Bobcat Toolcat™ 5610 Utility Work Machine Service Manual SN B2LH11001 & Above – PDF DOWNLOAD

Description

Bobcat Toolcat™ 5610 Utility Work Machine Service Manual SN B2LH11001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat Toolcat™ 5610 Utility Work Machine Service Manual SN B2LH11001 & Above – PDF DOWNLOAD

Language : English
Pages : 840
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat Toolcat™ 5610 Utility Work Machine Service Manual SN B2LH11001 & 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 B2LH11001 & Above – PDF DOWNLOAD

MAINTENANCE SAFETY....................................................................  3
CONTENTS..............................................................................  5
FOREWORD..............................................................................  7
	FOREWORD..........................................................................  9
	SAFETY INSTRUCTIONS............................................................... 11
	FIRE PREVENTION................................................................... 13
		Maintenance................................................................... 13
		Operation..................................................................... 13
		Electrical.................................................................... 13
		Hydraulic System.............................................................. 13
		Fueling....................................................................... 13
		Starting...................................................................... 13
		Spark Arrester Exhaust System................................................. 13
		Welding And Grinding.......................................................... 14
		Fire Extinguishers............................................................ 14
	SERIAL NUMBER LOCATIONS........................................................... 15
		Utility Work Machine Serial Number............................................ 15
		Engine Serial Number.......................................................... 15
	DELIVERY REPORT................................................................... 16
	UTILITY WORK MACHINE IDENTIFICATION............................................... 17
SAFETY 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........................................ 33
		Service Tool Harness Communicator - MEL1566................................... 34
		Remote Start Procedure........................................................ 35
	REMOTE START TOOL (SERVICE TOOL) KIT - 7217666.................................... 37
		Description................................................................... 37
		Remote Start Tool (Service Tool) - 7022042.................................... 38
		Service Tool Harness - 6689747................................................ 39
		Computer Service Tool Harness - 6689746....................................... 40
		Remote Start Procedure........................................................ 41
	SERVICE SCHEDULE.................................................................. 45
		Maintenance Intervals......................................................... 45
	AIR CLEANER SERVICE............................................................... 47
		Replacing Filter Elements..................................................... 47
	ENGINE COOLING SYSTEM............................................................. 49
		Checking Level................................................................ 49
		Cooling System Service Access Position........................................ 50
		Cleaning...................................................................... 52
		Removing And Replacing Coolant................................................ 53
	FUEL SYSTEM....................................................................... 55
		Fuel Specifications........................................................... 55
		Biodiesel Blend Fuel.......................................................... 55
		Filling The Fuel Tank......................................................... 56
		Fuel Filter................................................................... 57
		Removing Air From The Fuel System............................................. 58
		Filling A Portable Fuel Container............................................. 58
	ENGINE LUBRICATION SYSTEM......................................................... 59
		Checking And Adding Engine Oil................................................ 59
		Engine Oil Chart.............................................................. 59
		Removing And Replacing Oil And Filter......................................... 60
	HYDRAULIC / HYDROSTATIC SYSTEM.................................................... 61
		Checking Fluid................................................................ 61
		Hydraulic / Hydrostatic Fluid Chart........................................... 61
		Adding Fluid.................................................................. 62
		Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters......... 63
		Removing And Replacing Hydraulic Fluid........................................ 64
		Breather Cap.................................................................. 65
	TRANSAXLE (FRONT AND REAR)........................................................ 67
		Checking And Adding Lubricant................................................. 67
		Removing And Replacing Lubricant.............................................. 68
	BOB-TACH (HAND LEVER)............................................................. 69
		Inspection And Maintenance.................................................... 69
	BOB-TACH (POWER).................................................................. 71
		Inspection And Maintenance.................................................... 71
	LUBRICATING THE UTILITY WORK MACHINE.............................................. 73
		Lubrication Locations......................................................... 73
	TIRE MAINTENANCE.................................................................. 77
		Wheel Nuts.................................................................... 77
		Rotating...................................................................... 77
		Mounting...................................................................... 78
	PIVOT PINS........................................................................ 79
		Inspection And Maintenance.................................................... 79
	UTILITY WORK MACHINE STORAGE AND RETURN TO SERVICE................................ 81
		Storage....................................................................... 81
		Return To Service............................................................. 81
	STOPPING THE ENGINE AND LEAVING THE UTILITY WORK MACHINE.......................... 83
		Procedure..................................................................... 83
		Emergency Exit (When Equipped With Cab)....................................... 84
	SEAT BELT......................................................................... 85
		Inspection And Maintenance.................................................... 85
HYDRAULIC SYSTEM...................................................................... 87
