PDF Bobcat Toolcat 5600 Utility Work Machine Operation & Maintenance Manual SN A0W111001 & Above

Operation & Maintenance Manual Toolcat™ 5600 Utility Work Machine S/N A0W111001 & Above

EQUIPPED WITH TOOLCAT INTERLOCK CONTROL SYSTEM (TICS™) 6904791 (2-10) Revised (1-11) (6)

Printed in U.S.A.

© Bobcat Company 2011

OPERATOR SAFETY WARNINGS CORRECT

Operator must have instructions before operating the machine.

Untrained operators can cause injury or death.

WARNING

W-2001-0502

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

P-90216

Never use the machine without instructions. See machine signs (decals), Operation & Maintenance Manual, and Operator’s Handbook.

CORRECT

CORRECT

WRONG

B-19707

B-19677

B-21503

Always lower arm rest and fasten seat belts snugly.

Always keep arms and feet inside cab.

Never use machine without operator cab with ROPS and FOPS approval.

Always fasten your seat belt.

Never use machine as a man lift or work platform.

WRONG

WRONG

WRONG

B-21504

B-21505

B-21506

Do not use machine in atmosphere with explosive dust, explosive gas, or where exhaust can contact flammable material.

WRONG

Carry one rider only in the passenger seat.

Keep bystanders away from work area.

No riders in Cargo Box.

Always carry load as possible.

Slow down when turning.

low

as

Load, unload, and turn on flat level ground.

WRONG

WRONG

B-21499

B-21507

B-21476

B-21511

Never exceed capacities.

machine

load

Never leave machine with engine running, with lift arm up, or with cargo box up.

To park, put Travel Control Lever in PARK, put attachment flat on the ground and stop the engine.

Never modify equipment.

Use only attachments approved by Bobcat Company for this machine.

SAFETY EQUIPMENT The machine must be equipped with safety items necessary for each job. Ask your dealer for information on the safe use of attachments and accessories.

1. SEAT BELTS: Check fasteners, check for damaged webbing or buckle.

2. ARM REST: When up, it must deactivate travel and hydraulic functions.

3. CAB (ROPS and FOPS): It must be maintained in good condition.

4. OPERATOR’S HANDBOOK: Must be in the cab.

5. SAFETY SIGNS (DECALS): Replace if damaged.

6. SAFETY TREADS: Replace if damaged.

7. GRAB HANDLES: Replace if damaged.

8. LIFT ARM SUPPORT DEVICE: Replace if damaged.

9. CARGO BOX SUPPORT DEVICE: Replace if damaged.

10. TOOLCAT INTERLOCK CONTROL SYSTEM 1 (TICS): Check function.

OSW16-0409

2

CONTENTS CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 SAFETY & TRAINING RESOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 SYSTEM SETUP & ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 MACHINE SIGN TRANSLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 REFERENCE INFORMATION Write the correct information for YOUR Bobcat Utility Work Machine in the spaces below. Always use these numbers when referring to your Bobcat Utility Work Machine.

Work Machine Serial Number Engine Serial Number NOTES:

YOUR BOBCAT DEALER: ADDRESS: PHONE:

Doosan Benelux SA Drève Richelle 167 B-1410 Waterloo BELGIUM

Bobcat Company P.O. Box 128 Gwinner, ND 58040-0128 UNITED STATES OF AMERICA

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FOREWORD This Operation & Maintenance Manual was written to give the owner / operator instructions on the safe operation and maintenance of the Bobcat Toolcat utility work machine. READ AND UNDERSTAND THIS OPERATION & MAINTENANCE MANUAL BEFORE OPERATING YOUR BOBCAT TOOLCAT UTILITY WORK MACHINE. If you have any questions, see your Bobcat dealer. This manual may illustrate options and accessories not installed on your Toolcat Utility Work Machine.

BOBCAT COMPANY IS IS0 9001 CERTIFIED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 REGULAR MAINTENANCE ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Utility Work Machine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 UTILITY WORK MACHINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 FEATURES, ACCESSORIES AND ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Standard Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Options And Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Buckets Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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BOBCAT COMPANY IS IS0 9001 CERTIFIED

ISO 9001 is an international standard that specifies requirements for a quality management system that controls the processes and procedures which we use to design, develop, manufacture and distribute Bobcat products.

British Standards Institute (BSI) is the Certified Registrar Bobcat Company chose to assess the Company’s compliance with the ISO 9001 at Bobcat's manufacturing facilities in Gwinner and Bismarck, North Dakota (U.S.A.), Pontchateau (France), Dobris (Czech Republic) and the Bobcat corporate offices (Gwinner, Bismarck & West Fargo) in North Dakota.

Only certified assessors, like BSI, can grant registrations.

ISO 9001 means that as a company we say what we do and do what we say. In other words, we have established procedures and policies, and we provide evidence that the procedures and policies are followed.

CALIFORNIA PROPOSITION 65 WARNING Diesel Engine Exhaust And Some Of Its Constituents Are Known To The State Of California To Cause Cancer, Birth Defects And Other Reproductive Harm.

REGULAR MAINTENANCE ITEMS ENGINE OIL FILTER 6675517

BATTERY 6673865

HYDRAULIC / HYDROSTATIC FILTER 6668819 CASE DRAIN FILTER 6516722

FLUID, HYDRAULIC / HYDROSTATIC 6903117 - (2.5 U.S.gal) 6903118 - (5 U.S.gal) 6903119 - (55 U.S.gal)

AIR FILTER, OUTER 6983021

HYDRAULIC BREATHER CAP 6674690

AIR FILTER, INNER 6983022

PROPYLENE GLYCOL ANTI-FREEZE (1 U.S.gal) 6724094 - Premixed [-37°C (-34°F)] 6724354 - Concentrate TRANSAXLE LUBRICANT 6687120 - (2.5 U.S.gal)

FUEL FILTER 6667352 MOTOR OIL 6903105 . . . . . . . SAE 15W/40 CE/SG (12 qt) 6903106 . . . . . . . SAE 15W/40 CE/SG (1 U.S.gal) 6903113 . . . . . . . SAE 15W/40 CE/SG (2.5 U.S.gal)

6903109 . . . . . . SAE 30W CE/SG (12 qt) 6903110 . . . . . . SAE 30W CE/SG (1 U.S.gal) 6903111 . . . . . . SAE 30W CE/SG (2.5 U.S.gal)

6903107 . . . . . . . SAE 10W/30 CE/SG (12 qt) 6903108 . . . . . . . SAE 10W/30 CE/SG (1 U.S.gal) 6903112 . . . . . . . SAE 10W/30 CE/SG (2.5 U.S.gal)

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5600 Operation & Maintenance Manual

SERIAL NUMBER LOCATIONS

Engine Serial Number

Always use the serial number of the machine when requesting service information or when ordering parts.

Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation.

Figure 2

Figure 1 1

P-73841A P-73833

The engine serial number is located at the rear end of the valve cover (Item 1) [Figure 2].

DELIVERY REPORT B-23482

Figure 3

Utility Work Machine Serial Number The Toolcat™ utility work machine serial number plate is located on the front of the frame below the right fender [Figure 1].

Explanation of machine Serial Number: XXXX XXXXX Module 2. - Production Sequence (Series) Module 1. - Model / Engine Combination

B-16315

1. The four digit Model/Engine Combination Module number identifies the model number and engine combination.

The delivery report [Figure 3] must be completed by the dealer and signed by the owner or operator when the Bobcat loader is delivered. An explanation of the form must be given to the owner.

2. The five digit Production Sequence Number identifies the order which the machine is produced.

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5600 Operation & Maintenance Manual

UTILITY WORK MACHINE IDENTIFICATION

FRONT WINDOW

OPERATION & MAINTENANCE MANUAL, OPERATOR’S HANDBOOK

OPERATOR ARM REST

TILT CYLINDER

FRONT AUXILIARY QUICK COUPLERS

CARGO BOX SUPPORT DEVICE

CAB DOOR †BUCKET ATTACHMENT

TIRES LIFT ARM

LIFT ARM SUPPORT DEVICE

OPERATOR & PASSENGER SEATS WITH SEAT BELTS

z CAB (ROPS & FOPS) GRAB HANDLE

REAR WINDOW CARGO BOX CAB DOOR

BOB-TACH™ TAILGATE

RECEIVER HITCH

B-23474A B-23475B

† BUCKET - Buckets and other attachments are available for the Toolcat™ utility work machine. z ROPS, FOPS - Roll Over Protective Structure, per ISO 3471, and Falling Object Protective Structure per ISO 3449, Level I.

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5600 Operation & Maintenance Manual

FEATURES, ACCESSORIES AND ATTACHMENTS

Options And Accessories (Cont’d)

Standard Items

• •

The 5600 utility work machine is equipped with the following standard items: • • • • • • • • • • • • • • • • • • • • • • • • • • • •

•

Arm Rest, Driver’s Side (TICS) Beverage Holder Bob-Tach™ Cargo Box Support Device Integrated w/ Cylinder Cargo Box With Hydraulic Lift, Bolt-on Sides with Stake Pockets Cruise Control Engine & Hydraulic Monitor With Shutdown Four-Wheel Drive Front & Rear Suspension Front & Rear Windows Front Auxiliary Hydraulics Front Wheel & All Wheel Steer Modes Front Wipers Front Work Lights Hydraulically Controlled Joystick w/ Lift Arm Float Instrumentation: Hourmeter, Job Hours, Speedometer, Tachometer, Fuel Gauge, Engine Temperature, & Warning Lights Lift Arm Support Device Integrated w/ Cylinder Parking Brake Power Port (12 Volt) Power Steering with Tilt Wheel Quick Latch Tailgate Radiator Screen Kit Rear Receiver Hitch Seat Belts With 3-Point Restraint Spark Arrestor Exhaust System Tires 27 x 10.5 x 15 Trac Style Two-Speed Travel Variable Speed Hydrostatic Drive

• • • • • • • • • • • •

Specifications subject to change without notice.

Buckets Available

BUCKET

Many bucket styles, widths and different capacities are available for a variety of different applications. They include Construction & Industry, Low profile, Fertilizer and Snow, to name a few. See your Bobcat dealer for the correct bucket for your Bobcat loader and application.

Attachments

Options And Accessories

• • •

The machine can be equipped with the following options and field installed accessories.

• • • • • • • • • • • • • • • • • •

Keyless Start Lights Front & Rear Work Lights, Head Lights, Tail Lights, Brake Lights, Flashers, Direction Signals Mirrors Rear View Mirror Side Mirrors MSHA Pre-cleaner Power Bob-Tach Radio Kit Rear Window Guard Remote Hydraulics Receiver Hitch Accessories Stake Pocket - Bolt On Step Suspension Driver’s Seat Tires (Five Sizes in Two Styles Available) Translations

Attachment Control Device (7 Pin and 14 Pin) Auxiliary Hydraulics: High Flow Front Backup Alarm Battery, Heavy Duty Beacon or Strobe Light Cab Doors Cab Headliner Cab Heater Cab Heater and Air Conditioning Cab, Sound (Reduced Noise Level) Deluxe Operator Cab (with ROPS / FOPS Approval) Includes: Front & Rear Windows, Headliner, Dome Light Engine Block Heater Engine Guard, Lower Fire Extinguisher Fenders (standard or wide) Floor Adjustment Hose Guide Horn

•

• • • • • • • •

Auger Bale Handler Brooms Angle Broom Whisker Broom Blades Box Blade Dozer Blade Snow Blade V-Blade Chipper Dumping Hopper Farm Grapple Flail Cutter Grader Landplane Landscape Rake Mower

• • • • • • • • • • • • • • • • • •

Pallet Fork Rotary Cutter Seeder Snow Blower Snow Pusher Sod Layer Soil Conditioner Sprayer Spreader Stump Grinder Super Scraper Sweeper Tiller Tilt Tach Trencher Utility Fork Utility Grapple Water Kit

Other attachments may also be available for your machine. See your Bobcat dealer.

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5600 Operation & Maintenance Manual

SAFETY & TRAINING RESOURCES SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Safe Operation Is The Operator’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Safe Operation Needs A Qualified Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Avoid Silica Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Spark Arrestor Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 MACHINE SIGNS (DECALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 PUBLICATIONS AND TRAINING RESOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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SAFETY INSTRUCTIONS

•

An Operator’s Handbook is fastened to the operator cab of the machine. 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 Toolcat Utility Work Machine Operating Training Course is available through your Bobcat dealer. This course is intended to provide rules and practices of correct operation of the Toolcat Utility Work Machine.

The course is available in English and Spanish versions.

•

See the PUBLICATIONS AND TRAINING RESOURCES Page in this manual or your Bobcat dealer for Service and Parts Manuals, printed materials, videos, or training courses available. Also check the Bobcat web sites www.training.bobcat.com or www.bobcat.com

Before Operation Carefully follow the operating instructions in this manual.

and

maintenance

The Bobcat utility work machine is highly maneuverable and compact. It is rugged and useful under a wide variety of conditions. This presents an operator with hazards associated with off highway, rough terrain applications, common with Bobcat machine usage.

The Bobcat utility work machine has an internal combustion engine with resultant heat and exhaust. All exhaust gases can kill or cause illness so use the machine with adequate ventilation.

The dealer explains the capabilities and restrictions of the Bobcat utility work machine and attachment for each application. The dealer demonstrates the safe operation according to Bobcat instructional materials, which are also available to operators. The dealer can also identify unsafe modifications or use of unapproved attachments.

The attachments and buckets are designed for a Rated Operating Capacity (some have restricted lift heights).

They are designed for secure fastening to the Bobcat machine. The user must check with the dealer, or Bobcat literature, to determine safe loads of materials of specified densities for the machine - attachment combination.

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.

The following publications and training materials provide information on the safe use and maintenance of the Bobcat machine and attachments: •

The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine and attachment is in safe operating condition.

•

The Operation & Maintenance Manual delivered with the machine or attachment gives 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.

•

Call Before You Dig Dial 811 (USA Only) 1-888-258-0808 (USA & Canada) When you call, you will be directed to a location in your state / province, or city for information about buried lines (telephone, cable TV, water, sewer, gas, etc.).

Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.

SI TC-0208 13

5600 Operation & Maintenance Manual

SAFETY INSTRUCTIONS (CONT’D)

Safe Operation Needs A Qualified Operator For an operator to be qualified, he or she must not use drugs or alcoholic drinks which impair alertness or coordination while working. An operator who is taking prescription drugs must get medical advice to determine if he or she can safely operate a machine and attachment.

Safe Operation Is The Operator’s Responsibility

Safety Alert Symbol This symbol with a warning statement means: “Warning, be alert! Your safety is involved!”

Carefully read the message that follows.

A Qualified Operator Must Do The Following: Understand Regulations

Written

Instructions,

Rules

and

•

The written instructions from Bobcat Company include the Delivery Report, Operation & Maintenance Manual, Operator’s Handbook and machine signs (decals).

•

Check the rules and regulations at your location. The rules may include an employer’s work safety requirements. Regulations may apply to local driving requirements or use of a Slow Moving Vehicle (SMV) emblem. Regulations may identify a hazard such as a utility line.

WARNING Operator must have instructions before running the machine. Untrained operators can cause injury or death.

the

W-2001-1285

Have Training with Actual Operation

IMPORTANT

•

Operator training must consist of a demonstration and verbal instruction. This training is given by your Bobcat dealer before the product is delivered.

This notice identifies procedures which must be followed to avoid damage to the machine.

•

The new operator must start in an area without bystanders and use all the controls until he or she can operate the machine and attachment safely under all conditions of the work area. Always fasten seat belt before operating.

•

Operator Training Courses are available from your Bobcat dealer in English and Spanish. They provide information for safe and efficient equipment operation. Safety videos are also available.

I-2019-0284

DANGER

Know the Work Conditions

The signal word DANGER on the machine and in the manuals indicates a hazardous situation which, if not avoided, will result in death or serious injury.

•

Know the weight of the materials being handled.

Avoid exceeding the Rated Machine Load Capacities of the machine. Material which is very dense will be heavier than the same volume of less dense material.

Reduce the size of the load if handling dense material.

•

The operator must know any prohibited uses or work areas, for example, he or she needs to know about excessive slopes.

•

Know the location of any underground lines. Call local utilities or the TOLL FREE phone number found in the Before Operation Section of this manual.

•

Wear tight fitting clothing. Always wear safety glasses when doing maintenance or service. Safety glasses, respiratory equipment, hearing protection or Special Applications Kits are required for some work. See your Bobcat dealer about Bobcat Safety Equipment for your model.

D-1002-1107

WARNING The signal word WARNING on the machine and in the manuals indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

W-2044-1107

The Bobcat utility work machine and attachment must be in good operating condition before use.

Check all of the items on the Bobcat Service Schedule Decal under the 8-10 hour column or as shown in the Operation & Maintenance Manual.

SI TC-0208 14

5600 Operation & Maintenance Manual

FIRE PREVENTION

SAFETY INSTRUCTIONS (CONT’D) Avoid Silica Dust

Maintenance The machine and some attachments have components that are at high temperatures under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.

Cutting or drilling concrete containing sand or rock containing quartz may result in exposure to silica dust.

Do not exceed Permissible Exposure Limits (PEL) to silica dust as determined by OSHA or other job site Rules and Regulations. Use a respirator, water spray or other means to control dust. Silica dust can cause lung disease and is known to the state of California to cause cancer.

Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it can cause a fire hazard. Clean often to avoid this accumulation. Flammable debris in the engine compartment is a potential fire hazard.

The operator’s area, engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazards and overheating.

All fuels, most lubricants and some coolants mixtures are flammable. Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire.

Operation Do not use the machine where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.

Electrical

Check all electrical wiring and connections for damage.

Keep the battery terminals clean and tight. Repair or replace any damaged part or wires that are loose or frayed.

Battery gas can explode and cause serious injury. Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting. Do not jump start or charge a frozen or damaged battery. Keep any open flames or sparks away from batteries. Do not smoke in battery charging area.

SI TC-0208

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5600 Operation & Maintenance Manual

FIRE PREVENTION (CONT’D)

Welding And Grinding

Hydraulic System

Always clean the machine and attachment, disconnect the battery, and disconnect the wiring from the Bobcat controllers before welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding.

Check hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Hydraulic tubes and hoses must be properly routed and have adequate support and secure clamps.

Tighten or replace any parts that show leakage.

Have good ventilation when grinding or welding painted parts. Wear dust mask when grinding painted parts.

Toxic dust or gas can be produced.

Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

Dust generated from repairing nonmetallic parts such as hoods, fenders or covers can be flammable or explosive.

Repair such components in a well ventilated area away from open flames or sparks.

Fueling

Fire Extinguishers

Stop the engine and let it cool before adding fuel. No smoking! Do not refuel a machine near open flames or sparks. Fill the fuel tank outdoors.

Starting Do not use ether or starting fluids on any engine that has glow plugs. These starting aids can cause explosion and injure you or bystanders.

Know where fire extinguishers and first aid kits are located and how to use them. Inspect the fire extinguisher and service the fire extinguisher regularly.

Obey the recommendations on the instructions plate.

Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting.

Spark Arrestor Exhaust System The spark arrestor exhaust system is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot.

Check the spark arrestor exhaust system regularly to make sure it is maintained and working properly. Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler (if equipped).

Sl TC-0208

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5600 Operation & Maintenance Manual

MACHINE SIGNS (DECALS) Follow the instructions on all the machine signs (decals) that are on the machine. Replace any damaged machine signs and be sure they are in the correct locations. Machine signs are available from your Bobcat dealer.

BU Alarm 6737189

6814303 6814312

6814300 7135925 7135925 With Remote Rear Hydraulic Option

6808481 6814813

6814311 6814309

Inside Cab

7114129

6986515

7114128 (2)

6731757

6814302 (2)

6561383 (Behind Bob-Tach) 7128957

B-23474A

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5600 Operation & Maintenance Manual

MACHINE SIGNS (DECALS) (CONT’D) Follow the instructions on all the machine signs (decals) that are on the machine. Replace any damaged machine signs and be sure they are in the correct locations. Machine signs are available from your Bobcat dealer.

7169699

6804233 6814301

7134482A

6708929

7128961

7129653 (Inside Fuse Cover)

6814310

6595014 (2)

6814307 (2) Under Cargo Box 7129654 (Inside Fuse Cover) 7106629 With Remote Hydraulics Option

B-23475B

18

5600 Operation & Maintenance Manual

PUBLICATIONS AND TRAINING RESOURCES The following publications are also available for your Toolcat Utility Work Machine. You can order them from your Bobcat dealer.

OPERATOR’S HANDBOOK

For the latest information on Bobcat products and the Bobcat Company, visit our web site at www.bobcat.com.

6986515

- Provides basic operation instructions and safety warnings.

OPERATION & MAINTENANCE MANUAL 6904791 TOOLCAT UTILITY WORK MACHINE OPERATOR TRAINING COURSE

- Complete instructions on the correct operation and the routine maintenance of the Toolcat Utility Work Machine.

