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Bobcat Toolcat™ 5610 Utility Work Machine Service Manual SN A7Y711001 & Above – PDF DOWNLOAD
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Bobcat Toolcat™ 5610 Utility Work Machine Service Manual SN A7Y711001 & Above – PDF DOWNLOAD
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Description
Bobcat Toolcat™ 5610 Utility Work Machine Service Manual SN A7Y711001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat Toolcat™ 5610 Utility Work Machine Service Manual SN A7Y711001 & Above – PDF DOWNLOAD
Language : English
Pages : 793
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat Toolcat™ 5610 Utility Work Machine Service Manual SN A7Y711001 & 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.
IMPORTANT
This notice identifies procedures which must be followed to avoid damage to the machine
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments / implements:
- 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 / implement 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 / implement. 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.
SAFETY INSTRUCTIONS (CONT’D)
Use Safety Rules
• Read and follow instructions in the machine and the attachment’s / implement’s Operation & Maintenance Manual before operating.
Check for underground lines before operating attachment / implement (if applicable).
In addition to the design and configuration of equipment, hazard control and accident prevention are dependent upon the awareness, concern, prudence and proper training of personnel involved in the operation, transport, maintenance and storage of equipment.
Check that the Bob-Tach levers are in the locked position and the wedges are fully engaged into the mounting holes of the attachment (if applicable).
- Check that the implement is securely fastened to the machine.
- Operate the attachment / implement according to the Operation & Maintenance Manual.
- When learning to operate the attachment / implement, do it at a slow rate in an area clear of bystanders.
- DO NOT permit personnel to be in the work area when operating the machine and attachment / implement.
- The attachment / implement must be used ONLY on approved machines. See your Bobcat dealer for updated list of approved attachments / implements for each machine model. •
- O NOT modify equipment or add attachments / implements that exceed manufacturer’s specifications.
- DO NOT make any adjustments or repairs on the machine or attachment / implement while the engine is running.
- • Keep shields and guards in place. Replace if damaged.
- The dealer and owner / operator review the recommended uses of the product when delivered. If the owner / operator will be using the machine for a different application(s) he or she must ask the dealer for recommendations on the new use.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Bobcat Toolcat™ 5610 Utility Work Machine Service Manual SN A7Y711001 & Above – PDF DOWNLOAD
MAINTENANCE SAFETY...................................................................... 3 CONTENTS................................................................................ 5 FOREWORD................................................................................ 7 FOREWORD............................................................................ 9 SAFETY INSTRUCTIONS................................................................. 11 Use Safety Rules................................................................ 12 Safety Rules For Power Take-Off (PTO) Driven Implements......................... 13 FIRE PREVENTION..................................................................... 13 Maintenance..................................................................... 13 Operation....................................................................... 13 Electrical...................................................................... 13 Hydraulic System................................................................ 14 Fueling......................................................................... 14 Starting........................................................................ 14 Spark Arrester Exhaust System................................................... 14 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 OPERATOR CAB........................................................................ 27 Description..................................................................... 27 TRANSPORTING THE UTILITY WORK MACHINE ON A TRAILER.................................. 29 Loading And Unloading........................................................... 29 Fastening....................................................................... 29 TOWING THE UTILITY WORK MACHINE..................................................... 31 Procedure....................................................................... 31 REMOTE START TOOL KIT-MEL1563....................................................... 33 Remote Start Tool - MEL1563..................................................... 33 Service Tool Harness Control - MEL1565.......................................... 34 Service Tool Harness Communicator - MEL1566..................................... 35 Remote Start Procedure.......................................................... 36 REMOTE START TOOL (SERVICE TOOL) KIT - 6689779...................................... 39 Description..................................................................... 39 Remote Start Tool (Service Tool) - 6689778...................................... 40 Service Tool Harness - 6689747.................................................. 41 Computer Service Tool Harness - 6689746......................................... 42 Remote Start Procedure.......................................................... 43 SERVICE SCHEDULE.................................................................... 49 Chart........................................................................... 49 AIR CLEANER SERVICE................................................................. 51 Replacing Filter Elements....................................................... 51 ENGINE COOLING SYSTEM............................................................... 53 Checking Level.................................................................. 53 Cooling System Service Access Position.......................................... 54 Cleaning........................................................................ 56 Removing And Replacing Coolant.................................................. 57 FUEL SYSTEM......................................................................... 59 Fuel Specifications............................................................. 59 Biodiesel Blend Fuel............................................................ 59 Filling The Fuel Tank........................................................... 60 Fuel Filter..................................................................... 60 Removing Air From The Fuel System............................................... 61 Filling A Portable Fuel Container............................................... 61 ENGINE LUBRICATION SYSTEM........................................................... 63 Checking And Adding Engine Oil.................................................. 63 Engine Oil Chart................................................................ 63 Removing And Replacing Oil And Filter........................................... 64 HYDRAULIC / HYDROSTATIC SYSTEM...................................................... 65 Checking Fluid.................................................................. 65 Hydraulic / Hydrostatic Fluid Chart............................................. 65 Adding Fluid.................................................................... 