Bobcat V623 VersaHANDLER Service Manual – 6902407 (3-06)

(S/N: 367113001 & Above – S/N: 367213001 & Above – S/N: 367411001 & Above – S/N: 367511001 & Above)
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This workshop repair service manual PDF download for the V623 Bobcat VersaHANDLER® Telescopic Forklift has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

Bobcat VersaHANDLER V623
S/N: 367113001 & Above (with Cab)
S/N: 367213001 & Above (with Cab & Frame Leveling)
S/N: 367411001 & Above (with Canopy & Frame Leveling)
S/N: 367511001 & Above (with Canopy)

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
BOBCAT VERSAHANDLER IDENTIFICATION
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM AND ANALYSIS
ENGINE SERVICE
HEATING, VENTILATION, AIR CONDITIONING
SPECIFICATIONS
SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6902407 (3-06)
Total Pages : 894

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
Fire Prevention
SERIAL NUMBER LOCATIONS
VersaHANDLER Serial Number
Engine Serial Number
Other Serial Numbers
DELIVERY REPORT
BOBCAT VersaHANDLER IDENTIFICATION

SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE VERSAHANDLER
Procedure
OPERATOR CAB
Emergency Exit
Cab Door
Cab Door Window
TRANSPORTING THE VERSAHANDLER
Procedure
TOWING THE VERSAHANDLER
Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Element
ENGINE COOLING SYSTEM
Cleaning The Cooling System
Checking The Coolant Level
Replacing The Coolant
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Fuel Filter
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Oil Chart
Replacing Oil And Filter
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid
Replacing Hydraulic/Hydrostatic Filter
Replacing Hydraulic Fluid
AXLES (FRONT AND REAR)
Checking Oil Level (Planetary Carrier)
Draining Oil (Planetary Carrier)
Checking Oil Level (Rear Differential)
Draining Oil (Rear Differential)
Checking Oil Level (Front Differential)
Draining Oil (Front Differential)
LUBRICATION
Procedure
TIRE MAINTENANCE
Wheel Nuts
Tire Rotation
Tire Mounting
SPARK ARRESTOR MUFFLER
Cleaning
BOOM STOP
Installing Boom Stop
Removing Boom Stop
ENGINE COVER
Opening And Closing The Engine Cover
Adjusting The Latch
LATERAL OPERATOR RESTRAINT SYSTEM (LORS™)
System Inspection
System Maintenance

HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Troubleshooting Chart
Tightening Procedures
LIFT CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
BUCKET POSITIONING CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
EXTENSION CYLINDER
Cylinder Group Removal And Installation
Upper Tubeline Removal
Upper Tubeline Installation
Extension Cylinder Removal And Installation
Tubeline Tray Disassembly
Tubeline Tray Assembly
Parts Identification
Disassembly
Assembly
TILT CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
STEERING CYLINDER (FRONT)
Removal And Installation
Parts Identification
Disassembly
Assembly
STEERING CYLINDER (REAR)
Removal And Installation
Parts Identification
Disassembly
Assembly
DRIVE BOX
Parts Identification
Disassembly
Inspection
Assembly
MAIN RELIEF VALVE
Testing And Adjustment
Removal and Installation
QUICK TACH CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
FRAME LEVELING CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
STEERING MODE VALVE BLOCK
Removal And Installation
Parts Identification
Disassembly
Solenoid Testing
Assembly
BRAKE VALVE
Removal And Installation
Disassembly And Assembly
GEAR PUMP
Removal And Installation
Parts Identification
Disassembly And Assembly
FAN MOTOR
Removal And Installation
Parts Identification
Disassembly and Assembly
HYDRAULIC RESERVOIR
Removal And Installation
STEERING VALVE
Removal And Installation
Parts Identification
Parts Identification
Disassembly
Inspection
Assembly
HYDRAULIC CONTROL VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
End Housing Disassembly And Assembly
Lifting Valve Section Disassembly And Assembly
Tilting Valve Section Disassembly And Assembly
Telescoping Valve Section Disassembly And Assembly
Auxiliary Valve Section Disassembly And Assembly
Frame Leveling Valve Section Disassembly And Assembly (If Equipped)
Inlet-Outlet Valve Section Disassembly And Assembly
PORT RELIEF VALVES
Adjustment Procedure
FLOW CONTROL VALVE
Removal And Installation
JOYSTICK
Handle Removal And Installation
Joystick Removal And Installation
Parts Identification
Disassembly And Assembly
PARKING BRAKE
Pressure Switch Removal And Installation
Pressure Switch Disassembly And Assembly
Parking Brake Valve Removal And Installation
Parking Brake Valve Disassembly And Assembly
PRESSURE REDUCING VALVE
Testing
Removal And Installation
Disassembly And Assembly
ACCUMULATOR
Removal And Installation
TOW VALVE
Removal And Installation
Disassembly And Assembly
FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE
Removal And Installation
Disassembly And Assembly

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
Replenishing Valve Function
OIL COOLER
Removal And Installation
HYDROSTATIC DRIVE MOTOR
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
HYDROSTATIC PUMP
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly

DRIVE SYSTEM
TROUBLESHOOTING
Chart
AXLE AND DIFFERENTIAL (FRONT)
General Information
Planetary Carrier Parts Identification
Planetary Carrier Disassembly
Planetary Carrier Inspection
Wheel Hub Parts Identification
Wheel Hub Disassembly
Wheel Hub Inspection
Steering Knuckle Parts Identification
Steering Knuckle Disassembly
Axle Housing/Drive Axle Parts Identification
Axle Housing/Drive Axle Disassembly
Brake Group Parts Identification
Brake Group Disassembly
Brake Group Inspection
Differential Parts Identification
Differential Disassembly
Differential Inspection
Pinion Group Parts Identification
Pinion Group Disassembly
Pinion Group Inspection
Pinion Group Assembly
Differential Assembly
Brake Group Assembly
Axle Housing/Drive Axle Assembly
Steering Knuckle Assembly
Wheel Hub Assembly
Planetary Carrier Assembly
AXLE AND DIFFERENTIAL (REAR)
General Information
Planetary Carrier Parts Identification
Planetary Carrier Disassembly
Planetary Carrier Inspection
Wheel Hub Parts Identification
Wheel Hub Disassembly
Wheel Hub Inspection
Steering Knuckle Parts Identification
Steering Knuckle Disassembly
Axle Housing/Drive Axle Parts Identification
Axle Housing/Drive Axle Disassembly
Differential Parts Identification
Differential Disassembly
Differential Inspection
Pinion Group Parts Identification
Pinion Group Disassembly
Pinion Group Inspection
Pinion Group Assembly
Differential Assembly
Axle Housing/Drive Axle Assembly
Steering Knuckle Assembly
Wheel Hub Assembly
Planetary Carrier Assembly
FRONT AXLE
Removal
Installation
FRONT AXLE WITH FRAME LEVELING
Removal
Installation
AXLE PIVOT FRAME
Removal And Installation
Bushing Removal And Installation
AXLE TOE-IN
Adjustment
PARKING BRAKE
Releasing The Brake For Towing
Re-Activating The Brake
STEERING ANGLE ADJUSTMENT
Adjustment
DRIVESHAFT
Removal And Installation
SERVICE BRAKE
Description
Bleeding The Brake Circuit
REAR AXLE
Removal
Installation

MAIN FRAME
OPERATOR CAB
Removal And Installation
CANOPY
Removal and Installation
OPERATOR SEAT
Removal And Installation
BOOM ASSEMBLY
Removal And Installation
INNER BOOM
Removal
Installation
WEAR PADS (FRONT)
Removal And Installation
WEAR PADS (REAR)
Removal
Installation
ENGINE COVER
Gas Cylinder Removal And Installation
Removal And Installation
FUEL TANK
Removal And Installation
QUICK TACH
Removal And Installation
REAR WEIGHTS
Removal And Installation
FENDER
Removal And Installation
PIVOT LINK
Removal And Installation
DASH COVER/STEERING COLUMN COVER
Removal And Installation
JOYSTICK PANEL
Removal And Installation

ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
Description
Fuses, Diodes & Relays
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
ALTERNATOR
Removal And Installation
Adjusting The Alternator Belt
STARTER
Removal And Installation
Parts Identification
Disassembly And Assembly
Inspection And Repair
Magnetic Switch Test
LATERAL OPERATOR RESTRAINT SYSTEM (LOR’S™)
Restraint Bar Removal And Installation
Sensor Removal And Installation
Strut Removal And Installation
Strut Disassembly And Assembly
Restraint Bar Bushing Removal And Installation
Restraint Bar Bumper Removal And Installation
LIGHTS
Rear Light Removal And Installation
Front Light Removal And Installation
TRAVEL/SIGNAL LEVER
Removal And Installation
INSTRUMENT PANEL
Removal And Installation
SWITCH PANEL
Removal And Installation
BRAKE LIGHT SWITCH
Removal And Installation
Adjustment
FRONT WIPER MOTOR
Removal And Installation
TOP WIPER MOTOR
Removal And Installation
REAR WIPER MOTOR
Removal And Installation
PEDAL ASSEMBLY
Removal And Installation
Disassembly And Assembly
INCHING SWITCH
Removal And Installation
Adjustment