	HYDRAULIC / HYDROSTATIC SCHEMATICS................................................ 91
	HYDRAULIC SYSTEM INFORMATION...................................................... 95
		Glossary Of Hydraulic / Hydrostatic Symbols................................... 95
		Troubleshooting............................................................... 99
	CYLINDER (LIFT)...................................................................101
		Testing.......................................................................101
		Removal And Installation......................................................102
		Parts Identification..........................................................105
		Disassembly...................................................................106
		Assembly......................................................................107
	CYLINDER (TILT)...................................................................111
		Testing.......................................................................111
		Removal And Installation......................................................112
		Parts Identification..........................................................114
		Disassembly...................................................................115
		Assembly......................................................................116
	CYLINDER (THREE-POINT LIFT).......................................................119
		Testing.......................................................................119
		Removal And Installation......................................................121
		Parts Identification..........................................................123
		Disassembly...................................................................124
		Assembly......................................................................125
	CYLINDER (STEERING)...............................................................129
		Testing (Rear)................................................................129
		Testing (Front)...............................................................131
		Removal And Installation (Rear)...............................................132
		Removal And Installation (Front)..............................................135
		Parts Identification..........................................................138
		Disassembly And Assembly......................................................139
	CYLINDER (BOB-TACH)...............................................................145
		Testing.......................................................................145
		Removal And Installation......................................................146
		Parts Identification..........................................................147
		Disassembly...................................................................148
		Assembly......................................................................149
	MAIN RELIEF VALVE.................................................................153
		Description...................................................................153
		Auxiliary Main Relief Valve Testing...........................................153
		Auxiliary Main Relief Valve Removal And Installation..........................154
		Lift, Tilt And Cargo Box Main Relief Valve Testing............................155
		Lift, Tilt And Cargo Box Main Relief Valve Removal And Installation...........156
	PORT RELIEF VALVE.................................................................157
		Description...................................................................157
		Lift Port Relief Valve Testing (Base End).....................................157
		Lift Port Relief Valve Testing (Rod End)......................................158
		Tilt Port Relief Valve Testing................................................159
		Three-Point Port Relief Valve Testing (Base End)..............................161
	HYDRAULIC CONTROL VALVE...........................................................163
		Description...................................................................163
		Removal And Installation......................................................163
		Identification Chart..........................................................166
		Disassembly...................................................................167
		End Valve Section Disassembly And Assembly....................................170
		Three-Point Valve Section Disassembly And Assembly............................172
		Lift Valve Section Disassembly And Assembly...................................176
		Tilt Valve Section Disassembly And Assembly...................................181
		Mid Inlet / High Flow Valve Section Disassembly And Assembly..................185
		Auxiliary Valve Section Disassembly And Assembly..............................189
		Assembly......................................................................194
	STEERING SELECTOR VALVE...........................................................199
		Description...................................................................199
		Removal And Installation......................................................199
		Disassembly And Assembly......................................................202
	PILOT MANIFOLD W/O TRACTION CONTROL...............................................205
		Description...................................................................205
		Removal And Installation......................................................205
		Parts Identification..........................................................208
		Disassembly And Assembly......................................................209
	PILOT MANIFOLD WITH TRACTION CONTROL..............................................213
		Description...................................................................213
		Removal And Installation......................................................213
		Parts Identification..........................................................216
		Disassembly And Assembly......................................................217
	LIFT ARM (BYPASS).................................................................221
		Description...................................................................221
		Testing.......................................................................221
	HYDRAULIC PUMP....................................................................223
		Description...................................................................223
		Auxiliary Section Testing.....................................................224
		Lift, Tilt And Three-Point Section Testing....................................226
		Steering And Cooling Fan Section Testing......................................228
		Removal And Installation......................................................230
		Parts Identification..........................................................233
		Disassembly And Assembly......................................................234
	POWER STEERING PUMP...............................................................243
		Description...................................................................243
		Removal And Installation......................................................243
