Bobcat V638 VersaHANDLER Service Manual – 6986763 (4-10)

(S/N: A8HM11001 & Above – S/N: A8HN11001 & Above)
–
This workshop repair service manual PDF download for the V638 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® V638
S/N: A8HM11001 & Above (with Cab)
S/N: A8HN11001 & Above (with Canopy)

TABLE OF CONTENTS :

SAFETY & MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAINFRAME
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
SPECIFICATIONS
ALPHABETICAL INDEX
SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6986763 (4-10)
Total Pages : 937

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 !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

–

CONTENTS
FOREWORD
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrester Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATION
VersaHANDLER Serial Number
Engine Serial Number
Other Serial Numbers
DELIVERY REPORT
BOBCAT VersaHANDLER IDENTIFICATION

SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE VERSAHANDLER
Procedure
OPERATOR CAB / CANOPY
Cab Door
Cab Door Window
TRANSPORTING THE VERSAHANDLER ON A TRAILER
Loading And Unloading
Fastening
TOWING THE VersaHANDLER
Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Element(s)
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
Engine 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
ATTACHMENT FRAME
Inspection And Maintenance
TIRE MAINTENANCE
Wheel Nuts
Mounting
Rotating
SPARK ARRESTER MUFFLER
Cleaning
APPROVED BOOM STOP
Installing The Approved Boom Stop
Removing The Approved Boom Stop
ENGINE COVER
Opening And Closing The Engine Cover
LATERAL OPERATOR RESTRAINT SYSTEM (LORS)
System Inspection
Maintaining
CHAIN
Checking And Adjustment Procedure
Extend / Retract Chain Wear Check
STOPPING THE ENGINE AND LEAVING THE VERSAHANDLER
Procedure
VersaHANDLER STORAGE AND RETURN TO SERVICE
Storage
Return To Service
EMERGENCY EXIT
Rear Window

HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
Troubleshooting Chart
Tightening Procedures
LIFT CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
BUCKET POSITION CYLINDER
Removal And Installation
Removal And Installation (Cont’d)
Parts Identification
Disassembly
Assembly
EXTENSION CYLINDER
Cylinder Group Removal And Installation
Parts Identification
Disassembly
Assembly
TILT CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
STEERING CYLINDER (FRONT)
Removal
Installation
Disassembly
Assembly
STEERING CYLINDER (REAR)
Removal
Installation
Disassembly
Assembly
DRIVE BOX
Parts Identification
Disassembly
Assembly
Special Tools
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
Disassembly
Inspection
Assembly
HYDRAULIC CONTROL VALVE
Troubleshooting Chart (Controllers)
Telescoping Valve Section Troubleshooting
Auxiliary Valve Section Troubleshooting
Troubleshooting Chart (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 / Frame Leveling Valve Section Disassembly And Assembly
Inlet-Outlet Valve Section Disassembly And Assembly
PORT RELIEF VALVES
Adjustment Procedure
FLOW CONTROL VALVE
Removal And Installation
JOYSTICK
Removal And Installation
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
STABILIZER CYLINDER
Removal
Parts Identification
Disassembly
Assembly
Installation
STABILIZER CONTROL VALVE
Parts Identification
Removal
Installation

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
Replenishing Valve Function
OIL COOLER
Description
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
Steering Knuckle And Drive Axle Parts Identification
Steering Knuckle Disassembly
Drive Axle Disassembly
Brake System Parts Identification
Brake System Disassembly
Differential Parts Identification
Differential Disassembly
Bevel Pinion Parts Identification
Bevel Pinion Disassembly
Bevel Pinion Assembly
Differential Assembly
Brake System Assembly
Drive Axle Assembly
Steering Knuckle Assembly
Planetary Carrier Assembly
Special Tools
AXLE AND DIFFERENTIAL (REAR)
General Information
Planetary Carrier Parts Identification
Steering Knuckle And Drive Axle Parts Identification
Steering Knuckle Disassembly
Differential And Bevel Pinion Parts Identification
Differential Disassembly
Bevel Pinion Disassembly
Bevel Pinion Assembly
Differential Assembly
Steering Knuckle Assembly
Planetary Carrier Assembly
Special Tools
FRONT AXLE
Removal
Installation
AXLE TOE-IN
Adjustment
PARKING BRAKE
Releasing The Brake For Towing
Re-Activating The Brake
STEERING ANGLE ADJUSTMENT
Adjustment
DRIVE SHAFT
Removal And Installation
SERVICE BRAKE
Description
Bleeding The Brake Circuit
REAR AXLE
Removal
Installation

