Service Manual: Versahandler

VersaHANDLER
V518
Service
Manual
Dealer Copy -- Not for Resale

(S/N 367011001 - 367013000)
6901769 (3-06) Printed in U.S.A. © Bobcat Company 2006
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
CORRECT
Safety Alert Symbol: This symbol with a warning statement,

means: “Warning, be alert! Your safety
is involved!” Carefully read the
message that follows.
B-10731a
Never service the Bobcat
VersaHANDLER without instructions.
CORRECT WRONG WRONG

B-16082 B-16080 B-16079
Cleaning and maintenance are Disconnecting or loosening any Never work on VersaHANDLER
required daily. hydraulic tubeline, hose, fitting, with boom up unless boom is
component or a part failure can held by an approved boom stop.
cause boom to drop. Do not go Replace if damged.
under boom when raised unless Never modify equipment or add
supported by an approved boom attachments not approved by
stop. Replace if damaged. Bobcat Company.
WRONG WRONG WRONG
B-16081 B-16078 B-6589

B-16102 B-16102
Have good ventilation when Keep body, jewelry and clothing Lead-acid batteries produce
welding or grinding painted away from moving parts, flammable and explosive gases.
parts. electrical contact, hot parts and Keep arcs, sparks, flames and
Wear dust mask when grinding exhaust. lighted tobacco away from
painted parts. Toxic dust and gas Wear eye protection to guard batteries.
can be produced. from battery acid, compressed Batteries contain acid which
Avoid exhaust fume leaks which springs, fluids under pressure burns eyes or skin on contact.
can kill without warning. Exhaust and flying debris when engines Wear protective clothing. If acid
system must be tightly sealed. are running or tools are used. contacts body, flush well with
Use eye protection approved for water. For eye contact flush well
type of welding. and get immediate medical
attention.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation &
Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use
genuine Bobcat replacement parts.
MSW12-0805
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SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SYSTEM
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X HYDROSTATIC

SYSTEM
BOBCAT VERSAHANDLER IDENTIFICATION . . . . . . . . . . . . . . . . XI
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE

SYSTEM
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

MAIN FRAME
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

ELECTRICAL
SYSTEM &
ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . 60-01 ANALYSIS
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
ENGINE
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01 SERVICE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
HVAC
SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS
V518 VersaHANDLER
I Service Manual
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FOREWORD
This manual is for the Bobcat VersaHANDLER mechanic. It provides necessary servicing and
adjustment procedures for the Bobcat VersaHANDLER and its component parts and systems. Refer
to the Operation & Maintenance Manual for operating instructions, Starting procedure, daily checks,
etc.
A general inspection of the following items must be made after the VersaHANDLER has had service
or repair:
1. Check that ROPS/FOPS 9. Enclosure door latches must
(including right side window) open and close freely.
is in good condition and is not
modified.
2. Check that ROPS mounting 10. Attachment locking pins must

hardware is tightened and is function correctly and be in
Bobcat approved. good condition.
3. The seat belt must be 11. Safety treads must be in good

correctly installed, functional condition.

and in good condition.
4. Check boom support device, 12. Check for correct function of

replace if damaged. indicator lamps and gauges.
5. Machine signs must be 13. Check hydraulic fluid level,

legible and in the correct engine oil level and fuel
location. supply.
6. Check tires for wear and 14. Inspect for fuel, oil or
pressure. Use only approved hydraulic fluid leaks.
tires.
7. Check for correct function of 15. Lubricatethe VersaHANDLER.

the work lights.
8. The parking brake must 16. Check the condition of the

function correctly. battery and cables.
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II Service Manual
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17. Inspect the air cleaner for 20. Operate the VersaHANDLER
damage or leaks. Check the and check all functions.
condition of the element.
18. Check the electrical charging 21. Check for any field
system. modification not completed.
19. Inspect for loosen or broken 22. Recommend to the owner

parts or connections. that all necessary corrections
be made before the machine
is returned to service.

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the State of California
to cause cancer, birth defects and other
reproductive harm.
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III Service Manual
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V518 VersaHANDLER
IV Service Manual
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SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the

W-2003-0903 operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
WARNING • The AEM Safety Manual delivered with the machine
gives general safety information.
Warnings on the machine and in the manuals are for
your safety. Failure to obey warnings can cause • The Service Manual and Parts Manual are available
injury or death. from your dealer for use by mechanics to do shop-
W-2044-1285 type service and repair work.
• The VersaHANDLER Operator Training Course is

available through your local dealer or at
IMPORTANT www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
of correct operation of the VersaHANDLER.
This notice identifies procedures which must be
followed to avoid damage to the machine.
I-2019-0284
• The VersaHANDLER Safety Video is available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.
SI VH-0206 SM
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V Service Manual
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SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner/operator review the recommended

uses of the product when delivered. If the owner/operator
will be using the machine for a different application(s) he
or she must ask the dealer for recommendations on the
new use.

Call Before You Dig
1-888-258-0808
When you call, you will be directed to a location in
your state/city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.)
SI VH-0206 SM
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SAFETY INSTRUCTIONS (CONT’D) • Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump
Fire Prevention starting.
The machine and attachments have components that are • Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of high temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or Figure 1
sparks.
Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
will increase fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential hazard.
The spark arrestor muffler is designed to control the

emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
hot.
• Do not use the machine where exhaust, arcs, sparks

or hot components can contact flammable material,

explosive dust or gases.
• The operator cab, engine compartment, and engine

• Know where fire extinguishers and first aid kits are
cooling system must be inspected every day and
located and how to use them. Fire extinguishers are
cleaned if necessary to prevent fire hazard and
available from your Bobcat dealer [Figure 1].
overheating.
• Check all electrical wiring and connections for

damage. Keep the battery terminals clean and tight.
Repair or replace any damaged part.
• Check fuel and hydraulic tubes, hoses and fittings for

damage and leakage. Never use open flame or bare
skin to check for leaks. Tighten or replace any parts
that show leakage. Always clean fluid spills. Do not
use gasoline or diesel fuel for cleaning parts. Use
commercial nonflammable solvents.
• Do not use ether or starting fluids on any engine

which has glow plugs. These starting aids can cause
explosion and injure you or bystanders.
• Always clean the machine, disconnect the battery,

and disconnect the wiring from the controllers before
welding. Cover rubber hoses, battery and all other
flammable parts. Keep a fire extinguisher near the
machine when welding. Have good ventilation when
grinding or welding painted parts. Wear a dust mask
when grinding painted parts. Toxic dust or gas can be
produced.
• Stop the engine and let it cool before adding fuel. NO

SMOKING!
SI VH-0206 SM
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VII Service Manual
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V518 VersaHANDLER
VIII Service Manual
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SERIAL NUMBER LOCATIONS Engine Serial Number
Always use the serial number of the VersaHANDLER Figure 3

when requesting service information or when ordering
parts. Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
VersaHANDLER Serial Number
Figure 2
P-24123

P-24121
The front, on the right side of the chassis [Figure 2].
24123
The engine serial number is stamped on a plate near the

injection pump or at the rear of the cylinder block [Figure
3]. Always use the full number when ordering
replacement parts.
Other Serial Numbers
Some components may also have serial numbers.

Always use these serial numbers when requesting parts.
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IX Service Manual
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DELIVERY REPORT
The Delivery Report must be filled out by the dealer and

signed by the owner or operator when the
VersaHANDLER is delivered. An explanation of the form
must be given to the owner. Make sure it is filled out
completely [Figure 4].
Figure 4
B-16315
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X Service Manual
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BOBCAT VERSAHANDLER IDENTIFICATION
BOOM MIRROR OPERATOR HANDBOOK &

BOOM ANGLE LOAD CAPACITY CHARTS
TELESCOPING INDICATOR
INDICATOR BOOM
TELESCOPING
BOOM OPERATORS CAB
(ROPS/FOPS)
BOOM
STOP
SEAT
BELT

SAFETY TREAD TIRES
(under boom, (use only approved tires
on top of frame) at correct pressure)
BUCKET
ATTACHMENT
LIGHTS
MIRROR
ENGINE
COVER
B-15886
B-19821
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XII Service Manual
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SAFETY AND MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
AXLES (FRONT AND REAR) . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

Checking Oil Level (Front Differential) . . . . . . . . . . . . . . . 10-110-2
Checking Oil Level (Planetary Carrier) . . . . . . . . . . . . . . 10-110-1
Checking Oil Level (Rear Differential) . . . . . . . . . . . . . . . 10-110-2
Draining Oil (Front Differential) . . . . . . . . . . . . . . . . . . . . 10-110-3
Draining Oil (Planetary Carrier) . . . . . . . . . . . . . . . . . . . . 10-110-1
Draining Oil (Rear Differential). . . . . . . . . . . . . . . . . . . . . 10-110-2
BOOM STOP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Installing Boom Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Removing Boom Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-2

ENGINE COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Adjusting The Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Opening And Closing The Engine Cover . . . . . . . . . . . . . 10-160-1
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Fuel Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-100-1

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . 10-100-1
LIFTING AND BLOCKING THE VERSAHANDLER . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Continued On Next Page
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SAFETY AND MAINTENANCE (CONT’D)
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Cab Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
TOWING THE VERSAHANDLER . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

TRANSPORTING THE VERSAHANDLER . . . . . . . . . . . . . . . 10-30-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
V518 VersaHANDLER
LIFTING AND BLOCKING THE VERSAHANDLER Figure 10-10-2
Procedure
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Figure 10-10-1
Put the floor jack under the center of the rear axle. Lift the
Versa HANDLER and install jackstands [Figure 10-10-2].

Always park the machine on a level surface.
STOP the engine. Put the floor jack under the center of
the front axle. Lift the Versa HANDLER and install
jackstands [Figure 10-10-1].
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V518 VersaHANDLER
OPERATOR CAB Cab Door Window
Emergency Exit Figure 10-20-3
Figure 10-20-1
The cab door window can be opened completely. Push

the window all the way open until the latch on the cab
The left door and rear window provide exits. engages onto the door post (Item 1) [Figure 10-20-3] to
hold the window in the open position.
Open the rear window and exit through the rear window

opening [Figure 10-20-1]. Figure 10-20-4
Cab Door
Figure 10-20-2
Push the button (Item 1) [Figure 10-20-4] inside the cab

to disengage the latch and close the window.
The cab door can be locked (Item 1) [Figure 10-20-2]

with a key.
V518 VersaHANDLER
V518 VersaHANDLER
TRANSPORTING THE VERSAHANDLER
Procedure
Always drive the VersaHANDLER forward (heavy end

up) onto the transport vehicle.
Figure 10-30-1

The rear of the trailer must be blocked or supported
[Figure 10-30-1] when loading or unloading the
VersaHANDLER to prevent the front end of the trailer
from raising up.
Be sure the transport and towing vehicles are of

adequate size and capacity. (See Performance
Specifications on Page SPEC-10-1 for weight of
VersaHANDLER.)
Fasten the VersaHANDLER to the transport vehicle to

prevent it from moving during sudden stops or when
going up or down slopes.
• Block the wheels (Item 1) [Figure 10-30-1].
• Fasten the machine frame to the transport vehicle

(Items 2 & 3) [Figure 10-30-1].
• Attach the forks or bucket attachment to the transport

vehicle (Item 4) [Figure 10-30-1].
WARNING
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0494
V518 VersaHANDLER
V518 VersaHANDLER
TOWING THE VERSAHANDLER Figure 10-40-1
Procedure
Releasing Brake Disks: To release the brake disks, turn

The VersaHANDLER can be towed a short distance such each of the six (6) screws (Item 1) [Figure 10-40-1] only
as removing it from mud or loading onto a transport one half turn at a time; then repeat until all six screws are
vehicle. all the way in. (It will take 4 & 1/2 to 5 turns to fully
release the brakes.) Record the number of turns so that
you can return them to the same position later.

NOTE: If one screw is turned all the way in before you
start turning the others, the brake can be
damaged.
There are three screws on each side (right and left)

located 120° apart [Figure 10-40-1].
Figure 10-40-2
Turn the tow valve counterclockwise 90° (Item 1) [Figure

10-40-2] to TOWING POSITION.
Tow the VersaHANDLER at slow speed.
Block the wheels to prevent the machine from rolling. Engaging Brake Disks: After towing is completed, turn
the tow valve (Item 1) [Figure 10-40-2] clockwise 90° to
Raise the engine cover. the OPERATING POSITION.
Turn all six screws out, 1/2 turn at a time, to their original
position.
V518 VersaHANDLER
V518 VersaHANDLER
SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat VersaHANDLER.
Instructions are necessary before operating or servicing machine. Read
and understand the Operation & Maintenance Manual and signs (decals) on
WARNING machine. Follow warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2408-0801
SERVICE SCHEDULE HOURS
ITEM SERVICE REQUIRED 10 50 100 250

500 1000
Engine Oil Check the oil level and add oil as needed.
Hydraulic Fluid Check fluid level and add as needed.
Articulation Pins Lubricate with multi-purpose lithium based grease.
Safety Signs, Safety Tread and Check for damaged signs (decals) and safety tread and mirrors.
Mirrors Replace if damaged or worn.
Fuel Filter Clean the sediment bowl / water trap.
Nuts & Bolts Check for loose nuts and bolts. Tighten as needed.
Brakes Check for function. Service as necessary.
Back-up Alarm Check for function.

Tires Check for wear or damage. Inflate to correct pressure. Be sure all tires
are inflated to the same pressure. Use only approved tires.
Air Filter Clean the outer filter element. Do not use compressed air to clean the
filter. Check air filter system for damage or leaks.
Telescopic Boom Lubricate with multi-purpose lithium based grease. Check wear blocks
for adjustment.
Engine Cooling System Clean debris from oil cooler, radiator and air conditioner condenser.
Check coolant level cold in recovery tank. Add 53% propylene glycol
premixed with 47% water as needed. Check cooling system for leaks.
Hydraulic Hoses, Tubelines Check condition of hoses, tubelines and connectors. Repair or replace
and Connections. as needed.
Battery Check electrolyte level. Add distilled water as needed.
Wheel Nuts Check wheel nut torque. Tighten as needed to 217 ft. lbs. (159 Nm). †
Alternator and Air Conditioner Check belt tension and adjust as needed.
Belt
Engine Oil and Filter Replace the engine oil and filter. (See Capacities on Page SPEC-10-
2) for correct capacity. Use a genuine Bobcat filter.
Engine Air Filter Replace the outer filter element. Use a genuine Bobcat filter.
Fuel Filter Replace the fuel filter element. Use a genuine Bobcat filter.
Hydraulic Fluid Filter Replace the hydraulic filter element. Use a genuine Bobcat filter.
Hydraulic Fluid and Filter Replace the hydraulic fluid and filter element. (See Capacities on
Page SPEC-10-2) for correct capacity. Use a gen uine Bobcat filter.
Front & Rear Axle Fluid Replace the axle fluid. (See Capacities on Page SPEC-10-2) for
correct capacity.
Engine Coolant Check freeze protection of antifreeze -34°F (-30°C). Flush cool ing
system and replace coolant with premixed 53% propylene glycol and
47% water.
Telescopic Boom Wear Blocks Check for wear and adjust as needed. Replace as necessary.
Pivot Pins and Bushings Check for wear on the pivot pins and bushings.
Air Filter Replace the inner filter element. Use a genuine Bobcat filter.
† Check wheel nut torque every 8 hours for the first 24 hours.
Perform service first time, then as indicated in chart.
Check level.
Replace fluid first time, then as indicated in chart.
Or every 6 months.
Or every 12 months.
V518 VersaHANDLER
V518 VersaHANDLER
AIR CLEANER SERVICE Inner Filter
Replacing Filter Element Remove the outer element. (See above.)
Outer Filter NOTE: Make sure all sealing surfaces are free of dirt
and debris.
Figure 10-60-1
Figure 10-60-3
Loosen the filter housing clamp (Item 1) [Figure 10-60-

1]. Remove the inner filter (Item 1) [Figure 10-60-3] and
install a new element.
Release the fastener and remove the cover (Item 2)
[Figure 10-60-1]. Install the outer element.
Figure 10-60-2 Install the dust cover and fasten [Figure 10-60-1].
Connect the filter housing clamp (Item 1) [Figure 10-60-

1].
Pull the element straight out [Figure 10-60-2].
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
Install a new outer element.
Install the dust cover and fasten [Figure 10-60-1].
Connect the filter housing clamp.
Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.
V518 VersaHANDLER
V518 VersaHANDLER
ENGINE COOLING SYSTEM Checking The Coolant Level
Cleaning The Cooling System
IMPORTANT
WARNING AVOID ENGINE DAMAGE
Always use the correct ratio of water to anti freeze.
Wear safety glasses to prevent eye injury when any Too much antifreeze reduces cooling system
of the following conditions exist:
efficiency and may cause serious premature engine
• When fluids are under pressure.
• Flying debris or loose material is present. damage.
• Engine is running. Too little antifreeze reduces the additives which
• Tools are being used. protect the internal engine compo nents; reduces the
W-2019-1285 boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength
concentrated coolant can cause seri ous premature
Figure 10-70-1
engine damage.
I-2124-0497
Figure 10-70-3

Check the cooling system every day to prevent over-
heating, loss of performance or engine damage.
Open the engine cover (Item 1) [Figure 10-70-1].

Open the engine cover.
Figure 10-70-2
Check the coolant level in the coolant recovery tank.
The coolant level must be between the MIN and MAX

marks (Item 1) [Figure 10-70-3] on the coolant recovery
tank when the engine is cold.
Use low air pressure or water pressure to clean the

radiator and oil cooler [Figure 10-70-2].
Check cooling system for leaks.
V518 VersaHANDLER
ENGINE COOLING SYSTEM (CONT'D) Figure 10-70-5
Replacing The Coolant
WARNING
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1285
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to anti freeze.
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
damage.
Too little antifreeze reduces the additives which
protect the internal engine compo nents; reduces the

boiling point and freeze protection of the system.
Remove the engine block drain plug (Item 1) [Figure 10-
Always add a premixed solution. Adding full strength 70-5].
concentrated coolant can cause seri ous premature
engine damage. Open the drain valve (Item 2) [Figure 10-70-5] and drain
I-2124-0497 all of the coolant into a container. Dispose of used
coolant in an environmentally safe manner.
Figure 10-70-4 Close the drain valve.
Mix the coolant in a separate container.