6902643

- Introduces operator to step-by-step basics of the Utility Work Machine Operation.

SERVICE MANUAL 6904792 OPERATOR SAFETY VIDEO 6902430 - Provides basic safety instructions.

- Complete maintenance instructions for your Toolcat Utility Work Machine.

OPERATOR SAFETY DVD 6904762 - Provides basic safety instructions contained in all Bobcat Safety Videos in both English and Spanish.

19

5600 Operation & Maintenance Manual

20

5600 Operation & Maintenance Manual

OPERATING INSTRUCTIONS OPERATOR CONTROLS AND INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Indicator Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Floor Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Center Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 TOOLCAT INTERLOCK CONTROL SYSTEM (TICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 TICS And Arm Rest Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 BACK-UP ALARM SYSTEM (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 STEERING MODE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 TRAVEL DIRECTION CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Two-Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 DRIVE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 STOPPING THE UTILITY WORK MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 LIFT ARM BYPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

21

5600 Operation & Maintenance Manual

HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Lift Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Lift Arm Float Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Tilt Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Front Auxiliary Hydraulics Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Front Auxiliary Hydraulics Operation (CONTINUOUS FLOW) . . . . . . . . . . . . . . . . . . . . . .37 Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Relieve Hydraulic Pressure (Utility Work Machine And Attachment) . . . . . . . . . . . . . . . . .38 High-Flow Hydraulics Operation (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 REMOTE HYDRAULICS (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Quick Couplers And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Operating The Remote Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 ATTACHMENT CONTROL DEVICE (ACD) (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . .42 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Daily Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 PRE-STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Entering The Utility Work Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Seat And Steering Wheel Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Seat Belt Adjustment And Arm Rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Keyless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Cold Temperature Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Warming The Hydraulic / Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 MONITORING THE CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Key Switch And Keyless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Warning And Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 STOPPING THE ENGINE AND LEAVING THE UTILITY WORK MACHINE . . . . . . . . . . . . . .49 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Emergency Exit (When Equipped With Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 MACHINE LOAD CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Loader Rated Operating Capacity (ROC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Maximum Cargo Box Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Machine Rated Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Maximum Trailer Hitch Tongue Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Total Rated Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

22

5600 Operation & Maintenance Manual

ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Choosing The Correct Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Pallet Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Installing And Removing The Attachment (Hand Lever Bob-Tach) . . . . . . . . . . . . . . . . . . . 52 Installing And Removing The Attachment (Power Bob-Tach) . . . . . . . . . . . . . . . . . . . . . . .54 OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Inspect The Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Basic Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Operating With A Full Bucket And Empty Cargo Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Operating With An Empty Bucket And Loaded Cargo Box . . . . . . . . . . . . . . . . . . . . . . . . . 57 Filling And Emptying The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Leveling The Ground Using Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Work Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Opening And Closing The Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Raising And Lowering The Cargo Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hauling Loads In The Cargo Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Towing Equipment With The Utility Work Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 TOWING THE UTILITY WORK MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 TRANSPORTING THE UTILITY WORK MACHINE ON A TRAILER . . . . . . . . . . . . . . . . . . . 61 Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

23

5600 Operation & Maintenance Manual

24

5600 Operation & Maintenance Manual

Switch Panel

OPERATOR CONTROLS AND INSTRUMENT PANELS Overview

Figure 6

Figure 4

Switch Panel

D A

B

1

5

2

6

3

7

4

8

9 P-74770

E

C F

REF 1 2 3

Figure 5 4

G I 5 6

7

H

8

J

9

DESCRIPTION

FUNCTION / OPERATION

Horn (Option) Press right side to operate.

Not Used --Rotating Beacon or Press right side to turn ON; left Strobe Light (Option) to turn OFF. Light Selection Switch Left Position - headlights (Option) Center Position - front flood lights Right Position - front and rear flood lights Not Used --Power Bob-Tach Press and hold the up arrow to (Option) disengage the Bob-Tach wedges.

Press and hold the down arrow to engage the wedges into the mounting frame holes.

Hazard / Flasher Press right side to turn ON; left to Lights (Option) turn OFF. Direction Signal Lights come on when signal lever Indicators is moved.

Key Switch For starting and stopping engine.

View from operator’s seat [Figure 4] and [Figure 5].

REF

DESCRIPTION

A B C D

Switch Panel (See Switch Panel on Page 25.)

Control Panel (See Control Panel on Page 26.)

Center Console (See Center Console on Page 28.)

Travel Direction Control Lever and Two-Speed Control Switch (See TRAVEL DIRECTION CONTROL LEVER on Page 33.)

Brake Pedal (See BRAKE PEDAL on Page 33.)

Drive Pedal (See DRIVE PEDAL on Page 33.)

Steering Wheel Release for Steering Column Adjustment Direction Signal Lever Move up for left turn; down for right turn.

Floor Console (See Floor Console on Page 28.)

E F G H I J

25

5600 Operation & Maintenance Manual

OPERATOR CONTROLS AND INSTRUMENT PANELS (CONT’D)

REF

DESCRIPTION

FUNCTION / OPERATION

15 SPEED / HOURS / RPM (Cont’d)

Control Panel Figure 7 Control Panel 12

10

13

11

22

14

15

16

17

18

19

20

21

RPM

Shows the engine rpm.

Additional Menu Functions

Used to enter control panel setup mode. (See CONTROL PANEL SETUP on Page 124.)

Press to DECREASE vehicle speed while cruise control is engaged.

Press to INCREASE vehicle speed while cruise control is engaged.

While traveling at the desired speed, press the button to continue traveling at that speed.

(Cruise Control Icon, Item 35, [Figure 8], will be ON.) Press brake or press button again to disengage.

Press & release to turn lights ON; press & release again to turn OFF.

16 DECEL

17 ACCEL

18 CRUISE P-73842B

REF

DESCRIPTION

10 Engine Temperature Gauge 11 Display Screen (Liquid Crystal Display) 12 Fuel Gauge 13 Parking Brake

14 WORK

15 SPEED / HOURS / RPM

Speed

Hours

Job

FUNCTION / OPERATION Shows engine coolant temperature.

Speedometer/Hourmeter/Job/ RPM and Diagnostic Service Codes.

Shows amount of fuel in the tank.

Press to engage; press again to disengage. (Parking Brake Icon, Item 26, [Figure 8] will be ON.) Press button to engage Work Mode. (Work Icon Item 29, [Figure 8], will be ON.) Press again to disengage.

19 LIGHTS / CODES

Service Codes Used to reveal service codes in display screen. (See Viewing Service Codes on Page 121.)

20 Lift And Tilt Transport Press to lock out lift and tilt Lock functions when traveling on a road.

21 AUX-HYD (Std.) Press once to select Front Auxiliary Hydraulics. (Auxiliary Icon, Item 28, [Figure 8], will be ON.) (Must be selected for High Flow to operate.) (See Front Auxiliary Hydraulics Operation on Page 37.)

Press a second time to deselect Front Auxiliary Hydraulics.

22 Keypad for Keyless (See Keyless on Page 47.)

Start (Option)

Press button to toggle display screen between Speed (mph or km/hr.), Hours, Job Clock, and Engine rpm.

Shows machine speed in mph.

While on speed display screen, press and hold to change units of measure (English / Metric).

Shows the total operating hours of the machine.

Sets the display to record accumulated hours for a particular job. While on job display screen, press and hold until the display screen returns to zero. This process will clear the accumulated hours and begin recording job clock time again. (This does not affect the hourmeter which continues to record the total operating hours of the machine.)

26

5600 Operation & Maintenance Manual

OPERATOR CONTROLS AND INSTRUMENT PANELS (CONT’D) Indicator Icons Figure 8 Indicator Icons 23

24

25

26

27

28

29

30

31

32

33

34

35

36 B-19665

REF NO

INDICATOR ICONS

When Indicator Icon Is Lighted . . . .

Plugged Hydraulic Filter or High Hydraulic Temperature Low Engine Oil Pressure Low Fuel Level Parking Brake Engaged Glow Plugs Activated Auxiliary Hydraulics Engaged Work Mode Engaged Low Battery Voltage General Warning (See Viewing Service Codes on Page 121.)

32 Fasten Seat Belt Reminder 33 Lift Arm and Tilt Functions Deactivated 34 Return to PARK reminder (Must be in PARK to start engine.)

35 Cruise Control Engaged 36 High Speed Engaged 23 24 25 26 27 28 29 30 31

27

5600 Operation & Maintenance Manual

Center Console

OPERATOR CONTROLS AND INSTRUMENT PANELS (CONT’D)

Figure 10 Floor Console Figure 9

40

42 37

38

39

43

41 45 44 47

Floor Console REF DESCRIPTION NO 37 38

39

HVAC Fan Air Conditioner

Temperature Control

P-73838

FUNCTION / OPERATION 48

Turn clockwise to increase speed.

Press rear of switch to start; front to stop. Fan (Item 37) must be On for A/C to operate.

Turn clockwise to increase the cab temperature; counterclockwise to decrease.

49 50

46

52

51

Center Console REF NO

NOTE: Turning the air conditioner on with the temperature control set to the highest position will improve the function of the window defroster by drying the air. The air coming out of the vent will still be warm.

40 41 42 43 44

45 46 47 48

49 50

51 52

28

DESCRIPTION

P-73931B

FUNCTION / OPERATION

Joystick

Lift Arm, Tilt and Auxiliary Hydraulic operation.

Auxiliary See Attachment Operation & Hydraulic Maintenance Manual(s) for more Functions (Option) information.

Front Wiper/ Press rear of switch to turn ON; front Washer to turn OFF. Press and hold rear for washer.

Arm Rest --Cargo Box Dump Move lever up to dump; down to lower Cargo Box. Engine Speed Move forward to increase engine Control rpm; backward to decrease.

Steering Mode Press front of switch to select Front Wheel Steer; rear to select All Wheel Steer. (See STEERING MODE SELECTION on Page 32.)

Wheel Alignment Shows when wheels are aligned Indicator straight ahead.

High Flow Press front of switch to engage; rear Auxiliary to disengage. (Early model Hydraulics machines may have the high flow (Option) switch at position 51) Not Used --Power Plug Provides a 12 volt receptacle for accessories.

5600 Operation & Maintenance Manual

TOOLCAT INTERLOCK CONTROL SYSTEM (TICS)

ENGINE SPEED CONTROL

TICS And Arm Rest Operation

Operation

The Toolcat Interlock Control System (TICS) has a pivoting arm rest located on the left side of the operator’s seat.

Figure 12

Figure 11

1

B-19665

1

P-73925A

The engine speed control (Item 1) [Figure 12] is on the center console at the right side of the operator’s seat.

Move the engine speed control forward to increase the engine rpm and backward to decrease.

P-39399

The TICS requires the operator to be seated in the operating position with the arm rest [Figure 11] fully lowered before the lift, tilt and traction functions can be operated. The seat belt must be fastened anytime you operate or are a passenger riding in the machine.

There are display lights (Item 1) [Figure 11] located on the display control panel that must be OFF to operate the machine. When the operator raises the arm rest, the lift, tilt, auxiliary hydraulics and traction drive functions are deactivated.

WARNING AVOID INJURY OR DEATH The Toolcat Interlock Control System (TICS) must deactivate the lift, tilt, auxiliary hydraulics and traction drive functions. If it does not, contact your dealer for service. DO NOT MODIFY THE SYSTEM. W-2452-1102

29

5600 Operation & Maintenance Manual

PARKING BRAKE Operation Figure 13

1

P-73842A

Press the parking brake button (Item 1) [Figure 13] to engage the parking brake. If the button is pressed, you must press it again to disengage.

NOTE: The parking brake is also engaged when the Travel Direction Control Lever is in PARK position. Brake is disengaged when the lever is moved to the Forward or Reverse position.

30

5600 Operation & Maintenance Manual

Operation

BACK-UP ALARM SYSTEM (IF EQUIPPED) Description Figure 14

WARNING This machine is equipped with a motion alarm.

ALARM MUST SOUND! when operating forward or backward.

1

Failure to maintain a clear view in the direction of travel could result in serious injury or death.

The operator is responsible for the safe operation of this machine.

W-2786-0309

The back-up alarm will sound when the operator moves the Travel Direction Control Lever into the reverse position [Figure 17].

P-74285

The back-up alarm (Item 1) [Figure 14] (if equipped) is located at the rear of the machine.

If alarm does not sound or for adjustment instructions, see inspection and maintenance instructions for the back-up alarm system in the preventive maintenance section of this manual. (See BACK-UP ALARM SYSTEM (IF EQUIPPED) on Page 31.)

A back-up alarm is not a substitute for looking to the rear when operating the utility work machine in reverse, or for keeping bystanders away from the work area. Operators must always look in the direction of travel, including reverse, and must also keep bystanders away from the work area, even though the utility work machine is equipped with a back-up alarm.

Operators must be trained to always look in the direction of travel, including when operating the utility work machine in reverse and to keep bystanders away from the work area. Other workers should be trained to always keep away from the operator’s work area and travel path.

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5600 Operation & Maintenance Manual

Figure 16

STEERING MODE SELECTION Operation

1

4

WARNING 2

3 AVOID INJURY OR DEATH When operating the machine: • Keep the seat belts fastened snugly.

• The arm rest must be lowered.

• Keep your feet and arms inside the cab.

P-73933A

W-2454-1102

The steering mode can be selected either for Front Wheel Steer or All Wheel Steer operation.

Figure 15

All Wheel Steer allows the machine to turn in a smaller circle. In All Wheel Steer, the rear wheels follow the same track as the front wheels.

1 Front Wheel Steer - TO - All Wheel Steer • Turn the steering wheel until the wheel alignment indicator lights (Items 1 and 2) [Figure 16] are both ON. When the lights are both ON, the front AND rear wheels are pointing straight ahead • Press the rear of the switch (Item 3) [Figure 16] to engage All Wheel Steer.

P-73836

All Wheel Steer - TO - Front Wheel Steer • Turn the steering wheel until the rear wheel alignment indicator light (Item 2) [Figure 16] is ON. When the light is ON, the rear wheels are pointing straight ahead.

Turn the steering wheel (Item 1) [Figure 15] to the right or left to steer the machine.

• Press the front of the switch (Item 4) [Figure 16] to engage Front Wheel Steer.

B-22492

Tail Swing: When using the All-Wheel-Steer Mode, the front or rear of the machine will swing in the opposite direction of the turn. Always allow room for the turn on that side of the machine.

WARNING Leave adequate room for tail swing of machine when operating in All-Wheel-Steer Mode. Always look in the direction of travel.

W-2472-0903

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5600 Operation & Maintenance Manual

TRAVEL DIRECTION CONTROL LEVER

DRIVE PEDAL

Operation

Operation Use the Travel Direction Control Lever to select Forward or Reverse travel then press the Drive Pedal (Item 5) [Figure 17] to move the machine. To increase the speed of the machine, continue to press the Drive Pedal.

Release the Drive Pedal to stop the machine.

Figure 17

2

4

1

BRAKE PEDAL Operation Press the Brake Pedal (Item 6) [Figure 17] to stop the machine. The Brake Pedal will decelerate the machine faster than releasing the Drive Pedal only. Continue to press and hold the Brake Pedal to temporarily hold the machine in position until the Travel Direction Control Lever is returned to the PARK position or drive operation is resumed.

3

6

5 P-73843

The Travel Direction Control Lever (Item 1) [Figure 17] has three positions; Forward - PARK - Reverse (FPR).

Pull lever toward steering wheel and move the lever up (Item 2) [Figure 17] for forward travel.

Pull lever toward steering wheel and move the lever down (Item 3) [Figure 17] for reverse travel.

Put the lever in PARK whenever you stop the machine.

The PARK position automatically engages the parking brake.

NOTE: The Travel Direction Control Lever must be in PARK to start the engine.

Two-Speed Control Press the button (Item 4) [Figure 17] at the end of lever to engage high range. (High Speed icon, Item 36, [Figure 8], will be ON.) Press again to disengage.

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5600 Operation & Maintenance Manual

STOPPING THE UTILITY WORK MACHINE

WHEEL ALIGNMENT

Procedure

Procedure

Figure 18

Figure 19

4 3

3

1 2

2

1

P-73933A P-73844

Put the Steering Mode switch in All-Wheel-Steer (Item 1) [Figure 19].

Gradually release pressure on the Drive Pedal (Item 1) [Figure 18] until the machine comes to a complete stop.

Turn the steering wheel until the rear wheels are straight as indicated by the wheel alignment indicator (Item 2) [Figure 19].

Move Engine Speed Control (Item 2) [Figure 18] backward to decrease engine rpm.

Put the Steering Mode switch in Front Wheel Steer (Item 3) [Figure 19].

Move the Travel Direction Control Lever (Item 3) [Figure 18] to the PARK position.

Turn the steering wheel until the front wheels are straight as indicated by the wheel alignment indicator (Item 4) [Figure 19].

Lower the lift arm and put the attachment flat on the ground. Put all controls in neutral.

Turn the key OFF and remove the key to prevent use by unauthorized personnel. (Keyless Start: Press the STOP button.)

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5600 Operation & Maintenance Manual

Figure 21

LIFT ARM BYPASS Operation The lift arm bypass is used to lower the lift arm if the lift arm cannot be lowered during normal operation.

DANGER

1

P-64847

Move the joystick (Item 1) [Figure 21] forward until the lift arm slowly lowers.

P-90775

•

•

AVOID DEATH Never reach under or stand under raised lift arm unless supported by an approved lift arm support.

Moving a lift arm control or failure of a part can cause lift arm to drop.

D-1010-0709

Sit in the operator’s seat. Fasten the seat belt and lower the operator arm rest.

Turn the ignition to the ON position (Key Switch) or press the ENTER CODE button (Keyless).

Figure 20

1

P-67762

Press and hold the Lift and Tilt Transport Lock button (Item 1) [Figure 20].

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5600 Operation & Maintenance Manual

HYDRAULIC CONTROLS

Lift Arm Operation

Description

Pull the joystick backward to raise the lift arm (Item 1) [Figure 22].

Figure 22

Push the joystick forward to lower the lift arm (Item 2) [Figure 22].

1 3

IMPORTANT

2

2 Never drive forward when the hydraulic control for the lift arm is in float position.

B-19670 B-19669

I-2218-1102

1

Lift Arm Float Position P-73840

Push the joystick all the way forward (Item 3) [Figure 22] until it locks into the detent position.

Figure 23

Use the float position of the lift arm to level loose material ONLY while driving backward.

4

Pull the joystick backward to raise the lift arm (Item 1) [Figure 22] and release from float position.

5 5

Tilt Operation

4 Move the joystick to the right to tilt the bucket forward (Item 4) [Figure 23].

B-19668 B-19667

Move the joystick left to tilt the bucket backward (Item 5) [Figure 23].

P-73840

Movement of the joystick [Figure 22] and [Figure 23] controls the hydraulic cylinders for the lift and tilt functions.

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5600 Operation & Maintenance Manual

The thumb switch on the joystick now controls the front auxiliary hydraulic functions.

HYDRAULIC CONTROLS (CONT’D) Front Auxiliary Hydraulics Operation

Move the thumb switch to the left or to the right to control the front auxiliary hydraulics to operate an attachment.

(EXAMPLE: To open or close grapple teeth.) [Figure 26].

Figure 24

Move the thumb switch in the opposite direction to reverse the action of the attachment.

Front Auxiliary Hydraulics Operation (CONTINUOUS FLOW) Move and hold the thumb switch for the desired hydraulic movement then press the trigger switch on the joystick (Item 1) [Figure 26] for a constant flow of hydraulic fluid under pressure to the front auxiliary hydraulics.

(EXAMPLE: Sweeper operation)

P-66038

Press the trigger switch a second time to disengage continuous flow.

Front auxiliary hydraulics [Figure 24] are standard.

Figure 25

Quick Couplers To Connect: Remove dirt or debris from the surface of both the male and female couplers, and from the outside diameter of the male coupler. Visually check the couplers for corroding, cracking, damage or excessive wear. If any of these conditions exist, the coupler(s) must be replaced.

1

AUX HYD

To Disconnect: Hold the male coupler. Retract the sleeve of the female coupler until the couplers disconnect.

P-73842

WARNING

Press the auxiliary hydraulics button (Item 1) [Figure 25] to activate the front auxiliary hydraulics.

AVOID BURNS Hydraulic fluid, tubes, fittings and quick couplers can get hot when running machine and attachments.

Be careful when connecting and disconnecting quick couplers.

The switch on the joystick controls the auxiliary hydraulic functions.

Figure 26

W-2220-0396

B-18094D

1

B-18094C

P-73840

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5600 Operation & Maintenance Manual

HYDRAULIC CONTROLS (CONT’D)

High-Flow Hydraulics Operation (If Equipped)

Relieve Hydraulic Pressure (Utility Work Machine And Attachment)

Figure 28

1

WARNING

AUX HYD

AVOID BURNS Hydraulic fluid, tubes, fittings and quick couplers can get hot when running machine and attachments.

Be careful when connecting and disconnecting quick couplers.

