PDF Operator & Maintenance Manual Bobcat Toolcat 5600 - 1 MB
This official manual provides owners and operators with critical information on the Bobcat Toolcat™ 5600 Utility Work Machine (S/N A94Y11001 & Above).
It covers everything from instrument panels and controls to proper operating procedures and lubrication schedules.
Proper use of this guide will enhance safety, performance, and the service life of your machine.
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--- Page 1 ---
Operation & Maintenance Manual
Toolcat™ 5600 Utility Work Machine
S/N A00211001 & Above
S/N A00311001 & Above
EQUIPPED WITH
TOOLCAT INTERLOCK
CONTROL SYSTEM (TICS)
6904207 (9-05) Revised (6-08) (1) Printed in U.S.A. © Bobcat Company 2008
--- Page 3 ---
UTILITY WORK MACHINE IDENTIFICATION
OPERATION & MAINTENANCE
MANUAL, OPERATOR’S
FRONT WINDOW HANDBOOK
OPERATOR
ARM REST
TILT
CYLINDER
LIFT ARM
FRONT AUXILIARY
QUICK COUPLERS
CARGO BOX
SUPPORT DEVICE
CAB DOOR
†BUCKET
ATTACHMENT
BOB-TACH™ TIRES
z CAB
(ROPS & FOPS)
OPERATOR &
PASSENGER SEATS
WITH SEAT BELTS GRAB HANDLE
REAR WINDOW
CARGO BOX
CAB DOOR
TAILGATE
RECEIVER
HITCH
LIFT ARM
SUPPORT DEVICE B-23358
B-23359
† BUCKET - Buckets and other attachments are available for the Toolcat™ utility work machine.
z ROPS, FOPS - Roll Over Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure per ISO 3449,
Level I.
VII 5600 Operation & Maintenance Manual
--- Page 4 ---
PUBLICATIONS AND TRAINING RESOURCES
The following publications are also available for your
Bobcat Toolcat Utility Work Machine. You can order them OPERATOR’S
from your Bobcat dealer. HANDBOOK
For the latest information on Bobcat products and the 6901890
Bobcat Company, visit our web site at www.bobcat.com;
see also www.bobcatstore.com
- gives basic operation instructions and safety warnings.
OPERATION &
MAINTENANCE
MANUAL
6904207
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
6904209 OPERATOR SAFETY
VIDEO
6902430
- Provides basic safety instructions.
- complete maintenance instructions for your Toolcat utility
work machine.
XVII 5600 Operation & Maintenance Manual
--- Page 5 ---
TOOLCAT INTERLOCK CONTROL SYSTEM (TICS) LIFT ARM BY-PASS CONTROL
TICS And Arm Rest Operation Operation
The Toolcat Interlock Control System (TICS) has a Figure OI-8
pivoting arm rest located on the left side of the operator’s
seat.
Figure OI-7
1 P-64854
B-19665 1
P-51199
The lift arm by-pass is used to lower the lift arm in the
P-39399
event that you cannot lower the lift arm using the joystick.
The by-pass knob is located under the steering wheel
The TICS requires the operator to be seated in the (Inset) [Figure OI-8].
operating position with the arm rest [Figure OI-7] fully
lowered before the lift, tilt and traction functions can be Turn the by-pass knob (Item 1) [Figure OI-8] clockwise
operated. The seat belt must be fastened anytime you 1/4 turn, then pull out and hold until the lift arm slowly
operate or are a passenger riding in the machine. lowers.
There are display lights (Item 1) [Figure OI-7] 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
OI-9 5600 Operation & Maintenance Manual
--- Page 6 ---
POWER TAKE-OFF (PTO) (If Equipped) Safety Rules For PTO
Description
The Toolcat 5600 utility work machine Power Take-Off
(PTO) system is a hydraulically driven rear PTO WARNING
designated as Type I per ASAE S203.15. The PTO
system operates only at 540 RPM [@ 2700 RPM engine AVOID INJURY OR DEATH
speed and 22 HP (16,4 kW)]. The attachment or Warnings and instructions in this manual and on the
implement driveline should not exceed Category 4 per machine are for your protection.