NOTE: The loader is factory filled with propylene
glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.
Add premixed coolant, 47% water and 53% propylene

glycol to the recovery tank if the coolant level is low.
One gallon and one pint (4,3 L) of propylene glycol mixed

with one gallon (3,8 L) of water is the correct mixture of
coolant to provide a -34° F (-37° C) freeze protection.
Use a refractometer to check the condition of propylene

glycol in your cooling system.
Fill the radiator with the premixed coolant. Install the

radiator cap.
Add coolant to the recover tank. The coolant level must
be between the MIN and MAX marks (Item 2) [Figure 10-
Remove the cap (Item 1) [Figure 10-70-4] from the 70-4] on the coolant recovery tank.
coolant recovery tank.
Run the engine until it is at operating temperature.
Remove fan shield.
Stop the engine.
Check the coolant level in the recovery tank when cool.
Add coolant to the recovery tank as needed.
V518 VersaHANDLER
FUEL SYSTEM Fuel Filter
Fuel Specifications
Use only clean, high quality diesel fuel, Grade No. 2 or

Grade No. 1.
WARNING
The following is one suggested blending guideline which Always clean up spilled fuel or oil. Keep heat, flames,
should prevent fuel gelling problems in cold sparks or lighted tobacco away from fuel and oil.
temperatures: Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
TEMP. F° (C°) NO. 2 NO. 1
+15° (9°) 100% 0% See SERVICE SCHEDULE on Page 10-50-1 for the
Down to -20° (-29°) 50% 50% service interval when to clean the sediment bowl.
Below -20° (-29°) 0% 100%
Figure 10-80-2
See your fuel supplier for local recommendations.
Filling The Fuel Tank
WARNING

Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0887
Figure 10-80-1
Remove and clean the sediment bowl (Item 1) [Figure
10-80-2]. Install and tighten the sediment bowl.
See SERVICE SCHEDULE on Page 10-50-1 for the

service interval when to replace the fuel filter.
Remove the filter element (Item 2) [Figure 10-80-2].
Clean the area around the filter housing.
Put oil on the seal of the new filter element.
Install the fuel filter, and hand tighten.
Remove the fuel fill cap (Item 1) [Figure 10-80-1].
Use a clean, approved safety container to add fuel of the

correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING!
Install and tighten the fuel fill cap [Figure 10-80-1].
V518 VersaHANDLER
V518 VersaHANDLER
ENGINE LUBRICATION SYSTEM Oil Chart
Checking Engine Oil
Check the engine oil level every day before starting the
engine for the work shift.
Figure 10-90-1

Replacing Oil And Filter

service interval for replacing the engine oil and filter.
Open the engine cover and remove the dipstick (Item 1)
[Figure 10-90-1]. Run the engine until it is at operating temperature. Stop
the engine.
Keep the oil level between the marks on the dipstick
(INSET) [Figure 10-90-1]. Open the engine cover.
Use a good quality motor oil that meets API Service Remove the shield.
Classification of CD or better. (See Oil Chart below.)
Remove the oil filter (Item 2) [Figure 10-90-1].
Clean the filter housing surface.
Put clean oil on the new oil filter gasket.
Install the filter and hand tighten.
V518 VersaHANDLER
Figure 10-90-2
Remove the access panel at the rear of the engine

compartment. Remove the cap and install the drain hose

(Item 1) [Figure 10-90-2].
Drain the oil into a container and recycle or dispose of

used oil in an environmentally safe manner.
Remove drain hose and install cap.
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
W-2103-1285
V518 VersaHANDLER
ENGINE LUBRICATION SYSTEM (CONT'D)
Replacing Oil And Filter (Cont'd)
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
Failure to use care around combustibles can cause
W-2103-1285
Figure 10-90-3

Remove the filler cap (Item 1) [Figure 10-90-3].
Put oil in the engine. (See Capacities on Page SPEC-10-

2, for Capacity.) (See Oil Chart on Page 10-90-1.)
Install fill cap.
Start the engine and let it run for several minutes.
Stop the engine.
Check for leaks at the oil filter and check the oil level.
Add oil as needed if it is not at the top mark [Figure 10-

90-3] on the dipstick.
V518 VersaHANDLER
V518 VersaHANDLER
HYDRAULIC/HYDROSTATIC SYSTEM Replacing Hydraulic/Hydrostatic Filter
Checking And Adding Fluid
WARNING
WARNING Always clean up spilled fuel or oil. Keep heat, flames,
Diesel fuel or hydraulic fluid under pressure can Failure to use care around combustibles can cause
penetrate skin or eyes, causing serious injury or explosion or fire which can result in serious injury or
death. Fluid leaks under pressure may not be visible. death.
Use a piece of cardboard or wood to find leaks. Do W-2103-1285
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
correct service intervals.
W-2072-0496

Use only recommended fluid in the hydraulic system.
(See HYDRAULIC/HYDROSTATIC FLUID Remove the belt shield.
SPECIFICATIONS on Page SPEC-60-1.)
Figure 10-100-2
Stop the machine on a level surface. Lower the boom all
the way.

Stop the engine.
Figure 10-100-1
Remove the filter element (Item 1) [Figure 10-100-2].

Check the fluid level at the sight gauge (Item 1) [Figure
10-100-1]. Clean the surface of the filter housing where the seal
contacts the housing.
Remove the fill cap (Item 2) [Figure 10-100-1].
Put clean oil on the seal of the new filter element.
Add the fluid as needed until visible in the sight gauge
[Figure 10-100-1]. Install and hand tighten the filter element.
Install the fill cap. Close the engine cover before operating.
V518 VersaHANDLER
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)
Replacing Hydraulic Fluid
Figure 10-100-3
Remove the fill cap (Item 1) [Figure 10-100-3].
Figure 10-100-4

Remove the reservoir drain plug (Item 1) [Figure 10-100-
4] behind the right front wheel and drain the fluid into a
container. Recycle or dispose of the fluid in an
environmentally safe manner.
Add fluid until it it at the center of the sight gauge (Item 2)

[Figure 10-100-3].
Install the fill cap.
V518 VersaHANDLER
AXLES (FRONT AND REAR) Draining Oil (Planetary Carrier)
Checking Oil Level (Planetary Carrier) See SERVICE SCHEDULE on Page 10-50-1 for the
correct service interval.
Figure 10-110-1
Figure 10-110-2
Put the machine on a level surface with the plug

positioned as shown (Item 1) [Figure 10-110-1]. Put the machine on a level surface with the plug
positioned as shown (Item 1) [Figure 10-110-2].

Remove the plug (Item 1) [Figure 10-110-1]. The oil level
should be at the bottom edge of the plug hole. Remove the plug (Item 1) [Figure 10-110-2] and drain
into a container. Recycle or dispose of the used lubricant
Add gear lube through the hole if the oil level is below the in an environmentally safe manner.
hole. (See FUEL, COOLANT AND LUBRICANT Chart,
Contents Page SPEC-01 for capacity and type.) Reposition the plug hole and add gear lube until the lube
level is at the bottom edge of the plug hole (Item 1)
Install and tighten the plug. [Figure 10-110-1]. (See FUEL, COOLANT AND
LUBRICANT Chart, Contents Page SPEC-01 for capacity
Repeat the procedure for the other side. and type.)
Install and tighten the plug.
Repeat the procedure for the other side.
V518 VersaHANDLER
AXLES (FRONT AND REAR) (CONT'D) Draining Oil (Rear Differential)
Checking Oil Level (Rear Differential) See SERVICE SCHEDULE on Page 10-50-1 for the
Figure 10-110-3
Figure 10-110-4
With the machine on a level surface, remove the plug

(Item 1) [Figure 10-110-3]. The oil level should be at the With the machine on a level surface remove the plug
bottom edge of the plug hole. (Item 1) [Figure 10-110-4] and drain into a container.

Recycle or dispose of the used lubricant in an
Add oil through the hole if the oil level is below the hole. environmentally safe manner.
(See FUEL, COOLANT AND LUBRICANT Chart, Page
SPEC-01 for capacity and type.) Checking Oil Level (Front Differential)
Install and tighten the plug. Figure 10-110-5
Put the machine on a level surface with the plugs

positioned as shown (Item 1) [Figure 10-110-5].
Remove the plugs (Item 1) [Figure 10-110-5]. The oil

level should be at the bottom edge of the plug hole.
Add oil through the hole if the oil level is below the hole.
(See FUEL, COOLANT AND LUBRICANT Chart, Page
SPEC-01 for capacity and type.)
V518 VersaHANDLER
AXLES (FRONT AND REAR) (CONT'D)
Draining Oil (Front Differential)

Figure 10-110-6

With the machine on a level surface, remove the plug
(Item 1) [Figure 10-110-6] and drain into a container.
Recycle or dispose of the used lubricant in an
environmentally safe manner.
V518 VersaHANDLER
V518 VersaHANDLER
LUBRICATION Figure 10-120-3
Procedure
Lubricate as specified in the SERVICE SCHEDULE,

(See Operation and Maintenance Manual for Service
Schedule) for the best performance of the machine.
Record the operating hours each time you lubricate so

that it is performed at the correct interval.
Always use a good quality lithium based multi-purpose

grease. Apply lubricant until extra grease shows.
Lubricate the following locations on the VersaHANDLER:
Figure 10-120-1
3. Axle Oscillation - Rear Axle (Item 1) [Figure 10-120-
3].
Figure 10-120-4

1. Axle Pivots - Top and bottom (Item 1) [Figure 10-120-
1] all four wheels.
Figure 10-120-2
4. Attachment Frame Pivot (Item 1) [Figure 10-120-4].
2. Universal Joints - Front and Rear (Item 1) [Figure 10-

120-2].
V518 VersaHANDLER
LUBRICATION (CONT'D) Figure 10-120-7
Figure 10-120-5
7. Lift Cylinder Base End, Slave Cylinder Base End

(Item 1) [Figure 10-120-7].
5. Tilt Cylinder Base End [Figure 10-120-5].
Figure 10-120-8
Figure 10-120-6

8. Lift Cylinder Rod End, Slave Cylinder Rod End (Item
6. Tilt Cylinder Rod End (Item 1) [Figure 10-120-6]. 1) [Figure 10-120-8].
NOTE: Raise the boom and install Boom Stop (See

Installing Boom Stop on Page 10-150-1)
before lubricating the Boom and slave
Cylinders.
V518 VersaHANDLER
LUBRICATION (CONT'D) Figure 10-120-11
Figure 10-120-9
11. Boom Slide [Figure 10-120-11] (Four Places).
9. Boom Pivot (Item 1) [Figure 10-120-9] (Four Places).
Figure 10-120-10
10. Cab Door Hinges (Item 1) [Figure 10-120-10] (three

Places).
V518 VersaHANDLER
V518 VersaHANDLER
TIRE MAINTENANCE Tire Rotation
Wheel Nuts Check the tires regularly for wear, damage and pressure.
(See Tires on Page SPEC-10-2.)
Figure 10-130-1
Rear tires usually wear faster than front tires. To keep the
wear even, move the front tires to the rear and rear tires
to the front.
It is important to keep the same size tires on each side of

the loader. If different sizes are used, each tire will be
turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
Recommended tire pressure must be maintained to avoid

excessive tire wear and loss of stability and handling
capability. Check for the correct pressure before
operating the loader.
Tire Mounting

service interval to check the wheel nuts. The correct
torque is 200 ft.-lbs. (300 Nm) torque [Figure 10-130-1].
WARNING

Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1285
Tires are to be repaired only by an authorized person

using the correct procedures and type of equipment.
Tires and rims must always be checked for correct size

before mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
bead and rim flange must be lubricated with a rubber
lubricant before mounting the tire.
Avoid excessive pressure which can rupture the tire and

cause serious injury or death.
During inflation of the tire, check the tire pressure

frequently to avoid over inflation.
V518 VersaHANDLER
V518 VersaHANDLER
SPARK ARRESTOR MUFFLER
Procedure
IMPORTANT
This loader is factory equipped with a U.S.D.A.
WARNING Forestry Service approved spark arrestor muffler. It
is necessary to do maintenance on this spark
arrestor muffler to keep it in working condition. The
When the engine is running during service, the spark arrestor muffler must be serviced by dumping
Travel Direction Lever must be in neutral and the the spark chamber every 100 hours of operation.
parking brake engaged. Failure to do so can cause If this machine is operated on flammable forest,
injury or death. brush or grass covered land, it must be equipped
W-2397-0301
with a spark arrestor attached to the exhaust system
and maintained in working order. Failure to do so will
Figure 10-140-1 be in violation of California State Law, Section 4442
PRC.
Make reference to local laws and regulations for
spark arrestor requirements.
I-2022-0595

service interval for cleaning the spark arrestor muffler.
Do not operate the machine with a defective exhaust

system.
Stop the engine.
Remove the plug (Item 1) [Figure 10-140-1] from the

bottom of the muffler.
Start the engine and run for about 10 seconds while a

second person, wearing safety glasses, holds a piece of
wood over the outlet of the muffler.
This will force contaminants out through the cleanout

hole.
Stop the engine.
V518 VersaHANDLER
V518 VersaHANDLER
BOOM STOP Figure 10-150-2
If the boom is raised for service or maintenance, use the

following procedure to install and remove the boom stop.
Installing Boom Stop
• Put the VersaHANDLER on a flat, solid and level

surface.
• With the operator in the seat, the seat belt fastened,

Travel Direction Control and the parking brake
engaged, start the engine and raise the boom and
stop the engine.
Figure 10-150-1
• Install the boom stop over the rod of the boom

cylinder (the larger one) [Figure 10-150-2].
• Install the pins and secure with fasteners [Figure 10-

150-2].
• Start the engine and lower the boom slowly [Figure

10-150-2] so that the boom stop is held securely.
Removing Boom Stop
• Start the engine and raise the boom. Stop the engine.
• Remove the fasteners, pins and boom stop.
• Have a second person remove the boom stop (Item 1) • Put the boom stop in the storage position and secure
[Figure 10-150-1] from the storage position. with pins and fasteners.
• Start the engine and lower the boom
V518 VersaHANDLER
V518 VersaHANDLER
ENGINE COVER Adjusting The Latch
Opening And Closing The Engine Cover Figure 10-160-2
WARNING
AVOID INJURY OR DEATH
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 10-160-1
The engine cover latch (Item 1) [Figure 10-160-2] can be

adjusted in either direction for alignment with the door
latch.
Close the engine cover before operating the

VersaHANDLER.
Release the latch (Item 1) [Figure 10-160-1] and raise

the engine cover.
V518 VersaHANDLER
V518 VersaHANDLER
HYDRAULIC SYSTEM
BUCKET POSITIONING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-10
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
DRIVE BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-7
EXTENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
FAN MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-3
GEAR PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-3
HYDRAULIC CONTROL VALVE (S/N 367011001-367012500). . 20-170-1

Auxiliary Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-5
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-4
Inlet/Outlet Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-28
Lifting Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-22
Telescoping Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-10
Tilting Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-16
V518 VersaHANDLER
HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE (S/N 367012501-367013000) (CONT’D) 20-171-4

Auxiliary Valve Section Disassembly And Assembly . . . . . . . . . . . . . .20-171-28
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-171-5
End Housing Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . .20-171-6
Inlet-Outlet Valve Section Disassembly And Assembly . . . . . . . . . . . .20-171-40
Lifting Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . .20-171-7
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-171-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-171-1
Telescoping Valve Section Disassembly And Assembly . . . . . . . . . . .20-171-17
Tilting Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . .20-171-12
JOYSTICK (S/N 367012501-367013000) . . . . . . . . . . . . . . . . . . . . . . . . . .20-180-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-180-5
Handle Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-180-1
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-180-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-180-4
HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-10
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
QUICK TACH CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-4
STEERING CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
STEERING MODE VALVE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-5
V518 VersaHANDLER
HYDRAULIC SYSTEM (CONT’D)
STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-10
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-3
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-2
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-9
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-4
V518 VersaHANDLER
V518 VersaHANDLER
HYDRAULIC/HYDROSTATIC SCHEMATIC
V518 (S/N 367011001 - 367012500)
Printable Version Click Here
(Printed September 2004)

V518-VersaHle
LEGEND
1 RESERVOIR: 17 HYDRAULIC PUMP - Gear Type 34 BRAKE VALVE 363 PSI (25 Bar)
Capacity 68.8 Qts. (65 L) 4.2 GPM (16 L/min.) @ 2200 RPM
35 RELIEF VALVE 2320 PSI (160 Bar)
2 FILTER - Hydraulic 18 PRIORITY VALVE
36 RELIEF VALVE (2) 3553 PSI (245 Bar)
3 SPRING LOADED FILTER BYPASS 19 ANTI-CAVITATION VALVE
VALVE: 102 PSI (7 Bar) 37 SHUTTLE VALVE - Drive Pressure
20 ANTICAVITATION/WORK PORT RELIEF
4 TILT CYLINDER LOCK VALVE 38
VALVE 2756 PSI (190 Bar) MOTOR DISPLACEMENT CONTROL
3046 PSI (210 Bar)
SPOOL
5 TELESCOPIC CYLINDER LOCK 21 ANTICAVITATION/WORK PORT RELIEF
39 SHUTTLE VALVE - Drain
VALVE (2) - 1450 PSI (100 Bar) VALVE 3046 PSI (210 Bar)
22 ANTICAVITATION/WORK PORT RELIEF 40 VARIABLE CAPACITY DISPLACEMENT

6 BOOM CYLINDER LOCK VALVE - Lock VALVE 3336 PSI (230 Bar) BIDIRECTIONAL HYDROSTATIC MOTOR
Pressure - 5076 PSI (350 Bar)
23 ANTICAVITATION/WORK PORT RELIEF 41 SERVO PISTON - Swash Plate
7 BOOM CYLINDER LOCK VALVE - VALVE 3843 PSI (265 Bar) (Non-differential cylinder)
Release Pressure - 580 PSI (40 Bar)
24 LOAD COMPENSATING VALVE 42 RELIEF VALVE - 392 PSI (27 Bar)
8 SPRING LOADED OIL COOLER 109 PSI (7,5 Bar)
BY-PASS VALVE - NA PSI (NA Bar) 43 TOW VALVE
25 PRESSURE REDUCING VALVE
9 SOLENOID - Reverse Drive 290 PSI (20 Bar) 44 SHUTTLE VALVE
26 PILOT RELIEF VALVE 45

10 SOLENOID - Forward Drive AUXILIARY PRESSURE RELEASE
435 PSI (30 Bar) VALVE
11 RELIEF VALVE - Charge 27 FLUSHING VALVE 135 PSI (8,5 Bar)
46 CHECK VALVE
435 PSI (30 Bar)
28 RELIEF VALVE - Load Sense (LSRV)
12 RELIEF/REPLENISHING VALVE - 3626 PSI (250 Bar)
HIGH PRESSURE (2) - 6527 PSI (450
29 LOAD SENSE ACTIVATION VALVE
Bar)
13 VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP 30 TEST PORT(S)
14 CHARGE PUMP
31 PRESSURE SWITCH - Parking Brake
4.5 GPM (17 L/min.) @ 2200 RPM 247 PSI (17 Bar)
15 SERVO PISTON - Swash Plate
32 BRAKE VALVE 290 PSI (20 Bar)
16 HYDRAULIC PUMP - Gear type 33 DIRECTIONAL CONTROL VALVE

24.0 GPM (91 L/min.) @ 2200 RPM
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
Printed in U.S.A. V518-VersaHle (9-1-04)

61 of 724
HYDRAULIC/HYDROSTATIC
SCHEMATIC
V518 (S/N 367011001 - TELESCOPIC CYLINDER
46 46
367012500)
(PRINTED SEPTEMBER 2004) 5
MS-1328 4
5
45
TILT CYLINDER 44
V1
V2 CONTROL VALVE
7
6
LX
C2
B4
A4
AUXILIARY
SECONDARY AUX. BUCKET POSITIONING 46 CYLINDER
BUCKET PINS VALVE (OPTIONAL) CYLINDER BOOM CYLINDER SPOOL
EVP4
EV51
44
C4 C1 C3 C2 B3 A3
1004.40T
2400RPM
2200RPM
1400RPM
800RPM
T 20 TELESCOPIC
CYLINDER
11 COOLING 19 EVP3 SPOOL
8 24
PERKINS
MOTOR
76.5 kW
394 Nm
MAX.
A
MIN.
HYDRAULIC 44
B2 A2
QUICK COUPLERS OIL PUMP TILT
COOLER 1 HYD. 2 21 CYLINDER
EV1
FILTER 22 SPOOL
10 EVP2
24
15 A
3
B 44
9 B1 A1
M4 EV2 BOOM
M5 23 CYLINDER
M1 19 SPOOL
0°
U
13 EVP1
M2
Dealer CopyL2-- Not for ResaleHYD.
FILTER 24
L1 P
11 25
26
17
S
40 41 39 42
14 28
A T
M1 A B M3 M6
M LS
L2
12 27
FRONT AXLE 43 XB 30
12
B
S A
38
37 16 EV3
A
XA S GEAR
16
PUMP (2) 29 1
17
B
L1 M2 M4 M3 CE
18
CF
HYDRAULIC MOTOR LS
38
EV7
A
P A
T B
EV6
A2 32 31
A4 B4
A1 B1
REAR AXLE
L R LS T P
STEERING VALVE
A3 B3 46
36 B2 T
X
P
POWER JOYSTICK 30
EV60
2 ACCUM. PILOT
STEERING (ELECTRICAL)
A P T 1 3 DRAIN
X
U
36 BRAKE 33 PARKING BRAKE

35 46
PEDAL
34 VALVE
62 of 724
HYDRAULIC/HYDROSTATIC SCHEMATIC
V518 (S/N 367012501 - 567013000)
(Printed Septmber 2004)
Printable Version Click Here V-0597legend
LEGEND
1 RESERVOIR: 17 HYDRAULIC PUMP - Gear Type 34 BRAKE VALVE 363 PSI (25 Bar)
Capacity 68.8 Qts. (65 L) 4.2 GPM (16 L/min.) @ 2200 RPM
35 RELIEF VALVE 2320 PSI (160 Bar)
2 FILTER - Hydraulic 18 PRIORITY VALVE
36 RELIEF VALVE (2) 3553 PSI (245 Bar)
3 SPRING LOADED FILTER BYPASS 19 LOAD CHECK
VALVE: 102 PSI (7 Bar) 37 SHUTTLE VALVE - Drive Pressure
20 ANTICAVITATION/WORK PORT RELIEF
4 TILT CYLINDER LOCK VALVE 38
VALVE 3843 PSI (265 Bar) MOTOR DISPLACEMENT CONTROL
3480 PSI (240 Bar)
SPOOL - 2610 PSI (140 Bar)
5 TELESCOPIC CYLINDER LOCK 21 ANTICAVITATION/WORK PORT RELIEF
39 SHUTTLE VALVE - Drain
VALVE - 1450 PSI (100 Bar) VALVE 3045 PSI (210 Bar)
22 ANTICAVITATION/WORK PORT RELIEF 40 VARIABLE CAPACITY DISPLACEMENT

