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Bobcat Toolcat™ 5610 Utility Work Machine Service Manual SN APFB11001 & Above – PDF DOWNLOAD
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Description
Bobcat Toolcat™ 5610 Utility Work Machine Service Manual SN APFB11001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat Toolcat™ 5610 Utility Work Machine Service Manual SN APFB11001 & Above – PDF DOWNLOAD
Language : English
Pages : 872
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat Toolcat™ 5610 Utility Work Machine Service Manual SN APFB11001 & Above – PDF DOWNLOAD
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 APFB11001 & 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 AND 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...................................................................... 26 OPERATOR CAB...................................................................... 27 Description................................................................... 27 TRANSPORTING THE UTILITY WORK MACHINE ON A TRAILER................................ 29 Loading And Unloading......................................................... 29 Fastening..................................................................... 30 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 - 7217666.................................... 39 Description................................................................... 39 Remote Start Tool (Service Tool) - 7022042.................................... 40 Service Tool Harness - 6689747................................................ 41 Computer Service Tool Harness - 6689746....................................... 42 Remote Start Procedure........................................................ 43 SERVICE SCHEDULE.................................................................. 47 Maintenance Intervals......................................................... 47 AIR CLEANER SERVICE............................................................... 49 Replacing Filter Elements..................................................... 49 ENGINE COOLING SYSTEM............................................................. 51 Checking Level................................................................ 51 Cooling System Service Access Position........................................ 52 Cleaning...................................................................... 54 Removing And Replacing Coolant................................................ 55 FUEL SYSTEM....................................................................... 57 Fuel Specifications........................................................... 57 Biodiesel Blend Fuel.......................................................... 57 Filling The Fuel Tank......................................................... 58 Fuel Filter................................................................... 58 Removing Air From The Fuel System............................................. 59 Filling A Portable Fuel Container............................................. 60 ENGINE LUBRICATION SYSTEM......................................................... 61 Checking And Adding Engine Oil................................................ 61 Engine Oil Chart.............................................................. 61 Removing And Replacing Oil And Filter......................................... 62 Removing And Replacing Oil And Filter (Cont’d)................................ 63 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........................................ 68 Breather Cap.................................................................. 69 TRANSAXLE (FRONT AND REAR)........................................................ 71 Checking And Adding Lubricant................................................. 71 Removing And Replacing Lubricant.............................................. 72 BOB-TACH® (HAND LEVER)............................................................ 73 Inspection And Maintenance.................................................... 73 BOB-TACH® (POWER)................................................................. 75 Inspection And Maintenance.................................................... 75 LUBRICATING THE UTILITY WORK MACHINE.............................................. 77 Lubrication Locations......................................................... 77 TIRE MAINTENANCE.................................................................. 81 Wheel Nuts.................................................................... 81 Rotating...................................................................... 81 Mounting...................................................................... 81 SPARK ARRESTER MUFFLER............................................................ 83 Cleaning Procedure............................................................ 83 PIVOT PINS........................................................................ 85 Inspection And Maintenance.................................................... 85 UTILITY WORK MACHINE STORAGE AND RETURN TO SERVICE................................ 87 Storage....................................................................... 87 Return To Service............................................................. 87 STOPPING THE ENGINE AND LEAVING THE UTILITY WORK MACHINE.......................... 89 Procedure..................................................................... 89 Emergency Exit (When Equipped With Cab)....................................... 90 SEAT BELT......................................................................... 91 Inspection And Maintenance.................................................... 91 HYDRAULIC SYSTEM...................................................................... 93 HYDRAULIC / HYDROSTATIC SCHEMATICS................................................ 97 HYDRAULIC SYSTEM INFORMATION......................................................105 Glossary Of Hydraulic / Hydrostatic Symbols...................................105 Troubleshooting...............................................................109 CYLINDER (LIFT)...................................................................111 Testing.......................................................................111 Removal And Installation......................................................112 Parts Identification..........................................................115 Disassembly...................................................................116 Assembly......................................................................118 CYLINDER (TILT)...................................................................121 Testing.......................................................................121 Removal And Installation......................................................122 Parts Identification..........................................................124 Disassembly...................................................................125 Assembly......................................................................127 CYLINDER (THREE-POINT LIFT).......................................................129 Testing.......................................................................129 Removal And Installation......................................................131 Parts Identification..........................................................133 Disassembly...................................................................134 Assembly......................................................................136 