ASAE S331.5.
Failure to follow the warnings and instructions can
NOTE: Some attachments require a minimum engine cause serious injury or death.
power for proper operation. The PTO system W-2621-1104
can be used with attachments requiring up to
46 HP (34,3 kW) or 56 HP (41,8 kW) [on Model • Lower the lift arm, stop the engine and raise the arm
5600 equipped with a Turbo Charged engine]. rest before leaving the machine.
Type I attachments or implements exceeding
the approved towing capacity are not • Keep all shields in place. Replace damaged or
approved for use on the Toolcat 5600. Use of missing shields before operating
attachments or implements in applications
requiring more than 22 HP (16,4 kW) [PTO] • Follow warnings and instructions on machine signs
may result in less than optimum performance. (decals). Replace damaged or missing decals.
The PTO motor is operated using the Rear Auxiliary • Do not wear loose or bulky clothing around the PTO
Hydraulic system (See REAR AUXILIARY HYDRAULICS or other moving parts.
(If Equipped) on Page OI-17.)
• Keep bystanders away from PTO driven equipment,
The PTO is not approved for use in stationary and never allow children near machines.
applications where the operator is required to leave the
machine. The operator must be in the machine any time • Read and understand the manuals for the PTO driven
the PTO is being operated. equipment and be aware of safe operating
procedures and hazards that may not be readily
Mirrors are available and can be field installed. Mirrors apparent.
may be beneficial when using rear attached implements
and other attachments. • Always walk around equipment to avoid coming near
a turning PTO driveline. Stepping over, leaning
across or crawling under a turning PTO driveline can
lead to entanglement.
WARNING • Position the machine and attachment hitch correctly
to prevent driveline stress and separation.
AVOID INJURY OR DEATH
Before you leave the operator’s seat: • Use caution when turning. Turning too sharp can
• Lower the lift arm, put the attachment flat on the cause driveline damage.
ground.
• Put Travel Direction Control Lever in PARK.
• Stop the engine. • Periodically check on PTO operators to ensure a
• Raise operator arm rest. quick response in the event of an accident. Injuries
W-2443-1102 that would not ordinarily be fatal can be life
threatening if the victim is not found until hours later.
PTO accident victims require immediate medical
care.
OI-19 5600 Operation & Maintenance Manual
--- Page 7 ---
PRE-STARTING PROCEDURE Seat And Steering Wheel Adjustment
Entering The Utility Work Machine Figure OI-51
Figure OI-50
1
1
2
P-37861
Release the lever (Item 1) [Figure OI-51] to adjust the
seat distance from the steering wheel.
Turn the lever (Item 2) [Figure OI-51] to adjust the seat
cushion for weight of the operator.
Figure OI-52
P-66089
Enter the cab [Figure OI-50].
Read the Operation & Maintenance Manual and the 1
Operator’s Handbook (Item 1) [Figure OI-50] before
operating the machine.
P-64854
Release the steering column lock (Item 1) [Figure OI-52]
WARNING and move steering wheel up or down for comfortable
operation. Push lock up to secure.
Operator must have instructions before operating
the machine. Untrained operators can cause injury or
death.
W-2001-0502
OI-29 5600 Operation & Maintenance Manual
--- Page 8 ---
OPERATING PROCEDURE Operating With An Empty Bucket & Loaded Cargo
Box
Inspect The Work Area
Figure OI-71
Before beginning operation, inspect the work area for
unsafe conditions. LOADED CARGO BOX & EMPTY BUCKET
Look for sharp drop-offs or rough terrain. Have
underground utility lines (gas, water, sewer, irrigation,
etc.) located and marked.
Remove objects or other construction material that could
damage the loader or cause personal injury.
GOING UP SLOPE GOING DOWN SLOPE
Operating With A Full Bucket & Empty Cargo Box B-19659 B-19660
When operating on a public road or highway, always
follow local regulation. For example: Slow Moving Vehicle With empty bucket and a loaded cargo box, go down or
(SMV) Sign or directional signals may be required. up the slope with the heavy end toward the top of the
slope [Figure OI-71].