6 BOOM CYLINDER LOCK VALVE - Lock VALVE 3335 PSI (230 Bar) BIDIRECTIONAL HYDROSTATIC MOTOR
Pressure - 5076 PSI (350 Bar)
23 ANTICAVITATION/WORK PORT RELIEF 41 SERVO PISTON - Swash Plate
7 BOOM CYLINDER LOCK VALVE - VALVE 2755 PSI (190 Bar)
Release Pressure - 580 PSI (40 Bar)
24 COMPENSATOR 42 RELIEF VALVE - 392 PSI (27 Bar)
8 SPRING LOADED OIL COOLER
BY-PASS VALVE - NA PSI (NA Bar) 43 TOW VALVE
25 RELIEF VALVE
9 SOLENOID - Reverse Drive 218 PSI (15 Bar) 44 TELESCOPIC CYLINDER LOCK
26 RELIEF VALVE VALVE - 2030 PSI (140 Bar)
10 SOLENOID - Forward Drive 3408 PSI (235 Bar) 45 AUXILIARY PRESSURE RELEASE
VALVE
27 LOAD SENSE RELIEF CARTEIDGE
11 RELIEF VALVE - Charge N/A PSI (N/A Bar)
435 PSI (30 Bar)
28 BUCKET POSITIONING CYLINDER
12 RELIEF/REPLENISHING VALVE - LOCK VALVE - 3625 PSI (250 Bar)
HIGH PRESSURE (2) - 6527 PSI (450
29 LOAD SENSE ACTIVATION VALVE
Bar)
13 VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP 30 TEST PORT(S)
14 CHARGE PUMP
4.5 GPM (17 L/min.) @ 2200 RPM 31 PRESSURE SWITCH - Parking Brake
247 PSI (17 Bar)
15 SERVO PISTON - Swash Plate
32 BRAKE VALVE 290 PSI (20 Bar)
16 HYDRAULIC PUMP - Gear type
24.0 GPM (91 L/min.) @ 2200 RPM 33 DIRECTIONAL CONTROL VALVE
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
Printed in U.S.A. V0597Hle (9-1-04)

63 of 724
HYDRAULIC SCHEMATIC
V518 (S/N 367012501 - 567013000)
(PRINTED SEPTEMBER 2004)
4 BOOM
CYLINDER
V-0597
Printable Version Click Here 3/1 C2

CONTROL
pil VALVE T2
TILT
TELESCOPIC 5 24
CYLINDER
BUCKET CYLINDER 3/1 3/1 5 7
POSITIONING
V2
4/1
6
CYLINDER 28 V1 V2
A4 20
SECONDARY AUX. VALVE B4 BOOM
(OPTIONAL)
EV51 b4 a4
C4 19
21
1004.40T
24 00RP
22 00RP
C2 COOLING
1400RP
80 0MRP
C1 C3 A
M
M
M
MOTOR
8
76.5 kW
24
PERKIN
3 9 4
N IN m
T
MAXS
.
.
M
A3 22
2
QUICK B3 TILT
COUPLERS
EV1
b3 a3
10 19
a
1 3 15
23
BUCKET PINS
b
9 24
44 44 M4 EV2 A2
M5 TELESCOPIC
B2
U
M2
19
45 M1
L1
13
L2
24
A1
11
43 B1 AUXILIARY
FRONT
AXLE
S Dealer Copy -- Not for Resale
Y
14
pst
M1 39 L2 26
T1
M3 M6
A STEERING M
42 B VALVE
41 A B A
40
EV6
XB
30 25 27
12 12 P LS T
S A
37
B
EV7
A
XA 16
EF P T 2 3 JOYSTICK
EV8 S GEAR
B CF
PUMPS (2)
L1 M2
17
M4 M3 LS
a b
HYDRAULIC MOTOR 38 REAR AXLE
18
4
1
A1 A2
1
33
A P T B2
B1
POWER 32 2 2
3 P T
STEERING
L R LS T P EV3
36 MA X
U EV60
T
3 1
BRAKE
ACCUMULATOR 29
P X
PEDAL
31 30
VALVE
36 46
PARKING V-0597 (9-1-04)
BRAKE
Printed in USA
35
64 of 724
LIFT CYLINDER Figure 20-20-3
Removal And Installation
Figure 20-20-1
Remove the rod end pivot pin retainer pin (Item 1)

[Figure 20-20-3].
Figure 20-20-4
Raise the boom and support on adequate stands [Figure
20-20-1].

Figure 20-20-2
Support both cylinders using a cinch strap (Item 1)

[Figure 20-20-4].
Remove the rear cover (Item 1) [Figure 20-20-2] from

the machine.
V518 VersaHANDLER
LIFT CYLINDER (CONT'D) Figure 20-20-7
Removal And Installation (Cont'd)
Figure 20-20-5
2. The side window (Item 1) [Figure 20-20-7] and frame

openings (Item 2) [Figure 20-20-7] must be protected
from sparks.
Remove the upper pivot pin using a pin removal tool Figure 20-20-8
(Item 1) [Figure 20-20-5].

NOTE: If a nut must be welded onto the pin for
removal, the following three steps must be
performed.
Figure 20-20-6
3. The cylinder rod must be wrapped with a damp

welding blanket (Item 1) [Figure 20-20-8] to prevent
damage.
1. Rotate the battery disconnect switch (Item 1) [Figure

20-20-6] to the right to disconnect the power supply
from the battery.
V518 VersaHANDLER
Figure 20-20-9
Figure 20-20-12
Lift and support the cylinders using a hoist and lifting

strap (Item 1) [Figure 20-20-9]. Remove the cinch strap
(Item 2) [Figure 20-20-9].

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Remove the four hoses (Item 1) [Figure 20-20-11] &
I-2003-0888
[Figure 20-20-12] from the lift lock.
Figure 20-20-10 NOTE: Mark the hoses for correct installation.
Lower both cylinders onto a wood block (Item 1) [Figure

20-20-10].
V518 VersaHANDLER
Removal And Installation (Cont’d)
Figure 20-20-13
Lift and remove both cylinders from the machine [Figure

20-20-15].
NOTE: Protect the side window from possible

Remove the base end pivot pin retainer bolt (Item 1) damage.
[Figure 20-20-13].
Figure 20-20-16

Figure 20-20-14
Remove the bolt and nut (Item 1) [Figure 20-20-16] and

Remove the base end pivot pin [Figure 20-20-14]. separate the lift cylinder and bucket positioning cylinder.
V518 VersaHANDLER
LIFT CYLINDER (CONT'D)
Parts Identification
V518 VersaHANDLER
Disassembly
Figure 20-20-17
Carefully peen the lock ring from the head gland [Figure
20-20-19].
Figure 20-20-20
Put the cylinder in a vise [Figure 20-20-17].
Figure 20-20-18

Loosen the head gland [Figure 20-20-20].
Remove the four bolts (Item 1) [Figure 20-20-18] and

remove the lift lock (Item 2) [Figure 20-20-18].
V518 VersaHANDLER
Disassembly (Cont'd)
Figure 20-20-21
Remove the set screw (Item 1) [Figure 20-20-23] from

the piston.
Figure 20-20-24
Remove the rod assembly (Item 1) [Figure 20-20-21]
from the housing.

Figure 20-20-22
Support the cylinder rod on a wood block and remove the

piston [Figure 20-20-24].
Put the rod end of the cylinder rod in a vise [Figure 20-
20-22].
V518 VersaHANDLER
Figure 20-20-25
Remove the O-ring (Item 1) [Figure 20-20-27] from the

piston.
Figure 20-20-28
Remove the two wear rings (Item 1) [Figure 20-20-25]
and seal (Item 2) [Figure 20-20-25] from the piston.

Figure 20-20-26
Remove the head gland (Item 1) [Figure 20-20-28] from

the rod.
Remove the expander O-ring (Item 1) [Figure 20-20-26].
V518 VersaHANDLER
Figure 20-20-29
Remove the seal (Item 1) [Figure 20-20-31], wear ring

(Item 2) [Figure 20-20-31] and wiper (Item 3) [Figure 20-
20-31].
Remove the two O-rings (Item 1) [Figure 20-20-29] and

backup ring (Item 2) [Figure 20-20-29] from the head
gland.

Figure 20-20-30
Remove the wear ring (Item 1) [Figure 20-20-30].
V518 VersaHANDLER
Assembly
Figure 20-20-32
Install the center seal (Item 1) [Figure 20-20-34].
NOTE: The groove in the seal must point away from

the wiper seal (Item 1) [Figure 20-20-32].
Wash the cylinder parts in solvent and dry with
compressed air. Figure 20-20-35

Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
Lubricate all O-rings and seals with hydraulic oil during

installation.
Install the wiper (Item 1) [Figure 20-20-32], wear ring

(Item 2) [Figure 20-20-32] and seal (Item 3) [Figure 20-
20-32] into the head gland.
Figure 20-20-33
Install the two O-rings (Item 1) [Figure 20-20-35] and

backup ring (Item 2) [Figure 20-20-35].
Install the wear ring (Item 1) [Figure 20-20-33].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-20-36
Install the expander O-ring (Item 1) [Figure 20-20-38] on

the piston.
Figure 20-20-39
Install the head gland (Item 1) [Figure 20-20-36] onto the
rod.

Figure 20-20-37
Install the two wear rings (Item 1) [Figure 20-20-39] and

seal (Item 2) [Figure 20-20-39] onto the piston.
Install the O-ring (Item 1) [Figure 20-20-37] in the piston.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-20-40
Install and tighten the set screw (Item 1) [Figure 20-20-

42].
Figure 20-20-43
Clean off any old residue, and apply LOCTITE 242 or
equivalent to the threads on the rod [Figure 20-20-40].

Figure 20-20-41
Install the rod assembly (Item 1) [Figure 20-20-43] into

the housing.
Install the piston (Item 1) [Figure 20-20-41] on the rod

and tighten.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-20-44
Install the lift lock (Item 1) [Figure 20-20-46] onto the

cylinder and tighten the four bolts (Item 2) [Figure 20-20-
46].
Tighten the head gland [Figure 20-20-44].
Figure 20-20-45

Peen the lock ring into the groove in the head gland
[Figure 20-20-45].
V518 VersaHANDLER
V518 VersaHANDLER
BUCKET POSITIONING CYLINDER Figure 20-30-3
Figure 20-30-1
Remove the rod end pivot pin retainer pin (Item 1)

[Figure 20-30-3].
Figure 20-30-4
Raise the boom and support on adequate stands [Figure
20-30-1].

Figure 20-30-2
Support both cylinders using a cinch strap (Item 1)

[Figure 20-30-4].

the machine.
V518 VersaHANDLER
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-7
Figure 20-30-5
2. The side window (Item 1) [Figure 20-30-7] and frame

openings (Item 2) [Figure 20-30-7] must be protected
from sparks.
Remove the upper pivot pin using a pin removal tool Figure 20-30-8
(Item 1) [Figure 20-30-5].

NOTE: If a nut must be welded onto the pin for
removal the following three steps must be
performed.
Figure 20-30-6
3. The cylinder rod must be wrapped with a damp

welding blanket (Item 1) [Figure 20-30-8] to prevent
damage.
1. Rotate the battery disconnect switch (Item 1) [Figure

20-30-6] to the right to disconnect the power supply
from the battery.
V518 VersaHANDLER
Figure 20-30-9
Figure 20-30-12

(Item 2) [Figure 20-30-9].

Figure 20-30-10
Remove the four hoses (Item 1) [Figure 20-30-11] &

[Figure 20-30-12] from the lift lock.
NOTE: Mark the hoses for correct installation.

20-30-10].
IMPORTANT
damage the system.
I-2003-0888
V518 VersaHANDLER
Figure 20-30-13
Lift and remove both cylinders from the machine [Figure

20-30-15].
NOTE: Protect the side window from possible

Remove the base end pivot pin retainer bolt (Item 1) damage.
[Figure 20-30-13].
Figure 20-30-16

Figure 20-30-14
Remove the bolt and nut (Item 1) [Figure 20-30-16] and

Remove the base end pivot pin [Figure 20-30-14]. separate the lift cylinder and bucket positioning cylinder.
V518 VersaHANDLER
LIFT CYLINDER (CONT'D)
V518 VersaHANDLER
Disassembly
Figure 20-30-17
Remove the head gland [Figure 20-30-19].
Figure 20-30-20
Figure 20-30-18

from the housing.
20-30-18].
V518 VersaHANDLER
Figure 20-30-21
Remove the piston assembly (Item 1) [Figure 20-30-23]

from the rod.
Figure 20-30-24
Put the rod end of the cylinder in a vise [Figure 20-30-
21].

Figure 20-30-22

Support the cylinder rod on a wood block and remove the

set screw (Item 1) [Figure 20-30-22] from the piston.
V518 VersaHANDLER
Figure 20-30-25

the rod.
Figure 20-30-28
Figure 20-30-26

Remove the center seal (Item 1) [Figure 20-30-28] and
outer wear ring (Item 2) [Figure 20-30-28].

piston.
V518 VersaHANDLER
Figure 20-30-29
Remove any residue from the threads on the cylinder rod

[Figure 20-30-31].
Remove the outer wear ring (Item 1) [Figure 20-30-29]

and wiper (Item 2) [Figure 20-30-29].

Figure 20-30-30

V518 VersaHANDLER
Assembly
Figure 20-30-32
Install the wear ring (Item 1) [Figure 20-30-34].
Figure 20-30-35

compressed air.


installation.

backup ring (Item 2) [Figure 20-30-32] onto the head
gland.
Figure 20-30-33
Install the center seal (Item 1) [Figure 20-30-35].

Install the wiper (Item 1) [Figure 20-30-33] and wear ring

(Item 2) [Figure 20-30-33].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-30-36
Install the expander O-ring (Item 1) [Figure 20-30-38]

onto the piston.
Figure 20-30-39
rod.

Figure 20-30-37

seal (Item 2) [Figure 20-30-39].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-30-40
Install the set screw (Item 1) [Figure 20-30-42] into the

piston and tighten.
Figure 20-30-43
Install the piston (Item 1) [Figure 20-30-40] onto the rod.
Figure 20-30-41

Install the rod assembly (Item 1) [Figure 20-30-43] into
the housing.
Apply LOCTITE 242 or equivalent to the set screw (Item

1) [Figure 20-30-41].
V518 VersaHANDLER
BUCKET POSITIONING CYLINDER (CONT'D)
Assembly (Cont'd)
Figure 20-30-44
Figure 20-30-45

Carefully peen the lock ring over and into the nut [Figure
20-30-45].
V518 VersaHANDLER
V518 VersaHANDLER
EXTENSION CYLINDER Figure 20-40-3
Figure 20-40-1
Remove the two bolts (Item 1) [Figure 20-40-3] from the

top of the inner boom.
Installation: Tighten the bolts to 18 ft.-lbs. (24 Nm)

Remove the inner boom. (See Removal on Page 50-40- torque.
1.)
Figure 20-40-4

Remove the bolt (Item 1) [Figure 20-40-1] and washer
(Item 2) [Figure 20-40-1] from one side of the cylinder
pin.
Installation: Tighten the bolt to 188-210 ft.-lbs. (255-285

Nm) torque.
Figure 20-40-2
Remove the two hoses (Item 1) [Figure 20-40-4] from

the tubelines.
Remove the pin assembly (Item 1) [Figure 20-40-2] from

opposite side.
V518 VersaHANDLER
EXTENSION CYLINDER (CONT'D) Figure 20-40-7
Figure 20-40-5
Remove the harness (Item 1) [Figure 20-40-7] from the

connector housing (Item 2) [Figure 20-40-7].
NOTE: Mark the harness connector for correct

Remove the two hoses (Item 1) [Figure 20-40-5] from installation.
the bulkhead fittings.
Figure 20-40-8

Figure 20-40-6
Remove the tie straps (Item 1) [Figure 20-40-8] and pull

Remove the electrical connector (Item 1) [Figure 20-40- harness into the boom.
6] from the auxiliary valve.
V518 VersaHANDLER
Figure 20-40-9
With the extension cylinder assembly supported on a

work surface, remove the tie straps (Item 1) [Figure 20-
40-11].
For ease of installation temporarily tie a rope onto the two Figure 20-40-12
hoses (Item 1) [Figure 20-40-9] and wire harness (Item
2) [Figure 20-40-9].

Figure 20-40-10
Roll up the auxiliary harness (Item 1) [Figure 20-40-12]

and temporarily tie to the existing hose.
Remove the extension cylinder assembly from the boom

[Figure 20-40-10].
V518 VersaHANDLER
Figure 20-40-13
Remove the bolt (Item 1) [Figure 20-40-15] from the rod

end of the cylinder.
Lift and remove the tubelines from the top of the cylinder.
Loosen the tubeline clamp mounting bolts (Item 1)
[Figure 20-40-13]. Figure 20-40-16

NOTE: Mark the location of the tubelines for correct
assembly.
Figure 20-40-14
Remove the three bolts (Item 1) [Figure 20-40-16] and

bracket (Item 2) [Figure 20-40-16].
Slide the tubeline bracket assembly (Item 1) [Figure 20-

40-14] forward. Remove the four hoses (Item 2) [Figure
20-40-14] from the tubelines.
NOTE: Mark the hoses for correct assembly.
V518 VersaHANDLER
Figure 20-40-17
Lift and remove the extension cylinder from the tray

assembly [Figure 20-40-19].
Remove the three tubeline clamps (Item 1) [Figure 20-

40-17] and bracket (item 2) [Figure 20-40-17] from the
cylinder.

Figure 20-40-18
Remove the two tubelines (Item 1) [Figure 20-40-18]

from the block.
V518 VersaHANDLER
EXTENSION CYLINDER (CONT'D)
V518 VersaHANDLER
Disassembly
Figure 20-40-20
20-40-22].
Figure 20-40-23
Figure 20-40-21

Remove the head gland [Figure 20-40-23].
Remove the two fittings (Item 1) [Figure 20-40-21] and

relief valves (Item 2) [Figure 20-40-21].
V518 VersaHANDLER
Figure 20-40-24
Support the cylinder rod on a wood block [Figure 20-40-

26].
Figure 20-40-27
from the housing.

Figure 20-40-25
Loosen the set screw (Item 1) [Figure 20-40-27].

25].
V518 VersaHANDLER
Figure 20-40-28
Figure 20-40-31
Remove the piston assembly (Item 1) [Figure 20-40-28]

from the rod.

Figure 20-40-29

piston.

and the seal (Item 2) [Figure 20-40-29] from the piston.
V518 VersaHANDLER
Figure 20-40-32


the rod.

Figure 20-40-33
Remove the wiper (Item 1) [Figure 20-40-33] and seal

(Item 2) [Figure 20-40-33] from the head.
V518 VersaHANDLER
Assembly
Figure 20-40-35

cylinder rod.
Figure 20-40-38
compressed air.


installation.

backup ring (Item 2) [Figure 20-40-35] on the head
gland.
Figure 20-40-36
Install the wiper (Item 1) [Figure 20-40-36] and seal

(Item 2) [Figure 20-40-36].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-40-39
Install the piston (Item 1) [Figure 20-40-41] onto the rod

and hand tighten.
Figure 20-40-42
Install the expander O-ring (Item 1) [Figure 20-40-39].
Figure 20-40-40

Tighten the set screw (Item 1) [Figure 20-40-42].

seal (Item 2) [Figure 20-40-40] onto the piston.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-40-43
Using a punch seat the lock ring to keep the head gland
from turning [Figure 20-40-45].
Figure 20-40-46
Install the rod assembly (Item 1) [Figure 20-40-43] in to
the housing.