		Disassembly And Assembly......................................................244
	HYDRAULIC / HYDROSTATIC FILTER....................................................249
		Description...................................................................249
		Housing Removal And Installation..............................................249
		Case Drain Housing Removal And Installation...................................250
	CONTROL JOYSTICK..................................................................253
		Description...................................................................253
		Handle Removal And Installation...............................................253
	HYDRAULIC FLUID RESERVOIR.........................................................255
		Description...................................................................255
		Removal And Installation......................................................255
		Hydraulic Fluid Screen........................................................258
	OIL COOLER / RADIATOR.............................................................259
		Description...................................................................259
		Removal And Installation......................................................259
	AUXILIARY HYDRAULIC COUPLER BLOCK.................................................261
		Description...................................................................261
		Removal And Installation......................................................262
		Disassembly And Assembly (FFI/FI).............................................263
		Disassembly And Assembly (FFH/FH).............................................265
	REMOTE HYDRAULICS DIVERTER VALVE..................................................267
		Description...................................................................267
		Removal And Installation......................................................267
		Disassembly And Assembly......................................................269
	POWER BOB-TACH BLOCK..............................................................275
		Description...................................................................275
		Removal And Installation......................................................275
		Disassembly And Assembly......................................................277
	PTO HYDRAULIC MOTOR...............................................................283
		Description...................................................................283
		Removal And Installation......................................................283
		Parts Identification..........................................................287
		Disassembly...................................................................288
		Assembly......................................................................290
	DIVERTER VALVE (PTO)..............................................................295
		Description...................................................................295
		Solenoid Testing..............................................................295
		Removal And Installation......................................................295
		Disassembly And Assembly......................................................298
HYDROSTATIC SYSTEM....................................................................307
	HYDROSTATIC SYSTEM INFORMATION....................................................309
		Troubleshooting...............................................................309
		Description...................................................................310
	HYDROSTATIC DRIVE MOTOR...........................................................311
		Description...................................................................311
		Removal And Installation (Front)..............................................311
		Removal And Installation (Rear)...............................................314
		Parts Identification..........................................................317
		Disassembly...................................................................318
		Assembly......................................................................328
	CHARGE PRESSURE...................................................................335
		Description...................................................................335
		Testing.......................................................................335
	HYDROSTATIC PUMP..................................................................337
		Description...................................................................337
		Removal And Installation......................................................337
		Control Module Removal And Installation.......................................340
		Replenishing / High Pressure Relief Valve Removal And Installation............342
		Charge Relief Valve Removal And Installation..................................342
		Parts Identification..........................................................343
		Disassembly And Assembly......................................................345
		Mechanical Neutral Adjustment.................................................359
		Hydraulic Controller Neutral Adjustment.......................................364
	DRIVE BELT........................................................................369
		Description...................................................................369
		Exhaust Tube Removal And Installation.........................................369
		Shield Removal And Installation...............................................370
		Belt Adjustment...............................................................371
		Belt Replacement..............................................................372
		Tensioner Pulley Removal And Installation.....................................373
		Tensioner Pulley Disassembly..................................................374
DRIVE SYSTEM..........................................................................375
	BRAKE.............................................................................377
		Description...................................................................377
		Disassembly And Assembly (Front Transaxle)....................................378
		Disassembly And Assembly (Rear Transaxle).....................................378
	TRANSAXLE.........................................................................379
		Description...................................................................379
		Removal And Installation (Front)..............................................379
		Removal And Installation (Rear)...............................................383
		Brake Housing Disassembly And Assembly........................................387
		Primary Housing Disassembly And Assembly......................................390
	HUB...............................................................................397
		Description...................................................................397
		Removal And Installation......................................................397
	CV SHAFT..........................................................................399
		Description...................................................................399
