A Service Manual (sometimes referred to as a Repair, Technical, Workshop
or Shop Manual) is often
large and broken down in to sections for different parts of your equipment.
Service
manuals cover absolutely every aspect of your machine unless mentioned
otherwise. Sometimes, the
engine is covered in a separate service manual that is written specifically for
the
engine. Most of the time though, it’s included in the main service manual. A
service manual will
arm you with the same exact information that your local service center has and
includes
electrical and hydraulic diagrams and which are usually color and or large
foldout pages.
Most OEM service manuals will also include troubleshooting flow charts, error
codes and
exploded views of components which are a great help for disassembly and
re-assembly.

An Operator’s Manual typically describes basic equipment operation and
maintenance. This
is the manual distributed with your equipment at the time of purchase from the
dealer.

• MAINTENANCE SAFETY
• CONTENTS
• FOREWORD
• FOREWORD
• SAFETY INSTRUCTIONS
• FIRE PREVENTION
• Maintenance
• Operation
• Electrical
• Hydraulic System
• Fueling
• Starting
• Spark Arrestor Exhaust System
• Welding And Grinding
• Fire Extinguishers
• SERIAL NUMBER LOCATIONS
• Utility Work Machine Serial Number
• Engine Serial Number
• DELIVERY REPORT
• UTILITY WORK MACHINE IDENTIFICATION
• SAFETY & MAINTENANCE
• LIFTING AND BLOCKING THE UTILITY WORK MACHINE
• Procedure For Jackstand Placement On The Control Arms
• Procedure For Jackstand Placement On The Frame
• LIFT ARM SUPPORT DEVICE
• Installing
• Removing
• CARGO BOX SUPPORT DEVICE
• Installing
• Removing
• Raising The Cargo Box When Engine Is Not Running
• OPERATOR CAB
• Description
• TRANSPORTING THE UTILITY WORK MACHINE ON A TRAILER
• Loading And Unloading
• Fastening
• TOWING THE UTILITY WORK MACHINE
• Procedure
• REMOTE START TOOL KIT – MEL1563
• Remote Start Tool – MEL1563
• Service Tool Harness Control – MEL1565
• Service Tool Harness Communicator – MEL1566
• Remote Start Procedure
• REMOTE START TOOL (SERVICE TOOL) KIT – 6689779
• Description
• Remote Start Tool (Service Tool) – 6689778
• Service Tool Harness – 6689747
• Computer Service Tool Harness – 6689746
• Remote Start Procedure
• SERVICE SCHEDULE
• Chart
• AIR CLEANER SERVICE
• Replacing Filter Elements
• ENGINE COOLING SYSTEM
• Checking Level
• Cleaning
• Removing And Replacing Coolant
• FUEL SYSTEM
• Fuel Specifications
• Biodiesel Blend Fuel
• Filling The Fuel Tank
• Fuel Filter
• Removing Air From The Fuel System
• Filling A Portable Fuel Container
• ENGINE LUBRICATION SYSTEM
• Checking And Adding Engine Oil
• Engine Oil Chart
• Removing And Replacing Oil And Filter
• HYDRAULIC / HYDROSTATIC SYSTEM
• Checking Fluid
• Hydraulic / Hydrostatic Fluid Chart
• Adding Fluid
• Alternate Fill Procedure
• Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters
• Removing And Replacing Hydraulic Fluid
• Breather Cap
• TRANS AXLE (FRONT AND REAR)
• Checking And Adding Lubricant
• Removing And Replacing Lubricant
• BOB-TACH (HAND LEVER)
• Inspection And Maintenance
• BOB-TACH (POWER)
• Inspection And Maintenance
• LUBRICATING THE UTILITY WORK MACHINE
• Lubrication Locations
• TIRE MAINTENANCE
• Wheel Nuts
• Rotating
• Mounting
• SPARK ARRESTER MUFFLER
• Cleaning Procedure
• PIVOT PINS
• Inspection And Maintenance