65 Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters........... 66 Removing And Replacing Hydraulic Fluid.......................................... 67 Breather Cap.................................................................... 68 TRANSAXLE (FRONT AND REAR).......................................................... 69 Checking And Adding Lubricant................................................... 69 Removing And Replacing Lubricant................................................ 70 BOB-TACH (HAND LEVER)............................................................... 71 Inspection And Maintenance...................................................... 71 BOB-TACH (POWER).................................................................... 73 Inspection And Maintenance...................................................... 73 LUBRICATING THE UTILITY WORK MACHINE................................................ 75 Lubrication Locations........................................................... 75 TIRE MAINTENANCE.................................................................... 79 Wheel Nuts...................................................................... 79 Rotating........................................................................ 79 Mounting........................................................................ 79 SPARK ARRESTER MUFFLER.............................................................. 81 Cleaning Procedure.............................................................. 81 PIVOT PINS.......................................................................... 83 Inspection And Maintenance...................................................... 83 UTILITY WORK MACHINE STORAGE AND RETURN TO SERVICE.................................. 85 Storage......................................................................... 85 Return To Service............................................................... 85 STOPPING THE ENGINE AND LEAVING THE UTILITY WORK MACHINE............................ 87 Procedure....................................................................... 87 Emergency Exit (When Equipped With Cab)......................................... 87 SEAT BELT........................................................................... 89 Inspection And Maintenance...................................................... 89 HYDRAULIC SYSTEM........................................................................ 91 HYDRAULIC / HYDROSTATIC SCHEMATICS.................................................. 95 HYDRAULIC SYSTEM INFORMATION........................................................ 99 Glossary Of Hydraulic / Hydrostatic Symbols..................................... 99 Troubleshooting.................................................................103 CYLINDER (LIFT).....................................................................105 Testing.........................................................................105 Removal And Installation........................................................106 Parts Identification............................................................109 Disassembly.....................................................................110 Assembly........................................................................111 CYLINDER (TILT).....................................................................115 Testing.........................................................................115 Removal And Installation........................................................116 Parts Identification............................................................118 Disassembly.....................................................................119 Assembly........................................................................120 CYLINDER (THREE-POINT LIFT).........................................................123 Testing.........................................................................123 Removal And Installation........................................................125 Parts Identification............................................................127 Disassembly.....................................................................128 Assembly........................................................................129 CYLINDER (STEERING).................................................................133 Testing (Rear)..................................................................133 Testing (Front).................................................................135 Removal And Installation (Rear).................................................136 Removal And Installation (Front)................................................139 Parts Identification............................................................142 Disassembly And Assembly........................................................143 CYLINDER (BOB-TACH).................................................................149 Testing.........................................................................149 Removal And Installation........................................................150 Parts Identification............................................................151 Disassembly.....................................................................152 Assembly........................................................................153 MAIN RELIEF VALVE...................................................................157 Description.....................................................................157 Auxiliary Main Relief Valve Testing.............................................157 Auxiliary Main Relief Valve Removal And Installation............................158 Lift, Tilt And Three-Point Main Relief Valve Testing............................159 Lift, Tilt And Three-Point Main Relief Valve Removal And Installation...........160 PORT RELIEF VALVES..................................................................161 Description.....................................................................161 Lift Port Relief Valve Testing (Base End).......................................161 Lift Port Relief Valve Testing (Rod End)........................................162 Tilt Port Relief Valve Testing..................................................163 Three-Point Port Relief Valve Testing (Base End)................................165 HYDRAULIC CONTROL VALVE.............................................................167 Description.....................................................................167 Removal And Installation........................................................167 Identification Chart............................................................170 Disassembly.....................................................................171 End Valve Section Disassembly And Assembly......................................174 Three-Point Valve Section Disassembly And Assembly..............................176 Lift Valve Section Disassembly And Assembly.....................................180 Tilt Valve Section Disassembly And Assembly.....................................185 Mid Inlet / High flow Valve Section Disassembly And Assembly....................189 Auxiliary Valve Section Disassembly And Assembly................................193 Assembly........................................................................198 STEERING SELECTOR VALVE.............................................................203 Description.....................................................................203 Removal And Installation........................................................203 Disassembly And Assembly........................................................206 PILOT MANIFOLD......................................................................209 