		Removal And Installation (Front)..............................................399
		Removal And Installation (Rear)...............................................402
		Inner Boot Removal And Installation...........................................405
		Outer Boot Removal And Installation...........................................407
MAINFRAME.............................................................................411
	OPERATOR CAB......................................................................413
		Removal And Installation......................................................413
	OPERATOR SEAT.....................................................................423
		Removal And Installation......................................................423
		Seat Belt Removal And Installation............................................424
		Seat Pan Removal And Installation.............................................425
		Slide Rail Removal And Installation...........................................425
		Armrest Bracket Removal And Installation......................................426
		Armrest Removal And Installation..............................................426
	PASSENGER SEAT....................................................................427
		Removal And Installation......................................................427
		Seat Belt Removal And Installation............................................428
		Seat Pan Removal And Installation.............................................429
		Armrest Removal And Installation..............................................429
	BOB-TACH (HAND LEVER).............................................................431
		Description...................................................................431
		Removal And Installation......................................................431
		Lever And Wedge Disassembly And Assembly......................................432
	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....................................................................469
		Removal And Installation......................................................469
	FENDER............................................................................473
		Removal And Installation (Front)..............................................473
		Removal And Installation (Left Rear)..........................................474
		Removal And Installation (Right Rear).........................................475
	WINDOWS...........................................................................477
		Front, Rear And Lower Door Removal And Installation...........................477
		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
	HEADLINER.........................................................................495
		Removal And Installation......................................................495
ELECTRICAL SYSTEM AND ANALYSIS........................................................499
	ELECTRICAL SCHEMATICS.............................................................503
	ELECTRICAL SYSTEM INFORMATION.....................................................517
		Glossary Of Electrical Symbols................................................517
		Cab Harness Connectors........................................................520
		Mainframe Harness Connectors..................................................521
		Engine Harness Connectors.....................................................522
		Description...................................................................523
		Troubleshooting...............................................................524
		Fuse And Relay Location - Cab Panel...........................................525
		Fuse And Relay Location - Frame Panel.........................................526
		Solenoid Testing..............................................................527
	BATTERY...........................................................................529
		Removal And Installation......................................................529
		Servicing.....................................................................531
		Using A Booster Battery (Jump Starting).......................................532
	ALTERNATOR........................................................................533
		Belt Adjustment...............................................................533
		Belt Replacement..............................................................533
		Charging System Inspection....................................................534
		Alternator Voltage Testing....................................................535
		Low Voltage Testing...........................................................535
		High Voltage Testing..........................................................536
		Removal And Installation......................................................537
		Parts Identification..........................................................538
	STARTER...........................................................................539
		Testing.......................................................................539
		Removal And Installation......................................................540
		Parts Identification..........................................................541
	INSTRUMENT PANELS.................................................................543
		Display Controller Panel......................................................543
		Switch Panel..................................................................544
		Floor Console.................................................................545
		Center Console................................................................546
		Radio.........................................................................547
	LIGHTS............................................................................549
		Front Removal And Installation................................................549
	BOBCAT CONTROLLER (DISPLAY).......................................................551
		Description...................................................................551
		Connector Identification......................................................552
		Removal And Installation......................................................553
	BOBCAT CONTROLLER (DRIVE).........................................................555
		Description...................................................................555
		Connector Identification......................................................556
		Removal And Installation......................................................557
	ENGINE CONTROL UNIT (ECU).........................................................559
		Description...................................................................559
		Cleaning......................................................................560
		Removal And Installation......................................................561
	DIAGNOSTIC SERVICE CODES..........................................................563
		Description...................................................................563
		Service Codes List............................................................564
	CONTROL PANEL SETUP...............................................................569
