Complete repair service manual for Bobcat V623, V638, V723 VersaHANDLER, with all the technical information to maintain, diagnose, and repair like professional mechanics.

Bobcat V623, V638, V723 VersaHANDLER workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

6901155 (8-03) - V518, V623 Telescopic Tool Carrier (TTC) Operation & Maintenance Manual.pdf
6901675 (3-06) - V623 VersaHANDLER Service Manual.pdf
6902407 (3-06) - V623 VersaHANDLER Service Manual.pdf
6902760 (1-07) - V723 VersaHANDLER Service Manual.pdf
6904754 (12-06) - V638 VersaHANDLER Telescopic Tool Carrier (TTC) Operation & Maintenance Manual.pdf
6904755 (1-07) - V638 VersaHANDLER Service Manual.pdf
6986672 (12-07) - V518, V723 Telescopic Tool Carrier (TTC) Operation & Maintenance Manual.pdf
6986674 (12-07) - V638 VersaHANDLER Telescopic Tool Carrier (TTC) Operation & Maintenance Manual.pdf
6986675 (4-10) - V723 VersaHANDLER Service Manual.pdf
6986763 (4-10) - V638 VersaHANDLER Service Manual.pdf
6989575 (3-10) - V638 VersaHANDLER Telescopic Tool Carrier (TTC) Operation & Maintenance Manual.pdf
6989577 (3-10) - V518, V723 Telescopic Tool Carrier (TTC) Operation & Maintenance Manual.pdf

Total Pages: 5,122 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
6901155 (8-03) - V518, V623 Telescopic Tool Carrier (TTC) Operation & Maintenance Manual...1
  OPERATOR SAFETY WARNINGS...3
  CONTENTS...5
  FOREWORD...7
    SERIAL NUMBER LOCATIONS...9
      VersaHANDLER SERIAL NUMBER...9
      ENGINE SERIAL NUMBER...9
      OTHER SERIAL NUMBERS...9
    DELIVERY REPORT...10
    BOBCAT VersaHANDLER IDENTIFICATION...10
    FEATURES AND ACCESSORIES...11
  SAFETY...13
    SAFETY INSTRUCTIONS FOR THE BOBCAT VersaHANDLER TELESCOPIC TOOLCARRIER (TTC) AND ATTACHMENTS...15
    SAFE OPERATION IS THE OPERATOR’S RESPONSIBILITY...15
    BEFORE OPERATING THE BOBCATVersaHANDLER Telescopic Tool Carrier (TTC)...16
    FIRE PREVENTION...17
    MACHINE SIGNS (DECALS)...18
  OPERATING INSTRUCTIONS...21
    OPERATOR CONTROLS IDENTIFICATION...23
      Operator Components...23
      Travel Direction & Two–Speed Control...23
      Direction Signal...23
      Front Wiper / Washer / Headlight Dimmer...23
      Steering Wheel Tilt Adjustment...24
      Center Instrument Panel...25
      Right Instrument and Indicator Panel...26
      Parking Brake...27
      Accelerator Pedal...27
      Brake Pedal and Inching Control...27
      Frame Level Switch (V623 With Frame Level Only)...27
    HYDRAULIC CONTROLS...28
      Hydraulic Control Lever (Joystick)...28
    STEERING CONTROLS...29
      Steering Mode Selection...29
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS™)...30
    SERVICE SCHEDULE DECAL...31
    DAILY INSPECTION...31
      Daily Inspection and Maintenance:...31
    PRE–STARTING PROCEDURE...32
    STARTING THE ENGINE...33
    BEFORE USING THE VersaHANDLER...33
    ATTACHMENTS AND BUCKETS...34
      Installing The Bucket Or Attachment...34
      Removing The Bucket Or Attachment...35
      VersaHANDLER OPERATION...35
      Raising A Load And Extending The Boom...35
      Using Frame Leveling (V623 With Frame Level Only)...36
      Load Capacity Charts...37
    PARKING THE VersaHANDLER...38
    TRANSPORTING THE VersaHANDLER...38
    TOWING THE VersaHANDLER...39
  PREVENTIVE MAINTENANCE...41
    MAINTENANCE SAFETY...43
    SERVICE SCHEDULE...44
    OPERATOR CAB / CANOPY...45
      Emergency Exit (All Models)...45
    CAB DOOR (EARLIER MODELS)...45
      Cab Door Window (Earlier Models)...46
      Cab Door (Later Models)...47
      Cab Door Window (Later Models)...47
    BOOM STOP...48
      Installing Boom Stop...48
      Removing Boom Stop...48
    ENGINE COVER...48
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS™)...49
      System Inspection...49
      System Maintenance...49
    AIR CLEANER SERVICE...50
      Replacing Filter Element...50
    FUEL SYSTEM...51
      Fuel Specifications...51
      Filling The Fuel Tank...51
      Fuel Filter...51
    ENGINE LUBRICATION SYSTEM...52
      Checking Engine Oil...52
      Oil Chart...52
      Replacing Oil And Filter...52
    ENGINE COOLING SYSTEM...54
      Cleaning The Cooling System...54
      Checking The Coolant Level...54
      Replacing The Coolant...55
    ALTERNATOR BELT...56
      Adjusting...56
    SPARK ARRESTOR MUFFLER...56
    ELECTRICAL SYSTEM...57
      Description...57
      Battery & Terminal Maintenance...57
      Fuses, Diodes & Relays...57
      Using A Booster Battery (Jump Starting)...59
      Battery Disconnect Switch...59
    HYDRAULIC/HYDROSTATIC SYSTEM...60
      Checking And Adding Fluid...60
      Replacing Hydraulic/Hydrostatic Filter...60
    HYDRAULIC/HYDROSTATIC SYSTEM...61
      Replacing Hydraulic Fluid...61
    BRAKE CONTROL SYSTEM...61
      Inspection and Maintenance...61
    AXLES (FRONT AND REAR)...62
      Checking Oil Level (Front Differential)...62
      Draining Oil (Front Differential)...62
      Checking Oil Level (Rear Differential)...62
      Draining Oil (Rear Differential)...62
      Checking Oil Level (Planetary Carrier)...63
      Draining Oil (Planetary Carrier)...63
    TIRE MAINTENANCE...64
      Wheel Nuts...64
      Tire Mounting...64
      Tire Rotation...64
    TIRE PRESSURE...64
    LUBRICATION...65
    ATTACHMENT FRAME...69
      Inspection And Maintenance...69
  MACHINE SIGN TRANSLATIONS...71
  SPECIFICATIONS...85
    VersaHANDLER Telescopic Tool Carrier (TTC) SPECIFICATIONS...87
    BOBCAT APPROVED ATTACHMENTS & ACCESSORIES...89
    ATTACHMENTS...89
    ADDITIONAL PUBLICATIONS and TRAINING MATERIALS...90
  WARRANTY...91
6901675 (3-06) - V623 VersaHANDLER Service Manual...93
  MAINTENANCE SAFETY...95
  ALPHABETICAL INDEX...97
  CONTENTS...99
    FOREWORD...100
    SAFETY INSTRUCTIONS...103
      Fire Prevention...105
    SERIAL NUMBER LOCATIONS...107
      VersaHANDLER Serial Number...107
      Engine Serial Number...107
      Other Serial Numbers...107
    DELIVERY REPORT...108
    BOBCAT VersaHANDLER IDENTIFICATION...108
  SAFETY AND MAINTENANCE...109
    LIFTING AND BLOCKING THE VERSAHANDLER...111
      Procedure...111
    OPERATOR CAB...113
      Emergency Exit...113
      Cab Door...113
      Cab Door Window...113
    TRANSPORTING THE VERSAHANDLER...115
      Procedure...115
    TOWING THE VERSAHANDLER...117
      Procedure...117
    SERVICE SCHEDULE...119
      Chart...119
    AIR CLEANER SERVICE...121
      Replacing Filter Element...121
    ENGINE COOLING SYSTEM...123
      Cleaning The Cooling System...123
      Checking The Coolant Level...123
      Replacing The Coolant...124
    FUEL SYSTEM...125
      Fuel Specifications...125
      Filling The Fuel Tank...125
      Fuel Filter...125
    ENGINE LUBRICATION SYSTEM...127
      Checking Engine Oil...127
      Oil Chart...127
      Replacing Oil And Filter...127
    HYDRAULIC/HYDROSTATIC SYSTEM...129
      Checking And Adding Fluid...129
      Replacing Hydraulic/Hydrostatic Filter...129
      Replacing Hydraulic Fluid...130
    AXLES (FRONT AND REAR)...131
      Checking Oil Level (Planetary Carrier)...131
      Draining Oil (Planetary Carrier)...131
      Checking Oil Level (Rear Differential)...132
      Draining Oil (Rear Differential)...132
      Checking Oil Level (Front Differential)...132
      Draining Oil (Front Differential)...132
    LUBRICATION...133
      Procedure...133
    TIRE MAINTENANCE...139
      Wheel Nuts...139
      Tire Rotation...139
      Tire Mounting...139
    SPARK ARRESTOR MUFFLER...141
    BOOM STOP...143
      Installing Boom Stop...143
      Removing Boom Stop...143
    ENGINE COVER...145
      Opening And Closing The Engine Cover...145
      Adjusting The Latch...145
  HYDRAULIC SYSTEM...147
    HYDRAULIC/HYDROSTATIC SCHEMATICS...151
    HYDRAULIC SYSTEM INFORMATION...153
      Troubleshooting Chart...156
      Tightening Procedures...157
    LIFT CYLINDER...159
      Removal And Installation...159
      Parts Identification...163
      Disassembly...164
      Assembly...169
    BUCKET POSITIONING CYLINDER...175
      Removal And Installation...175
      Parts Identification...178
      Disassembly...179
      Assembly...183
    EXTENSION CYLINDER...187
      Removal And Installation...187
      Parts Identification...192
      Disassembly...193
      Assembly...198
    TILT CYLINDER...203
      Removal And Installation...203
      Parts Identification...204
      Disassembly...205
      Assembly...209
    STEERING CYLINDER...213
      Removal And Installation...213
      Parts Identification...215
      Disassembly...216
      Assembly...219
    DRIVE BOX...225
      Parts Identification...225
      Disassembly...226
      Inspection...231
      Assembly...232
    MAIN RELIEF VALVE...239
      Testing And Adjustment...239
      Removal and Installation...240
    QUICK TACH CYLINDER...241
      Removal And Installation...241
      Parts Identification...243
      Disassembly...244
      Assembly...247
    FRAME LEVELING CYLINDER...249
      Removal And Installation...249
      Parts Identification...251
      Disassembly...252
      Assembly...257
    STEERING MODE VALVE BLOCK...263
      Removal And Installation...263
      Parts Identification...264
      Disassembly...265
      Solenoid Testing...267
      Assembly...267
    BRAKE VALVE...269
      Removal And Installation...269
    GEAR PUMP...271
      Removal And Installation...271
      Parts Identification...274
      Disassembly And Assembly...275
    FAN MOTOR...281
      Removal And Installation...281
      Parts Identification...283
      Disassembly and Assembly...284
    HYDRAULIC RESERVOIR...287
      Removal And Installation...287
    STEERING VALVE...289
      Removal And Installation...289
      Parts Identification...290
      Disassembly...291
      Inspection...297
      Assembly...298
    HYDRAULIC CONTROL VALVE (S/N 367111001- 367112500 AND 367211001-367212500)...305
      Removal And Installation...305
      Parts Identification...307
      Disassembly And Assembly...308
      Frame Leveling Valve Section (Optional)...309
      Auxiliary Valve Section...314
      Telescoping Valve Section...319
      Tilting Valve Section...320
      Lifting Valve Section...326
      Inlet/Outlet Valve Section...332
    HYDRAULIC CONTROL VALVE (S/N 367112501- 367113000 AND 367212501-367213000)...333
      Removal And Installation...333
      Parts Identification...337
      Disassembly And Assembly...338
      End Housing Disassembly And Assembly...338
      Lifting Valve Section Disassembly And Assembly...339
      Tilting Valve Section Disassembly And Assembly...344
      Telescoping Valve Section Disassembly And Assembly...349
      Auxiliary Valve Section Disassembly And Assembly...362
      Frame Leveling Valve Section Disassembly And Assembly (If Equipped)...372
      Inlet-Outlet Valve Section Disassembly And Assembly...383
    JOYSTICK (S/N 367112501-367113000 AND 367212501-367213000)...389
      Handle Removal And Installation...389
      Joystick Removal And Installation...390
      Parts Identification...392
      Disassembly And Assembly...393
  HYDROSTATIC SYSTEM...399
    HYDROSTATIC SYSTEM INFORMATION...401
      Troubleshooting Chart...401
      Replenishing The Valve Function...402
    OIL COOLER...403
      Removal And Installation...403
    HYDROSTATIC DRIVE MOTOR...405
      Removal And Installation...405
      Parts Identification...406
      Disassembly...409
      Inspection...424
      Assembly...426
    HYDROSTATIC PUMP...443
      Removal And Installation...443
      Parts Identification...446
      Disassembly...451
      Inspection...464
      Assembly...468
  DRIVE SYSTEM...483
    TROUBLESHOOTING...485
      Chart...485
    AXLE AND DIFFERENTIAL...487
      General Information...487
      Planetary Carrier Parts Identification...487
      Planetary Carrier Disassembly...488
      Planetary Carrier Inspection...490
      Wheel Hub Parts Identification...491
      Wheel Hub Disassembly...492
      Wheel Hub Inspection...495
      Steering Knuckle Parts Identification...495
      Steering Knuckle Disassembly...496
      Axle Housing/Drive Axle Parts Identification...498
      Axle Housing/Drive Axle Disassembly...499
      Brake Group Parts Identification...504
      Brake Group Disassembly...504
      Brake Housing Inspection...510
      Differential Parts Identification...511
      Differential Disassembly...511
      Differential Inspection...514
      Pinion Group Parts Identification...515
      Pinion Group Disassembly...516
      Pinion Group Inspection...518
      Pinion Group Assembly...519
      Differential Assembly...525
      Brake Group Assembly...528
      Axle Housing/Drive Axle Assembly...538
      Steering Knuckle Assembly...543
      Wheel Hub Assembly...546
      Planetary Carrier Assembly...548
    FRONT AXLE...551
      Removal...551
      Installation...557
    FRONT AXLE WITH FRAME LEVELING...563
      Removal...563
      Installation...568
    AXLE PIVOT FRAME...575
      Removal And Installation...575
      Bushing Removal And Installation...576
    AXLE TOE-IN...577
      Adjustment...577
    PARKING BRAKE...579
      Releasing The Brake For Towing...579
      Re-Activating The Brake...580
    STEERING ANGLE ADJUSTMENT...581
      Adjustment...581
    DRIVESHAFT...583
      Removal And Installation...583
  MAIN FRAME...585
    OPERATOR CAB...587
      Removal And Installation...587
    OPERATOR SEAT...595
      Removal And Installation...595
    BOOM ASSEMBLY...597
      Removal And Installation...597
    INNER BOOM...601
      Removal...601
      Installation...603
    WEAR PADS (FRONT)...605
      Removal And Installation...605
    WEAR PADS (REAR)...607
      Removal...607
      Installation...607
    ENGINE COVER...609
      Gas Cylinder Removal And Installation...609
      Removal And Installation...609
    FUEL TANK...611
      Removal And Installation...611
    QUICK TACH...615
      Removal And Installation...615
    REAR WEIGHTS...617
      Removal And Installation...617
    FENDER...619
      Removal And Installation...619
    PIVOT LINK...621
      Removal And Installation...621
  ELECTRICAL SYSTEM AND ANALYSIS...625
    ELECTRICAL SCHEMATICS...627
    ELECTRICAL SYSTEM INFORMATION...635
      Troubleshooting Chart...635
      Description...636
      Fuses, Diodes & Relays...636
    BATTERY...639
      Removal And Installation...639
      Servicing...640
      Using A Booster Battery (Jump Starting)...641
    ALTERNATOR...643
      Removal And Installation...643
    STARTER...645
      Removal And Installation...645
      Parts Identification...646
      Disassembly...647
      Inspection And Repair...651
      Assembly...654
    JOYSTICK PANEL...657
      Removal And Installation...657
    LIGHTS...659
      Rear Removal And Installation...659
      Front Removal And Installation...660
    TRAVEL/SIGNAL LEVER...661
      Removal And Installation...661
    INSTRUMENT PANEL...663
      Removal And Installation...663
    SWITCH PANEL...665
      Removal And Installation...665
    DASH COVER/STEERING COLUMN COVER...667
      Removal And Installation...667
    FRONT WIPER MOTOR...669
      Removal And Installation...669
    TOP WIPER MOTOR...673
      Removal And Installation...673
    REAR WIPER MOTOR...675
      Removal And Installation...675
    PEDAL ASSEMBLY...677
      Removal And Installation...677
    BRAKE LIGHT SWITCH...679
      Removal And Installation...679
      Adjustment...679
    INCHING SWITCH...681
      Removal And Installation...681
      Adjustment...681
    JOYSTICK (S/N 367111001-367112500 AND 367211001-367212500)...683
      Removal And Installation...683
  ENGINE SERVICE...685
    TROUBLESHOOTING...689
      Chart...689
    ENGINE SPEED CONTROL...691
      Removal And Installation...691
      Adjustment...691
    MUFFLER...693
      Removal And Installation...693
    AIR CLEANER...695
      Housing Removal And Installation...695
    RADIATOR...697
      Removal And Installation...697
      Disassembly And Assembly...700
    ENGINE AND ENGINE MOUNTS...703
      Removal And Installation...703
    ENGINE COMPONENTS AND TESTING...707
      Fuel Injection Pump Removal And Installation...707
      Fuel Injector Removal And Installation...710
      Fuel Injector Checking...713
      Checking The Fuel Lift Pump...714
      Fuel Lift Pump Removal And Installation...714
    ENGINE/HYDROSTAT ASSEMBLY...715
      Removal And Installation...715
    FLYWHEEL AND HOUSING...727
      Removal And Installation...727
      Ring Gear Removal...730
      Ring Gear Installation...730
    RECONDITIONING THE ENGINE...731
      Intake Manifold Removal and Installation...731
      Exhaust Manifold Removal and Installation...732
      Cylinder Head Disassembly...733
      Cylinder Head Removal...734
      Cylinder Head Inspection...735
      Cylinder Head Installation...736
      Rocker Shaft Disassembly And Assembly...739
      Valve Removal...740
      Valve Springs Checking...740
      Valve Depth Checking...741
      Valve Guides Checking...741
      Valve Guide Removal...742
      Valve Guide Installation...742
      Valves Checking...743
      Cutting A Valve Seat...743
      Valve Seat Assembly...744
      Changing Valve Springs (With Cylinder Head Installed)...745
      Valve Clearance Adjustment...746
      Timing Case And Drive Assembly Description...747
      Timing Cover Removal...747
      Timing Cover Installation...748
      Front Oil Seal Removal...749
      Front Oil Seal Installation...749
      Timing Case And Gear Removal...749
      Timing Case And Gear Installation...750
      Camshaft And Tappets Removal...752
      Camshaft And Tappets Installation...753
      Pistons And Connecting Rods Description...754
      Pistons And Connecting Rods Removal...754
      Pistons And Connecting Rods Disassembly...756
      Piston Ring End Gap...756
      Piston Ring Installation...756
      Piston Ring Groove Clearance...757
      Connecting Rod Inspection...758
      Connecting Rod Bushing Replacement...758
      Piston And Connecting Rod Assembly...758
      Piston And Connecting Rod Installation...758
      Checking Piston Height...760
      Crankshaft And Bearings Description...761
      Crankshaft And Bearings Removal...761
      Inspection Of Crankshaft And Bearings...763
      Crankshaft And Bearings Installation...763
      Rear Oil Seal Removal...765
      Rear Oil Seal Housing Positioning...765
      Rear Oil Seal Installation...765
      Checking Crankshaft End Play...766
      Cooling System Description...767
      Thermostat Removal and Installation...768
      Thermostat Testing...768
      Water Pump Removal...769
      Water Pump Installation...769
      Engine Lubrication System Description...770
      Oil Filter Adapter Removal...771
      Oil Filter Adapter Installation...771
      Oil Pan Removal And Installation...772
      Oil Screen And Pick-up Tube...772
      Oil Pump Removal...773
      Oil Pump Installation...774
      Oil Pump Disassembly And Assembly...775
      Oil Pressure Relief Valve Disassembly And Assembly...775
      Engine Block Description...776
      Engine Block Disassembly And Assembly...776
      Piston Cooling Jet Removal...777
      Piston Cooling Jet Installation...777
      Piston Cooling Jet Alignment...777
      Inspection...777
      Cylinder Liner Inspection...778
      Cylinder Liner Removal...779
      Cylinder Liner Installation...780
      Turbo Charger Troubleshooting...781
      Turbo Charger Description...782
      Turbo Charger Removal and Installation...782
  HEATING, VENTILATION, AIR CONDITIONING...785
    AIR CONDITIONING SYSTEM FLOW...788
      Principals...788
      Chart...789
    COMPONENTS...791
      Identification...791
    SAFETY...793
      Safety Equipment...793
    REGULAR MAINTENANCE...795
      Filter Element Removal And Installation...795
      Compressor Drive Belt Inspection...796
      Cleaning The Condenser...796
    BASIC TROUBLESHOOTING...797
      Poor A/C Performance...797
      Compressor Drive Belt Inspection...797
      Checking The Electrical System...798
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...803
      Compressor Oil...803
      Compressor Oil Check...803
      Component Replacement And Refrigeration Leaks...804
    SYSTEM TROUBLESHOOTING CHART...805
    TEMPERATURE/PRESSURE...809
      Chart...809
    AIR CONDITIONING SERVICE...811
      Chart...811
    SYSTEM CHARGING AND RECLAMATION...813
      Reclamation Procedure...813
      Charging Procedure With A Manifold Gauge Set...816
      Charging Procedure...817
    COMPRESSOR...819
      Removal And Installation...819
      Compressor Clutch Disassembly...820
    CONDENSER...825
      Removal And Installation...825
    RECEIVER/DRIER...827
      Removal And Installation...827
    PRESSURE SWITCH...829
      Removal And Installation...829
    EVAPORATOR/BLOWER UNIT...831
      Removal And Installation...831
    EXPANSION VALVE...833
      Removal And Installation...833
    HEATER ASSEMBLY...835
      Removal And Installation...835
      Fan Removal And Installation...836
      Core Removal And Installation...836
  SPECIFICATIONS...839
    VERSAHANDLER SPECIFICATIONS...841
      Dimensional Specifications...841
      Performance Specifications...841
      Engine...841
      Controls...841
      Drive System...841
      Tires...842
      Hydraulic System...842