• UTILITY WORK MACHINE STORAGE AND RETURN TO SERVICE
• Storage
• Return To Service
• STOPPING THE ENGINE AND LEAVING THE UTILITY WORK MACHINE
• Procedure
• Emergency Exit (When Equipped With Cab)
• SEAT BELT
• Inspection And Maintenance
• HYDRAULIC SYSTEM
• HYDRAULIC / HYDROSTATIC SCHEMATICS
• HYDRAULIC SYSTEM INFORMATION
• Glossary Of Hydraulic / Hydrostatic Symbols
• Troubleshooting
• CYLINDER (LIFT)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (TILT)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (CARGO BOX)
• Testing
• Removal And Installation (Left Side)
• Removal And Installation (Right Side)
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (STEERING)
• Testing (Rear)
• Testing (Front)
• Removal And Installation (Rear)
• Removal And Installation (Front)
• Parts Identification
• Disassembly And Assembly
• CYLINDER (BOB-TACH)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• MAIN RELIEF VALVE
• Description
• Auxiliary Main Relief Valve Testing
• Auxiliary Main Relief Valve Removal And Installation
• Lift, Tilt And Cargo Box Main Relief Valve Testing
• Lift, Tilt And Cargo Box Main Relief Valve Removal And Installation
• PORT RELIEF VALVES
• Description
• Lift Port Relief Valve Testing (Base End)
• Lift Port Relief Valve Testing (Rod End)
• Tilt Port Relief Valve Testing
• HYDRAULIC CONTROL VALVE
• Description
• Removal And Installation
• Identification Chart
• Disassembly
• End Valve Section Disassembly And Assembly
• Box Valve Section Disassembly And Assembly
• Lift Valve Section Disassembly And Assembly
• Tilt Valve Section Disassembly And Assembly
• Mid Inlet / High flow Valve Section Disassembly And Assembly
• Auxiliary Valve Section Disassembly And Assembly
• Assembly
• STEERING SELECTOR VALVE
• Description
• Removal And Installation
• Disassembly And Assembly
• PILOT MANIFOLD
• Description
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• LIFT ARM (BYPASS)
• Description
• Testing
• HYDRAULIC PUMP
• Description
• Auxiliary Section Testing
• Lift, Tilt And Cargo Box Section Testing
• Steering And Cooling Fan Section Testing
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• POWER STEERING PUMP
• Description
• Removal And Installation
• Disassembly And Assembly
• HYDRAULIC / HYDROSTATIC FILTER
• Description
• Housing Removal And Installation
• Case Drain Housing Removal And Installation
• CONTROL JOYSTICK
• Description
• Handle Removal And Installation
• HYDRAULIC FLUID RESERVOIR
• Description
• Removal And Installation
• Hydraulic Fluid Screen
• OIL COOLER
• Description
• Removal And Installation
• AUXILIARY HYDRAULIC COUPLER BLOCK
• Description
• Removal And Installation
• Disassembly And Assembly
• REMOTE HYDRAULICS DIVERTER VALVE
• Description
• Removal And Installation
• Disassembly And Assembly
• POWER BOB-TACH BLOCK
• Description
• Removal And Installation
• Disassembly And Assembly
• DIVERTER VALVE (REAR AUXILIARY)
• Description
• Solenoid Testing
• Removal And Installation
• Disassembly And Assembly
• HYDROSTATIC SYSTEM
• HYDROSTATIC SYSTEM INFORMATION
• Troubleshooting
• Description
• HYDROSTATIC MOTOR
• Description
• Removal And Installation (Front)
• Removal And Installation (Rear)
• Parts Identification
• Disassembly
• Assembly
• CHARGE PRESSURE
• Description
• Testing
• HYDROSTATIC PUMP
• Description
• Removal And Installation
• Control Module Removal And Installation
