Bobcat V417 VersaHANDLER Workshop Repair Service Manual - 6987144

(S/N: AC1C11001 & Above - S/N: AC1D11001 & Above) 
- 
This workshop repair service manual PDF download for the V417 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® V417
S/N: AC1C11001 & Above (with Cab)
S/N: AC1D11001 & 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 : 6987144 (4-10)
Total Pages : 868


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.

-

MAINTENANCE SAFETY
CONTENTS
FOREWORD
    FOREWORD
    SAFETY INSTRUCTIONS
    FIRE PREVENTION
        Maintenance
        Operation
        Electrical
        Hydraulic System
        Fueling
        Starting
        Spark Arrestor Exhaust System
        Welding And Grinding
        Fire Extinguishers
    SERIAL NUMBER LOCATION
        VersaHANDLER Serial Number
        Engine Serial Number
        Other Serial Numbers
    DELIVERY REPORT
    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
        Releasing The Brake Discs
        Towing
        Engaging The Brake Discs
    SERVICE SCHEDULE
        Chart
    AIR CLEANER SERVICE
        Replacing The Filter Element
    ENGINE COOLING SYSTEM
        Cleaning
        Removing And Replacing The Coolant
        Checking Level
    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 The Hydraulic / Hydrostatic Filters
        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 Mounting
        Tire Rotation
        Tire Pressure
    SPARK ARRESTOR MUFFLER
        Procedure
    APPROVED BOOM STOP
        Installing
        Removing
    ENGINE COVER
        Opening And Closing The Engine Cover
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS)
        System Inspection
        System Maintenance
    REMOTE START
        Connecting to the VersaHANDLER
        Remote Start Procedure (For Tools MEL1563 And MEL1565)
        Remote Start Procedure (For Tool Kit P/N 6689779)
    VersaHANDLER STORAGE AND RETURN TO SERVICE
        Storage
        Return To Service
    STOPPING THE ENGINE AND LEAVING THE VERSAHANDLER
        Procedure
    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 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
        Installation
        Parts Identification
        Disassembly
        Assembly
    STEERING CYLINDER (REAR)
        Removal
        Installation
        Parts Identification
        Disassembly
        Assembly
    DRIVE BOX
        Parts Identification
        Disassembly
        Assembly
        Special Tools
    MAIN RELIEF VALVE
        Testing And Adjustment
        Removal And Installation
    PORT RELIEF VALVES
        Parts Identification
        Adjustment Procedure
    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
    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
        Telescoping and Auxiliary Valve Section Disassembly And Assembly
        Lifting and Tilting Valve Section Disassembly And Assembly
        Inlet-Outlet Valve Section Disassembly And Assembly
    JOYSTICK
        Removal And Installation
    PARKING BRAKE
        Parking And Passive Brake Switch Removal And Installation
        Parking And Passive Brake Switch Disassembly And Assembly
    WORKGROUP LOCKOUT VALVE
        Testing
        Removal And Installation
        Disassembly And Assembly
    TOW VALVE
        Removal And Installation
        Disassembly And Assembly
    FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE
        Removal And Installation
        Disassembly And Assembly
    MANIFOLD
        Removal And Installation
        Disassembly
        
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 (S/N AC1C11001 - AC1C11999, AC1D11001 - AC1D11999)
        Removal And Installation
        Parts Identification
        Disassembly
        Inspection
        Assembly
    HYDROSTATIC PUMP (S/N AC1C12000 & ABOVE, AC1D12000 & ABOVE)
        Removal And Installation
        Parts Identification
        Shaft Disassembly
        Relief Valves Disassembly And Assembly
        Charge Pump Disassembly
        Piston Pump Disassembly
        Solenoid Block Disassembly
        Inspection
        Piston Pump Assembly
        Charge Pump Assembly
        Solenoid Block Assembly
        Shaft Assembly
    DRIVE BELT
        Description
        Shield Removal And Installation
        Adjusting
        Belt Removal And Installation
        Tensioner Pulley Removal And Installation
        Tensioner Pulley Parts Identification
        Tensioner Pulley Disassembly And Assembly
        