      Electrical System...842
      Capacities...842
    ENGINE SPECIFICATIONS...843
      General...843
      Cylinder Head...843
      Valve Guides...843
      Exhaust Valves...843
      Intake Valves...844
      Valve Springs...844
      Rocker Shaft, Rockers And Bushings...845
      Pistons And Piston Rings...845
      Connecting Rods And Bearings...846
      Crankshaft...846
      Crankshaft Re-Grind Data...847
      Main Bearings...848
      Thrust Washers...848
      Camshaft And Thrust Washer...848
      Cylinder Block...848
      Cylinder Liners...849
      Fuel Injection Pump...849
      Fuel Injectors...849
      Fuel Lift Pump...849
      Timing Case And Timing Gears...850
      Oil Pump, Gear And Relief Valve...851
      Turbocharger...851
      Flywheel...851
      Water Pump And Thermostat...852
      Engine Torque...853
    LOADER TORQUE SPECIFICATIONS...855
      Axle...855
      Boom...855
      Drive Box...855
      Drive Motor...855
      Engine...855
      Hydraulic Pump...856
    TORQUE SPECIFICATIONS FOR BOLTS...857
      Torque for General SAE Bolts...857
      Torque For General Metric Bolts...858
    HYDRAULIC CONNECTION SPECIFICATIONS...859
      O-ring Face Seal Connection...859
      Straight Thread O-ring Fitting...859
      Tubelines And Hoses...859
      Flare Fitting...860
      O-ring Flare Fitting...861
      Port Seal Fitting...863
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...865
      Specifications...865
    CONVERSIONS...867
      Decimal And Millimeter Equivalents...867
      U.S. To Metric Conversion...868
  SMR...869
    V623-1...869
    V623-2...871
    V623-3...873
    V623-4...875
6902407 (3-06) - V623 VersaHANDLER Service Manual...877
  MAINTENANCE SAFETY...879
  ALPHABETICAL INDEX...881
  CONTENTS...883
    FOREWORD...884
    SAFETY INSTRUCTIONS...887
      Fire Prevention...889
    SERIAL NUMBER LOCATIONS...891
      VersaHANDLER Serial Number...891
      Engine Serial Number...891
      Other Serial Numbers...891
    DELIVERY REPORT...892
    BOBCAT VersaHANDLER IDENTIFICATION...892
  SAFETY AND MAINTENANCE...893
    LIFTING AND BLOCKING THE VERSAHANDLER...895
      Procedure...895
    OPERATOR CAB...897
      Emergency Exit...897
      Cab Door...897
      Cab Door Window...897
    TRANSPORTING THE VERSAHANDLER...899
      Procedure...899
    TOWING THE VERSAHANDLER...901
      Procedure...901
    SERVICE SCHEDULE...903
      Chart...903
    AIR CLEANER SERVICE...905
      Replacing Filter Element...905
    ENGINE COOLING SYSTEM...907
      Cleaning The Cooling System...907
      Checking The Coolant Level...907
      Replacing The Coolant...908
    FUEL SYSTEM...909
      Fuel Specifications...909
      Filling The Fuel Tank...909
      Fuel Filter...909
    ENGINE LUBRICATION SYSTEM...911
      Checking Engine Oil...911
      Oil Chart...911
      Replacing Oil And Filter...911
    HYDRAULIC/HYDROSTATIC SYSTEM...913
      Checking And Adding Fluid...913
      Replacing Hydraulic/Hydrostatic Filter...913
      Replacing Hydraulic Fluid...914
    AXLES (FRONT AND REAR)...915
      Checking Oil Level (Planetary Carrier)...915
      Draining Oil (Planetary Carrier)...915
      Checking Oil Level (Rear Differential)...916
      Draining Oil (Rear Differential)...916
      Checking Oil Level (Front Differential)...916
      Draining Oil (Front Differential)...916
    LUBRICATION...917
      Procedure...917
    TIRE MAINTENANCE...923
      Wheel Nuts...923
      Tire Rotation...923
      Tire Mounting...923
    SPARK ARRESTOR MUFFLER...925
      Cleaning...925
    BOOM STOP...927
      Installing Boom Stop...927
      Removing Boom Stop...927
    ENGINE COVER...929
      Opening And Closing The Engine Cover...929
      Adjusting The Latch...929
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS™)...931
      System Inspection...931
      System Maintenance...932
  HYDRAULIC SYSTEM...933
    HYDRAULIC/HYDROSTATIC SCHEMATICS...937
    HYDRAULIC SYSTEM INFORMATION...941
      Troubleshooting Chart...944
      Tightening Procedures...945
    LIFT CYLINDER...947
      Removal And Installation...947
      Parts Identification...951
      Disassembly...952
      Assembly...957
    BUCKET POSITIONING CYLINDER...963
      Removal And Installation...963
      Parts Identification...966
      Disassembly...967
      Assembly...971
    EXTENSION CYLINDER...975
      Cylinder Group Removal And Installation...975
      Upper Tubeline Removal...977
      Upper Tubeline Installation...977
      Extension Cylinder Removal And Installation...979
      Tubeline Tray Disassembly...981
      Tubeline Tray Assembly...983
      Parts Identification...987
      Disassembly...988
      Assembly...992
    TILT CYLINDER...997
      Removal And Installation...997
      Parts Identification...998
      Disassembly...999
      Assembly...1003
    STEERING CYLINDER (FRONT)...1007
      Removal And Installation...1007
      Parts Identification...1009
      Disassembly...1010
      Assembly...1013
    STEERING CYLINDER (REAR)...1019
      Removal And Installation...1019
      Parts Identification...1021
      Disassembly...1022
      Assembly...1025
    DRIVE BOX...1031
      Parts Identification...1031
      Disassembly...1032
      Inspection...1037
      Assembly...1038
    MAIN RELIEF VALVE...1045
      Testing And Adjustment...1045
      Removal and Installation...1046
    QUICK TACH CYLINDER...1047
      Removal And Installation...1047
      Parts Identification...1049
      Disassembly...1050
      Assembly...1053
    FRAME LEVELING CYLINDER...1055
      Removal And Installation...1055
      Parts Identification...1057
      Disassembly...1058
      Assembly...1063
    STEERING MODE VALVE BLOCK...1069
      Removal And Installation...1069
      Parts Identification...1071
      Disassembly...1072
      Solenoid Testing...1074
      Assembly...1074
    BRAKE VALVE...1077
      Removal And Installation...1077
      Disassembly And Assembly...1078
    GEAR PUMP...1081
      Removal And Installation...1081
      Parts Identification...1084
      Disassembly And Assembly...1085
    FAN MOTOR...1091
      Removal And Installation...1091
      Parts Identification...1093
      Disassembly and Assembly...1094
    HYDRAULIC RESERVOIR...1097
      Removal And Installation...1097
    STEERING VALVE...1099
      Removal And Installation...1099
      Parts Identification...1100
      Parts Identification...1101
      Disassembly...1102
      Inspection...1108
      Assembly...1108
    HYDRAULIC CONTROL VALVE...1115
      Removal And Installation...1115
      Parts Identification...1119
      Disassembly And Assembly...1120
      End Housing Disassembly And Assembly...1120
      Lifting Valve Section Disassembly And Assembly...1121
      Tilting Valve Section Disassembly And Assembly...1126
      Telescoping Valve Section Disassembly And Assembly...1131
      Auxiliary Valve Section Disassembly And Assembly...1144
      Frame Leveling Valve Section Disassembly And Assembly (If Equipped)...1154
      Inlet-Outlet Valve Section Disassembly And Assembly...1165
    PORT RELIEF VALVES...1171
      Adjustment Procedure...1171
    FLOW CONTROL VALVE...1173
      Removal And Installation...1173
    JOYSTICK...1175
      Handle Removal And Installation...1175
      Joystick Removal And Installation...1176
      Parts Identification...1178
      Disassembly And Assembly...1179
    PARKING BRAKE...1185
      Pressure Switch Removal And Installation...1185
      Pressure Switch Disassembly And Assembly...1187
      Parking Brake Valve Removal And Installation...1188
      Parking Brake Valve Disassembly And Assembly...1189
    PRESSURE REDUCING VALVE...1191
      Testing...1191
      Removal And Installation...1191
      Disassembly And Assembly...1193
    ACCUMULATOR...1195
      Removal And Installation...1195
    TOW VALVE...1197
      Removal And Installation...1197
      Disassembly And Assembly...1198
    FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE...1203
      Removal And Installation...1203
      Disassembly And Assembly...1205
  HYDROSTATIC SYSTEM...1209
    HYDROSTATIC SYSTEM INFORMATION...1211
      Troubleshooting Chart...1211
      Replenishing Valve Function...1212
    OIL COOLER...1213
      Removal And Installation...1213
    HYDROSTATIC DRIVE MOTOR...1215
      Removal And Installation...1215
      Parts Identification...1216
      Disassembly...1219
      Inspection...1234
      Assembly...1236
    HYDROSTATIC PUMP...1253
      Removal And Installation...1253
      Parts Identification...1256
      Disassembly...1261
      Inspection...1274
      Assembly...1278
  DRIVE SYSTEM...1293
    TROUBLESHOOTING...1295
      Chart...1295
    AXLE AND DIFFERENTIAL (FRONT)...1297
      General Information...1297
      Planetary Carrier Parts Identification...1297
      Planetary Carrier Disassembly...1298
      Planetary Carrier Inspection...1300
      Wheel Hub Parts Identification...1301
      Wheel Hub Disassembly...1302
      Wheel Hub Inspection...1305
      Steering Knuckle Parts Identification...1305
      Steering Knuckle Disassembly...1306
      Axle Housing/Drive Axle Parts Identification...1308
      Axle Housing/Drive Axle Disassembly...1309
      Brake Group Parts Identification...1314
      Brake Group Disassembly...1314
      Brake Group Inspection...1320
      Differential Parts Identification...1321
      Differential Disassembly...1321
      Differential Inspection...1324
      Pinion Group Parts Identification...1325
      Pinion Group Disassembly...1326
      Pinion Group Inspection...1328
      Pinion Group Assembly...1329
      Differential Assembly...1335
      Brake Group Assembly...1338
      Axle Housing/Drive Axle Assembly...1348
      Steering Knuckle Assembly...1353
      Wheel Hub Assembly...1356
      Planetary Carrier Assembly...1358
    AXLE AND DIFFERENTIAL (REAR)...1361
      General Information...1361
      Planetary Carrier Parts Identification...1361
      Planetary Carrier Disassembly...1362
      Planetary Carrier Inspection...1364
      Wheel Hub Parts Identification...1365
      Wheel Hub Disassembly...1366
      Wheel Hub Inspection...1369
      Steering Knuckle Parts Identification...1369
      Steering Knuckle Disassembly...1370
      Axle Housing/Drive Axle Parts Identification...1372
      Axle Housing/Drive Axle Disassembly...1373
      Differential Parts Identification...1376
      Differential Disassembly...1376
      Differential Inspection...1383
      Pinion Group Parts Identification...1384
      Pinion Group Disassembly...1385
      Pinion Group Inspection...1388
      Pinion Group Assembly...1389
      Differential Assembly...1395
      Axle Housing/Drive Axle Assembly...1406
      Steering Knuckle Assembly...1409
      Wheel Hub Assembly...1412
      Planetary Carrier Assembly...1414
    FRONT AXLE...1417
      Removal...1417
      Installation...1423
    FRONT AXLE WITH FRAME LEVELING...1429
      Removal...1429
      Installation...1434
    AXLE PIVOT FRAME...1441
      Removal And Installation...1441
      Bushing Removal And Installation...1442
    AXLE TOE-IN...1443
      Adjustment...1443
    PARKING BRAKE...1445
      Releasing The Brake For Towing...1445
      Re-Activating The Brake...1446
    STEERING ANGLE ADJUSTMENT...1447
      Adjustment...1447
    DRIVESHAFT...1449
      Removal And Installation...1449
    SERVICE BRAKE...1451
      Description...1451
      Bleeding The Brake Circuit...1451
    REAR AXLE...1453
      Removal...1453
      Installation...1456
  MAIN FRAME...1461
    OPERATOR CAB...1463
      Removal And Installation...1463
    CANOPY...1471
      Removal and Installation...1471
    OPERATOR SEAT...1477
      Removal And Installation...1477
    BOOM ASSEMBLY...1479
      Removal And Installation...1479
    INNER BOOM...1483
      Removal...1483
      Installation...1485
    WEAR PADS (FRONT)...1487
      Removal And Installation...1487
    WEAR PADS (REAR)...1489
      Removal...1489
      Installation...1489
    ENGINE COVER...1491
      Gas Cylinder Removal And Installation...1491
      Removal And Installation...1491
    FUEL TANK...1493
      Removal And Installation...1493
    QUICK TACH...1497
      Removal And Installation...1497
    REAR WEIGHTS...1499
      Removal And Installation...1499
    FENDER...1501
      Removal And Installation...1501
    PIVOT LINK...1503
      Removal And Installation...1503
    DASH COVER/STEERING COLUMN COVER...1507
      Removal And Installation...1507
    JOYSTICK PANEL...1511
      Removal And Installation...1511
  ELECTRICAL SYSTEM AND ANALYSIS...1513
    ELECTRICAL SCHEMATICS...1515
    ELECTRICAL SYSTEM INFORMATION...1523
      Troubleshooting Chart...1523
      Description...1524
      Fuses, Diodes & Relays...1524
    BATTERY...1527
      Removal And Installation...1527
      Servicing...1528
      Using A Booster Battery (Jump Starting)...1529
    ALTERNATOR...1531
      Removal And Installation...1531
      Adjusting The Alternator Belt...1532
    STARTER...1533
      Removal And Installation...1533
      Parts Identification...1534
      Disassembly And Assembly...1535
      Inspection And Repair...1543
      Magnetic Switch Test...1546
    LATERAL OPERATOR RESTRAINT SYSTEM (LOR’S™)...1549
      Restraint Bar Removal And Installation...1549
      Sensor Removal And Installation...1550
      Strut Removal And Installation...1552
      Strut Disassembly And Assembly...1553
      Restraint Bar Bushing Removal And Installation...1554
      Restraint Bar Bumper Removal And Installation...1554
    LIGHTS...1555
      Rear Light Removal And Installation...1555
      Front Light Removal And Installation...1556
    TRAVEL/SIGNAL LEVER...1557
      Removal And Installation...1557
    INSTRUMENT PANEL...1559
      Removal And Installation...1559
    SWITCH PANEL...1561
      Removal And Installation...1561
    BRAKE LIGHT SWITCH...1563
      Removal And Installation...1563
      Adjustment...1563
    FRONT WIPER MOTOR...1565
      Removal And Installation...1565
    TOP WIPER MOTOR...1569
      Removal And Installation...1569
    REAR WIPER MOTOR...1571
      Removal And Installation...1571
    PEDAL ASSEMBLY...1573
      Removal And Installation...1573
      Disassembly And Assembly...1574
    INCHING SWITCH...1579
      Removal And Installation...1579
      Adjustment...1579
  ENGINE SERVICE...1581
    TROUBLESHOOTING...1585
      Chart...1585
    ENGINE SPEED CONTROL...1587
      Removal And Installation...1587
      Adjustment...1588
    MUFFLER...1591
      Removal And Installation...1591
    AIR CLEANER...1593
      Housing Removal And Installation...1593
    RADIATOR...1595
      Removal And Installation...1595
      Disassembly And Assembly...1598
    ENGINE AND ENGINE MOUNTS...1601
      Removal And Installation...1601
    ENGINE COMPONENTS AND TESTING...1605
      Fuel Injection Pump Removal And Installation...1605
      Fuel Injector Removal And Installation...1608
      Fuel Injector Checking...1611
      Checking The Fuel Lift Pump...1612
      Fuel Lift Pump Removal And Installation...1612
    ENGINE/HYDROSTAT ASSEMBLY...1613
      Removal And Installation...1613
    FLYWHEEL AND HOUSING...1623
      Removal And Installation...1623
      Checking...1626
      Ring Gear Removal...1626
      Ring Gear Installation...1626
    RECONDITIONING THE ENGINE...1627
      Intake Manifold Removal and Installation...1627
      Exhaust Manifold Removal and Installation...1628
      Cylinder Head Disassembly...1629
      Cylinder Head Removal...1630
      Cylinder Head Inspection...1631
      Cylinder Head Installation...1632
      Rocker Shaft Disassembly And Assembly...1635
      Valve Removal...1636
      Valve Springs Checking...1636
      Valve Depth Checking...1637
      Valve Guides Checking...1637
      Valve Guide Removal...1638
      Valve Guide Installation...1638
      Valves Checking...1639
      Cutting A Valve Seat...1639
      Valve Seat Assembly...1640
      Changing Valve Springs (With Cylinder Head Installed)...1641
      Valve Clearance Adjustment...1642
      Timing Case And Drive Assembly Description...1643
      Timing Cover Removal...1643
      Timing Cover Installation...1644
      Front Oil Seal Removal...1645
      Front Oil Seal Installation...1645
      Timing Case And Gear Removal...1645
      Timing Case And Gear Installation...1647
      Camshaft And Tappets Removal...1648
      Camshaft And Tappets Installation...1649
      Pistons And Connecting Rods Description...1650
      Pistons And Connecting Rods Removal...1650
      Pistons And Connecting Rods Disassembly...1652
      Piston Ring End Gap...1652
      Piston Ring Installation...1652
      Piston Ring Groove Clearance...1653
      Connecting Rod Inspection...1654
      Connecting Rod Bushing Replacement...1654
      Piston And Connecting Rod Assembly...1654
      Piston And Connecting Rod Installation...1654
      Checking Piston Height...1656
      Crankshaft And Bearings Description...1657
      Crankshaft And Bearings Removal...1657
      Inspection Of Crankshaft And Bearings...1659
      Crankshaft And Bearings Installation...1659
      Rear Oil Seal Removal...1661
      Rear Oil Seal Housing Positioning...1661
      Rear Oil Seal Installation...1661
      Checking Crankshaft End Play...1662
      Cooling System Description...1663
      Thermostat Removal and Installation...1664
      Thermostat Testing...1664
      Water Pump Removal...1665
      Water Pump Installation...1665
      Engine Lubrication System Description...1666
      Oil Filter Adapter Removal...1667
      Oil Filter Adapter Installation...1667
      Oil Pan Removal And Installation...1668
      Oil Screen And Pick-up Tube...1668
      Oil Pump Removal...1669
      Oil Pump Installation...1670
      Oil Pump Disassembly And Assembly...1671
      Oil Pressure Relief Valve Disassembly And Assembly...1671
      Engine Block Description...1672
      Engine Block Disassembly And Assembly...1672
      Piston Cooling Jet Removal...1673
      Piston Cooling Jet Installation...1673
      Piston Cooling Jet Alignment...1673
      Inspection...1673
      Cylinder Liner Inspection...1674
      Cylinder Liner Removal...1675
      Cylinder Liner Installation...1676
      Turbo Charger Troubleshooting...1677
      Turbo Charger Description...1678
      Turbo Charger Removal and Installation...1678
  HEATING, VENTILATION, AIR CONDITIONING...1681
    AIR CONDITIONING SYSTEM FLOW...1684
      Principals...1684
      Chart...1685
    COMPONENTS...1687
      Identification...1687
    SAFETY...1689
      Safety Equipment...1689
    REGULAR MAINTENANCE...1691
      Filter Element Removal And Installation...1691
      Compressor Drive Belt Inspection...1692
      Cleaning The Condenser...1692
    BASIC TROUBLESHOOTING...1693
      Poor A/C Performance...1693
      Compressor Drive Belt Inspection...1693
      Checking The Electrical System...1694
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...1699
      Compressor Oil...1699
      Compressor Oil Check...1699
      Component Replacement And Refrigeration Leaks...1700
    SYSTEM TROUBLESHOOTING CHART...1701
    TEMPERATURE/PRESSURE...1705
      Chart...1705
    AIR CONDITIONING SERVICE...1707
      Chart...1707
    SYSTEM CHARGING AND RECLAMATION...1709
      Reclamation Procedure...1709
      Charging Procedure With A Manifold Gauge Set...1712
      Charging Procedure...1713
    COMPRESSOR...1715
      Removal And Installation...1715
      Compressor Clutch Disassembly And Assembly...1716
    CONDENSER...1721
      Removal And Installation...1721
    RECEIVER/DRIER...1723
      Removal And Installation...1723
    PRESSURE SWITCH...1725
      Removal And Installation...1725
    EVAPORATOR/BLOWER UNIT...1727
      Removal And Installation...1727
    EXPANSION VALVE...1729
      Removal And Installation...1729
    HEATER ASSEMBLY...1731
      Removal And Installation...1731
      Fan Removal And Installation...1732
      Core Removal And Installation...1732
  SPECIFICATIONS...1735
    VERSAHANDLER SPECIFICATIONS...1737
      Dimensional Specifications...1737
      Performance Specifications...1737
      Controls...1737
      Engine...1737
      Drive System...1738
      Tires...1738
      Hydraulic System...1738
      Electrical System...1738
      Instrument Panel...1738
      Capacities...1738
    ENGINE SPECIFICATIONS...1739
      General...1739
      Cylinder Head...1739
      Valve Guides...1739
      Exhaust Valves...1739
      Intake Valves...1740
      Valve Springs...1740
      Rocker Shaft, Rockers And Bushings...1741
      Pistons And Piston Rings...1741
      Connecting Rods And Bearings...1742
      Crankshaft...1742
      Crankshaft Re-Grind Data...1743
      Main Bearings...1744
      Thrust Washers...1744
      Camshaft And Thrust Washer...1744
      Cylinder Block...1744
      Cylinder Liners...1745
      Fuel Injection Pump...1745
      Fuel Injectors...1745
      Fuel Lift Pump...1745
      Timing Case And Timing Gears...1746
      Oil Pump, Gear And Relief Valve...1747
      Turbocharger...1747
      Flywheel...1747
      Water Pump And Thermostat...1748
      Engine Torque...1749
    MACHINE TORQUE SPECIFICATIONS...1751
      Axle...1751
      Boom...1751
      Drive Box...1751
      Drive Motor...1751
      Engine...1751