• Replenishing / High Pressure Relief Valve Removal And Installation
• Charge Relief Valve Removal And Installation
• Parts Identification
• Disassembly And Assembly
• Mechanical Neutral Adjustment
• Hydraulic Controller Neutral Adjustment
• DRIVE BELT
• Description
• Shield Removal And Installation
• Adjusting
• Belt Replacement
• Tensioner Pulley Removal And Installation
• Tensioner Pulley Disassembly
• DRIVE SYSTEM
• BRAKE
• Description
• Disassembly And Assembly (Front Trans Axle)
• Disassembly And Assembly (Rear Trans Axle)
• TRANS AXLE
• Description
• Removal And Installation (Front)
• Removal And Installation (Rear)
• Brake Housing Disassembly And Assembly
• Primary Housing Disassembly And Assembly
• HUB
• Description
• Removal And Installation
• CV SHAFT
• Description
• Removal And Installation (Front)
• Removal And Installation (Rear)
• Inner Boot Removal And Installation
• Outer Boot Removal And Installation
• MAINFRAME
• OPERATOR CAB
• Removal And Installation
• OPERATOR SEAT
• Removal And Installation
• Seat Belt Removal And Installation
• Seat Pan Removal And Installation
• Slide Rail Removal And Installation
• Arm Rest Bracket Removal And Installation
• Arm Rest Removal And Installation
• PASSENGER SEAT
• Removal And Installation
• Seat Belt Removal And Installation
• Seat Pan Removal And Installation
• Arm Rest Removal And Installation
• BOB-TACH (HAND LEVER)
• Description
• Removal And Installation
• Lever And Wedge Disassembly And Assembly
• BOB-TACH (POWER)
• Description
• Removal And Installation
• Lever And Wedge Disassembly And Assembly
• LIFT ARM
• Removal And Installation
• CARGO BOX
• Removal And Installation
• STEERING COLUMN
• Removal And Installation
• FUEL TANK
• Removal And Installation
• Fuel Level Sender Removal And Installation
• DRIVE AND BRAKE PEDALS
• Description
• Removal And Installation
• Drive Pedal Disassembly And Assembly
• SHOCKS
• Removal And Installation
• CONTROL ARMS
• Removal And Installation (Lower Arm)
• Removal And Installation (Upper Arm)
• Inspection
• Ball Joint Removal And Installation
• SPINDLE
• Removal And Installation
• TIE ROD
• Description
• Removal And Installation
• Toe Adjustment Procedure
• FLOOR CONSOLE
• Access Cover Removal And Installation (Side)
• Access Cover Removal And Installation (Top)
• CENTER CONSOLE
• Removal And Installation
• FENDER
• Removal And Installation (Front)
• Removal And Installation (Left Rear)
• Removal And Installation (Right Rear)
• WINDOWS
• Front, Rear And Lower Door Removal And Installation
• Upper Door Removal And Installation
• ELECTRICAL SYSTEM & ANALYSIS
• ELECTRICAL SCHEMATICS
• ELECTRICAL SYSTEM INFORMATION
• Glossary Of Electrical Symbols
• Cab Harness Connectors
• Mainframe / Engine Harness Connectors
• Description
• Troubleshooting
• Fuse And Relay Location – Cab Panel
• Fuse And Relay Location – Frame Panel
• Solenoid Testing
• BATTERY
• Removal And Installation
• Servicing
• Using A Booster Battery (Jump Starting)
• ALTERNATOR BELT
• Belt Adjustment
• Belt Replacement
• Charging System Inspection
• Alternator Voltage Testing
• Low Voltage Testing
• High Voltage Testing
• Removal And Installation
• Parts Identification
• STARTER
• Testing
• Removal And Installation
• Parts Identification
• INSTRUMENT PANELS
• Display Controller Panel
• Switch Panel
• Floor Console
• Center Console
• LIGHTS
• Front Removal And Installation