DRIVE SYSTEM
    TROUBLESHOOTING
        Chart
    AXLE AND DIFFERENTIAL (FRONT)
        Description
        Planetary Carrier And Wheel Hub Parts Identification
        Planetary Carrier Disassembly
        Wheel Hub Disassembly
        Steering Knuckle and Drive Shaft Parts Identification
        Steering Knuckle Disassembly
        Axle Housing / Drive Shaft Disassembly
        Brake Group Parts Identification
        Brake Group Disassembly
        Differential Parts Identification
        Differential Disassembly
        Pinion Group Parts Identification
        Pinion Group Disassembly
        Pinion Group Assembly
        Differential Assembly
        Brake Group Assembly
        Axle Housing / Drive Shaft Assembly
        Steering Knuckle Assembly
        Wheel Hub Assembly
        Planetary Carrier Assembly
        Special Tools
    AXLE AND DIFFERENTIAL (REAR)
        Description
        Planetary Carrier And Wheel Hub Parts Identification
        Planetary Carrier Disassembly
        Wheel Hub Disassembly
        Steering Knuckle and Drive Shaft Parts Identification
        Steering Knuckle Disassembly
        Axle Housing / Drive Shaft Disassembly
        Differential Parts Identification
        Pinion Group Parts Identification
        Pinion Group Disassembly
        Pinion Group Assembly
        Differential Assembly
        Steering Knuckle Assembly
        Wheel Hub Assembly
        Planetary Carrier Assembly
        Special Tools
    FRONT AXLE
        Removal
        Installation
    AXLE TOE-IN
        Adjustment
    PARKING BRAKE
        Releasing The Brake Discs
        Engaging The Brake Discs
    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 AC1C12999 & BELOW)
        Removal And Installation
    OPERATOR CAB (S/N AC1C13000 & ABOVE)
        Removal And Installation
    CANOPY
        Removal And Installation
    OPERATOR SEAT
        Removal And Installation
        Disassembly And Assembly
    BOOM ASSEMBLY
        Removal And Installation
    INNER BOOM
        Removal
        Installation
    WEAR PADS (FRONT)
        Removal And Installation
    WEAR PADS (REAR)
        Removal
        Installation
    ENGINE COVER
        Locking Mechanism Removal And Installation
        Removal And Installation
        Lock
    FUEL TANK
        Removal And Installation
    BOB-TACH
        Removal And Installation
        Lever And Wedge Disassembly And Assembly
    REAR WEIGHTS
        Removal And Installation
    FENDER
        Removal And Installation
    JOYSTICK PANEL (S/N AC1C12999 & BELOW, AC1D12999 & BELOW)
        Cover Removal and Installation
    JOYSTICK PANEL (S/N AC1C13000 & ABOVE, AC1D13000 & ABOVE)
        Cover Removal and Installation
    DASH COVER / STEERING COLUMN COVER (S/N AC1C12999 & BELOW, AC1D12999 & BELOW)
        Steering Column Cover Removal And Installation
        Dash Cover Removal And Installation
    DASH COVER / STEERING COLUMN COVER (S/N AC1C13000 & ABOVE, AC1D13000 & ABOVE)
        Dash Cover Removal And Installation
        Steering Column Cover Removal And Installation
        
ELECTRICAL SYSTEM & ANALYSIS
    ELECTRICAL SCHEMATICS
    ELECTRICAL SYSTEM INFORMATION (S/N AC1C12999 & BELOW, AC1D12999 & BELOW)
        Troubleshooting Chart
        Description
        Fuses, Diodes And Relays
    ELECTRICAL SYSTEM INFORMATION (S/N AC1C13000 & ABOVE, AC1D13000 & ABOVE)
        Troubleshooting Chart
        Description
        Fuses, Diodes And Relays
    BATTERY
        Removal And Installation
        Servicing
        Using A Booster Battery (Jump Starting)
    ALTERNATOR
        Removal And Installation
        Belt Adjustment
        Belt Replacement
    STARTER
        Testing
        Removal And Installation
        Parts Identification
    LATERAL OPERATOR RESTRAINT SYSTEM (LORS)
        Restraint Bar Removal And Installation
        Sensor Removal And Installation
        Restraint Bar Bumper Removal And Installation
    LIGHTS
        Rear Light Removal And Installation
        Front Light Removal And Installation
    TRAVEL LEVER (S/N AC1C12999 & BELOW, AC1D12999 & BELOW)
        Removal And Installation
    TRAVEL LEVER (S/N AC1C13000 & ABOVE, AC1D13000 & ABOVE)
        Removal And Installation
    INSTRUMENT PANEL (S/N AC1C12999 & BELOW, AC1D12999 & BELOW)
        Removal And Installation
    INSTRUMENT PANEL (S/N AC1C13000 & ABOVE, AC1D13000 & ABOVE)
        Removal And Installation
    SWITCH PANEL (S/N AC1C13000 & ABOVE, S/N AC1D13000 & ABOVE)
        Removal And Installation
    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
    SERVICE SOFTWARE
        Connecting Remote Start Tool To Laptop Computer
        Connecting Remote Start Tool (Service Tool)
        Connecting Remote Start Tool To VersaHANDLER
        Entering The Service Software
        Calibrate Inch Pedal
    MAIN CONTROLLER
        Removal And Installation
        Connector Identification
    DIAGNOSTIC SERVICE CODES
        Viewing Service Codes
        Service Codes List
        