Always warm up the engine and hydrostatic system
before operating the loader.
WARNING
IMPORTANT AVOID INJURY OR DEATH
• Keep the lift arm as low as possible.
Machines warmed up with moderate engine speed • Do not travel or turn with the lift arm up.
and light load have longer life. • Turn on level ground. Slow down when turning.
I-2015-0284
• Go up and down slopes, not across them.
• Keep the heavy end of the machine uphill.
• Do not overload the machine.
Operate with the engine at full speed for maximum Failure to obey warnings can cause the machine to
horsepower. Push the Drive Control Pedal only a small tip or roll over and cause injury or death.
amount to operate the machine. W-2444-1102
New operators must operate the machine in an open Raise the bucket only high enough to avoid obstructions
area without bystanders. Operate the controls until the on rough ground.
machine can be handled at a efficient and safe rate for all
conditions of the work area.
Figure OI-70
LOADED BUCKET & EMPTY CARGO BOX
GOING UP SLOPE GOING DOWN SLOPE
B-19663 B-19661
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 OI-70].
OI-39 5600 Operation & Maintenance Manual
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING 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-2003-0903
CORRECT CORRECT
Safety Alert Symbol: This
symbol with a warning
statement, means: “Warning, be
alert! Your safety is involved!”
Carefully read the message that
follows. B-10731a B-21495
Never service the machine Cleaning and maintenance are
without instructions. required daily.
WRONG WRONG WRONG
B-21498 B-21499 B-21500 B-21509
Have good ventilation when Disconnecting or loosening any Never work on the machine with
welding or grinding painted parts. hydraulic tubeline, hose, fitting, lift arm or cargo box up unless
Wear dust mask when grinding component or a part failure can supported by an approved
painted parts. Toxic dust and gas cause lift arm or cargo box to support device. Replace if
can be produced. drop. Do not go under lift arm or damaged.
Avoid exhaust fume leaks which cargo box when raised unless Never modify equipment or add
can kill without warning. Exhaust supported by an approved lift attachments not approved by
system must be tightly sealed. arm or cargo box support device. Bobcat Company.
Replace it if damaged.
WRONG WRONG WRONG
B-21497 B-21496 B-6589
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust machine exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact, flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep side access doors closed attention.
running, while smoking or when except for service.
near open flame.
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.
MSW25-0805
PM-5 5600 Operation & Maintenance Manual
--- Page 11 ---
OPERATOR CAB HEATING AND AIR CONDITIONING
Description Cleaning and Maintenance
Figure PM-12 The heating system requires regular inspection and
maintenance. See the SERVICE SCHEDULE for
intervals. (See SERVICE SCHEDULE on Page PM-7.)
Filters
See CAB AIR FILTERS for filter cleaning and
replacement. (See CAB AIR FILTER on Page PM-16.)
Evaporator Coil
Figure PM-13
P-64708
The machine has an operator cab (ROPS and FOPS)
[Figure PM-12] as standard equipment to protect the
operator from rollover and falling objects. The seat belt
must be worn for rollover protection. Check with your 1
dealer if the operator cab has been damaged or modified.
ROPS / FOPS - Roll Over Protective Structure per SAE
J1040 and ISO 3471, and Falling Object Protective
Structure per ISO 3449, Level I. P-64827
Level I
Remove the filter (Item 1) [Figure PM-13] and use a
Protection from falling bricks, small concrete blocks, and vacuum to clean the evaporator coils.
hand tools encountered in operations such as highway
maintenance, landscaping, and other construction site If the coils require a more thorough cleaning, the heater /
services. air conditioning unit must be disconnected from the front
of the cab. (See your Bobcat dealer.)
WARNING Air Conditioning Lubrication
Run the air conditioner for about 5 minutes every week to
lubricate the internal components. (In winter too.)
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to Troubleshooting
the cab can cause loss of operator protection from
If the fan does not run or the air conditioning does not
rollover and falling objects, and result in injury or
turn on, check the fuse. (See ELECTRICAL SYSTEM on
death.