MAINFRAME
OPERATOR CAB (S/N A8HM12999 & BELOW)
Removal And Installation
OPERATOR CAB (S/N A8HM13000 & ABOVE)
Removal And Installation
CANOPY
Removal And Installation
OPERATOR SEAT
Removal And Installation
FIXED BOOM
Removal
Installation
END BOOM
Removal
Installation
WEAR PADS (FRONT)
Removal
Installation
WEAR PADS (REAR)
Removal
Installation
ENGINE COVER
Gas Cylinder Removal And Installation
Removal And Installation
AIR INTAKE COWLING
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 (S/N A8HM12999 & BELOW, S/N A8HN12999 & BELOW)
Removal And Installation
DASH COVER / STEERING COLUMN COVER (S/N A8HM13000 & ABOVE, S/N A8HN13000 & ABOVE)
Removal And Installation
JOYSTICK PANEL (S/N A8HM12999 & BELOW, S/N A8HN12999 & BELOW)
Removal And Installation
JOYSTICK PANEL (S/N A8HM13000 & ABOVE, S/N A8HN13000 & ABOVE)
Removal And Installation
INTERMEDIATE BOOM
Removal
Installation
BOOM TRAY
Removal And Installation
STABILIZER FRAME
Removal
Installation

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION (S/N A8HM12999 & BELOW, S/N A8HN12999 & BELOW)
Troubleshooting Chart
Description
Fuses, Diodes And Relays
ELECTRICAL SYSTEM INFORMATION (S/N A8HM13000 & ABOVE, S/N A8HN13000 & ABOVE)
Troubleshooting Chart
Description
Fuses, Diodes And 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
Inspection And Repair
Assembly
LATERAL OPERATOR RESTRAINT SYSTEM (LORS)
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 (S/N A8HM12999 & BELOW, S/N A8HN12999 & BELOW)
Removal And Installation
TRAVEL / SIGNAL LEVER (S/N A8HM13000 & ABOVE, S/N A8HN13000 & ABOVE)
Removal And Installation
INSTRUMENT PANEL
Removal And Installation
SWITCH PANEL (S/N A8HM12999 & BELOW, S/N A8HN12999 & BELOW)
Removal And Installation
Parts Identification
SWITCH PANEL (S/N A8HM13000 & ABOVE, S/N A8HN13000 & ABOVE)
Removal And Installation
Parts Identification
BRAKE LIGHT SWITCH
Removal And Installation
Adjustment
WIPER MOTOR (FRONT)
Removal And Installation
WIPER MOTOR (TOP)
Removal And Installation
WIPER MOTOR (REAR)
Removal And Installation
PEDAL ASSEMBLY
Removal And Installation
Disassembly And Assembly
INCHING SWITCH
Removal And Installation
Adjustment
SERVICE SOFTWARE
Connecting The Laptop Computer
Entering The Service Software
Monitor Screen
Warnings Screen
Calibrate Inch Pedal
Calibrate Creep Potentiometer
Program / Update Susmic Controller
FRAME LEVEL SPEED SWITCH
Description
Removal
Installation

ENGINE SERVICE
TROUBLESHOOTING
Chart
ENGINE SPEED CONTROL
Removal And Installation
MUFFLER
Removal And Installation
AIR CLEANER
Housing Removal And Installation
OIL COOLER / RADIATOR
Removal And Installation
Disassembly And Assembly
ENGINE AND ENGINE MOUNTS
Removal And Installation
ENGINE COMPONENTS AND TESTING
Fuel Injection Pump Removal
Fuel Injection Pump Installation
Fuel Injector Removal And Installation
Checking The Fuel Lift Pump
Fuel Lift Pump Removal And Installation
Compression Checking
Glow Plug Checking
Glow Plugs Removal And Installation
ENGINE TIMING
Procedure
ENGINE / HYDROSTAT ASSEMBLY
Removal And Installation
FLYWHEEL AND HOUSING
Removal And Installation
Ring Gear Removal
Ring Gear Installation
RECONDITIONING THE ENGINE
Turbocharger Troubleshooting
Turbocharger Description
Turbocharger Removal And Installation
Exhaust Manifold Removal And Installation
Fuel Injector Cover Removal And Installation
Rocker Cover Removal And Installation
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
Crankshaft Pulley Removal And Installation
Front Oil Seal Removal And 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
Lubricating Oil Cooler Removal And Installation
Water Pump Removal
Water Pump Installation
Engine Lubrication System Description
Oil Filter Adapter Removal And 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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
AIR CONDITIONING SYSTEM FLOW
Principles
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
Gauge Pressure Related Troubleshooting
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 (S/N A8HM12999 & BELOW)
Removal And Installation
CONDENSER (S/N A8HM13000 & ABOVE)
Removal And Installation
RECEIVER / DRIER
Removal And Installation
PRESSURE SWITCH
Removal And Installation
EVAPORATOR / BLOWER UNIT (S/N A8HM12999 & BELOW)
Removal And Installation
EVAPORATOR / BLOWER / HEATER UNIT (S/N A8HM13000 & ABOVE)
Removal And Installation
EXPANSION VALVE (S/N A8HM12999 & BELOW)
Removal And Installation
EXPANSION VALVE (S/N A8HM13000 & ABOVE)
Removal And Installation
HEATER ASSEMBLY
Removal And Installation
Fan Removal And Installation
Core Removal And Installation

SPECIFICATIONS
VERSAHANDLER SPECIFICATIONS
Machine Dimensions
Performance Specifications
Engine
Controls
Drive System
Tires
Capacities
Hydraulic System
Electrical
Instrument Panel
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 Component
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
Port Seal Fitting
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalent Chart
U.S. To Metric Conversion Chart

ALPHABETICAL INDEX

SERVICE MANUAL REVISION
Revision No: V638 – 1

–