Figure 20-40-44
Install the two fittings (Item 1) [Figure 20-40-46] and two

relief valves (Item 2) [Figure 20-40-46].
V518 VersaHANDLER
V518 VersaHANDLER
TILT CYLINDER NOTE: Mark the hoses for correct installation.
Removal And Installation Figure 20-50-3
Figure 20-50-1
Install a lifting ring (Item 1) [Figure 20-50-3] and hoist to

the top of the cylinder.
Remove the quick tach assembly. (See Removal And
Installation on Page 50-90-1.) Figure 20-50-4

Raise the boom approximately 1-1/2 ft. and install a wood
block under the boom [Figure 20-50-1].
IMPORTANT
damage the system.
I-2003-0888
Figure 20-50-2
If equipped with secondary auxiliary hydraulics remove
the tubeline (Item 1) [Figure 20-50-4].

the tubelines.
V518 VersaHANDLER
TILT CYLINDER (CONT'D) Figure 20-50-7
Figure 20-50-5
Lower the cylinder from the boom and remove [Figure

20-50-7].
Remove the pivot pin retainer bolt (Item 1) [Figure 20-

50-5].

Figure 20-50-6
Remove the pivot pin [Figure 20-50-6].
V518 VersaHANDLER
TILT CYLINDER (CONT'D)
V518 VersaHANDLER
Disassembly
Figure 20-50-8
Remove the relief cartridge (Item 1) [Figure 20-50-10].
Figure 20-50-11
Figure 20-50-9

Remove the set screw (Item 1) [Figure 20-50-11].

the cylinder.
NOTE: Mark the location for correct assembly.
V518 VersaHANDLER
Figure 20-50-12

14].
Figure 20-50-15
Figure 20-50-13

Support the cylinder rod on a wood block [Figure 20-50-
15].
Remove the rod assembly (Item 1) [Figure 20-50-13].
V518 VersaHANDLER
Figure 20-50-16

Figure 20-50-19
Remove the lock ring (Item 1) [Figure 20-50-16].
Figure 20-50-17

Remove the expander ring (Item 1) [Figure 20-50-19].
Remove the piston (Item 1) [Figure 20-50-17] from the

rod.
V518 VersaHANDLER
Figure 20-50-20
Remove the two O-rings (Item 1) [Figure 20-50-22] from

the head.
Figure 20-50-23
inside of the piston.

Figure 20-50-21
Remove the seal (Item 1) [Figure 20-50-23] from the

piston.

the rod.
V518 VersaHANDLER
Figure 20-50-24
Remove the snap ring (Item 1) [Figure 20-50-26].
Figure 20-50-27
Figure 20-50-25

Remove the cushion sleeve (Item 1) [Figure 20-50-27]
from the head gland.
Remove the wiper (Item 1) [Figure 20-50-25] and seal

(Item 2) [Figure 20-50-25] from the head gland.
V518 VersaHANDLER
Assembly
Figure 20-50-28

(Item 2) [Figure 20-50-30] into the head gland.
Figure 20-50-31
compressed air.


installation.
Install the cushion sleeve (Item 1) [Figure 20-50-28] into

the head gland.
Figure 20-50-29
Install the expander O-ring (Item 1) [Figure 20-50-31].
Install the snap ring (Item 1) [Figure 20-50-29].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-50-32

rod.
Figure 20-50-35
Install the seal (Item 1) [Figure 20-50-32] into the piston.
Figure 20-50-33

Install the O-ring (Item 1) [Figure 20-50-35] inside the
piston.
Install the two O-rings (Item 1) [Figure 20-50-33] onto

the head gland.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-50-36
Clean off any old residue, and apply LOCTITE 242 or

equivalent to the threads on the rod [Figure 20-50-38].
Figure 20-50-39
onto the piston.

Figure 20-50-37
Install the piston (Item 1) [Figure 20-50-39] onto the rod.

seal (Item 2) [Figure 20-50-37].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-50-40
Figure 20-50-43
Install the lock ring (Item 1) [Figure 20-50-40].
Figure 20-50-41

Apply LOCTITE 242 or equivalent to the set screw (Item
1) [Figure 20-50-43].
Install the piston/rod assembly (Item 1) [Figure 20-50-

41] into the housing.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-50-44
Install the two hoses (Item 1) [Figure 20-50-46].
Install the set screw (Item 1) [Figure 20-50-44] and

tighten.

Figure 20-50-45
Install the relief cartridge (Item 1) [Figure 20-50-45].
V518 VersaHANDLER
V518 VersaHANDLER
STEERING CYLINDER Figure 20-60-3
Figure 20-60-1
Remove the tie rod end from the axle [Figure 20-60-3].
Figure 20-60-4
Remove the axle. (See Removal on Page 40-30-1.)
Loosen the tie rod jam nut (Item 1) [Figure 20-60-1],

mark the location of the nut for ease of assembly.
Installation: Tighten the jam nut to 185 ft.-lbs. (250 Nm)

torque.
Figure 20-60-2
Remove the tie rod ends (Item 1) [Figure 20-60-4] from

the steering cylinder.
Loosen and remove the tie rod nut (Item 1) [Figure 20-
60-2].
Installation: Tighten the nut to 160 ft.-lbs. (220 Nm)

torque.
V518 VersaHANDLER
STEERING CYLINDER (CONT'D) Figure 20-60-7
Figure 20-60-5
Remove the three bolts (Item 1) [Figure 20-60-7] from

the cylinder retainer plate.
Assembly: Apply Loctite 270 to the three bolts and

Remove both clamps (Item 1) [Figure 20-60-5] and tighten to 88 ft.-lbs. (120 Nm) torque.
remove the centering sensor (Item 2) [Figure 20-60-5]
from the cylinder. Figure 20-60-8

Figure 20-60-6
Remove the cylinder from the axle [Figure 20-60-8].
Remove the fitting (Item 1) [Figure 20-60-6] from the

cylinder.
V518 VersaHANDLER
STEERING CYLINDER (CONT'D)
V518 VersaHANDLER
Disassembly
Figure 20-60-9
Drive the head gland (Item 1) [Figure 20-60-11] inwards.

Remove the internal snap ring (Item 2) [Figure 20-60-
11].
Put the cylinder in a vise and remove the tie rod swivel Figure 20-60-12
ends (Item 1) [Figure 20-60-9] from the rod.

Figure 20-60-10
Remove the rod assembly from the housing [Figure 20-

60-12].
Place a drain pan under the cylinder, remove the fitting

(Item 1) [Figure 20-60-10] and snap ring (Item 2) [Figure
20-60-10] from the cylinder.
NOTE: Rotate the cylinder in the vise so the fitting

port (Item 3) [Figure 20-60-10] is positioned
down to allow the oil to drain into the pan.
V518 VersaHANDLER
Figure 20-60-13
Remove the wiper seal (Item 1) [Figure 20-60-15].
Figure 20-60-16
Remove the head assembly (Item 1) [Figure 20-60-13]

and spacer (Item 2) [Figure 20-60-13] from the rod.

Figure 20-60-14
Remove the backup ring (Item 1) [Figure 20-60-16] and

rod seal (Item 2) [Figure 20-60-16] from the head gland.
Remove the outer seal (Item 1) [Figure 20-60-14] from

the head.
V518 VersaHANDLER
Figure 20-60-17
Figure 20-60-20
Remove the wear ring (Item 1) [Figure 20-60-17] and

magnetic sensor ring (Item 2) [Figure 20-60-17] from the
piston.

Figure 20-60-18
Remove the wiper seal (Item 1) [Figure 20-60-20] from

the housing.
Remove the seal (Item 1) [Figure 20-60-18].
V518 VersaHANDLER
Figure 20-60-21

damage. Replace any damaged parts [Figure 20-60-22]
& [Figure 20-60-23].
Remove the backup ring (Item 1) [Figure 20-60-21] and Lubricate all O-rings and seals with hydraulic oil during
rod seal (Item 2) [Figure 20-60-21] from the housing. installation.

Assembly Figure 20-60-24
Use the following tools to assembly the cylinder:
MEL1396-Seal Installation Tool

MEL1033-Rod Seal Installation Tool
compressed air.
Figure 20-60-22
Install the rod seal on the rod seal installation tool

[Figure 20-60-24].
NOTE: During installation the O-ring side of the seal

must be toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 20-

60-24].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-60-25

onto the piston.
NOTE: The expander O-ring (Item 1) [Figure 20-60-27]

Install the rod seal in the housing [Figure 20-60-25]. is installed in the piston groove closest to the
machined end of the cylinder rod.
Figure 20-60-26

Figure 20-60-28
Install the backup ring (Item 1) [Figure 20-60-26] and

wiper seal (Item 2) [Figure 20-60-26] into the housing. Install a new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-60-28].
Allow the seal to stretch for 30 seconds before installing it

on the piston.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-60-29
Install a new seal into the head gland [Figure 20-60-31].
Figure 20-60-32
Install the seal (Item 1) [Figure 20-60-29] onto the

piston, over the expander O-ring.

Figure 20-60-30
Install a new backup ring (Item 1) [Figure 20-60-32] and

wiper seal (Item 2) [Figure 20-60-32] into the head
gland.
Install the magnetic sensor ring (Item 1) [Figure 20-60-

30] and wear ring (Item 2) [Figure 20-60-30].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-60-33
Lubricate the piston and seal and install into the housing
[Figure 20-60-35].
Figure 20-60-36
Install a new outer seal (Item 1) [Figure 20-60-33] onto
the head gland.

Figure 20-60-34
Lubricate and install the head gland into the housing and
install the internal snap ring (Item 1) [Figure 20-60-36].
Install the spacer (Item 1) [Figure 20-60-34] and head

(Item 2) [Figure 20-60-34] onto the machined end (Item
3) [Figure 20-60-34] of the cylinder rod.
V518 VersaHANDLER
STEERING CYLINDER (CONT'D)
Assembly (Cont'd)
Figure 20-60-37
Pull the cylinder rod out until you are able to install the
snap ring (Item 1) [Figure 20-60-37] onto the groove in
the head gland.

Install the fitting (Item 2) [Figure 20-60-37].
Figure 20-60-38
Install the tie rod swivel ends (Item 1) [Figure 20-60-38]

onto the cylinder rod. Tighten to 406 ft.-lbs. (300 Nm)
torque.
V518 VersaHANDLER
V518 VersaHANDLER
DRIVE BOX
V518 VersaHANDLER
DRIVE BOX (CONT'D) Figure 20-70-3
Disassembly
Remove the front axle. (See Removal on Page 40-30-1.)
Remove the drive motor. (See Removal And Installation

on Page 30-30-1.)
Figure 20-70-1
Remove the eight cover mounting bolts (Item 1) [Figure

20-70-3].
Figure 20-70-4

Mark the mounting flange and housing for correct
assembly. Remove the eight mounting bolts (Item 1)
[Figure 20-70-1]. Remove the mounting flange.
Figure 20-70-2
Install two guide bolts (Item 1) [Figure 20-70-4] to

support the housing cover when removing it from the
dowels.
Place a drain pan under the drive box and remove the
hose (Item 1) [Figure 20-70-2].
V518 VersaHANDLER
Figure 20-70-5
With the cover supported on a work surface, remove the

snap ring (Item 1) [Figure 20-70-6].
Figure 20-70-7

Remove the cover from the rear housing [Figure 20-70-
5]. Remove the bearing from the shaft [Figure 20-70-7].
Remove the two guide bolts (Item 1) [Figure 20-70-5].
V518 VersaHANDLER
Figure 20-70-8

shaft.
Figure 20-70-11
Remove the gear (Item 1) [Figure 20-70-8] from the
shaft.

Figure 20-70-9
Remove the shaft seal (Item 1) [Figure 20-70-11] from

the housing.
Remove the shaft from the bearing and housing [Figure

20-70-9].
V518 VersaHANDLER
Figure 20-70-12
Install two guide bolts (Item 1) [Figure 20-70-14] and

remove the six remaining mounting bolts.
Remove the bearing from the housing [Figure 20-70-12].
Figure 20-70-13

Remove two of the rear housing mounting bolt (Item 1)
[Figure 20-70-13].
V518 VersaHANDLER
Figure 20-70-15
With the cover supported on a work surface, remove the

gear/bearing assembly (Item 1) [Figure 20-70-16].
Figure 20-70-17

Remove the rear cover from the axle housing [Figure 20-
70-15]. Remove the snap ring (Item 1) [Figure 20-70-17] from
the bearing.
V518 VersaHANDLER
DRIVE BOX (CONT'D) Inspection
Disassembly (Cont'd) Figure 20-70-20
Figure 20-70-18
Inspect the gears for cracked or damaged teeth. Replace

any damaged parts [Figure 20-70-20].
Using a press, remove both bearings from the gear
[Figure 20-70-18]. Figure 20-70-21

Figure 20-70-19
Inspect the splines on the shaft for wear or damaged.

Replace if worn or damaged [Figure 20-70-21].
rear housing.
V518 VersaHANDLER
Assembly
IMPORTANT
damage the system.
I-2003-0888
Figure 20-70-22
Figure 20-70-25

Figure 20-70-23
Clean all sealant residue from the mounting surfaces
(Item 1) [Figure 20-70-24] & [Figure 20-70-25].
Clean all LOCTITE residue from the mounting flange bolt

holes (Item 2) [Figure 20-70-25].
Clean all LOCTITE from the mounting bolts.
Prior to assembly
Clean all sealant residue from the mating surfaces (Item
1) [Figure 20-70-22] & [Figure 20-70-23] on both
housings.
Clean all LOCTITE residue from mounting plate bolt
holes (Item 2) [Figure 20-70-23].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-70-26
Install the snap ring (Item 1) [Figure 20-70-28] in the

groove in the bearing.
Figure 20-70-29
Install the plug into the rear housing [Figure 20-70-26].
Figure 20-70-27

Apply a small amount of LOCTITE 609 or equivalent into
the bearing seat in the rear housing [Figure 20-70-29].
Install both bearings (Item 1) [Figure 20-70-27] onto the

gear.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-70-30
Install the gear/bearing assembly (Item 1) [Figure 20-70-

30] into the rear housing.

Figure 20-70-31
Install the two guide bolts (Item 1) [Figure 20-70-32] into

the axle mounting flange.
Install the rear cover onto the axle mounting flange

[Figure 20-70-32].
Apply a 3 mm bead of LOCTITE 510 gasket eliminator

(or equivalent) to the axle mounting flange (Item 1)
[Figure 20-70-31] in the pattern shown.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-70-33
Install the seal (Item 1) [Figure 20-70-35] into the

housing.
Figure 20-70-36
Apply LOCTITE 270 (or equivalent) to the six mounting
bolts (Item 1) [Figure 20-70-33] and install. Tighten to 88
ft.-lbs. (120 Nm) torque.

Figure 20-70-34
Install the shaft (Item 1) [Figure 20-70-36] through the

seal (Item 2) [Figure 20-70-36] and support the housing
with blocks.
Apply LOCTITE 270 (or equivalent) to the two remaining

mounting bolts (Item 1) [Figure 20-70-34]. Install and
tighten the bolts to 88 ft.-lbs. (120 Nm) torque.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-70-37
Install the gear (Item 1) [Figure 20-70-39] onto the shaft.
Figure 20-70-40
Apply a small amount of LOCTITE 609 (or equivalent)

into the bearing seat [Figure 20-70-37].

Figure 20-70-38
Install the bearing (Item 1) [Figure 20-70-40] onto the

shaft.
Install the bearing onto the shaft until it is fully seated in

the housing [Figure 20-70-38].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-70-41
Install the snap ring (Item 1) [Figure 20-70-41] onto the

shaft.

Figure 20-70-42
Install two guide bolts (Item 1) [Figure 20-70-43].
Install the cover [Figure 20-70-43].
NOTE: The splines and gears must be aligned to fully

install the cover onto the dowels.
Apply a 3 mm bead of LOCTITE 510 Gasket Eliminator

(or equivalent) to the rear housing surface (Item 1)
[Figure 20-70-42] in the pattern shown.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-70-44
Reconnect the hose (Item 1) [Figure 20-70-46] and

tighten.
Figure 20-70-47
Install six cover bolts (Item 1) [Figure 20-70-44] and
remove the guide bolts (Item 2) [Figure 20-70-44].

Figure 20-70-45
Install the mounting flange (Item 1) [Figure 20-70-47]

and tighten the eight mounting bolts (Item 2) [Figure 20-
70-47] to 44 ft.-lbs. (60 Nm) torque.
Install the two remaining cover bolts (Item 1) [Figure 20-

70-45]. Tighten all bolts to 44 ft.-lbs. (60 Nm) torque.
V518 VersaHANDLER
QUICK TACH CYLINDER Figure 20-90-3
Figure 20-90-1
Remove the bolt (Item 1) [Figure 20-90-3] from each

side of the cylinder.
Figure 20-90-4
Rotate the quick tach forward and place on wood blocks
[Figure 20-90-1].

Figure 20-90-2
Remove the end bushing (Item 1) [Figure 20-90-4].

the cylinder.
NOTE: Mark the hoses for correct assembly.
V518 VersaHANDLER
QUICK TACH CYLINDER (CONT'D) Figure 20-90-7
Figure 20-90-5
Remove the roll pin (Item 1) [Figure 20-90-7] and

remove the extension rod (Item 2) [Figure 20-90-7] from
the cylinder rod.
Remove the roll pin (Item 1) [Figure 20-90-5]. Figure 20-90-8
Figure 20-90-6

Remove the cylinder (Item 1) [Figure 20-90-8].
Remove the washer (Item 1) [Figure 20-90-6] and spring

(Item 2) [Figure 20-90-6] from the cylinder rod extension.
V518 VersaHANDLER
QUICK TACH CYLINDER (CONT'D)
V518 VersaHANDLER
Disassembly
Figure 20-90-9
Figure 20-90-12
Place the cylinder in a vise [Figure 20-90-9].
Figure 20-90-10

from the housing.
Remove the two fittings (Item 1) [Figure 20-90-10].
V518 VersaHANDLER
Figure 20-90-13
Remove the head (Item 1) [Figure 20-90-15] from each

rod.
Figure 20-90-16
Loosen the second head gland (Item 1) [Figure 20-90-
13] on the opposite side.

Figure 20-90-14
Remove the O-rings (Item 1) [Figure 20-90-16] from

each head gland.

from the housing.
V518 VersaHANDLER
Figure 20-90-17
Remove the expander O-ring (Item 1) [Figure 20-90-19]

from each piston.
Remove the seal (Item 1) [Figure 20-90-17] and wiper

(Item 2) [Figure 20-90-17] from each head gland.

Figure 20-90-18
Remove the wear ring (Item 1) [Figure 20-90-18] and

seal (Item 2) [Figure 20-90-18] from each piston.
V518 VersaHANDLER
Assembly

compressed air.


installation.
Figure 20-90-20

(Item 2) [Figure 20-90-22] in each head gland.

Figure 20-90-23

Install a new expander O-ring (Item 1) [Figure 20-90-20]
on each piston.
Figure 20-90-21
Install the two O-rings (Item 1) [Figure 20-90-23] on

each head gland.
Install a new seal (Item 1) [Figure 20-90-21] and wear

ring (Item 2) [Figure 20-90-21] on each piston.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-90-24
Tighten both head glands [Figure 20-90-26].
Install each head gland (Item 1) [Figure 20-90-24] onto

the rod.

Figure 20-90-25
Install each rod assembly (Item 1) [Figure 20-90-25] into

the housing.
V518 VersaHANDLER
STEERING MODE VALVE BLOCK

IMPORTANT
Figure 20-110-1
damage the system.
I-2003-0888
Figure 20-110-3
Remove the Pilot Pressure Block.
Remove each retainer screw (Item 1) [Figure 20-110-1]

from the two solenoids.
Remove the wire connectors from the solenoids.
NOTE: Mark the location of the wire connectors for

ease of assembly. Remove the two hoses (Item 1) [Figure 20-110-3] and
tubelines (Item 2) [Figure 20-110-3].
Figure 20-110-2
NOTE: Mark the location of the tubelines and hoses.
Figure 20-110-4
Remove the four plastic caps (Item 1) [Figure 20-110-2]

and remove the four solenoid mounting bolts.
NOTE: Mark the location of the solenoids on the Remove the four mounting bolts (Item 1) [Figure 20-110-
block. 4]. Remove the block.
Remove the solenoids from the block.
V518 VersaHANDLER
STEERING MODE VALVE BLOCK (CONT'D)
V518 VersaHANDLER
STEERING MODE VALVE BLOCK (CONT'D)
Disassembly
IMPORTANT
Mark the location of the solenoids to the block for correct
assembly. When repairing hydrostatic and hydraulic systems,
Figure 20-110-5 parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
Figure 20-110-7

Remove and discard the four O-rings (Item 1) [Figure
20-110-5] from the housing.
Figure 20-110-6
Remove each coil (Item 1) [Figure 20-110-7] from the

solenoid shaft.
Figure 20-110-8
Remove the nuts (Item 1) [Figure 20-110-6] from each

end of the solenoid.
NOTE: Mark the location of the solenoid.
Remove and discard the O-ring (Item 1) [Figure 20-110-

8] from the coil.
V518 VersaHANDLER
STEERING MODE VALVE BLOCK (CONT'D) Figure 20-110-11
Figure 20-110-9

11] from the housing.
Figure 20-110-12
Remove the solenoid shaft (Item 1) [Figure 20-110-9],
pin (Item 2) [Figure 20-110-9], spring (Item 3) [Figure
20-110-9] and spring retainer (Item 4) [Figure 20-110-9]

from the housing.
Figure 20-110-10
Carefully remove the spool (Item 1) [Figure 20-110-12]

from the housing.
Inspect the spool for wear. Replace as needed.