• BOBCAT CONTROLLER (DISPLAY)
• Description
• Connector Identification
• Removal And Installation
• BOBCAT CONTROLLER (DRIVE)
• Description
• Connector Identification
• Removal And Installation
• DIAGNOSTIC SERVICE CODES
• Description
• Service Codes List
• CONTROL PANEL SETUP
• Enter Setup
• Two-Speed
• High Flow
• Horsepower Management
• Tire Size
• Save Setup
• Exit Setup
• PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START)
• Password Description
• Changing The Owner And Operator Passwords
• Password Lockout Feature
• TOOLCAT INTERLOCK CONTROL SYSTEM (TICS)
• Description
• Inspecting The TICS
• Maintaining The TICS
• Lift Arm Bypass Procedure
• Testing The Lift Arm Bypass Procedure
• ARM REST SENSOR
• Description
• Removal And Installation
• SPEED SENSORS
• Description
• Removal And Installation (Front Trans Axle)
• WHEEL POSITION SENSORS
• Description
• Removal And Installation (Front)
• Removal And Installation (Rear)
• Adjusting (In The Machine)
• Adjusting (Out Of The Machine)
• SERVICE PC (LAPTOP COMPUTER)
• Connecting Remote Start Tool
• Connecting Remote Start Tool (Service Tool)
• CALIBRATION
• Description
• Throttle Position Sensor Calibration
• Drive System Calibration
• Brake Pedal Calibration
• Travel Pedal Calibration
• TRAVEL DIRECTION CONTROL LEVER
• Description
• Removal And Installation
• FLYWHEEL RPM SENSOR
• Description
• Adjusting
• ELECTRIC COOLING FAN
• Description
• Removal And Installation
• MAINTENANCE CLOCK
• Description
• Setup
• Reset
• BACK-UP ALARM SYSTEM (IF EQUIPPED)
• Description
• Inspecting
• ENGINE SERVICE
• ENGINE INFORMATION
• Description
• Specifications
• Torque Values
• Troubleshooting
• Engine Removal And Installation
• Engine Mount Replacement
• Compression – Checking
• ENGINE SPEED CONTROL
• Removal And Installation (Position Sensing)
• Removal And Installation (Non Position Sensing)
• Speed Control Cable Removal And Installation
• MUFFLER
• Removal And Installation
• AIR CLEANER
• Housing Removal And Installation
• ENGINE COOLING SYSTEM
• Radiator Removal And Installation
• Hydraulic Fan Removal And Installation
• Hydraulic Fan Disassembly And Assembly
• Water Pump Removal And Installation
• Water Pump Disassembly And Assembly
• Thermostat Housing Removal And Installation
• Thermostat – Checking
• LUBRICATION SYSTEM
• Oil Pan Removal And Installation
• Oil Pump Removal And Installation
• Front Cover / Oil Pump Oil Seal Removal And Installation
• Relief Valve – Testing
• Oil Pump Inspection
• Oil Filter Cooler Removal And Installation
• Engine Oil Pressure – Testing
• FUEL SYSTEM
• Fuel Shutoff Solenoid – Checking
• Fuel Shutoff Solenoid Removal And Installation
• Fuel Injection Pump – Checking
• Fuel Injection Pump Assembly Removal And Installation
• Governor Housing Disassembly And Assembly
• Governor Disassembly And Assembly
• Fuel Camshaft Removal And Installation
• Fuel Injection Pump Removal And Installation
• Fuel Injection Pump – Timing
• Fuel Injector Removal And Installation
• Fuel Injector Nozzle Pressure – Checking
• Nozzle Spray Condition
• Valve Seat Tightness
• CYLINDER HEAD
• Glow Plugs – Testing
• Glow Plugs Removal And Installation
• Valve Clearance Adjustment
• Valve Timing – Checking
• Cylinder Head Removal And Installation
• Cylinder Head Disassembly And Assembly
• Cylinder Head – Servicing
• Cylinder Head Top Clearance
• Valve Guide – Checking