      Hydraulic Pump...1752
    TORQUE SPECIFICATIONS FOR BOLTS...1753
      Torque for General SAE Bolts...1753
      Torque For General Metric Bolts...1754
    HYDRAULIC CONNECTION SPECIFICATIONS...1755
      O-ring Face Seal Connection...1755
      Straight Thread O-ring Fitting...1755
      Tubelines And Hoses...1755
      Flare Fitting...1756
      O-ring Flare Fitting...1757
      Port Seal Fitting...1759
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...1761
      Specifications...1761
    CONVERSIONS...1763
      Decimal And Millimeter Equivalents...1763
      U.S. To Metric Conversion...1764
  SMR...1765
    V623-1...1765
    V623-2...1767
    V623-3...1769
6902760 (1-07) - V723 VersaHANDLER Service Manual...1771
  MAINTENANCE SAFETY...1773
  ALPHABETICAL INDEX...1775
  CONTENTS...1777
    FOREWORD...1779
    SAFETY INSTRUCTIONS...1781
      Fire Prevention...1783
    SERIAL NUMBER LOCATION...1785
      VersaHANDLER Serial Number...1785
      Engine Serial Number...1785
      Other Serial Numbers...1785
    DELIVERY REPORT...1786
    BOBCAT VersaHANDLER IDENTIFICATION...1787
  SAFETY AND MAINTENANCE...1789
    LIFTING AND BLOCKING THE VERSAHANDLER...1791
      Procedure...1791
    OPERATOR CAB/CANOPY...1793
      Emergency Exit...1793
      Cab Door...1794
      Cab Door Window...1794
    TRANSPORTING THE VersaHANDLER...1795
      Procedure...1795
    TOWING THE VersaHANDLER...1797
      Procedure (For S/N 367811001 - 367812000, S/N 368011001 - 368012000 and S/N 368111001 - 368112000)...1797
      Procedure (For S/N 367812001 & Above, S/N 368012001 & Above, S/N 368112001 & Above)...1798
    SERVICE SCHEDULE...1799
    AIR CLEANER SERVICE...1801
      Replacing Filter Element...1801
    ENGINE COOLING SYSTEM...1803
      Cleaning The Cooling System...1803
      Checking The Coolant Level...1803
      Replacing The Coolant...1804
    FUEL SYSTEM...1805
      Fuel Specifications...1805
      Filling The Fuel Tank...1805
      Fuel Filter...1805
    ENGINE LUBRICATION SYSTEM...1807
      Checking Engine Oil...1807
      Oil Chart...1807
      Replacing Oil And Filter...1808
    HYDRAULIC/HYDROSTATIC SYSTEM...1809
      Checking And Adding Fluid...1809
      Replacing Hydraulic/Hydrostatic Filter...1810
      Replacing Hydraulic Fluid...1810
    AXLES (FRONT AND REAR) (For S/N 367811001 - 367812000, S/N 368011001 - 368012000, S/N 36811001 - 368112000)...1811
      Checking Oil Level (Planetary Carrier)...1811
      Draining Oil (Planetary Carrier)...1811
      Checking Oil Level (Rear Differential)...1812
      Draining Oil (Rear Differential)...1812
      Checking Oil Level (Front Differential)...1812
      Draining Oil (Front Differential)...1812
    AXLES (FRONT AND REAR) (For S/N 367812001 and Above, S/N 368012001 and Above, S/N 368112001 and Above)...1813
      Checking Oil Level (Planetary Carrier)...1813
      Draining Oil (Planetary Carrier)...1813
      Checking Oil Level (Rear Differential)...1814
      Draining Oil (Rear Differential)...1814
      Checking Oil Level (Front Differential)...1814
      Draining Oil (Front Differential)...1815
    LUBRICATION (For S/N 367811001 - 367812000, S/N 368011001 - 368012000 and S/N 368111001 - 368112000)...1817
      Procedure...1817
      Procedure (Cont’d...1821
    LUBRICATION (For S/N 367812001 and Above, S/N 368012001 and Above, S/N 368112001 and Above)...1823
      Procedure...1823
    TIRE MAINTENANCE...1829
      Wheel Nuts (For S/N 367811001 - 367812000, S/N 368011001 - 368012000 and S/N 368111001 - 368112000)...1829
    SPARK ARRESTOR MUFFLER...1831
      Cleaning...1831
    APPROVED BOOM STOP...1833
      Installing The Approved Boom Stop...1833
      Removing The Approved Boom Stop...1833
    ENGINE COVER...1835
      Opening And Closing The Engine Cover...1835
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS™)...1837
      System Inspection...1837
      System Maintenance...1838
  HYDRAULIC SYSTEM...1839
    HYDRAULIC/HYDROSTATIC SCHEMATICS...1843
    HYDRAULIC SYSTEM INFORMATION...1851
      Troubleshooting Chart...1854
      Tightening Procedures...1855
    LIFT CYLINDER...1857
      Removal And Installation...1857
      Parts Identification...1861
      Disassembly...1862
      Assembly...1867
    BUCKET POSITIONING CYLINDER...1873
      Removal And Installation...1873
    BUCKET POSITIONING CYLINDER (CONT’D)...1876
      Parts Identification...1876
      Disassembly...1877
      Assembly...1881
    EXTENSION CYLINDER...1885
      Cylinder Group Removal And Installation...1885
      Upper Tubeline Removal...1887
      Upper Tubeline Installation...1887
      Extension Cylinder Removal And Installation...1889
      Tubeline Tray Disassembly...1891
      Tubeline Tray Assembly...1893
      Parts Identification...1897
      Disassembly...1898
      Assembly...1902
    TILT CYLINDER...1907
      Removal And Installation...1907
      Parts Identification...1908
      Disassembly...1909
      Assembly...1913
    STEERING CYLINDER (FRONT) (For S/N 367811001 - 367812000, S/N 368011001 - 368012000 and S/N 368111001 - 368112000)...1917
      Removal And Installation...1917
      Parts Identification...1919
      Disassembly...1920
      Assembly...1923
    STEERING CYLINDER (FRONT) (For S/N 367812001 and Above, S/N 368012001 and Above, S/N 368112001 and Above)...1929
      Removing The Steering Cylinder...1929
      Disassembling The Steering Cylinder...1933
      Assembling The Steering Cylinder...1935
    STEERING CYLINDER (REAR) (For S/N 367811001 - 367812000, S/N 368011001 - 368012000 and S/N 368111001 - 368112000)...1939
      Removal And Installation...1939
      Parts Identification...1941
      Disassembly...1942
      Assembly...1945
    STEERING CYLINDER (REAR) (For S/N 367812001 and Above, S/N 368012001 and Above, S/N 368112001 and Above)...1951
      Removing The Steering Cylinder...1951
      Installing The Steering Cylinder...1953
      Disassembling The Steering Cylinder...1955
      Assembling The Steering Cylinder...1957
    DRIVE BOX (For S/N 367811001 - 367812000, S/N 368011001 - 368012000 and S/N 368111001 - 368112000)...1961
      Parts Identification...1961
      Disassembly...1962
      Inspection...1967
      Assembly...1968
    DRIVE BOX (For S/N 367812001 and Above, S/N 368012001 and Above, S/N 368112001 and Above)...1975
      Parts Identification...1975
      Disassembly...1976
      Assembly...1980
      Special Tools...1983
    MAIN RELIEF VALVE...1985
      Testing And Adjustment...1985
      Removal And Installation...1986
    QUICK TACH CYLINDER...1987
      Removal And Installation...1987
      Parts Identification...1989
      Disassembly...1990
      Assembly...1993
    FRAME LEVELING CYLINDER...1995
      Removal And Installation (For S/N 367811001 - 367812000, S/N 368011001 - 368012000 and S/N 368111001 - 368112000)...1995
      Removal And Installation (For S/N 367812001 & Above, S/N 368012001 & Above, S/N 368112001 & Above)...1996
      Removal...1997
      Parts Identification...1998
      Disassembly...1999
      Assembly...2004
    STEERING MODE VALVE BLOCK...2011
      Removal And Installation...2011
      Parts Identification...2013
      Disassembly...2014
      Solenoid Testing...2016
      Assembly...2016
    BRAKE VALVE...2019
      Removal And Installation...2019
      Disassembly And Assembly...2020
    GEAR PUMP...2023
      Removal And Installation...2023
      Parts Identification...2026
      Disassembly And Assembly...2027
    FAN MOTOR...2033
      Removal And Installation...2033
      Parts Identification...2037
      Disassembly And Assembly...2038
    HYDRAULIC RESERVOIR...2041
      Removal And Installation...2041
    STEERING VALVE...2043
      Removal And Installation...2043
      Parts Identification...2044
      Disassembly...2045
      Inspection...2051
      Assembly...2051
    HYDRAULIC CONTROL VALVE...2059
      Troubleshooting Chart (Controllers)...2059
      Telescoping Valve Section Troubleshooting...2060
      Auxiliary Valve Section Troubleshooting...2064
      Troubleshooting Chart (Control Valve)...2068
      Removal And Installation...2069
      Parts Identification...2073
      Disassembly And Assembly...2074
      End Housing Disassembly And Assembly...2075
      Lifting Valve Section Disassembly And Assembly...2076
      Tilting Valve Section Disassembly And Assembly...2081
      Telescoping Valve Section Disassembly And Assembly...2086
      Auxiliary/Frame Leveling Valve Section Disassembly And Assembly...2098
      Inlet-Outlet Valve Section Disassembly And Assembly...2108
    PORT RELIEF VALVES...2113
      Adjustment Procedure...2113
    FLOW CONTROL VALVE...2115
      Removal And Installation...2115
    JOYSTICK...2117
      Removal And Installation...2117
    PARKING BRAKE...2119
      Pressure Switch Removal And Installation...2119
      Pressure Switch Disassembly And Assembly...2121
      Parking Brake Valve Removal And Installation...2122
      Parking Brake Valve Disassembly And Assembly...2123
    PRESSURE REDUCING VALVE...2125
      Testing...2125
      Removal And Installation...2126
      Disassembly And Assembly...2127
    ACCUMULATOR...2129
      Removal And Installation...2129
    TOW VALVE...2131
      Removal And Installation...2131
      Disassembly And Assembly...2132
  HYDROSTATIC SYSTEM...2137
    HYDROSTATIC SYSTEM INFORMATION...2139
      Troubleshooting Chart...2139
      Replenishing Valve Function...2140
    OIL COOLER...2141
      Description...2141
    HYDROSTATIC DRIVE MOTOR...2143
      Removal And Installation...2143
      Parts Identification...2144
      Inspection...2162
      Assembly...2164
    HYDROSTATIC PUMP...2181
      Removal And Installation...2181
      Parts Identification...2184
      Disassembly...2189
      Inspection...2201
      Assembly...2205
  DRIVE SYSTEM...2221
    TROUBLESHOOTING...2225
      Chart...2225
    AXLE AND DIFFERENTIAL (FRONT) (For S/N 367811001 - 367812000, S/N 368011001 - 368012000 and S/N 368111001 - 368112000)...2227
      General Information...2227
      Planetary Carrier Parts Identification...2227
      Planetary Carrier Disassembly...2228
      Planetary Carrier Inspection...2230
      Wheel Hub Parts Identification...2231
      Wheel Hub Disassembly...2232
      Wheel Hub Inspection...2235
      Steering Knuckle Parts Identification...2235
      Steering Knuckle Disassembly...2236
      Axle Housing/Drive Axle Parts Identification...2238
      Axle Housing/Drive Axle Disassembly...2239
      Brake Group Parts Identification...2244
      Brake Group Disassembly...2244
      Brake Group Inspection...2250
      Differential Parts Identification...2251
      Differential Disassembly...2251
      Differential Inspection...2254
      Pinion Group Parts Identification...2255
      Pinion Group Disassembly...2256
      Pinion Group Inspection...2258
      Pinion Group Assembly...2259
      Differential Assembly...2265
      Brake Group Assembly...2268
      Axle Housing/Drive Axle Assembly...2278
      Steering Knuckle Assembly...2283
      Wheel Hub Assembly...2286
      Planetary Carrier Assembly...2288
    AXLE AND DIFFERENTIAL (REAR) (For S/N 367811001 - 367812000, S/N 368011001 - 368012000 and S/N 368111001 - 368112000)...2291
      General Information...2291
      Planetary Carrier Parts Identification...2291
      Planetary Carrier Disassembly...2292
      Planetary Carrier Inspection...2294
      Wheel Hub Parts Identification...2295
      Wheel Hub Disassembly...2296
      Wheel Hub Inspection...2299
      Steering Knuckle Parts Identification...2299
      Steering Knuckle Disassembly...2300
      Axle Housing/Drive Axle Parts Identification...2302
      Axle Housing/Drive Axle Disassembly...2303
      Differential Parts Identification...2306
      Differential Disassembly...2306
      Differential Inspection...2313
      Pinion Group Parts Identification...2314
      Pinion Group Disassembly...2315
      Pinion Group Inspection...2318
      Pinion Group Assembly...2319
      Differential Assembly...2325
      Axle Housing/Drive Axle Assembly...2336
      Steering Knuckle Assembly...2339
      Wheel Hub Assembly...2342
      Planetary Carrier Assembly...2344
    AXLE AND DIFFERENTIAL (FRONT) (For S/N 367812001 and Above, S/N 368012001 and Above, S/N 368112001 and Above)...2347
      General Information...2347
      Planetary Carrier Parts Identification...2347
      Planetary Carrier Disassembly...2348
      Steering Knuckle And Drive Axle Parts Identification...2353
      Steering Knuckle Disassembly...2354
      Drive Axle Disassembly...2356
      Brake System Identification...2358
      Brake System Disassembly...2359
      Differential Parts Identification...2363
      Differential Disassembly...2364
      Bevel Pinion Parts Identification...2369
      Bevel Pinion Disassembly...2370
      Bevel Pinion Assembly...2373
      Differential Assembly...2382
      Brake System Assembly...2387
      Drive Axle Assembly...2394
      Steering Knuckle Assembly...2396
      Planetary Carrier Assembly...2399
      Special Tools...2404
    AXLE AND DIFFERENTIAL (REAR) (For S/N 367812001 and Above, S/N 368012001 and Above, S/N 368112001 and Above)...2405
      General Information...2405
      Planetary Carrier Parts Identification...2405
      Planetary Carrier Disassembly...2406
      Steering Knuckle And Drive Axle Parts Identification...2411
      Steering Knuckle Disassembly...2412
      Differential And Bevel Pinion Parts Identification...2414
      Differential Disassembly...2415
      Bevel Pinion Disassembly...2419
      Bevel Pinion Assembly...2422
      Differential Assembly...2430
      Steering Knuckle Assembly...2435
      Planetary Carrier Assembly...2438
      Special Tools...2442
    FRONT AXLE WITHOUT FRAME LEVELING (For S/N 367811001 - 367812000)...2443
      Removal...2443
      Installation...2449
    FRONT AXLE WITH FRAME LEVELING (For S/N 368011001 - 368012000 and S/N 368111001 - 368112000)...2455
      Removal...2455
      Installation...2460
    AXLE PIVOT FRAME (S/N 367811001 - 367812000, S/ N 368011001 - 368012000 and S/N 368111001 - 368112000)...2467
      Removal And Installation...2467
      Bushing Removal And Installation...2468
    FRONT AXLE (For S/N 367812001 and Above, S/N 368012001 and Above, S/N 368112001 and Above)...2469
      Removal...2469
      Installation...2476
    AXLE TOE-IN (For S/N 367811001 - 367812000, S/N 368011001 - 368012000 and S/N 368111001 - 368112000)...2483
      Adjustment...2483
    AXLE TOE-IN (For S/N 367812001 and Above, S/N 368012001 and Above, S/N 368112001 and Above)...2485
      Adjustment...2485
    PARKING BRAKE (For S/N 367811001 - 367812000, S/N 368011001 - 368012000 and S/N 368111001 - 368112000)...2487
      Releasing The Brake For Towing...2487
      Re-Activating The Brake...2488
    PARKING BRAKE (For S/N 367812001 and Above, S/N 368012001 and Above, S/N 368112001 and Above)...2489
      Releasing The Brake For Towing...2489
      Re-Activating The Brake...2490
    STEERING ANGLE ADJUSTMENT (For S/N 367811001 - 367812000, S/N 368011001 - 368012000 and S/N 368111001 - 368112000)...2491
      Adjustment...2491
    STEERING ANGLE ADJUSTMENT (For S/N 367812001 and Above, S/N 368012001 and Above, S/N 368112001 and Above)...2493
      Adjustment...2493
    DRIVESHAFT...2495
      Removal And Installation (S/N 367811001 - 367812000, S/N 368011001 - 368012000 and S/N 368111001 - 368112000)...2495
      Removal And Installation (S/N 367812001 & Above, S/ N 368012001 & Above, S/N 368112001 & Above)...2495
    SERVICE BRAKE (For S/N 367811001 - 367812000, S/N 368011001 - 368012000 and S/N 368111001 - 368112000)...2497
      Description...2497
      Bleeding The Brake Circuit...2497
    SERVICE BRAKE (For S/N 367812001 and Above, S/N 368012001 and Above, S/N 368112001 and Above)...2499
      Description...2499
      Bleeding The Brake Circuit...2499
    REAR AXLE (For S/N 367811001 - 367812000, S/N 368011001 - 368012000 and S/N 368111001 - 368112000)...2501
      Removal...2501
      Installation...2504
    REAR AXLE (For S/N 367812001 and Above, S/N 368012001 and Above, S/N 368112001 and Above)...2509
      Removal...2509
      Installation...2512
  MAIN FRAME...2517
    OPERATOR CAB...2519
      Removal And Installation...2519
    CANOPY...2527
      Removal And Installation...2527
    OPERATOR SEAT...2533
      Removal And Installation...2533
    BOOM ASSEMBLY...2535
      Removal And Installation...2535
    INNER BOOM...2539
      Removal...2539
      Installation...2541
    WEAR PADS (FRONT)...2543
      Removal And Installation...2543
    WEAR PADS (REAR)...2545
      Removal...2545
      Installation...2545
    ENGINE COVER...2547
      Gas Cylinder Removal And Installation...2547
      Removal And Installation...2547
    AIR INTAKE COWLING...2549
      Removal And Installation...2549
    FUEL TANK...2551
      Removal And Installation...2551
    QUICK-TACH...2555
      Removal And Installation...2555
    REAR WEIGHTS...2557
      Removal And Installation...2557
    FENDER...2559
      Removal And Installation (S/N 367811001 - 367812000, S/N 368011001 - 368012000 and S/N 368111001 - 368112000)...2559
      Removal And Installation (S/N 367812001 & Above, S/ N 368012001 & Above, S/N 368112001 & Above)...2559
    PIVOT LINK...2561
      Removal And Installation...2561
    DASH COVER/STEERING COLUMN COVER...2565
      Removal And Installation...2565
    JOYSTICK PANEL...2569
      Removal And Installation...2569
  ELECTRICAL SYSTEM AND ANALYSIS...2571
    ELECTRICAL SCHEMATICS...2573
    ELECTRICAL SYSTEM INFORMATION...2595
      Troubleshooting Chart...2595
      Description...2596
      Fuses, Diodes & Relays...2596
    BATTERY...2599
      Removal And Installation...2599
      Servicing...2600
      Using A Booster Battery (Jump Starting)...2601
    ALTERNATOR...2603
      Removal And Installation...2603
      Adjusting The Alternator Belt...2604
    STARTER...2605
      Removal And Installation...2605
      Disassembly...2606
      Inspection And Repair...2611
      Assembly...2615
    LATERAL OPERATOR RESTRAINT SYSTEM (LOR’S™)...2621
      Restraint Bar Removal And Installation...2621
      Sensor Removal And Installation...2622
      Strut Removal And Installation...2624
      Strut Disassembly And Assembly...2625
      Restraint Bar Bushing Removal And Installation...2626
      Restraint Bar Bumper Removal And Installation...2626
    LIGHTS...2627
      Rear Light Removal And Installation...2627
      Front Light Removal And Installation...2628
    TRAVEL/SIGNAL LEVER...2629
      Removal And Installation...2629
    INSTRUMENT PANEL...2631
      Removal And Installation...2631
    SWITCH PANEL...2633
      Removal And Installation...2633
    BRAKE LIGHT SWITCH...2635
      Removal And Installation...2635
      Adjustment...2635
    FRONT WIPER MOTOR...2637
      Removal And Installation...2637
    TOP WIPER MOTOR...2641
      Removal And Installation...2641
    REAR WIPER MOTOR...2643
      Removal And Installation...2643
    PEDAL ASSEMBLY...2645
      Removal And Installation...2645
      Disassembly And Assembly...2646
    INCHING SWITCH...2651
      Removal And Installation...2651
      Adjustment...2651
    SERVICE SOFTWARE...2653
      Connecting The Laptop Computer...2653
      Entering The Service Software...2654
      Monitor Screen...2655
      Warnings Screen...2656
      Calibrate Inch Pedal...2657
      Calibrate Creep Potentiometer...2659
      Program/Update Susmic Controller...2660
    FRAME LEVEL SPEED SWITCH...2663
      Description...2663
      Removal...2663
      Installation...2664
      Disassembly And Assembly...2665
  ENGINE SERVICE...2667
    TROUBLESHOOTING...2671
      Chart...2671
    ENGINE SPEED CONTROL...2673
      Removal And Installation...2673
    MUFFLER...2675
      Removal And Installation...2675
    AIR CLEANER...2677
      Housing Removal And Installation...2677
    OIL COOLER/RADIATOR...2679
      Removal And Installation...2679
      Disassembly And Assembly...2681
    ENGINE AND ENGINE MOUNTS...2683
      Removal And Installation...2683
    ENGINE COMPONENTS AND TESTING...2687
      Fuel Injection Pump Removal...2687
      Fuel Injection Pump Installation...2690
      Fuel Injectors Removal And Installation...2693
      Checking The Fuel Lift Pump...2695
      Fuel Lift Pump Removal And Installation...2696
      Compression Checking...2697
      Glow Plugs Checking...2698
      Glow Plugs Removal And Installation...2698
    ENGINE TIMING...2701
      Procedure...2701
    ENGINE/HYDROSTAT ASSEMBLY...2703
      Removal And Installation...2703
    FLYWHEEL AND HOUSING...2715
      Removal And Installation...2715
      Ring Gear Removal...2718
      Ring Gear Installation...2718
    RECONDITIONING THE ENGINE...2719
      Turbo Charger Troubleshooting...2719
      Turbo Charger Description...2720
      Turbo Charger Removal And Installation...2720
      Exhaust Manifold Removal And Installation...2722
      Fuel Injector Cover Removal And Installation...2722
      Rocker Cover Removal And Installation...2723
      Cylinder Head Removal...2724
      Cylinder Head Inspection...2726
      Cylinder Head Installation...2726
      Rocker Shaft Disassembly And Assembly...2729
      Valve Removal...2729
      Valve Springs Checking...2730
      Valve Depth Checking...2730