10] from the solenoid shaft.
V518 VersaHANDLER
STEERING MODE VALVE BLOCK (CONT'D) Figure 20-110-15
Solenoid Testing
Figure 20-110-13
Install a new O-ring (Item 1) [Figure 20-110-15] into the

housing.
Figure 20-110-16
Use a circuit tester, touch one probe to the prong and the
other probe to the other prong [Figure 20-110-13], there
must be continuity. If there is no continuity, the solenoid is

bad.
Assembly
Clean all components with solvent and dry with

compressed air.
Apply oil to all new O-rings before installation.
Figure 20-110-14
Install a new O-ring (Item 1) [Figure 20-110-16] onto the

solenoid shaft.
Carefully install the spool (Item 1) [Figure 20-110-14].
V518 VersaHANDLER
STEERING MODE BLOCK (CONT'D) Figure 20-110-19
Assembly (Cont'd)
Figure 20-110-17
Install each coil (Item 1) [Figure 20-110-19] onto the

solenoid shaft, install and tighten the nuts (Item 2)
[Figure 20-110-19].
Install the spring retainer (Item 1) [Figure 20-110-17], Figure 20-110-20

spring (Item 2) [Figure 20-110-17], pin (Item 3) [Figure
20-110-17] and solenoid shaft (Item 4) [Figure 20-110-

17] into the housing.
Figure 20-110-18
Install new O-rings (Item 1) [Figure 20-110-20] onto the

solenoid housing.

coil.
V518 VersaHANDLER
BRAKE VALVE Figure 20-120-2
Figure 20-120-1
Remove the two Allen head screws (Item 1) [Figure 20-

120-2] and remove the brake valve.
Remove the dash cover/column cover. (See Removal

And Installation on Page 60-100-1.)

Remove the three hoses (Item 1) [Figure 20-120-1] from
the brake valve.
NOTE: Mark hoses for correct assembly.
IMPORTANT
damage the system.
I-2003-0888
V518 VersaHANDLER
162 of 724
GEAR PUMP Remove the hose (Item 1) [Figure 20-130-2] and
tubeline (Item 2) [Figure 20-130-2] from the pump.
Figure 20-130-3
IMPORTANT
damage the system.
I-2003-0888
Figure 20-130-1
Remove the four bolts (Item 1) [Figure 20-130-3] from

the upper and lower manifold block (Item 2) [Figure 20-
130-3]. Remove both manifold blocks.
Installation: Apply LOCTITE 242 (or equivalent) onto the

mounting bolts and tighten to 18 ft.-lbs. (25 Nm) torque.
Figure 20-130-4
Drain the hydraulic reservoir.
Remove the operator cab. (See Removal And Installation

on Page 50-10-1.)

the flow divider valve.
Figure 20-130-2
Remove both mounting bolts (Item 1) [Figure 20-130-4].
Installation: Tighten the mounting bolts to 52 to 59 ft.-

lbs. (50-80 Nm) torque.
Remove the gear pump.
V518 VersaHANDLER
GEAR PUMP (CONT'D)
V518 VersaHANDLER
GEAR PUMP (CONT'D) Figure 20-130-7
Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
Figure 20-130-5
Remove the flow divider from the housing [Figure 20-
130-7].
Figure 20-130-8

Mark the pump housing for correct assembly and remove
the fittings (Item 1) [Figure 20-130-5].
Figure 20-130-6
Remove the fitting (Item 1) [Figure 20-130-8], O-ring
(Item 2) [Figure 20-130-8], spring (Item 3) [Figure 20-
130-8], spring seat (Item 4) [Figure 20-130-8] and spool
(Item 5) [Figure 20-130-8] from the housing (Item 6)
[Figure 20-130-8].
NOTE: Always use new O-rings.
Remove the four bolts (Item 1) [Figure 20-130-6].
Assembly: Tighten the bolts to 25 ft.-lbs. (33 Nm) torque.
V518 VersaHANDLER
Disassembly And Assembly (Cont'd)
Figure 20-130-9
To remove the orifice assembly (Item 1) [Figure 20-130-

11] from the spool, a holding fixture will have to be made
from a 0.750 inch thick x 1.500 inches wide x 2.0 inches
long (19 mm) thick x 38 mm wide x 50 mm long) piece of
Remove the plug (Item 1) [Figure 20-130-9] and O-ring hardwood. Drill a 0.550 inch (14 mm) hole in the center of
(Item 2) [Figure 20-130-9] from the housing. the hardwood block. Cut the block lengthwise [Figure
20-130-10].

Figure 20-130-10
Place both halves of the hardwood block around the
spool. Clamp the blocks in a vise [Figure 20-130-11].
NOTE: Do not use anything other than hardwood

blocks to grip the spool, or the spool will be
damaged.
Figure 20-130-12
Remove the screen (Item 1) [Figure 20-130-12] from the

orifice (Item 2) [Figure 20-130-12] and clean.
V518 VersaHANDLER
Figure 20-130-13
Remove both O-rings (Item 1) [Figure 20-130-15] from

the housing.
Figure 20-130-16
Remove the housing/gear assembly (Item 1) [Figure 20-
130-13] from the main housing.

Figure 20-130-14
Remove the backup ring (Item 1) [Figure 20-130-16] and

seal ring (Item 2) [Figure 20-130-16] from the gear
holder.
Remove the housing (Item 1) [Figure 20-130-14] from Assembly: The seal ring (Item 2) [Figure 20-130-16] is
the gear assembly (Item 2) [Figure 20-130-14]. installed onto the gear holder first followed by the backup
ring.
Assembly: The position of the small opening (Item 3)
[Figure 20-130-14] on the gear holders will point towards
the port (Item 4) [Figure 20-130-14] on the housing.
V518 VersaHANDLER
Figure 20-130-17
Turn the housing over and remove the mount plate

[Figure 20-130-19].
Figure 20-130-20
17] from the flange.

Figure 20-130-18

drive shaft (Item 2) [Figure 20-130-18].
Assembly: Tighten the bolts to 25 ft.-lbs. (33 Nm) torque.
V518 VersaHANDLER
Figure 20-130-21
Remove the two thrust plates (Item 1) [Figure 20-130-

23], seal ring (Item 2) [Figure 20-130-23] and backup
ring (Item 3) [Figure 20-130-23] from the gears.
Remove the shaft seal (Item 1) [Figure 20-130-21]. Assembly: The seal ring (Item 2) [Figure 20-130-23] will
be installed on the thrust plate (Item 1) [Figure 20-130-
Figure 20-130-22 23] first followed by the backup ring (Item 3) [Figure 20-

130-23].
Remove the O-ring (Item 1) [Figure 20-130-22] and gear

assembly (Item 2) [Figure 20-130-22] from the housing.
Assembly: The position of the V portion (Item 3) [Figure

20-130-22] on the thrust plate must point towards the
larger port (Item 4) [Figure 20-130-22] on the housing.
V518 VersaHANDLER
V518 VersaHANDLER
FAN MOTOR Figure 20-140-3
IMPORTANT
damage the system.
I-2003-0888
Figure 20-140-1
Remove the lower hose (Item 1) [Figure 20-140-3] from
the cooling fan motor.
Figure 20-140-4

Open the hood.
Remove the three mounting bolts (item 1) [Figure 20-

140-1] and remove the safety shield.
Remove the upper mounting bolt (Item 1) [Figure 20-
Figure 20-140-2 140-4] and lower mounting bolt (Item 2) [Figure 20-140-
4] from both sides of the cooling fan mounting bracket.
Remove the cooling fan assembly and place on a work

surface.
Remove the upper hose (Item 1) [Figure 20-140-2] from

the cooling fan motor.
V518 VersaHANDLER
FAN MOTOR (CONT'D) Figure 20-140-7
Figure 20-140-5
Remove the fan blade mounting flange from the shaft

[Figure 20-140-7].
Figure 20-140-8
Remove the four mounting bolts (Item 1) [Figure 20-140-
5]. Remove the fan blade assembly from the motor.

Figure 20-140-6
Remove the four nuts (Item 1) [Figure 20-140-8].
Remove the mounting bracket from the motor.
Remove the nut (Item 1) [Figure 20-140-6] from fan

motor shaft.
V518 VersaHANDLER
FAN MOTOR (CONT'D)
V518 VersaHANDLER
Disassembly and Assembly
IMPORTANT
damage the system.
I-2003-0888
Figure 20-140-9
Remove the end cap (Item 1) [Figure 20-140-10] from
the pump housing.
Figure 20-140-11

Mark the pump housing for proper assembly [Figure 20-
140-9].
NOTE: The pump may appear different but the

procedure is the same. Remove and discard the O-ring (Item 1) [Figure 20-140-
11].
Remove the four nuts (Item 1) [Figure 20-140-9] from
the pump stud bolts. Assembly: Always use new O-rings.
Assembly: Tighten the bolt to 25 ft.-lbs. (33 Nm) torque.
NOTE: If the long studs are loose in the pump

mounting flange, replace the assembly or
remove the studs, clean the threads, apply
LOCTITE to the threads. Install the studs in
the mounting flange and let set for 10-15
minutes before assembling the pump. If the
studs turn, the correct torque can not be
applied to the nuts when the pump is
assembled.
V518 VersaHANDLER
Figure 20-140-12
Remove the thrust plate (Item 1) [Figure 20-140-14].
Assembly: The thrust plate opening (Item 2) [Figure 20-

140-14] must be installed toward the pressure side of the
Remove the spacers and O-rings (Item 1) [Figure 20- pump.
140-12] from the pump.
Figure 20-140-15

Figure 20-140-13
Remove the pump housing (Item 1) [Figure 20-140-15]

from the end plate (Item 2) [Figure 20-140-15].
spacer (Item 2) [Figure 20-140-13] and discard.
Assembly: Always use new O-rings.
V518 VersaHANDLER
Figure 20-140-16
Remove the gears (Item 1) [Figure 20-140-17] from the

bearing housings (Item 2) [Figure 20-140-17].
Inspect the gears and bearing housings for wear. If parts

Remove the gears and holders (Item 1) [Figure 20-140- are worn replace the complete pump.
16] from the pump housing (Item 2) [Figure 20-140-16].
V518 VersaHANDLER
HYDRAULIC RESERVOIR Figure 20-150-3
Figure 20-150-1
Remove the two filter mounting bolts (Item 1) [Figure 20-

150-3]. Lower the filter.
Figure 20-150-4
Remove the engine/hydrostat assembly. (See Removal

Remove the air cleaner housing. (See Housing Removal
Remove the hose (Item 1) [Figure 20-150-1] from the

hydraulic reservoir.
Figure 20-150-2
Remove the reservoir mounting bolt (Item 1) [Figure 20-

150-4].
Remove the reservoir.
Remove the hydraulic tank breather hose (Item 1)

[Figure 20-150-2].
V518 VersaHANDLER
178 of 724
STEERING VALVE Figure 20-160-2
IMPORTANT
damage the system.
I-2003-0888
Figure 20-160-1
remove the steering valve.

Remove the five hoses (Item 1) [Figure 20-160-1] from

the steering valve.
V518 VersaHANDLER
STEERING VALVE (CONT'D)
V518 VersaHANDLER
STEERING VALVE (CONT'D) Figure 20-160-5
Disassembly
IMPORTANT
damage the system.
I-2003-0888
Figure 20-160-3
Remove the seven end cap bolts (Item 1) [Figure 20-
160-5].
Figure 20-160-6

Mark the housing for correct assembly [Figure 20-160-
3].
Figure 20-160-4
Remove the end cap (Item 1) [Figure 20-160-6].
Remove the fittings (Item 1) [Figure 20-160-4] from the

steering valve [Figure 20-160-4].
V518 VersaHANDLER
Figure 20-160-7
Remove the geroler assembly (Item 1) [Figure 20-160-

9].
Figure 20-160-10
7].

Figure 20-160-8

valve plate.
Remove the spacer gear (Item 1) [Figure 20-160-8].
V518 VersaHANDLER
Figure 20-160-11

housing.
Figure 20-160-14
Remove the drive shaft (Item 1) [Figure 20-160-11].
Figure 20-160-12

Mark the location of the three ports (Item 1) [Figure 20-
160-14] for correct assembly.
Remove the valve plate (Item 1) [Figure 20-160-12].
V518 VersaHANDLER
Figure 20-160-15
Remove the seal retainer ring (Item 1) [Figure 20-160-

17].
Figure 20-160-18
Remove the three pins (Item 1) [Figure 20-160-15] from
each port.

NOTE: Record the location of each pin for correct
assembly.
Figure 20-160-16
Remove the seal housing (Item 1) [Figure 20-160-18] by

prying upward.
Remove the three check balls (Item 1) [Figure 20-160-

16] from each port.
NOTE: Record the location of each check ball for

correct assembly.
V518 VersaHANDLER
Figure 20-160-19

Figure 20-160-22
Remove and discard the seal (Item 1) [Figure 20-160-
19].

Figure 20-160-20
Remove the two thrust washers (Item 1) [Figure 20-160-

22] and thrust bearing (Item 2) [Figure 20-160-22] from
the spool.
Remove and discard the quad ring seal (Item 1) [Figure

20-160-20].
V518 VersaHANDLER
Figure 20-160-23
Remove the spool (Item 1) [Figure 20-160-25] from the

sleeve (Item 2) [Figure 20-160-25].
NOTE: If the spool and sleeve will not slide or rotate

Remove the control spool/sleeve assembly (Item 1) within each other freely or in the housing,
[Figure 20-160-23] from the metering end of the housing they must be replaced.
(Item 2) [Figure 20-160-23].

Figure 20-160-26
NOTE: When removing the spool, keep the drive pin
(Item 3) [Figure 20-160-23] horizontal. If the
pin becomes vertical, it may drop from the
spool and get caught in an oil passage inside
the housing.
Figure 20-160-24
Remove the springs (Item 1) [Figure 20-160-26] from the

spool.
NOTE: There are six springs positioned three per

side and back to back.
Remove the drive pin (Item 1) [Figure 20-160-24].
V518 VersaHANDLER
STEERING VALVE (CONT'D) Inspection
Disassembly (Cont'd) Figure 20-160-29
Figure 20-160-27
Inspect the spool (Item 1) [Figure 20-160-29] and sleeve

(Item 2) [Figure 20-160-29] for any damage or wear.
Remove the two check valve plugs (Item 1) [Figure 20- Replace as needed.
160-27], springs (Item 2) [Figure 20-160-27], ball seat
(Item 3) [Figure 20-160-27] and check ball (Item 4) Figure 20-160-30

[Figure 20-160-27] from the housing.
NOTE: Record the location of each check ball

assembly for correct assembly.
Figure 20-160-28
Inspect the drive shaft (Item 1) [Figure 20-160-30] for

damage or wear.
Remove the check valve plug (Item 1) [Figure 20-160-

28], spring (Item 2) [Figure 20-160-28] and poppet (Item
3) [Figure 20-160-28] from the housing.
NOTE: Record the location of the port for correct

assembly.
V518 VersaHANDLER
Assembly
IMPORTANT
damage the system.
I-2003-0888
Figure 20-160-31
Install the check ball (Item 1) [Figure 20-160-33], ball
seat (Item 2) [Figure 20-160-33], spring (Item 3) [Figure
20-160-33] and plug (Item 4) [Figure 20-160-33] into the
correct port marked earlier.
Turn each of the port plugs (Item 3) [Figure 20-160-32]

and (Item 4) [Figure 20-160-33] in the housing until they

are tight, then back each of them out 1-1/2 turns.
Figure 20-160-34
Prior to assembly, clean and lightly oil all parts.
Install a new O-ring (Item 1) [Figure 20-160-31] on the

three check valve plugs.
Figure 20-160-32
Install the springs (Item 1) [Figure 20-160-34] into the

spool.
NOTE: There are six springs and should be

positioned three per side and back to back.
Install the poppet (Item 1) [Figure 20-160-32], spring

(Item 2) [Figure 20-160-32] and plug (Item 3) [Figure
20-160-32] into the correct port marked earlier.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-160-35
Install the control spool/sleeve assembly (Item 1) [Figure

20-160-37] into the metering end of the housing (Item 2)
[Figure 20-160-37].
Install the spool (Item 1) [Figure 20-160-35] into the NOTE: When installing the spool assembly keep the
sleeve (Item 2) [Figure 20-160-35]. drive pin (Item 3) [Figure 20-160-37]
horizontal. If the pin becomes vertical it may

NOTE: The spool should turn freely inside the sleeve. drop from the spool and get caught in an oil
passage inside the housing.
Figure 20-160-36
Figure 20-160-38
Install the drive pin (Item 1) [Figure 20-160-36].

Install the two thrust washers (Item 1) [Figure 20-160-
38] and thrust bearing (Item 2) [Figure 20-160-38] on the
spool.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-160-39
Install a new seal (Item 1) [Figure 20-160-41].
Figure 20-160-42

housing.

Figure 20-160-40
Install the seal housing (Item 1) [Figure 20-160-42].
Install a new quad ring seal (Item 1) [Figure 20-160-40].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-160-43
Install the three pins (Item 1) [Figure 20-160-45] in their

proper port (marked earlier).
Figure 20-160-46
Install the seal retainer ring (Item 1) [Figure 20-160-43].
Figure 20-160-44

housing groove.
Install the three check balls (Item 1) [Figure 20-160-44]

in their proper port (marked earlier).
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-160-47

valve plate groove.
Figure 20-160-50
Align and install the 14 hole valve plate (Item 1) [Figure
20-160-47] on the housing.

Figure 20-160-48
Install the geroler assembly (Item 1) [Figure 20-160-50]

onto the valve plate and drive shaft.
Align the groove (Item 1) [Figure 20-160-48] in the drive

shaft with the drive pin (Item 2) [Figure 20-160-48] and
install the drive shaft.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 20-160-51
Install the end cap using the seven bolts (Item 1) [Figure
20-160-53]. Tighten to 8-13 ft.-lbs. (5,9-9,5 Nm) torque in
a criss cross pattern.
Install the spacer gear (Item 1) [Figure 20-160-51]. Figure 20-160-54
Figure 20-160-52

Install the fittings (Item 1) [Figure 20-160-54] as shown.

geroler plate groove.
V518 VersaHANDLER
V518 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367011001- Figure 20-170-2
367012500)
IMPORTANT
damage the system.
I-2003-0888
Figure 20-170-1 Remove the hose (Item 1) [Figure 20-170-2] from the
lower left front of the control valve.
Figure 20-170-3

Remove the rear cover.
Remove the ten hoses from the top of the control valve
[Figure 20-170-1].
Remove the four connectors (Item 1) by sliding the lock
NOTE: Mark the hoses for correct installation. (Item 2) [Figure 20-170-3] forward and lifting on the
connector.
NOTE: Mark the location of the connectors for

correct assembly.
V518 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367011001-
367012500) (CONT'D)
Figure 20-170-4
Remove the hose retainer bracket and hose (Item 1)

[Figure 20-170-4] from the bottom of the control valve

mount plate.
Figure 20-170-5
Remove the three valve mounting bolts (Item 1) [Figure

20-170-5].
Remove the valve assembly.
V518 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367011001-367012500) (CONT'D)
V518 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367011001- Assembly: Tighten the thru-bolt nuts (Item 1) [Figure
367012500) (CONT'D) 20-170-7] to 16-19 ft.-lbs. (22-26 Nm) torque.
Disassembly And Assembly Figure 20-170-8
IMPORTANT
damage the system.
I-2003-0888
Figure 20-170-6
Remove the end housing (Item 1) [Figure 20-170-8] from

the control valve.
Figure 20-170-9

Mark all of the sections of the control valve for proper
installation [Figure 20-170-6].
Remove all hydraulic fittings.
Figure 20-170-7
Remove the five O-rings (Item 1) [Figure 20-170-9] from

the end housing.
Remove the thru-bolt nuts (Item 1) [Figure 20-170-7]

and washers.
V518 VersaHANDLER
367012500) (CONT'D)
Auxiliary Valve Section
Figure 20-170-10
Remove the four controller mounting screws (Item 1)

[Figure 20-170-12].
Assembly: Tighten the screws to 70 in.-lbs. (0.8 Nm)

torque.
Remove the auxiliary valve section (Item 1) [Figure 20-
170-10]. Remove the controller from the auxiliary valve section.