CYLINDER (STEERING)...............................................................139 Testing (Rear)................................................................139 Testing (Front)...............................................................141 Removal And Installation (Rear)...............................................142 Removal And Installation (Front)..............................................145 Parts Identification..........................................................148 Disassembly And Assembly......................................................149 CYLINDER (BOB-TACH®)..............................................................155 Testing.......................................................................155 Removal And Installation......................................................156 Parts Identification..........................................................157 Disassembly...................................................................158 Assembly......................................................................159 MAIN RELIEF VALVE.................................................................163 Description...................................................................163 Auxiliary Main Relief Valve Testing...........................................163 Auxiliary Main Relief Valve Removal And Installation..........................164 Lift, Tilt And Cargo Box Main Relief Valve Testing............................165 Lift, Tilt And Cargo Box Main Relief Valve Removal And Installation...........166 PORT RELIEF VALVES................................................................167 Description...................................................................167 Lift Port Relief Valve Testing (Base End).....................................167 Lift Port Relief Valve Testing (Rod End)......................................168 Tilt Port Relief Valve Testing................................................169 Three-Point Port Relief Valve Testing (Base End)..............................171 HYDRAULIC CONTROL VALVE...........................................................173 Description...................................................................173 Removal And Installation......................................................173 Identification Chart..........................................................176 Disassembly...................................................................177 End Valve Section Disassembly And Assembly....................................180 Three-Point Valve Section Disassembly And Assembly............................182 Lift Valve Section Disassembly And Assembly...................................186 Tilt Valve Section Disassembly And Assembly...................................190 Mid Inlet / High-Flow Valve Section Disassembly And Assembly..................195 Auxiliary Valve Section Disassembly And Assembly..............................199 Assembly......................................................................203 STEERING SELECTOR VALVE...........................................................209 Description...................................................................209 Removal And Installation......................................................209 Disassembly And Assembly......................................................212 PILOT MANIFOLD W/O TRACTION CONTROL...............................................215 Description...................................................................215 Removal And Installation (Early Models).......................................215 Parts Identification (Early Models)...........................................218 Disassembly And Assembly (Early Models).......................................219 Removal And Installation (Later Models).......................................223 Parts Identification (Later Models)...........................................226 Disassembly And Assembly (Later Models).......................................227 PILOT MANIFOLD WITH TRACTION CONTROL..............................................231 Description...................................................................231 Removal And Installation......................................................231 Parts Identification..........................................................234 Disassembly And Assembly......................................................235 LIFT ARM (BYPASS).................................................................239 Description...................................................................239 Testing.......................................................................239 HYDRAULIC PUMP....................................................................241 Description...................................................................241 Auxiliary Section Testing.....................................................241 Lift, Tilt And Three-Point Section Testing....................................243 Steering And Cooling Fan Section Testing......................................245 Removal And Installation......................................................247 Parts Identification..........................................................249 Disassembly And Assembly......................................................250 POWER STEERING PUMP...............................................................259 Description...................................................................259 Removal And Installation......................................................259 Disassembly And Assembly......................................................260 HYDRAULIC / HYDROSTATIC FILTER....................................................265 Description...................................................................265 Housing Removal And Installation..............................................265 Case Drain Housing Removal And Installation...................................266 CONTROL JOYSTICK (S/N APFB11001 - APFB11227)......................................269 Description...................................................................269 Handle Removal And Installation...............................................269 CONTROL JOYSTICK (S/N APFB11228 & ABOVE)..........................................271 Description...................................................................271 Handle Removal And Installation...............................................271 HYDRAULIC FLUID RESERVOIR.........................................................273 Description...................................................................273 Removal And Installation......................................................273 Hydraulic Fluid Screen........................................................276 OIL COOLER........................................................................277 Description...................................................................277 Removal And Installation......................................................277 AUXILIARY HYDRAULIC COUPLER BLOCK.................................................281 Description...................................................................281 Removal And Installation......................................................281 Disassembly And Assembly......................................................282 REMOTE HYDRAULICS DIVERTER VALVE..................................................285 Description...................................................................285 Removal And Installation......................................................285 