Description.....................................................................209 Removal And Installation........................................................209 Parts Identification............................................................212 Disassembly And Assembly........................................................213 LIFT ARM (BYPASS)...................................................................217 Description.....................................................................217 Testing.........................................................................217 HYDRAULIC PUMP......................................................................219 Description.....................................................................219 Auxiliary Section Testing.......................................................220 Lift, Tilt And Three-Point Section Testing......................................222 Steering And Cooling Fan Section Testing........................................224 Removal And Installation........................................................226 Parts Identification............................................................228 Disassembly And Assembly........................................................229 POWER STEERING PUMP.................................................................239 Description.....................................................................239 Removal And Installation........................................................239 Disassembly And Assembly........................................................240 HYDRAULIC / HYDROSTATIC FILTER......................................................245 Description.....................................................................245 Housing Removal And Installation................................................245 Case Drain Housing Removal And Installation.....................................246 CONTROL JOYSTICK S/N APFB11227 & BELOW..............................................249 Description.....................................................................249 Handle Removal And Installation.................................................249 CONTROL JOYSTICK S/N APFB11228 & ABOVE..............................................251 Description.....................................................................251 Handle Removal And Installation.................................................251 HYDRAULIC FLUID RESERVOIR...........................................................253 Description.....................................................................253 Removal And Installation........................................................253 Hydraulic Fluid Screen..........................................................256 OIL COOLER..........................................................................257 Description.....................................................................257 Removal And Installation........................................................257 AUXILIARY HYDRAULIC COUPLER BLOCK...................................................261 Description.....................................................................261 Removal And Installation........................................................261 Disassembly And Assembly........................................................262 REMOTE HYDRAULICS DIVERTER VALVE....................................................265 Description.....................................................................265 Removal And Installation........................................................265 Disassembly And Assembly........................................................267 POWER BOB-TACH BLOCK................................................................273 Description.....................................................................273 Removal And Installation........................................................273 Disassembly And Assembly........................................................275 PTO HYDRAULIC MOTOR.................................................................281 Description.....................................................................281 Removal And Installation........................................................281 Parts Identification............................................................285 Disassembly.....................................................................286 Assembly........................................................................288 DIVERTER VALVE (PTO)................................................................293 Description.....................................................................293 Solenoid Testing................................................................293 Removal And Installation........................................................293 Disassembly And Assembly........................................................296 HYDROSTATIC SYSTEM......................................................................305 HYDROSTATIC SYSTEM INFORMATION......................................................307 Troubleshooting.................................................................307 Description.....................................................................308 HYDROSTATIC DRIVE MOTOR.............................................................309 Description.....................................................................309 Removal And Installation (Front)................................................309 Removal And Installation (Rear).................................................312 Parts Identification............................................................315 Disassembly.....................................................................316 Assembly........................................................................326 CHARGE PRESSURE.....................................................................333 Description.....................................................................333 Testing.........................................................................333 HYDROSTATIC PUMP....................................................................335 Description.....................................................................335 Removal And Installation........................................................335 Control Module Removal And Installation.........................................339 Replenishing / High Pressure Relief Valve Removal And Installation..............341 Charge Relief Valve Removal And Installation....................................341 Parts Identification............................................................342 Disassembly And Assembly........................................................344 Mechanical Neutral Adjustment...................................................358 Hydraulic Controller Neutral Adjustment.........................................364 DRIVE BELT..........................................................................369 Description.....................................................................369 Shield Removal And Installation.................................................369 Adjusting.......................................................................370 Belt Removal And Installation...................................................371 Tensioner Pulley Removal And Installation.......................................372 Tensioner Pulley Parts Identification...........................................373 Tensioner Pulley Disassembly....................................................374 Tensioner Pulley Assembly.......................................................375 DRIVE SYSTEM............................................................................377 