		Enter Setup...................................................................569
		Two-Speed.....................................................................569
		High Flow.....................................................................569
		Horsepower Management.........................................................569
		Tire Size.....................................................................569
		Save Setup....................................................................569
		Exit Setup....................................................................569
	PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START)...................................571
		Password Description..........................................................571
		Changing The Owner And Operator Passwords.....................................571
		Password Lockout Feature......................................................572
	TOOLCAT INTERLOCK CONTROL SYSTEM (TICS™)..........................................573
		Description...................................................................573
		Inspecting The TICS™..........................................................573
		Maintaining The TICS™.........................................................573
		Lift Arm Bypass Procedure.....................................................574
		Inspecting....................................................................574
	ARMREST SENSOR....................................................................575
		Description...................................................................575
		Removal And Installation......................................................575
	SPEED SENSOR (FRONT TRANSAXLE)....................................................577
		Description...................................................................577
		Removal And Installation......................................................577
	SPEED SENSOR (PTO MOTOR)..........................................................579
		Description...................................................................579
		Removal.......................................................................579
		Installation..................................................................580
	WHEEL POSITION SENSORS............................................................583
		Description...................................................................583
		Removal And Installation (Front)..............................................583
		Removal And Installation (Rear)...............................................584
		Adjusting (In The Machine)....................................................586
		Adjusting (Out Of The Machine)................................................587
	SERVICE PC (LAPTOP COMPUTER)......................................................589
		Connecting Remote Start Tool..................................................589
		Connecting Remote Start Tool (Service Tool)...................................589
	CALIBRATION.......................................................................591
		Description...................................................................591
		Throttle Position Sensor Calibration..........................................591
		Drive System Calibration......................................................592
		Brake Pedal Calibration.......................................................593
		Travel Pedal Calibration......................................................594
	TRAVEL DIRECTION CONTROL LEVER....................................................595
		Description...................................................................595
		Removal And Installation......................................................595
	ELECTRIC COOLING FAN..............................................................597
		Description...................................................................597
		Removal And Installation......................................................597
	MAINTENANCE CLOCK.................................................................599
		Description...................................................................599
		Setup.........................................................................599
		Reset.........................................................................601
	BACK-UP ALARM SYSTEM..............................................................603
		Description...................................................................603
		Inspecting....................................................................603
	FRONT HORN........................................................................605
		Description...................................................................605
		Removal And Installation......................................................605
		Troubleshooting...............................................................606
	TRACTION CONTROL..................................................................607
		Description...................................................................607
		Operation.....................................................................607
		Removal And Installation......................................................608
	ELECTRICAL / HYDRAULIC CONTROLS...................................................611
		Description...................................................................611
		Identification Chart ACD Group 0..............................................612
		Identification Chart ACD Group 1..............................................612
		Identification Chart ACD Group 2..............................................613
		Identification Chart ACD Group 3..............................................613
ENGINE SERVICE........................................................................615
	ENGINE INFORMATION................................................................619
		Description...................................................................619
		Specifications................................................................620
		Sensor Location...............................................................622
		Torque Values.................................................................628
		Troubleshooting...............................................................630
		Engine Removal And Installation...............................................632
		Engine Mount Replacement......................................................637
		Compression - Testing.........................................................638
		Injector Signal - Testing.....................................................640
		Injector Signal - Testing (In-Line)...........................................642
	ENGINE SPEED CONTROL..............................................................645
		Removal And Installation......................................................645
		Disassembly And Assembly......................................................645
	DIESEL OXIDATION CATALYST (DOC)...................................................647
		Removal And Installation......................................................647
	AIR CLEANER.......................................................................649
