Bobcat V723 B4C311001 & Up 7324187 (Preview)
MAINTENANCE SAFETY
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
DELIVERY REPORT
BOBCAT VERSAHANDLER IDENTIFICATION
SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE VERSAHANDLER
Procedure
OPERATOR CAB
Description
Cab Door
Cab Door Window
Rear Cab Window
Cab Light
TRANSPORTING THE VERSAHANDLER ON A TRAILER
Loading And Unloading
Fastening
TOWING THE VERSAHANDLER
Procedure
SERVICE SCHEDULE
Maintenance Intervals
ENGINE AIR CLEANER
Replacing Filter Elements
Daily Check
Replacing Filter Elements
ENGINE COOLING SYSTEM
Cleaning
Checking Level
Removing And Replacing The Coolant
FUEL SYSTEM
Fuel Specifications
Biodiesel Blend Fuel
Filling The Fuel Tank
Fuel Filter
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil Chart
Removing And Replacing Oil And Filter
HYDRAULIC / HYDROSTATIC SYSTEM
Checking And Adding Fluid
Hydraulic / Hydrostatic Fluid Chart
Removing And Replacing Hydraulic Fluid
Removing And Replacing Hydraulic / Hydrostatic Filter
Removing And Replacing Hydraulic Charge Filter
Fill / Breather Cap
AXLES (FRONT AND REAR)
Checking And Adding Oil (Planetary Carrier)
Removing And Replacing Oil (Planetary Carrier)
Checking And Adding Oil (Rear Differential)
Removing And Replacing Oil (Rear Differential)
Checking And Adding Oil (Front Differential)
Removing And Replacing Oil (Front Differential)
Checking And Adding Oil (Reduction Box)
Removing And Replacing Oil (Reduction Box)
LUBRICATING THE VERSAHANDLER
Lubrication Locations
ATTACHMENT CARRIER
Inspection And Maintenance
TIRE MAINTENANCE
Wheel Nuts
Rotating
Wheel Replacement
Mounting
Pressure
APPROVED BOOM STOP
Installing The Approved Boom Stop
Removing The Approved Boom Stop
ENGINE COVER
Opening And Closing
STOPPING THE ENGINE AND LEAVING THE VERSAHANDLER
Procedure
EMERGENCY EXIT
Rear Window
VERSAHANDLER STORAGE AND RETURN TO SERVICE
Storage
Return To Service
LIFTING THE VERSAHANDLER
Procedure
REMOTE START TOOL (SERVICE TOOL) KIT – MEL1563
Remote Start Tool – MEL1563
Service Tool Harness Control – MEL1565
Service Tool Harness Communicator – MEL1566
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666
Remote Start Tool (Service Tool) – 7022042
VersaHANDLER Service Tool Harness – 6689747
Computer Service Tool Harness – 6689746
Remote Start Procedure
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
SELF LEVELING CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
SELF LEVELING CYLINDER (LOCK VALVE)
Removal And Installation
EXTENSION CYLINDER
Cylinder Group Removal And Installation
Upper Tubeline Removal And Installation
Extension Cylinder Removal And Installation
Tubeline Tray Disassembly
Parts Identification
Disassembly
Assembly
TILT CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
STEERING CYLINDER (FRONT / REAR)
Removal
Installation
Disassembly
Assembly
GEAR CONTROL CYLINDER
Removal
Parts Identification
Disassembly
Assembly
Installation
COLLECTOR BLOCK
Removal And Installation
Parts Identification
Disassembly And Assembly
BRAKE VALVE
Removal And Installation
GEAR PUMP
Steering And Valve Gear Pump Direct Test
Removal And Installation
Parts Identification
Disassembly And Assembly
FAN MOTOR
Removal And Installation
Parts Identification (Single Speed Version) (Standard)
Disassembly And Assembly (Single Speed Version) (Standard)
Parts Identification (Variable Speed Version) (Optional)
Disassembly And Assembly (Variable Speed Version) (Optional)
HYDRAULIC FLUID RESERVOIR
Removal And Installation
STEERING VALVE
Removal And Installation
HYDRAULIC CONTROL VALVE
Troubleshooting Chart (Solenoid Valves)
Valve Section Troubleshooting
Troubleshooting Chart (Control Valve)
Main Relief Valve Testing And Adjustment
Main Relief Valve Removal And Installation
Removal And Installation
Parts Identification
Disassembly And Assembly
Inlet-Outlet Valve Section 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
End Housing Disassembly And Assembly
PORT RELIEF VALVES
Testing
Replacement Procedure
BOOM SUSPENSION VALVE ACCUMULATOR
Removal And Installation
AUXILIARY HYDRAULIC FLOW
Testing The Auxiliary Hydraulic Flow
