.............................................................................536 Adjusting...............................................................................536 ELECTRIC COOLING FAN........................................................................538 Description.............................................................................538 Removal And Installation................................................................538 ENGINE SERVICE..................................................................................540 ENGINE INFORMATION..........................................................................542 Description.............................................................................542 Engine Specifications-Kubota V2203-M-DI.................................................543 Engine Specifications-Kubota V2003-M-DI-T (Turbo).......................................547 Engine Torque Values....................................................................552 Troubleshooting.........................................................................553 Engine Removal And Installation.........................................................555 Engine Mount Replacement................................................................566 Compression - Checking..................................................................567 ENGINE SPEED CONTROL........................................................................568 Removal And Installation................................................................568 Speed Control Cable Removal And Installation............................................568 MUFFLER.....................................................................................570 Removal And Installation................................................................570 AIR CLEANER.................................................................................572 Housing Removal And Installation........................................................572 ENGINE COOLING SYSTEM.......................................................................574 Radiator Removal And Installation.......................................................574 Radiator Mount Removal And Installation.................................................576 Hydraulic Fan Removal And Installation..................................................577 Hydraulic Fan Disassembly And Assembly..................................................579 Water Pump Removal And Installation.....................................................581 Water Pump Disassembly And Assembly.....................................................581 Thermostat Housing Removal And Installation.............................................582 LUBRICATION SYSTEM..........................................................................584 Oil Pan Removal And Installation........................................................584 Oil Pump Removal And Installation.......................................................585 Oil Pump Inspection.....................................................................586 Engine Oil Pressure - Testing...........................................................587 FUEL SYSTEM.................................................................................588 Fuel Camshaft Removal And Installation..................................................588 Fuel Camshaft Governor Disassembly And Assembly.........................................589 Fuel Shutoff Solenoid - Checking........................................................590 Fuel Shutoff Solenoid Removal And Installation..........................................590 Fuel Injection Pump Removal And Installation (Turbo)....................................591 Fuel Injection Pump Removal And Installation (Non- Turbo)...............................594 Injection Pump - Timing.................................................................598 Fuel Injector Removal And Installation..................................................600 Fuel Injector Nozzle Pressure - Checking................................................602 Nozzle Spray Condition..................................................................602 Valve Seat Tightness....................................................................603 CYLINDER HEAD...............................................................................604 Glow Plugs - Testing....................................................................604 Glow Plugs Removal And Installation.....................................................605 Valve Clearance Adjustment..............................................................606 Valve Timing - Checking.................................................................607 Cylinder Head Removal And Installation..................................................607 Cylinder Head Disassembly And Assembly..................................................610 Cylinder Head - Servicing...............................................................611 Cylinder Head Top Clearance.............................................................611 Valve Guide - Checking..................................................................612 Reconditioning The Valve And Valve Seat.................................................614 Valve Spring............................................................................615 Valve Tappets...........................................................................616 Rocker Arm And Shaft - Checking.........................................................616 CRANKSHAFT AND PISTONS......................................................................618 Piston And Connecting Rod Removal And Installation......................................618 Piston And Connecting Rod - Servicing...................................................619 Cylinder Bore - Checking................................................................622 Connecting Rod Alignment................................................................622 Crankshaft Gear Removal And Installation................................................623 Crankshaft And Bearings Removal And Installation........................................623 Crankshaft And Bearings - Servicing.....................................................625 CAMSHAFT AND TIMING GEARS...................................................................630 Timing Gearcase Cover Removal And Installation..........................................630 Timing Gears Backlash - Checking........................................................632 Idler Gear And Camshaft Removal And Installation........................................633 Camshaft - Servicing....................................................................634 Idler Gear And Shaft - Servicing........................................................635 TURBOCHARGER................................................................................638 Description.............................................................................638 Testing.................................................................................638 Removal And Installation................................................................639 FLYWHEEL AND HOUSING........................................................................642 Flywheel Removal And Installation.......................................................642 Ring Gear Removal And Installation......................................................642 Housing Removal And Installation........................................................643 HEATING, VENTILATION, AIR CONDITIONING..........................................................644 AIR CONDITIONING SYSTEM FLOW................................................................647 Description.............................................................................647 Chart...................................................................................648 Components..............................................................................649 