      Valve Guides Checking...2731
      Valve Guide Removal...2732
      Valve Guide Installation...2732
      Valves Checking...2733
      Cutting A Valve Seat...2733
      Valve Seat Assembly...2734
      Changing Valve Springs (With Cylinder Head Installed)...2735
      Valve Clearance Adjustment...2736
      Timing Case And Drive Assembly Description...2737
      Timing Cover Removal...2737
      Timing Cover Installation...2737
      Crankshaft Pulley Removal And Installation...2737
      Front Oil Seal Removal And Installation...2737
      Timing Case And Gear Removal...2738
      Timing Case And Gear Installation...2739
      Camshaft And Tappets Removal...2741
      Camshaft And Tappets Installation...2742
      Pistons And Connecting Rods Description...2744
      Pistons And Connecting Rods Removal...2744
      Pistons And Connecting Rods Disassembly...2746
      Piston Ring End Gap...2746
      Piston Ring Installation...2746
      Piston Ring Groove Clearance...2747
      Connecting Rod Inspection...2748
      Connecting Rod Bushing Replacement...2748
      Piston And Connecting Rod Assembly...2748
      Piston And Connecting Rod Installation...2748
      Checking Piston Height...2750
      Crankshaft And Bearings Description...2751
      Crankshaft And Bearings Removal...2751
      Inspection Of Crankshaft And Bearings...2753
      Crankshaft And Bearings Installation...2753
      Rear Oil Seal Removal...2755
      Rear Oil Seal Housing Positioning...2755
      Rear Oil Seal Installation...2755
      Checking Crankshaft End Play...2756
      Cooling System Description...2757
      Thermostat Removal and Installation...2758
      Thermostat Testing...2758
      Lubricating Oil Cooler Removal And Installation...2758
      Water Pump Removal...2759
      Water Pump Installation...2759
      Engine Lubrication System Description...2760
      Oil Filter Adapter Removal And Installation...2761
      Oil Pan Removal And Installation...2761
      Oil Screen And Pick-up Tube...2762
      Oil Pump Removal...2762
      Oil Pump Installation...2763
      Oil Pump Disassembly And Assembly...2764
      Oil Pressure Relief Valve Disassembly And Assembly...2764
      Engine Block Description...2765
      Engine Block Disassembly And Assembly...2765
      Piston Cooling Jet Removal...2766
      Piston Cooling Jet Installation...2766
      Piston Cooling Jet Alignment...2766
      Inspection...2766
      Cylinder Liner Inspection...2767
      Cylinder Liner Removal...2768
      Cylinder Liner Installation...2769
  HEATING, VENTILATION, AIR CONDITIONING...2771
    AIR CONDITIONING SYSTEM FLOW...2773
      Principals...2773
      Chart...2774
    COMPONENTS...2775
      Identification...2775
    SAFETY...2777
      Safety Equipment...2777
    REGULAR MAINTENANCE...2779
      Filter Element Removal And Installation...2779
      Compressor Drive Belt Inspection...2780
      Cleaning The Condenser...2780
    BASIC TROUBLESHOOTING...2781
      Poor A/C Performance...2781
      Compressor Drive Belt Inspection...2781
      Checking The Electrical System...2782
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...2787
      Compressor Oil...2787
      Compressor Oil Check...2787
      Component Replacement And Refrigeration Leaks...2788
    SYSTEM TROUBLESHOOTING CHART...2789
    TEMPERATURE/PRESSURE...2793
      Chart...2793
    AIR CONDITIONING SERVICE...2795
      Chart...2795
    SYSTEM CHARGING AND RECLAMATION...2797
      Reclamation Procedure...2797
      Charging Procedure With A Manifold Gauge Set...2800
      Charging Procedure...2801
    COMPRESSOR...2803
      Removal And Installation...2803
      Compressor Clutch Disassembly And Assembly...2804
    CONDENSER...2809
      Removal And Installation...2809
    RECEIVER/DRIER...2811
      Removal And Installation...2811
    PRESSURE SWITCH...2813
      Removal And Installation...2813
    EVAPORATOR/BLOWER UNIT...2815
      Removal And Installation...2815
    EXPANSION VALVE...2817
      Removal And Installation...2817
    HEATER ASSEMBLY...2819
      Removal And Installation...2819
      Fan Removal And Installation...2820
      Core Removal And Installation...2820
  SPECIFICATIONS...2823
    VersaHANDLER SPECIFICATIONS...2825
      Dimensional Specifications...2825
      Performance Specifications...2826
      Engine...2826
      Controls...2826
      Drive System...2826
      Tires...2827
      Capacities...2827
      Hydraulic System...2827
      Electrical System...2827
      Instrument Panel...2827
    ENGINE SPECIFICATIONS...2829
      General...2829
      Cylinder Head...2829
      Valve Guides...2829
      Exhaust Valves...2830
      Intake Valves...2830
      Valve Springs...2830
      Rocker Shaft, Rockers And Bushings...2831
      Pistons And Piston Rings...2831
      Connecting Rods And Bearings...2832
      Crankshaft...2832
      Crankshaft Re-Grind Data...2833
      Main Bearings...2834
      Thrust Washers...2834
      Camshaft And Thrust Washer...2834
      Cylinder Block...2834
      Cylinder Liners...2835
      Fuel Injection Pump...2835
      Fuel Injectors...2835
      Fuel Lift Pump...2835
      Timing Case And Timing Gears...2836
      Oil Pump, Gear And Relief Valve...2837
      Turbocharger...2837
      Flywheel...2837
      Water Pump And Thermostat...2838
      Engine Torque Component...2839
    MACHINE TORQUE SPECIFICATIONS...2841
      Axle...2841
      Boom...2841
      Drive Box...2841
      Drive Motor...2841
      Engine...2842
      Hydraulic Pump...2842
    TORQUE SPECIFICATIONS FOR BOLTS...2843
      Torque for General SAE Bolts...2843
      Torque For General Metric Bolts...2844
    HYDRAULIC CONNECTION SPECIFICATIONS...2845
      O-ring Face Seal Connection...2845
      Straight Thread O-ring Fitting...2845
      Tubelines And Hoses...2845
      Flare Fitting...2846
      O-ring Flare Fitting...2847
      Port Seal Fitting...2849
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...2851
      Specifications...2851
    CONVERSIONS...2853
      Decimal And Millimeter Equivalents...2853
      U.S. To Metric Conversion Chart...2853
  SMR...2855
    V723-1...2855
    V723-2...2857
    V723-3...2859
    V723-4...2861
    V723-5...2863
6904754 (12-06) - V638 VersaHANDLER Telescopic Tool Carrier (TTC) Operation & Maintenance Manual...2865
  OPERATOR SAFETY WARNINGS...2867
  CONTENTS...2869
  FOREWORD...2871
    SERIAL NUMBER LOCATION...2873
      VersaHANDLER Serial Number...2873
      Engine Serial Number...2873
    DELIVERY REPORT...2874
    BOBCAT VersaHANDLER IDENTIFICATION...2875
    FEATURES, ACCESSORIES AND ATTACHMENTS...2876
      Avaliable Tires...2876
      Attachments...2876
  SAFETY...2877
    SAFETY INSTRUCTIONS...2879
      Before Operation...2879
      Safe Operation Is The Operator’s Responsibility...2880
      Safe Operation Needs A Qualified Operator...2880
      Fire Prevention...2881
    MACHINE SIGNS (DECALS)...2882
  OPERATING INSTRUCTIONS...2885
    OPERATOR CONTROLS IDENFICATION...2887
      Operator Components...2887
      Travel Direction & Two-Speed Control...2887
      Steering Wheel...2887
      Direction Signal...2888
      Front Wiper/Washer/Headlight Dimmer...2888
      Horn...2888
      Steering Wheel Tilt Adjustment...2888
      Center Instrument Panel...2889
      Right Instrument And Indicator Panel...2890
      Accelerator Pedal...2891
      Brake Pedal And Inching Control...2891
      Frame Level Switch...2892
    HYDRAULIC CONTROLS...2893
      Hydraulic Control Lever (Joystick)...2893
    STEERING CONTROLS...2894
      Steering Mode Selection...2894
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS)...2895
    SERVICE SCHEDULE DECAL...2896
    DAILY INSPECTION...2896
      Daily Inspection And Maintenance...2896
    PRE-STARTING PROCEDURE...2897
    STARTING THE ENGINE...2898
    BEFORE USING THE VersaHANDLER...2899
    ATTACHMENTS AND BUCKETS...2900
      Installing The Bucket Or Attachment...2900
      Releasing Auxiliary Hydraulic Pressure...2901
      Removing The Bucket Or Attachment...2901
    VersaHANDLER OPERATION...2902
      Raising A Load And Extending The Boom...2902
      Using Frame Leveling...2903
      Using Stabilizers (If Equipped)...2904
      Load Capacity Charts...2905
    PARKING THE VERSAHANDLER...2906
    TRANSPORTING THE VersaHANDLER...2906
    LIFTING THE VersaHANDLER...2907
    TOWING THE VersaHANDLER...2908
  PREVENTIVE MAINTENANCE...2911
    MAINTENANCE SAFETY...2913
    SERVICE SCHEDULE...2915
    OPERATOR CAB/CANOPY...2916
      Emergency Exit...2916
      Cab Door...2917
      Cab Door Window...2917
    APPROVED BOOM STOP...2918
      Installing The Approved Boom Stop...2918
      Removing The Approved Boom Stop...2918
    ENGINE COVER...2918
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS)...2919
      System Inspection...2919
      System Maintenance...2920
    AIR CLEANER SERVICE...2921
      Replacing Filter Element...2921
    FUEL SYSTEM...2923
      Fuel Specifications...2923
      Filling The Fuel Tank...2923
      Fuel Filter...2923
    ENGINE LUBRICATION SYSTEM...2924
      Checking Engine Oil...2924
      Oil Chart...2924
      Replacing Oil And Filter...2925
    ENGINE COOLING SYSTEM...2926
      Cleaning The Cooling System...2926
      Checking The Coolant Level...2926
      Replacing The Coolant...2927
    ALTERNATOR BELT...2928
      Adjusting...2928
    SPARK ARRESTOR MUFFLER...2929
    ELECTRICAL SYSTEM...2930
      Description...2930
      Battery & Terminal Maintenance...2930
      Fuses, Diodes & Relays...2930
      Using A Booster Battery (Jump Starting)...2932
      Battery Disconnect Switch...2933
    HYDRAULIC/HYDROSTATIC SYSTEM...2934
      Checking And Adding Fluid...2934
      Replacing Hydraulic/Hydrostatic Filter...2934
      Replacing Hydraulic Fluid...2935
    BRAKE CONTROL SYSTEM...2936
      Inspection And Maintenance...2936
    AXLES (FRONT AND REAR)...2937
      Checking Oil Level (Planetary Carrier)...2937
      Draining Oil (Planetary Carrier)...2937
      Checking Oil Level (Rear Differential)...2938
      Draining Oil (Rear Differential)...2938
      Checking Oil Level (Front Differential)...2938
      Draining Oil (Front Differential)...2939
    TIRE MAINTENANCE...2940
      Wheel Nuts...2940
      Tire Mounting...2940
      Tire Rotation...2940
      Tire Pressure...2940
    LUBRICATION...2941
    ATTACHMENT FRAME...2945
      Inspection And Maintenance...2945
    CHAIN CHECKING AND ADJUSTING PROCEDURE...2946
      Checking/adjustment Procedure...2946
      Extend/retract Chain Wear Check...2947
  MACHINE SIGN TRANSLATIONS...2949
    SERVICE SCHEDULE...2951
      English (6918234)...2951
      French (Not Available At Time Of Printing)...2951
      Spanish (Not Available At Time Of Printing)...2952
    WARNING...2953
      English (6809613)...2953
      French (6809613FR)...2953
      Spanish (6809613AR)...2954
    DANGER...2955
      English (6918255)...2955
      French (6918255FR)...2955
      Spanish (6918255AR)...2955
    WARNING/DANGER...2956
      English (6809614)...2956
      French (6809614FR)...2956
      Spanish (6809614AR)...2956
      English (6809610)...2956
      French (6809610FR)...2956
      Spanish (6809610AR)...2956
      English (6577754)...2957
      French (6577754FR)...2957
      Spanish (6577754AR)...2957
      English (6908056)...2957
      French (6908056FR)...2957
      Spanish (6908056AR)...2957
      English (6809606)...2958
      French (6809606FR)...2958
      Spanish (6809606AR)...2958
      English (6809607)...2959
      French (6809607FR)...2959
      Spanish (6809607AR)...2959
    WARNING...2960
      English (6809622)...2960
      French (6809622FR)...2960
      Spanish (6809622AR)...2960
      French (6809608FR)...2961
      Spanish (6809608AR)...2961
      English (6960068)...2962
      French (6960068FR)...2962
      Spanish (6960068AR)...2962
      English (6911376)...2963
      French (6911376FR)...2963
      Spanish (6911376AR)...2963
  SPECIFICATIONS...2965
    VersaHANDLER TELESCOPIC TOOL CARRIER (TTC)...2967
      Dimensional Specifications...2967
      Performance Specifications...2968
      Engine...2968
      Controls...2968
      Drive System...2968
      Tires...2969
      Capacities...2969
      Hydraulic System...2969
      Electrical System...2969
      Instrument Panel...2969
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS...2970
  WARRANTY...2971
6904755 (1-07) - V638 VersaHANDLER Service Manual...2973
  MAINTENANCE SAFETY...2975
  ALPHABETICAL INDEX...2977
  CONTENTS...2979
    FOREWORD...2981
    SAFETY INSTRUCTIONS...2983
      Fire Prevention...2985
    SERIAL NUMBER LOCATION...2987
      VersaHANDLER Serial Number...2987
      Engine Serial Number...2987
      Other Serial Numbers...2987
    DELIVERY REPORT...2988
    BOBCAT VersaHANDLER IDENTIFICATION...2989
  SAFETY AND MAINTENANCE...2991
    LIFTING AND BLOCKING THE VERSAHANDLER...2993
      Procedure...2993
    OPERATOR CAB/CANOPY...2995
      Emergency Exit...2995
      Cab Door...2996
      Cab Door Window...2996
    TRANSPORTING THE VersaHANDLER...2997
      Procedure...2997
    TOWING THE VersaHANDLER...2999
      Procedure...2999
    SERVICE SCHEDULE...3001
    AIR CLEANER SERVICE...3003
      Replacing Filter Element...3003
    ENGINE COOLING SYSTEM...3005
      Cleaning The Cooling System...3005
      Checking The Coolant Level...3005
      Replacing The Coolant...3006
    FUEL SYSTEM...3007
      Fuel Specifications...3007
      Filling The Fuel Tank...3007
      Fuel Filter...3007
    ENGINE LUBRICATION SYSTEM...3009
      Checking Engine Oil...3009
      Oil Chart...3009
      Replacing Oil And Filter...3010
    HYDRAULIC/HYDROSTATIC SYSTEM...3011
      Checking And Adding Fluid...3011
      Replacing Hydraulic/Hydrostatic Filter...3011
      Replacing Hydraulic Fluid...3012
    AXLES (FRONT AND REAR)...3013
      Checking Oil Level (Planetary Carrier)...3013
      Draining Oil (Planetary Carrier)...3013
      Checking Oil Level (Rear Differential)...3014
      Checking Oil Level (Front Differential)...3014
      Draining Oil (Front Differential)...3015
    LUBRICATION...3017
      Procedure...3017
    ATTACHMENT FRAME...3021
      Inspection And Maintenance...3021
    TIRE MAINTENANCE...3023
      Wheel Nuts...3023
      Tire Rotation...3024
      Tire Mounting...3024
    SPARK ARRESTOR MUFFLER...3027
      Cleaning...3027
    APPROVED BOOM STOP...3029
      Installing The Approved Boom Stop...3029
      Removing The Approved Boom Stop...3029
    ENGINE COVER...3031
      Opening And Closing The Engine Cover...3031
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS™)...3033
      System Inspection...3033
      System Maintenance...3034
    CHAIN CHECKING AND ADJUSTING PROCEDURE...3035
      Checking/Adjustment Procedure...3035
      Extend/Retract Chain Wear Check...3036
  HYDRAULIC SYSTEM...3037
    HYDRAULIC/HYDROSTATIC SCHEMATICS...3041
    HYDRAULIC SYSTEM INFORMATION...3043
      Troubleshooting Chart...3046
      Tightening Procedures...3047
    LIFT CYLINDER...3049
      Removal And Installation...3049
      Parts Identification...3052
      Disassembly...3053
      Assembly...3058
    BUCKET POSITIONING CYLINDER...3063
      Removal And Installation...3063
      Removal And Installation (Cont’d)...3065
      Parts Identification...3066
      Disassembly...3067
      Disassembly (Cont'd)...3070
      Assembly...3071
    EXTENSION CYLINDER...3075
      Cylinder Group Removal And Installation...3075
      Parts Identification...3078
    TILT CYLINDER...3085
      Removal And Installation...3085
      Disassembly...3088
    STEERING CYLINDER (FRONT)...3095
      Removing The Steering Cylinder...3095
      Installing The Steering Cylinder...3097
      Disassembling The Steering Cylinder...3099
      Assembling The Steering Cylinder...3101
    STEERING CYLINDER (REAR)...3105
      Removing The Steering Cylinder...3105
      Installing The Steering Cylinder...3107
      Disassembling The Steering Cylinder...3109
      Assembling The Steering Cylinder...3110
    DRIVE BOX...3115
      Parts Identification...3115
      Disassembly...3116
      Assembly...3120
      Special Tools...3123
    MAIN RELIEF VALVE...3125
      Testing And Adjustment...3125
      Removal And Installation...3126
    QUICK TACH CYLINDER...3127
      Removal And Installation...3127
      Parts Identification...3129
      Disassembly...3130
      Assembly...3133
    FRAME LEVELING CYLINDER...3135
      Removal And Installation...3135
      Parts Identification...3137
      Disassembly...3138
      Assembly...3143
    STEERING MODE VALVE BLOCK...3149
      Removal And Installation...3149
      Parts Identification...3151
      Disassembly...3152
      Solenoid Testing...3154
      Assembly...3154
    BRAKE VALVE...3157
      Removal And Installation...3157
      Disassembly And Assembly...3158
    GEAR PUMP...3161
      Removal And Installation...3161
      Parts Identification...3164
      Disassembly And Assembly...3165
    FAN MOTOR...3171
      Removal And Installation...3171
      Parts Identification...3175
      Disassembly And Assembly...3176
    HYDRAULIC RESERVOIR...3179
      Removal And Installation...3179
    STEERING VALVE...3181
      Removal And Installation...3181
      Parts Identification...3182
      Disassembly...3183
      Inspection...3186
      Assembly...3186
    HYDRAULIC CONTROL VALVE...3191
      Troubleshooting Chart (Controllers)...3191
      Telescoping Valve Section Troubleshooting...3192
      Auxiliary Valve Section Troubleshooting...3196
      Troubleshooting Chart (Control Valve)...3200
      Removal And Installation...3201
      Parts Identification...3205
      Disassembly And Assembly...3206
      End Housing Disassembly And Assembly...3207
      Lifting Valve Section Disassembly And Assembly...3208
      Tilting Valve Section Disassembly And Assembly...3213
      Telescoping Valve Section Disassembly And Assembly...3218
      Auxiliary/Frame Leveling Valve Section Disassembly And Assembly...3230
      Inlet-Outlet Valve Section Disassembly And Assembly...3240
    PORT RELIEF VALVES...3245
      Adjustment Procedure...3245
    FLOW CONTROL VALVE...3247
      Removal And Installation...3247
    JOYSTICK...3249
      Removal And Installation...3249
    PARKING BRAKE...3251
      Pressure Switch Removal And Installation...3251
      Pressure Switch Disassembly And Assembly...3253
      Parking Brake Valve Removal And Installation...3254
      Parking Brake Valve Disassembly And Assembly...3254
    PRESSURE REDUCING VALVE...3257
      Testing...3257
      Removal And Installation...3258
      Disassembly And Assembly...3259
    ACCUMULATOR...3261
      Removal And Installation...3261
    TOW VALVE...3263
      Removal And Installation...3263
      Disassembly And Assembly...3264
  HYDROSTATIC SYSTEM...3269
    HYDROSTATIC SYSTEM INFORMATION...3271
      Troubleshooting Chart...3271
      Replenishing Valve Function...3272
    OIL COOLER...3273
      Description...3273
    HYDROSTATIC DRIVE MOTOR...3275
      Removal And Installation...3275
      Parts Identification...3276
      Disassembly...3279
      Inspection...3294
      Assembly...3296
    HYDROSTATIC PUMP...3313
      Removal And Installation...3313
      Parts Identification...3316
      Disassembly...3321
      Inspection...3333
      Assembly...3337
    CUSTOMER PACKING LIST...3318
  DRIVE SYSTEM...3353
    TROUBLESHOOTING...3355
      Chart...3355
    AXLE AND DIFFERENTIAL (FRONT)...3357
      General Information...3357
      Planetary Carrier Parts Identification...3357
      Planetary Carrier Disassembly...3358
      Planetary Carrier Disassembly (Cont’d)...3361
      Steering Knuckle And Drive Axle Parts Identification...3363
      Steering Knuckle Disassembly...3364
      Drive Axle Disassembly...3366
      Brake system Identification...3368
      Brake System Disassembly...3369
      Differential Parts Identification...3373
      Differential Disassembly...3374
      Bevel pinion Parts Identification...3379
      Bevel Pinion Disassembly...3380
      Bevel Pinion Disassembly (Cont’d)...3381
      Bevel Pinion Assembly...3383
      Setting Ring And Pinion Backlash...3395
      Brake System Assembly...3397
      Drive Axle Assembly...3404
      Steering Knuckle Assembly...3406
      Steering Knuckle Assembly (Cont’d)...3407
      Planetary Carrier Assembly...3409
      Special Tools...3414
    AXLE AND DIFFERENTIAL (REAR)...3415
      General Information...3415
      Planetary Carrier Parts Identification...3415
      Steering Knuckle And Drive Axle Parts Identification...3421
      Steering Knuckle Disassembly...3422
      Differential and Bevel Pinion Parts Identification...3424
      Differential Disassembly...3425
      Bevel Pinion Disassembly...3429
      Bevel Pinion Assembly...3432
      Bevel Pinion Assembly (Cont’d)...3436
      Differential Assembly...3440
      Steering Knuckle Assembly...3445
      Planetary Carrier Assembly...3448
      Special Tools...3452
    FRONT AXLE...3453
      Removal...3453
      Installation...3460
    AXLE TOE-IN...3467
      Adjustment...3467
    PARKING BRAKE...3469
      Releasing The Brake For Towing...3469
      Re-Activating The Brake...3470
    STEERING ANGLE ADJUSTMENT...3471
      Adjustment...3471
    DRIVESHAFT...3473
