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Bobcat Toolcat™ 5600 Utility Work Machine Service Manual SNA0W111001 & Above – PDF DOWNLOAD
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Description
Bobcat Toolcat™ 5600 Utility Work Machine Service Manual SNA0W111001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat Toolcat™ 5600 Utility Work Machine Service Manual SNA0W111001 & Above – PDF DOWNLOAD
Language : English
Pages : 741
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat Toolcat™ 5600 Utility Work Machine Service Manual SNA0W111001 & Above – 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
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Bobcat Toolcat™ 5600 Utility Work Machine Service Manual SNA0W111001 & Above – PDF DOWNLOAD
MAINTENANCE SAFETY.................................................................... 3 CONTENTS.............................................................................. 5 FOREWORD.............................................................................. 7 FOREWORD.......................................................................... 9 SAFETY INSTRUCTIONS............................................................... 11 FIRE PREVENTION................................................................... 13 Maintenance................................................................... 13 Operation..................................................................... 13 Electrical.................................................................... 13 Hydraulic System.............................................................. 13 Fueling....................................................................... 13 Starting...................................................................... 13 Spark Arrester Exhaust System................................................. 13 Welding And Grinding.......................................................... 14 Fire Extinguishers............................................................ 14 SERIAL NUMBER LOCATIONS........................................................... 15 Utility Work Machine Serial Number............................................ 15 Engine Serial Number.......................................................... 15 DELIVERY REPORT................................................................... 16 UTILITY WORK MACHINE IDENTIFICATION............................................... 17 SAFETY & MAINTENANCE.................................................................. 19 LIFTING AND BLOCKING THE UTILITY WORK MACHINE..................................... 23 Procedure For Jackstand Placement On The Control Arms......................... 23 Procedure For Jackstand Placement On The Frame................................ 24 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.............................. 28 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 TOOL KIT - MEL1563................................................... 35 Remote Start Tool - MEL1563................................................... 35 Service Tool Harness Control - MEL1565........................................ 36 Service Tool Harness Communicator - MEL1566................................... 37 Remote Start Procedure........................................................ 38 REMOTE START TOOL (SERVICE TOOL) KIT - 6689779.................................... 41 Description................................................................... 41 Remote Start Tool (Service Tool) - 6689778.................................... 42 Service Tool Harness - 6689747................................................ 43 Computer Service Tool Harness - 6689746....................................... 44 Remote Start Procedure........................................................ 45 SERVICE SCHEDULE.................................................................. 49 Chart......................................................................... 49 AIR CLEANER SERVICE............................................................... 51 Replacing Filter Elements..................................................... 51 ENGINE COOLING SYSTEM............................................................. 53 Checking Level................................................................ 53 Cleaning...................................................................... 54 Removing And Replacing Coolant................................................ 54 FUEL SYSTEM....................................................................... 55 Fuel Specifications........................................................... 55 Biodiesel Blend Fuel.......................................................... 55 Filling The Fuel Tank......................................................... 56 Fuel Filter................................................................... 56 Removing Air From The Fuel System............................................. 57 Filling A Portable Fuel Container............................................. 57 ENGINE LUBRICATION SYSTEM......................................................... 59 Checking And Adding Engine Oil................................................ 59 Engine Oil Chart.............................................................. 59 Removing And Replacing Oil And Filter......................................... 60 HYDRAULIC / HYDROSTATIC SYSTEM.................................................... 61 Checking Fluid................................................................ 61 Hydraulic / Hydrostatic Fluid Chart........................................... 61 Adding Fluid.................................................................. 61 Alternate Fill Procedure...................................................... 62 Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters......... 63 Removing And Replacing Hydraulic Fluid........................................ 64 Breather Cap.................................................................. 66 TRANS AXLE (FRONT AND REAR)....................................................... 67 Checking And Adding Lubricant................................................. 67 Removing And Replacing Lubricant.............................................. 68 BOB-TACH (HAND LEVER)............................................................. 69 Inspection And Maintenance.................................................... 69 BOB-TACH (POWER).................................................................. 71 Inspection And Maintenance.................................................... 71 LUBRICATING THE UTILITY WORK MACHINE.............................................. 73 Lubrication Locations......................................................... 73 TIRE MAINTENANCE.................................................................. 75 Wheel Nuts.................................................................... 75 Rotating...................................................................... 75 Mounting...................................................................... 75 SPARK ARRESTER MUFFLER............................................................ 77 Cleaning Procedure............................................................ 77 PIVOT PINS........................................................................ 79 Inspection And Maintenance.................................................... 79 UTILITY WORK MACHINE STORAGE AND RETURN TO SERVICE................................ 81 Storage....................................................................... 81 Return To Service............................................................. 81 STOPPING THE ENGINE AND LEAVING THE UTILITY WORK MACHINE.......................... 83 Procedure..................................................................... 83 Emergency Exit (When Equipped With Cab)....................................... 