BRAKE...............................................................................379 Description.....................................................................379 Disassembly And Assembly (Front Transaxle)......................................379 Disassembly And Assembly (Rear Transaxle).......................................379 TRANSAXLE...........................................................................381 Description.....................................................................381 Removal And Installation (Front)................................................381 Removal And Installation (Rear).................................................385 Brake Housing Disassembly And Assembly..........................................389 Primary Housing Disassembly And Assembly........................................392 HUB.................................................................................399 Description.....................................................................399 Removal And Installation........................................................399 CV SHAFT............................................................................401 Description.....................................................................401 Removal And Installation (Front)................................................401 Removal And Installation (Rear).................................................404 Inner Boot Removal And Installation.............................................407 Outer Boot Removal And Installation.............................................409 MAINFRAME...............................................................................413 OPERATOR CAB........................................................................415 Removal And Installation........................................................415 OPERATOR SEAT.......................................................................425 Removal And Installation........................................................425 Seat Belt Removal And Installation..............................................426 Seat Pan Removal And Installation...............................................427 Slide Rail Removal And Installation.............................................427 Arm Rest Bracket Removal And Installation.......................................428 Arm Rest Removal And Installation...............................................428 PASSENGER SEAT......................................................................429 Removal And Installation........................................................429 Seat Belt Removal And Installation..............................................430 Seat Pan Removal And Installation...............................................431 Arm Rest Removal And Installation...............................................431 BOB-TACH (HAND LEVER)...............................................................433 Description.....................................................................433 Removal And Installation........................................................433 Lever And Wedge Disassembly And Assembly........................................434 BOB-TACH (POWER)....................................................................435 Description.....................................................................435 Removal And Installation........................................................435 Lever And Wedge Disassembly And Assembly........................................437 LIFT ARM............................................................................439 Removal And Installation........................................................439 REAR COVER..........................................................................441 Opening And Closing.............................................................441 Removal And Installation........................................................442 Latch Removal And Installation..................................................443 Latch Adjusting.................................................................444 Rubber Bumper Adjusting.........................................................445 STEERING COLUMN.....................................................................447 Removal And Installation........................................................447 FUEL TANK...........................................................................449 Removal And Installation........................................................449 Fuel Level Sender Removal And Installation......................................451 DRIVE AND BRAKE PEDALS..............................................................453 Description.....................................................................453 Removal And Installation........................................................453 Drive Pedal Disassembly And Assembly............................................454 SHOCKS..............................................................................455 Removal And Installation........................................................455 CONTROL ARMS........................................................................457 Removal And Installation (Lower Arm)............................................457 Removal And Installation (Upper Arm)............................................458 Inspection......................................................................459 Ball Joint Removal And Installation.............................................460 SPINDLE.............................................................................461 Removal And Installation........................................................461 TIE ROD.............................................................................463 Description.....................................................................463 Removal And Installation........................................................463 Toe Adjustment Procedure........................................................464 FLOOR CONSOLE.......................................................................467 Access Cover Removal And Installation (Side)....................................467 Access Cover Removal And Installation (Top).....................................467 CENTER CONSOLE S/N APFB11227 & BELOW................................................469 Removal And Installation........................................................469 CENTER CONSOLE S/N APFB11228 & ABOVE................................................471 Removal And Installation........................................................471 FENDER..............................................................................475 Removal And Installation (Front)................................................475 Removal And Installation (Left Rear)............................................476 Removal And Installation (Right Rear)...........................................477 WINDOWS.............................................................................479 Front, Rear And Lower Door Removal And Installation.............................479 Upper Door Removal And Installation.............................................480 THREE-POINT HITCH...................................................................483 Lift Rod Removal And Installation...............................................483 Top Link Removal And Installation...............................................483 Lower Link Removal And Installation.............................................484 Stabilizer Removal And Installation.............................................485 Rock Shaft Removal..............................................................486 Rock Shaft Installation.........................................................491 ELECTRICAL SYSTEM & ANALYSIS............................................................495 ELECTRICAL SCHEMATICS...............................................................499 ELECTRICAL SYSTEM INFORMATION.......................................................512 Glossary Of Electrical Symbols..................................................512 Cab Harness Connectors..........................................................515 Mainframe / Engine Harness Connectors...........................................516 Description.....................................................................517 Troubleshooting.................................................................518 Fuse And Relay Location - Cab Panel.............................................519 Fuse And Relay Location - Frame Panel...........................................520 Solenoid Testing................................................................521 BATTERY.............................................................................522 Removal And Installation........................................................522 Servicing.......................................................................523 Using A Booster Battery (Jump Starting).........................................524 ALTERNATOR..........................................................................526 Belt Adjustment.................................................................526 Belt Replacement................................................................526 Charging System Inspection......................................................527 Alternator Voltage Testing......................................................528 Low Voltage Testing.............................................................529 High Voltage Testing............................................................529 Removal And Installation........................................................530 Parts Identification............................................................531 STARTER.............................................................................532 Testing.........................................................................532 Removal And Installation........................................................533 Parts Identification............................................................534 INSTRUMENT PANELS...................................................................536 Display Controller Panel........................................................536 Switch Panel....................................................................537 Floor Console...................................................................538 Center Console (With Early Model Joystick)......................................539 Center Console (With Later Model Joystick)......................................540 Display Controller Panel Removal And Installation...............................541 LIGHTS..............................................................................542 Front Removal And Installation..................................................542 BOBCAT CONTROLLER (DISPLAY).........................................................544 Description.....................................................................544 Connector Identification........................................................545 Removal And Installation........................................................546 BOBCAT CONTROLLER (DRIVE)...........................................................548 Description.....................................................................548 Connector Identification........................................................549 Removal And Installation........................................................550 DIAGNOSTIC SERVICE CODES............................................................552 Description.....................................................................552 Service Codes List..............................................................553 DISPLAY CONTROLLER PANEL SETUP......................................................556 Enter Setup.....................................................................556 Two-Speed.......................................................................556 High Flow.......................................................................556 Horsepower Management...........................................................556 Tire Size.......................................................................556 Save Setup......................................................................556 Exit Setup......................................................................556 PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START).....................................558 Password Description............................................................558 Changing The Owner And Operator Passwords.......................................558 Password Lockout Feature........................................................559 TOOLCAT INTERLOCK CONTROL SYSTEM (TICS).............................................560 Description.....................................................................560 Inspecting The TICS.............................................................560 Maintaining The TICS............................................................560 Lift Arm Bypass Procedure.......................................................561 Inspecting......................................................................561 ARM REST SENSOR.....................................................................562 Description.....................................................................562 Removal And Installation........................................................562 SPEED SENSOR (FRONT TRANSAXLE)......................................................564 Description.....................................................................564 Removal And Installation........................................................564 SPEED SENSOR (PTO MOTOR)............................................................566 Description.....................................................................566 Removal.........................................................................566 Installation....................................................................567 WHEEL POSITION SENSORS..............................................................570 Description.....................................................................570 Removal And Installation (Front)................................................570 Removal And Installation (Rear).................................................571 Adjusting (In The Machine)......................................................573 Adjusting (Out Of The Machine)..................................................574 SERVICE PC (LAPTOP COMPUTER)........................................................578 Connecting Remote Start Tool....................................................578 Connecting Remote Start Tool (Service Tool).....................................578 CALIBRATION.........................................................................580 Description.....................................................................580 Throttle Position Sensor Calibration............................................580 Drive System Calibration........................................................581 Brake Pedal Calibration.........................................................582 Travel Pedal Calibration........................................................583 TRAVEL DIRECTION CONTROL LEVER......................................................584 Description.....................................................................584 Removal And