      Removal And Installation...3473
    SERVICE BRAKE...3475
      Description...3475
      Bleeding The Brake Circuit...3475
    REAR AXLE...3477
      Removal...3477
      Installation...3480
  MAIN FRAME...3485
    OPERATOR CAB...3487
      Removal And Installation...3487
    CANOPY...3495
      Removal And Installation...3495
    OPERATOR SEAT...3501
      Removal And Installation...3501
    FIXED BOOM...3503
      Removal...3503
      Installation...3505
    END BOOM...3507
      Removal...3507
    END BOOM...3509
      Installation...3509
    WEAR PADS (FRONT)...3511
      Removal...3511
      Installation...3512
    WEAR PADS (REAR)...3515
      Removal...3515
    WEAR PADS (REAR)...3516
      Installation...3516
    ENGINE COVER...3517
      Gas Cylinder Removal And Installation...3517
      Removal And Installation...3517
    AIR INTAKE COWLING...3519
      Removal And Installation...3519
    FUEL TANK...3521
      Removal And Installation...3521
    QUICK TACH...3525
      Removal And Installation...3525
    REAR WEIGHTS...3527
      Removal And Installation...3527
    FENDER...3529
      Removal And Installation...3529
    DASH COVER/STEERING COLUMN COVER...3531
      Removal And Installation...3531
    JOYSTICK PANEL...3535
      Removal And Installation...3535
    INTERMEDIATE BOOM...3537
      Removal...3537
    INTERMEDIATE BOOM...3538
      Installation...3538
    BOOM TRAY...3541
      Removal And Installation...3541
    CHAIN CHECKING AND ADJUSTING PROCEDURE...3545
      Checking/Adjustment Procedure...3545
  ELECTRICAL SYSTEM AND ANALYSIS...3547
    ELECTRICAL SCHEMATICS...3549
    ELECTRICAL SYSTEM INFORMATION...3559
      Troubleshooting Chart...3559
      Description...3560
      Fuses, Diodes & Relays...3560
    BATTERY...3563
      Removal And Installation...3563
      Servicing...3564
      Using A Booster Battery (Jump Starting)...3565
    ALTERNATOR...3567
      Removal And Installation...3567
      Adjusting The Alternator Belt...3568
    STARTER...3569
      Removal And Installation...3569
      Parts Identification...3570
      Disassembly...3571
      Inspection And Repair...3576
      Assembly...3580
    LATERAL OPERATOR RESTRAINT SYSTEM (LOR’S™)...3585
      Restraint Bar Removal And Installation...3585
      Strut Removal And Installation...3588
      Strut Disassembly And Assembly...3589
      Restraint Bar Bushing Removal And Installation...3590
      Restraint Bar Bumper Removal And Installation...3590
    LIGHTS...3591
      Rear Light Removal And Installation...3591
      Front Light Removal And Installation...3592
    TRAVEL/SIGNAL LEVER...3593
      Removal And Installation...3593
    INSTRUMENT PANEL...3595
      Removal And Installation...3595
    SWITCH PANEL...3597
      Removal And Installation...3597
    BRAKE LIGHT SWITCH...3599
      Removal And Installation...3599
      Adjustment...3599
    FRONT WIPER MOTOR...3601
      Removal And Installation...3601
    TOP WIPER MOTOR...3605
      Removal And Installation...3605
    REAR WIPER MOTOR...3607
      Removal And Installation...3607
    PEDAL ASSEMBLY...3609
      Removal And Installation...3609
      Disassembly And Assembly...3610
    INCHING SWITCH...3615
      Removal And Installation...3615
      Adjustment...3615
    SERVICE SOFTWARE...3617
      Connecting The Laptop Computer...3617
      Entering The Service Software...3618
      Monitor Screen...3619
      Warnings Screen...3620
      Calibrate Inch Pedal...3621
      Calibrate Creep Potentiometer...3623
      Program/Update Susmic Controller...3624
    FRAME LEVEL SPEED SWITCH...3627
      Description...3627
      Removal...3627
      Installation...3628
  ENGINE SERVICE...3629
    TROUBLESHOOTING...3633
      Chart...3633
    ENGINE SPEED CONTROL...3635
      Removal And Installation...3635
    MUFFLER...3637
      Removal And Installation...3637
    AIR CLEANER...3639
      Housing Removal And Installation...3639
    OIL COOLER/RADIATOR...3641
      Removal And Installation...3641
      Disassembly And Assembly...3643
    ENGINE AND ENGINE MOUNTS...3645
      Removal And Installation...3645
    ENGINE COMPONENTS AND TESTING...3649
      Fuel Injection Pump Removal...3649
      Fuel Injection Pump Installation...3652
      Fuel Injectors Removal And Installation...3655
      Checking The Fuel Lift Pump...3657
      Fuel Lift Pump Removal And Installation...3658
      Compression Checking...3659
      Glow Plugs Checking...3660
      Glow Plugs Removal And Installation...3660
    ENGINE TIMING...3663
      Procedure...3663
    ENGINE/HYDROSTAT ASSEMBLY...3665
      Removal And Installation...3665
    FLYWHEEL AND HOUSING...3677
      Removal And Installation...3677
      Ring Gear Removal...3680
      Ring Gear Installation...3680
    RECONDITIONING THE ENGINE...3681
      Turbo Charger Troubleshooting...3681
      Turbo Charger Description...3682
      Turbo Charger Removal And Installation...3682
      Exhaust Manifold Removal And Installation...3684
      Fuel Injector Cover Removal And Installation...3684
      Rocker Cover Removal And Installation...3685
      Cylinder Head Removal...3686
      Cylinder Head Inspection...3688
      Cylinder Head Installation...3688
      Rocker Shaft Disassembly And Assembly...3691
      Valve Removal...3691
      Valve Springs Checking...3692
      Valve Depth Checking...3692
      Valve Guides Checking...3693
      Valve Guide Removal...3694
      Valve Guide Installation...3694
      Valves Checking...3695
      Cutting A Valve Seat...3695
      Valve Seat Assembly...3696
      Changing Valve Springs (With Cylinder Head Installed)...3697
      Valve Clearance Adjustment...3698
      Timing Case And Drive Assembly Description...3699
      Timing Cover Removal...3699
      Timing Cover Installation...3699
      Crankshaft Pulley Removal And Installation...3699
      Front Oil Seal Removal And Installation...3699
      Timing Case And Gear Removal...3700
      Timing Case And Gear Installation...3701
      Camshaft And Tappets Removal...3703
      Camshaft And Tappets Installation...3704
      Pistons And Connecting Rods Description...3706
      Pistons And Connecting Rods Removal...3706
      Pistons And Connecting Rods Disassembly...3708
      Piston Ring End Gap...3708
      Piston Ring Groove Clearance...3709
      Connecting Rod Inspection...3710
      Connecting Rod Bushing Replacement...3710
      Piston And Connecting Rod Assembly...3710
      Checking Piston Height...3712
      Crankshaft And Bearings Description...3713
      Crankshaft And Bearings Removal...3713
      Inspection Of Crankshaft And Bearings...3715
      Crankshaft And Bearings Installation...3715
      Rear Oil Seal Removal...3717
      Rear Oil Seal Housing Positioning...3717
      Rear Oil Seal Installation...3717
      Checking Crankshaft End Play...3718
      Cooling System Description...3719
      Thermostat Removal and Installation...3720
      Thermostat Testing...3720
      Lubricating Oil Cooler Removal And Installation...3720
      Water Pump Removal...3721
      Water Pump Installation...3721
      Engine Lubrication System Description...3722
      Oil Filter Adapter Removal And Installation...3723
      Oil Pan Removal And Installation...3723
      Oil Screen And Pick-up Tube...3724
      Oil Pump Removal...3724
      Oil Pump Installation...3725
      Oil Pump Disassembly And Assembly...3726
      Oil Pressure Relief Valve Disassembly And Assembly...3726
      Engine Block Description...3727
      Engine Block Disassembly And Assembly...3727
      Piston Cooling Jet Removal...3728
      Piston Cooling Jet Installation...3728
      Piston Cooling Jet Alignment...3728
      Inspection...3728
      Cylinder Liner Inspection...3729
      Cylinder Liner Removal...3730
      Cylinder Liner Installation...3731
  HEATING, VENTILATION, AIR CONDITIONING...3733
    AIR CONDITIONING SYSTEM FLOW...3735
      Principals...3735
      Chart...3736
    COMPONENTS...3737
      Identification...3737
    SAFETY...3739
      Safety Equipment...3739
    REGULAR MAINTENANCE...3741
      Filter Element Removal And Installation...3741
      Compressor Drive Belt Inspection...3742
      Cleaning The Condenser...3742
    BASIC TROUBLESHOOTING...3743
      Poor A/C Performance...3743
      Compressor Drive Belt Inspection...3743
      Checking The Electrical System...3744
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...3749
      Compressor Oil...3749
      Compressor Oil Check...3749
      Component Replacement And Refrigeration Leaks...3750
    SYSTEM TROUBLESHOOTING CHART...3751
    TEMPERATURE/PRESSURE...3755
      Chart...3755
    AIR CONDITIONING SERVICE...3757
      Chart...3757
    SYSTEM CHARGING AND RECLAMATION...3759
      Reclamation Procedure...3759
      Charging Procedure With A Manifold Gauge Set...3762
      Charging Procedure...3763
    COMPRESSOR...3765
      Removal And Installation...3765
      Compressor Clutch Disassembly And Assembly...3766
    CONDENSER...3771
      Removal And Installation...3771
    RECEIVER/DRIER...3773
      Removal And Installation...3773
    PRESSURE SWITCH...3775
      Removal And Installation...3775
    EVAPORATOR/BLOWER UNIT...3777
      Removal And Installation...3777
    EXPANSION VALVE...3779
      Removal And Installation...3779
    HEATER ASSEMBLY...3781
      Removal And Installation...3781
      Fan Removal And Installation...3782
      Core Removal And Installation...3782
  SPECIFICATIONS...3785
    VersaHANDLER SPECIFICATIONS...3787
      Dimensional Specifications...3787
      Performance Specifications...3788
      Engine...3788
      Controls...3788
      Drive System...3788
      Tires...3789
      Capacities...3789
      Hydraulic System...3789
      Electrical System...3789
      Instrument Panel...3789
    ENGINE SPECIFICATIONS...3791
      General...3791
      Cylinder Head...3791
      Valve Guides...3791
      Exhaust Valves...3792
      Intake Valves...3792
      Valve Springs...3792
      Rocker Shaft, Rockers And Bushings...3793
      Pistons And Piston Rings...3793
      Connecting Rods And Bearings...3794
      Crankshaft...3794
      Crankshaft Re-Grind Data...3795
      Main Bearings...3796
      Thrust Washers...3796
      Camshaft And Thrust Washer...3796
      Cylinder Block...3796
      Cylinder Liners...3797
      Fuel Injection Pump...3797
      Fuel Injectors...3797
      Fuel Lift Pump...3797
      Timing Case And Timing Gears...3798
      Oil Pump, Gear And Relief Valve...3799
      Turbocharger...3799
      Flywheel...3799
      Water Pump And Thermostat...3800
      Engine Torque Component...3801
    MACHINE TORQUE SPECIFICATIONS...3803
      Axle...3803
      Boom...3803
      Drive Box...3803
      Drive Motor...3803
      Engine...3804
      Hydraulic Pump...3804
    TORQUE SPECIFICATIONS FOR BOLTS...3805
      Torque for General SAE Bolts...3805
      Torque For General Metric Bolts...3806
    HYDRAULIC CONNECTION SPECIFICATIONS...3807
      O-ring Face Seal Connection...3807
      Straight Thread O-ring Fitting...3807
      Tubelines And Hoses...3807
      Port Seal Fitting...3808
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...3809
      Specifications...3809
    CONVERSIONS...3811
      Decimal And Millimeter Equivalents...3811
      U.S. To Metric Conversion...3811
  SMR...3813
    V638-1...3813
6986672 (12-07) - V518, V723 Telescopic Tool Carrier (TTC) Operation & Maintenance Manual...3815
  OPERATOR SAFETY WARNINGS...3817
  CONTENTS...3819
  FOREWORD...3821
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...3823
    SERIAL NUMBER LOCATION...3824
      VersaHANDLER Serial Number...3824
      Engine Serial Number...3824
    DELIVERY REPORT...3825
    BOBCAT VersaHANDLER IDENTIFICATION...3826
    FEATURES, ACCESSORIES AND ATTACHMENTS...3827
      Attachments...3827
  SAFETY...3829
    SAFETY INSTRUCTIONS...3831
      Before Operation...3831
      Safe Operation Is The Operator’s Responsibility...3832
      Safe Operation Needs A Qualified Operator...3832
      Avoid Silica Dust...3833
    FIRE PREVENTION...3833
      Maintenance...3833
      Operation...3833
      Electrical...3833
      Hydraulic System...3834
      Fueling...3834
      Starting...3834
      Spark Arrestor Exhaust System...3834
      Welding And Grinding...3834
      Fire Extinguishers...3834
    MACHINE SIGNS (DECALS)...3835
    ADDITIONAL PUBLICATIONS AND TRAINING RESOURCES...3837
  OPERATING INSTRUCTIONS...3839
    OPERATOR CONTROLS IDENFICATION...3841
      Operator Components...3841
      Travel Direction And Two-Speed Control...3841
      Steering Wheel...3841
      Direction Signal...3842
      Front Wiper/Washer/Headlight Dimmer...3842
      Horn...3842
      Steering Wheel Tilt Adjustment...3842
      Center Instrument Panel...3843
      Center Instrument Panel [Figure OI-7]...3843
      Right Instrument And Indicator Panel...3844
      Right Instrument And Indicator Panel [Figure OI-8]...3844
      Parking Brake...3845
      Accelerator Pedal...3845
      Brake Pedal And Inching Control...3845
      Frame Level Switch (V723 With Frame Level Only)...3846
    HYDRAULIC CONTROLS...3847
      Hydraulic Control Lever (Joystick)...3847
    STEERING CONTROLS...3848
      Steering Mode Selection...3848
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS™)...3849
    SERVICE SCHEDULE DECAL...3850
    DAILY INSPECTION...3850
      Daily Inspection And Maintenance...3850
    PRE-STARTING PROCEDURE...3851
    STARTING THE ENGINE...3852
    BEFORE USING THE VersaHANDLER...3853
    ATTACHMENTS AND BUCKETS...3854
      Installing The Bucket Or Attachment...3854
      Releasing Auxiliary Hydraulic Pressure (For V518)...3855
      Releasing Auxiliary Hydraulic Pressure (For V723)...3855
      Removing The Bucket Or Attachment...3855
    VersaHANDLER OPERATION...3856
      Inspecting The Work Area...3856
      Operation...3856
      Operating With A Full Bucket...3856
      Operating With An Empty Bucket...3857
      Filling And Emptying The Bucket...3857
      Digging And Filling A Hole...3858
      Raising A Load And Extending The Boom...3859
      Using Frame Leveling (V723 With Frame Level Only)...3860
      Load Capacity Charts...3861
    PARKING THE VersaHANDLER...3862
    TRANSPORTING THE VersaHANDLER...3862
    LIFTING THE VersaHANDLER...3863
    TOWING THE VersaHANDLER (FOR V518)...3864
    TOWING THE VersaHANDLER (FOR V723)...3866
  PREVENTIVE MAINTENANCE...3869
    MAINTENANCE SAFETY...3871
    SERVICE SCHEDULE...3873
    OPERATOR CAB/CANOPY...3874
      Emergency Exit...3874
      Cab Door...3875
      Cab Door Window...3875
    APPROVED BOOM STOP...3876
      Installing The Approved Boom Stop...3876
      Removing The Approved Boom Stop...3876
    ENGINE COVER...3876
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS™)...3877
      System Inspection...3877
      System Maintenance...3878
    AIR CLEANER SERVICE...3879
      Replacing Filter Element...3879
    FUEL SYSTEM...3881
      Fuel Specifications...3881
      Filling The Fuel Tank...3881
      Fuel Filter...3881
    ENGINE LUBRICATION SYSTEM...3882
      Checking Engine Oil...3882
      Oil Chart...3882
      Replacing Oil And Filter...3883
    ENGINE COOLING SYSTEM...3884
      Cleaning The Cooling System...3884
      Checking The Coolant Level...3884
      Replacing The Coolant...3885
    ALTERNATOR BELT...3886
      Adjusting...3886
    SPARK ARRESTOR MUFFLER...3887
    ELECTRICAL SYSTEM...3888
      Description...3888
      Battery And Terminal Maintenance...3888
      Fuses, Diodes And Relays...3888
      Using A Booster Battery (Jump Starting)...3890
      Battery Disconnect Switch...3891
    HYDRAULIC/HYDROSTATIC SYSTEM...3892
      Checking And Adding Fluid...3892
      Replacing Hydraulic/Hydrostatic Filter...3892
      Replacing Hydraulic Fluid...3893
    BRAKE CONTROL SYSTEM...3894
      Inspection And Maintenance...3894
    AXLES (FRONT AND REAR)...3895
      Checking Oil Level (Differential)...3895
      Draining Oil (Differential)...3895
      Checking Oil Level (Front Axle Drop Box)...3895
      Draining Oil (Front Axle Drop Box)...3895
      Checking Oil Level (Planetary Carrier)...3896
      Draining Oil (Planetary Carrier)...3896
    TIRE MAINTENANCE...3897
      Wheel Nuts...3897
      Tire Mounting...3897
      Tire Rotation...3897
      Tire Pressure...3897
    LUBRICATION...3898
    ATTACHMENT FRAME...3902
      Inspection And Maintenance...3902
  MACHINE SIGN TRANSLATIONS...3903
    SERVICE SCHEDULE (6913156)...3905
    WARNING (6809613)...3908
    DANGER (6918255)...3910
    WARNING (6809614)...3911
    DANGER (6809610)...3911
    WARNING (6577754)...3912
    WARNING (6908056)...3912
    WARNING (6809606)...3913
    DANGER (6809607)...3914
    WARNING (6809622)...3915
    WARNING (6809608))...3916
    WARNING (6960068)...3917
    WARNING (6911376)...3919
  SPECIFICATIONS...3921
    VersaHANDLER TELESCOPIC TOOL CARRIER (TTC) SPECIFICATIONS...3923
      Dimensional Specifications...3923
      Performance Specifications...3924
      Engine...3924
      Fan Pump...3924
      Controls...3925
      Drive System...3925
      Tires...3925
      Capacities...3926
      Hydraulic System...3926
      Electrical System...3926
      Instrument Panel...3926
  WARRANTY...3927
  ALPHABETICAL INDEX...3931
6986674 (12-07) - V638 VersaHANDLER Telescopic Tool Carrier (TTC) Operation & Maintenance Manual...3933
  OPERATOR SAFETY WARNINGS...3935
  CONTENTS...3937
  FOREWORD...3939
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...3941
    SERIAL NUMBER LOCATION...3942
      VersaHANDLER Serial Number...3942
      Engine Serial Number...3942
    DELIVERY REPORT...3943
    BOBCAT VersaHANDLER IDENTIFICATION...3944
    FEATURES, ACCESSORIES AND ATTACHMENTS...3945
      Attachments...3945
  SAFETY & TRAINING RESOURCES...3947
    SAFETY INSTRUCTIONS...3949
      Before Operation...3949
      Safe Operation Is The Operator’s Responsibility...3950
      Safe Operation Needs A Qualified Operator...3950
      Avoid Silica Dust...3951
    FIRE PREVENTION...3951
      Maintenance...3951
      Operation...3951
      Electrical...3951
      Hydraulic System...3952
      Fueling...3952
      Starting...3952
      Spark Arrestor Exhaust System...3952
      Welding And Grinding...3952
      Fire Extinguishers...3952
    MACHINE SIGNS (DECALS)...3953
    PUBLICATIONS AND TRAINING RESOURCES...3955
  OPERATING INSTRUCTIONS...3957
    OPERATOR CONTROLS IDENFICATION...3959
      Operator Components...3959
      Travel Direction and Two-Speed Control...3959
      Steering Wheel...3959
      Direction Signal...3960
      Front Wiper/Washer/Headlight Dimmer...3960
      Horn...3960
      Steering Wheel Tilt Adjustment...3960
      Center Instrument Panel...3961
      Right Instrument And Indicator Panel...3962
      Accelerator Pedal...3963
      Brake Pedal And Inching Control...3963
      Frame Level Switch...3964
    HYDRAULIC CONTROLS...3965
      Hydraulic Control Lever (Joystick)...3965
    STEERING CONTROLS...3966
      Steering Mode Selection...3966
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS™)...3967
    DAILY INSPECTION...3968
      Daily Inspection And Maintenance...3968
    PRE-STARTING PROCEDURE...3969
    STARTING THE ENGINE...3970
    BEFORE USING THE VersaHANDLER...3971
    ATTACHMENTS AND BUCKETS...3972
      Installing The Bucket Or Attachment...3972
      Releasing Auxiliary Hydraulic Pressure...3973
      Removing The Bucket Or Attachment...3973
    VersaHANDLER OPERATION...3974
      Inspecting The Work Area...3974
      Operation...3974
      Operating With A Full Bucket...3974
      Operating With An Empty Bucket...3975
      Filling And Emptying The Bucket...3975
      Digging And Filling A Hole...3976
      Raising A Load And Extending The Boom...3977
      Using Frame Leveling...3978
      Using Stabilizers (If Equipped)...3979
      Load Capacity Charts...3980
    PARKING THE VERSAHANDLER...3981
    TRANSPORTING THE VersaHANDLER...3981
    LIFTING THE VersaHANDLER...3982
    TOWING THE VersaHANDLER...3983
  PREVENTIVE MAINTENANCE...3985
    MAINTENANCE SAFETY...3987
    SERVICE SCHEDULE...3989
    OPERATOR CAB/CANOPY...3990
      Emergency Exit...3990
      Cab Door...3991
      Cab Door Window...3991
    APPROVED BOOM STOP...3992
      Installing The Approved Boom Stop...3992
      Removing The Approved Boom Stop...3992
    ENGINE COVER...3992
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS™)...3993
      System Inspection...3993
      System Maintenance...3994
    AIR CLEANER SERVICE...3995
      Replacing Filter Element...3995
    FUEL SYSTEM...3997
      Fuel Specifications...3997
      Filling The Fuel Tank...3997
      Fuel Filter...3997
    ENGINE LUBRICATION SYSTEM...3998
      Checking Engine Oil...3998
      Oil Chart...3998
      Replacing Oil And Filter...3999
    ENGINE COOLING SYSTEM...4000
      Cleaning The Cooling System...4000
      Checking The Coolant Level...4000
      Replacing The Coolant...4001
    ALTERNATOR BELT...4002
      Adjusting...4002
    SPARK ARRESTOR MUFFLER...4003
    ELECTRICAL SYSTEM...4004
      Description...4004
      Battery And Terminal Maintenance...4004
      Fuses, Diodes And Relays...4004
      Fuses, Diodes And Relays (Cont’d)...4005
      Using A Booster Battery (Jump Starting)...4006