83 SEAT BELT......................................................................... 85 Inspection And Maintenance.................................................... 85 HYDRAULIC SYSTEM...................................................................... 87 HYDRAULIC / HYDROSTATIC SCHEMATICS................................................ 91 HYDRAULIC SYSTEM INFORMATION...................................................... 95 Glossary Of Hydraulic / Hydrostatic Symbols................................... 95 Troubleshooting............................................................... 99 CYLINDER (LIFT)...................................................................101 Testing.......................................................................101 Removal And Installation......................................................102 Parts Identification..........................................................105 Disassembly...................................................................106 Assembly......................................................................107 CYLINDER (TILT)...................................................................111 Testing.......................................................................111 Removal And Installation......................................................112 Parts Identification..........................................................114 Disassembly...................................................................115 Assembly......................................................................116 CYLINDER (CARGO BOX)..............................................................119 Testing.......................................................................119 Removal And Installation (Left Side)..........................................120 Removal And Installation (Right Side).........................................122 Parts Identification..........................................................123 Disassembly...................................................................124 Assembly......................................................................125 CYLINDER (STEERING)...............................................................129 Testing (Rear)................................................................129 Testing (Front)...............................................................130 Removal And Installation (Rear)...............................................131 Removal And Installation (Front)..............................................134 Parts Identification..........................................................137 Disassembly And Assembly......................................................138 CYLINDER (BOB-TACH)...............................................................143 Testing.......................................................................143 Removal And Installation......................................................144 Parts Identification..........................................................145 Disassembly...................................................................146 Assembly......................................................................147 MAIN RELIEF VALVE.................................................................151 Description...................................................................151 Auxiliary Main Relief Valve Testing...........................................151 Auxiliary Main Relief Valve Removal And Installation..........................152 Lift, Tilt And Cargo Box Main Relief Valve Testing............................153 Lift, Tilt And Cargo Box Main Relief Valve Removal And Installation...........154 PORT RELIEF VALVES................................................................155 Description...................................................................155 Lift Port Relief Valve Testing (Base End).....................................155 Lift Port Relief Valve Testing (Rod End)......................................156 Tilt Port Relief Valve Testing................................................157 HYDRAULIC CONTROL VALVE...........................................................159 Description...................................................................159 Removal And Installation......................................................159 Identification Chart..........................................................162 Disassembly...................................................................163 End Valve Section Disassembly And Assembly....................................166 Box Valve Section Disassembly And Assembly....................................168 Lift Valve Section Disassembly And Assembly...................................172 Tilt Valve Section Disassembly And Assembly...................................177 Mid Inlet / High flow Valve Section Disassembly And Assembly..................181 Auxiliary Valve Section Disassembly And Assembly..............................185 Assembly......................................................................190 STEERING SELECTOR VALVE...........................................................195 Description...................................................................195 Removal And Installation......................................................195 Disassembly And Assembly......................................................197 PILOT MANIFOLD....................................................................199 Description...................................................................199 Removal And Installation......................................................199 Parts Identification..........................................................201 Disassembly And Assembly......................................................202 LIFT ARM (BYPASS).................................................................207 Description...................................................................207 Testing.......................................................................207 HYDRAULIC PUMP....................................................................209 Description...................................................................209 Auxiliary Section Testing.....................................................210 Lift, Tilt And Cargo Box Section Testing......................................212 Steering And Cooling Fan Section Testing......................................214 Removal And Installation......................................................216 Parts Identification..........................................................218 Disassembly And Assembly......................................................219 POWER STEERING PUMP...............................................................229 Description...................................................................229 Removal And Installation......................................................229 Disassembly And Assembly......................................................230 HYDRAULIC / HYDROSTATIC FILTER....................................................235 Description...................................................................235 Housing Removal And Installation..............................................235 Case Drain Housing Removal And Installation...................................236 CONTROL JOYSTICK S/N A94Y11001- A94Y12003, S/ N A94Y12005 - A94Y12034.............237 Description...................................................................237 Handle Removal And Installation...............................................237 CONTROL JOYSTICK S/N A94Y12004, S/N A94Y12035 & ABOVE.............................239 Description...................................................................239 Handle Removal And Installation...............................................239 HYDRAULIC FLUID