W-2069-0200
Page PM-26.)
If the air conditioning system circulates warm air, the
refrigerant may need to be recharged. (See your Bobcat
dealer.)
PM-15 5600 Operation & Maintenance Manual
--- Page 12 ---
Removing And Replacing Coolant NOTE: The loader is factory filled with propylene
glycol coolant (purple color). DO NOT mix
Figure PM-32 propylene glycol with ethylene glycol.
Add premixed coolant, 47% water and 53% propylene
1 glycol to the recovery tank. (See Checking on Page PM-
23.)
2 One gallon and one pint (4,3 L) of propylene glycol
P-51209 mixed with one gallon (3,8 L) of water is the correct
mixture of coolant to provide a -34°F (-37°C) freeze
protection.
Add premixed coolant to the coolant recovery tank until it
is at the full mark. Install the cap.
Start the engine and let it run until it is at operating
P-51215 temperature.
Stop the engine and check the coolant level. Add
Raise the cargo box and install the Cargo Box Support premixed coolant to the recovery tank as needed.
Device. Stop the engine.
Lower the cargo box.
Remove the cap (Item 1) [Figure PM-32] from the
coolant recovery tank.
Open the radiator drain valve (Item 2) [Figure PM-32]
and drain the coolant into a container.
Reuse or dispose of the used coolant in an
environmentally safe manner.
Close the drain valve.
PM-25 5600 Operation & Maintenance Manual
--- Page 13 ---
AXLE / DIFFERENTIAL (FRONT AND REAR) Removing And Replacing Lubricant
Checking And Adding Lubricant Figure PM-49
Stop the machine on a level surface and stop the engine.
Figure PM-47
1
1
P-39573
Remove the drain plug at the bottom of the differential
FRONT AXLE
P-39396 (Item 1) [Figure PM-49].
Drain the lubricant into a container and dispose of it in an
Figure PM-48 environmentally safe manner.
Install and tighten drain plug.
Remove check plug (Item 1) [Figure PM-47] & [Figure
PM-48] and fill as shown above.
1 NOTE: When adding axle housing lubricant (See
Drive System on Page SPEC-6) for correct
fluid type.
REAR AXLE
P-39574
Remove the check plug (Item 1) [Figure PM-47] &
[Figure PM-48] from the front or rear housing.
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.
NOTE: When adding axle housing lubricant (See
Drive System on Page SPEC-6) for correct
fluid type.
Install and tighten the plug.
PM-35 5600 Operation & Maintenance Manual
--- Page 14 ---
SYSTEM SETUP & ANALYSIS
DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . SA-3
Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-3
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-4
DISPLAY CONTROLLER PANEL SETUP . . . . . . . . . . . . . . . . . SA-6
Changing The Operator Password . . . . . . . . . . . . . . . . . . . . SA-6
Display Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-6
Job Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-7
Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-6
Password Entry (For Starting And Operating The Machine) . SA-6
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . SA-7
RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-7
SYSTEM SETUP
& ANALYSIS
(SA)
SA-1 5600 Operation & Maintenance Manual
--- Page 15 ---
SERVICE SCHEDULE (7120002)
MST-3 5600 Operation & Maintenance Manual
--- Page 16 ---
TOOLCAT 5600 UTILITY WORK MACHINE
SPECIFICATIONS
Dimensions
• Dimensions are given for machine equipped with standard tires and bucket and may vary with other bucket types. All
dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
• Where applicable, specification conform to SAE, ANSI or ISO standards and are subject to change without notice.
65°
40°
80.7 in.
(2050 mm)
23.7 in. 22.0 in.
84.3 in.
(602 mm) (566 mm) (2141 mm)
42.8 in.
(1087 mm)
62.3 in.
(1582 m m)
10.2
28°
20.2 in. 30°
(513 mm)
10.2 in.
20.8 in. (259 mm) 85 in.
(528 mm) (2159 mm)
149.8 in.
(3805 mm) B-25303
186.8 in.
(4745 mm)