Bobcat V417 VersaHANDLER Workshop Repair Service Manual – 6904956

(S/N: A7MK11001 & Above – S/N: A7ML11001 & Above)
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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: A7MK11001 & Above (With Cab)
S/N: A7ML11001 & Above (With Canopy)

TABLE OF CONTENTS :

DELIVERY REPORT
FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATION
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 : 6904956 (6-09)
Total Pages : 771

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

SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE VERSAHANDLER
Procedure
OPERATOR CAB/CANOPY
Emergency Exit
Cab Door
Cab Door Window
TRANSPORTING THE VERSAHANDLER
Procedure
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 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 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 The Approved Boom Stop
Removing The Approved Boom Stop
ENGINE COVER
Opening And Closing The Engine Cover
LATERAL OPERATOR RESTRAINT SYSTEM (LORS™)
System Inspection
System Maintenance
REMOTE START
Connecting to the VersaHANDLER

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)
Removing the Steering Cylinder
Installing the Steering Cylinder
Parts Identification
Disassembling the Steering Cylinder
Assembling the Steering Cylinder
STEERING CYLINDER (REAR)
Removing the Steering Cylinder
Parts Identification
Disassembling the Steering Cylinder
Assembling the Steering Cylinder
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
Removal And Installation
Parts Identification
Disassembly
Inspection
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
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
Assembly And Disassembly
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
Joystick Panel Cover Removal and Installation
DASH COVER/STEERING COLUMN COVER
Steering Column Cover Removal And Installation
Dash Cover Removal And Installation

ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
Description
Fuses, Diodes And Relays
Fuses, Diodes & Relays (Cont’d)
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
ALTERNATOR
Removal And Installation
Adjusting The Alternator Belt
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
Removal And Installation
INSTRUMENT PANEL
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 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
TURBOCHARGER
Description
Testing
Removal And Installation
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Housing Removal And Installation

HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW
Description
Chart
COMPONENTS
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
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 TELESCOPIC TOOL CARRIER (TTC) SPECIFICATIONS
Machine Dimensions
Performance
Engine
Controls
Drive System
Tires
Capacities
Hydraulic System
Electrical System
Instrument Panel
ENGINE SPECIFICATIONS
Specifications
Torque Values
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 Equivalents
U.S. To Metric Conversion

SERVICE MANUAL REVISION
Revision No: V417 – 1

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