RESERVOIR.........................................................241 Description...................................................................241 Removal And Installation......................................................241 Hydraulic Fluid Screen........................................................244 OIL COOLER........................................................................245 Description...................................................................245 Removal And Installation......................................................245 AUXILIARY HYDRAULIC COUPLER BLOCK.................................................251 Description...................................................................251 Removal And Installation......................................................251 Disassembly And Assembly......................................................252 REMOTE HYDRAULICS DIVERTER VALVE..................................................255 Description...................................................................255 Removal And Installation......................................................255 Disassembly And Assembly......................................................256 POWER BOB-TACH BLOCK..............................................................257 Description...................................................................257 Removal And Installation......................................................257 Disassembly And Assembly......................................................259 DIVERTER VALVE (REAR AUXILIARY)...................................................265 Description...................................................................265 Solenoid Testing..............................................................265 Removal And Installation......................................................265 Disassembly And Assembly......................................................268 HYDROSTATIC SYSTEM....................................................................277 HYDROSTATIC SYSTEM INFORMATION....................................................279 Troubleshooting...............................................................279 Description...................................................................280 HYDROSTATIC MOTOR.................................................................281 Description...................................................................281 Removal And Installation (Front)..............................................281 Removal And Installation (Rear)...............................................284 Parts Identification..........................................................288 Disassembly...................................................................289 Assembly......................................................................299 CHARGE PRESSURE...................................................................305 Description...................................................................305 Testing.......................................................................305 HYDROSTATIC PUMP..................................................................307 Description...................................................................307 Removal And Installation......................................................307 Control Module Removal And Installation.......................................311 Replenishing / High Pressure Relief Valve Removal And Installation............313 Charge Relief Valve Removal And Installation..................................313 Parts Identification..........................................................314 Disassembly And Assembly......................................................316 Mechanical Neutral Adjustment.................................................330 Hydraulic Controller Neutral Adjustment.......................................335 DRIVE BELT........................................................................339 Description...................................................................339 Shield Removal And Installation...............................................339 Adjusting.....................................................................340 Belt Replacement..............................................................342 Tensioner Pulley Removal And Installation.....................................344 Tensioner Pulley Parts Identification.........................................345 Tensioner Pulley Disassembly..................................................346 Tensioner Pulley Assembly.....................................................347 DRIVE SYSTEM..........................................................................349 BRAKE.............................................................................351 Description...................................................................351 Disassembly And Assembly (Front Trans Axle)...................................351 Disassembly And Assembly (Rear Trans Axle)....................................351 TRANS AXLE........................................................................353 Description...................................................................353 Removal And Installation (Front)..............................................353 Removal And Installation (Rear)...............................................357 Brake Housing Disassembly And Assembly........................................361 Primary Housing Disassembly And Assembly......................................364 HUB...............................................................................371 Description...................................................................371 Removal And Installation......................................................371 CV SHAFT..........................................................................373 Description...................................................................373 Removal And Installation (Front)..............................................373 Removal And Installation (Rear)...............................................376 Inner Boot Removal And Installation...........................................379 Outer Boot Removal And Installation...........................................381 MAINFRAME.............................................................................385 OPERATOR CAB......................................................................387 Removal And Installation......................................................387 OPERATOR SEAT.....................................................................397 Removal And Installation......................................................397 Seat Belt Removal And Installation............................................398 Seat Pan Removal And Installation.............................................399 Slide Rail Removal And Installation...........................................399 Arm Rest Bracket Removal And Installation.....................................400 Arm Rest Removal And Installation.............................................400 PASSENGER SEAT....................................................................401 Removal And Installation......................................................401 Seat Belt Removal And Installation............................................402 Seat Pan Removal And Installation.............................................403 Arm Rest Removal And Installation.............................................403 BOB-TACH (HAND LEVER).............................................................405 Description...................................................................405 Removal And Installation......................................................405 Lever And Wedge Disassembly And Assembly......................................406 BOB-TACH (POWER)..................................................................407 Description...................................................................407 Removal And Installation......................................................407 Lever And Wedge Disassembly And Assembly......................................409 LIFT ARM..........................................................................411 Removal And Installation......................................................411 CARGO BOX.........................................................................413 Removal And Installation......................................................413 STEERING COLUMN...................................................................415 Removal And Installation......................................................415 FUEL TANK.........................................................................417 Removal And Installation......................................................417 Fuel Level Sender Removal And Installation....................................419 DRIVE AND BRAKE PEDALS............................................................421 Description...................................................................421 Removal And Installation......................................................421 Drive Pedal Disassembly And Assembly..........................................422 SHOCKS............................................................................423 Removal And Installation......................................................423 CONTROL ARMS......................................................................425 Removal And Installation (Lower Arm)..........................................425 Removal And Installation (Upper Arm)..........................................426 Inspection....................................................................427 Ball Joint Removal And Installation...........................................428 SPINDLE...........................................................................429 Removal And Installation......................................................429 TIE ROD...........................................................................431 Description...................................................................431 Removal And Installation......................................................431 Toe Adjustment Procedure......................................................432 FLOOR CONSOLE.....................................................................435 Access Cover Removal And Installation (Side)..................................435 Access Cover Removal And Installation (Top)...................................435 CENTER CONSOLE S/N A94Y11001 - A94Y12003, S/N A94Y12005 - A94Y12034...............437 Removal And Installation......................................................437 CENTER CONSOLE S/N A94Y12004, S/N A94Y12035 & ABOVE...............................439 Removal And Installation......................................................439 FENDER............................................................................443 Removal And Installation (Front)..............................................443 Removal And Installation (Left Rear)..........................................444 Removal And Installation (Right Rear).........................................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 Cab Harness Connectors........................................................471 Mainframe / Engine Harness Connectors.........................................472 Description...................................................................473 Troubleshooting...............................................................474 Fuse And Relay Location - Cab Panel...........................................475 Fuse And Relay Location - Frame Panel.........................................476 Solenoid Testing..............................................................477 BATTERY...........................................................................478 Removal And Installation......................................................478 Servicing.....................................................................479 Using A Booster Battery (Jump Starting).......................................480 ALTERNATOR........................................................................482 Belt Adjustment...............................................................482 Belt Replacement..............................................................482 Charging System Inspection....................................................483 Alternator Voltage Testing....................................................484 Low Voltage Testing...........................................................485 High Voltage Testing..........................................................485 Removal And Installation......................................................486 Parts Identification..........................................................487 STARTER...........................................................................488 Testing.......................................................................488 Removal And Installation......................................................489 Parts Identification..........................................................490 INSTRUMENT PANELS.................................................................492 Display Controller Panel......................................................492 Switch Panel..................................................................493 Floor Console.................................................................494 Center Console (With Early Model Joystick)....................................494 Center Console (With Later Model Joystick)....................................495 Display Controller Panel Removal And Installation.............................496 Light Bulb Removal And Installation (S/N A0W111001 - A0W111722)...............497 Light Bulb Removal And Installation (S/N A0W111723 & Above)...................497 LIGHTS............................................................................498 Front Removal And Installation................................................498 BOBCAT CONTROLLER (DISPLAY).......................................................500 Description...................................................................500 Connector Identification......................................................501 Removal And Installation......................................................502 BOBCAT CONTROLLER (DRIVE).........................................................504 Description...................................................................504 Connector Identification......................................................505 Removal And Installation......................................................506 DIAGNOSTIC SERVICE CODES..........................................................508 Description...................................................................508 Service Codes List............................................................509 DISPLAY CONTROLLER PANEL SETUP....................................................512 Display Screen Selection......................................................512 Two-Speed.....................................................................512 High Flow.....................................................................512 Horsepower Management.........................................................512 Tire Size.....................................................................512 Save Setup....................................................................512 Exit Setup....................................................................512 Password Description..........................................................513 