W-2220-0396 P-73842

Front Auxiliary Quick Couplers Figure 29 Figure 27

1

2 When Connecting: Push the quick couplers tightly together and hold for five seconds; the pressure is automatically released as the couplers are connected.

P-73933A

After auxiliary hydraulics is activated (Item 1) [Figure 28], press the high-flow switch (Item 1) [Figure 29] on the center console. (The High-Flow icon on the switch will be ON.)

When Disconnecting: Push the quick couplers tightly together and hold for five seconds; then retract the sleeve until the couplers disconnect.

Press high-flow switch again to deselect high flow.

NOTE: Early model machines may have the high-flow switch in switch position (Item 2) [Figure 29].

IMPORTANT If the High Flow is engaged, High Horsepower Hydraulics will flow through the auxiliary hydraulic quick couplers. Damage to unapproved attachments can result. See your Bobcat dealer for approved high flow attachments.

I-2227-0204

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5600 Operation & Maintenance Manual

REMOTE HYDRAULICS (OPTION)

Quick Couplers And Hoses

Description

Figure 31

The remote hydraulic system uses the cargo box hydraulic circuit to supply hydraulic oil through a selector valve to two poppet style quick couplers.

The remote hydraulics can be used for rear attachments that require hydraulic function such as extending and retracting a hydraulic cylinder.

1

Figure 30 2 1

P-74651

Remove the plugs from the quick couplers. Clean both the implement male couplers and the utility vehicle female couplers (Item 1) [Figure 31] before connecting.

Figure 32

P-74670

The quick couplers (Item 1) and the selector valve (Item 2) are mounted under the right side of the cargo box at the rear of the machine [Figure 30].

1

P-74697

To Connect: Pull back on the collar of the female couplers (Item 1) [Figure 32]. Push couplers together, release the collar when the couplers are fully engaged and locked.

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5600 Operation & Maintenance Manual

REMOTE HYDRAULICS (OPTION) (CONT’D)

Figure 34

Quick Couplers And Hoses (Cont’d) Figure 33

1

P74697

To Disconnect: Pull back on the collar (Item 1) [Figure 34] and pull the male coupler out to disconnect.

MS2039

Secure the hoses to prevent damage [Figure 33]. (The hose bracket shown is an example only, contact you implement dealer for a hose bracket for your implement.)

WARNING AVOID BURNS Hydraulic fluid, tubes, fittings and quick couplers can get hot when running machine and attachments.

Be careful when connecting and disconnecting quick couplers.

IMPORTANT

W-2220-0396

To prevent hose damage caused by dragging on the ground, rubbing, pinching, etc.: • Support attachment and implement hydraulic hoses using available hose guides or supports.

• Contact your implement or attachment dealer for available hose guides or supports.

NOTE: Always clean the couplers and install the rubber plugs when the remote hydraulics are not used to prevent dirt from getting into the quick couplers.

I-2260-0707

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5600 Operation & Maintenance Manual

REMOTE HYDRAULICS (OPTION) (CONT’D)

WARNING

Operating The Remote Hydraulics Figure 35

A

ACCIDENTAL MACHINE MOVEMENT CAN CAUSE INJURY OR DEATH • Check the Control Selector Lever position and quick couplers located under cargo box on the passenger side of the machine before operating the cargo box/remote hydraulics switch.

• Keep bystanders away.

B

W-2619-1104

Function Chart [Figure 35] and [Figure 36] DIVERTER SWITCH LEVER POSITION POSITION

P-74668

A A B B

Move the selector valve lever to position “A” [Figure 35] for remote hydraulic operation.

Enter the machine, fasten the seat belt and lower the arm rest.

Up Down Up Down

CARGO BOX

REMOTE HYDRAULICS

----Up Down

1 (Black) 2 (Red) -----

Start the engine.

Figure 36

1

2 P-74669A

The cargo box lever on the center console [Figure 36] controls the remote hydraulics when the selector valve is in the “A” position.

Move the lever (Item 1) [Figure 36] up to pressurize the top quick coupler (1).

Move the lever (Item 2) [Figure 36] down to pressurize the bottom quick coupler (2).

NOTE: Return the selector valve lever to position “B” [Figure 35] to operate the cargo box.

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5600 Operation & Maintenance Manual

ATTACHMENT CONTROL DEVICE (ACD) (IF EQUIPPED) Description Figure 37

1

P-66038

Connect the attachment electrical harness to the attachment control device (Item 1) [Figure 37].

Figure 38

2 1

3

P-73837B

Auxiliary hydraulic function switches (Items 1, 2, and 3) [Figure 38] are used to control some attachment functions through the attachment control device.

See the appropriate attachment maintenance manual for control details.

operation

&

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5600 Operation & Maintenance Manual

DAILY INSPECTION Figure 39

7134482ENUS-V

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5600 Operation & Maintenance Manual

DAILY INSPECTION (CONT’D) Daily Inspection And Maintenance

IMPORTANT

Maintenance work must be done at regular intervals to be sure that the machine is in good operating condition.

Failure to do so will result in excessive wear and early failures. The Service Checklist And Schedule [Figure 39] is a guide for correct maintenance of the machine. It is located on the rear of the operator cab and (See Service Schedule (7134482) on Page 129.)

•

Check seat belts and replace if damaged.

•

Check Operator’s Cab (ROPS and FOPS).

•

Check Toolcat Interlock Control System (TICS) function.

•

Repair broken or loose parts.

•

Clean engine of flammable material. (Cargo Box Support Device must be installed.)

•

Clean pedal area and windows.

•

Check engine oil level.

•

Check the hydraulic fluid level. (Cargo Box Support Device must be installed.)

•

Check the tire condition and tire pressure.

•

Monitor the control panel for fuel level, coolant temperature and other engine and hydraulic functions.

•

Machine Signs (Decals), replace if damaged or missing.

•

•

PRESSURE WASHING DECALS Never direct the stream at a low angle toward the decal that could damage the decal causing it to peel from the surface.

Direct the stream at a 90 degree angle and at least 300 mm (12 in) from the decal. Wash from the center of the decal toward the edges.

I-2226-0910

WARNING AVOID INJURY OR DEATH 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.

W-2003-0807

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5600 Operation & Maintenance Manual

PRE-STARTING PROCEDURE

Seat And Steering Wheel Adjustment

Entering The Utility Work Machine

Figure 41

Figure 40 1

1 P-73850

Release the lever (Item 1) [Figure 41] to adjust the seat distance from the steering wheel.

2 Figure 42

1 P-73954

Enter the cab using the grab bar (Item 1) [Figure 40].

Read the Operation & Maintenance Manual and the Operator’s Handbook (Item 2) [Figure 40] before operating the machine.

P-73849

Release the steering column lock (Item 1) [Figure 42] and move steering wheel up or down for comfortable operation. Push lock up to secure.

WARNING Operator must have instructions before operating the machine. Untrained operators can cause injury or death.

W-2001-0502

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5600 Operation & Maintenance Manual

PRE-STARTING PROCEDURE (CONT’D)

STARTING THE ENGINE All controls must be in NEUTRAL POSITION before starting the engine.

Keep feet and arms inside the cab.

Seat Belt Adjustment And Arm Rest Figure 43

WARNING AVOID INJURY OR DEATH When operating the machine: • Keep the seat belts fastened snugly.

• The arm rest must be lowered.

• Keep your feet and arms inside the cab.

W-2454-1102

Key Switch Figure 44 P-39399

Fasten the seat belt snugly and lower the operator arm rest [Figure 43]. Adjust the belt so that it fits snug around the lower part of your hips. Passenger must also fasten seat belt.

OFF

B-19665

1 ON

START

IMPORTANT Check the seat belt and shoulder belt retractors for correct operation.

P-73847

Turn the key to the ON position [Figure 44].

If the glow plug icon (Item 1) [Figure 44] is ON, wait for it to go OFF. Turn the key to START position and release it when the engine starts.The key will return to the ON position [Figure 44].

(See Cold Temperature Starting on Page 47.)

STOP THE ENGINE IF ANY WARNING LIGHTS DO NOT GO OFF.

Keep retractors clean and replace as necessary.

I-2199-0200

WARNING AVOID INJURY OR DEATH When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible gases which can kill without warning.

W-2050-0807

Pull the engine speed control fully backward and turn the key switch OFF [Figure 44] to stop the engine.

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5600 Operation & Maintenance Manual

STARTING THE ENGINE (CONT’D)

Pull the engine speed control fully backward and press the STOP button (Item 5) [Figure 45] to stop the engine.

Keyless Password Lockout Feature - (See Password Lockout Feature on Page 126.)

Figure 45

Cold Temperature Starting 1

3

If the temperature is below 0°C (32°F), use the following procedure to make starting the engine easier:

2

•

Replace the engine oil with the correct type and viscosity for the anticipated starting temperature.

(See Checking And Adding Engine Oil on Page 86.)

•

Make sure the battery is fully charged.

•

Install an engine heater.

5

4

6 P-48314D

Press the START button (Item 4) [Figure 45] (or turn the key to START position) [Figure 44] and release when the engine starts.

Press the ENTER CODE button (Item 1). The display screen (Item 2) will illuminate and there will be two short beeps. [CodE] will appear on the display screen (Item 2) [Figure 45].

WARNING

Use the keypad (Item 3) [Figure 45] to enter the password. For each digit that you enter, a dash will appear on the display screen. (You will have 40 seconds to enter the password or the process will abort and you will need to start over.) There will be one long beep when the password is entered correctly.

• •

NOTE: If the password was incorrect there will be three short beeps and [Error] will appear on the display screen (Item 2). Press the ENTER CODE button (Item 1) [Figure 45] again and start over. After three failed attempts, you must wait three minutes to try again.

AVOID INJURY OR DEATH Engines can have hot parts and hot exhaust gas.

Keep flammable material away.

Do not use machines in atmosphere containing explosive gas.

W-2051-1086

Warming The Hydraulic / Hydrostatic System Let the engine run for a minimum of 5 minutes to warm the engine and the hydrostatic transmission fluid before operating.

If the glow plug icon (Item 6) [Figure 45] is ON, wait for it to go OFF.

If the warning light comes ON when operating (cold), more warm up time is needed.

Press the START button (Item 4) [Figure 45] and release it when the engine starts.

IMPORTANT Do not engage the starter for longer than 15 seconds at a time. Longer use can damage the starter by overheating. Allow starter to cool for one minute before using starter again.

I-2034-0700

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5600 Operation & Maintenance Manual

MONITORING THE CONTROL PANEL Key Switch And Keyless Figure 46

1 P-73842

After the engine is running, frequently monitor the control panel [Figure 46] for error conditions.

Several of the function icons (Item 1) [Figure 46] are associated with error conditions and will come on when an error condition occurs. (See Indicator Icons on Page 27.)

Warning And Shutdown When a WARNING condition exists, the associated icon light will come ON and there will be 3 beeps from the alarm. Be aware that, if this condition is allowed to continue, there may be damage to the engine or machine hydraulic systems.

When a SHUTDOWN condition exists, the associated icon light will come ON and there will be a continuous beep from the alarm and the monitoring system will automatically stop the engine in 10 seconds. The engine can be restarted to move or relocate the machine.

The SHUTDOWN feature is associated with the following icons: General Warning Engine Oil Pressure Engine Coolant Temperature Hydraulic Oil Temperature Hydrostatic Charge Pressure

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5600 Operation & Maintenance Manual

STOPPING THE ENGINE AND LEAVING THE UTILITY WORK MACHINE

Emergency Exit (When Equipped With Cab) Figure 49

Procedure Figure 47

1

P-48299 P-66047

The cab door on the opposite side of the machine is used as an emergency exit [Figure 49].

Put the Travel Direction Control Lever (Item 1) [Figure 47] in PARK.

Alternate Emergency Exit: Lower the lift arm, put the attachment flat on the ground [Figure 47] and stop the engine.

The rear window in each door can be used as an alternate emergency exit. Release the latch and open the rear window.

Figure 48 1

P-39399

Press the red release button (Item 1) [Figure 48] to disconnect the seat belt.

Raise the arm rest [Figure 48] to deactivate lift, tilt, auxiliary and traction drive functions.

Remove the key and exit the cab.

WARNING Always park machine on flat, level ground.

W-2441-1102

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5600 Operation & Maintenance Manual

MACHINE LOAD CAPACITIES

Machine Rated Capacity

Loader Rated Operating Capacity (ROC)

The total capacity that the machine can handle when the lift arm and cargo box are used together is up to 997 kg (2200 lb). This includes the combined weight of load on lift arm, cargo box load, operator and passenger.

The operating load on the lift arms with a standard dirt bucket is 680 kg (1500 lb). If longer buckets or other attachments such as a Pallet Fork is used, the load center is moved forward and lift arm capacity is reduced.

Maximum Trailer Hitch Tongue Weight

Maximum Cargo Box Load

The maximum vertical load that can be applied to the receiver hitch (if equipped) is 227 kg (500 lb).

The maximum load that can be carried in the Cargo Box of the machine is 907 kg (2000 lb).

Total Rated Capacity The maximum load that can be applied to the machine while towing is 1905 kg (4200 lb). This includes the combined weight of the load on the lift arm, cargo box load, operator, passenger and tow weight (if equipped with receiver hitch).

Figure 50

C E D B A

Decal Inside Cab

B-22493

Refer to [Figure 50] for references below.

A - Loader Rated Operating Capacity (ROC)* = 680 kg (1500 lb) Maximum B - Operator and Passenger Weight C - Maximum Cargo Box Load = 907 kg (2000 lb) D - Maximum Trailer Hitch Tongue Weight = 227 kg (500 lb) E - Tow Weight = 1814 kg (4000 lb) (Including weight of trailer) (If A plus C = 0 lb.)

Machine Rated Capacity = A plus B plus C = 997 kg (2200 lb) (A) must not exceed 680 kg (1500 lb) Total Rated Capacity (when towing) = A plus B plus C plus E = 1905 kg (4200 lb) Maximum (A) must not exceed 680 kg (1500 lb) (C) must not exceed 907 kg (2000 lb) A + B + C must not exceed 997 kg (2200 lb) * Loader ROC is determined by using a standard dirt bucket and material of normal density, such as dirt or dry gravel. If longer buckets or other attachments such as Pallet forks are used, the load center is moved forward and the lift arm capacity is reduced. If very dense material is loaded, the volume must be reduced.

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5600 Operation & Maintenance Manual

ATTACHMENTS

Pallet Fork

Choosing The Correct Bucket

Figure 52

1

WARNING

Load varies with model of pallet fork being used.

AVOID INJURY OR DEATH Never use attachments or buckets which are not approved by Bobcat Company. Buckets and attachments for safe loads of specified densities are approved for each model. Unapproved attachments can cause injury or death.

W-2052-0907

B-17255

NOTE: Warranty is void if non-approved attachments are used.

If a pallet fork attachment is used, the load center moves forward and reduces the load capacity.

The dealer can identify, for each model, the attachments and buckets approved by Bobcat. The buckets and attachments are approved for load capacity and for secure fastening to the Bob-Tach.

The maximum load to be carried when using a pallet fork is shown on a decal located on the pallet fork frame (Item 1) [Figure 52].

The load capacity is shown on a label in the operator cab.

(See Performance on Page 145.)

WARNING

Load capacity is determined by using a standard dirt bucket, and material of normal density, such as dirt or dry gravel. If longer buckets are used, the load center is moved forward and reduces the load capacity. If very dense material is loaded, the volume must be reduced.

AVOID INJURY OR DEATH Do not exceed load capacity. Excessive load can cause tipping or loss of control.

Figure 51

W-2442-1102

WRONG See your Bobcat dealer for more information about pallet fork inspection, maintenance and replacement. See your Bobcat dealer for load capacity when using a pallet fork and for other available attachments.

B-21476

Exceeding the load capacity [Figure 51] can cause the following problems: 1.

2.

3.

4.

Steering may be difficult.

Tires may wear faster.

There will be a loss of stability.

The life of the machine will be reduced.

Use the correct size bucket for the type and density of material being handled. For safe handling of materials and avoiding machine damage, the attachment (or bucket) should handle a full load without going over the load capacity for the loader.

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5600 Operation & Maintenance Manual

Figure 54

ATTACHMENTS (CONT’D) Installing And Removing The Attachment (Hand Lever Bob-Tach) The Bob-Tach is used for fast changing of buckets and attachments. See the attachment Operation & Maintenance Manual to install other attachments.

WARNING Bob-Tach levers have spring tension. Hold lever tightly and release slowly. Failure to obey warning can cause injury.

P-66045A

Be sure the Bob-Tach levers do not hit the bucket or attachment.

W-2054-1285

Installing

Tilt the Bob-Tach backward until the cutting edge of the bucket is slightly off the ground [Figure 54].

Figure 53

Figure 55 1

P-66044A P-66046

Pull the Bob-Tach levers all the way up (Item 1) [Figure 53].

Stop the engine and exit the cab.

Enter the cab and fasten the seat belt. Lower the operator arm rest, start the engine and disengage the parking brake.

WARNING

Lower the lift arm and tilt the Bob-Tach forward.

AVOID INJURY OR DEATH Before you leave the operator’s seat: • Lower the lift arm, put the attachment flat on the ground.

• Put Travel Direction Control Lever in PARK. • Stop the engine.

• Raise operator arm rest.

Drive forward until the top edge of the Bob-Tach is completely under the top flange of the bucket [Figure 53] (or other attachment).

W-2443-1102

Push down on the Bob-Tach levers [Figure 55] until they are fully engaged in the locked position.

If the lever does not engage in the locked position, see your Bobcat dealer for maintenance.

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5600 Operation & Maintenance Manual

Figure 57

ATTACHMENTS (CONT’D) Installing And Removing The Attachment (Hand Lever Bob-Tach) (Cont’d) Figure 56

P-66045A

1

B-15177

Pull the Bob-Tach levers all the way up [Figure 57].

The wedges (Item 1) [Figure 56] must extend through the holes in the mounting frame of the bucket (or attachment), securely fastening the bucket or attachment to the Bob-Tach.

Disconnect the hydraulic hoses, if necessary.

Enter the cab and fasten the seat belt. Lower the arm rest and start the engine.

Figure 58

WARNING Bob-Tach wedges must extend through the holes in attachment. Lever(s) must be fully down and locked.

Failure to secure wedges can allow attachment to come off and cause injury or death.

W-2102-0497

Removing Put the attachment flat on the ground and lower or close the hydraulic equipment.

Put the attachment flat on the ground and lower or close the hydraulic equipment.

P-66044A

If the attachment is hydraulically and / or attachment electrical harness controlled (i.e.: sweeper, auger, etc.):

Tilt the Bob-Tach forward.

Stop the engine and relieve hydraulic pressure in the auxiliary circuit. (See Relieve Hydraulic Pressure (Utility Work Machine And Attachment) on Page 38.)

Move backward, away from the bucket or attachment [Figure 58].

Put the Travel Direction Control Lever in PARK, unfasten the seat belt, raise the arm rest, and exit the cab.

Disconnect the hydraulic hoses and / or the attachment electrical harness connection (if equipped).

Enter the utility work machine and perform the prestart procedure.

(See PRE-STARTING PROCEDURE on Page 45.)

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5600 Operation & Maintenance Manual

Figure 61

ATTACHMENTS (CONT’D) Installing And Removing The Attachment (Power Bob-Tach) Installing The Bob-Tach is used for fast changing of buckets and attachments. See the attachment Operation & Maintenance Manual to install other attachments.

Perform the PRE-STARTING PROCEDURE. (See PRESTARTING PROCEDURE on Page 45.)

Lower the lift arm and tilt the Bob-Tach forward.

Figure 59

P76586

1

Be sure the Bob-Tach levers do not hit the bucket or attachment.

2 Tilt the Bob-Tach backward until the cutting edge of the bucket is slightly off the ground [Figure 61].

2

P76585

Press and hold the Bob-Tach “WEDGES UP” switch (Item 1) until the levers are in the unlocked position (Item 2) [Figure 59] (wedges fully raised).

Figure 60

P76588

Drive forward until the top edge of the Bob-Tach is completely under the top flange of the bucket [Figure 60] (or other attachment).

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Figure 63

ATTACHMENTS (CONT’D) Installing And Removing The Attachment (Power Bob-Tach) (Cont’d) Figure 62

1

1 B-15177

The wedges (Item 1) [Figure 63] must extend through the holes in the mounting frame of the bucket (or attachment), securely fastening the bucket or attachment to the Bob-Tach.

WARNING Bob-Tach wedges must extend through the holes in attachment. Lever(s) must be fully down and locked.

Failure to secure wedges can allow attachment to come off and cause injury or death.

W-2102-0497 P-76587A

NOTE: The Power Bob-Tach system has continuous pressurized hydraulic oil to keep the wedges in the engaged position and prevent attachment disengagement. Because the wedges can slowly lower, the operator may need to reactivate the switch (WEDGES UP) before installing an attachment to be sure both wedges are fully raised before installing the attachment.

Press and hold the Bob-Tach “WEDGES DOWN” switch (Item 1) until the levers are fully engaged in the locked position (Item 2) [Figure 62] (wedges fully extended).