		Housing Removal And Installation..............................................649
	ENGINE COOLING SYSTEM.............................................................651
		Cooling System Service Access Position........................................651
		Radiator / Oil Cooler Removal And Installation................................653
		Hydraulic Fan Removal And Installation........................................655
		Hydraulic Fan Disassembly And Assembly........................................658
		Water Pump Removal And Installation...........................................661
		Thermostat Housing Removal And Installation...................................662
		Testing The Thermostat........................................................663
	LUBRICATION SYSTEM................................................................665
		Description...................................................................665
		Oil Pan Removal And Installation..............................................666
		Oil Pump Removal And Installation.............................................667
		Oil Pump Relief Valve Description.............................................668
		Oil Pump Relief Valve Removal And Installation................................668
		Oil Cooler Removal And Installation...........................................669
		Oil Filter Head Removal And Installation......................................670
		Oil Cooler Bypass Description.................................................671
		Oil Cooler Bypass Removal And Installation....................................671
	FUEL SYSTEM.......................................................................673
		Description...................................................................673
		High Pressure Pump Removal And Installation...................................674
		Fuel Temperature Sensor Removal And Installation..............................677
		Fuel Cooler Removal And Installation..........................................678
		Fuel Cooler Bypass Valve Removal And Installation.............................678
		Fuel Recirculation Valve Removal And Installation.............................679
		Fuel Rail Assembly Removal And Installation...................................680
		Fuel Injector Removal And Installation........................................682
		Removing Air From The Fuel System.............................................684
	CYLINDER HEAD.....................................................................687
		Glow Plugs Testing............................................................687
		Glow Plugs Removal And Installation...........................................688
		Valve Clearance Adjustment....................................................689
		Cylinder Head Removal And Installation........................................691
		Cylinder Head Disassembly And Assembly........................................694
		Cylinder Head Inspection......................................................696
		Cylinder Head Top Clearance...................................................697
		Valve Step Height.............................................................698
		Valve Stem Height.............................................................698
		Valve Guide...................................................................699
		Valve.........................................................................699
		Valve Spring..................................................................700
		Rocker Arm Shaft Disassembly and Assembly.....................................701
		Rocker Arm Shaft Inspection...................................................702
		Push Rod Inspection...........................................................702
	CRANKSHAFT AND PISTONS............................................................703
		Piston And Connecting Rod Removal And Installation............................703
		Piston And Connecting Rod Inspection..........................................704
		Crankshaft Removal And Installation...........................................706
		Cylinder Block Inspection.....................................................709
		Crankshaft Inspection.........................................................711
		Engine Component Class........................................................712
	CAMSHAFT..........................................................................715
		Removal And Installation......................................................715
		Inspecting....................................................................716
	GEARCASE..........................................................................719
		Gearcase Cover Removal And Installation.......................................719
		Gear Backlash.................................................................720
		Gear Timing...................................................................721
		Idle Gear Removal And Installation............................................722
	TURBOCHARGER......................................................................723
		Description...................................................................723
		Removal And Installation......................................................723
		Inspection....................................................................726
	FLYWHEEL AND HOUSING..............................................................729
		Flywheel Removal And Installation.............................................729
		Ring Gear Removal And Installation............................................730
		Housing Removal And Installation..............................................730
	EXHAUST GAS RECIRCULATION (EGR) SYSTEM............................................735
		Description...................................................................735
		Removal And Installation......................................................736
		Disassembly And Assembly......................................................738
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)......................................741
	AIR CONDITIONING SYSTEM FLOW......................................................743
		Description...................................................................743
		A/C System Diagram............................................................744
		Components....................................................................745
		Safety Equipment..............................................................748
	REGULAR MAINTENANCE...............................................................749
		Filter Elements Removal And Installation......................................749
		Compressor Drive Belt Inspection..............................................750
		Condenser.....................................................................750
		Air Conditioning Service Chart................................................751
		A/C Evaporator Coil...........................................................752
	TROUBLESHOOTING...................................................................753
		Blower Motor Does Not Operate.................................................753
		Blower Motor Operates Normally But Air Flow Is Insufficient...................753
		Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....753