Safety Equipment........................................................................652 REGULAR MAINTENANCE.........................................................................654 Filter Elements Removal And Installation................................................654 Compressor Drive Belt Inspection........................................................655 Condenser...............................................................................655 Air Conditioning Service Chart..........................................................656 A/C Evaporator Coil.....................................................................657 TROUBLESHOOTING.............................................................................658 Blower Motor Does Not Operate...........................................................658 Blower Motor Operates Normally But Air Flow Is Insufficient.............................658 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..............658 The Compressor Does Not Operate At All Or Operates Improperly...........................659 Gauge Pressure Related Troubleshooting..................................................660 Temperature / Pressure Chart............................................................662 Poor A/C Performance....................................................................663 HVAC Repair And Leaks...................................................................663 Electrical System.......................................................................664 Engine Coolant Bypassing The Heater Valve...............................................671 Heater Valve Not Opening Or Closing.....................................................672 SYSTEM CHARGING AND RECLAMATION.............................................................674 Refrigerant Identification..............................................................674 Reclamation And Charging With Recovery / Charging Unit..................................675 Charging With A Manifold Gauge Set......................................................677 COMPRESSOR..................................................................................680 Belt Adjusting..........................................................................680 Removal And Installation................................................................680 Oil.....................................................................................681 Oil Check...............................................................................682 Clutch Disassembly And Assembly.........................................................684 CONDENSER...................................................................................688 Removal And Installation................................................................688 RECEIVER / DRIER............................................................................690 Receiver / Drier Removal And Installation...............................................690 Pressure Relief Valve Removal And Installation..........................................691 Pressure Switch Removal And Installation................................................692 EVAPORATOR / HEATER UNIT....................................................................694 Removal And Installation................................................................694 THERMOSTAT..................................................................................698 Removal And Installation................................................................698 EXPANSION VALVE.............................................................................700 Removal And Installation................................................................700 EVAPORATOR COIL.............................................................................702 Removal And Installation................................................................702 HEATER COIL.................................................................................704 Removal And Installation With A/C.......................................................704 BLOWER FAN..................................................................................706 Removal And Installation................................................................706 HEATER VALVE................................................................................708 Removal And Installation................................................................708 Disassembly And Assembly................................................................708 SPECIFICATIONS..................................................................................710 TOOLCAT 5600 UTILITY WORK MACHINE SPECIFICATIONS............................................712 Dimensions..............................................................................712 Performance.............................................................................713 Controls................................................................................713 Engine..................................................................................713 Hydraulic System........................................................................714 Electrical..............................................................................714 Power Take-Off (PTO) System (Option)....................................................715 Drive System............................................................................715 Capacities..............................................................................715 Tires...................................................................................715 TORQUE SPECIFICATIONS FOR BOLTS.............................................................716 Torque For General SAE Bolts............................................................716 Torque For General Metric Bolts.........................................................717 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................718 O-ring Face Seal Connection.............................................................718 Straight Thread O-ring Fitting..........................................................719 Tubelines And Hoses.....................................................................719 Flare Fitting...........................................................................719 O-ring Flare Fitting....................................................................720 Port Seal Fitting.......................................................................722 Quick-Lok™ Fitting......................................................................723 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................724 Specifications..........................................................................724 CONVERSIONS.................................................................................726 Decimal And Millimeter Equivalent Chart.................................................726 U.S. To Metric Conversion Chart.........................................................727 ALPHABETICAL INDEX..............................................................................728 SERVICE MANUAL REVISION.........................................................................730 Revision No: 5600 - 1.......................................................................730 Revision No: 5600 - 2.......................................................................732 Revision No: 5600 - 3.......................................................................734 Revision No: 5600 - 4.......................................................................736 Revision No: 5600 - 5.......................................................................738 Revision No: 5600 - 6.......................................................................740 Revision No: 5600 - 7.......................................................................742
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