If the lever does not engage in the locked position, see your Bobcat dealer for maintenance.

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Figure 65

ATTACHMENTS (CONT’D) Installing And Removing The Attachment (Power Bob-Tach) (Cont’d) Removing Lower the lift arm and put the attachment flat on the ground.

If the attachment is hydraulically and / or attachment electrical harness controlled (i.e.: sweeper, auger, etc.): Stop the engine and relieve hydraulic pressure in the auxiliary circuit. (See Relieve Hydraulic Pressure (Utility Work Machine And Attachment) on Page 38.)

Put the Travel Direction Control Lever in PARK, unfasten the seat belt, raise the arm rest, and exit the cab.

P76588

Disconnect the hydraulic hoses and / or the attachment electrical harness connection (if equipped).

Tilt the Bob-Tach forward and move the utility work machine backward, away from the bucket or attachment [Figure 65].

Enter the utility work machine and perform the prestart procedure.

(See PRE-STARTING PROCEDURE on Page 45.)

NOTE: The Power Bob-Tach system has continuous pressurized hydraulic oil to keep the wedges in the engaged position and prevent attachment disengagement. Because the wedges can slowly lower, the operator may need to reactivate the switch (WEDGES UP) before removing an attachment to be sure both wedges are fully raised before removing the attachment.

Figure 64

1

2

2

P-76587A

Press and hold the Bob-Tach “WEDGES UP” switch (Item 1) until the levers are in the unlocked position (Item 2) [Figure 64] (wedges fully raised).

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5600 Operation & Maintenance Manual

OPERATING PROCEDURE

Operating With A Full Bucket And Empty Cargo Box

Inspect The Work Area

Figure 66

Before beginning operation, inspect the work area for unsafe conditions.

LOADED BUCKET & EMPTY CARGO BOX

Look for sharp drop-offs or rough terrain. Have underground utility lines (gas, water, sewer, irrigation, etc.) located and marked. Work slowly in areas of underground utilities.

Remove objects or other construction material that could damage the machine or cause personal injury.

GOING UP SLOPE

GOING DOWN SLOPE

B-19663

B-19661

Always check ground conditions before starting your work: •

Look for signs of instability such as cracks or settlement.

•

Be aware of weather conditions that can affect ground stability.

•

With a loaded bucket and empty cargo box, go up or down the slope with the heavy end toward the top of the slope [Figure 66].

Operating With An Empty Bucket And Loaded Cargo Box

Check for adequate traction if working on a slope.

Figure 67

Basic Operating Instructions

LOADED CARGO BOX & EMPTY BUCKET When operating on a public road or highway, always follow local regulation. For example: Slow Moving Vehicle (SMV) Sign or directional signals may be required.

Always warm up the engine and hydrostatic system before operating the loader.

IMPORTANT Machines warmed up with moderate engine speed and light load have longer life.

GOING UP SLOPE

GOING DOWN SLOPE

B-19659

B-19660

With empty bucket and a loaded cargo box, go down or up the slope with the heavy end toward the top of the slope [Figure 67].

I-2015-0284

Operate with the engine at full speed for maximum horsepower. Push the Drive Pedal only a small amount to operate the machine.

WARNING

New operators must operate the machine in an open area without bystanders. Operate the controls until the machine can be handled at a efficient and safe rate for all conditions of the work area.

• • • • • • •

Operating Near An Edge Or Water Keep the utility work machine as far back from the edge as possible and the machine wheels perpendicular to the edge so that if part of the edge collapses, the machine can be moved back.

MACHINE TIPPING OR ROLL OVER CAN CAUSE SERIOUS INJURY OR DEATH Keep the lift arm as low as possible.

Do not travel or turn with the lift arm up.

Turn on level ground. Slow down when turning.

Go up and down slopes, not across them.

Keep the heavy end of the machine uphill.

Do not overload the machine.

Check for adequate traction.

W-2444-1109

Always move the utility work machine back at any indication the edge may be unstable.

Raise the bucket only high enough to avoid obstructions on rough ground.

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OPERATING PROCEDURE (CONT’D)

Emptying

Filling And Emptying The Bucket

Keep the bucket low when moving to the area where you want to dump the material.

Filling Move the machine slowly to the dump area.

Figure 68 Figure 70 A A C

D C

D

B

B-19672

B-19688

Lower the lift arm all the way (Item A) and tilt the bucket forward (Item D) [Figure 68] until the cutting edge is on the ground. Drive slowly forward to push the bucket slightly into the material.

B

While raising the lift arm (Item B), tilt the bucket forward (Item D) [Figure 70] to keep it level and help prevent material from falling off the back of the bucket.

Figure 69

Tilt the bucket all the way forward (Item D) [Figure 70] to empty the bucket.

A

C

B-19675

D B

Raise the lift arm (Item B) and tilt the bucket backward (Item C) [Figure 69].

WARNING Load, unload and turn on flat level ground. Do not exceed operating capacity shown on sign (decal) in cab. Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

W-2445-1102

Drive backward away from the material.

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OPERATING PROCEDURE (CONT’D)

Work Mode Operation

Leveling The Ground Using Float

The Work Mode feature changes the drive system to a more aggressive response when operating in low range while maintaining hydraulic and traction power.

Figure 71 A C

You can use the Work Mode while digging or loading material, when maneuvering the machine to install an attachment or when using a tiller or trencher.

D

Figure 73 B

B-19674

1 Raise the lift arm (Item B) and tilt the bucket forward (Item D) [Figure 71].

Push the joystick all the way forward (Item A) [Figure 71] until it locks into detent position to engage the float. The lift arm will slowly lower.

2

IMPORTANT

P-73843

Never drive forward when the hydraulic control for the lift arm is in float position.

Press the Work Mode button (Item 1) [Figure 73].

I-2218-1102

Select forward or reverse travel direction.

Drive backward to level loose material.

Press the Drive Control Pedal (Item 2) [Figure 73].

Pull the joystick backward (Item B) [Figure 71] to unlock the lift arm from the float position.

WARNING

Backfilling Figure 72

AVOID INJURY OR DEATH Before you leave the operator’s seat: • Lower the lift arm, put the attachment flat on the ground.

• Put Travel Direction Control Lever in PARK. • Stop the engine.

• Raise operator arm rest.

A C

B-19673

D

W-2443-1102

B

Lower the lift arm (Item A) and put the cutting edge of the bucket on the ground (Item D) [Figure 72]. Drive forward to the edge of the hole to push the material into the hole.

Tilt the bucket forward (Item D) [Figure 72] as soon as it is past the edge of the hole.

If necessary, raise the lift arms to empty the bucket.

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OPERATING PROCEDURE (CONT’D)

Hauling Loads In The Cargo Box

Opening And Closing The Tailgate

Put the Travel Direction Control Lever in PARK, stop the engine and raise the operator’s arm rest before loading Cargo Box.

Figure 74

Never allow riders in the Cargo Box and do not exceed the Cargo Box load capacity. (See Decal inside cab) or (See Capacities on Page 147.)

1

Be sure to secure the load to the Cargo Box so that it does not shift when the machine is moving.

Keep the load within the sides and ends of the Cargo Box and keep the load evenly distributed.

P-73853

Avoid top-heavy loads. The load’s center of gravity may affect the handling, steering, and braking of the Work Machine.

2

Towing Equipment With The Utility Work Machine

P-73846

Do not exceed the towing capacity or the trailer hitch tongue weight capacity of the Utility Work Machine. (See Decal inside cab) or (See Capacities on Page 147.)

Release latch (Item 1) on both sides and open the tailgate (Item 2) [Figure 74].

Do not put heavy loads on the tailgate.

Close the tailgate. The tailgate will latch as it closes.

Do not tow a vehicle or trailer on public streets or highways.

Raising And Lowering The Cargo Box

Do not allow riders in a vehicle being towed.

Figure 75

Avoid sudden starts, sudden stops, and tight turns when towing. Slow down when driving on wet, slippery or rough terrains. Allow for additional stopping distance when towing loads.

Avoid stopping on a slope when towing. If you must stop on a slope, avoid sudden starts or rolling backward and stopping suddenly.

1

Slow down when towing equipment downhill by letting up on the drive pedal or pressing the brake pedal as necessary.

Always park towed equipment on level ground.

2

Make sure the coupler is of adequate capacity for the load being towed.

P-73852

Move the cargo box dump lever up (Item 1) to raise the cargo box. Move the cargo box dump lever down (Item 2) [Figure 75] to lower.

NOTE: Attempting to lower the cargo box with the cargo box support device engaged WILL damage the machine.

TOWING THE UTILITY WORK MACHINE Procedure Because of the design of the utility work machine, there is not a recommended towing procedure.

WARNING • • • • •

AVOID INJURY OR DEATH DO NOT exceed maximum Cargo Box Load Capacity.

DO NOT drive machine with Cargo Box raised.

Load, unload and turn on flat level ground.

Make sure loads in Cargo Box are secured.

Slow down when turning.

•

The utility work machine can be lifted onto a transport vehicle.

•

The utility work machine can be skidded a short distance to move for service (EXAMPLE: Move onto a transport vehicle.) without damage to the hydrostatic system. (The tires/tracks will not turn.)

There might be slight wear to the tires/tracks when the utility work machine is skidded.

The towing chain (or cable) must be rated at one and one-half times the weight of the utility work machine.

(See Performance on Page 145.)

W-2455-1102

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It may be necessary to remove items installed in the receiver hitch (Item 1) [Figure 77] before loading or unloading to prevent them from hitting the ground.

TRANSPORTING THE UTILITY WORK MACHINE ON A TRAILER Loading And Unloading

Fastening

WARNING

Use the following procedure to fasten the machine to the transport vehicle to prevent it from moving during turns, sudden stops or when going up and down slopes.

AVOID SERIOUS INJURY OR DEATH Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.

Fully lower any bucket or attachment. Put the Travel Direction Control Lever in the PARK position. Stop the engine. Move the controls to neutral and raise the arm rest.

W-2058-0807

Figure 78 Be sure the transport and towing vehicles are of adequate size and capacity for the weight of machine.

(See Performance on Page 145.)

Figure 76

1

P-76026

Support

P-64703

Fasten the front of machine using the front tie down point (Item 1) [Figure 78].

A machine with an attachment must be loaded or unloaded forward. A machine without an attachment can be loaded or unloaded either forward or backward [Figure 76].

Figure 79

The rear of the trailer must be blocked or supported [Figure 76] when loading or unloading to prevent the front end of the trailer from raising up.

Figure 77 1

P-73851

1

Fasten the rear of machine using the rear tie down point (Item 1) [Figure 79].

P-73848A

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PREVENTIVE MAINTENANCE MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 TOOLCAT INTERLOCK CONTROL SYSTEM (TICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Inspecting The TICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Maintaining The TICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 LIFT ARM BYPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 BACK-UP ALARM SYSTEM (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 NEUTRAL START SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 CARGO BOX SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Raising The Cargo Box When Engine Is Not Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 PARKING BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 CAB FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Cleaning And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Fresh Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Recirculating Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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HEATING AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Cleaning And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Air Conditioning Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 PASSENGER SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83 Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83 Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 Filling A Portable Fuel Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 Checking And Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 Engine Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 Removing And Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89 Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Fuse And Relay Location - Cab Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Fuse And Relay Location - Frame Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Removing And Installing Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 Checking Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 Alternate Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters . . . . . . . . . . . . .97 Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 64

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SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 SUPPORTING THE MACHINE ON JACKSTANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 TRANS AXLE (FRONT AND REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Checking And Adding Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Removing And Replacing Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 AIR CONDITIONING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 LUBRICATING THE UTILITY WORK MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 BOB-TACH (POWER OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 UTILITY WORK MACHINE STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . 117 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

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MAINTENANCE SAFETY WARNING

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.

W-2003-0807

CORRECT

CORRECT

P-90216

B-21495

machine

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B-21498

B-21499

Have good ventilation when welding or grinding painted parts.

Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.

Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.

Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arm or cargo box to drop. Do not go under lift arm or cargo box when raised unless supported by an approved lift arm or cargo box support device.

Replace it if damaged.

Never work on the machine with lift arm or cargo box up unless supported by an approved support device. Replace if damaged.

Never modify equipment or add attachments not approved by Bobcat Company.

WRONG

WRONG

WRONG

B-21497

B-21496

B-6589

Stop, cool and clean engine of flammable materials before checking fluids.

Never service or adjust machine with the engine running unless instructed to do so in the manual.

Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes.

Never fill fuel tank with engine running, while smoking or when near open flame.

Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust.

Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used.

Use eye protection approved for type of welding.

Keep side access doors closed except for service.

Lead-acid batteries produce flammable and explosive gases.

Keep arcs, sparks, flames and lighted tobacco away from batteries.

Batteries contain acid which burns eyes or skin on contact.

Wear protective clothing. If acid contacts body, flush well with water. For eye contact, flush well and get immediate medical attention.

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!”

Carefully read the message that follows.

Never service the without instructions.

B-21500

B-21509

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts.

MSW25-0409

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SERVICE SCHEDULE Chart Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat product.

WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, 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.

W-2003-0199

SERVICE SCHEDULE ITEM Engine Oil Hydraulic Fluid Engine Air Filter and Air System Engine Cooling System

HOURS

SERVICE REQUIRED

8-10

[4] [5] [6] [7]

[7] [7]

[7]

100 250 500 1000

Check the oil level and add as needed. Do not overfill.

Check level and add as needed.

Check condition indicator or display. Service only when required. Check for leaks and damaged components. Do not use compressed air to clean elements.

Clean debris from oil cooler and radiator. Check coolant level cold, add premixed coolant as needed.

Check the condition of seat belts. Check for correct operation of the TICS. Clean dirt and debris from moving parts.

Seat Belt, Toolcat™ Interlock Control System (TICS) (operator’s arm rest) Lift Arm, Cylinders, Bob-Tach, Pivot Lubricate with multi-purpose lithium based grease.

Pins and Wedges Tires Check for damaged tires and correct air pressure. Inflate tires to MAXIMUM pressure shown on the sidewall.

Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or safety treads that are damaged or worn.

Operator Cab Check the condition of the cab.

Indicators and Lights Check for correct operation of all indicators and lights.

Fuel Filter Remove the trapped water.

Heater / Air Conditioning Filter (If Clean or replace filter as needed during heating and cooling seasons.

Equipped) Parking Brake Check function.

Wheel Nuts Check for loose wheel nuts and tighten to correct torque. See TIRE MAINTENANCE in this Manual.

Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or Tubelines replace as needed.

Spark Arrestor Muffler Empty Spark Chamber.

Battery Check cables, connections and electrolyte level. Add distilled water as needed.

Trans Axle Lubricant Check lubricant level; add as needed.

Fuel Filter Replace filter element.

Alternator, Water Pump, A/C Belt Check for damage and correct tension. Adjust or replace as needed.

Engine Oil and Filter Replace oil and filter. Use CF / CG4 or better grade oil and Bobcat filter.

Engine / Hydrostatic Belt Check for wear or damage.

Hydraulic / Hydrostatic Filter Replace the filter element.

Hydraulic Reservoir Breather Cap Replace the reservoir breather cap.

Engine Valves Adjust the engine valves. See your Bobcat dealer for this service.

Hydraulic Reservoir Replace the fluid.

Trans Axle Lubricant Replace the lubricant.

Coolant Replace the coolant

[1] [2] [3]

50

[1]

[2] [4] [3]

[5] [6] Every 2 years

Check every 8-10 hours for the first 24 hours; then as scheduled.

First oil and filter change must occur at 50 hours; then as scheduled.

Replace the hydraulic / hydrostatic filter element after the first 50 hours; and thereafter when the transmission warning light comes ON while operating or as scheduled.

Check after the first 50 hours; then as scheduled.

Replace the hydraulic / hydrostatic fluid after the first 100 hours; then as scheduled.

First trans axle lubricant change must occur at 300 hours; then as scheduled.

Or every 12 months.

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TOOLCAT INTERLOCK CONTROL SYSTEM (TICS)

Maintaining The TICS

Description

Use the correct service interval to inspect and maintain the arm rest. (See SERVICE SCHEDULE on Page 69.)

The Toolcat Interlock Control System (TICS) is controlled by the left arm rest.

Figure 81

The interlock system requires the operator to lower the arm rest in order to operate the machine.

When the arm rest is up, the lift, tilt, auxiliary hydraulics and traction control functions are deactivated.

Inspecting The TICS Sit in the seat and fasten the seat belt. Lower the arm rest all the way down. Start the engine.

Operate the joystick to check that both the lift and tilt functions operate correctly. Raise the lift arm until the attachment is about 600 mm (2 ft) off the ground.

1 P-39399

Raise the arm rest. Move the joystick in all four directions. There must be no motion of the lift arm functions or tilt functions when the joystick is moved.

Use compressed air to clean any debris or dirt from the pivot parts (Item 1) [Figure 81]. Do not lubricate. Inspect all mounting hardware and tighten as necessary.

Lower the arm rest. Lower the lift arm.

If the TICS does not function correctly, check for free movement of the arm rest. Check electrical connections and for excessive wear. Replace parts that are worn or damaged. Use only genuine Bobcat replacement parts.

Figure 80

B-19665

WARNING

1

AVOID INJURY OR DEATH The Toolcat Interlock Control System (TICS) must deactivate the lift, tilt, auxiliary hydraulics and traction drive functions. If it does not, contact your dealer for service. DO NOT MODIFY THE SYSTEM. W-2452-1102 P-73842

2 B-19665

Activate the auxiliary hydraulics (Item 1) [Figure 80], raise the arm rest, and verify that the auxiliary hydraulics are deactivated.

When the arm rest is raised, three icons will be ON (Item 2) [Figure 80].

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5600 Operation & Maintenance Manual

Figure 82

LIFT ARM BYPASS The lift arm bypass is used to lower the lift arm if the lift arm cannot be lowered during normal operation. The operator releases the hydraulic fluid from the base end of the lift cylinder allowing the lift arm to slowly lower to the transport position.

Inspecting

1

DANGER P-67762

Press and hold the Lift and Tilt Transport Lock button (Item 1) [Figure 82].

Figure 83 P-90775

•

•

AVOID DEATH Never reach under or stand under raised lift arm unless supported by an approved lift arm support.

Moving a lift arm control or failure of a part can cause lift arm to drop.

D-1010-0709

1 Sit in the operator’s seat. Fasten the seat belt and lower the operator arm rest. Start the engine.

Raise the lift arm 2 m (6 ft) off the ground.

P-64847

Stop the engine.

Move the joystick (Item 1) [Figure 83] forward until the lift arm slowly lowers.

Turn the ignition to the ON position (Key Switch) or press the ENTER CODE button (Keyless).

NOTE: This inspection is performed with the engine off.

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Figure 84

SEAT BELT Inspection And Maintenance

1

WARNING

3

Failure to properly inspect and maintain the seat belt can cause lack of operator restraint resulting in serious injury or death.

W-2466-0703

2

Check the seat belt daily for correct function.

4

Inspect the seat belt system thoroughly yearly or more often if the machine is exposed to severe environmental conditions or applications.

The seat belt system should be repaired or replaced if it shows cuts, fraying, extreme or unusual wear, significant discolorations due to ultraviolet (UV) rays from the sun, dusty / dirty conditions, abrasion to the seat belt webbing, or damage to the buckle, latch plate, retractor (if equipped), and hardware.

B-22283A

The items below are referenced in [Figure 84].

1. Check the webbing. If the system is equipped with a retractor, pull the webbing completely out and inspect the full length of the webbing. Look for cuts, wear, fraying, dirt and stiffness.

2. Check the buckle and latch for proper function. Make sure latch plate is not excessively worn or deformed and buckle is not damaged.

3. Check the retractor web storage device (if equipped) by extending the seat belt webbing to determine if it extends and retracts the webbing correctly.

4. Check webbing in areas exposed to ultraviolet (UV) rays from the sun or extreme dust or dirt. If the original color of the webbing in these areas is extremely faded and / or the webbing is packed with dirt, the webbing strength may have weakened.

See your Bobcat dealer for approved seat belt system replacement parts for your machine.

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5600 Operation & Maintenance Manual

Figure 87

BACK-UP ALARM SYSTEM (IF EQUIPPED) Description

2

This Toolcat utility work machine may be equipped with a back-up alarm system. The back-up alarm will sound when the key switch is in the ON position (Key Switch) or press ENTER CODE button (Keyless) and the operator moves the Travel Direction Control Lever to the reverse travel position.

1

Inspecting Figure 85 P-74284

Inspect the back-up alarm electrical connections (Item 1) and the wire harness (Item 2) [Figure 87] for tightness and damage. Repair or replace any damaged components.

1

NOTE: Alarm removed for photo clarity.

Figure 88 P-74312

Inspect for damaged or missing back-up alarm decal (Item 1) [Figure 85] located on the panel next to the operator’s seat. Replace if required.

Enter the utility work machine and perform the PRESTARTING PROCEDURE. (See PRE-STARTING PROCEDURE on Page 45.)