Disassembly And Assembly......................................................287 POWER BOB-TACH® BLOCK (S/N APFB11001 - APFB11255).................................293 Description...................................................................293 Removal And Installation......................................................293 Disassembly And Assembly......................................................295 POWER BOB-TACH® BLOCK (S/N APFB11256 & ABOVE).....................................301 Description...................................................................301 Removal And Installation......................................................301 Disassembly And Assembly......................................................303 PTO HYDRAULIC MOTOR...............................................................309 Description...................................................................309 Removal And Installation......................................................309 Parts Identification..........................................................313 Disassembly...................................................................314 Assembly......................................................................317 DIVERTER VALVE (PTO)..............................................................323 Description...................................................................323 Solenoid Testing..............................................................323 Removal And Installation......................................................323 Disassembly And Assembly......................................................326 HYDROSTATIC SYSTEM....................................................................335 HYDROSTATIC SYSTEM INFORMATION....................................................337 Troubleshooting...............................................................337 Description...................................................................338 HYDROSTATIC DRIVE MOTOR...........................................................339 Description...................................................................339 Removal And Installation (Front)..............................................339 Removal And Installation (Rear)...............................................342 Parts Identification..........................................................345 Disassembly...................................................................346 Assembly......................................................................356 CHARGE PRESSURE...................................................................363 Description...................................................................363 Testing.......................................................................363 HYDROSTATIC PUMP..................................................................365 Description...................................................................365 Removal And Installation......................................................365 Control Module Removal And Installation.......................................368 Replenishing / High Pressure Relief Valve Removal And Installation............370 Charge Relief Valve Removal And Installation..................................370 Parts Identification..........................................................371 Disassembly And Assembly......................................................373 Mechanical Neutral Adjustment.................................................387 Hydraulic Controller Neutral Adjustment.......................................393 DRIVE BELT........................................................................397 Description...................................................................397 Shield Removal And Installation...............................................397 Belt Adjustment...............................................................398 Belt Replacement..............................................................399 Tensioner Pulley Removal And Installation.....................................401 Tensioner Pulley Disassembly..................................................402 DRIVE SYSTEM..........................................................................403 BRAKE.............................................................................405 Description...................................................................405 Disassembly And Assembly (Front Transaxle)....................................405 Disassembly And Assembly (Rear Transaxle).....................................405 TRANSAXLE.........................................................................407 Description...................................................................407 Removal And Installation (Front)..............................................407 Removal And Installation (Rear)...............................................411 Brake Housing Disassembly And Assembly........................................415 Primary Housing Disassembly And Assembly......................................418 HUB...............................................................................425 Description...................................................................425 Removal And Installation......................................................425 CV SHAFT..........................................................................427 Description...................................................................427 Removal And Installation (Front)..............................................427 Removal And Installation (Rear)...............................................430 Inner Boot Removal And Installation...........................................432 Outer Boot Removal And Installation...........................................434 MAINFRAME.............................................................................437 OPERATOR CAB......................................................................439 Removal And Installation......................................................439 OPERATOR SEAT.....................................................................449 Removal And Installation......................................................449 Seat Belt Removal And Installation............................................450 Seat Pan Removal And Installation.............................................451 Slide Rail Removal And Installation...........................................451 Arm Rest Bracket Removal And Installation.....................................452 Arm Rest Removal And Installation.............................................452 PASSENGER SEAT....................................................................453 Removal And Installation......................................................453 Seat Belt Removal And Installation............................................454 Seat Pan Removal And Installation.............................................455 Arm Rest Removal And Installation.............................................455 BOB-TACH® (HAND LEVER)............................................................457 Description...................................................................457 Removal And Installation......................................................457 Lever And Wedge Disassembly And Assembly......................................458 BOB-TACH® (POWER).................................................................459 Description...................................................................459 Removal And