Installation........................................................584 FLYWHEEL RPM SENSOR.................................................................586 Description.....................................................................586 Adjusting.......................................................................586 ELECTRIC COOLING FAN................................................................588 Description.....................................................................588 Removal And Installation........................................................588 MAINTENANCE CLOCK...................................................................590 Description.....................................................................590 Setup...........................................................................590 Reset...........................................................................592 BACK-UP ALARM SYSTEM................................................................594 Description.....................................................................594 Inspecting......................................................................594 ENGINE SERVICE..........................................................................596 ENGINE INFORMATION..................................................................598 Description.....................................................................598 Specifications..................................................................599 Torque Values...................................................................604 Troubleshooting.................................................................605 Engine Removal And Installation.................................................607 Engine Mount Replacement........................................................613 Compression - Checking..........................................................614 ENGINE SPEED CONTROL................................................................616 Removal And Installation (Position Sensing).....................................616 Removal And Installation (Non Position Sensing).................................616 Speed Control Cable Removal And Installation....................................617 MUFFLER.............................................................................620 Removal And Installation........................................................620 AIR CLEANER.........................................................................622 Housing Removal And Installation................................................622 ENGINE COOLING SYSTEM...............................................................624 Cooling System Service Access Position..........................................624 Radiator Removal And Installation...............................................627 Hydraulic Fan Removal And Installation..........................................629 Hydraulic Fan Disassembly And Assembly..........................................632 Water Pump Removal And Installation.............................................634 Water Pump Disassembly And Assembly.............................................635 Thermostat Housing Removal And Installation.....................................635 LUBRICATION SYSTEM..................................................................636 Oil Pan Removal And Installation................................................636 Oil Pump Removal And Installation...............................................638 Oil Pump Inspection.............................................................638 Engine Oil Pressure - Testing...................................................639 FUEL SYSTEM.........................................................................640 Fuel Camshaft Removal And Installation..........................................640 Fuel Camshaft Governor Disassembly And Assembly.................................641 Fuel ShutOff Solenoid - Checking................................................642 Fuel ShutOff Solenoid Removal And Installation..................................642 Fuel Injection Pump Removal And Installation....................................643 Injection Pump - Timing.........................................................646 Fuel Injector Removal And Installation..........................................648 Fuel Injector Nozzle Pressure - Checking........................................650 Nozzle Spray Condition..........................................................650 Valve Seat Tightness............................................................651 CYLINDER HEAD.......................................................................652 Glow Plugs - Testing............................................................652 Glow Plugs Removal And Installation.............................................652 Valve Clearance Adjustment......................................................654 Valve Timing - Checking.........................................................655 Cylinder Head Removal And Installation..........................................655 Cylinder Head Disassembly And Assembly..........................................658 Cylinder Head - Servicing.......................................................659 Cylinder Head Top Clearance.....................................................659 Valve Guide - Checking..........................................................660 Reconditioning The Valve And Valve Seat.........................................662 Valve Spring....................................................................663 Valve Tappets...................................................................664 Rocker Arm And Shaft - Checking.................................................664 CRANKSHAFT AND PISTONS..............................................................666 Piston And Connecting Rod Removal And Installation..............................666 Piston And Connecting Rod - Servicing...........................................667 Cylinder Bore - Checking........................................................670 Connecting Rod Alignment........................................................670 Crankshaft Gear Removal And Installation........................................671 Crankshaft And Bearings Removal And Installation................................671 Crankshaft And Bearings - Servicing.............................................673 CAMSHAFT AND TIMING GEARS...........................................................678 Timing Gearcase Cover Removal And Installation..................................678 Timing Gears Backlash - Checking................................................680 Idler Gear And Camshaft Removal And Installation................................681 Camshaft - Servicing............................................................682 Idler Gear And Shaft - Servicing................................................683 TURBOCHARGER........................................................................684 Description.....................................................................684 Testing.........................................................................684 Removal And Installation........................................................685 FLYWHEEL AND HOUSING................................................................688 Flywheel Removal And Installation...............................................688 Ring Gear Removal And Installation..............................................688 Housing Removal And Installation................................................689 HEATING, VENTILATION, AIR CONDITIONING..................................................694 AIR CONDITIONING SYSTEM FLOW........................................................696 