1

Turn the key switch to the ON position (Key Switch) or press ENTER CODE button (Keyless) but do not start the engine.

Move the Travel Direction Control Lever (Item 1) [Figure 88] to the reverse travel position. The back-up alarm must sound.

P-64854

The backup alarm activation switch is an integral part of the Travel Direction Control Lever (Item 1) [Figure 88].

Figure 86

If the back-up alarm does not sound, [with the key switch in the ON position (Key Switch) or press ENTER CODE button (Keyless) but engine not running and the Travel Direction Control Lever (Item 1) [Figure 88] is in the reverse travel position] check for 12 volt power at the electrical connector (Item 1) [Figure 87].

1

If no power is detected, check harness connectors to make sure all connections are correct.

Repair or replace components as needed.

P-74285

The back-up alarm (Item 1) [Figure 86] is located at the rear of the utility work machine.

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5600 Operation & Maintenance Manual

NEUTRAL START SYSTEM Inspecting The Toolcat work machine is equipped with a Neutral Start System. The Travel Direction Control Lever must be in PARK for the engine to start.

Figure 89

1

P-64854

To check the function of the Neutral Start System, place the Travel Direction Control Lever (Item 1) [Figure 89] in FORWARD and turn the key switch to START position (Key Switch) or enter password and press Start button (Keyless). The engine must not start.

Repeat this procedure with the Travel Direction Control Lever in REVERSE. If the engine starts when the Travel Direction Control Lever is in FORWARD or REVERSE, see your Bobcat dealer for service.

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5600 Operation & Maintenance Manual

Figure 91

LIFT ARM SUPPORT DEVICE Installing

WARNING

2 1

Never work on a machine with the lift arm up unless the lift arm is supported by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arm or attachment to fall and cause injury or death.

W-2447-1102

P-73894

Swing the lift arm support (Item 1) [Figure 91] toward the cylinder rod. Raise and place into position on top of cylinder base. Lift arm support must contact cylinder rod

WARNING Service lift arm support device if damaged. Using a damaged lift arm support can cause lift arm to drop causing injury or death.

Tab on each side of lift arm support (Item 2) [Figure 91] will hook in place around cylinder base when properly installed.

W-2448-1102

Enter the cab, lower the arm rest, fasten the seat belt and start the engine.

Remove any attachment from the Bob-Tach and fully lower the lift arm before performing this procedure.

Lower the lift arm until it is supported by the support device.

Figure 90

Stop the engine and exit the cab.

Removing Enter the cab, lower the arm rest, fasten the seat belt and start the engine.

Raise the lift arm all the way up.

1

Stop the engine and exit the cab.

Position the lift arm support and latch securely into the storage position.

P-73895

Enter the cab, lower the arm rest, fasten the seat belt and start the engine.

Pull the latch (Item 1) [Figure 90] up to release the lift arm support.

Fully lower the lift arm.

Enter the cab, lower the arm rest, fasten the seat belt and start the engine.

Stop the engine and exit the cab.

Raise the lift arm all the way up.

Stop the engine and exit the cab.

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5600 Operation & Maintenance Manual

Figure 92

CARGO BOX SUPPORT DEVICE Installing

2

WARNING

1

Never work on a machine with the cargo box up unless the cargo box is supported by an approved support device. Failure to use an approved support device can allow the cargo box to fall and cause injury or death.

3

W-2449-1102 P-73893

Release the storage latch (Item 1) and lower the support (Item 2) on to the cylinder rod (Item 3) [Figure 92].

DANGER

Figure 93

P-90784

AVOID DEATH Never reach under or work under raised cargo box unless supported by an approved support.

D-1011-0709 P-73896

Enter the cab, lower the arm rest, fasten the seat belt, start the engine and lower the cargo box until it is supported by the support device [Figure 93].

WARNING Service cargo box support device if damaged or if parts are missing. Using a damaged support or with missing parts can cause cargo box to drop causing injury or death.

Removing Enter the cab, lower the arm rest, fasten the seat belt, start the engine and raise the cargo box all the way.

W-2450-1102

Stop the engine and exit the cab.

Empty the cargo box before installing the cargo box support device.

Raise cargo box support until it latches securely into the storage position.

Enter the cab, lower the arm rest, fasten the seat belt, start the engine and raise the cargo box all the way.

Enter the cab, lower the arm rest, fasten the seat belt, start the engine and lower the cargo box all the way.

Stop the engine and exit the cab.

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5600 Operation & Maintenance Manual

The parking brake function check should be performed on a slope of approximately 11 degrees. Conduct the check in an area free of objects and bystanders.

CARGO BOX SUPPORT DEVICE (CONT’D) Raising The Cargo Box When Engine Is Not Running Figure 94

Back the machine up the slope and put the Travel Direction Control Lever in PARK. The machine must not move.

If the machine moves after the inspection procedure, see your Bobcat dealer for service.

OPERATOR CAB Description Figure 96 P-48298A

Install lift straps (or chains) through the stake holes at the front of the cargo box [Figure 94].

Fasten the lift straps to a hoist.

Raise the hoist until the cargo box is all the way up.

Install cargo box support device. (See Installing on Page 76.)

PARKING BRAKE SYSTEM P-73868

Inspection And Maintenance

The machine has an operator cab (ROPS and FOPS) [Figure 96] as standard equipment to protect the operator from rollover and falling objects. The seat belt must be worn for rollover protection. Check with your dealer if the operator cab has been damaged or modified.

The Toolcat is equipped with a Parking Brake System.

Figure 95

ROPS / FOPS - Roll Over Protective Structure per ISO 3471, and Falling Object Protective Structure per ISO 3449, Level I.

2

Level I

1

Protection from falling bricks, small concrete blocks, and hand tools encountered in operations such as highway maintenance, landscaping, and other construction site services.

WARNING

P-73843

When the Travel Direction Control Lever (Item 1) [Figure 95] is in PARK, the Parking Brake is engaged.

Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat Company. Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.

The Parking Brake can also be engaged separately by pressing the Parking Brake button (Item 2) [Figure 95] on the instrument panel. If the Parking Brake is engaged using the Parking Brake button, the button must be pressed again to disengage.

W-2069-0200

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5600 Operation & Maintenance Manual

CAB FILTERS

Recirculating Air Filter

Cleaning And Maintenance

The recirculating air filter is located on the right end of the heater / air conditioning housing.

The heating system requires regular inspection and maintenance. (See SERVICE SCHEDULE on Page 69.)

Figure 99

Fresh Air Filter Figure 97

1 1

P-74090

Remove the plastic grate (Item 1) [Figure 99] covering the filter.

P-64828

Figure 100 The fresh air filter is located under the right front fender [Figure 97].

Remove the two thumb bolts and remove the filter housing (Item 1) [Figure 97].

Figure 98 1

P-73870

Use the ring (Item 1) [Figure 100] to pull the filter out.

Shake the filter or use low air pressure to remove dirt.

The filter can be cleaned several times in this manner, then it must be replaced. If air flow from the fan is reduced, the filter may need replacement.

P-66075

Remove the filter and shake it or use low air pressure to remove dirt [Figure 98]. The filter can be cleaned several times in this manner, then it must be replaced.

Reinstall the filter.

Reinstall the filter and housing.

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5600 Operation & Maintenance Manual

Figure 103

HEATING AND AIR CONDITIONING Cleaning And Maintenance The heating system requires regular inspection and maintenance. See the SERVICE SCHEDULE for intervals. (See SERVICE SCHEDULE on Page 69.)

Filters

1

See CAB AIR FILTERS for filter cleaning replacement. (See CAB FILTERS on Page 78.)

and

Evaporator Figure 101

P-73951

Use a vacuum to clean the evaporator coils (Item 1) [Figure 103].

If the coils require a more thorough cleaning, the heater / air conditioning unit must be disconnected from the front of the cab. (See your Bobcat dealer.)

Reinstall the filter and plastic grate.

1 Air Conditioning Lubrication Run the air conditioning for about 5 minutes every week to lubricate the internal components. (In winter too.)

P-74090

Troubleshooting Remove the plastic grate (Item 1) [Figure 101] covering the filter.

If the fan does not run or the air conditioning does not turn on, check the fuse. (See Fuse And Relay Location Frame Panel on Page 91.)

Figure 102

If the air conditioning system circulates warm air, the refrigerant may need to be recharged. (See your Bobcat dealer.)

1

P-73870

Use the ring (Item 1) [Figure 102] to pull the filter out.

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5600 Operation & Maintenance Manual

AIR CLEANER SERVICE

Inner Filter

Replacing Filter Elements

Replace the inner filter every third time the outer filter is replaced or when the red ring still shows in the indicator window after the outer filter has been replaced.

DANGER

Release the fasteners and remove the cover (Item 3) [Figure 104]. Clean any debris or dust from the cover.

Figure 105

P-90784

1

AVOID DEATH Never reach under or work under raised cargo box unless supported by an approved support.

D-1011-0709

P-73872A

Raise the cargo box and install the approved cargo box support device. (See CARGO BOX SUPPORT DEVICE on Page 76.)

Figure 106

For the interval to service the air cleaner (See SERVICE SCHEDULE on Page 69.)

Check the air intake hose, the inner and outer filter elements and the air cleaner housing for cracks, tears or damage. Check to make sure all connections are tight.

Outer Filter Figure 104

1 2

1

3

P-73873

Twist the outer filter element (Item 1) [Figure 105] approximately 1/8 turn counterclockwise and remove.

Remove the inner element (Item 1) [Figure 106], if required, by sliding it straight out.

P-73874A

Clean the inside of the filter housing. (Do not use compressed air.)

NOTE: The locking tabs in the air cleaner housing that hold the outer filter in place MUST be thoroughly cleaned to ensure proper seating of both filters.

P-73871A

Install the inner element (if removed). Install the outer element taking care to properly engage it into the air cleaner housing locking tabs. Turn the element approximately 1/8 turn clockwise to lock in place.

Replace the outer filter element only when the red ring (Item 1) [Figure 104] shows in the window of the condition indicator.

Install the cover (Item 3) [Figure 104] ensuring correct orientation and engage the fasteners.

NOTE: Before replacing the filter element, push the condition indicator button (Item 2) [Figure 104]. Start the engine and run it at fast idle, then stop the engine. If the red ring does not show, do not replace the filter element.

Remove the cargo box support device and lower the cargo box. (See CARGO BOX SUPPORT DEVICE on Page 76.)

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5600 Operation & Maintenance Manual

Figure 109

OPERATOR SEAT Removal And Installation Figure 107

1

1

P-67205

Disconnect the arm rest sensor connector (Item 1) [Figure 109].

P-67432

Figure 110 Remove the two front seat mounting nuts (Item 1) [Figure 107] that secure the operator seat.

Installation: Tighten the mounting nuts to 24 - 26 N•m (18 - 19 ft-lb) torque.

Figure 108

1

1

P-67207

Remove the [Figure 110].

seat

belt

mounting

bolt

(Item

1)

Installation: Tighten the mounting bolt to 84 - 92 N•m (62 - 68 ft-lb) torque.

P-67208

Remove seat from operator cab.

Slide the seat towards the front of the operator cab and remove the two rear seat mounting bolts (Item 1) [Figure 108] from the operator seat.

Reverse the removal procedure to install the operator seat.

Installation: Tighten the mounting bolts to 43 - 47 N•m (32 - 35 ft-lb) torque.

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5600 Operation & Maintenance Manual

Figure 113

PASSENGER SEAT Removal And Installation Figure 111

1

1 P-51252

P-67203

Remove the bolt (Item 1) [Figure 113] from the seat.

Remove seat from operator cab.

Remove the two front seat mounting nuts (Item 1) [Figure 111] from the passenger seat.

Installation: Tighten the mounting bolt to 84 - 92 N•m (62 - 68 ft-lb) torque.

Installation: Tighten the nuts to 24 - 26 N•m (18 - 19 ftlb) torque.

Figure 112

1

P-51253

Remove the two seat mounting bolts (Item [Figure 112] from behind the passenger seat.

1)

Installation: Tighten the mounting bolts to 43 - 47 N•m (32 - 35 ft-lb) torque.

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5600 Operation & Maintenance Manual

FUEL SYSTEM

Biodiesel Blend Fuel

Fuel Specifications

Biodiesel blend fuel has unique qualities that should be considered before using in this machine:

Use only clean, high quality diesel fuel, Grade No. 2 or Grade No. 1.

•

Cold weather conditions can lead to plugged fuel system components and hard starting.

The following is one suggested blending guideline which should prevent fuel gelling during cold temperatures:

•

Biodiesel blend fuel is an excellent medium for microbial growth and contamination which can cause corrosion and plugging of fuel system components.

•

Use of biodiesel blend fuel may result in premature failure of fuel system components, such as plugged fuel filters and deteriorated fuel lines.

•

Shorter maintenance intervals may be required, such as cleaning the fuel system and replacing fuel filters and fuel lines.

•

Using biodiesel blended fuels containing more than five percent biodiesel can affect engine life and cause deterioration of hoses, tubelines, injectors, injector pump and seals.

TEMPERATURE C° (F°)

NO. 2

NO. 1

-9°(+15°)

100%

0%

Down to -29° (-20°)

50%

50%

Below -29° (-20°)

0%

100%

The following fuels may be used in this machine: •

Low Sulfur (500 ppm sulfur) Diesel Fuel.

•

Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel.

•

Biodiesel Blend Fuel - Must contain no more than five percent biodiesel mixed with low sulfur or ultra low sulfur petroleum based diesel. This is commonly marketed as B5 blended diesel fuel. B5 blended diesel fuel must meet ASTM D975 (US Standard) or EN590 (EU Standard) specifications.

Apply the following guidelines if biodiesel blend fuel is used: •

Ensure the fuel tank is as full as possible at all times to prevent moisture from collecting in the fuel tank.

•

Ensure that the fuel tank cap is securely tightened.

•

Biodiesel blend fuel can damage painted surfaces, remove all spilled fuel from painted surfaces immediately.

•

Drain all water from the fuel filter daily before operating the machine.

•

Do not exceed engine oil change interval. Extended oil change intervals can cause engine damage.

•

Before vehicle storage; drain the fuel tank, refill with 100% petroleum diesel fuel, add fuel stabilizer and run the engine for at least 30 minutes.

NOTE: Biodiesel blend fuel does not have long term stability and should not be stored for more than three months.

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5600 Operation & Maintenance Manual

FUEL SYSTEM (CONT’D)

Fuel Filter

Filling The Fuel Tank

Remove water from, or replace the fuel filter at the correct interval. (See SERVICE SCHEDULE on Page 69.)

Figure 114 1

Figure 115

P-73865A

2

1

P-73875A

P-73867A

WARNING

P-73869

Removing Water:

AVOID INJURY OR DEATH Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire.

The fuel filter is located under the right side access cover [Figure 115].

W-2063-0807

Loosen the drain (Item 1) [Figure 115] at the bottom of the filter element to remove water from the filter. Close the drain.

Remove the fill cap (Item 1) [Figure 114].

Use a clean, approved safety container to add fuel of the correct specification. Add fuel only in an area that has free movement of air and no open flames or sparks. NO SMOKING!

Replacing Element: Remove the filter element (Item 2) [Figure 115].

NOTE: Be sure the filter gasket is removed with the old fuel filter.

Install and tighten the fuel cap (Item 1) [Figure 114].

Clean the area around the filter housing.

Put clean oil on the seal of the new filter element.

Install the fuel filter, and hand tighten.

Remove air from the fuel system. (See Removing Air From The Fuel System on Page 85.)

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5600 Operation & Maintenance Manual

FUEL SYSTEM (CONT’D)

Filling A Portable Fuel Container

Removing Air From The Fuel System

Static electric spark can explosively ignite gasoline vapors when filling ungrounded portable containers.

Always put the container ON THE GROUND before filling.

WARNING

Keep the nozzle in contact with container while filling.

AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire.

NEVER fill container in the cargo box or on the machine.

W-2103-0508

WARNING

After replacing the filter element or when the fuel tank has run out of fuel, air must be removed from the fuel system before starting the engine.

FIRE AND EXPLOSION CAN CAUSE SERIOUS INJURY OR DEATH Static electric spark can explosively ignite gasoline vapors when filling ungrounded portable containers.

• ALWAYS place the container ON THE GROUND before filling.

• Keep the nozzle in contact with container while filling.

• NEVER fill container in the cargo box, storage bins or on the machine.

Be sure the engine is cool.

Open the right side access cover.

Figure 116

W-2801-0709

1

2

P-73907

Open the valve (Item 1) on the injector pump and squeeze the hand pump (Item 2) [Figure 116] until fuel comes from the valve with no air bubbles.

Close the valve (Item 1) [Figure 116].

With the operator in the seat, seat belt fastened, arm rest lowered and Travel Direction Control Lever in PARK, start the engine.

Repeat until the engine starts.

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5600 Operation & Maintenance Manual

ENGINE LUBRICATION SYSTEM

Removing And Replacing Oil And Filter

Checking And Adding Engine Oil

Follow the service interval for replacing the engine oil and filter. (See SERVICE SCHEDULE on Page 69.)

Figure 117

Run the engine until it is at operating temperature.

Stop the engine.

1 Figure 119

P-73878

1

Check the engine oil level every day.

The engine oil dipstick is located inside the right side access cover.

P-73879

Remove the dipstick (Item 1) [Figure 117] to check the oil level.

The engine oil drain and filter are located under the machine at the right side access cover.

Keep the oil level between the marks on the dipstick.

Engine Oil Chart

Remove the drain plug (Item 1) [Figure 119]. Drain the oil into a container and recycle or dispose of used oil in an environmentally safe manner.

Figure 118 ENGINE OIL RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)

NOTE: Some machines have a belly pan (option or accessory) under the engine area. The belly pan has holes in it for access to drain and filters.

Reinstall the drain plug.

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API CLASSIFICATION CI-4 OR BETTER) [1] Synthetic Oil - Use recommendation from Synthetic Oil Manufacturer.

Use good quality motor oil that meets API Service Classification of CD or better.

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5600 Operation & Maintenance Manual

Figure 121

ENGINE LUBRICATION SYSTEM (CONT’D) Removing And Replacing Oil And Filter (Cont’d) Figure 120

1

2 P-73877

1

Remove the fill cap (Item 1) [Figure 121].

P-73878

Put the correct quantity of oil in the engine. (See Capacities on Page 147.)

Remove the oil filter (Item 1) [Figure 120] and clean the filter housing surface.

Start the engine and let it run for several minutes. Stop the engine and check for leaks at the filter.

Use genuine Bobcat filter only.

Remove the dipstick (Item 2) [Figure 121] and check the oil level. (See Checking And Adding Engine Oil on Page 86.)

Put clean oil on the new filter gasket, install the filter and hand tighten.

Add oil as needed if it is not at the top mark on the dipstick.

Install the dipstick.

WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire.

W-2103-0508

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5600 Operation & Maintenance Manual

ENGINE COOLING SYSTEM Checking Level

WARNING

Figure 122 AVOID BURNS Do not remove radiator cap when the engine is hot.

You can be seriously burned.

W-2070-1203

2

The coolant level in the recovery tank must be between the marks on the tank (Item 2) [Figure 122] when the engine is cool.

NOTE: The cooling system is factory filled with propylene glycol coolant (purple color). DO NOT mix propylene glycol with ethylene glycol.

1

P-67906

The coolant recovery tank (Item 1) [Figure 122] is located behind the cab.

IMPORTANT

Raise the cargo box and install the Cargo Box Support Device. (See CARGO BOX SUPPORT DEVICE on Page 76.) Stop the engine.

AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze.

Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage.

WARNING

Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system.

Never work on a machine with the cargo box up unless the cargo box is supported by an approved support device. Failure to use an approved support device can allow the cargo box to fall and cause injury or death.

Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage.

I-2124-0497

W-2449-1102

Propylene Glycol Add premixed coolant; 47% water 53% propylene glycol to the recovery tank if the coolant level is low.

WARNING

One gallon and one pint of propylene glycol mixed with one gallon of water is the correct mixture of coolant to provide a -37°C (-34°F) freeze protection.

AVOID INJURY Stop the engine and allow to cool before adding coolant or you can be burned.

W-2106-0907

Use a refractometer to check the condition of propylene glycol in your cooling system.

Remove the cargo box support device (See CARGO BOX SUPPORT DEVICE on Page 76.) and lower the cargo box.

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5600 Operation & Maintenance Manual

ENGINE COOLING SYSTEM (CONT’D)

Removing And Replacing Coolant

Cleaning

Figure 124

WARNING

2 1

AVOID INJURY Use safety goggles when using air or water under pressure. Do not use cold water to clean a hot engine.

P-67906A

W-2064-0907

Check the cooling system every day to prevent overheating, loss of performance or engine damage.

P-67734A

Raise the cargo box and install the Cargo Box Support Device. (See CARGO BOX SUPPORT DEVICE on Page 76.) Stop the engine.

Raise the cargo box and install the Cargo Box Support Device. (See CARGO BOX SUPPORT DEVICE on Page 76.) Stop the engine.