Installation......................................................459 Lever And Wedge Disassembly And Assembly......................................461 LIFT ARM..........................................................................463 Removal And Installation......................................................463 REAR COVER........................................................................465 Opening And Closing...........................................................465 Removal And Installation......................................................466 Latch Removal And Installation................................................467 Latch Adjusting...............................................................468 Rubber Bumper Adjusting.......................................................469 STEERING COLUMN...................................................................471 Removal And Installation......................................................471 FUEL TANK.........................................................................473 Removal And Installation......................................................473 Fuel Level Sender Removal And Installation....................................475 DRIVE AND BRAKE PEDALS............................................................477 Description...................................................................477 Removal And Installation......................................................477 Drive Pedal Disassembly And Assembly..........................................478 SHOCKS............................................................................479 Removal And Installation......................................................479 CONTROL ARMS......................................................................481 Removal And Installation (Lower Arm)..........................................481 Removal And Installation (Upper Arm)..........................................482 Inspection....................................................................483 Ball Joint Removal And Installation...........................................484 SPINDLE...........................................................................485 Removal And Installation......................................................485 TIE ROD...........................................................................487 Description...................................................................487 Removal And Installation......................................................487 Toe Adjustment Procedure......................................................488 FLOOR CONSOLE.....................................................................491 Access Cover Removal And Installation (Side)..................................491 Access Cover Removal And Installation (Top)...................................491 CENTER CONSOLE (S/N APFB11001 - APFB11227)........................................493 Removal And Installation......................................................493 CENTER CONSOLE (S/N APFB11228 & ABOVE)............................................495 Removal And Installation......................................................495 FENDER............................................................................499 Removal And Installation (Front)..............................................499 Removal And Installation (Left Rear)..........................................500 Removal And Installation (Right Rear).........................................501 WINDOWS...........................................................................503 Front, Rear And Lower Door Removal And Installation...........................503 Upper Door Removal And Installation...........................................506 THREE-POINT HITCH.................................................................509 Lift Rod Removal And Installation.............................................509 Top Link Removal And Installation.............................................509 Lower Link Removal And Installation...........................................510 Stabilizer Removal And Installation...........................................511 Rock Shaft Removal............................................................512 Rock Shaft Installation.......................................................516 HEADLINER.........................................................................519 Removal And Installation......................................................519 ELECTRICAL SYSTEM AND ANALYSIS........................................................521 ELECTRICAL SCHEMATICS.............................................................525 ELECTRICAL SYSTEM INFORMATION.....................................................551 Glossary Of Electrical Symbols................................................551 Cab Harness Connectors........................................................554 Mainframe / Engine Harness Connectors.........................................555 Description...................................................................556 Troubleshooting...............................................................557 Fuse And Relay Location - Cab Panel...........................................558 Fuse And Relay Location - Frame Panel.........................................559 Solenoid Testing..............................................................560 BATTERY...........................................................................561 Removal And Installation......................................................561 Servicing.....................................................................563 Using A Booster Battery (Jump Starting).......................................564 ALTERNATOR........................................................................565 Belt Adjustment...............................................................565 Belt Replacement..............................................................565 Charging System Inspection....................................................566 Alternator Voltage Testing....................................................567 Low Voltage Testing...........................................................568 High Voltage Testing..........................................................568 Removal And Installation......................................................569 Parts Identification..........................................................571 STARTER...........................................................................573 Testing.......................................................................573 Removal And Installation......................................................574 Parts Identification..........................................................575 INSTRUMENT PANELS.................................................................577 Display Controller Panel......................................................577 Switch Panel..................................................................578 Floor Console.................................................................579 Center Console (With Early Model Joystick)....................................580 Center Console (With Later Model Joystick)....................................581 Radio.........................................................................582 LIGHTS............................................................................585 Front Removal And Installation................................................585 BOBCAT CONTROLLER (DISPLAY).......................................................587 