Figure 20-170-11 Figure 20-170-13
Remove the seven O-rings (Item 1) [Figure 20-170-11] Remove the five O-rings (Item 1) [Figure 20-170-13]
from the valve section. from the controller.
V518 VersaHANDLER
367012500) (CONT'D)
Auxiliary Valve Section (Cont'd)
Figure 20-170-14
Carefully remove the filter (Item 1) [Figure 20-170-16]

from the controller.
Figure 20-170-17
Remove the three orifices (Item 1) [Figure 20-170-14]


NOTE: Mark the location of the orifices for correct
assembly.
Figure 20-170-15
Clean and inspect the filter (Item 1) [Figure 20-170-17]

for wear or damage.
Check the O-ring (Item 1) [Figure 20-170-15] on each

orifice removed, and replace as needed.
V518 VersaHANDLER
367012500) (CONT'D)
Figure 20-170-18
Remove the three O-rings (Item 1) [Figure 20-170-20]

from the control box.
Figure 20-170-21
Remove the four mounting screws (Item 1) [Figure 20-

170-18] from the control box.

torque.
Figure 20-170-19
Remove the spool assembly (Item 1) [Figure 20-170-21]

from the auxiliary valve section.
Remove the control box assembly (Item 1) [Figure 20-

170-19] from the auxiliary valve section.
V518 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367011001- Assembly: Tighten the actuator to 6 ft.-lbs. (0.8 Nm)
367012500) (CONT'D) torque.
Auxiliary Valve Section (Cont'd) Figure 20-170-24
Figure 20-170-22
Remove the actuator (Item 1), O-ring (Item 2), spring

retainer (Item 3 and spring (Item 4) [Figure 20-170-24].
To remove the end from the spool, a holding fixture will from the spool.
have to be made from a 0.750 inch thick x 1.500 inch

wide x 2.0 inch long (19 mm thick x 38 mm wide x 50 mm Figure 20-170-25
long) piece of hardwood. Drill a 0.6250 inch (15 mm) hole
in the center of the hardwood block. Cut the block
lengthwise [Figure 20-170-22].
Figure 20-170-23

end of the spool.
Assembly: Tighten the plug to 6 ft.-lbs. (0.8 NM) torque.

spool, next to the end cover. Clamp the blocks in a vise
[Figure 20-170-23].

damaged.
Remove the actuator (Item 1) [Figure 20-170-23] from

the end of the spool.
V518 VersaHANDLER
367012500) (CONT'D)
Figure 20-170-26
Check the spool (Item 1) [Figure 20-170-27] for

scratches, or wear. Replace as needed.
Check the O-ring (Item 1) [Figure 20-170-26] on the

plug. Replace as needed.
V518 VersaHANDLER
367012500) (CONT'D)
Telescoping Valve Section
Figure 20-170-28

[Figure 20-170-30].

torque.
Remove the telescoping valve section (Item 1) [Figure
20-170-28]. Remove the controller from the telescoping valve section.

Figure 20-170-29 Figure 20-170-31
V518 VersaHANDLER
367012500) (CONT'D)
Telescoping Valve Section (Cont'd)
Figure 20-170-32

Figure 20-170-35


assembly.
Figure 20-170-33

for wear or damage.

V518 VersaHANDLER
367012500) (CONT'D)
Figure 20-170-36

Figure 20-170-39


torque.
Figure 20-170-37

from the telescoping valve section.

170-37] from the telescoping valve section.
V518 VersaHANDLER
Telescoping Valve Section (Cont'd) Figure 20-170-42
Figure 20-170-40

retainer (Item 3) and spring (Item 4) [Figure 20-170-42]

Figure 20-170-41

end of the spool.
Assembly: Tighten the plug to 6 ft.-lbs. (0.8 Nm) torque.

[Figure 20-170-41].

damaged.

V518 VersaHANDLER
367012500) (CONT'D)
Figure 20-170-44

valve section.
Figure 20-170-47


Figure 20-170-45


V518 VersaHANDLER
367012500) (CONT'D)
Figure 20-170-48

valve section.
Replace the O-ring on the plug.
Remove the spring/check valve (Item 1) [Figure 20-170- Figure 20-170-51

48] from the valve section.

Figure 20-170-49
Remove the spring/check valve (Item 1) [Figure 20-170-

Check the check valve for damage or wear. Replace as

needed [Figure 20-170-49].
V518 VersaHANDLER
367012500) (CONT'D)
Tilting Valve Section
Figure 20-170-52

[Figure 20-170-54].

torque.
Remove the tilting valve section (Item 1) [Figure 20-170-
52]. Remove the controller from the tilting valve section.

Figure 20-170-53 Figure 20-170-55
V518 VersaHANDLER
367012500) (CONT'D)
Tilting Valve Section (Cont'd)
Figure 20-170-56

Figure 20-170-59


assembly.
Figure 20-170-57

for wear or damage.

V518 VersaHANDLER
367012500) (CONT'D)
Figure 20-170-60

Figure 20-170-63


torque.
Figure 20-170-61

from the telescoping valve section.

170-61] from the telescoping valve section.
V518 VersaHANDLER
Tilting Valve Section (Cont'd) Figure 20-170-66
Figure 20-170-64


Figure 20-170-65

end of the spool.

[Figure 20-170-65].

damaged.

V518 VersaHANDLER
367012500) (CONT'D)
Figure 20-170-68

valve section.
Figure 20-170-71


Figure 20-170-69


V518 VersaHANDLER
367012500) (CONT'D)
Figure 20-170-72
Remove the spring/poppet assembly (Item 1) [Figure 20-

170-74] from the valve section.
Figure 20-170-75


Figure 20-170-73
Check the spring/poppet assembly for damage or wear

[Figure 20-170-75].

valve section.
V518 VersaHANDLER
367012500) (CONT'D)
Lifting Valve Section
Figure 20-170-76

[Figure 20-170-78].

torque.
Remove the lifting valve section (Item 1) [Figure 20-170-
76]. Remove the controller from the telescoping valve section.

Figure 20-170-77 Figure 20-170-79
V518 VersaHANDLER
367012500) (CONT'D)
Lifting Valve Section (Cont'd)
Figure 20-170-80

Figure 20-170-83


assembly.
Figure 20-170-81

for wear or damage.

V518 VersaHANDLER
367012500) (CONT'D)
Figure 20-170-84

Figure 20-170-87


torque.
Figure 20-170-85

from the lifting valve section.

170-85] from the lifting valve section.
V518 VersaHANDLER
Lifting Valve Section (Cont'd) Figure 20-170-90
Figure 20-170-88


Figure 20-170-89

end of the spool.

[Figure 20-170-89].

damaged.

V518 VersaHANDLER
367012500) (CONT'D)
Figure 20-170-92

valve section.
Figure 20-170-95


Figure 20-170-93


V518 VersaHANDLER
367012500) (CONT'D)
Figure 20-170-96

Figure 20-170-99


Figure 20-170-97
Check the spring/poppet assembly for damage or wear

[Figure 20-170-99].

valve section.
V518 VersaHANDLER
367012500) (CONT'D)
Inlet/Outlet Valve Section
Figure 20-170-100
Remove the spool (Item 1) and spring (Item 2) [Figure

20-170-102] from the valve.
Assembly: The rounded part of the spring (Item 3)

[Figure 20-170-102] must go next to the spool.
valve.

Figure 20-170-101
Remove the O-ring (Item 1) [Figure 20-170-101] from

the plug. Replace as needed.
V518 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367012501- NOTE: Mark all hoses and tubelines for correct
367013000) installation.
Relieve hydraulic pressure. Drain the hydraulic reservoir.

(See Replacing Hydraulic Fluid on Page 10-100-2.)
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by 2 1
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290 P-47777
Remove the tubeline (Item 1) and hose (Item 2) [Figure

20-171-2].
IMPORTANT

Figure 20-171-3
When making repairs on hydraulic system, clean the
work area before disassemble and keep all parts
clean. Always use caps and plugs on hoses,
damage the system.
I-2056-0793
Figure 20-171-1
1
P-47778
Remove the two hoses (Item 1) [Figure 20-171-3].
P18414
Remove the rear cover (Item 1) [Figure 20-171-1].
V518 VersaHANDLER
367013000) (CONT’D)
Figure 20-171-4 1
2
1 1
P-47781
1
1
Remove the four hoses (Item 1) and tubeline (Item 2)
[Figure 20-171-6].
P-47779
Figure 20-171-7

the control valve.

1
Figure 20-171-5
1 1
P-47782
1
Disconnect the two wire connectors (Item 1) [Figure 20-

171-7] from the main wire harness.
P-47780
NOTE: Mark the location of the connectors for correct
installation.
the control valve.
V518 VersaHANDLER
367013000) (CONT’D)
Figure 20-171-8
1 1
P-47784
Remove the two mounting bolts (Item 1) [Figure 20-171-

10] from the control valve.
P-47783
Figure 20-171-11

front right hand side of the control valve.

Figure 20-171-9
1
P-47786
Install a hoist and lift strap (Item 1) [Figure 20-171-11]

on the control valve.
P-47785
Use care not to damage the tubelines or fittings.
Remove the mounting bolt (Item 1) [Figure 20-171-9] Raise the hoist and remove the control valve.
from the front right hand side of the control valve.
V518 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367012501-367013000) (CONT’D)
1. VALVE
2. LIFTING ELEMENT
3. TILTING ELEMENT
4. TELESCOPE ELEMENT
5. EQUIPMENT ELEMENT
6. INLET ELEMENT
7. REGULATION KIT
8. PRESS RELIEF VALVE
9. SEAL KIT
10. SEAL KIT
11. FLOW REGULATOR
12. SEAL KIt
13. SEAL KIT
14. OUTLET ELEMENT
15. PLUG
16. TIE ROD KIT
17. FILTER
spc003066
V518 VersaHANDLER
367013000) (CONT’D)
Clean the outside of the control valve before

disassembly.
Mark the outside of the control valve for ease of

assembly.
IMPORTANT
P-47794
clean. Always use caps and plugs on hoses, Remove all hydraulic fittings [Figure 20-171-13].
damage the system. Figure 20-171-14
I-2056-0793
Figure 20-171-12

1
1
P-47795
P-47793
Remove the three nuts (Item 1) [Figure 20-171-14] from
the tie rod bolts.
Remove the tubeline (Item 1) [Figure 20-171-12]. Assembly: Tighten the nuts to 26 ft.-lbs. (35 Nm) torque.
V518 VersaHANDLER
367013000) (CONT’D)
End Housing Disassembly And Assembly
Figure 20-171-15
P-42985
1 Remove the O-ring (Item 1) [Figure 20-171-17] from the

plug.
P-47796
Remove the end housing (Item 1) [Figure 20-171-15].

Figure 20-171-16
1
2
P-42984
Remove the dust cap (Item 1) and plug (Item 2) [Figure

20-171-16] from the end housing.
V518 VersaHANDLER
367013000) (CONT’D)
Lifting Valve Section Disassembly And Assembly
Figure 20-171-18
1 1
P-42989

valve section.
P-47797
Figure 20-171-21
Remove the lifting valve section (Item 1) [Figure 20-171-

18].

Figure 20-171-19 1
2
1
P-42990
Remove the two O-rings (Item 1) and backup ring (Item

1
2) [Figure 20-171-21] from the plug.
P-42987
Remove the four O-rings (Item 1) [Figure 20-171-19]

from the valve section.
V518 VersaHANDLER
367013000) (CONT’D)

(Cont’d)
Figure 20-171-22
P-42993

cover.
1
P-42991 Figure 20-171-25
Loosen the four screws (Item 1) [Figure 20-171-22].

Assembly: Tighten the screws to 7 ft,-lbs. (10 Nm)
torque.
Figure 20-171-23
2
2
1
P-42995
1
Remove the spring (Item 1) and spring retainer (Item 2)

[Figure 20-171-25] from the spool.
P-42992
Remove the four screws (Item 1) and cover (Item 2)

[Figure 20-171-23].
V518 VersaHANDLER
367013000) (CONT’D)

(Cont’d)
Figure 20-171-26
P-42997
Assembly: Tighten the screws to 7 ft.-lbs. (10 Nm)

P-42996 torque.
Figure 20-171-29
Remove the relief valve (Item 1) [Figure 20-171-26] from

the valve section.
Assembly: Tighten the relief valve to 33 ft.-lbs. (45 Nm)

torque.
2
Figure 20-171-27
1
1
2
1 P-42998

[Figure 20-171-29] from the valve section.
P-42988

2) [Figure 20-171-27] from the relief valve.
V518 VersaHANDLER
367013000) (CONT’D)

(Cont’d)
Figure 20-171-30
P-44000

valve section.
P-42993 Figure 20-171-33
Remove the O-ring (item 1) [Figure 20-171-30] from the

cover.
Figure 20-171-31
2
1
P-44275
Remove the two plugs (Item 1) [Figure 20-171-33] from

the valve section.
P-42999 Assembly: Tighten the plugs to 20-24 ft.-lbs. (27-33 Nm)

torque.

V518 VersaHANDLER
367013000) (CONT’D)

(Cont’d)
Figure 20-171-34 1
2
1
P-44278
Loosen the plug (Item 1) [Figure 20-171-36].
Assembly: Tighten the plug to 40-49 ft.-lbs. (54-66 Nm)

P-44276 torque.
Figure 20-171-37
Remove the spring (Item 1) and poppet (Item 2) [Figure

20-171-34] from the plugs.
Figure 20-171-35
1 3
P-44279
Remove the plug (Item 1) poppet (Item 2) and guide

P-44277 (Item 3) [Figure 20-171-37] from the valve section.

plugs.
V518 VersaHANDLER
367013000) (CONT’D)

(Cont’d)
Figure 20-171-38
1
1
P-44002

P-44280 Figure 20-171-41

plug.
Tilting Valve Section Disassembly And Assembly

1
Figure 20-171-39
P-44003

the valve section,
Assembly: Tighten the relief valve to 33 ft,-lbs. (45 Nm)

torque.
P-44001
Remove the tilting valve section (Item 1) [Figure 20-171-

39]
V518 VersaHANDLER
367013000) (CONT’D)

(Cont’d)
Figure 20-171-42
2
1
1
1
P-44005

P-42988 Figure 20-171-45

Figure 20-171-43
P-42993
1
cover.
P-44004
Loosen the four screws (Item 1) [Figure 20-171-43] on

the cover.
Assembly: Tighten the screws to 7 ft.-lbs. (10 Nm)

torque.
V518 VersaHANDLER
367013000) (CONT’D)

(Cont’d)
1
Figure 20-171-46 2
2
1
P-42988

P-44006 Figure 20-171-49

Figure 20-171-47
1 1
P-44008

the cover.
P-44007 Assembly: Tighten the screws to 7 ft.-lbs. (10 Nm)

torque.

the valve section.
Assembly: Tighten the relief valve to 33 ft.-lbs. (45 Nm)

torque.
V518 VersaHANDLER
367013000) (CONT’D)

(Cont’d)
Figure 20-171-50
2
1
2
1
P-44010

P-44009 Figure 20-171-53

Figure 20-171-51
1
P-44011

valve section.
P-42993

cover.
V518 VersaHANDLER
367013000) (CONT’D)

(Cont’d)
1
Figure 20-171-54
P-44277
1
plugs.
P-44275 Figure 20-171-57

the valve section.
Assembly: Tighten the plugs to 20-24 ft.-lbs. (27-33 Nm) 1

torque.
Figure 20-171-55
2
1
P-44278
Assembly: Tighten the plug to 40-49 ft.-lbs. (54-66 Nm)

torque.
P-44276

V518 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367012501- Telescoping Valve Section Disassembly And
367013000) (CONT’D) Assembly
Tilting Valve Section Disassembly And Assembly Figure 20-171-60

(Cont’d)
Figure 20-171-58 1
2
P-47799
1
P-44279 Remove the telescoping valve section (Item 1) [Figure
20-171-60].

Figure 20-171-61
(Item 3) [Figure 20-171-58] from the valve section.
Figure 20-171-59
1 1
P-44013
P-44280 Remove the four O-rings (Item 1) [Figure 20-171-61]


plug.
V518 VersaHANDLER
367013000) (CONT’D)
Telescoping Valve Section Disassembly And

Assembly (Cont’d)
Figure 20-171-62
P-44016
1 Remove the O-ring (Item 1) [Figure 20-171-64] from the

controller assembly.
P-44014 Figure 20-171-65
Remove the two screws (Item 1) [Figure 20-171-62]

from the controller assembly.
Assembly: Tighten the screws to 10-12 ft.-lbs. (14-16

Nm) torque.
Figure 20-171-63
1
P-44017
Remove the two couplers (Item 1) [Figure 20-171-65]

1
P-44015
Remove the controller assembly (Item 1) [Figure 20-171-

V518 VersaHANDLER
367013000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-66
2
1
P-44020

[Figure 20-171-68] from the controller assembly.
P-44018 Figure 20-171-69
Remove the two O-rings (Item 1) [Figure 20-171-66]

from the couplers.
Figure 20-171-67
P-44021
1

cover.
1
P-44019

the controller assembly.
Assembly: Tighten the screws to 2-3 ft.-lbs. (3-3,5 Nm)

torque.
V518 VersaHANDLER
367013000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-70
1
2
P-44024
1
Remove the port block (Item 1) from the controller (Item
2) [Figure 20-171-72].
P-44022

cover.
Figure 20-171-71
P-44023

plug.
V518 VersaHANDLER
367013000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-73
1 P-47811
2
from the valve.
P-47808 Figure 20-171-76
Remove the valve cartridges (Item 1) and O-ring (Item 2)

[Figure 20-171-73] from the controller.
1
Figure 20-171-74
1 P-44028
2
5
from the spool.
4
3
P-47810
Remove the cover (Item 1), poppet (Item 2), spool (Item
3) and spacer (Item 4) from the valve (Item 5) [Figure 20-
171-74].
V518 VersaHANDLER
367013000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-77
1
1
P-44037
Loosen the screw (Item 1) [Figure 20-171-79] on the

piston.
P-44036 Assembly: Tighten the screw to 7 ft.-lbs. (10 Nm) torque.
Figure 20-171-80

the valve section.
Assembly: Tighten the valve to 33 ft.-lbs. (45 Nm)

torque.
Figure 20-171-78
1
2 2
1
1
P-44038
Remove the screw (Item 1) and piston (Item 2) [Figure

20-171-80] from the adapter.
P-42988

V518 VersaHANDLER
367013000) (CONT’D)

Assembly (Cont’d)
1
Figure 20-171-81
2
P-42990

1 2) [Figure 20-171-83] from the plug.
P-44039 Figure 20-171-84

from the piston.
Figure 20-171-82
1
1
P-44041
Loosen the two screws (item 1) [Figure 20-171-84] on

the cover.

torque.

valve section.
V518 VersaHANDLER
367013000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-85
1
1
P-44045
Loosen the adapter (Item 1) [Figure 20-171-87].
Assembly: Tighten the adapter to 7-8 ft.-lbs. (9-11 Nm)

P-44042 torque.
Figure 20-171-88
Remove the two screws (Item 1) and cover (Item 2)

Figure 20-171-86
P-44046
1 Remove the adapter (Item 1) [Figure 20-171-88] from

P-44044 the spool.
Install a hex wrench in the screw (Item 1) [Figure 20-

171-86] on the end of the spool.
V518 VersaHANDLER
367013000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-89
P-44049
Assembly: Install the countersunk side of the washer

(Item 1) [Figure 20-171-91] into the valve section.
P-44047 Figure 20-171-92
Remove the O-ring (Item 1)[Figure 20-171-89] from the

adapter.
Figure 20-171-90
1
P-44050

valve section.
P-44048 NOTE: When the spool is removed, use care not to

scratch the spool surface and do not
interchange spools and valve blocks.
Remove the washer (Item 1) [Figure 20-171-90] from the
valve section.
V518 VersaHANDLER
367013000) (CONT’D)
Telescoping Valve Section Disassembly And Cut