Password Entry (For Starting And Operating The Machine).......................513 Changing The Owner And Operator Passwords.....................................513 Password Lockout Feature......................................................514 TOOLCAT INTERLOCK CONTROL SYSTEM (TICS)...........................................516 Description...................................................................516 Inspecting The TICS...........................................................516 Maintaining The TICS..........................................................516 Lift Arm Bypass Procedure.....................................................517 Testing The Lift Arm Bypass Procedure.........................................517 ARM REST SENSOR...................................................................518 Description...................................................................518 Removal And Installation......................................................518 SPEED SENSORS.....................................................................520 Description...................................................................520 Removal And Installation (Front Trans Axle)...................................520 WHEEL POSITION SENSORS............................................................522 Description...................................................................522 Removal And Installation (Front)..............................................522 Removal And Installation (Rear)...............................................523 Adjusting (In The Machine)....................................................524 Adjusting (Out Of The Machine)................................................525 SERVICE PC (LAPTOP COMPUTER)......................................................526 Connecting Remote Start Tool..................................................526 Connecting Remote Start Tool (Service Tool)...................................526 CALIBRATION.......................................................................528 Description...................................................................528 Throttle Position Sensor Calibration..........................................528 Drive System Calibration......................................................529 Brake Pedal Calibration.......................................................530 Travel Pedal Calibration......................................................531 TRAVEL DIRECTION CONTROL LEVER....................................................532 Description...................................................................532 Removal And Installation......................................................532 FLYWHEEL RPM SENSOR...............................................................534 Description...................................................................534 Adjusting.....................................................................534 ELECTRIC COOLING FAN..............................................................536 Description...................................................................536 Removal And Installation......................................................536 MAINTENANCE CLOCK.................................................................538 Description...................................................................538 Setup.........................................................................538 Reset.........................................................................540 BACK-UP ALARM SYSTEM..............................................................542 Description...................................................................542 Inspecting....................................................................542 ENGINE SERVICE........................................................................544 ENGINE INFORMATION................................................................546 Description...................................................................546 Specifications................................................................547 Torque Values.................................................................552 Troubleshooting...............................................................553 Engine Removal And Installation...............................................555 Engine Mount Replacement......................................................561 Compression - Checking........................................................562 ENGINE SPEED CONTROL..............................................................564 Removal And Installation (Position Sensing)...................................564 Removal And Installation (Non Position Sensing)...............................564 Speed Control Cable Removal And Installation..................................565 MUFFLER...........................................................................568 Removal And Installation......................................................568 AIR CLEANER.......................................................................570 Housing Removal And Installation..............................................570 ENGINE COOLING SYSTEM.............................................................572 Radiator Removal And Installation.............................................572 Hydraulic Fan Removal And Installation........................................575 Hydraulic Fan Disassembly And Assembly........................................577 Water Pump Removal And Installation...........................................580 Water Pump Disassembly And Assembly...........................................580 Thermostat Housing Removal And Installation...................................581 LUBRICATION SYSTEM................................................................582 Oil Pan Removal And Installation..............................................582 Oil Pump Removal And Installation.............................................584 Oil Pump Inspection...........................................................585 Engine Oil Pressure - Testing.................................................586 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..................................591 Injection Pump - Timing.......................................................594 Fuel Injector Removal And Installation........................................596 Fuel Injector Nozzle Pressure - Checking......................................598 Nozzle Spray Condition........................................................598 Valve Seat Tightness..........................................................599 CYLINDER HEAD.....................................................................600 Glow Plugs - Testing..........................................................600 Glow Plugs Removal And Installation...........................................600 Valve Clearance Adjustment....................................................602 Valve Timing - Checking.......................................................603 Cylinder Head Removal And Installation........................................603 Cylinder Head Disassembly And Assembly........................................606 Cylinder Head - Servicing.....................................................607 Cylinder Head Top Clearance...................................................607 Valve Guide - Checking........................................................608 Reconditioning The Valve And Valve Seat.......................................610 Valve Spring..................................................................611 Valve Tappets.................................................................612 Rocker Arm And Shaft - Checking...............................................612 CRANKSHAFT AND PISTONS............................................................614 