Description.....................................................................696 Chart...........................................................................697 Components......................................................................698 Safety Equipment................................................................701 REGULAR MAINTENANCE.................................................................702 Filter Elements Removal And Installation........................................702 Compressor Drive Belt Inspection................................................703 Condenser.......................................................................703 Air Conditioning Service Chart..................................................704 A/C Evaporator Coil.............................................................705 TROUBLESHOOTING.....................................................................706 Blower Motor Does Not Operate...................................................706 Blower Motor Operates Normally But Air Flow Is Insufficient.....................706 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal......706 The Compressor Does Not Operate At All Or Operates Improperly...................707 Gauge Pressure Related Troubleshooting..........................................708 Temperature / Pressure Chart....................................................710 Poor A/C Performance............................................................711 HVAC Repair And Leaks...........................................................711 Electrical System...............................................................712 Engine Coolant Bypassing The Heater Valve.......................................721 Heater Valve Not Opening Or Closing.............................................722 SYSTEM CHARGING AND RECLAMATION.....................................................724 Refrigerant Identification......................................................724 Reclamation And Charging With Recovery / Charging Unit..........................725 Charging With A Manifold Gauge Set..............................................727 COMPRESSOR..........................................................................730 Belt Adjustment.................................................................730 Belt Replacement................................................................730 Removal And Installation........................................................732 Oil.............................................................................733 Oil Check.......................................................................734 Clutch Disassembly And Assembly.................................................736 CONDENSER...........................................................................740 Removal And Installation........................................................740 RECEIVER / DRIER....................................................................742 Receiver / Drier Removal And Installation.......................................742 Pressure Relief Valve Removal And Installation..................................743 Pressure Switch Removal And Installation........................................744 EVAPORATOR / HEATER UNIT............................................................746 Removal And Installation........................................................746 THERMOSTAT..........................................................................748 Removal And Installation........................................................748 EXPANSION VALVE.....................................................................750 Removal And Installation........................................................750 EVAPORATOR COIL.....................................................................752 Removal And Installation........................................................752 HEATER COIL.........................................................................754 Removal And Installation With A/C...............................................754 BLOWER FAN..........................................................................756 Removal And Installation........................................................756 HEATER VALVE........................................................................758 Removal And Installation........................................................758 Disassembly And Assembly........................................................758 SPECIFICATIONS..........................................................................760 (5610) UTILITY WORK MACHINE SPECIFICATIONS..........................................762 Machine Dimensions (With 27 Inch Tires And Without Three-Point Hitch Option)....762 Machine Dimensions (With 27 Inch Tires And With Three-Point Hitch Option).......763 Machine Dimensions (With 29 Inch Tires And Without Three-Point Hitch Option)....764 Machine Dimensions (With 29 Inch Tires And With Three-Point Hitch Option).......765 Performance.....................................................................766 Controls........................................................................766 Engine..........................................................................767 Hydraulic System................................................................767 Electrical......................................................................768 Power Take-Off (PTO) System.....................................................768 Drive System....................................................................768 Capacities......................................................................768 Tires...........................................................................769 TORQUE SPECIFICATIONS FOR BOLTS.....................................................770 Torque For General SAE Bolts....................................................770 Torque For General Metric Bolts.................................................771 HYDRAULIC CONNECTION SPECIFICATIONS.................................................772 O-ring Face Seal Connection.....................................................772 Straight Thread O-ring Fitting..................................................773 Tubelines And Hoses.............................................................773 Flare Fitting...................................................................773 O-ring Flare Fitting............................................................774 Port Seal Fitting...............................................................776 Quick-Lok™ Fitting..............................................................777 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS........................................778 Specifications..................................................................778 CONVERSIONS.........................................................................780 Decimal And Millimeter Equivalent Chart.........................................780 U.S. To Metric Conversion Chart.................................................781 SERVICE TOOLS REQUIRED..............................................................782 Remote Start Tools..............................................................782 Hydraulic Tools.................................................................783 Mainframe And Drive Tools.......................................................785 Electrical Tools................................................................785 Engine Tools....................................................................786 HVAC Tools......................................................................788 ALPHABETICAL INDEX......................................................................790
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