		The Compressor Does Not Operate At All Or Operates Improperly.................754
		Gauge Pressure Related Troubleshooting........................................755
		Temperature / Pressure Chart..................................................757
		Poor A/C Performance..........................................................758
		HVAC Repair And Leaks.........................................................758
		Electrical System.............................................................759
		Engine Coolant Bypassing The Heater Valve.....................................768
		Heater Valve Not Opening Or Closing...........................................769
	SYSTEM CHARGING AND RECLAMATION...................................................771
		Refrigerant Identification....................................................771
		Reclamation And Charging With Recovery / Charging Unit........................772
		Charging With A Manifold Gauge Set............................................774
	COMPRESSOR........................................................................777
		Belt Adjustment...............................................................777
		Belt Replacement..............................................................777
		Removal And Installation......................................................778
		Oil...........................................................................779
		Oil Check.....................................................................780
	CONDENSER.........................................................................781
		Removal And Installation......................................................781
	RECEIVER / DRIER..................................................................783
		Receiver / Drier Removal And Installation.....................................783
		Pressure Relief Valve Removal And Installation................................784
		Pressure Switch Removal And Installation......................................785
	EVAPORATOR / HEATER UNIT..........................................................787
		Removal And Installation......................................................787
	THERMOSTAT........................................................................791
		Description...................................................................791
		Removal And Installation......................................................792
	EXPANSION VALVE...................................................................795
		Removal And Installation......................................................795
	EVAPORATOR COIL...................................................................797
		Removal And Installation......................................................797
	HEATER COIL.......................................................................799
		Removal And Installation With A/C.............................................799
	BLOWER FAN........................................................................801
		Removal And Installation......................................................801
	HEATER VALVE......................................................................803
		Removal And Installation......................................................803
		Disassembly And Assembly......................................................803
SPECIFICATIONS........................................................................805
	(5610) UTILITY WORK MACHINE SPECIFICATIONS........................................807
		Dimensions (With 27 Inch Tires And Without Three-Point Hitch Option)..........807
		Dimensions (With 27 Inch Tires And With Three-Point Hitch Option).............808
		Dimensions (With 29 Inch Tires And Without Three-Point Hitch Option)..........809
		Dimensions (With 29 Inch Tires And With Three-Point Hitch Option).............810
		Performance...................................................................811
		Controls......................................................................811
		Engine........................................................................812
		Hydraulic System..............................................................813
		Electrical....................................................................813
		Power Take-Off (PTO) System...................................................814
		Drive System..................................................................814
		Capacities....................................................................814
		Tires.........................................................................814
	TECHNICAL SERVICE GUIDE SPECIFICATIONS............................................815
		Engine........................................................................815
		Engine Torques................................................................815
		Cooling System................................................................815
		Loader Torques................................................................816
		Hydraulic / Hydrostatic System................................................816
		Fuel Consumption..............................................................816
	TORQUE SPECIFICATIONS FOR BOLTS...................................................817
		Torque For General SAE Bolts..................................................817
		Torque For General Metric Bolts...............................................818
	HYDRAULIC CONNECTION SPECIFICATIONS...............................................819
		O-ring Face Seal Connection...................................................819
		Straight Thread O-ring Fitting................................................820
		Tubelines And Hoses...........................................................820
		Flare Fitting.................................................................820
		O-ring Flare Fitting..........................................................821
		Port Seal Fitting.............................................................823
		Quick-Lok™ Fitting............................................................824
	HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS......................................825
		Specifications................................................................825
	CONVERSIONS.......................................................................827
		Decimal And Millimeter Equivalent Chart.......................................827
		U.S. To Metric Conversion Chart...............................................828
	SERVICE TOOLS REQUIRED............................................................829
		Remote Start Tools............................................................829
		Hydraulic Tools...............................................................830
		Mainframe And Drive Tools.....................................................832
		Electrical Tools..............................................................832
		Engine Tools..................................................................833
		HVAC Tools....................................................................836
ALPHABETICAL INDEX....................................................................837

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