      Battery Disconnect Switch...4007
    HYDRAULIC/HYDROSTATIC SYSTEM...4008
      Checking And Adding Fluid...4008
      Replacing Hydraulic/Hydrostatic Filter...4008
      Replacing Hydraulic Fluid...4009
    BRAKE CONTROL SYSTEM...4010
      Inspection And Maintenance...4010
    AXLES (FRONT AND REAR)...4011
      Checking Oil Level (Planetary Carrier)...4011
      Draining Oil (Planetary Carrier)...4011
      Checking Oil Level (Rear Differential)...4012
      Draining Oil (Rear Differential)...4012
      Checking Oil Level (Front Differential)...4012
      Draining Oil (Front Differential)...4013
    TIRE MAINTENANCE...4014
      Wheel Nuts...4014
      Tire Mounting...4014
      Tire Rotation...4014
      Tire Pressure...4014
    LUBRICATION...4015
    ATTACHMENT FRAME...4019
      Inspection And Maintenance...4019
    CHAIN CHECKING AND ADJUSTING PROCEDURE...4020
      Checking/Adjustment Procedure...4020
      Extend/Retract Chain Wear Check...4021
  MACHINE SIGN TRANSLATIONS...4023
    SERVICE SCHEDULE (6918234)...4025
    WARNING (6809613)...4028
    DANGER (6918255)...4030
    WARNING (6809614)...4031
    DANGER (6809610)...4031
    WARNING (6577754)...4031
    WARNING (6908056)...4032
    WARNING (6809606)...4033
    DANGER (6809607)...4034
    WARNING (6809622)...4035
    WARNING (6809608)...4036
    WARNING (6960068)...4037
    WARNING (6911376)...4039
  SPECIFICATIONS...4041
    VersaHANDLER TELESCOPIC TOOL CARRIER (TTC) SPECIFICATIONS...4043
      Dimensional Specifications...4043
      Performance Specifications...4044
      Engine...4044
      Fan Pump...4044
      Controls...4045
      Drive System...4045
      Tires...4045
      Capacities...4046
      Hydraulic System...4046
      Electrical System...4046
      Instrument Panel...4046
  WARRANTY...4047
  ALPHABETICAL INDEX...4051
6986675 (4-10) - V723 VersaHANDLER Service Manual...4053
  CONTENTS...4057
  MAINTENANCE SAFETY...4055
  FOREWORD...4059
    FOREWORD...4061
    SAFETY INSTRUCTIONS...4063
    FIRE PREVENTION...4064
      Maintenance...4064
      Operation...4064
      Electrical...4064
      Hydraulic System...4065
      Fueling...4065
      Starting...4065
      Spark Arrestor Exhaust System...4065
      Welding And Grinding...4065
      Fire Extinguishers...4065
    SERIAL NUMBER LOCATION...4066
      VersaHANDLER Serial Number...4066
      Engine Serial Number...4066
      Other Serial Numbers...4066
    DELIVERY REPORT...4067
    BOBCAT VersaHANDLER IDENTIFICATION...4068
  SAFETY AND MAINTENANCE...4069
    LIFTING AND BLOCKING THE VERSAHANDLER...4071
      Procedure...4071
    OPERATOR CAB / CANOPY...4073
      Cab Door...4073
      Cab Door Window...4074
    TRANSPORTING THE VERSAHANDLER ON A TRAILER...4075
      Loading And Unloading...4075
      Fastening...4075
    TOWING THE VersaHANDLER...4077
      Procedure...4077
    SERVICE SCHEDULE...4079
      Chart...4079
    AIR CLEANER SERVICE...4081
      Replacing Filter Element...4081
    ENGINE COOLING SYSTEM...4083
      Cleaning The Cooling System...4083
      Checking The Coolant Level...4083
      Replacing The Coolant...4084
    FUEL SYSTEM...4087
      Fuel Specifications...4087
      Filling The Fuel Tank...4087
      Fuel Filter...4087
    ENGINE LUBRICATION SYSTEM...4089
      Checking Engine Oil...4089
      Engine Oil Chart...4089
      Replacing Oil And Filter...4090
    HYDRAULIC / HYDROSTATIC SYSTEM...4091
      Checking And Adding Fluid...4091
      Replacing Hydraulic / Hydrostatic Filter...4091
      Replacing Hydraulic Fluid...4092
    AXLES (FRONT AND REAR)...4093
      Checking Oil Level (Differential)...4093
      Draining Oil (Differential)...4093
      Checking Oil Level (Front Axle Drop Box)...4093
      Draining Oil (Front Axle Drop Box)...4093
      Checking Oil Level (Planetary Carrier)...4094
      Draining Oil (Planetary Carrier)...4094
    LUBRICATION...4095
      Procedure...4095
    TIRE MAINTENANCE...4099
      Wheel Nuts...4099
      Mounting...4099
      Rotating...4099
    SPARK ARRESTOR MUFFLER...4101
      Cleaning...4101
    APPROVED BOOM STOP...4103
      Installing The Approved Boom Stop...4103
      Removing The Approved Boom Stop...4103
    ENGINE COVER...4105
      Opening And Closing The Engine Cover...4105
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS)...4107
      System Inspection...4107
      System Maintenance...4108
    VersaHANDLER STORAGE AND RETURN TO SERVICE...4109
      Storage...4109
      Return To Service...4109
    STOPPING THE ENGINE AND LEAVING THE VERSAHANDLER...4111
      Procedure...4111
    EMERGENCY EXIT...4113
      Rear Window...4113
  HYDRAULIC SYSTEM...4115
    HYDRAULIC / HYDROSTATIC SCHEMATICS...4119
    HYDRAULIC SYSTEM INFORMATION...4123
      Glossary Of Hydraulic / Hydrostatic Symbols...4123
      Troubleshooting Chart...4126
      Tightening Procedures...4127
    LIFT CYLINDER...4129
      Removal And Installation...4129
      Parts Identification...4133
      Disassembly...4134
      Assembly...4139
    BUCKET POSITIONING CYLINDER...4145
      Removal And Installation...4145
      Parts Identification...4148
      Disassembly...4149
      Assembly...4153
    EXTENSION CYLINDER...4157
      Cylinder Group Removal And Installation...4157
      Upper Tubeline Removal...4159
      Upper Tubeline Installation...4160
      Extension Cylinder Removal And Installation...4162
      Tubeline Tray Disassembly...4164
      Tubeline Tray Assembly...4167
      Parts Identification...4170
      Disassembly...4171
      Assembly...4176
    TILT CYLINDER...4181
      Removal And Installation...4181
      Parts Identification...4182
      Disassembly...4183
      Assembly...4187
    STEERING CYLINDER (FRONT)...4191
      Removal...4191
      Installation...4193
      Disassembly...4195
      Assembly...4197
    STEERING CYLINDER (REAR)...4201
      Removal...4201
      Installation...4203
      Disassembly...4205
      Assembly...4207
    DRIVE BOX...4211
      Parts Identification...4211
      Disassembly...4212
      Assembly...4216
      Special Tools...4219
    MAIN RELIEF VALVE...4221
      Testing...4221
      Adjustment...4222
      Removal And Installation...4222
    QUICK-TACH CYLINDER...4223
      Removal And Installation...4223
      Parts Identification...4225
      Disassembly...4226
      Assembly...4229
    FRAME LEVELING CYLINDER...4231
      Removal And Installation...4231
      Parts Identification...4233
      Disassembly...4234
      Assembly...4239
    STEERING MODE VALVE BLOCK...4245
      Removal And Installation...4245
      Parts Identification...4247
      Disassembly...4248
      Solenoid Testing...4250
      Assembly...4250
    BRAKE VALVE...4253
      Removal And Installation...4253
      Disassembly And Assembly...4254
    GEAR PUMP...4257
      Removal And Installation...4257
      Parts Identification...4260
      Disassembly And Assembly...4261
    FAN MOTOR...4267
      Removal And Installation...4267
      Parts Identification...4271
      Disassembly And Assembly...4272
    HYDRAULIC RESERVOIR...4275
      Removal And Installation...4275
    STEERING VALVE...4277
      Removal And Installation...4277
      Parts Identification...4278
      Disassembly...4279
      Inspection...4285
      Assembly...4286
    HYDRAULIC CONTROL VALVE...4293
      Troubleshooting Chart (Controllers)...4293
      Telescoping Valve Section Troubleshooting...4294
      Auxiliary Valve Section Troubleshooting...4298
      Troubleshooting Chart (Control Valve)...4302
      Removal And Installation...4303
      Parts Identification...4307
      Disassembly And Assembly...4308
      End Housing Disassembly And Assembly...4309
      Lifting Valve Section Disassembly And Assembly...4310
      Tilting Valve Section Disassembly And Assembly...4315
      Telescoping Valve Section Disassembly And Assembly...4320
      Auxiliary / Frame Leveling Valve Section Disassembly And Assembly...4332
      Inlet-Outlet Valve Section Disassembly And Assembly...4342
    PORT RELIEF VALVES...4347
      Adjustment Procedure...4347
    FLOW CONTROL VALVE...4349
      Removal And Installation...4349
    JOYSTICK...4351
      Removal And Installation...4351
    PARKING BRAKE...4353
      Pressure Switch Removal And Installation...4353
      Pressure Switch Disassembly And Assembly...4355
      Valve Removal And Installation...4356
      Valve Disassembly And Assembly...4357
    PRESSURE REDUCING VALVE...4359
      Testing...4359
      Removal And Installation...4360
      Disassembly And Assembly...4361
    ACCUMULATOR...4363
      Removal And Installation...4363
    TOW VALVE...4365
      Removal And Installation...4365
      Disassembly And Assembly...4366
  HYDROSTATIC SYSTEM...4371
    HYDROSTATIC SYSTEM INFORMATION...4373
      Troubleshooting Chart...4373
      Replenishing Valve Function...4374
    OIL COOLER...4375
      Description...4375
    HYDROSTATIC DRIVE MOTOR...4377
      Removal And Installation...4377
      Parts Identification...4378
      Inspection...4396
      Assembly...4398
    HYDROSTATIC PUMP...4415
      Removal And Installation...4415
      Parts Identification...4418
      Disassembly...4423
      Inspection...4435
      Assembly...4439
  DRIVE SYSTEM...4455
    TROUBLESHOOTING...4457
      Chart...4457
    AXLE AND DIFFERENTIAL (FRONT)...4459
      General Information...4459
      Planetary Carrier Parts Identification...4459
      Planetary Carrier Disassembly...4460
      Steering Knuckle And Drive Axle Parts Identification...4465
      Steering Knuckle Disassembly...4466
      Drive Axle Disassembly...4468
      Brake System Identification...4470
      Brake System Disassembly...4471
      Differential Parts Identification...4475
      Differential Disassembly...4476
      Bevel Pinion Parts Identification...4481
      Bevel Pinion Disassembly...4482
      Pinion Group Assembly...4485
      Differential Assembly...4493
      Brake System Assembly...4499
      Drive Axle Assembly...4505
      Steering Knuckle Assembly...4507
      Planetary Carrier Assembly...4510
      Special Tools...4514
    AXLE AND DIFFERENTIAL (REAR)...4515
      General Information...4515
      Planetary Carrier Parts Identification...4515
      Planetary Carrier Disassembly...4516
      Steering Knuckle And Drive Axle Parts Identification...4521
      Steering Knuckle Disassembly...4522
      Differential And Bevel Pinion Parts Identification...4524
      Differential Disassembly...4525
      Bevel Pinion Disassembly...4529
      Bevel Pinion Assembly...4532
      Differential Assembly...4540
      Steering Knuckle Assembly...4545
      Planetary Carrier Assembly...4548
      Special Tools...4552
    FRONT AXLE...4553
      Removal...4553
      Installation...4560
    AXLE TOE-IN...4567
      Adjustment...4567
    PARKING BRAKE...4569
      Releasing The Brake For Towing...4569
      Re-Activating The Brake...4570
    STEERING ANGLE ADJUSTMENT...4571
      Adjustment...4571
    DRIVESHAFT...4573
      Removal And Installation...4573
    SERVICE BRAKE...4575
      Description...4575
      Bleeding The Brake Circuit...4575
    REAR AXLE...4577
      Removal...4577
      Installation...4580
  MAIN FRAME...4585
    OPERATOR CAB (S/N A8HL12999 & BELOW, A8HP12999 & BELOW)...4587
      Removal And Installation...4587
    OPERATOR CAB (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE)...4595
      Removal And Installation...4595
    CANOPY...4603
      Removal And Installation...4603
    OPERATOR SEAT...4609
      Removal And Installation...4609
    BOOM ASSEMBLY...4611
      Removal And Installation...4611
    INNER BOOM...4615
      Removal...4615
      Installation...4617
    WEAR PADS (FRONT)...4619
      Removal And Installation...4619
    WEAR PADS (REAR)...4621
      Removal...4621
      Installation...4621
    ENGINE COVER...4623
      Gas Cylinder Removal And Installation...4623
      Removal And Installation...4623
    AIR INTAKE COWLING...4625
      Removal And Installation...4625
    FUEL TANK...4627
      Removal And Installation...4627
    QUICK-TACH...4631
      Removal And Installation...4631
    REAR WEIGHTS...4633
      Removal And Installation...4633
    FENDER...4635
      Removal And Installation...4635
    PIVOT LINK...4637
      Removal And Installation...4637
    DASH COVER / STEERING COLUMN COVER (S/N A8HL12999 & BELOW, A8HP12999 & BELOW, A8HK11001 & ABOVE)...4641
      Removal And Installation...4641
    DASH COVER / STEERING COLUMN COVER (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE)...4645
      Removal And Installation...4645
    JOYSTICK PANEL (S/N A8HL12999 & BELOW, S/N A8HP12999 & BELOW, A8HK11001 & ABOVE)...4649
      Removal And Installation...4649
    JOYSTICK PANEL (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE)...4651
      Removal And Installation...4651
  ELECTRICAL SYSTEM & ANALYSIS...4653
    ELECTRICAL SCHEMATICS...4655
    ELECTRICAL SYSTEM INFORMATION (S/N A8HL12999 & BELOW, A8HP12999 & BELOW, A8HK11001 & ABOVE)...4678
      Troubleshooting Chart...4678
      Description...4679
      Fuses, Diodes And Relays...4679
    ELECTRICAL SYSTEM INFORMATION (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE)...4682
      Troubleshooting Chart...4682
      Description...4683
      Fuses, Diodes And Relays...4683
    BATTERY...4686
      Removal And Installation...4686
      Servicing...4687
      Using A Booster Battery (Jump Starting)...4688
    ALTERNATOR...4690
      Removal And Installation...4690
      Adjusting The Alternator Belt...4691
    STARTER...4692
      Removal And Installation...4692
      Disassembly...4693
      Inspection And Repair...4698
      Assembly...4702
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS)...4708
      Restraint Bar Removal And Installation...4708
      Sensor Removal And Installation...4709
      Strut Removal And Installation...4711
      Strut Disassembly And Assembly...4712
      Restraint Bar Bushing Removal And Installation...4713
      Restraint Bar Bumper Removal And Installation...4713
    LIGHTS...4714
      Rear Light Removal And Installation...4714
      Front Light Removal And Installation...4715
    TRAVEL / SIGNAL LEVER (S/N A8HL12999 & BELOW, A8HP12999 & BELOW, A8HK11001 & ABOVE)...4718
      Removal And Installation...4718
    TRAVEL / SIGNAL LEVER (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE)...4720
      Removal And Installation...4720
    INSTRUMENT PANEL...4722
      Removal And Installation...4722
    SWITCH PANEL (S/N A8HL12999 & BELOW, S/N A8HP12999 & BELOW, S/N A8HK11001 & ABOVE)...4724
      Removal And Installation...4724
    SWITCH PANEL (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE)...4726
      Removal And Installation...4726
      Parts Identification...4727
    BRAKE LIGHT SWITCH...4730
      Removal And Installation...4730
      Adjustment...4730
    WIPER MOTOR (FRONT)...4732
      Removal And Installation...4732
    WIPER MOTOR (TOP)...4736
      Removal And Installation...4736
    WIPER MOTOR (REAR)...4738
      Removal And Installation...4738
    PEDAL ASSEMBLY...4740
      Removal And Installation...4740
      Disassembly And Assembly...4741
    INCHING SWITCH...4746
      Removal And Installation...4746
      Adjustment...4746
    SERVICE SOFTWARE...4748
      Connecting The Laptop Computer...4748
      Entering The Service Software...4749
      Monitor Screen...4750
      Warnings Screen...4752
      Calibrate Inch Pedal...4753
      Calibrate Creep Potentiometer...4754
      Program / Update Susmic Controller...4756
    FRAME LEVEL SPEED SWITCH...4758
      Description...4758
      Removal...4758
      Installation...4759
      Disassembly And Assembly...4759
  ENGINE SERVICE...4760
    TROUBLESHOOTING...4764
      Chart...4764
    ENGINE SPEED CONTROL...4766
      Removal And Installation...4766
    MUFFLER...4768
      Removal And Installation...4768
    AIR CLEANER...4770
      Housing Removal And Installation...4770
    OIL COOLER / RADIATOR...4772
      Removal And Installation...4772
      Disassembly And Assembly...4775
    ENGINE AND ENGINE MOUNTS...4778
      Removal And Installation...4778
    ENGINE COMPONENTS AND TESTING...4782
      Fuel Injection Pump Removal...4782
      Fuel Injection Pump Installation...4785
      Fuel Injectors Removal And Installation...4788
      Checking The Fuel Lift Pump...4790
      Fuel Lift Pump Removal And Installation...4791
      Compression Checking...4791
      Glow Plug Checking...4792
      Glow Plugs Removal And Installation...4793
    ENGINE TIMING...4794
      Procedure...4794
    ENGINE / HYDROSTAT ASSEMBLY...4796
      Removal And Installation...4796
    FLYWHEEL AND HOUSING...4810
      Removal And Installation...4810
      Ring Gear Removal...4813
      Ring Gear Installation...4813
    RECONDITIONING THE ENGINE...4814
      Turbocharger Troubleshooting...4814
      Turbocharger Description...4815
      Turbocharger Removal And Installation...4815
      Exhaust Manifold Removal And Installation...4817
      Fuel Injector Cover Removal And Installation...4817
      Rocker Cover Removal And Installation...4818
      Cylinder Head Removal...4819
      Cylinder Head Inspection...4821
      Cylinder Head Installation...4822
      Rocker Shaft Disassembly And Assembly...4825
      Valve Removal...4825
      Valve Springs Checking...4826
      Valve Depth Checking...4826
      Valve Guides Checking...4827
      Valve Guide Removal...4828
      Valve Guide Installation...4828
      Valves Checking...4829
      Cutting A Valve Seat...4829
      Valve Seat Assembly...4830
      Changing Valve Springs (With Cylinder Head Installed)...4831
      Valve Clearance Adjustment...4832
      Timing Case And Drive Assembly Description...4833
      Timing Cover Removal...4833
      Timing Cover Installation...4833
      Crankshaft Pulley Removal And Installation...4833
      Front Oil Seal Removal And Installation...4833
      Timing Case And Gear Removal...4834
      Timing Case And Gear Installation...4835
      Camshaft And Tappets Removal...4837
      Camshaft And Tappets Installation...4838
      Pistons And Connecting Rods Description...4839
      Pistons And Connecting Rods Removal...4839
      Pistons And Connecting Rods Disassembly...4841
      Piston Ring End Gap...4841
      Piston Ring Installation...4841
      Piston Ring Groove Clearance...4842
      Connecting Rod Inspection...4843
      Connecting Rod Bushing Replacement...4843
      Piston And Connecting Rod Assembly...4843
      Piston And Connecting Rod Installation...4843
      Checking Piston Height...4845
      Crankshaft And Bearings Description...4845
      Crankshaft And Bearings Removal...4845
      Inspection Of Crankshaft And Bearings...4847
      Crankshaft And Bearings Installation...4848
      Rear Oil Seal Removal...4849
      Rear Oil Seal Housing Positioning...4849
      Rear Oil Seal Installation...4850
      Checking Crankshaft End Play...4850
      Cooling System Description...4851
      Thermostat Removal and Installation...4852
      Thermostat Testing...4853
      Lubricating Oil Cooler Removal And Installation...4853
      Water Pump Removal...4853
      Water Pump Installation...4853
      Engine Lubrication System Description...4854
      Oil Filter Adapter Removal And Installation...4855
      Oil Pan Removal And Installation...4855
      Oil Screen And Pick-up Tube...4856
      Oil Pump Removal...4856
      Oil Pump Installation...4857
      Oil Pump Disassembly And Assembly...4858
      Oil Pressure Relief Valve Disassembly And Assembly...4858
      Engine Block Description...4859
      Engine Block Disassembly And Assembly...4859
      Piston Cooling Jet Removal...4860
      Piston Cooling Jet Installation...4860
      Piston Cooling Jet Alignment...4860
      Inspection...4860
      Cylinder Liner Inspection...4861
      Cylinder Liner Removal...4862
      Cylinder Liner Installation...4863
  HEATING, VENTILATION AND AIR CONDITIONING (HVAC)...4864
    AIR CONDITIONING SYSTEM FLOW...4866
      Principles...4866
      Chart...4867
    COMPONENTS...4868
      Identification...4868
    SAFETY...4872
      Safety Equipment...4872
    REGULAR MAINTENANCE...4874
      Filter Element Removal And Installation...4874
      Compressor Drive Belt Inspection...4874
      Cleaning The Condenser...4875
    BASIC TROUBLESHOOTING...4876
      Poor A/C Performance...4876
      Compressor Drive Belt Inspection...4877
      Checking The Electrical System...4878
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...4884
      Compressor Oil...4884
      Compressor Oil Check...4884
      Component Replacement And Refrigeration Leaks...4886
    SYSTEM TROUBLESHOOTING...4888
      Chart...4888
      Gauge Pressure Related Troubleshooting...4889
    TEMPERATURE/PRESSURE...4892
      Chart...4892
    AIR CONDITIONING SERVICE...4894
      Chart...4894
    SYSTEM CHARGING AND RECLAMATION...4896
      Reclamation Procedure...4896
      Charging Procedure With A Manifold Gauge Set...4899
      Charging Procedure...4900
    COMPRESSOR...4902
      Removal And Installation...4902
      Compressor Clutch Disassembly And Assembly...4903
    CONDENSER (S/N A8HL12999 & BELOW, A8HP12999 & BELOW, A8HK11001 & ABOVE)...4908
      Removal And Installation...4908
    CONDENSER (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE)...4910