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
Calibration
Swash Plate Calibration – Neutral Range
Swash Plate Calibration – Maximum Range
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
CHARGE PRESSURE
Description
Testing And Adjusting
MULTI-FUNCTION VALVES
Description
Testing
DRIVE SYSTEM
DRIVE SYSTEM TROUBLESHOOTING
Chart
AXLE AND DIFFERENTIAL (FRONT)
Description
Planetary Carrier Parts Identification
Planetary Carrier Disassembly
Steering Knuckle And Drive Axle Parts Identification
Steering Knuckle Disassembly
Drive Axle 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
Drive Axle Assembly
Steering Knuckle Assembly
Planetary Carrier Assembly
AXLE AND DIFFERENTIAL (REAR)
Description
Planetary Carrier Parts Identification
Planetary Carrier Disassembly
Steering Knuckle And Drive Axle Parts Identification
Steering Knuckle Disassembly
Differential Parts Identification
Differential Disassembly
Pinion Group Parts Identification
Pinion Group Disassembly
Pinion Group Assembly
Differential Assembly
Steering Knuckle Assembly
Planetary Carrier Assembly
FRONT AXLE
Removal And Installation
AXLE TOE-IN
Adjustment
PARKING BRAKE
Releasing The Brake For Towing
Adjustment
Brake Cylinder Removal
Brake Cylinder Disassembly And Assembly
Brake Disc Removal And Installation
Brake Cylinder Installation
STEERING ANGLE ADJUSTMENT
Adjustment
DRIVE SHAFT
Rear Drive Shaft Removal And Installation
Front Drive Shaft Removal And Installation
SERVICE BRAKE
Description
Bleeding The Brake Circuit
REAR AXLE
Removal And Installation
GEAR BOX
Removal And Installation
Parts Identification
Disassembly
Assembly
MAINFRAME
OPERATOR CAB
Removal And Installation
OPERATOR SEAT
Removal And Installation
FIXED BOOM
Removal
Installation
INNER BOOM
Removal And Installation
WEAR PADS (FRONT)
Removal And Installation
WEAR PADS (REAR)
Removal And Installation
ENGINE COVER
Gas Cylinder Removal And Installation
Removal And Installation
FUEL TANK
Removal And Installation
ATTACHMENT CARRIER (QUICK-TACH)
Removal And Installation
COUNTERWEIGHT
Removal And Installation
FENDER
Removal And Installation
STEERING COLUMN COVER
Removal And Installation
DASH COVER
Removal And Installation
JOYSTICK PANEL
Removal And Installation
ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Cab Harness Connectors
Engine Harness Connectors
DEF Harness Connectors
Mainframe Harness Connectors
Troubleshooting Chart
Description
Fuses And Relay Location / Identification
BATTERY
Battery Maintenance
Using A Booster Battery (Jump Starting)
Removing And Installing The Battery
ALTERNATOR
Belt Adjustment
Belt Checking
Belt Replacement
Removal And Installation
STARTER
Testing
Removal And Installation
LIGHTS
Rear Light Removal And Installation
Rear Light Bulb Replacement
Front Light Removal And Installation
Front Light Bulb Replacement
SIGNAL LEVER
Removal And Installation
DISPLAY
Removal And Installation
INSTRUMENT PANELS
Right Instrument And Indicator Panel Removal And Installation
Left Instrument Panel Removal And Installation
BOOM ANGLE SENSOR
Removal And Installation
Calibration
FRONT WIPER MOTOR
Removal And Installation
TOP WIPER MOTOR
Removal And Installation
REAR WIPER MOTOR
Removal And Installation
PEDAL ASSEMBLY
Removal And Installation
INCHING SENSOR
Removal And Installation
Calibration
SERVICE PC (LAPTOP COMPUTER)
Connecting Remote Start Tool (Service Tool) – MEL1563
Connecting Remote Start Tool (Service Tool) – 7217666
FUEL LEVEL SENDER
Removal And Installation
JOYSTICK
Removal And Installation
MAINTENANCE CLOCK
Description
Setup
Reset
RETRACT SENSOR
Removal And Installation
Adjustment
ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Sensor Location
Torque Values
Troubleshooting
Removal And Installation
Compression – Testing
Oil Pressure Testing (At Oil Sensor On Block)
Oil Pressure Testing (At Turbocharger Oil Inlet)
ENGINE AND HYDROSTAT ASSEMBLY
Removal And Installation
ENGINE SPEED CONTROL
Removal And Installation
EXHAUST PIPE
Removal And Installation
AIR CLEANER
Housing Removal And Installation
ENGINE COOLING SYSTEM
Oil Cooler / Intercooler / Radiator Removal And Installation
Expansion Tank Removal And Installation