Description...................................................................587 Connector Identification......................................................588 Removal And Installation......................................................589 BOBCAT CONTROLLER (DRIVE).........................................................591 Description...................................................................591 Connector Identification......................................................592 Removal And Installation......................................................593 DIAGNOSTIC SERVICE CODES..........................................................595 Description...................................................................595 Service Codes List............................................................596 CONTROL PANEL SETUP...............................................................599 Enter Setup...................................................................599 Two-Speed.....................................................................599 High Flow.....................................................................599 Horsepower Management.........................................................599 Tire Size.....................................................................599 Save Setup....................................................................599 Exit Setup....................................................................599 PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START)...................................601 Password Description..........................................................601 Changing The Owner And Operator Passwords.....................................601 Password Lockout Feature......................................................602 TOOLCAT INTERLOCK CONTROL SYSTEM (TICS™)..........................................603 Description...................................................................603 Inspecting The TICS™..........................................................603 Maintaining The TICS™.........................................................603 Lift Arm Bypass Procedure.....................................................604 Inspecting....................................................................604 ARM REST SENSOR...................................................................605 Description...................................................................605 Removal And Installation......................................................605 SPEED SENSOR (FRONT TRANSAXLE)....................................................607 Description...................................................................607 Removal And Installation......................................................607 SPEED SENSOR (PTO MOTOR)..........................................................609 Description...................................................................609 Removal.......................................................................609 Installation..................................................................610 WHEEL POSITION SENSORS............................................................613 Description...................................................................613 Removal And Installation (Front)..............................................613 Removal And Installation (Rear)...............................................615 Adjusting (In The Machine)....................................................617 Adjusting (Out Of The Machine)................................................618 SERVICE PC (LAPTOP COMPUTER)......................................................619 Connecting Remote Start Tool..................................................619 Connecting Remote Start Tool (Service Tool)...................................619 CALIBRATION.......................................................................621 Description...................................................................621 Throttle Position Sensor Calibration..........................................621 Drive System Calibration......................................................622 Brake Pedal Calibration.......................................................623 Travel Pedal Calibration......................................................624 TRAVEL DIRECTION CONTROL LEVER....................................................625 Description...................................................................625 Removal And Installation......................................................625 FLYWHEEL RPM SENSOR...............................................................627 Description...................................................................627 Adjusting.....................................................................627 ELECTRIC COOLING FAN..............................................................629 Description...................................................................629 Removal And Installation......................................................629 MAINTENANCE CLOCK.................................................................631 Description...................................................................631 Setup.........................................................................631 Reset.........................................................................633 BACK-UP ALARM SYSTEM..............................................................635 Description...................................................................635 Inspecting....................................................................635 FRONT HORN........................................................................637 Description...................................................................637 Removal And Installation......................................................637 Troubleshooting...............................................................638 TRACTION CONTROL..................................................................639 Description...................................................................639 Operation.....................................................................639 Removal And Installation......................................................640 ENGINE SERVICE........................................................................643 ENGINE INFORMATION................................................................647 Description...................................................................647 Specifications................................................................648 Torque Values.................................................................652 Troubleshooting...............................................................652 Engine Removal And Installation...............................................654 Engine Mount Replacement......................................................661 Compression - Checking........................................................662 ENGINE SPEED CONTROL..............................................................663 Removal And Installation (Position Sensing)...................................663 ENGINE SPEED CONTROL..............................................................664 Removal And Installation (Non Position Sensing)...............................664 Speed Control Cable Removal And Installation..................................665 MUFFLER...........................................................................667 