Assembly (Cont’d)
Figure 20-171-93
0.710” 2.0”
3
2
1
1.500”
0.750”
B-14674
To remove the spring assembly from the spool a holding

fixture will have to be made from a .750 inch thick x 1.500
inch wide x 2.0 inch long (19 mm thick x 38 mm wide x 51
P-44051 mm long) piece of hardwood. Drill a 0.710 inch (18 mm)
hole in the center of the hardwood block. Cut the block
Remove the O-ring (Item 1) seal (Item 2) and retainer

(Item 3) [Figure 20-171-93] from the spool. Figure 20-171-96
Figure 20-171-94
P-33886
P-44053
Using the wood blocks clamp the spool (Item 1) [Figure
20-171-96] in a vise.
Assembly: The lip on the seal (Item 1) [Figure 20-171-
94] fits inside the retainer (Item 3) [Figure 20-171-93]. NOTE: Do not use anything other than hardwood
damaged.
Loosen the screw (Item 2) [Figure 20-171-96]].
Assembly: Tighten the screw to 7 ft.-lbs. (10 Nm) torque.
V518 VersaHANDLER
367013000) (CONT’D)

Assembly (Cont’d) 2
Figure 20-171-97 1
P-44276
1
4
3 Remove the spring (Item 1) and poppet (Item 2) [Figure

2
P-44052 Figure 20-171-100
Remove the screw (Item 1), spring retainer (Item 2),

spring (Item 3) and spring retainer (Item 4) [Figure 20-
171-97] from the spool.
1
Figure 20-171-98
P-44277
1 Remove the O-ring (Item 1) [Figure 20-171-100] from

the plugs.
P-44275

the valve section;
Assembly: Tighten the plugs to 20-24 ft.-lbs. (27-33 Nm)

torque.
V518 VersaHANDLER
367013000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-101
1
P-44280

the plug.
P-44278 Auxiliary Valve Section Disassembly And Assembly
Figure 20-171-104

Assembly: Tighten the plug to 40-49 ft.-lbs. (54-66 Nm) 1
torque.
Figure 20-171-102
3 P-47800
2 Remove the auxiliary valve section (Item 1) [Figure 20-

171-104].
1
P-44279

V518 VersaHANDLER
367013000) (CONT’D)
Auxiliary Valve Section Disassembly And Assembly

(Cont’d)
Figure 20-171-105
P-47803
1
Remove the controller assembly (Item 1) [Figure 20-171-
P-47801 Figure 20-171-108

Figure 20-171-106
P-47804
1
the controller assembly.
P-47802
Remove the two screws (Item 1) [Figure 20-171-106]]

Assembly: Tighten the screws to 10-12 ft.-lbs. (14-16

Nm) torque.
V518 VersaHANDLER
367013000) (CONT’D)

(Cont’d)
Figure 20-171-109
1
2
P-44018
1
from the couplers.
P-47805 Figure 20-171-112
Remove the two screws (Item 1) from the connecting

flange (Item 2) [Figure 20-171-109]. Remove the
connecting flange.
Figure 20-171-110
P-44060

1
Assembly: Tighten the screws to 2-3 ft.-lbs. (3-3,5 Nm)
torque.
P-47806
Remove the two couplers (Item 1) [Figure 20-171-110]

from the connecting flange.
V518 VersaHANDLER
367013000) (CONT’D)

(Cont’d)
Figure 20-171-113
1
2
1
P-44022

cover.
P-44061 Figure 20-171-116

[Figure 20-171-113] from the controller assembly.
Figure 20-171-114
1
P-44023
1 Remove the O-ring (Item 1) [Figure 20-171-116] from

the plug.
P-44021

cover.
V518 VersaHANDLER
367013000) (CONT’D)
Auxiliary Valve Section Disassembly And Assembly 1

(Cont’d)
2
Figure 20-171-117 5
3
4
P-47810
Remove the cover (Item 1), poppet (Item 2), spool (Item
2
3) and spacer (Item 4) from the valves (Item 5) [Figure
1 20-171-119].
P-44062
Figure 20-171-120
Remove the controller (Item 1) from the port block (Item

2) [Figure 20-171-117].
Figure 20-171-118 1
P-44065
1 Remove the three O-rings (Item 1) [Figure 20-171-120]

from the spools.
P-47808
Remove the two valve cartridges (Item 1) and O-ring

(Item 2) [Figure 20-171-118] from the controller.
V518 VersaHANDLER
367013000) (CONT’D)

(Cont’d)
2
Figure 20-171-121 1
1
1
P-47813
1
2) [Figure 20-171-123] from the plugs.
P-47811 Figure 20-171-124

from the valves.
Figure 20-171-122
P-47814
Loosen the screw (Item 1) [Figure 20-171-124] on the

piston.
P-47812 Assembly: Tighten the screw to 7 ft.-lbs. (10 Nm) torque.
Remove the plug (Item 1) [Figure 20-171-122]. (Both

sides)
V518 VersaHANDLER
367013000) (CONT’D)

(Cont’d)
Figure 20-171-125
P-47817
2
Loosen the two screws (Item 1) [Figure 20-171-127] on
the cover.
1
torque.
Remove the screw (Item 1) and piston (Item 2) [Figure

Figure 20-171-128
20-171-125] from the adapter.
Figure 20-171-126
1
2
1
P-47818
P-47816 Remove the two screws (Item 1) and cover (Item 2)


from the piston.
V518 VersaHANDLER
367013000) (CONT’D)

(Cont’d)
Figure 20-171-129
1 P-47820
Loosen the adapter (Item 1) [Figure 20-171-131].
Assembly: Tighten the adapter to 7-8 ft.-lbs. (9-11 Nm)

P-47825 torque.
Figure 20-171-132

the cover.
Figure 20-171-130
2
1
P-47821
1
Remove the adapter (Item 1) and washer (Item 2)

P-47819 [Figure 20-171-132] from the valve section.
Install a hex wrench in the screw (Item 1) [Figure 20-

171-130].
V518 VersaHANDLER
367013000) (CONT’D)

(Cont’d)
Figure 20-171-133
1
P-47822

valve section.
P-44049 NOTE: When the spool is removed, use care not to

scratch the spool surface and do not
interchange spools and valve blocks.
Assembly: Install the countersunk side of the washer

(Item 1) [Figure 20-171-133] into the valve section. Figure 20-171-136
Figure 20-171-134
3
2
1
P-44051
P-44047
Remove the O-ring (Item 1), seal (Item 2) and retainer
(Item 3) [Figure 20-171-136] from the spool.
the adapter.
V518 VersaHANDLER
367013000) (CONT’D)

(Cont’d)
Figure 20-171-137
2
1
1
P-33886
Using the wood blocks clamp the spool (Item 1) [Figure

20-171-139] in a vise.
P-44053 NOTE: Do not use anything other than hardwood

damaged.
Assembly: The lip on the seal (Item 1) [Figure 20-171-

137] fits inside the retainer. Loosen the screw (Item 2) [Figure 20-171-139].
Figure 20-171-138 Assembly: Tighten the screw to 7 ft.-lbs. (10 Nm) torque.
Cut Figure 20-171-140
0.710” 2.0”
1 4
1.500”
0.750”
B-14674
3
2
P-44052
To remove the spring assembly from the spool a holding
fixture will have to be made from a .750 inch thick x 1.500
inch wide x 2.0 inch long (19 mm thick x 38 mm wide x 51 Remove the screw (Item 1), spring retainer (Item 2),
mm long) piece of hardwood. Drill a 0.710 inch (18 mm) spring (Item 3) and spring retainer (Item 4) [Figure 20-
hole in the center of the hardwood block. Cut the block 171-140] from the spool.
V518 VersaHANDLER
367013000) (CONT’D)

(Cont’d)
Figure 20-171-141 1
P-44277
1
the plugs.
P-47823 Figure 20-171-144

the valve section. 1
Assembly: Tighten the plugs to 20-24 ft.-lbs. (27-33 Nm)

torque.
Figure 20-171-142
2
1
P-44282
Assembly: Tighten the plug to 40-49 ft.lbs. (54-66 Nm)

torque.
P-44276

V518 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367012501-
367013000) (CONT’D)

(Cont’d)
Figure 20-171-145
3
2
1
P-47824
Remove the plug (Item 1), poppet (Item 2) and guide

Figure 20-171-146
P-44280

the plug.
V518 VersaHANDLER
367013000) (CONT’D)
Inlet-Outlet Valve Section Disassembly And

Assembly
1
Figure 20-171-147
1
P-44106

the plug.
P-44104 Figure 20-171-150

1
Figure 20-171-148
P-44107
Remove the spring (Item 1) [Figure 20-171-150] from

the valve section.
P-44105

valve section.
Assembly: Tighten the plug to 74 ft.-lbs. (100 Nm)

torque.
V518 VersaHANDLER
367013000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-151 1
P-44110
Remove the relief valve (Item 1) [Figure 20-171-153]

P-44108 Assembly: Tighten the relief valve to 33 ft.-lbs. (45 Nm)

torque.

Figure 20-171-154
valve section.
Assembly: Tighten the plug to 15 ft.-lbs. (20 Nm) torque.
Figure 20-171-152
2
1
P-44111

P-44109

the plug.
V518 VersaHANDLER
367013000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-155 1
1 P-44268

the plug.
P-44112 Figure 20-171-158
Remove the flow regulator valve (Item 1) [Figure 20-171-

Assembly: Tighten the flow regulator valve to 15 ft.-lbs.

(20 Nm) torque.
1
Figure 20-171-156
4
P-44269
3
2 1
Remove the screen (Item 1) [Figure 20-171-158] from
the valve.
P-44265
Remove the plug (Item 1), shim (Item 2), spring (Item 3)
and spool (Item 4) [Figure 20-171-156] from the valve.
V518 VersaHANDLER
367013000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-159
1
P-44115
1 2
the test fitting.
P-44267 Figure 20-171-162

2) [Figure 20-171-159] from the flow regulator valve.
Figure 20-171-160 1
P-44116
Remove the cap (Item 1) [Figure 20-171-162] from the

test fitting.
P-44114 Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear or damage. Replace any worn

Remove the test fitting (Item 1) [Figure 20-171-160] from or damaged parts.
the valve section.
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.
V518 VersaHANDLER
V518 VersaHANDLER
JOYSTICK (S/N 367012501-367013000) Figure 20-180-3
Handle Removal And Installation
Remove the dash cover/steering column cover. (See

Removal And Installation on Page 60-100-1.) 1
Remove the joystick panel. (See Removal And 1

Installation on Page 60-50-1.)
Figure 20-180-1
1
P-42894
1
Remove the four mounting bolts (Item 1) and spacer nuts
(Item 2) [Figure 20-180-3].
Installation: Note the location and quantity of the spacer

nuts for correct installation.

Figure 20-180-4
P-47776
1
Disconnect the electrical connector (Item 1) [Figure 20-
180-1].
Figure 20-180-2
1
P-42895
Remove the grommet and wire harness retainer (Item 1)

P-42893
Raise the dust boot (Item 1) [Figure 20-180-2].
V518 VersaHANDLER
JOYSTICK (S/N 367012501-367013000) (CONT’D) Figure 20-180-7
Handle Removal And Installation (Cont’d)
Figure 20-180-5
P-42893
Raise the dust boot (Item 1) [Figure 20-180-7].

P-42898
Figure 20-180-8
Loosen the nut (Item 1) [Figure 20-180-5] and turn the

handle counterclockwise.

Remove the handle/harness assembly from the dust 1
boot.
Joystick Removal And Installation

1
Removal And Installation on Page 60-100-1.) 1
Remove the joystick panel. (See Removal And 2

P-42894
Figure 20-180-6
Remove the four mounting bolts (Item 1) and spacer nuts

(Item 2) [Figure 20-180-8].
Installation: Note the location and quantity of the spacer

nuts for correct installation.
1
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
P-47776
and possible death if proper medical treatment by a
physician familiar with this injury is not received
Disconnect the electrical connector (Item 1) [Figure 20- immediately.
180-6]. W-2145-0290
V518 VersaHANDLER
Joystick Removal And Installation (Cont’d)
IMPORTANT 1

clean. Always use caps and plugs on hoses,
damage the system.
I-2056-0793
P-42896
Figure 20-180-9
Remove the joystick assembly (Item 1) [Figure 20-180-

10].

1
P-42895
Remove the six hoses (Item 1) [Figure 20-180-9] from

the joystick.
Install caps and plugs.
V518 VersaHANDLER
JOYSTICK (S/N 367012501-367013000) (CONT’D)
1. Handle
2. Dust Boot
3. Nut
4. Swivel Joint
5. Shim
6. Plate
7. Plunger Assembly 1
8. Seal
9. Spool Assembly
10. Spring
11. Valve Body (Top)
12. O-Ring 2
13. Alignment Pin
14. Valve Body (Bottom)
15. Bolt

3
7
8
10
11
12
12
13 13
14
12
15
B-16943
B-16943
V518 VersaHANDLER

1
Clean the outside of the joystick before disassembly.
Mark the outside of the joystick for ease of assembly.
Figure 20-180-11
2
1
P-42899
2
Remove the handle (Item 1) and dust boot (Item 2)

[Figure 20-180-13].
Figure 20-180-14
P-42897

1
Raise the dust boot (Item 1) and remove the wire
harness retainer and grommet (Item 2) [Figure 20-180-
11].
Figure 20-180-12
3
P-42900
2 Remove the swivel joint (Item 1) [Figure 20-180-14].
P-42898
Lower the dust boot (Item 1) and loosen the nut (Item 2)
[Figure 20-180-12].
Rotate the handle (Item 3) [Figure 20-180-12]

counterclockwise to remove.
V518 VersaHANDLER
Disassembly And Assembly (Cont’d)

1
Figure 20-180-15
2
2
P-42902
Remove the plate (Item 1) [Figure 20-180-17] from the

P-42901 housing.
Figure 20-180-18
Assembly: The swivel joint (Item 1) should make light
contact evenly with the plungers (Item 2) [Figure 20-180-
15].

1
Figure 20-180-16
P-42904
Mark and remove the four plunger assemblies (Item 1)

P-42903
NOTE: Install the plunger assemblies in the same
bore the plungers were removed from.
Remove the shim (Item 1)[Figure 20-180-16] from the
swivel joints.
V518 VersaHANDLER
Figure 20-180-19 1
3
1
P-42907

P-42905 rod.
Figure 20-180-22
Remove the O-ring (Item 1) and rod (Item 2) from the
plunger body (Item 3) [Figure 20-180-19].

1
Figure 20-180-20
P-42908
1
Mark and remove the four spool assemblies (Item 1)

P-42906 [Figure 20-180-22] from the housing.
NOTE: Install the spool assemblies in the same bore

Remove the O-ring (Item 1) [Figure 20-180-20] from the the spools were removed from.
inside of the plunger body.
V518 VersaHANDLER

1
Figure 20-180-23
P-42913
Remove the four springs (Item 1) [Figure 20-180-25]

P-42909 from the housing,
Figure 20-180-26
Compress the spring (Item 1) to remove the retainer
(Item 2) [Figure 20-180-23].

Figure 20-180-24 1
4
P-42914
3
2
1 Remove the bolt (Item 1) [Figure 20-180-26] from the
P-42910 end cap.
Remove the retainer (Item 1), piston (Item 2), spring

(Item 3) and shims (Item 4) from the spool (Item 5)
[Figure 20-180-24].
V518 VersaHANDLER
Figure 20-180-27 1
P-42918

P-42915 from the housing,
Clean all parts in solvent and dry with compressed air.

Remove the O-ring (Item 1) [Figure 20-180-27] from the Inspect the push rod crown for wear. Replace all
bolt. components showing excessive wear.

Mark the sections for correct assembly. Always install new seals and O-rings.
Figure 20-180-28 Lubricate the components with clean hydraulic oil during
assembly.
P-42916
Remove the end cap (Item 1) from the housing (Item 2)

[Figure 20-180-28].
V518 VersaHANDLER
V518 VersaHANDLER
HYDROSTATIC SYSTEM
HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-18
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-5
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-16
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-24
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-7
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-20
Prior to assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-24
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

V518 VersaHANDLER
278 of 724
OIL COOLER Figure 30-20-3
IMPORTANT
damage the system.
I-2003-0888
OPEN THE HOOD

Disconnect the three hoses (Item 1) [Figure 30-20-1],
Remove the air cleaner housing. (See Housing Removal [Figure 30-20-2] & [Figure 30-20-3] from the oil cooler.
Install caps and plugs on the fittings.
Figure 30-20-1
Figure 30-20-4

Figure 30-20-2
Remove the two retaining nuts (Item 1) [Figure 30-20-4].
Lift and remove the oil cooler.
V518 VersaHANDLER
280 of 724
HYDROSTATIC DRIVE MOTOR
Remove the front axle. (See Removal on Page 40-30-1.)
Figure 30-30-1
Install a chain hoist and lifting strap to lift and support the

drive motor [Figure 30-30-1].

1] from the drive motor.
Assembly: Tighten the mounting bolts to 140-155 ft.-lbs.

(190-210 Nm) torque.
Remove the hydrostatic drive motor from the axle

housing.
V518 VersaHANDLER
281 of 724 30-30-1 Sevice Manual
HYDROSTATIC DRIVE MOTOR (CONT'D)
V518 VersaHANDLER
Parts Identification (Cont’d)
V518 VersaHANDLER
Parts Identification (Cont’d)
V518 VersaHANDLER
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-4
Disassembly
IMPORTANT
damage the system.
I-2003-0888
Figure 30-30-2
Remove the solenoid nut (Item 1) [Figure 30-30-4].
Figure 30-30-5

Place the hydrostatic drive motor on a work surface,
mark the sections for correct assembly [Figure 30-30-2].
Figure 30-30-3 Remove the solenoid (Item 1) [Figure 30-30-5] from the
shaft.

remove the solenoid housing.
V518 VersaHANDLER
Figure 30-30-6
Remove the O-ring (Item 1) [Figure 30-30-8] and pin

(Item 2) [Figure 30-30-8] from the solenoid shaft (Item 3)
[Figure 30-30-8].
Remove and discard the O-ring (Item 1) [Figure 30-30-6] Figure 30-30-9
from the solenoid.

Figure 30-30-7
Loosen the large nut (Item 1) [Figure 30-30-9] on the

compensator valve.
Remove the solenoid shaft (Item 1) [Figure 30-30-7] and Do not loosen the small nut (Item 2) [Figure 30-30-9].
O-ring (Item 2) [Figure 30-30-7] from the housing.
V518 VersaHANDLER
Figure 30-30-10

housing.
Figure 30-30-13
Remove the adjusting screw (Item 1) [Figure 30-30-10],
valve spring (Item 2) [Figure 30-30-10] and spool
assembly (Item 3) [Figure 30-30-10] from the housing.

Figure 30-30-11

13] from the plug.

11] from the adjustment screw.
V518 VersaHANDLER
Figure 30-30-14
Remove the spool (Item 1) [Figure 30-30-16].
Remove the two fittings (Item 1) [Figure 30-30-14] from

the housing.

Figure 30-30-15
Remove both spool limiters (Item 1) [Figure 30-30-15].
V518 VersaHANDLER
Figure 30-30-17
Lift and remove the end cap (Item 1) [Figure 30-30-19]

from the housing.
Figure 30-30-20
Remove and discard the six O-rings (Item 1) [Figure 30-
30-17] from the housing.

Figure 30-30-18
Remove the gasket (Item 1) [Figure 30-30-20] from the

end cap.
Remove the eight bolts (Item 1) [Figure 30-30-18] from

the end cap.
V518 VersaHANDLER
Figure 30-30-21
Figure 30-30-24

end cap.

Figure 30-30-22
Remove the plug (Item 1) [Figure 30-30-24], spring (Item

2) [Figure 30-30-24], spring seat (Item 3) [Figure 30-30-
24] and spool (Item 4) [Figure 30-30-24] from the
housing.

piston.
V518 VersaHANDLER
Figure 30-30-25
Remove the plug (Item 1) [Figure 30-30-27], spring (Item

2) [Figure 30-30-27] and spring seat (Item 3) [Figure 30-
Remove and discard the O-ring (Item 1) [Figure 30-30- Figure 30-30-28
25] from the plug.