      Removal And Installation...4910
    RECEIVER / DRIER...4912
      Removal And Installation...4912
    PRESSURE SWITCH...4914
      Removal And Installation...4914
    EVAPORATOR / BLOWER UNIT (S/N A8HL12999 & BELOW, A8HP12999 & BELOW, A8HK11001 & ABOVE)...4916
      Removal And Installation...4916
    EVAPORATOR / BLOWER UNIT (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE)...4918
      Removal And Installation...4918
    EXPANSION VALVE (S/N A8HL12999 & BELOW, A8HP12999 & BELOW, A8HK11001 & ABOVE)...4920
      Removal And Installation...4920
    EXPANSION VALVE (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE)...4922
      Removal And Installation...4922
    HEATER ASSEMBLY...4924
      Removal And Installation...4924
      Fan Removal And Installation...4925
      Core Removal And Installation...4926
  SPECIFICATIONS...4928
    VersaHANDLER SPECIFICATIONS...4930
      Machine Dimensions...4930
      Performance...4931
      Engine...4931
      Fan Pump...4931
      Controls...4932
      Drive System...4932
      Tires...4932
      Capacities...4933
      Hydraulic System...4933
      Electrical...4933
      Instrument Panel...4933
    ENGINE SPECIFICATIONS...4934
      General...4934
      Cylinder Head...4934
      Valve Guides...4934
      Exhaust Valves...4935
      Intake Valves...4935
      Valve Springs...4935
      Rocker Shaft, Rockers And Bushings...4936
      Pistons And Piston Rings...4936
      Connecting Rods And Bearings...4937
      Crankshaft...4937
      Crankshaft Re-Grind Data...4938
      Main Bearings...4939
      Thrust Washers...4939
      Camshaft And Thrust Washer...4939
      Cylinder Block...4939
      Cylinder Liners...4940
      Fuel Injection Pump...4940
      Fuel Injectors...4940
      Fuel Lift Pump...4940
      Timing Case And Timing Gears...4941
      Oil Pump, Gear And Relief Valve...4942
      Turbocharger...4942
      Flywheel...4942
      Water Pump And Thermostat...4943
      Engine Torque Component...4944
    MACHINE TORQUE SPECIFICATIONS...4946
      Axle...4946
      Boom...4946
      Drive Box...4946
      Drive Motor...4946
      Engine...4947
      Hydraulic Pump...4947
    TORQUE SPECIFICATIONS FOR BOLTS...4948
      Torque for General SAE Bolts...4948
      Torque For General Metric Bolts...4949
    HYDRAULIC CONNECTION SPECIFICATIONS...4950
      O-ring Face Seal Connection...4950
      Straight Thread O-ring Fitting...4950
      Tubelines And Hoses...4950
      Flare Fitting...4951
      O-ring Flare Fitting...4952
      Port Seal Fitting...4954
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...4956
      Specifications...4956
    CONVERSIONS...4958
      Decimal And Millimeter Equivalent Chart...4958
      U.S. To Metric Conversion Chart...4958
  ALPHABETICAL INDEX...4960
  SERVICE MANUAL REVISION...4964
    Revision No: V723 - 1...4964
6986763 (4-10) - V638 VersaHANDLER Service Manual...4966
  CONTENTS...4970
  FOREWORD...4972
    FOREWORD...4974
    SAFETY INSTRUCTIONS...4976
    FIRE PREVENTION...4977
      Maintenance...4977
      Operation...4977
      Electrical...4977
      Hydraulic System...4978
      Fueling...4978
      Starting...4978
      Spark Arrester Exhaust System...4978
      Welding And Grinding...4978
      Fire Extinguishers...4978
    SERIAL NUMBER LOCATION...4979
      VersaHANDLER Serial Number...4979
      Engine Serial Number...4979
      Other Serial Numbers...4979
    DELIVERY REPORT...4980
    BOBCAT VersaHANDLER IDENTIFICATION...4981
  SAFETY & MAINTENANCE...4982
    LIFTING AND BLOCKING THE VERSAHANDLER...4984
      Procedure...4984
    OPERATOR CAB / CANOPY...4986
      Cab Door...4987
      Cab Door Window...4987
    TRANSPORTING THE VERSAHANDLER ON A TRAILER...4988
      Loading And Unloading...4988
      Fastening...4988
    TOWING THE VersaHANDLER...4990
      Procedure...4990
    SERVICE SCHEDULE...4992
      Chart...4992
    AIR CLEANER SERVICE...4994
      Replacing Filter Element(s)...4994
    ENGINE COOLING SYSTEM...4996
      Cleaning The Cooling System...4996
      Checking The Coolant Level...4997
      Replacing The Coolant...4997
    FUEL SYSTEM...5000
      Fuel Specifications...5000
      Filling The Fuel Tank...5000
      Fuel Filter...5000
    ENGINE LUBRICATION SYSTEM...5002
      Checking Engine Oil...5002
      Engine Oil Chart...5002
      Replacing Oil And Filter...5003
    HYDRAULIC / HYDROSTATIC SYSTEM...5004
      Checking And Adding Fluid...5004
      Replacing Hydraulic / Hydrostatic Filter...5004
      Replacing Hydraulic Fluid...5005
    AXLES (FRONT AND REAR)...5006
      Checking Oil Level (Planetary Carrier)...5006
      Draining Oil (Planetary Carrier)...5006
      Checking Oil Level (Rear Differential)...5007
      Draining Oil (Rear Differential)...5007
      Checking Oil Level (Front Differential)...5007
      Draining Oil (Front Differential)...5008
    LUBRICATION...5010
      Procedure...5010
    ATTACHMENT FRAME...5014
      Inspection And Maintenance...5014
    TIRE MAINTENANCE...5016
      Wheel Nuts...5016
      Mounting...5016
      Rotating...5016
    SPARK ARRESTER MUFFLER...5018
      Cleaning...5018
    APPROVED BOOM STOP...5020
      Installing The Approved Boom Stop...5020
      Removing The Approved Boom Stop...5020
    ENGINE COVER...5022
      Opening And Closing The Engine Cover...5022
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS)...5024
      System Inspection...5024
      Maintaining...5025
    CHAIN...5026
      Checking And Adjustment Procedure...5026
      Extend / Retract Chain Wear Check...5027
    STOPPING THE ENGINE AND LEAVING THE VERSAHANDLER...5028
      Procedure...5028
    VersaHANDLER STORAGE AND RETURN TO SERVICE...5030
      Storage...5030
      Return To Service...5030
    EMERGENCY EXIT...5032
      Rear Window...5032
  HYDRAULIC SYSTEM...5034
    HYDRAULIC / HYDROSTATIC SCHEMATICS...5038
    HYDRAULIC SYSTEM INFORMATION...5041
      Glossary Of Hydraulic / Hydrostatic Symbols...5041
      Troubleshooting Chart...5044
      Tightening Procedures...5045
    LIFT CYLINDER...5047
      Removal And Installation...5047
      Parts Identification...5050
      Disassembly...5051
      Assembly...5056
    BUCKET POSITION CYLINDER...5061
      Removal And Installation...5061
      Removal And Installation (Cont’d)...5063
      Parts Identification...5064
      Disassembly...5065
      Assembly...5069
    EXTENSION CYLINDER...5073
      Cylinder Group Removal And Installation...5073
      Parts Identification...5076
      Disassembly...5077
      Assembly...5081
    TILT CYLINDER...5085
      Removal And Installation...5085
      Parts Identification...5088
      Disassembly...5089
      Assembly...5093
    STEERING CYLINDER (FRONT)...5097
      Removal...5097
      Installation...5099
      Disassembly...5101
      Assembly...5103
    STEERING CYLINDER (REAR)...5107
      Removal...5107
      Installation...5109
      Disassembly...5111
      Assembly...5113
    DRIVE BOX...5117
      Parts Identification...5117
      Disassembly...5118
      Assembly...5122
      Special Tools...5125
    MAIN RELIEF VALVE...5127
      Testing And Adjustment...5127
      Removal And Installation...5128
    QUICK-TACH CYLINDER...5129
      Removal And Installation...5129
      Parts Identification...5131
      Disassembly...5132
      Assembly...5135
    FRAME LEVELING CYLINDER...5137
      Removal And Installation...5137
      Parts Identification...5139
      Disassembly...5140
      Assembly...5145
    STEERING MODE VALVE BLOCK...5151
      Removal And Installation...5151
      Parts Identification...5153
      Disassembly...5154
      Solenoid Testing...5156
      Assembly...5156
    BRAKE VALVE...5159
      Removal And Installation...5159
      Disassembly And Assembly...5160
    GEAR PUMP...5163
      Removal And Installation...5163
      Parts Identification...5166
      Disassembly And Assembly...5167
    FAN MOTOR...5173
      Removal And Installation...5173
      Parts Identification...5177
      Disassembly And Assembly...5178
    HYDRAULIC RESERVOIR...5181
      Removal And Installation...5181
    STEERING VALVE...5183
      Removal And Installation...5183
      Parts Identification...5184
      Disassembly...5185
      Inspection...5188
      Assembly...5188
    HYDRAULIC CONTROL VALVE...5193
      Troubleshooting Chart (Controllers)...5193
      Telescoping Valve Section Troubleshooting...5194
      Auxiliary Valve Section Troubleshooting...5198
      Troubleshooting Chart (Control Valve)...5202
      Removal And Installation...5203
      Parts Identification...5207
      Disassembly And Assembly...5208
      End Housing Disassembly And Assembly...5209
      Lifting Valve Section Disassembly And Assembly...5210
      Tilting Valve Section Disassembly And Assembly...5215
      Telescoping Valve Section Disassembly And Assembly...5220
      Auxiliary / Frame Leveling Valve Section Disassembly And Assembly...5232
      Inlet-Outlet Valve Section Disassembly And Assembly...5242
    PORT RELIEF VALVES...5247
      Adjustment Procedure...5247
    FLOW CONTROL VALVE...5249
      Removal And Installation...5249
    JOYSTICK...5251
      Removal And Installation...5251
    PARKING BRAKE...5253
      Pressure Switch Removal And Installation...5253
      Pressure Switch Disassembly And Assembly...5255
      Parking Brake Valve Removal And Installation...5256
      Parking Brake Valve Disassembly And Assembly...5256
    PRESSURE REDUCING VALVE...5259
      Testing...5259
      Removal And Installation...5260
      Disassembly And Assembly...5261
    ACCUMULATOR...5263
      Removal And Installation...5263
    TOW VALVE...5265
      Removal And Installation...5265
      Disassembly And Assembly...5266
    STABILIZER CYLINDER...5271
      Removal...5271
      Parts Identification...5273
      Disassembly...5274
      Assembly...5277
      Installation...5279
    STABILIZER CONTROL VALVE...5281
      Parts Identification...5281
      Removal...5282
      Installation...5283
  HYDROSTATIC SYSTEM...5285
    HYDROSTATIC SYSTEM INFORMATION...5287
      Troubleshooting Chart...5287
      Replenishing Valve Function...5288
    OIL COOLER...5289
      Description...5289
    HYDROSTATIC DRIVE MOTOR...5291
      Removal And Installation...5291
      Parts Identification...5292
      Disassembly...5295
      Inspection...5310
      Assembly...5312
    HYDROSTATIC PUMP...5329
      Removal And Installation...5329
      Parts Identification...5332
      Disassembly...5337
      Inspection...5349
      Assembly...5353
  DRIVE SYSTEM...5369
    TROUBLESHOOTING...5371
      Chart...5371
    AXLE AND DIFFERENTIAL (FRONT)...5373
      General Information...5373
      Planetary Carrier Parts Identification...5373
      Planetary Carrier Disassembly...5374
      Steering Knuckle And Drive Axle Parts Identification...5379
      Steering Knuckle Disassembly...5380
      Drive Axle Disassembly...5382
      Brake System Parts Identification...5384
      Brake System Disassembly...5385
      Differential Parts Identification...5389
      Differential Disassembly...5390
      Bevel Pinion Parts Identification...5395
      Bevel Pinion Disassembly...5396
      Bevel Pinion Assembly...5399
      Differential Assembly...5408
      Brake System Assembly...5413
      Drive Axle Assembly...5419
      Steering Knuckle Assembly...5421
      Planetary Carrier Assembly...5424
      Special Tools...5428
    AXLE AND DIFFERENTIAL (REAR)...5429
      General Information...5429
      Planetary Carrier Parts Identification...5429
      Steering Knuckle And Drive Axle Parts Identification...5435
      Steering Knuckle Disassembly...5436
      Differential And Bevel Pinion Parts Identification...5438
      Differential Disassembly...5439
      Bevel Pinion Disassembly...5443
      Bevel Pinion Assembly...5446
      Differential Assembly...5454
      Steering Knuckle Assembly...5459
      Planetary Carrier Assembly...5462
      Special Tools...5466
    FRONT AXLE...5467
      Removal...5467
      Installation...5474
    AXLE TOE-IN...5481
      Adjustment...5481
    PARKING BRAKE...5483
      Releasing The Brake For Towing...5483
      Re-Activating The Brake...5484
    STEERING ANGLE ADJUSTMENT...5485
      Adjustment...5485
    DRIVE SHAFT...5487
      Removal And Installation...5487
    SERVICE BRAKE...5489
      Description...5489
      Bleeding The Brake Circuit...5489
    REAR AXLE...5491
      Removal...5491
      Installation...5494
  MAINFRAME...5499
    OPERATOR CAB (S/N A8HM12999 & BELOW)...5501
      Removal And Installation...5501
    OPERATOR CAB (S/N A8HM13000 & ABOVE)...5509
      Removal And Installation...5509
    CANOPY...5517
      Removal And Installation...5517
    OPERATOR SEAT...5523
      Removal And Installation...5523
    FIXED BOOM...5525
      Removal...5525
      Installation...5527
    END BOOM...5531
      Removal...5531
      Installation...5533
    WEAR PADS (FRONT)...5535
      Removal...5535
      Installation...5536
    WEAR PADS (REAR)...5539
      Removal...5539
      Installation...5540
    ENGINE COVER...5541
      Gas Cylinder Removal And Installation...5541
      Removal And Installation...5541
    AIR INTAKE COWLING...5543
      Removal And Installation...5543
    FUEL TANK...5545
      Removal And Installation...5545
    QUICK-TACH...5549
      Removal And Installation...5549
    REAR WEIGHTS...5551
      Removal And Installation...5551
    FENDER...5553
      Removal And Installation...5553
    PIVOT LINK...5555
      Removal And Installation...5555
    DASH COVER / STEERING COLUMN COVER (S/N A8HM12999 & BELOW, S/N A8HN12999 & BELOW)...5559
      Removal And Installation...5559
    DASH COVER / STEERING COLUMN COVER (S/N A8HM13000 & ABOVE, S/N A8HN13000 & ABOVE)...5563
      Removal And Installation...5563
    JOYSTICK PANEL (S/N A8HM12999 & BELOW, S/N A8HN12999 & BELOW)...5567
      Removal And Installation...5567
    JOYSTICK PANEL (S/N A8HM13000 & ABOVE, S/N A8HN13000 & ABOVE)...5569
      Removal And Installation...5569
    INTERMEDIATE BOOM...5571
      Removal...5571
      Installation...5572
    BOOM TRAY...5575
      Removal And Installation...5575
    STABILIZER FRAME...5579
      Removal...5579
      Installation...5580
  ELECTRICAL SYSTEM & ANALYSIS...5583
    ELECTRICAL SCHEMATICS...5585
    ELECTRICAL SYSTEM INFORMATION (S/N A8HM12999 & BELOW, S/N A8HN12999 & BELOW)...5607
      Troubleshooting Chart...5607
      Description...5608
      Fuses, Diodes And Relays...5608
    ELECTRICAL SYSTEM INFORMATION (S/N A8HM13000 & ABOVE, S/N A8HN13000 & ABOVE)...5611
      Troubleshooting Chart...5611
      Description...5612
      Fuses, Diodes And Relays...5612
    BATTERY...5615
      Removal And Installation...5615
      Servicing...5616
      Using A Booster Battery (Jump Starting)...5617
    ALTERNATOR...5619
      Removal And Installation...5619
      Adjusting The Alternator Belt...5620
    STARTER...5621
      Removal And Installation...5621
      Parts Identification...5622
      Disassembly...5623
      Inspection And Repair...5628
      Assembly...5632
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS)...5637
      Restraint Bar Removal And Installation...5637
      Sensor Removal And Installation...5638
      Strut Removal And Installation...5640
      Strut Disassembly And Assembly...5641
      Restraint Bar Bushing Removal And Installation...5642
      Restraint Bar Bumper Removal And Installation...5642
    LIGHTS...5643
      Rear Light Removal And Installation...5643
      Front Light Removal And Installation...5644
    TRAVEL / SIGNAL LEVER (S/N A8HM12999 & BELOW, S/N A8HN12999 & BELOW)...5647
      Removal And Installation...5647
    TRAVEL / SIGNAL LEVER (S/N A8HM13000 & ABOVE, S/N A8HN13000 & ABOVE)...5649
      Removal And Installation...5649
    INSTRUMENT PANEL...5651
      Removal And Installation...5651
    SWITCH PANEL (S/N A8HM12999 & BELOW, S/N A8HN12999 & BELOW)...5653
      Removal And Installation...5653
      Parts Identification...5654
    SWITCH PANEL (S/N A8HM13000 & ABOVE, S/N A8HN13000 & ABOVE)...5657
      Removal And Installation...5657
      Parts Identification...5658
    BRAKE LIGHT SWITCH...5661
      Removal And Installation...5661
      Adjustment...5661
    WIPER MOTOR (FRONT)...5663
      Removal And Installation...5663
    WIPER MOTOR (TOP)...5667
      Removal And Installation...5667
    WIPER MOTOR (REAR)...5669
      Removal And Installation...5669
    PEDAL ASSEMBLY...5671
      Removal And Installation...5671
      Disassembly And Assembly...5672
    INCHING SWITCH...5677
      Removal And Installation...5677
      Adjustment...5677
    SERVICE SOFTWARE...5679
      Connecting The Laptop Computer...5679
      Entering The Service Software...5680
      Monitor Screen...5681
      Warnings Screen...5683
      Calibrate Inch Pedal...5684
      Calibrate Creep Potentiometer...5685
      Program / Update Susmic Controller...5687
    FRAME LEVEL SPEED SWITCH...5689
      Description...5689
      Removal...5689
      Installation...5690
  ENGINE SERVICE...5691
    TROUBLESHOOTING...5695
      Chart...5695
    ENGINE SPEED CONTROL...5697
      Removal And Installation...5697
    MUFFLER...5699
      Removal And Installation...5699
    AIR CLEANER...5701
      Housing Removal And Installation...5701
    OIL COOLER / RADIATOR...5703
      Removal And Installation...5703
      Disassembly And Assembly...5706
    ENGINE AND ENGINE MOUNTS...5709
      Removal And Installation...5709
    ENGINE COMPONENTS AND TESTING...5713
      Fuel Injection Pump Removal...5713
      Fuel Injection Pump Installation...5716
      Fuel Injector Removal And Installation...5719
      Checking The Fuel Lift Pump...5721
      Fuel Lift Pump Removal And Installation...5722
      Compression Checking...5722
      Glow Plug Checking...5723
      Glow Plugs Removal And Installation...5724
    ENGINE TIMING...5725
      Procedure...5725
    ENGINE / HYDROSTAT ASSEMBLY...5727
      Removal And Installation...5727
    FLYWHEEL AND HOUSING...5741
      Removal And Installation...5741
      Ring Gear Removal...5744
      Ring Gear Installation...5744
    RECONDITIONING THE ENGINE...5745
      Turbocharger Troubleshooting...5745
      Turbocharger Description...5746
      Turbocharger Removal And Installation...5746
      Exhaust Manifold Removal And Installation...5748
      Fuel Injector Cover Removal And Installation...5748
      Rocker Cover Removal And Installation...5749
      Cylinder Head Removal...5750
      Cylinder Head Inspection...5752
      Cylinder Head Installation...5753
      Rocker Shaft Disassembly And Assembly...5756
      Valve Removal...5756
      Valve Springs Checking...5757
      Valve Depth Checking...5757
      Valve Guides Checking...5758
      Valve Guide Removal...5759
      Valve Guide Installation...5759
      Valves Checking...5760
      Cutting A Valve Seat...5760
      Valve Seat Assembly...5761
      Changing Valve Springs (With Cylinder Head Installed)...5762
      Valve Clearance Adjustment...5763
      Timing Case And Drive Assembly Description...5764
      Timing Cover Removal...5764
      Timing Cover Installation...5764
      Crankshaft Pulley Removal And Installation...5764
      Front Oil Seal Removal And Installation...5764
      Timing Case And Gear Removal...5765
      Timing Case And Gear Installation...5766
      Camshaft And Tappets Removal...5768
      Camshaft And Tappets Installation...5769
      Pistons And Connecting Rods Description...5770
      Pistons And Connecting Rods Removal...5770
      Pistons And Connecting Rods Disassembly...5772
      Piston Ring End Gap...5772
      Piston Ring Installation...5772
      Piston Ring Groove Clearance...5773
      Connecting Rod Inspection...5774
      Connecting Rod Bushing Replacement...5774
      Piston And Connecting Rod Assembly...5774
      Piston And Connecting Rod Installation...5774
      Checking Piston Height...5776
      Crankshaft And Bearings Description...5776
      Crankshaft And Bearings Removal...5776
      Inspection Of Crankshaft And Bearings...5778
      Crankshaft And Bearings Installation...5779
      Rear Oil Seal Removal...5780
      Rear Oil Seal Housing Positioning...5780
      Rear Oil Seal Installation...5781
      Checking Crankshaft End Play...5781
      Cooling System Description...5782
      Thermostat Removal and Installation...5783
      Thermostat Testing...5784
      Lubricating Oil Cooler Removal And Installation...5784
      Water Pump Removal...5784
      Water Pump Installation...5784
      Engine Lubrication System Description...5785
      Oil Filter Adapter Removal And Installation...5786
      Oil Pan Removal And Installation...5786
      Oil Screen And Pick-up Tube...5787
      Oil Pump Removal...5787
      Oil Pump Installation...5788
      Oil Pump Disassembly And Assembly...5789
      Oil Pressure Relief Valve Disassembly And Assembly...5789
      Engine Block Description...5790
      Engine Block Disassembly And Assembly...5790
      Piston Cooling Jet Removal...5791
      Piston Cooling Jet Installation...5791
      Piston Cooling Jet Alignment...5791
      Inspection...5791
      Cylinder Liner Inspection...5792
      Cylinder Liner Removal...5793
      Cylinder Liner Installation...5794
  HEATING, VENTILATION AND AIR CONDITIONING (HVAC)...5795