Removal And Installation......................................................667 AIR CLEANER.......................................................................669 Housing Removal And Installation..............................................669 ENGINE COOLING SYSTEM.............................................................671 Cooling System Service Access Position........................................671 Radiator Removal And Installation.............................................674 Hydraulic Fan Removal And Installation........................................676 Hydraulic Fan Disassembly And Assembly........................................679 Water Pump Removal And Installation...........................................682 Water Pump Disassembly And Assembly...........................................682 Thermostat Housing Removal And Installation...................................683 Thermostat - Checking.........................................................684 LUBRICATION SYSTEM................................................................685 Oil Pan Removal And Installation..............................................685 Oil Pump Removal And Installation.............................................685 Front Cover / Oil Pump Oil Seal Removal And Installation......................686 Relief Valve - Testing........................................................687 Oil Pump Inspection...........................................................687 Oil Filter Cooler Removal And Installation....................................689 Engine Oil Pressure - Testing.................................................689 FUEL SYSTEM.......................................................................691 Fuel Shutoff Solenoid - Checking..............................................691 Fuel Shutoff Solenoid Removal And Installation................................691 Fuel Injection Pump - Checking................................................692 Fuel Injection Pump Assembly Removal And Installation.........................693 Governor Housing Disassembly And Assembly.....................................696 Governor Disassembly And Assembly.............................................698 Fuel Camshaft Removal And Installation........................................700 Fuel Injection Pump Removal And Installation..................................703 Fuel Injection Pump - Timing..................................................705 Fuel Injector Removal And Installation........................................707 Fuel Injector Nozzle Pressure - Checking......................................708 Nozzle Spray Condition........................................................709 Valve Seat Tightness..........................................................709 CYLINDER HEAD.....................................................................711 Glow Plugs - Testing..........................................................711 Glow Plugs Removal And Installation...........................................712 Valve Clearance Adjustment....................................................713 Valve Timing - Checking.......................................................714 Cylinder Head Removal And Installation........................................715 Cylinder Head Disassembly And Assembly........................................718 Cylinder Head - Servicing.....................................................718 Cylinder Head Top Clearance...................................................719 Valve Guide - Checking........................................................720 Valve Guide Removal And Installation..........................................720 Reconditioning The Valve And Valve Seat.......................................721 Valve Spring..................................................................723 Valve Tappets.................................................................724 Rocker Arm And Shaft - Checking...............................................725 Bridge Arm And Bridge Arm Shaft - Checking....................................725 Bridge Arm Shaft Removal And Installation.....................................726 Push Rod Alignment - Checking.................................................727 CRANKSHAFT AND PISTONS............................................................729 Piston And Connecting Rod Removal And Installation............................729 Piston And Connecting Rod - Servicing.........................................730 Cylinder Bore - Checking......................................................734 Connecting Rod Alignment......................................................735 Crankshaft Gear Removal And Installation......................................735 Crankshaft And Bearings Removal And Installation..............................736 Crankshaft And Bearings - Servicing...........................................739 CAMSHAFT AND TIMING GEARS.........................................................743 Timing Gearcase Cover Removal.................................................743 Timing Gearcase Cover Installation............................................743 Timing Gears Backlash - Checking..............................................746 Idler Gear And Camshaft Removal And Installation..............................746 Camshaft - Servicing..........................................................747 Idler Gear And Shaft - Servicing..............................................748 TURBOCHARGER......................................................................751 Description...................................................................751 Testing.......................................................................751 Removal And Installation......................................................752 FLYWHEEL AND HOUSING..............................................................755 Flywheel Removal And Installation.............................................755 Ring Gear Removal And Installation............................................756 Housing Removal And Installation..............................................757 EXHAUST GAS RECIRCULATION (EGR) SYSTEM............................................761 Description...................................................................761 Testing.......................................................................762 Removal And Installation......................................................765 Disassembly And Assembly......................................................766 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)......................................767 AIR CONDITIONING SYSTEM FLOW......................................................769 Description...................................................................769 Chart.........................................................................770 Components....................................................................771 Safety Equipment..............................................................774 REGULAR MAINTENANCE...............................................................775 Filter Elements Removal And Installation......................................775 Compressor Drive Belt Inspection..............................................776 Condenser.....................................................................776 Air Conditioning Service Chart................................................777 A/C Evaporator Coil...........................................................778 TROUBLESHOOTING...................................................................779 