Figure 123

Remove the cap (Item 1) [Figure 124] from the coolant recovery tank.

2

Connect a short length of hose to the coolant drain valve (Item 2) [Figure 124].

1

P-73882A

Open the coolant drain valve (Item 2) [Figure 124] and drain the coolant into a container.

Close the drain valve.

Reuse or dispose of the environmentally safe manner.

P-73881

Unlatch the hook (Item 1) holding the debris screen in place and remove the screen (Item 2) [Figure 123].

used

coolant

in

an

Add premixed coolant to the coolant recovery tank until it is at the full mark. Install the cap.

Use low air or water pressure to remove debris in the area of the radiator and oil cooler.

Start the engine and allow to run until it is at operating temperature.

Stop the engine and check the coolant level. Add premixed coolant to the recovery tank as needed.

IMPORTANT

Remove the cargo box support device (See CARGO BOX SUPPORT DEVICE on Page 76.) and lower the cargo box.

Do not use a pressure washer to clean the radiator and oil cooler. High pressure can damage the fins.

I-2219-1102

Check the cooling system for leaks.

Reinstall the screen.

Remove the cargo box support device (See CARGO BOX SUPPORT DEVICE on Page 76.) and lower the cargo box.

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5600 Operation & Maintenance Manual

Figure 127

ELECTRICAL SYSTEM Description

1

2

4

3

5

6

8

7

9

10

The machine has a 12 volt, negative ground, alternator charging system. The electrical system is protected by fuses and relays. The fuses will protect the electrical system when there is an electrical overload. The reason for the overload must be found before starting the engine again.

Fuse And Relay Location - Cab Panel Figure 125 11

12

13

14

15 P-73886

There is a decal [Figure 127] inside the cab fuse and relay panel cover which shows location and size of fuses.

Description and amp ratings (or relays) are also shown below.

1

REF

DESCRIPTION

1

Attachment Control Device (ACD)

25

11 Switched Power

R

2

Attachment Control Device (ACD)

25

12 Light

R

3

Control Panel

25

13 Wiper

R

4

Console Switches/ Wheel Position

20

14 Drive Lights (Option)

R

5

Light Relay

30

15 Not Used

R

6

Drive Lights (Option)

10

7

Turn Signals/ Flasher (Option)

10

8

Horn/Radio/Power Port/Dome Light

30

9

Front Wipers

20

10 Console Switches/ Direction Lever

15

P-73856

The cab fuse and relay panel (Item 1) [Figure 125] is located inside the cab on the left side of the floor console.

Figure 126

AMP REF

DESCRIPTION

AMP

R = Relay

P-73857

Remove the cover to get access to the fuses and relays [Figure 126].

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5600 Operation & Maintenance Manual

Figure 130

ELECTRICAL SYSTEM (CONT’D) Fuse And Relay Location - Frame Panel

2

1

3

4

5

6

8

7

9

10

Figure 128

11

13

12

14

15 P-73885

1

There is a decal [Figure 130] inside the frame fuse and relay panel cover which shows location and size of fuses.

Description and amp ratings (or relays) are also shown below.

P-73884

The frame fuse and relay panel (Item 1) [Figure 128] is located inside the cab below the operator’s seat.

REF

Figure 129

P-73855

DESCRIPTION

AMP REF

DESCRIPTION

AMP

1

Drive Controller

25

11 Fuel Shut-Off

R

2

Fuel Shut-Off Relay

25

12 Marker Lights (Option)

R

3

Left Marker Lights (Option)

10

13 Glow Plugs

R

4

Right Marker Lights (Option)

10

14 Brake Light (Option)

R

5

Brake Lights (Option)

10

15 Starter

R

6

Condenser Fan

25

7

Blower Motor

25

8

Spare

-

9

Spare

-

10 Spare

-

R = Relay Remove the cover to get access to the fuses and relays [Figure 129].

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5600 Operation & Maintenance Manual

ELECTRICAL SYSTEM (CONT’D) Battery Maintenance

WARNING AVOID INJURY OR DEATH Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

W-2065-0807

Figure 131

P-09589

P-09590

Always clean the battery terminals and cable ends when installing a new or used battery [Figure 131].

Check the electrolyte level in the battery (If needed). Add distilled water as necessary.

Put grease on the battery terminals and cable ends to prevent corrosion.

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5600 Operation & Maintenance Manual

ELECTRICAL SYSTEM (CONT’D)

Connect the end of the first cable (Item 1) to the positive (+) terminal of the booster battery. Connect the other end of the same cable to the battery terminal (Item 2) [Figure 132] of the machine starter.

Using A Booster Battery (Jump Starting) If it is necessary to use a booster battery to start the engine, BE CAREFUL! There must be one person in the operator’s seat and one person to connect and disconnect the battery cables.

Connect the end of the second cable (Item 3) to the negative terminal of the booster battery. Connect the other end of the same cable (Item 4) [Figure 132] to a ground point on the machine.

The key switch must be OFF. The booster battery must be 12 volt.

Start the engine.

After the engine has started, remove the ground (-) cable (Item 4) [Figure 132] first. Remove the cable from the positive terminal (Item 2) [Figure 132]. Then remove the cables from the booster battery.

WARNING BATTERY GAS CAN EXPLODE AND CAUSE SERIOUS INJURY OR DEATH Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at machine frame.

IMPORTANT Damage to the charging system can occur if: • Engine is operated with battery cables disconnected.

• Battery cables are connected when using a fast charger or when welding. (Remove both cables from the battery.)

• Extra battery cables (booster cables) are connected incorrectly.

Do not jump start or charge a frozen or damaged battery. Warm battery to 16°C (60°F) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging.

W-2066-0910

Figure 132

I-2217-0610

2

4

P-73860

1

3

P-39258

Open the right side access cover.

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5600 Operation & Maintenance Manual

Figure 134

ELECTRICAL SYSTEM (CONT’D) Removing And Installing Battery

WARNING AVOID INJURY OR DEATH Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

1

2

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

P-73859

Remove the battery hold down bolt (Item 1) and battery hold down clamp (Item 2) [Figure 134].

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

Remove the battery.

W-2065-0807

NOTE: When installing the battery, do not touch any metal parts with the battery terminals.

Figure 133

Install the battery.

2

Install and tighten the battery hold down clamp and bolt.

1 Connect the negative (-) cable last to prevent sparks.

Connect and tighten the battery cables.

Remove the cargo box support device (See CARGO BOX SUPPORT DEVICE on Page 76.) and lower the cargo box.

P-73858

WARNING

Raise the cargo box and install the cargo box support device. (See CARGO BOX SUPPORT DEVICE on Page 76.) Stop the engine.

BATTERY GAS CAN EXPLODE AND CAUSE SERIOUS INJURY OR DEATH Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at machine frame.

WARNING

Do not jump start or charge a frozen or damaged battery. Warm battery to 16°C (60°F) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging.

Never work on a machine with the Cargo Box up unless the Cargo Box is supported by an approved Cargo Box Support Device.

W-2451-1102

W-2066-0910

Disconnect the negative (-) cable (Item 1) [Figure 133].

Disconnect the positive (+) cable (Item 2) [Figure 133].

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5600 Operation & Maintenance Manual

HYDRAULIC / HYDROSTATIC SYSTEM

Hydraulic / Hydrostatic Fluid Chart

Checking Fluid

Figure 136

Use only recommended fluid in the hydraulic system.

(See Hydraulic System on Page 146.)

HYDRAULIC / HYDROSTATIC FLUID RECOMMENDED ISO VISCOSITY GRADE (VG) AND VISCOSITY INDEX (VI)

Put the machine on a level surface, lower the lift arm, and tilt the Bob-Tach fully back.

Raise the cargo box and install the cargo box support device. (See CARGO BOX SUPPORT DEVICE on Page 76.) Stop the engine.

DANGER TEMPERATURE RANGE ANTICIPATED DURING MACHINE USE [1] VG 100; Minimum VI 120 [2] VG 46; Minimum VI 140 [3] Synthetic Fluid; VG 46; Minimum VI 150 [4] BOBCAT Hydraulic / Hydrostatic Fluid

P-90784

AVOID DEATH Never reach under or work under raised cargo box unless supported by an approved support.

Use only recommended fluid in the hydraulic system [Figure 136]. (See Hydraulic System on Page 146.)

D-1011-0709

Adding Fluid Figure 135

Figure 137

1

1

P-73861

P-73943

Check the fluid level in the sight gauge (Item 1) [Figure 135]. The fluid level is correct when at the center of the sight gauge.

If needed, remove the fill / breather cap (Item 1) [Figure 137] and add fluid. See chart [Figure 136] for correct hydraulic / hydrostatic fluid.

Remove the cargo box support device (See CARGO BOX SUPPORT DEVICE on Page 76.) and lower the cargo box.

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5600 Operation & Maintenance Manual

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)

Check for proper hydraulic fluid level. (See Checking Fluid on Page 95.)

Alternate Fill Procedure Add (See Adding Fluid on Page 95.) or remove (See Removing And Replacing Hydraulic Fluid on Page 99.) hydraulic fluid to reach the proper level.

This procedure is used when there is not enough hydraulic fluid in the hydraulic tank to fully raise the cargo box.

Remove the cargo box support device (See CARGO BOX SUPPORT DEVICE on Page 76.) and lower the cargo box.

Remove the operator seat. (See OPERATOR SEAT on Page 81.)

Figure 138

1

P-73912

Remove the hydraulic plug (Item 1) [Figure 138] and add hydraulic fluid. See chart [Figure 136] for correct hydraulic / hydrostatic fluid.

Replace the operator seat (See OPERATOR SEAT on Page 81.) when enough fluid has been added to safely operate the machine.

Start the engine and fully raise the cargo box. (See CARGO BOX SUPPORT DEVICE on Page 76.)

WARNING Never work on a machine with the cargo box up unless the cargo box is supported by an approved support device. Failure to use an approved support device can allow the cargo box to fall and cause injury or death.

W-2449-1102

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5600 Operation & Maintenance Manual

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)

Figure 139

Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters

DANGER 1

P-73943

Loosen the fill / breather cap (Item 1) [Figure 139] to relieve hydraulic system pressure.

P-90784

AVOID DEATH Never reach under or work under raised cargo box unless supported by an approved support.

Figure 140

D-1011-0709

Raise the cargo box and install the approved cargo box support device. (See CARGO BOX SUPPORT DEVICE on Page 76.)

1

Replace the filters at the correct interval. (See SERVICE SCHEDULE on Page 69.)

P-73906

WARNING

Remove the hydrostatic filter (Item 1) [Figure 140] (near the left rear wheel).

AVOID INJURY OR DEATH Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible.

Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

W-2072-0807

Stop the engine and allow it to cool.

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5600 Operation & Maintenance Manual

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters (Cont’d) Figure 141

1 P-74087

Remove the case drain filter (Item 1) [Figure 141] (near the right rear wheel).

Clean the surface of the filter housings where the filter seal contacts the housing.

Put clean oil on the seal of the new filters. Install and hand tighten.

Tighten fill / breather cap.

Start the engine and operate the hydraulic controls. Stop the engine and check for leaks at the filters.

Check fluid level and add as needed. (See Checking Fluid on Page 95.)

Remove the cargo box support device (See CARGO BOX SUPPORT DEVICE on Page 76.) and lower the cargo box.

WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire.

W-2103-0508

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5600 Operation & Maintenance Manual

Figure 143

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Removing And Replacing Hydraulic Fluid Replace hydraulic fluid at the correct service interval.

(See SERVICE SCHEDULE on Page 69.)

Replace the fluid if it becomes contaminated or after major repair.

1

Always replace the hydraulic / hydrostatic filters whenever the hydraulic fluid is replaced.

Raise the cargo box and install the cargo box support device. (See CARGO BOX SUPPORT DEVICE on Page 76.) Stop the engine.

P-67758

Remove the screen (Item 1) [Figure 143].

Figure 144

WARNING Never work on a machine with the Cargo Box up unless the Cargo Box is supported by an approved Cargo Box Support Device.

W-2451-1102

Figure 142

P-73942

1

Siphon the fluid into an appropriately sized container (See Capacities on Page 147.) [Figure 144].

Dispose of the used fluid in an environmentally safe manner.

Install the screen and fill to the proper level. (See Adding Fluid on Page 95.)

P-73943

Remove the cargo box support device (See CARGO BOX SUPPORT DEVICE on Page 76.) and lower the cargo box.

Remove the hydraulic fill / breather cap (Item 1) [Figure 142].

WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire.

W-2103-0508

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5600 Operation & Maintenance Manual

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Breather Cap Replace breather cap at the correct service interval. (See SERVICE SCHEDULE on Page 69.)

Raise the cargo box and install the cargo box support device. (See CARGO BOX SUPPORT DEVICE on Page 76.) Stop the engine.

WARNING Never work on a machine with the Cargo Box up unless the Cargo Box is supported by an approved Cargo Box Support Device.

W-2451-1102

Figure 145

1

P-73943

Thoroughly clean the area around the breather cap.

Remove the breather cap (Item 1) [Figure 145] and discard.

Install new breather cap.

Remove the cargo box support device (See CARGO BOX SUPPORT DEVICE on Page 76.) and lower the cargo box.

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5600 Operation & Maintenance Manual

Figure 147

SPARK ARRESTOR MUFFLER Cleaning Procedure Clean the spark arrestor muffler at the correct service interval. (See SERVICE SCHEDULE on Page 69.) Do not operate the machine with a defective exhaust system.

1

WARNING Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety goggles.

Failure to obey can cause serious injury.

P-73863

W-2011-1285

Remove the plug (Item 1) [Figure 147] from the cleanout hole in the muffler.

Start the engine.

WARNING

Have a second person, standing to the side of the machine, hold a block of wood over the outlet of the muffler (with the engine running) for about 10 seconds.

AVOID INJURY OR DEATH When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible gases which can kill without warning.

This will force contaminants out the cleanout hole.

Stop the engine and install the plug.

Install the fender and louvered panel.

W-2050-0807

Stop the engine and allow it to cool.

IMPORTANT

Figure 146 This machine is factory equipped with a U.S.D.A. Forestry Service approved spark arrestor exhaust system.

The spark arrestor muffler, if equipped, must be cleaned to keep it in working condition. The spark arrestor muffler must be serviced by dumping the spark chamber every 100 hours of operation.

1

On some models, the turbocharger functions as the spark arrestor and must operate correctly for proper spark arrestor function.

If this machine is operated on flammable forest, brush, or grass covered land, it must be equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442.

PRC. Refer to local laws and regulations for spark arrestor requirements.

P-73862

Remove the right rear fender and louvered panel (Item 1) [Figure 146].

I-2284-0409

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SUPPORTING THE MACHINE ON JACKSTANDS

Figure 148

Procedure For service work under the machine, or to remove the wheels, always support the machine with jackstands or blocks of adequate capacity for weight of machine (See Performance on Page 145.)

2

2

1

DANGER

3

1

P-74150

Place the jackstands (Item 1) on the control arms (Item 2) [Figure 148] at the front of the machine.

NOTE: When lifting the machine place the jack under the trans axle (Item 3) [Figure 148].

P-90775

•

•

AVOID DEATH Never reach under or stand under raised lift arm unless supported by an approved lift arm support.

Moving a lift arm control or failure of a part can cause lift arm to drop.

Figure 149

2

D-1010-0709

2

Install the approved lift arm support device. (See Installing on Page 75.)

Always park the machine on a level surface.

1

WARNING

3

1

P-74148

AVOID INJURY OR DEATH 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.

Place the jackstands (Item 1) on the control arms (Item 2) [Figure 149] at the rear of the machine.

NOTE: When lifting the machine place the jack under the trans axle (Item 3) [Figure 149].

For service work requiring axle or suspension component removal see your Bobcat dealer.

W-2003-0807

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5600 Operation & Maintenance Manual

TIRE MAINTENANCE

Mounting

Wheel Nuts

Tires are to be repaired only by an authorized person using the proper procedures and safe equipment.

NOTE: Remove center cap before attempting to remove wheel.

Tires and rims must always be checked for correct size before mounting. Check rim and tire bead for damage.

Check the wheel nut torque at the correct service interval (See SERVICE SCHEDULE on Page 69.)

The rim flange must be cleaned and free of rust.

The correct torque is 129 - 142 N•m (95 - 105 ft lb).

The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire.

Rotating Avoid excessive pressure which can rupture the tire and cause serious injury or death.

Check the tires regularly for wear, damage and pressure.

During inflation of the tire, check the tire pressure frequently to avoid over inflation.

IMPORTANT WARNING

Inflate tires to the MAXIMUM pressure shown on the sidewall of the tire. DO NOT mix brands of tires used on the same machine.

AVOID INJURY OR DEATH Do not inflate tires above specified pressure. Failure to use correct tire mounting procedure can cause an explosion which can result in injury or death.

I-2057-1010

Figure 150

W-2078-1007

P-64707A

Rear tires usually wear faster than front tires. To keep tire wear even, move the front tires to the rear and rear tires to the front [Figure 150].

It is important to keep the same size tires on each side of the machine. If different sizes are used, each tire will be turning at a different rate and cause excessive wear. The tread bars of all the tires must face the same direction.

Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability. Check for correct pressure before operating.

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5600 Operation & Maintenance Manual

Figure 152

TRANS AXLE (FRONT AND REAR) Checking And Adding Lubricant

1

DANGER REAR AXLE

Remove the check plug (Item 1) [Figure 151] and [Figure 152] from the front and rear housing.

P-90775

•

•

P-73898

AVOID DEATH Never reach under or stand under raised lift arm unless supported by an approved lift arm support.

Moving a lift arm control or failure of a part can cause lift arm to drop.

If lubricant can be reached with the tip of your finger through the hole, the level is correct.

If the level is low, add lubricant through the check plug hole until lubricant flows from the hole.

D-1010-0709

NOTE: When adding trans axle lubricant (See Drive System on Page 147.) for correct fluid type.

Raise the lift arm and install the approved lift arm support device.(See Installing on Page 75.)

Install and tighten the plug.

Always park the machine on a level surface.

Lower the lift arm.

Figure 151

1

FRONT AXLE

P-73899

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5600 Operation & Maintenance Manual

Figure 153

TRANS AXLE (FRONT AND REAR) (CONT’D) Removing And Replacing Lubricant

DANGER 1

P-73900

P-90775

•

•

AVOID DEATH Never reach under or stand under raised lift arm unless supported by an approved lift arm support.

Moving a lift arm control or failure of a part can cause lift arm to drop.

Remove the drain plug at the bottom of the trans axle housing (Item 1) [Figure 153].

Drain the lubricant into a container and dispose of it in an environmentally safe manner.

D-1010-0709

Install and tighten drain plug.

Raise the lift arm and install the approved lift arm support device.(See Installing on Page 75.)

Remove check plug (Item 1) [Figure 151] [Figure 152] and fill with trans axle lubricant.

and

Always park the machine on a level surface.

NOTE: When adding trans axle lubricant (See Drive System on Page 147.) for correct fluid type.

Lower the lift arm.

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5600 Operation & Maintenance Manual

ALTERNATOR BELT

AIR CONDITIONING BELT

Belt Adjustment

Belt Adjustment

Stop the engine.

Figure 155

Remove the passenger seat. (See PASSENGER SEAT on Page 82.)

Figure 154

2

1 1

P-73862

Remove the right rear fender and louvered panel (Item 1) [Figure 155].

P-67897

Figure 156

Loosen the mounting and adjustment bolts (Item 1) [Figure 154].

Move the top of the alternator as shown [Figure 154] to tighten the belt.

1

The tension is correct with 6 mm (1/4 in) belt movement at mid span (Item 2) [Figure 154] to tighten the belt, when 67 N (15 lbf) is applied to the belt.

Tighten the mounting and adjustment bolts (Item 1) [Figure 154].

Install the passenger seat. (See PASSENGER SEAT on Page 82.)

P-73863

Belt Replacement Loosen adjustment and mounting [Figure 156].

Stop the engine.

Remove the passenger seat. (See PASSENGER SEAT on Page 82.)

bolts

(Item

1)

Move the compressor unit to tighten the belt until there is 6 mm (1/4 in) belt movement at mid span, when 67 N (15 lbf) is applied to the belt.

Loosen the mounting and adjustment bolts (Item 1) [Figure 154] and move the alternator toward the engine.

Remove the belt.

Install the fender and louvered panel.

Install the new belt and adjust as shown under Belt Adjustment. (See Belt Adjustment on Page 106.)

Install the passenger seat. (See PASSENGER SEAT on Page 82.)

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5600 Operation & Maintenance Manual

Figure 159

AIR CONDITIONING BELT (CONT’D) Belt Replacement Figure 157

1

2

1

P-73864

Loosen the adjustment and mounting bolts (Item 1) [Figure 159].

P-73862

Move the compressor unit to loosen the belt (Item 2) [Figure 159] all the way. Remove the belt.

Remove the right rear fender and louvered panel (Item 1) [Figure 157].

Install the new belt and adjust as shown in Belt Adjustment. (See Belt Adjustment on Page 106.)