Cooling System Check
Cooling System Inspection
Water Pump Removal And Installation
Thermostat Housing Removal And Installation
Thermostat – Testing
LUBRICATION SYSTEM
Description
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Relief Valve Description
Oil Suction Pipe Removal And Installation
Oil Cooler Removal And Installation
Oil Cooler Bypass Description
Remote Oil Filter Adapter Removal And Installation
Remote Oil Filter Head Removal And Installation
FUEL SYSTEM
Description
High Pressure Pump Removal And Installation
High Pressure Pump Drive Gear Removal And Installation
Fuel Temperature Sensor Removal And Installation
Fuel Cooler Removal And Installation
Fuel Bypass Valve Removal And Installation
Fuel Rail Assembly Removal And Installation
Fuel Injector Removal And Installation
CYLINDER HEAD
Intake Air Heater Removal And Installation
Intake Air Heater Tube Removal And Installation
Valve Clearance Adjustment
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head Inspection
Cylinder Head Top Clearance
Valve Step Height
Valve Stem Height
Valve Guide
Valve
Valve Spring
Rocker Arm Shaft Disassembly And Assembly
Rocker Arm Shaft Inspection
Push Rod Inspection
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod Inspection
Timing Wheel Removal And Installation
Crankshaft Removal And Installation
Cylinder Block Inspection
Crankshaft Inspection
Connecting Rod Inspection
Engine Component Class
CAMSHAFT
Removal And Installation
Inspecting
GEARCASE
Gear Backlash
Gear End Play
Gear Timing
Idle Gear Removal And Installation
Idle Gear Inspection
TURBOCHARGER
Description
Removal And Installation
Inspection
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Housing Removal And Installation
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Description
Removal And Installation
Disassembly And Assembly
SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM
Description
Diesel Exhaust Fluid (DEF) / AdBlue® Level
DeSOX Process
SCR System Codes
Diesel Exhaust Fluid (DEF) / AdBlue® Unsatisfactory Quality
SCR System Component Tampering
EGR Impeded
Diesel Exhaust Fluid (DEF) / AdBlue® Dosing Interruption
Removal And Installation
Dosing Module Removal And Installation
DIESEL OXIDATION CATALYST (DOC)
Removal And Installation
DIESEL EXHAUST FLUID (DEF) TANK
Removal And Installation
DEF Tank Fan Removal And Installation
Coolant Valve Removal And Installation
Dosing Control Unit (DCU) Removal And Installation
Supply Module Removal And Installation
Supply Module Filter Removal And Installation
HEATING, VENTILATION, AIR CONDITIONING (HVAC)
AIR CONDITIONING SYSTEM FLOW
Description
Chart
Components
Safety Equipment
REGULAR MAINTENANCE
Filters
Air Conditioning Belt Adjustment
Belt Replacement
Cleaning The Condenser
Air Conditioning Lubrication
Air Conditioning Service Chart
Evaporator / Heater Coil
A/C SYSTEM TROUBLESHOOTING
Blower Motor Does Not Operate
Blower Motor Operates Normally, But Air Flow Is Insufficient
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
The Compressor Does Not Operate At All, Or Operates Improperly
Gauge Pressure Related Troubleshooting
Temperature / Pressure Chart
Poor A/C Performance
HVAC Repair And Leaks
Electrical System
SYSTEM CHARGING AND RECLAMATION
Reclamation And Charging With Recovery / Charging Unit
COMPRESSOR
Removal And Installation
Oil
Oil Check
Clutch Disassembly And Assembly
CONDENSER
Removal And Installation
RECEIVER / DRIER
Removal And Installation
PRESSURE SWITCH
Removal And Installation
EVAPORATOR / HEATER UNIT
Removal And Installation
THERMOSTAT
Description
Removal And Installation
EXPANSION VALVE
Removal And Installation
SPECIFICATIONS
VERSAHANDLER SPECIFICATIONS
Machine Dimensions
Performance
Engine
Controls
Steering
Brakes
Drive System
Tires
Capacities
Hydraulic System
Electrical System
Instrument Panel
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 Equivalent Chart
U.S. To Metric Conversion Chart
SERVICE TOOLS REQUIRED
Remote Start Tools
Hydraulic Tools
Electrical Tools
Engine Tools
HVAC Tools
ALPHABETICAL INDEX
SERVICE SCHEDULE SYMBOLS
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