Blower Motor Does Not Operate.................................................779 Blower Motor Operates Normally But Air Flow Is Insufficient...................779 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....779 The Compressor Does Not Operate At All Or Operates Improperly.................780 Gauge Pressure Related Troubleshooting........................................781 Temperature / Pressure Chart..................................................783 Poor A/C Performance..........................................................784 HVAC Repair And Leaks.........................................................784 Electrical System.............................................................785 Engine Coolant Bypassing The Heater Valve.....................................792 Heater Valve Not Opening Or Closing...........................................793 SYSTEM CHARGING AND RECLAMATION...................................................795 Refrigerant Identification....................................................795 Reclamation And Charging With Recovery / Charging Unit........................796 Charging With A Manifold Gauge Set............................................798 COMPRESSOR........................................................................801 Belt Adjustment...............................................................801 Belt Replacement..............................................................801 Removal And Installation......................................................802 Oil...........................................................................803 Oil Check.....................................................................803 Clutch Disassembly And Assembly...............................................805 CONDENSER.........................................................................809 Removal And Installation......................................................809 RECEIVER / DRIER..................................................................811 Receiver / Drier Removal And Installation.....................................811 Pressure Relief Valve Removal And Installation................................812 Pressure Switch Removal And Installation......................................813 EVAPORATOR / HEATER UNIT..........................................................815 Removal And Installation......................................................815 THERMOSTAT (S/N APFB11001 - APFB11254)............................................819 Removal And Installation......................................................819 THERMOSTAT (S/N APFB11255 & ABOVE)................................................821 Description...................................................................821 Removal And Installation......................................................822 EXPANSION VALVE...................................................................825 Removal And Installation......................................................825 EVAPORATOR COIL...................................................................827 Removal And Installation......................................................827 HEATER COIL.......................................................................829 Removal And Installation With A/C.............................................829 BLOWER FAN........................................................................831 Removal And Installation......................................................831 HEATER VALVE......................................................................833 Removal And Installation......................................................833 Disassembly And Assembly......................................................833 SPECIFICATIONS........................................................................835 (5610) UTILITY WORK MACHINE SPECIFICATIONS........................................837 Dimensions (With 27 Inch Tires And Without Three-Point Hitch Option)..........837 Dimensions (With 27 Inch Tires And With Three-Point Hitch Option).............838 Dimensions (With 29 Inch Tires And Without Three-Point Hitch Option)..........839 Dimensions (With 29 Inch Tires And With Three-Point Hitch Option).............840 Performance...................................................................841 Controls......................................................................841 Engine........................................................................842 Hydraulic System..............................................................842 Electrical....................................................................843 Power Take-Off (PTO) System...................................................843 Drive System..................................................................843 Capacities....................................................................843 Tires.........................................................................844 TECHNICAL SERVICE GUIDE SPECIFICATIONS............................................845 Engine........................................................................845 Engine Torques................................................................845 Cooling System................................................................845 Loader Torques................................................................846 Hydraulic / Hydrostatic System................................................846 Fuel Consumption..............................................................846 TORQUE SPECIFICATIONS FOR BOLTS...................................................847 Torque For General SAE Bolts..................................................847 Torque For General Metric Bolts...............................................848 HYDRAULIC CONNECTION SPECIFICATIONS...............................................849 O-ring Face Seal Connection...................................................849 Straight Thread O-ring Fitting................................................850 Tubelines And Hoses...........................................................850 Flare Fitting.................................................................850 O-ring Flare Fitting..........................................................851 Port Seal Fitting.............................................................853 Quick-Lok™ Fitting............................................................854 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS......................................855 Specifications................................................................855 CONVERSIONS.......................................................................857 Decimal And Millimeter Equivalent Chart.......................................857 U.S. To Metric Conversion Chart...............................................858 SERVICE TOOLS REQUIRED............................................................859 Remote Start Tools............................................................859 Hydraulic Tools...............................................................860 Mainframe And Drive Tools.....................................................862 Electrical Tools..............................................................862 Engine Tools..................................................................863 HVAC Tools....................................................................865 ALPHABETICAL INDEX....................................................................867
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