ENGINE SERVICE
TROUBLESHOOTING
Chart
ENGINE SPEED CONTROL
Removal And Installation
Adjustment
MUFFLER
Removal And Installation
AIR CLEANER
Housing Removal And Installation
RADIATOR
Removal And Installation
Disassembly And Assembly
ENGINE AND ENGINE MOUNTS
Removal And Installation
ENGINE COMPONENTS AND TESTING
Fuel Injection Pump Removal And Installation
Fuel Injector Removal And Installation
Fuel Injector Checking
Checking The Fuel Lift Pump
Fuel Lift Pump Removal And Installation
ENGINE/HYDROSTAT ASSEMBLY
Removal And Installation
FLYWHEEL AND HOUSING
Removal And Installation
Checking
Ring Gear Removal
Ring Gear Installation
RECONDITIONING THE ENGINE
Intake Manifold Removal and Installation
Exhaust Manifold Removal and Installation
Cylinder Head Disassembly
Cylinder Head Removal
Cylinder Head Inspection
Cylinder Head Installation
Rocker Shaft Disassembly And Assembly
Valve Removal
Valve Springs Checking
Valve Depth Checking
Valve Guides Checking
Valve Guide Removal
Valve Guide Installation
Valves Checking
Cutting A Valve Seat
Valve Seat Assembly
Changing Valve Springs (With Cylinder Head Installed)
Valve Clearance Adjustment
Timing Case And Drive Assembly Description
Timing Cover Removal
Timing Cover Installation
Front Oil Seal Removal
Front Oil Seal Installation
Timing Case And Gear Removal
Timing Case And Gear Installation
Camshaft And Tappets Removal
Camshaft And Tappets Installation
Pistons And Connecting Rods Description
Pistons And Connecting Rods Removal
Pistons And Connecting Rods Disassembly
Piston Ring End Gap
Piston Ring Installation
Piston Ring Groove Clearance
Connecting Rod Inspection
Connecting Rod Bushing Replacement
Piston And Connecting Rod Assembly
Piston And Connecting Rod Installation
Checking Piston Height
Crankshaft And Bearings Description
Crankshaft And Bearings Removal
Inspection Of Crankshaft And Bearings
Crankshaft And Bearings Installation
Rear Oil Seal Removal
Rear Oil Seal Housing Positioning
Rear Oil Seal Installation
Checking Crankshaft End Play
Cooling System Description
Thermostat Removal and Installation
Thermostat Testing
Water Pump Removal
Water Pump Installation
Engine Lubrication System Description
Oil Filter Adapter Removal
Oil Filter Adapter Installation
Oil Pan Removal And Installation
Oil Screen And Pick-up Tube
Oil Pump Removal
Oil Pump Installation
Oil Pump Disassembly And Assembly
Oil Pressure Relief Valve Disassembly And Assembly
Engine Block Description
Engine Block Disassembly And Assembly
Piston Cooling Jet Removal
Piston Cooling Jet Installation
Piston Cooling Jet Alignment
Inspection
Cylinder Liner Inspection
Cylinder Liner Removal
Cylinder Liner Installation
Turbo Charger Troubleshooting
Turbo Charger Description
Turbo Charger Removal and Installation

HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW
Principals
Chart
COMPONENTS
Identification
SAFETY
Safety Equipment
REGULAR MAINTENANCE
Filter Element Removal And Installation
Compressor Drive Belt Inspection
Cleaning The Condenser
BASIC TROUBLESHOOTING
Poor A/C Performance
Compressor Drive Belt Inspection
Checking The Electrical System
GENERAL AIR CONDITIONING SERVICE GUIDELINES
Compressor Oil
Compressor Oil Check
Component Replacement And Refrigeration Leaks
SYSTEM TROUBLESHOOTING CHART
TEMPERATURE/PRESSURE
Chart
AIR CONDITIONING SERVICE
Chart
SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
Charging Procedure With A Manifold Gauge Set
Charging Procedure
COMPRESSOR
Removal And Installation
Compressor Clutch Disassembly And Assembly
CONDENSER
Removal And Installation
RECEIVER/DRIER
Removal And Installation
PRESSURE SWITCH
Removal And Installation
EVAPORATOR/BLOWER UNIT
Removal And Installation
EXPANSION VALVE
Removal And Installation
HEATER ASSEMBLY
Removal And Installation
Fan Removal And Installation
Core Removal And Installation

SPECIFICATIONS
VERSAHANDLER SPECIFICATIONS
Dimensional Specifications
Performance Specifications
Controls
Engine
Drive System
Tires
Hydraulic System
Electrical System
Instrument Panel
Capacities
ENGINE SPECIFICATIONS
General
Cylinder Head
Valve Guides
Exhaust Valves
Intake Valves
Valve Springs
Rocker Shaft, Rockers And Bushings
Pistons And Piston Rings
Connecting Rods And Bearings
Crankshaft
Crankshaft Re-Grind Data
Main Bearings
Thrust Washers
Camshaft And Thrust Washer
Cylinder Block
Cylinder Liners
Fuel Injection Pump
Fuel Injectors
Fuel Lift Pump
Timing Case And Timing Gears
Oil Pump, Gear And Relief Valve
Turbocharger
Flywheel
Water Pump And Thermostat
Engine Torque
MACHINE TORQUE SPECIFICATIONS
Axle
Boom
Drive Box
Drive Motor
Engine
Hydraulic Pump
TORQUE SPECIFICATIONS FOR BOLTS
Torque for General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
O-ring Face Seal Connection
Straight Thread O-ring Fitting
Tubelines And Hoses
Flare Fitting
O-ring Flare Fitting
Port Seal Fitting
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion

SERVICE MANUAL REVISION
V623-1
V623-2
V623-3

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