Bobcat V623 VersaHANDLER Workshop Repair Service Manual - 6901675

(S/N: 367111001 - 367113000 - S/N: 367211001 - 367213000} 
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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: 367111001 - 367113000
S/N: 367211001 - 367213000


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 : 6901675 (3-06)
Total Pages : 784


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
    BOOM STOP
        Installing Boom Stop
        Removing Boom Stop
    ENGINE COVER
        Opening And Closing The Engine Cover
        Adjusting The Latch
        
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
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    TILT CYLINDER
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    STEERING CYLINDER
        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
    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 (S/N 367111001- 367112500 AND 367211001-367212500)
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
        Frame Leveling Valve Section (Optional)
        Auxiliary Valve Section
        Telescoping Valve Section
        Tilting Valve Section
        Lifting Valve Section
        Inlet/Outlet Valve Section
    HYDRAULIC CONTROL VALVE (S/N 367112501- 367113000 AND 367212501-367213000)
        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
    JOYSTICK (S/N 367112501-367113000 AND 367212501-367213000)
        Handle Removal And Installation
        Joystick Removal And Installation
        Parts Identification
        Disassembly And Assembly
        
HYDROSTATIC SYSTEM
    HYDROSTATIC SYSTEM INFORMATION
        Troubleshooting Chart
        Replenishing The 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
        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 Housing 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
    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
        
MAIN FRAME
    OPERATOR CAB
        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
        
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
    STARTER
        Removal And Installation
        Parts Identification
        Disassembly
        Inspection And Repair
        Assembly
    JOYSTICK PANEL
        Removal And Installation
    LIGHTS
        Rear Removal And Installation
        Front Removal And Installation
    TRAVEL/SIGNAL LEVER
        Removal And Installation
    INSTRUMENT PANEL
        Removal And Installation
    SWITCH PANEL
        Removal And Installation
    DASH COVER/STEERING COLUMN COVER
        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
    BRAKE LIGHT SWITCH
        Removal And Installation
        Adjustment
    INCHING SWITCH
        Removal And Installation
        Adjustment
    JOYSTICK (S/N 367111001-367112500 AND 367211001-367212500)
        Removal And Installation
        
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
        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
    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
        Engine
        Controls
        Drive System
        Tires
        Hydraulic System
        Electrical System
        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
    LOADER 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
    V623-4
    
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