Figure 158

Install the belt shield.

Install the fender and louvered panel.

1

3

2

P-73863

Remove the belt shield mounting bolts (Item 1) and loosen the lower belt shield mounting bolt (Item 2).

Remove the belt shield (Item 3) [Figure 158].

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5600 Operation & Maintenance Manual

Figure 161

DRIVE BELT Belt Adjustment Raise the cargo box and install the approved lift arm support device. (See CARGO BOX SUPPORT DEVICE on Page 76.) Stop the engine.

1 3

DANGER

2

P-73866

Remove the belt shield mounting bolts (Item 1) and loosen the lower belt shield mounting bolt (Item 2).

Remove the belt shield (Item 3) [Figure 161].

P-90784

AVOID DEATH Never reach under or work under raised cargo box unless supported by an approved support.

Figure 162

D-1011-0709

2 Disconnect the negative (-) battery cable.

Figure 160

3

1

P-73887

1 Loosen the bolt (Item 1) [Figure 162] on the idler assembly.

Use a pry bar to push the idler assembly (Item 2) against the belt (Item 3) [Figure 162].

P-73888

Remove the muffler (Item 1) [Figure 160].

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5600 Operation & Maintenance Manual

Figure 164

DRIVE BELT (CONT'D) Belt Adjustment (Cont’d) Figure 163

1

2

1

P-73897

P-73887

Tighten the mounting bolt (Item 1) [Figure 164] to 43 - 47 N•m (32 - 35 ft-lb) torque.

P-73897A

Install the belt shield and mounting bolts.

Correct tension is reached when the dial indicator (Item 1) is parallel with the tensioner mounting casting (Item 2) [Figure 163].

Install the muffler.

Connect the negative (-) battery cable.

Run the engine for a few minutes.

Stop the engine and recheck the dial indicator position.

Readjust if necessary.

Remove the cargo box support device (See CARGO BOX SUPPORT DEVICE on Page 76.) and lower the cargo box.

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5600 Operation & Maintenance Manual

Figure 166

DRIVE BELT (CONT'D) Belt Replacement Raise the cargo box and install the approved lift arm support device. (See CARGO BOX SUPPORT DEVICE on Page 76.) Stop the engine.

1

3

DANGER

2

P-73863

Remove the belt shield mounting bolts (Item 1) and loosen the lower belt shield mounting bolt (Item 2).

Remove the belt shield (Item 3) [Figure 166].

P-90784

AVOID DEATH Never reach under or work under raised cargo box unless supported by an approved support.

Figure 167

D-1011-0709

1

Disconnect the negative (-) battery cable.

Figure 165

2

P-73864

1 Loosen the adjustment and mounting bolts (Item 1) [Figure 167].

Move the compressor unit to loosen the belt (Item 2) [Figure 167] all the way. Remove the belt.

P-73862

Remove the right rear fender and louvered panel (Item 1) [Figure 165].

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5600 Operation & Maintenance Manual

Figure 170

DRIVE BELT (CONT'D) Belt Replacement (Cont’d) Figure 168

2 1

1

3 P-67700A

Loosen and remove the bolt (Item 1) [Figure 170] on the spring loaded drive idler.

P-73888

Remove the muffler (Item 1) [Figure 168].

Remove the [Figure 170].

spring

loaded

drive

idler

Figure 169

Remove the drive belt (Item 3) [Figure 170].

(Item

2)

Install the new drive belt.

Install the spring loaded drive idler and bolt.

1

Adjust the drive belt. (See Belt Adjustment on Page 108.)

Install the drive belt shield and fasteners.

3 2

Install the muffler.

Install the air conditioning compressor drive belt (If equipped). (See Belt Replacement on Page 107.)

Install the air conditioning belt shield and fasteners.

P-73866

Install the fender and louvered panel.

Remove the belt shield mounting bolts (Item 1) and loosen the lower belt shield mounting bolt (Item 2).

Remove the belt shield (Item 3) [Figure 169].

Connect the negative (-) battery cable.

Remove the cargo box support device (See CARGO BOX SUPPORT DEVICE on Page 76.) and lower the cargo box.

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5600 Operation & Maintenance Manual

Figure 173

LUBRICATING THE UTILITY WORK MACHINE Lubrication Locations Lubricate as specified for the best performance of the machine (See SERVICE SCHEDULE on Page 69.)

3

Record the operating hours each time you lubricate the machine.

Always use a good quality lithium based multi-purpose grease. Apply lubricant until extra grease shows.

4

Stop the engine.

Lubricate the following:

P-66052

Figure 171 3. Base End Tilt Cylinder Pivot Pin (1) [Figure 173].

4. Lift Arm Pivot (2) [Figure 173].

Figure 174 6

1

P-73944

5

1. Rod End Lift Cylinder (1) [Figure 171] (between arm uprights).

P-73908

Figure 172 5. Rod End Tilt Cylinder (1) [Figure 174].

6. Upper Guide Link Pivot (2) [Figure 174].

2

P-74151

2. Base End Lift Cylinder (1) [Figure 172] (under machine).

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5600 Operation & Maintenance Manual

Figure 177

LUBRICATING THE UTILITY WORK MACHINE (CONT’D) Lubrication Locations (Cont’d) Figure 175

11

P-73909

7 9

11. Upper Ball Joints (All 4 Wheels) (4) [Figure 177].

8

Figure 178

P-66055

7. Lower Bucket Link Pivot (1) [Figure 175].

8. Lower Guide Link Pivot (1) [Figure 175].

9. Bob-Tach Pivot Pin (1) [Figure 175].

Figure 176 12

P-76020

12. Cargo Box Cylinder (Both Sides) (4) [Figure 178].

10 P-66054A

10. Bob-Tach Wedges (Both Sides) (2) [Figure 176].

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5600 Operation & Maintenance Manual

PIVOT PINS Inspection And Maintenance Figure 179

1

P-66056

Two pivot pins are held in position with a bolt and lock nut (Item 1) [Figure 179].

Check that the lock nuts are tightened to 43 - 47 N•m (32 - 35 ft-lb) torque.

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5600 Operation & Maintenance Manual

BOB-TACH (HAND LEVER)

WARNING

Inspection And Maintenance Figure 180

Bob-Tach wedges must extend through the holes in attachment. Lever(s) must be fully down and locked.

Failure to secure wedges can allow attachment to come off and cause injury or death.

1

W-2102-0497

Figure 182

P-66057A

Move the Bob-Tach levers (Item 1) [Figure 180] down to engage the wedges. The levers and wedges must move freely.

Figure 181 B-17460

1 Inspect the mounting frame on the attachment and BobTach, linkages and wedges for excessive wear or damage [Figure 182]. Replace any parts that are damaged, bent or missing. Look for cracked welds. Keep all fasteners tight. Contact your Bobcat dealer for repair or replacement parts.

2

Lubricate the wedges. (See SERVICE SCHEDULE on Page 69.) and (See LUBRICATING THE UTILITY WORK MACHINE on Page 112.)

Wedge must contact lower edge of hole in the attachment.

N-17022

B-15177

The wedges must extend through the holes in the attachment mounting frame (Item 2) [Figure 181].

The spring loaded wedge (Item 1) must contact the lower edge of the hole in the attachment (Item 2) [Figure 181].

If the wedge does not contact the lower edge of the hole [Figure 181], the attachment will be loose and can come off the Bob-Tach.

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5600 Operation & Maintenance Manual

BOB-TACH (POWER OPTION)

Figure 184

Inspection And Maintenance 1 Figure 183 2

1

Wedge must contact lower edge of hole in the attachment.

N-17022

B-15177

The wedges must extend through the holes in the attachment mounting frame (Item 2) [Figure 184].

UNLOCKED

The spring loaded wedge (Item 1) must contact the lower edge of the hole in the attachment (Item 2) [Figure 184].

UNLOCKED

2

If the wedge does not contact the lower edge of the hole [Figure 184], the attachment will be loose and can come off the Bob-Tach.

2 LOCKED

LOCKED

Figure 185

P-76587A

Press and hold the Bob-Tach “WEDGES UP” switch (Item 1) until the levers (Item 2) [Figure 183] are in the unlocked position (wedges fully raised).

Press and hold the Bob-Tach “WEDGES DOWN” switch (Item 1) until the levers (Item 2) [Figure 183] are in the locked position (wedges fully raised).

B-17460

The levers and wedges must move freely.

Inspect the mounting frame on the attachment and BobTach, linkages and wedges for excessive wear or damage [Figure 185]. Replace any parts that are damaged, bent or missing. Look for cracked welds. Keep all fasteners tight. Contact your Bobcat dealer for repair or replacement parts.

WARNING Bob-Tach wedges must extend through the holes in attachment. Lever(s) must be fully down and locked.

Failure to secure wedges can allow attachment to come off and cause injury or death.

Lubricate the wedges. (See SERVICE SCHEDULE on Page 69.) and (See LUBRICATING THE UTILITY WORK MACHINE on Page 112.)

W-2102-0497

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5600 Operation & Maintenance Manual

Return To Service

UTILITY WORK MACHINE STORAGE AND RETURN TO SERVICE

After the machine has been in storage, it is necessary to follow a list of items to return the machine to service.

Storage Sometimes it may be necessary to store your machine for an extend period of time. Below is a list of items to perform before storage.

•

Check the engine and hydraulic oil levels; check coolant level.

•

Install a fully charged battery.

•

Thoroughly clean the machine including the engine compartment.

•

Remove grease from exposed cylinder rods.

•

Check all belt tensions.

•

Lubricate the machine as shown in the Operation & Maintenance Manual.

•

Lubricate the machine as shown in the Operation & Maintenance Manual.

•

Replace worn or damaged parts.

•

•

Park the machine in a dry protected shelter.

Check tire inflation and remove blocks from under frame.

•

Lower the lift arm all the way and put the bucket or attachment flat on the ground.

•

Remove cover from exhaust pipe opening.

•

•

Put grease on any exposed cylinder rods.

•

Put fuel stabilizer in the fuel tank and run the engine a few minutes to circulate the stabilizer to the pump and fuel injectors.

Start the engine and let run for a few minutes while observing the instrument panels and systems for correct operation.

•

Operate machine, check for correct function.

•

Stop the engine and check for leaks. Repair as needed.

•

Drain and flush the cooling system. Refill with premixed coolant.

•

Replace all fluids and filters (engine, hyd. / hydros.).

•

Replace air cleaner, heater and air conditioning filters.

•

Put blocks under the frame to remove weight from the tires.

•

Put all controls in neutral position.

•

Remove the battery. Be sure the electrolyte level is correct then charge the battery. Store it in a cool, dry place above freezing temperatures and charge it periodically during storage.

•

Cover the exhaust pipe opening.

•

Tag the machine to indicate that it is in storage condition.

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5600 Operation & Maintenance Manual

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5600 Operation & Maintenance Manual

SYSTEM SETUP & ANALYSIS DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Enter Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Two-Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 High Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 Horsepower Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Tire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Save Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Exit Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START) . . . . . . . . . . . . . . . . . . . . . .125 Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Changing The Owner And Operator Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

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5600 Operation & Maintenance Manual

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5600 Operation & Maintenance Manual

DIAGNOSTIC SERVICE CODES Viewing Service Codes Figure 186

2

1

B-19665H

Turn the key on (key switch) or press ENTER CODE (keyless). Press and hold the LIGHTS button (Item 1) for two seconds to view Diagnostic Service Codes in the display screen (Item 2) [Figure 186]. If more than one Diagnostic Service Code is present, the codes will scroll on the display.

NOTE: Corroded or loose grounds can cause multiple service codes and/or abnormal symptoms. The same symptoms could apply if the voltage is low, such as loose or corroded battery cables. If you observe these symptoms, check grounds and positive leads first.

The Diagnostic Service Codes will help your dealer identify and correct problems with your machine.

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5600 Operation & Maintenance Manual

DIAGNOSTIC SERVICE CODES (CONT'D) Service Codes List CODE

DESCRIPTION

CODE

DESCRIPTION

02-16 02-17 03-09 03-10 03-11 03-14 03-15 03-22 04-14 04-15 06-10 06-11 06-13 06-15 06-18 07-10

Hydraulic Charge Filter Not Connected Hydraulic Charge Filter Plugged Battery Voltage Low Battery Voltage High Battery Voltage Extremely High Battery Voltage Extremely Low Battery Voltage In Shutdown Battery Voltage Out Of Range Low Engine Oil Pressure Extremely Low Engine Oil Pressure In Shutdown Engine Speed High Engine Speed Extremely High Engine Speed No Signal Engine Speed In Shutdown Engine Speed Out Of Range Hydraulic Oil Temperature High

13-05 13-06 13-07 14-02 14-03 18-05 18-06 18-07 21-02 21-03 22-02 22-03 29-02 29-03 30-28 31-28

07-11 07-15 07-21

50-01 50-02 50-04 50-05 50-07 50-08 50-09 50-10

Brake Pedal Out Of Range Low FPR No Signal FPR Multi-Signal Front Speed Sensor Out Of Range High Front Speed Sensor Out Of Range Low

09-21

Hydraulic Oil Temperature Extremely High Hydraulic Oil Temperature In Shutdown Hydraulic Oil Temperature Out Of Range High Hydraulic Oil Temperature Out Of Range Low Engine Coolant Temperature High Engine Coolant Temperature Extremely High Engine Coolant Temperature In Shutdown Engine Coolant Temperature Out Of Range High Engine Coolant Temperature Out Of Range Low Fuel Level Out Of Range High

Fuel Shutoff Hold Solenoid Short To Battery Fuel Shutoff Hold Solenoid Short To Ground Fuel Shutoff Hold Solenoid Open Circuit Fuel Shutoff Pull Solenoid Error ON Fuel Shutoff Pull Solenoid Error OFF Spool Lock Short To Battery Spool Lock Short To Ground Spool Lock Open Glow Plug Error ON Glow Plug Error OFF Starter Error ON Starter Error OFF High Flow Solenoid Error ON High Flow Solenoid Error OFF Controller Memory Failure Interrupted Power (also occurs after software updates) Failure Travel Pedal Out Of Range High Travel Pedal Out Of Range Low Brake Pedal Out Of Range High

50-12

Rear Speed Sensor Out Of Range Low

09-22

Fuel Level Out Of Range Low

50-13

Front Speed Sensor Open Circuit

Front Auxiliary PWM Switch Out Of Range High Front Auxiliary PWM Switch Out Of Range Low Front Auxiliary PWM Switch Not in Neutral

50-14

Rear Speed Sensor Open Circuit

50-19

Swash Plate Sensor Out Of Range High

50-20

Swash Plate Sensor Out Of Range Low

07-22 08-10 08-11 08-15 08-21 08-22

12-21 12-22 12-23

122

50-11

Rear Speed Sensor Out Of Range High

5600 Operation & Maintenance Manual

DIAGNOSTIC SERVICE CODES (CONT'D) Service Codes List (Cont’d) CODE

DESCRIPTION

CODE

DESCRIPTION

50-24 50-25 50-26 50-27 50-28 50-29 50-30 50-31 50-32 50-33 50-34 50-35 50-36 50-39 50-40 50-41 50-42 50-43 50-44 50-45 50-46 50-47 50-48 50-49 50-50 50-51

Battery Voltage Out Of Range High Battery Voltage Out Of Range Low Recovery Mode 5V Supply 1 Out Of Range High 5V Supply 1 Out Of Range Low 5V Supply 2 Out Of Range High 5V Supply 2 Out Of Range Low FWD Drive Coil Max Current FWD Drive Coil Over Current FWD Drive Coil Under Current Pump Not Calibrated Servo Coil Max Current Servo Coil Over Current REV Drive Coil Max Current REV Drive Coil Over Current REV Drive Coil Under Current Throttle Sensor Not Calibrated Aux Base Coil Max Current Aux Base Coil Over Current Aux Rod Coil Max Current Aux Rod Coil Over Current Two Speed Output Short To Ground Two Speed Output Short To Battery Brake Coil Max Current Brake Coil Over Current Brake Coil Under Current

50-52 50-53 50-54 50-55 50-56 50-57 50-59 50-65 50-66 50-67 50-70 50-73 50-74 50-75 50-76 50-77 50-78 50-99 50-100 63-05 63-06 64-05 64-06 64-07 67-05 67-06

Brake Lights Short To Battery Brake Lights Short To Ground Swash Plate Not In Neutral Swash Plate Unresponsive CAN Communications Fault Drive Controller Not Calibrated Swash Plate Position Uncommanded Aux Base Coil Under Current Aux Rod Coil Under Current Servo Coil Under Current Fan Coil In Error Throttle Sensor Ch A Out Of Range High Throttle Sensor Ch A Out Of Range Low Throttle Sensor Ch B Out Of Range High Throttle Sensor Ch B Out Of Range Low Aux Diverter Error ON Aux Diverter Error OFF In Calibration Mode Software Update Console Sensor Short To Battery Console Sensor Short To Ground Switched Power Relay Short to Battery Switched Power Relay Short To Ground Switched Power Relay Open Circuit Power Bob-Tach Short To Battery Power Bob-Tach Short To Ground

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5600 Operation & Maintenance Manual

CONTROL PANEL SETUP

High Flow

Enter Setup

If high flow is installed, the display screen (Item 1) will show [H FLO] or [L FLO]. Press the WORK button (Item 2) [Figure 187] to toggle between high flow or normal flow.

Figure 187 1

2

3

Continue to horsepower management screen for additional changes by pressing the SPEED / HOURS / RPM button (Item 3) OR press and hold SPEED / HOURS / RPM button (Item 3) until [donE] appears on display screen (Item 1) [Figure 187] to save and exit setup.

Horsepower Management The display screen (Item 1) will show [HP 1] for enabled or [HP 0] for disabled. Press the WORK button (Item 2) [Figure 187] to toggle between enabled or disabled.

B-19665J

The key switch must be OFF and the engine stopped to enter setup mode.

Continue to tire size screen for additional changes by pressing the SPEED / HOURS / RPM button (Item 3) OR press and hold SPEED / HOURS / RPM button (Item 3) until [donE] appears on display screen (Item 1) [Figure 187] to save and exit setup.

Press and hold the SPEED/HOURS/RPM button (Item 3) [Figure 187] until the display screen lights up.

Press the SPEED/HOURS/RPM button (Item 3) until [RPM] appears on the display screen (Item 1) [Figure 187].

Tire Size

Press and hold the SPEED/HOURS/RPM button (Item 3) [Figure 187] for three seconds.

The display screen (Item 1) will show [27 in] for 27 inch tires or [29 in] for 29 inch tires. Press the WORK button (Item 2) [Figure 187] to toggle between 27 inch tires or 29 inch tires.

NOTE: Each press of the SPEED/HOURS/RPM button while in the setup mode will toggle between the following screens: two-speed, high flow, horsepower management, and tire size.

Press the SPEED / HOURS / RPM button (Item 3) to return the display to the two-speed screen OR press and hold SPEED / HOURS / RPM button (Item 3) until [donE] appears on display screen (Item 1) [Figure 187] to save and exit setup.

Key switch machines will go directly to the two-speed screen. (See Two-Speed on Page 124.)

Save Setup Keyless start machines will show [CodE] on the display screen (Item 1) [Figure 187].

To save selections, press and hold SPEED / HOURS / RPM button (Item 3) until [donE] appears on display screen (Item 1) [Figure 187] to save and exit setup.

Enter the owner password. The two-speed screen will appear after entering the last digit of the password.

Exit Setup Two-Speed To exit without saving, turn the key switch to run or wait 30 seconds without pressing any buttons.

If two-speed is installed, the display screen (Item 1) will show [2-SPd] or [1-SPd]. Press the WORK button (Item 2) [Figure 187] to toggle between two-speed or single speed.

Continue to high flow screen for additional changes by pressing the SPEED / HOURS / RPM button (Item 3) OR press and hold SPEED / HOURS / RPM button (Item 3) until [donE] appears on display screen (Item 1) [Figure 187] to save and exit setup.

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Changing The Owner And Operator Passwords

PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START)

Press the ENTER CODE button (Item 2). The display screen (Item 3) will illuminate and there will be two short beeps. [CodE] will appear in the display screen (Item 3) [Figure 188].

Password Description Figure 188 2

3

Perform password entry using the owner password, but do not start the engine.

Press and hold the ENTER CODE button (Item 2) [Figure 188] for three seconds. [CodE 0] will appear on the display screen.

1

Press the ENTER CODE button (Item 2) until the desired operator code [CodE 1], [CodE 2], or [CodE 3] appears.

[CodE 0] is the owner password, the other codes are operator passwords. You now have 40 seconds to use the keypad (Item 1) [Figure 188] to enter each digit of a new four digit password.

B-19665H

All new machines with keyless start arrive at Bobcat dealerships with the keypad in locked mode. This means that a password must be used to start the engine.

Enter the new four digit password. After the fourth digit is entered, there will be two short beeps and [rPEAt] will appear.

For security purposes, your dealer may change the password and also set it in the locked mode. Your dealer will provide you with the password.