• Valve Guide Removal And Installation
• Reconditioning The Valve And Valve Seat
• Valve Spring
• Valve Tappets
• Rocker Arm And Shaft – Checking
• Bridge Arm And Bridge Arm Shaft – Checking
• Bridge Arm Shaft Removal And Installation
• Push Rod Alignment – Checking
• CRANKSHAFT AND PISTONS
• Piston And Connecting Rod Removal And Installation
• Piston And Connecting Rod – Servicing
• Cylinder Bore – Checking
• Connecting Rod Alignment
• Crankshaft Gear Removal And Installation
• Crankshaft And Bearings Removal And Installation
• Crankshaft And Bearings – Servicing
• CAMSHAFT AND TIMING GEARS
• Timing Gearcase Cover Removal
• Timing Gearcase Cover Installation
• Timing Gears Backlash – Checking
• Idler Gear And Camshaft Removal And Installation
• Camshaft – Servicing
• Idler Gear And Shaft – Servicing
• TURBOCHARGER
• Description
• Testing
• Removal And Installation
• FLYWHEEL AND HOUSING
• Flywheel Removal And Installation
• Ring Gear Removal And Installation
• Housing Removal And Installation
• HEATING, VENTILATION, AIR CONDITIONING
• AIR CONDITIONING SYSTEM FLOW
• Description
• Chart
• Components
• Safety Equipment
• REGULAR MAINTENANCE
• Filter Elements Removal And Installation
• Compressor Drive Belt Inspection
• Condenser
• Air Conditioning Service Chart
• A/C Evaporator Coil
• TROUBLESHOOTING
• Blower Motor Does Not Operate
• Blower Motor Operates Normally But Air Flow Is Insufficient
• Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
• The Compressor Does Not Operate At All Or Operates Improperly
• Gauge Pressure Related Troubleshooting
• Temperature / Pressure Chart
• Poor A/C Performance
• HVAC Repair And Leaks
• Electrical System
• Engine Coolant Bypassing The Heater Valve
• Heater Valve Not Opening Or Closing
• SYSTEM CHARGING AND RECLAMATION
• Refrigerant Identification
• Reclamation And Charging With Recovery / Charging Unit
• Charging With A Manifold Gauge Set
• COMPRESSOR
• Belt Adjustment
• Belt Replacement
• Removal And Installation
• Oil
• Oil Check
• Clutch Disassembly And Assembly
• CONDENSER
• Removal And Installation
• RECEIVER / DRIER
• Receiver / Drier Removal And Installation
• Pressure Relief Valve Removal And Installation
• Pressure Switch Removal And Installation
• EVAPORATOR / HEATER UNIT
• Removal And Installation
• THERMOSTAT
• Removal And Installation
• EXPANSION VALVE
• Removal And Installation
• EVAPORATOR COIL
• Removal And Installation
• HEATER COIL
• Removal And Installation With A/C
• BLOWER FAN
• Removal And Installation
• HEATER VALVE
• Removal And Installation
• Disassembly And Assembly
• SPECIFICATIONS
• (5600) UTILITY WORK MACHINE SPECIFICATIONS
• Dimensions (With 27 Inch Tires)
• Dimensions (With 29 Inch Tires)
• Performance
• Controls
• Engine
• Hydraulic System
• Electrical
• Drive System
• Capacities
• Tires
• TORQUE SPECIFICATIONS FOR BOLTS
• Torque For General SAE Bolts
• Torque For General Metric Bolts
• HYDRAULIC CONNECTION SPECIFICATIONS
• O-ring Face Seal Connection
• Straight Thread O-ring Fitting
• Tubelines And Hoses
• Flare Fitting
• O-ring Flare Fitting
• Port Seal Fitting
• Quick-Lok™ Fitting
• HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
• Specifications
• CONVERSIONS
• Decimal And Millimeter Equivalent Chart
• U.S. To Metric Conversion Chart
• ALPHABETICAL INDEX
• SERVICE MANUAL REVISION
• Revision No: 5600 – 1
• Revision No: 5600 – 2