    AIR CONDITIONING SYSTEM FLOW...5797
      Principles...5797
      Chart...5798
    COMPONENTS...5799
      Identification...5799
    SAFETY...5803
      Safety Equipment...5803
    REGULAR MAINTENANCE...5805
      Filter Element Removal And Installation...5805
      Compressor Drive Belt Inspection...5805
      Cleaning The Condenser...5806
    BASIC TROUBLESHOOTING...5807
      Poor A/C Performance...5807
      Compressor Drive Belt Inspection...5808
      Checking The Electrical System...5809
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...5815
      Compressor Oil...5815
      Compressor Oil Check...5815
      Component Replacement And Refrigeration Leaks...5817
    SYSTEM TROUBLESHOOTING...5819
      Chart...5819
      Gauge Pressure Related Troubleshooting...5820
    TEMPERATURE / PRESSURE...5823
      Chart...5823
    AIR CONDITIONING SERVICE...5825
      Chart...5825
    SYSTEM CHARGING AND RECLAMATION...5827
      Reclamation Procedure...5827
      Charging Procedure With A Manifold Gauge Set...5830
      Charging Procedure...5831
    COMPRESSOR...5833
      Removal And Installation...5833
      Compressor Clutch Disassembly And Assembly...5836
    CONDENSER (S/N A8HM12999 & BELOW)...5849
      Removal And Installation...5849
    CONDENSER (S/N A8HM13000 & ABOVE)...5851
      Removal And Installation...5851
    RECEIVER / DRIER...5853
      Removal And Installation...5853
    PRESSURE SWITCH...5855
      Removal And Installation...5855
    EVAPORATOR / BLOWER UNIT (S/N A8HM12999 & BELOW)...5857
      Removal And Installation...5857
    EVAPORATOR / BLOWER / HEATER UNIT (S/N A8HM13000 & ABOVE)...5859
      Removal And Installation...5859
    EXPANSION VALVE (S/N A8HM12999 & BELOW)...5861
      Removal And Installation...5861
    EXPANSION VALVE (S/N A8HM13000 & ABOVE)...5863
      Removal And Installation...5863
    HEATER ASSEMBLY...5865
      Removal And Installation...5865
      Fan Removal And Installation...5866
      Core Removal And Installation...5867
  SPECIFICATIONS...5869
    VERSAHANDLER SPECIFICATIONS...5871
      Machine Dimensions...5871
      Performance Specifications...5872
      Engine...5872
      Controls...5872
      Drive System...5872
      Tires...5873
      Capacities...5873
      Hydraulic System...5873
      Electrical...5873
      Instrument Panel...5873
    ENGINE SPECIFICATIONS...5875
      General...5875
      Cylinder Head...5875
      Valve Guides...5875
      Exhaust Valves...5876
      Intake Valves...5876
      Valve Springs...5876
      Rocker Shaft, Rockers And Bushings...5877
      Pistons And Piston Rings...5877
      Connecting Rods And Bearings...5878
      Crankshaft...5878
      Crankshaft Re-Grind Data...5879
      Main Bearings...5880
      Thrust Washers...5880
      Camshaft And Thrust Washer...5880
      Cylinder Block...5880
      Cylinder Liners...5881
      Fuel Injection Pump...5881
      Fuel Injectors...5881
      Fuel Lift Pump...5881
      Timing Case And Timing Gears...5882
      Oil Pump, Gear And Relief Valve...5883
      Turbocharger...5883
      Flywheel...5883
      Water Pump And Thermostat...5884
      Engine Torque Component...5885
    MACHINE TORQUE SPECIFICATIONS...5887
      Axle...5887
      Boom...5887
      Drive Box...5887
      Drive Motor...5887
      Engine...5888
      Hydraulic Pump...5888
    TORQUE SPECIFICATIONS FOR BOLTS...5889
      Torque for General SAE Bolts...5889
      Torque For General Metric Bolts...5890
    HYDRAULIC CONNECTION SPECIFICATIONS...5891
      O-ring Face Seal Connection...5891
      Straight Thread O-ring Fitting...5891
      Tubelines And Hoses...5891
      Port Seal Fitting...5892
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...5893
      Specifications...5893
    CONVERSIONS...5895
      Decimal And Millimeter Equivalent Chart...5895
      U.S. To Metric Conversion Chart...5895
  ALPHABETICAL INDEX...5897
  SERVICE MANUAL REVISION...5901
    Revision No: V638 - 1...5901
6989575 (3-10) - V638 VersaHANDLER Telescopic Tool Carrier (TTC) Operation & Maintenance Manual...5903
  OPERATOR SAFETY WARNINGS...5905
  CONTENTS...5907
  FOREWORD...5909
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...5911
    REGULAR MAINTENANCE ITEMS...5911
    SERIAL NUMBER LOCATION...5912
      VersaHANDLER Serial Number...5912
      Engine Serial Number...5912
    DELIVERY REPORT...5913
    BOBCAT VersaHANDLER IDENTIFICATION...5914
    FEATURES, ACCESSORIES AND ATTACHMENTS...5915
      Standard Items...5915
      Options And Accessories...5915
      Available Tires...5915
      Attachments...5915
      Front Window Guard Kit...5916
      Front Window Guard Kit Inspection And Maintenance...5916
  SAFETY & TRAINING RESOURCES...5917
    SAFETY INSTRUCTIONS...5919
      Before Operation...5919
      Safe Operation Is The Operator’s Responsibility...5920
      Safe Operation Needs A Qualified Operator...5920
      Avoid Silica Dust...5921
    FIRE PREVENTION...5921
      Maintenance...5921
      Operation...5921
      Electrical...5921
      Hydraulic System...5922
      Fueling...5922
      Starting...5922
      Spark Arrestor Exhaust System...5922
      Welding And Grinding...5922
      Fire Extinguishers...5922
    PUBLICATIONS AND TRAINING RESOURCES...5923
    MACHINE SIGNS (DECALS)...5924
  OPERATING INSTRUCTIONS...5927
    OPERATOR CONTROLS IDENFICATION...5931
      Operator Components...5931
      Travel Direction And Two-Speed Control...5931
      Steering Wheel...5932
      Direction Signal...5932
      Front Wiper / Washer / Headlight Dimmer...5932
      Horn...5932
      Steering Wheel Tilt Adjustment...5933
      Center Instrument Panel...5934
      Right Instrument And Indicator Panel...5935
      Left Instrument Panel...5937
      Left Side Instrument Panel...5937
      Heater / Air Conditioning Controls (If Equipped)...5937
      Right Rear Console...5937
      Rear Console...5938
      Accelerator Pedal...5938
      Brake Pedal And Inching Control...5938
      Frame Level Switch (If Equipped)...5939
    OPERATOR CANOPY (ROPS / FOPS)...5940
      Description...5940
    OPERATOR CAB (ROPS / FOPS)...5940
      Description...5940
      Cab Door...5941
      Cab Door Window...5941
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS)...5942
    STEERING CONTROLS...5943
      Steering Mode Selection...5943
    PARKING BRAKE...5944
      Operation...5944
    EMERGENCY EXIT...5944
      Rear Window...5944
    BACK-UP ALARM SYSTEM...5945
      Description...5945
      Operation...5945
    DRIVING AND STEERING THE VERSAHANDLER...5946
      4-Wheel Steering Mode...5946
      Stopping The VersaHANDLER (4-Wheel Steering Mode)...5947
      2-Wheel Steering Mode...5948
      Stopping The VersaHANDLER (2-Wheel Steering Mode)...5949
      Crab Steering Mode...5950
      Stopping The VersaHANDLER (Crab Steering Mode)...5951
    HYDRAULIC CONTROLS...5952
      Hydraulic Control Lever (Joystick)...5952
      Auxiliary Hydraulic Release...5953
    DAILY INSPECTION...5954
      Daily Inspection And Maintenance...5954
    PRE-STARTING PROCEDURE...5956
      Entering The VersaHANDLER...5956
      Operation & Maintenance Manual And Operator’s Handbook Locations...5956
      Seat Adjustment...5957
      Seat Belt Adjustment...5957
      Panel Switch Position...5958
      Lateral Operator Restraint System (LORS) (If Equipped)...5958
    STARTING THE ENGINE...5959
      Cold Temperature Starting...5960
      Warming The Hydraulic / Hydrostatic System...5960
    MONITORING THE DISPLAY PANELS...5961
      Panel...5961
    STOPPING THE ENGINE AND LEAVING THE VERSAHANDLER...5961
      Procedure...5961
    ATTACHMENTS...5962
      Installing And Removing The Attachment (Quick - Tach)...5962
      Installing And Removing The Attachment (Adapter Frame) (Hand Lever Bob-Tach)...5964
      Inspecting The Work Area...5967
      Basic Operating Instructions...5967
      Driving On Public Roads...5967
      Operating With A Full Bucket...5968
      Operating With An Empty Bucket...5968
      Filling And Emptying The Bucket...5969
      Digging And Filling A Hole...5970
      Raising A Load And Extending The Boom...5971
      Using Frame Leveling...5972
      Using Stabilizers (If Equipped)...5973
      Load Capacity Charts...5974
    TOWING THE VersaHANDLER...5975
      Procedure...5975
    LIFTING THE VersaHANDLER...5977
    TRANSPORTING THE VersaHANDLER...5978
      Loading And Unloading...5978
      Fastening...5978
  PREVENTIVE MAINTENANCE...5979
    MAINTENANCE SAFETY...5983
    SERVICE SCHEDULE...5985
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS)...5986
      System Inspection...5986
      Maintaining...5987
    SEAT BELT...5988
      Inspection And Maintenance...5988
    APPROVED BOOM STOP...5989
      Installing The Approved Boom Stop...5989
      Removing The Approved Boom Stop...5989
    BACK-UP ALARM SYSTEM...5990
      Description...5990
      Inspecting...5990
    ENGINE COVER...5991
      Opening And Closing...5991
    HEATING, VENTILATION AND AIR CONDITIONING SYSTEM (HVAC)...5992
      Cleaning And Maintenance...5992
      Filters...5992
      Condenser...5992
      Air Conditioning Lubrication...5992
      Troubleshooting...5992
    AIR CLEANER SERVICE...5993
      Replacing Filters...5993
    FUEL SYSTEM...5995
      Fuel Specifications...5995
      Biodiesel Blend Fuel...5995
      Filling The Fuel Tank...5995
      Fuel Filter...5996
      Removing Air From The Fuel System...5996
    ENGINE LUBRICATION SYSTEM...5997
      Checking And Adding Engine Oil...5997
      Engine Oil Chart...5997
      Replacing And Replacing Oil And Filter...5998
    ENGINE COOLING SYSTEM...5999
      Cleaning...5999
      Removing And Replacing The Coolant...6000
      Checking Level...6001
    ELECTRICAL SYSTEM...6002
      Description...6002
      Fuses, Diode And Relay Location / Identification...6002
      Battery Maintenance...6004
      Using A Booster Battery (Jump Starting)...6005
      Removing And Installing Battery...6006
      Battery Disconnect Switch...6008
    HYDRAULIC / HYDROSTATIC SYSTEM...6009
      Checking And Adding Fluid...6009
      Hydraulic / Hydrostatic Fluid Chart...6009
      Removing And Replacing Hydraulic / Hydrostatic Fluid...6010
      Removing And Replacing Hydraulic / Hydrostatic Filter...6011
      Breather Cap...6011
    BRAKE CONTROL SYSTEM...6012
      Inspection And Maintenance...6012
    SPARK ARRESTOR MUFFLER...6013
    TIRE MAINTENANCE...6014
      Wheel Nuts...6014
      Rotating...6014
      Mounting...6014
      Tire Pressure...6014
    AXLES (FRONT AND REAR)...6015
      Checking And Adding Oil (Planetary Carrier)...6015
      Removing And Replacing Oil (Planetary Carrier)...6015
      Checking And Adding Oil (Rear Differential)...6016
      Removing And Replacing Oil (Rear Differential)...6016
      Checking And Adding Oil (Front Differential)...6017
      Removing And Replacing Oil (Front Differential)...6018
      Checking And Adding Oil (Front Drop Box)...6019
      Removing And Replacing Oil (Front Drop Box)...6019
    ALTERNATOR BELT...6020
      Belt Adjusting...6020
      Belt Replacement...6020
    LUBRICATING THE VersaHANDLER...6021
      Lubrication Locations...6021
    PIVOT PIN...6025
      Inspection And Maintenance...6025
    ATTACHMENT FRAME...6026
      Inspection And Maintenance...6026
    ADAPTER FRAME (BOB-TACH) (HAND LEVER)...6027
      Inspection And Maintenance...6027
    CHAIN CHECKING AND ADJUSTING PROCEDURE...6028
      Checking / Adjustment Procedure...6028
      Extend / Retract Chain Wear Check...6029
    VersaHANDLER STORAGE AND RETURN TO SERVICE...6030
      Storage...6030
      Return To Service...6030
  MACHINE SIGN TRANSLATIONS...6031
    MACHINE SIGN TRANSLATIONS...6033
      Service Schedule (6918234)...6033
      Warning (6809613)...6036
      Danger (6918255)...6038
      Warning (6809614)...6039
      Danger (6809610)...6039
      Warning (6577754)...6039
      Warning (6908056)...6039
      Warning (6809606)...6040
      Danger (6809607)...6040
      Warning (6809622)...6041
      Warning (6809608))...6042
      Warning (6960068)...6042
      Warning (6911376)...6044
  SPECIFICATIONS...6045
    VersaHANDLER TELESCOPIC TOOL CARRIER (TTC) SPECIFICATIONS...6047
      Dimensional Specifications...6047
      Performance Specifications...6048
      Engine...6048
      Fan Pump...6048
      Controls...6048
      Drive System...6048
      Hydraulic System...6049
      Electrical System...6049
      Instrument Panel...6049
      Capacities...6049
      Tires...6049
  WARRANTY...6051
    WARRANTY...6053
  ALPHABETICAL INDEX...6055
6989577 (3-10) - V518, V723 Telescopic Tool Carrier (TTC) Operation & Maintenance Manual...6057
  OPERATOR SAFETY WARNINGS...6059
  CONTENTS...6061
  FOREWORD...6063
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...6065
    REGULAR MAINTENANCE ITEMS...6065
    SERIAL NUMBER LOCATION...6066
      VersaHANDLER Serial Number...6066
      Engine Serial Number...6066
    DELIVERY REPORT...6067
    VersaHANDLER IDENTIFICATION...6068
    FEATURES, ACCESSORIES AND ATTACHMENTS...6069
      Standard Items...6069
      Options And Accessories...6069
      Available Tires...6069
      Attachments...6069
      Front Window Guard Kit...6070
      Front Window Guard Kit Inspection And Maintenance...6070
  SAFETY & TRAINING RESOURCES...6071
    SAFETY INSTRUCTIONS...6073
      Before Operation...6073
      Safe Operation Is The Operator’s Responsibility...6074
      Safe Operation Needs A Qualified Operator...6074
      Avoid Silica Dust...6075
    FIRE PREVENTION...6075
      Maintenance...6075
      Operation...6075
      Electrical...6075
      Hydraulic System...6076
      Fueling...6076
      Starting...6076
      Spark Arrestor Exhaust System...6076
      Welding And Grinding...6076
      Fire Extinguishers...6076
    ADDITIONAL PUBLICATIONS AND TRAINING RESOURCES...6077
    MACHINE SIGNS (DECALS)...6078
  OPERATING INSTRUCTIONS...6081
    OPERATOR CONTROLS IDENTIFICATION...6085
      Operator Components...6085
      Travel Direction And Two-Speed Control...6085
      Steering Wheel...6086
      Direction Signal...6086
      Front Wiper / Washer / Headlight Dimmer...6086
      Horn...6086
      Steering Wheel Tilt Adjustment...6087
      Center Instrument Panel...6088
      Right Instrument And Indicator Panel...6089
      Left Instrument Panel...6091
      Left Side Instrument Panel...6091
      Heater / Air Conditioning Controls (If Equipped)...6091
      Right Rear Console...6091
      Rear Console...6092
      Accelerator Pedal...6092
      Brake Pedal And Inching Control...6092
      Frame Level Switch (If Equipped)...6093
    OPERATOR CANOPY (ROPS / FOPS)...6094
      Description...6094
    OPERATOR CAB (ROPS / FOPS)...6094
      Description...6094
      Cab Door...6095
      Cab Door Window...6095
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS)...6096
    STEERING CONTROLS...6097
      Steering Mode Selection...6097
    PARKING BRAKE...6098
      Operation...6098
    EMERGENCY EXIT...6098
      Rear Window...6098
    BACK-UP ALARM SYSTEM...6099
      Description...6099
      Operation...6099
    DRIVING AND STEERING THE VERSAHANDLER...6100
      4-Wheel Steering Mode...6100
      Stopping The VersaHANDLER (4-Wheel Steering Mode)...6101
      2-Wheel Steering Mode...6102
      Stopping The VersaHANDLER (2-Wheel Steering Mode)...6103
      Crab Steering Mode...6104
      Stopping The VersaHANDLER (Crab Steering Mode)...6105
    HYDRAULIC CONTROLS...6106
      Hydraulic Control Lever (Joystick)...6106
      Auxiliary Hydraulic Release (For V518)...6107
      Auxiliary Hydraulic Release (For V723)...6107
    DAILY INSPECTION...6108
      Daily Inspection And Maintenance...6108
    PRE-STARTING PROCEDURE...6110
      Entering The VersaHANDLER...6110
      Operation & Maintenance Manual And Operator’s Handbook Locations...6110
      Seat Adjustment...6111
      Seat Belt Adjustment...6111
      Panel Switch Position...6112
      Lateral Operator Restraint System (LORS) (If Equipped)...6112
    STARTING THE ENGINE...6113
      Cold Temperature Starting...6114
      Warming The Hydraulic / Hydrostatic System...6114
    MONITORING THE DISPLAY PANELS...6115
      Panel...6115
    STOPPING THE ENGINE AND LEAVING THE VERSAHANDLER...6115
      Procedure...6115
    ATTACHMENTS...6116
      Installing And Removing The Attachment (Quick - Tach)...6116
      Installing And Removing The Attachment (Adapter Frame) (Hand Lever Bob-Tach)...6118
    OPERATING PROCEDURE...6121
      Inspecting The Work Area...6121
      Basic Operating Instructions...6121
      Driving On Public Roads...6121
      Operating With A Full Bucket...6122
      Operating With An Empty Bucket...6122
      Filling And Emptying The Bucket...6123
      Digging And Filling A Hole...6124
      Raising A Load And Extending The Boom...6125
      Using Frame Leveling (V723 With Frame Level Only)...6126
      Load Capacity Charts...6127
    TOWING THE VersaHANDLER (FOR V518)...6128
      Procedure...6128
    TOWING THE VersaHANDLER (FOR V723)...6130
    LIFTING THE VersaHANDLER...6132
    TRANSPORTING THE VersaHANDLER...6133
      Loading And Unloading...6133
      Fastening...6133
  PREVENTIVE MAINTENANCE...6135
    MAINTENANCE SAFETY...6139
    SERVICE SCHEDULE...6141
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS)...6142
      System Inspection...6142
      Maintaining...6143
    SEAT BELT...6144
      Inspection And Maintenance...6144
    APPROVED BOOM STOP...6145
      Installing The Approved Boom Stop...6145
      Removing The Approved Boom Stop...6145
    BACK-UP ALARM SYSTEM...6146
      Description...6146
      Inspecting...6146
    ENGINE COVER...6147
      Opening And Closing...6147
    HEATING, VENTILATION AND AIR CONDITIONING SYSTEM (HVAC)...6148
      Cleaning And Maintenance...6148
      Filters...6148
      Condenser...6148
      Air Conditioning Lubrication...6148
      Troubleshooting...6148
    AIR CLEANER SERVICE...6149
      Replacing Filters...6149
    FUEL SYSTEM...6151
      Fuel Specifications...6151
      Biodiesel Blend Fuel...6151
      Filling The Fuel Tank...6151
      Fuel Filter...6152
      Removing Air From The Fuel System...6152
    ENGINE LUBRICATION SYSTEM...6153
      Checking And Adding Engine Oil...6153
      Engine Oil Chart...6153
      Removing And Replacing Oil And Filter...6154
    ENGINE COOLING SYSTEM...6155
      Cleaning...6155
      Removing And Replacing The Coolant...6156
      Checking Level...6157
    ELECTRICAL SYSTEM...6158
      Description...6158
      Fuses, Diode And Relay Location / Identification...6158
      Battery Maintenance...6160
      Using A Booster Battery (Jump Starting)...6161
      Removing And Installing Battery...6163
      Battery Disconnect Switch...6165
    HYDRAULIC / HYDROSTATIC SYSTEM...6166
      Checking And Adding Fluid...6166
      Hydraulic / Hydrostatic Fluid Chart...6166
      Removing And Replacing Hydraulic / Hydrostatic Fluid...6167
      Removing And Replacing Hydraulic / Hydrostatic Filter...6168
      Breather Cap...6168
    BRAKE CONTROL SYSTEM...6169
      Inspection And Maintenance...6169
    SPARK ARRESTER MUFFLER...6170
    TIRE MAINTENANCE...6171
      Wheel Nuts...6171
      Rotating...6171
      Mounting...6171
      Tire Pressure...6171
    AXLES (FRONT AND REAR)...6172
      Checking And Adding Oil (Planetary Carrier)...6172
      Removing And Replacing Oil (Planetary Carrier)...6172
      Checking And Adding Oil (Rear Differential)...6173
      Removing And Replacing Oil (Rear Differential)...6173
      Checking And Adding Oil (Front Differential)...6174
      Removing And Replacing Oil (Front Differential)...6175
      Checking And Adding Oil (Front Drop Box)...6176
      Removing And Replacing Oil (Front Drop Box)...6176
    ALTERNATOR BELT...6177
      Belt Adjusting...6177
      Belt Replacement...6177
    LUBRICATING THE VersaHANDLER...6178
      Lubrication Locations...6178
    PIVOT PIN...6181
      Inspection And Maintenance...6181
    ATTACHMENT FRAME...6182
      Inspection And Maintenance...6182
    ADAPTER FRAME (BOB-TACH) (HAND LEVER)...6183
      Inspection And Maintenance...6183
    VersaHANDLER STORAGE AND RETURN TO SERVICE...6184
      Storage...6184
      Return To Service...6184
  MACHINE SIGN TRANSLATIONS...6185
    MACHINE SIGN TRANSLATIONS...6187
      Service Schedule (6913156)...6187
      Warning (6809613)...6190
      Danger (6809618)...6192
      Danger (6913554)...6192
      Warning (6809614)...6193
      Danger (6809610)...6193
      Warning (6577754)...6193
      Warning (6908056)...6193
      Warning (6809606)...6194
      Danger (6809607)...6194
      Warning (6809622)...6195
      Warning (6809608)...6196
      Warning (6960068)...6196
      Warning (6911376)...6198
  SPECIFICATIONS...6199
    VersaHANDLER TELESCOPIC TOOL CARRIER (TTC) SPECIFICATIONS...6201
      Dimensional Specifications...6201
      Performance...6202
      Engine...6202
      Fan Pump...6202
      Controls...6202
      Drive System...6202
      Hydraulic System...6203
      Electrical System...6203
      Instrument Panel...6203
      Capacities...6203
      Tires...6203
  WARRANTY...6205
    WARRANTY...6207
  ALPHABETICAL INDEX...6209
 
Bobcat V623, V638, V723 VersaHANDLER Repair Service Manuals + Operation & Maintenance Manuals