Re-enter the new four digit password to verify. If the new passwords match, there will be two short beeps, [CodE] will appear for 1 second and then the display screen will return to the last displayed screen.

Master Password A permanent, randomly selected password set at the factory which cannot be changed. This password is used for service by the Bobcat dealer if the owner password is not known; or to change the owner password.

Owner Password There is only one owner password [CodE 0]. It must be used to change the owner or operator passwords.

See below for changing the operator password.

Operator Password There can be up to three operator passwords [CodE 1], [CodE 2], and [CodE 3].

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To start a locked system, press the ENTER CODE button (Item 3), enter the password using the keypad (Item 5), and press the START button (Item 4) [Figure 189]. (See Keyless on Page 47.)

PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START) (CONT’D) Password Lockout Feature Figure 189 3

2

1 5

4 B-19665H

The password lockout feature allows the operator to unlock the system so that it is possible to start the engine without entering a password.

Press the ENTER CODE button (Item 3). The display screen (Item 2) will illuminate and there will be two short beeps. [CodE] will appear in the display screen (Item 2) [Figure 189].

Perform password entry using the owner password. (The engine can be started or stopped.)

Press the lock / unlock button (Item 1). The display screen (Item 2) [Figure 189] will continuously alternate from [UnLoc] to [CodE] at 1 second periods.

Enter owner password again.

[UnLoc] will appear in the display screen (Item 2) [Figure 189] and there will be two short beeps.

To start an unlocked system, press the ENTER CODE button (Item 3) and press the START button (Item 4) [Figure 189].

When you stop the engine with the system unlocked, you will hear two short beeps every 3 seconds for 15 seconds.

Pressing STOP a second time will cancel the unlock reminder and turn off the controller.

To lock the system again, press the lock / unlock button (Item 1). The display screen (Item 2) [Figure 189] will continuously alternate from [Loc] to [CodE] at 1 second periods. Enter the owner password during the next 15 seconds to complete the action.

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MACHINE SIGN TRANSLATIONS MACHINE SIGN TRANSLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Service Schedule (7134482) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Machine Load Capacities (6814303) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 Cargo Box Support (7128961) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Operation Instruction (6814309) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Danger (7114128) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Wheel Alignment (6814813) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Warning (7114129) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134 Warning (6814300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Lift Arm Support (7128957) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Warning (6814301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Coolant (6708929) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 Warning (6814310) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Warning (6814302) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Danger (6814307) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Bob-Tach (6561383) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Auxiliary Coupler (6731757) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Joystick (6814312) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138 Warning (6737189) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Warning (6804233) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Warning (7146237) (Remote Hydraulics Option Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

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MACHINE SIGN TRANSLATIONS Service Schedule (7134482)

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MACHINE SIGN TRANSLATIONS (CONT’D) Service Schedule (7134482) (Cont’d)

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MACHINE SIGN TRANSLATIONS (CONT’D) Service Schedule (7134482) (Cont’d)

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MACHINE SIGN TRANSLATIONS (CONT’D) Machine Load Capacities (6814303)

Cargo Box Support (7128961)

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MACHINE SIGN TRANSLATIONS (CONT’D) Operation Instruction (6814309)

Danger (7114128)

Wheel Alignment (6814813)

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MACHINE SIGN TRANSLATIONS (CONT’D) Warning (7114129)

Warning (6814300)

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MACHINE SIGN TRANSLATIONS (CONT’D) Lift Arm Support (7128957)

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MACHINE SIGN TRANSLATIONS (CONT’D) Warning (6814301)

Warning (6814310)

Coolant (6708929)

Warning (6814302)

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MACHINE SIGN TRANSLATIONS (CONT’D) Danger (6814307)

Auxiliary Coupler (6731757)

Bob-Tach (6561383)

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MACHINE SIGN TRANSLATIONS (CONT’D) Joystick (6814312)

Warning (6737189)

Warning (6804233)

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MACHINE SIGN TRANSLATIONS (CONT’D) Warning (7146237) (Remote Hydraulics Option Only)

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SPECIFICATIONS (5600) UTILITY WORK MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Dimensions (With 27 Inch Tires) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Dimensions (With 29 Inch Tires) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

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(5600) UTILITY WORK MACHINE SPECIFICATIONS Dimensions (With 27 Inch Tires) • •

Dimensions are given for machine equipped with optional tires and standard bucket and may vary with other buckets.

All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by parentheses.

Where applicable, specification conform to SAE, ANSI or ISO standards and are subject to change without notice.

65°

40° 2748 mm (108.2 in)

2057 mm (81 in)

518 mm (20.4 in)

45°

2116 mm (83.3 in)

1013 mm (39.9 in) 1509 mm (59.4 in)

30°

235 mm (9.25 in)

465 mm (18.3 in) 3668 mm (144.4 in)

2235 mm (88 in) 4354 mm (171.4 in) 4613 mm (181.6 in)

30° 1524 mm (60 in)

1575 mm (62 in)

84.3 in.

(2141 mm) 1257 mm (49.5 in)

Ground Clearance Trans Axles . . . . . . . . . . . 203 mm (8 in) Box Inside Dimensions (LxWxH) . . . . . . . 1422 x 1300 x 254 mm (LxWxH) . . . . . . . . . . (56 x 51.2 x 10 in)

45° 2083 mm (82 in)

Turning Diameter All Wheel Steer . . . . . . 5334 mm (210 in) Front Wheel Steer . . . . 8407 mm (331 in)

932 mm (36.7 in) 645 mm (25.4 in)

36°

Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the loader parts.

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(5600) UTILITY WORK MACHINE SPECIFICATIONS (CONT’D) Dimensions (With 29 Inch Tires) • •

Dimensions are given for machine equipped with optional tires and standard bucket and may vary with other buckets.

All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by parentheses.

Where applicable, specification conform to SAE, ANSI or ISO standards and are subject to change without notice.

65°

40° 2774 mm (109.2 in)

2083 mm (82 in)

493 mm (19.4 in)

45°

2141 mm (84.3 in)

988 mm (38.9 in) 1534 mm (60.4 in)

30°

260 mm (10.25 in)

490 mm (19.3 in) 3668 mm (144.4 in)

2235 mm (88 in)

4354 mm (171.4 in) 4613 mm (181.6 in)

30°

1575 mm (62 in)

84.3 in.

1524 mm (2141 mm) (60 in) 1257 mm (49.5 in)

Ground Clearance Trans Axles . . . . . . . . . . . 229 mm (9 in) 45°

Box Inside Dimensions (LxWxH) . . . . . . . 1422 x 1300 x 254 mm (LxWxH) . . . . . . . . . . . . (56 x 51.2 x 10 in)

2108 mm (83 in)

Turning Diameter All Wheel Steer . . . . . . 5334 mm (210 in) Front Wheel Steer . . . . 8407 mm (331 in)

958 mm (37.7 in) 671 mm (26.4 in)

36°

Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the loader parts.

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(5600) UTILITY WORK MACHINE SPECIFICATIONS (CONT’D) Performance Load Capacity - Loader Rated Operating Capacity - Cargo Box Load (Maximum) - Machine Rated Capacity - Trailer Hitch Tongue Weight (Max) - Total Rated Capacity

680 kg (1500 lb) 907 kg (2000 lb) 997 kg (2200 lb)* 227 kg (500 lb) 1905 kg (4200 lb)** * Combined weight of load on lift arm, cargo box load, operator and passenger. ** Combined weight of the load on lift arm. cargo box load, operator, passenger and tow weight (If equipped with receiver hitch)

Tipping Load (SAE Rating)

1361 kg (3000 lb)

Operating Weight

2490 kg (5490 lb)

Travel Speed - Work Mode (Forward & Reverse) - Low Range (Forward & Reverse) - High Range (Forward Only)

With 29 Inch Tires 0 - 14,5 km/h (0 - 9 mph) 0 - 14,5 km/h (0 - 9 mph) 0 - 29 km/h (0 - 18 mph)

With 27 Inch Tires 0 - 13,7 km/h (0 - 8.5 mph) 0 - 13,7 km/h (0 - 8.5 mph) 0 - 27,4 km/h (0 - 17 mph)

Controls Vehicle Steering

Steering Wheel

Loader Hydraulics - Lift and Tilt - Front Auxiliary Engine

Joystick Switch on Joystick Hand lever engine speed control; key-type starter switch (or optional keyless start).

Starting Aid

Glow Plugs automatically activated as needed.

Service Brake

Hydrostatic transmission system controlled by foot pedal.

Parking Brake (Std.)

Spring Applied Pressure Release (SAPR) activated by the park position of the travel direction control lever or automatically when engine is stopped.

Engine Make / Model

Kubota V2003-M-DI-T

Fuel / Cooling

Diesel / Liquid

Horsepower (SAE Net)

41,8 kW (56 hp) @ 2800 rpm

Low Idle rpm

1025 - 1225 rpm

High Idle rpm

2875 - 2975 rpm

Number of Cylinders

4

Displacement

2,0 L (122.0 in3)

Bore / Stroke

83,0 mm / 92,4 mm (3.268 in / 3.638 in)

Lubrication

Gear Pump Pressure System with Filter

Crankcase Ventilation Air Cleaner

Open Breathing Replaceable dry paper cartridge with separate safety element

Ignition

Compression

Engine Coolant

Propylene Glycol / Water Mixture

Starting Aid

Glow Plugs

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(5600) UTILITY WORK MACHINE SPECIFICATIONS (CONT’D) Hydraulic System Pump Type

Engine driven, gear type

Pump Capacity - Auxiliary - With High Flow Option - Work - Steering

71,4 L/min (18.9 U.S. gpm) 105,7 L/min (27.9 U.S. gpm) 34,4 L/min (9.1 U.S. gpm) 22,9 L/min (6 U.S. gpm)

System Relief at Quick Couplers

20684,2 kPa (207 bar) (3000 psi)

Filter (Hydraulic)

Full flow replaceable, 10-micron synthetic media element with 317,2 kPa (3,2 bar) (46 psi) internal cold-weather bypass valve

Hydraulic Cylinders

Double-acting; tilt cylinders have cushioning feature on dump and rollback

Bore Diameter - Lift Cylinder - Tilt Cylinder - Cargo Box Cylinder (2)

63,5 mm (2.5 in) 63,5 mm (2.5 in) 50,8 mm (2.0 in)

Rod Diameter - Lift Cylinder - Tilt Cylinder - Cargo Box Cylinder (2)

38,1 mm (1.5 in) 38,1mm (1.5 in) 25,4 mm (1.0 in)

Stroke 581,4 mm (22.89 in) 415,0 mm (16.34 in) 159,5 mm (6.28 in)

- Lift Cylinder - Tilt Cylinder - Cargo Box Cylinder (2) Control Valve

Manually operated, open center, series type with float detent on lift

Fluid Type (Hydraulic/Hydrostatic)

FLUID, Hydraulic/Hydrostatic 6903117 - (2.5 U.S. gal) 6903118 - (5 U.S. gal) 6903119 - (55 U.S. gal)

Electrical Alternator

Belt driven, 90 amps, open

Battery

12 volts, 600 cold cranking amps @ -18°C (0°F), 115 minute reserve capacity

Starter

12 volts, gear reduction type, 2,99 kW (4.02 hp)

Instrumentation

Gauges: Engine Coolant Temperature, Fuel Gauge Screen Display: Diagnostic Codes, Hourmeter, Job Clock (resetable), Speedometer, Tachometer.

Warning lights (Red): Fuel Level, General Warning, High Hyd. Temperature, Lift Arm and Tilt Transport Lock, Low Engine Oil Pressure, Low Battery Voltage, Parking Brake.

Indicator Lights (Amber): Auxiliary Hyd. Enabled, Cruise Control Engaged reminder, Glow Plugs Activated, Return to Park reminder, Two-Speed engaged reminder, Work Mode indicator.

Buttons: Auxiliary Hydraulics, Cruise Control, Decelerate, Accelerate, Display (speed, hours, rpm), Lift Arm and Tilt Transport Lock, Lights, Parking Brake, Work Mode.

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(5600) UTILITY WORK MACHINE SPECIFICATIONS (CONT’D) Drive System Main Drive

Fully hydrostatic, 4-wheel drive

Transmission

Infinitely variable tandem hydrostatic piston pumps, driving two fully reversing hydrostatic motors

Final Drive

Front and rear trans axles

Wheel Bolts

Eight 12 mm wheel bolts fixed to axle hubs

Trans Axle

Provided both front and rear

Trans Axle Lubricant (Front And Rear)

Trans Axle Housing Lubricant (P/N 6687120)

Capacities Fuel Tank

75,7 L (20 U.S.gal)

Engine Lubrication And Filter

7,1 L (7.5 qt)

Engine Cooling System

11,4 L (12 qt)

Hydraulic/Hydrostatic Reservoir

14 L (3.7 U.S. gal) @ Sight Glass

Hydraulic/Hydrostatic System

39,7 L (42 qt)

Trans Axle (Front And Rear)

5,2 L (5.54 qt) each

Tires Sizes - Trac - Turf Recommended Pressure

27 x 8.5 - 15, 27 x 10.5 - 15, 29 x 10.5 - 15 27 x 10.5 - 15, 29 x 12.5 - 15 Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT mix brands of tires used on the same machine.

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WARRANTY WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

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WARRANTY

WARRANTY Bobcat Utility Work Machines Bobcat Company warrants to its authorized dealers and authorized dealers of Bobcat Equipment Ltd., who in turn warrant to the owner, that each new Bobcat Utility Work Machine will be free from proven defects in material and workmanship with respect to (i) all components of the product except as otherwise specified herein for twelve (12) months, (ii) the drive belt from the hydrostatic pump to the engine, for thirty six (36) months, provided that after the initial twelve month warranty period, such warranty shall be limited to parts only and does not include labor, (iii) Bobcat brand tires, for twelve (12) months on a prorated basis based on the remaining depth of the tire at the time any defect is discovered, and (iv) Bobcat brand batteries, for an additional twelve (12) months after the initial twelve month warranty period, provided that Bobcat Company shall only reimburse a fixed portion of the cost of replacing the battery during such additional twelve months. The foregoing time periods shall all commence after delivery by the authorized Bobcat dealer to the original buyer.

During the warranty period, the authorized Bobcat dealer shall repair or replace, at Bobcat Company's option, without charge for parts and labor, any part of the Bobcat product except as otherwise specified herein which fails because of defects in material or workmanship. The owner shall provide the authorized Bobcat dealer with prompt written notice of the defect and allow reasonable time for repair or replacement.

Bobcat Company may, at its option, require failed parts to be returned to the factory. Travel time of mechanics and transportation of the Bobcat product to the authorized Bobcat dealer for warranty work are the responsibility of the owner. The remedies provided in this warranty are exclusive.

This warranty does not apply to diesel engine fuel injection pumps and injectors or tires (except Bobcat brand tires). The owner shall rely solely on the warranty, if any, of the respective manufacturers thereof. This warranty does not cover replacement of scheduled service items such as oil, filters, tune-up parts, and other high-wear items. This warranty does not cover damages resulting from abuse, accidents, alterations, use of the Bobcat product with any accessory or attachment not approved by Bobcat Company, air flow obstructions, or failure to maintain or use the Bobcat product according to the instructions applicable to it.

THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES AND CONDITIONS, EXCEPT THE WARRANTY OF TITLE. BOBCAT COMPANY DISCLAIMS ALL OTHER WARRANTIES AND CONDITIONS, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OR CONDITIONS OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL BOBCAT COMPANY OR THE AUTHORIZED BOBCAT DEALER BE LIABLE FOR ANY SPECIAL, INCIDENTAL, INDIRECT OR CONSEQUENTIAL DAMAGES WHATSOEVER, INCLUDING, BUT NOT LIMITED TO, LOSS OR INTERRUPTION OF BUSINESS, LOST PROFITS, OR LOSS OF MACHINE USE, WHETHER BASED ON CONTRACT, WARRANTY, TORT, NEGLIGENCE, STRICT LIABILITY, STATUTE OR OTHERWISE, EVEN IF BOBCAT COMPANY OR THE AUTHORIZED BOBCAT DEALER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. THE TOTAL LIABILITY OF BOBCAT COMPANY AND THE AUTHORIZED BOBCAT DEALERS WITH RESPECT TO THE PRODUCT AND SERVICES FURNISHED HEREUNDER SHALL NOT EXCEED THE PURCHASE PRICE OF THE PRODUCT UPON WHICH SUCH LIABILITY IS BASED.

6902334 (2-09)

Printed in U.S.A.

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ALPHABETICAL INDEX (5600) UTILITY WORK MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 143 AIR CLEANER SERVICE . . . . . . . . . . . . . . . 80 AIR CONDITIONING BELT . . . . . . . . . . . . 106 ALTERNATOR BELT . . . . . . . . . . . . . . . . . 106 ATTACHMENT CONTROL DEVICE (ACD) (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . 42 ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . 51 BACK-UP ALARM SYSTEM (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 BACK-UP ALARM SYSTEM (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 BOBCAT COMPANY IS IS0 9001 CERTIFIED .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .7 BOB-TACH (HAND LEVER) . . . . . . . . . . . . 115 BOB-TACH (POWER OPTION) . . . . . . . . . 116 BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . 33 CAB FILTERS . . . . . . . . . . . . . . . . . . . . . . . 78 CARGO BOX SUPPORT DEVICE . . . . . . . . 76 CONTROL PANEL SETUP . . . . . . . . . . . . 124 DAILY INSPECTION . . . . . . . . . . . . . . . . . . 43 DELIVERY REPORT . . . . . . . . . . . . . . . . . . . 8 DIAGNOSTIC SERVICE CODES . . . . . . . 121 DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . 108 DRIVE PEDAL . . . . . . . . . . . . . . . . . . . . . . . 33 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . 90 ENGINE COOLING SYSTEM . . . . . . . . . . . 88 ENGINE LUBRICATION SYSTEM . . . . . . . . 86 ENGINE SPEED CONTROL . . . . . . . . . . . . 29 FEATURES, ACCESSORIES AND ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . 10 FIRE PREVENTION . . . . . . . . . . . . . . . . . . . 15 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 83 HEATING AND AIR CONDITIONING . . . . . 79 HYDRAULIC / HYDROSTATIC SYSTEM . . 95 HYDRAULIC CONTROLS . . . . . . . . . . . . . . 36 LIFT ARM BYPASS . . . . . . . . . . . . . . . . . . . 35 LIFT ARM BYPASS . . . . . . . . . . . . . . . . . . . 71 LIFT ARM SUPPORT DEVICE . . . . . . . . . . 75 LUBRICATING THE UTILITY WORK MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . 112 MACHINE LOAD CAPACITIES . . . . . . . . . . 50 MACHINE SIGN TRANSLATIONS . . . . . . . 129

MACHINE SIGNS (DECALS) . . . . . . . . . . . . 17 MAINTENANCE SAFETY . . . . . . . . . . . . . . 67 MONITORING THE CONTROL PANEL . . . . 48 NEUTRAL START SYSTEM . . . . . . . . . . . . . 74 OPERATING PROCEDURE . . . . . . . . . . . . . 57 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . 77 OPERATOR CONTROLS AND INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 OPERATOR SAFETY WARNINGS . . . . . . . . 1 OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . 81 PARKING BRAKE SYSTEM . . . . . . . . . . . . . 77 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . 30 PASSENGER SEAT . . . . . . . . . . . . . . . . . . . 82 PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START) . . . . . . . . . . . . . . . . . . . 125 PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . 114 PRE-STARTING PROCEDURE . . . . . . . . . . 45 PUBLICATIONS AND TRAINING RESOURCES . . . . . . . . . . . . . . . . . . . . . . . . 19 REGULAR MAINTENANCE ITEMS . . . . . . . . 7 REMOTE HYDRAULICS (OPTION) . . . . . . . 39 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . 13 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 72 SERIAL NUMBER LOCATIONS . . . . . . . . . . . 8 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . 69 SPARK ARRESTOR MUFFLER . . . . . . . . . 101 STARTING THE ENGINE . . . . . . . . . . . . . . . 46 STEERING MODE SELECTION . . . . . . . . . 32 STOPPING THE ENGINE AND LEAVING THE UTILITY WORK MACHINE . . . . . . . . . . . . . 49 STOPPING THE UTILITY WORK MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 SUPPORTING THE MACHINE ON JACKSTANDS . . . . . . . . . . . . . . . . . . . . . . 102 TIRE MAINTENANCE . . . . . . . . . . . . . . . . 103 TOOLCAT INTERLOCK CONTROL SYSTEM (TICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 TOOLCAT INTERLOCK CONTROL SYSTEM (TICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 TOWING THE UTILITY WORK MACHINE . . 60 TRANS AXLE (FRONT AND REAR) . . . . . 104 TRANSPORTING THE UTILITY WORK MACHINE ON A TRAILER . . . . . . . . . . . . . . 61 TRAVEL DIRECTION CONTROL LEVER . . 33 153

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UTILITY WORK MACHINE IDENTIFICATION 9 UTILITY WORK MACHINE STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . 117 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . 151 WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . 34

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