Piston And Connecting Rod Removal And Installation............................614 Piston And Connecting Rod - Servicing.........................................615 Cylinder Bore - Checking......................................................618 Connecting Rod Alignment......................................................618 Crankshaft Gear Removal And Installation......................................619 Crankshaft And Bearings Removal And Installation..............................619 Crankshaft And Bearings - Servicing...........................................621 CAMSHAFT AND TIMING GEARS.........................................................626 Timing Gearcase Cover Removal And Installation................................626 Timing Gears Backlash - Checking..............................................628 Idler Gear And Camshaft Removal And Installation..............................629 Camshaft - Servicing..........................................................630 Idler Gear And Shaft - Servicing..............................................631 TURBOCHARGER......................................................................632 Description...................................................................632 Testing.......................................................................632 Removal And Installation......................................................633 FLYWHEEL AND HOUSING..............................................................636 Flywheel Removal And Installation.............................................636 Ring Gear Removal And Installation............................................636 Housing Removal And Installation..............................................637 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)......................................642 AIR CONDITIONING SYSTEM FLOW......................................................644 Description...................................................................644 Chart.........................................................................645 Components....................................................................646 Safety Equipment..............................................................649 REGULAR MAINTENANCE...............................................................652 Filter Elements Removal And Installation......................................652 Compressor Drive Belt Inspection..............................................653 Condenser.....................................................................653 Air Conditioning Service Chart................................................654 A/C Evaporator Coil...........................................................655 TROUBLESHOOTING...................................................................656 Blower Motor Does Not Operate.................................................656 Blower Motor Operates Normally But Air Flow Is Insufficient...................656 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....656 The Compressor Does Not Operate At All Or Operates Improperly.................657 Gauge Pressure Related Troubleshooting........................................658 Temperature / Pressure Chart..................................................660 Poor A/C Performance..........................................................661 HVAC Repair And Leaks.........................................................661 Electrical System.............................................................662 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........................................................................696 Removal And Installation......................................................696 EXPANSION VALVE...................................................................698 Removal And Installation......................................................698 EVAPORATOR COIL...................................................................700 Removal And Installation......................................................700 HEATER COIL.......................................................................702 Removal And Installation With A/C.............................................702 BLOWER FAN........................................................................704 Removal And Installation......................................................704 HEATER VALVE (S/N A0W111001 - A0W111373)..........................................706 Removal And Installation......................................................706 Disassembly And Assembly......................................................706 HEATER VALVE (S/N A0W111374 & ABOVE)..............................................708 Removal And Installation......................................................708 Disassembly And Assembly......................................................708 SPECIFICATIONS........................................................................710 (5600) UTILITY WORK MACHINE SPECIFICATIONS........................................712 Dimensions (With 27 Inch Tires)...............................................712 Dimensions (With 29 Inch Tires)...............................................713 Performance...................................................................714 Controls......................................................................714 Engine........................................................................714 Hydraulic System..............................................................715 Electrical....................................................................715 Drive System..................................................................716 Capacities....................................................................716 Tires.........................................................................716 TORQUE SPECIFICATIONS FOR BOLTS...................................................718 Torque For General SAE Bolts..................................................718 Torque For General Metric Bolts...............................................719 HYDRAULIC CONNECTION SPECIFICATIONS...............................................720 O-ring Face Seal Connection...................................................720 Straight Thread O-ring Fitting................................................721 Tubelines And Hoses...........................................................721 Flare Fitting.................................................................721 O-ring Flare Fitting..........................................................722 Port Seal Fitting.............................................................724 Quick-Lok™ Fitting............................................................725 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS......................................726 Specifications................................................................726 CONVERSIONS.......................................................................728 Decimal And Millimeter Equivalent Chart.......................................728 U.S. To Metric Conversion Chart...............................................729 SERVICE TOOLS REQUIRED............................................................730 Remote Start Tools............................................................730 Hydraulic Tools...............................................................731 Mainframe And Drive Tools.....................................................733 Electrical Tools..............................................................733 Engine Tools..................................................................734 HVAC Tools....................................................................736 ALPHABETICAL INDEX....................................................................738
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