ENGINE SERVICE
    ENGINE INFORMATION
        Description
        Troubleshooting
        Compression - Checking
    ENGINE AND ENGINE MOUNTS
        Removal And Installation
    ENGINE AND HYDROSTAT ASSEMBLY
        Removal And Installation
    ENGINE SPEED CONTROL
        Removal and Installation
    MUFFLER
        Removal And Installation
    AIR CLEANER
        Removal And Installation
        Air Intake Cowling Removal And Installation
    ENGINE COOLING SYSTEM
        Radiator Removal And Installation
        Fan Removal And Installation
        Water Pump Removal And Installation
        Water Pump Disassembly And Assembly
        Thermostat Housing Removal And Installation
    LUBRICATION SYSTEM
        Oil Pan Removal And Installation
        Oil Pump Removal And Installation
        Oil Pump Inspection
        Oil Filter Cooler Removal And Installation
        Engine Oil Pressure - Testing
    FUEL SYSTEM
        Fuel Camshaft Removal And Installation
        Injection Pump Governor Housing Removal And Installation
        Injection Pump Governor Housing Disassembly And Assembly
        Fuel Shutoff Solenoid - Checking
        Fuel Shutoff Solenoid Removal And Installation
        Fuel Injection Pump Removal And Installation
        Fuel Injection Pump Housing Removal
        Fuel Injection Pump Housing Installation
        Injection Pump Timing
        Fuel Injector Removal and Installation
        Fuel Injector Nozzle Pressure - Checking
        Nozzle Spraying Condition
        Valve Seat Tightness
    CYLINDER HEAD
        Intake Air Heater - Testing
        Intake Air Heater Removal And Installation
        Valve Clearance Adjustment
        Valve Timing - Checking
        Cylinder Head Removal And Installation
        Cylinder Head Disassembly And Assembly
        Cylinder Head - Servicing
        Cylinder Head Top Clearance
        Valve Guide - Checking
        Reconditioning The Valve And Valve Seat
        Valve Spring
        Valve Tappets
        Rocker Arm And Shaft - Checking
    CRANKSHAFT AND PISTONS
        Piston And Connecting Rod Removal And Installation
        Piston And Connecting Rod - Servicing
        Cylinder Bore Checking
        Connecting Rod Alignment
        Crankshaft Gear Removal And Installation
        Crankshaft And Bearings Removal and Installation
        Crankshaft And Bearings - Servicing
    CAMSHAFT AND TIMING GEARS
        Timing Gearcase Cover Removal And Installation
        Timing Gears Backlash - Checking
        Camshaft - Servicing
        Idle Gear And Shaft Removal And Installation
        Idler Gear And Shaft - Servicing
        Balancer Shaft Servicing
    TURBOCHARGER
        Description
        Testing
        Removal And Installation
    FLYWHEEL AND HOUSING
        Flywheel Removal And Installation
        Ring Gear Removal And Installation
        Housing Removal And Installation
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM
        Checking The Function Of EGR System
        Disassembly And Assembly
        
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
    AIR CONDITIONING SYSTEM FLOW
        Description
        Chart
    COMPONENTS (S/N AC1C12999 & BELOW)
        Identification
    COMPONENTS (S/N AC1C13000 & ABOVE)
        Identification
    SAFETY
        Safety Equipment
    REGULAR MAINTENANCE
        Filter Element Removal And Installation
        Compressor And Alternator Drive Belt Inspection
        Cleaning The Condenser
    BASIC TROUBLESHOOTING
        Poor A/C Performance
        Compressor And Alternator 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
        Chart
        Gauge Pressure Related Troubleshooting
    TEMPERATURE AND PRESSURE
        Chart
    AIR CONDITIONING SERVICE
        Chart
    SYSTEM CHARGING AND RECLAMATION
        Reclamation Procedure
        Charging Procedure With A Manifold Gauge Set
    COMPRESSOR
        Removal And Installation
        Compressor Clutch Disassembly And Assembly
    CONDENSER (S/N AC1C12999 & BELOW)
        Removal And Installation
    CONDENSER (S/N AC1C13000 & ABOVE)
        Removal And Installation
    RECEIVER / DRIER
        Removal And Installation
    PRESSURE SWITCH
        Removal And Installation
    EVAPORATOR/BLOWER UNIT (S/N AC1C12999 & BELOW)
        Removal And Installation
    EVAPORATOR / BLOWER UNIT (S/N AC1C13000 & ABOVE)
        Removal And Installation
    EXPANSION VALVE (S/N AC1C12999 & bELOW)
        Removal And Installation
    EXPANSION VALVE (S/N AC1C13000 & ABOVE)
        Removal And Installation
    HEATER ASSEMBLY
        Removal And Installation
        Fan Removal And Installation
        Core Removal And Installation
        
SPECIFICATIONS
    VersaHANDLER TELESCOPIC TOOL CARRIER (TTC) SPECIFICATIONS
        Machine Dimensions
        Performance
        Engine
        Controls
        Drive System
        Tires
        Capacities
        Hydraulic System
        Electrical System
        Instrument Panel
    ENGINE SPECIFICATIONS
        General
        Fuel System
        Cylinder Head
        Valve Guides
        Valve Tappets
        Exhaust Valves
        Intake Valves
        Valve Springs
        Valve Timing
        Rocker Arm
        Camshaft
        Timing Gear
        Piston And Piston Ring
        Connecting Rod
        Cylinder Bore
        Crankshaft
        Oil Pump
        Cooling System
        Intake Air Heater
        Torque Values
        Engine Torque Component
    MACHINE TORQUE SPECIFICATIONS
        Specifications
    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 Equivalent Chart
        U.S. To Metric Conversion Chart
        
ALPHABETICAL INDEX

SERVICE MANUAL REVISION
    Revision No: V417 - 1
    
    -