Figure 30-30-26

28] from the plug.
V518 VersaHANDLER
Figure 30-30-29
Remove the valve segment (Item 1) [Figure 30-30-31]

from the cylinder.
Figure 30-30-32
Loosen and remove the relief valve (Item 1) [Figure 30-

Figure 30-30-30

32]. Remove eight mounting bolts (Item 2) [Figure 30-
30-32] from the mounting plate.
Remove the plug (Item 1) [Figure 30-30-30], O-rings

30-30] and poppet (Item 4) [Figure 30-30-30] from the
relief valve housing (Item 5) [Figure 30-30-30].
V518 VersaHANDLER
Figure 30-30-33
Remove the cylinder block (Item 1) [Figure 30-30-35]

and synchronizing shaft assembly (Item 2) [Figure 30-
Remove the mounting plate (Item 1) [Figure 30-30-33] NOTE: It is not important that the pistons are installed
using a suitable puller. in their original position.

Figure 30-30-34 Figure 30-30-36
Remove and discard the seal (Item 1) [Figure 30-30-34] Remove the bearing plate (Item 1) [Figure 30-30-36]
from the mounting plate. from the cylinder block.
V518 VersaHANDLER
Figure 30-30-37
Press the piston/shaft assembly from the housing

[Figure 30-30-39].
DO NOT damage the pistons.

Remove the bearing from the cylinder block [Figure 30-
30-37]. Figure 30-30-40

DO NOT damage the bearing plate surface of the
cylinder block.
Figure 30-30-38
Pry up the peened notch (Item 1) [Figure 30-30-40] in

the ring nut.

housing.
V518 VersaHANDLER
Figure 30-30-41
Using a clamp, compress the spring seat and spring, and

drive the pin (Item 1) [Figure 30-30-43] inwards. Release
the clamp.
Remove the ring nut (Item 1) [Figure 30-30-41] from the Figure 30-30-44
shaft.

Figure 30-30-42
Remove the pin (Item 1) [Figure 30-30-44], spring (Item

2) [Figure 30-30-44] and spring seat (Item 3) [Figure 30-
30-44] from the shaft assembly.
Remove the large bearing and race (Item 1) [Figure 30-
30-42], small bearing and race (Item 2) [Figure 30-30-
42] and spacer (Item 3) [Figure 30-30-42] from the shaft.
V518 VersaHANDLER
Figure 30-30-45
Inspect the cylinder block assembly for wear or damage.

The piston bores (Item 1) [Figure 30-30-47] must be
smooth. The races for the synchronizing shaft rollers
(Item 2) [Figure 30-30-47] must not be worn.
Remove the piston rings (Item 1) [Figure 30-30-45] from
the pistons. If there is any defect in the cylinder block or pistons, the
complete rotating group must be replaced.

NOTE: If any portion of the shaft assembly, bearings
or races must be replaced, the complete shaft/
bearing assembly must be ordered. The only
serviceable part is the piston rings (Item 1)
[Figure 30-30-45].
Inspection
Clean all parts in solvent and use air pressure to dry

them. DO NOT use cloth or paper as small pieces of
material can get into the system and cause damage.
Figure 30-30-46
Inspect the running (bronze) surface of the bearing plate

(Item 1) [Figure 30-30-46] and locating pin holes (Item 2)
[Figure 30-30-46] for wear. Replace if damaged or worn.
V518 VersaHANDLER
Inspection (Cont'd)
Figure 30-30-48
Inspect the valve segment for damage or wear on the

sealing surface (Item 1) [Figure 30-30-50].
Check that the spindle is located correctly in the valve

Inspect the piston (Item 1) [Figure 30-30-48] for wear or segment by measuring distance "A" [Figure 30-30-50]. If
damage. this dimension is not within 1.36 to 1.37 inch (34.5 to 34.7
mm) the assembly must be replaced.

Figure 30-30-49
Inspect the swash plate running surface (Item 1) [Figure

30-30-49] in the end cap for wear or damage.
V518 VersaHANDLER
Assembly
IMPORTANT
damage the system.
I-2003-0888
Prior to assembly
Clean and lightly oil all parts prior to assembly. Install the pin (Item 1) [Figure 30-30-53] as shown.
Figure 30-30-51 NOTE: Clamp is removed for photo clarity.
Figure 30-30-54

Install the spring (Item 1) [Figure 30-30-51] and spring
seat (Item 2) [Figure 30-30-51] into the shaft assembly
(Item 3) [Figure 30-30-51].
Support the shaft assembly in a press without causing
Figure 30-30-52 damage to the pistons, install the large bearing and race
(Item 1) [Figure 30-30-54], spacer (Item 2) [Figure 30-
30-54] and small bearing and race (Item 3) [Figure 30-
30-54] into the shaft assembly.
NOTE: Be sure not to over press the bearings, they

should be able to roll freely.
Using a clamp, compress the spring and spring seat

[Figure 30-30-52].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-55
Press the piston/shaft assembly into the housing [Figure

30-30-57].
DO NOT DAMAGE THE PISTONS.

Install the ring nut (Item 1) [Figure 30-30-55] onto the
shaft. Figure 30-30-58

NOTE: Do not over tighten the ring nut and that there
is no noticeable looseness in the bearing.
Figure 30-30-56
Install a new seal (Item 1) [Figure 30-30-58] into the

mounting plate until it is fully seated.
Using a punch seat the ring nut into the groove in the
shaft. [Figure 30-30-56].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-59

mounting plate.
Figure 30-30-62
housing.

Figure 30-30-60
Press a new bearing into the cylinder block until it is

located 0.53 to 0.55 inch (13.5 to 14.0 mm) below the
bearing plate surface [Figure 30-30-62].
Install the mounting plate onto the housing, install the

eight mounting bolts (Item 1) [Figure 30-30-60] and
tighten to 46 ft.-lbs. (63 Nm) torque.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-63
Install the bearing plate (Item 1) [Figure 30-30-65] with

the bronze surface facing up onto the cylinder block.
Figure 30-30-66
Figure 30-30-64

Position the housing on end, tip the three pistons (Item 1)
Install new piston rings (Item 1) [Figure 30-30-63] onto [Figure 30-30-66] closest to the minimum angle stop out
the pistons, make sure the spherical surface (Item 1) toward the housing.
[Figure 30-30-64] conforms to the shape of the piston.
An identification mark (Item 2) [Figure 30-30-63] &

[Figure 30-30-64] is on the "outer" side of the piston ring.
The ends of the piston rings must NOT overlap each

other.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-67
NOTE: The recess (Item 1) [Figure 30-30-69] on each

roller MUST face the synchronizing shaft.
Figure 30-30-70
Install the synchronizing shaft support pin (Item 1)
[Figure 30-30-67] into the cylinder block and retain with
grease.

Figure 30-30-68
Install the synchronizing shaft support pin (Item 1)

[Figure 30-30-70] into the motor shaft assembly and
retain with grease.
Install the six synchronizing shaft rollers (Item 1) [Figure

30-30-68] onto the synchronizing shaft and retain with
grease.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-71
If the cylinder block (Item 1) [Figure 30-30-73] is properly

installed, there should be very little rotational free-play
between the block and the motor shaft.
Install the synchronizing shaft and rollers (Item 1) [Figure NOTE: A brass rod may be used to guide the pistons
30-30-71] into the motor shaft races. When properly into their bores.
installed the synchronizing shaft should move freely in all

directions. Lubricate the pistons and cylinder block bores with
hydraulic oil.
NOTE: The motor shaft end of the synchronizing shaft
is smaller than the cylinder end.
Figure 30-30-72
When installing the cylinder block, the races (Item 1)

[Figure 30-30-72] in the cylinder block must be
positioned so the synchronizing shaft rollers (Item 2)
[Figure 30-30-72] and pistons (Item 3) [Figure 30-30-71]
and their bores (Item 2) [Figure 30-30-72] are aligned.
Install the six pistons (Item 3) [Figure 30-30-71] into the

cylinder bores, tilt the block so the synchronizing shaft
rollers enter their races in the block and the support pin
(Item 3) [Figure 30-30-72] enter the recess.
Lift the cylinder block slightly and guide the three

remaining pistons in position.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-74
Lubricate and install the piston (Item 1) [Figure 30-30-

76] into the end cap.
Figure 30-30-77
Install a new gasket (Item 1) [Figure 30-30-74] onto the
housing.

Install the valve segment (Item 2) [Figure 30-30-74] onto
the cylinder block and retain with heavy grease.
NOTE: The hole (Item 3) [Figure 30-30-74] in the valve

segment should be opposite the minimum
displacement adjustment screw (Item 4)
[Figure 30-30-74].
Figure 30-30-75
NOTE: Note the position of the hole (Item 1) [Figure

30-30-77] in the end cap.
Install a new seal (Item 1) [Figure 30-30-75] onto the

piston.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-78

plug.
Figure 30-30-81
Assemble the poppet (Item 1) [Figure 30-30-78] and
spring (Item 2) [Figure 30-30-78] into the relief valve
housing (Item 3) [Figure 30-30-78] using new O-ring

(Item 4) [Figure 30-30-78] and plug (Item 5) [Figure 30-
30-78].
Figure 30-30-79
Install the spool (Item 1) [Figure 30-30-81], spring seat

30-81] and plug (Item 4) [Figure 30-30-81] into the
housing and tighten to 30 ft.-lbs. (41 Nm) torque.
Install the relief valve (Item 1) [Figure 30-30-79] into the

housing and tighten to 38 ft.-lbs. (52 Nm) torque.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-82
Align the hole in the piston (Item 1) [Figure 30-30-84]

and the valve segment (Item 2) [Figure 30-30-84].
Figure 30-30-85
plug.

Figure 30-30-83
Install the end cap housing and tighten the eight bolts
(Item 1) [Figure 30-30-85] to 85 ft.-lbs. (115 Nm) torque.
Install the spring seat (Item 1) [Figure 30-30-83], spring

(Item 2) [Figure 30-30-83] and plug (Item 3) [Figure 30-
30-83] into the housing and tighten to 30 ft.-lbs. (41 Nm)
torque.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-86
Install the plug (Item 1) [Figure 30-30-88] into the

housing.
Figure 30-30-89
Install six new O-rings (Item 1) [Figure 30-30-86] onto
the housing.

Figure 30-30-87

adjustment screw.

plug.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-90
Install a new O-ring (Item 1) [Figure 30-30-92] and

solenoid shaft assembly (Item 2) [Figure 30-30-92] into
the housing.
Install the spool (Item 1) [Figure 30-30-90], spring (Item Figure 30-30-93
2) [Figure 30-30-90] and adjusting screw (Item 3)
[Figure 30-30-90] into the housing and tighten to 7 ft.-

lbs. (9 Nm) torque.
Figure 30-30-91
Install the solenoid housing (Item 1) [Figure 30-30-93]

onto the shaft and install a new O-ring (Item 2) [Figure
30-30-93].

solenoid shaft.
Lightly lubricate the pin (Item 2) [Figure 30-30-91] and

install into the solenoid shaft.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-94
Install the solenoid nut (Item 1) [Figure 30-30-94] and

hand tighten.

Figure 30-30-95
Install the solenoid housing assembly (Item 1) [Figure

30-30-95]. Tighten the bolts to 58 ft.-lbs. (78 Nm) torque.
V518 VersaHANDLER
V518 VersaHANDLER
HYDROSTATIC PUMP Figure 30-40-3
Figure 30-40-1

3] from the hydrostatic pump.
Assembly: Tighten the mounting bolts to 69-78 ft.-lbs.

Remove the gear pumps. (See Removal And Installation (94-106 Nm) torque.
on Page 20-130-1.)

Remove the return hose (Item 1) [Figure 30-40-1] from

the hydrostatic pump.
Figure 30-40-2
Install a chain hoist and lifting strap to lift and support the
hydrostatic pump [Figure 30-40-2].
V518 VersaHANDLER
HYDROSTATIC PUMP (CONT'D)
V518 VersaHANDLER
Parts Identification (Cont'd)
V518 VersaHANDLER
V518 VersaHANDLER
V518 VersaHANDLER
V518 VersaHANDLER
HYDROSTATIC PUMP (CONT'D) Figure 30-40-6
Disassembly
IMPORTANT
damage the system.
I-2003-0888
Figure 30-40-4
Remove the retainer bolt (Item 1) [Figure 30-40-6].
Remove the coupler gear (Item 2) [Figure 30-40-6] from
the shaft.
Figure 30-40-7

Remove and discard the filter (Item 1) [Figure 30-40-4].
Figure 30-40-5
Remove the three bolts (Item 1) [Figure 30-40-7].
Remove the retainer plate (Item 2) [Figure 30-40-7] from

the pump housing.
Remove the filter head (Item 1) [Figure 30-40-5] from the

pump housing.
V518 VersaHANDLER
Figure 30-40-8
Remove the snap ring (Item 1) [Figure 30-40-10] and

spacer washer (Item 2) [Figure 30-40-10] from the shaft.
Figure 30-40-11
Remove the shaft and bearing assembly from the
housing [Figure 30-40-8].

NOTE: If the shaft or bearing assembly become stuck
in the housing, lightly tap on the shaft.
Figure 30-40-9
Remove the bearing (Item 1) [Figure 30-40-11] from the

shaft.
Remove the shaft seal (Item 1) [Figure 30-40-9] from the

shaft.
V518 VersaHANDLER
Place the pump on the work surface with the charge

pump up.
Mark the pump housings for correct assembly.
Before removing the relief valve mark the plug, lock nut
and housing for approximate assembly adjustment.
Figure 30-40-12

14].
NOTE: Remove the lifting bracket (Item 2) [Figure 30-

40-14] from the pump.
Figure 30-40-15

Remove the relief valve lock nut (Item 1) [Figure 30-40-
12] and the plug (Item 2) [Figure 30-40-12].
Figure 30-40-13

15] from the flange adapter.
Remove the flange adapter (Item 2) [Figure 30-40-15].
Remove the spring and relief poppet from the charge

pump housing [Figure 30-40-13].
V518 VersaHANDLER
Figure 30-40-16
Remove the charge pump cover (Item 1) [Figure 30-40-

18].
Figure 30-40-19
Lift and remove the charge pump (Item 1) [Figure 30-40-
16] from the pump housing.

Figure 30-40-17
Only if wear marks are present, remove the bushing

(Item 1) [Figure 30-40-19] from the charge pump cover
(Item 2) [Figure 30-40-19].
Remove the six bolts (Item 1) [Figure 30-40-17] and

remove the retaining plate (Item 2) [Figure 30-40-17]
from the charge pump.
V518 VersaHANDLER
Figure 30-40-20
Remove the charge pump gears (Item 1) [Figure 30-40-

22].
Figure 30-40-23
Remove the coupler (Item 1) [Figure 30-40-20].
Figure 30-40-21

Remove the eccentric ring (Item 1) [Figure 30-40-23]
and alignment pin (Item 2) [Figure 30-40-23] from the
pump.
Remove the charge pump shaft (Item 1) [Figure 30-40-
21] and key (Item 2) [Figure 30-40-21] from the pump. Note the position of the alignment pin.
V518 VersaHANDLER
Figure 30-40-24
For proper operation, if the plugs are removed from the

housing they must be returned to their original position
[Figure 30-40-26].
Remove the charge pump wear plate (Item 1) [Figure Installation: Tighten the servo relief valve plug (Item 1)
30-40-24]. [Figure 30-40-26] to 9 ft.-lbs. (12 Nm) torque. Tighten the
rotation pipe plugs (Item 2) [Figure 30-40-26] to 4 ft.-lbs.

Remove the O-ring (Item 2) [Figure 30-40-24]. (5.4 Nm) torque.
Figure 30-40-25 Figure 30-40-27
Remove the swash plate leveler spring shims (Item 1) Remove the multi-function valve assemblies (Item 1)
[Figure 30-40-25] from the spring pockets. [Figure 30-40-27] from the housing.
Inspect the journal bearing (Item 2) [Figure 30-40-25].

Replace as needed.
V518 VersaHANDLER
Figure 30-40-28
Remove both spring seats (Item 1) [Figure 30-40-30]

from the swash plate leveler.
Figure 30-40-31
Remove the gasket (Item 1) [Figure 30-40-28] and the
valve plate (Item 2) [Figure 30-40-28] from the housing.
Note the direction of the arrows (Item 3) [Figure 30-40-

28] on the valve plate for proper assembly.
Figure 30-40-29
Remove the swash plate hold down spring (Item 1)

[Figure 30-40-31].
Remove the two leveler springs (Item 1) [Figure 30-40-

29].
V518 VersaHANDLER
Figure 30-40-32

34]. Loosen and remove both guide posts (Item 2)
[Figure 30-40-34].
Mark the position of the side cover. Figure 30-40-35
Remove the six bolts (Item 1) [Figure 30-40-32] from the

side cover.
Figure 30-40-33
Remove the leveler (Item 1) [Figure 30-40-35] and slide

inserts (Item 2) [Figure 30-40-35] from the side cover.
Inspect the slide inserts for wear or damage.
Remove the side cover/swash plate leveler assembly Replace if needed.

from the housing [Figure 30-40-33].
V518 VersaHANDLER
Figure 30-40-36
Remove the four solenoid mounting bolts (Item 1)

[Figure 30-40-38].
Figure 30-40-39
Remove the six solenoid manifold mounting bolts (Item
1) [Figure 30-40-36]. Remove the manifold (Item 2)
[Figure 30-40-36].

Figure 30-40-37
Remove the solenoids (Item 1) [Figure 30-40-39] from

the manifold.
Remove the gasket (Item 1) [Figure 30-40-37] from the

manifold.
V518 VersaHANDLER
Figure 30-40-40
Remove the cage locator link (Item 1) [Figure 30-40-42]

from the swash plate.
Figure 30-40-43
Remove and discard the three O-rings (Item 1) [Figure
30-40-40] from the solenoid.

Figure 30-40-41
Remove the cylinder block (Item 1) [Figure 30-40-43]

through the housing end opening. The swash plate and
piston assembly will remain in the housing.
Remove the anchor pin (Item 1) [Figure 30-40-41].
V518 VersaHANDLER
Figure 30-40-44
Remove the swash plate bearings (Item 1) [Figure 30-

Figure 30-40-47
Remove the swash plate/piston assembly (Item 1)
[Figure 30-40-44] from the pump housing.

Figure 30-40-45
Remove the swash plate bearing races (Item 1) [Figure

30-40-47] from the housing.
Remove the four slipper guide bearing retainer bolts

(Item 1) [Figure 30-40-45].
V518 VersaHANDLER
Figure 30-40-48

remove the servo adjustment cover.
Figure 30-40-51
Remove the bronze slider block (Item 1) [Figure 30-40-
48] from the servo piston.

Mark the position of the servo end covers.
Figure 30-40-49
Measure and record the adjustment setting for

approximate installation adjustment [Figure 30-40-51].
Remove the three bolts and remove the servo end cover.
Remove and discard both O-rings (Item 1) [Figure 30-
40-49].
V518 VersaHANDLER
Figure 30-40-52
Remove the servo piston (Item 1) [Figure 30-40-52] from

the housing (Item 2) [Figure 30-40-52].

52].
V518 VersaHANDLER
Inspection
Figure 30-40-53
Inspect the servo piston and seal rings (Item 1) [Figure

30-40-55] for wear. If worn, remove the seal rings and
expander O-rings from the piston.
Clean all parts in solvent and use air pressure to dry Install new expander O-rings into the grooves in the
them. DO NOT use cloth or paper as small pieces of servo piston. Carefully install the piston seal rings over
material can get into the system and cause damage. the expander rings. Do not overstretch the piston seal

rings.
Check the wear plate (Item 1) [Figure 30-40-53] and
charge pump gears (Item 2) [Figure 30-40-53] for Figure 30-40-56
damage or wear.
Figure 30-40-54
Lubricate the seal rings and carefully slide the servo

piston (Item 1) [Figure 30-40-56] into the cylinder (Item
2) [Figure 30-40-56]. Allow the assembly to set for 5
Check the valve plate [Figure 30-40-54], the surface minutes to allow the seal rings to return to their original
must be smooth and free of scratches. If scratches can size.
be felt with a finger nail, replace the part.
V518 VersaHANDLER
Inspection (Cont'd)
Figure 30-40-57
Servo arm (Item 1) [Figure 30-40-59] alignment is critical

for proper pump operation. For this reason, removal of
the servo arm from the swash plate is not recommended.
Check the swash plate assembly surface, it must be If the servo arm must be removed from the swash plate.
smooth and free of scratches [Figure 30-40-57]. Remove the swash plate guide bolt (Item 2) [Figure 30-
40-59] and the servo arm mounting bolt (Item 3) [Figure

Figure 30-40-58 30-40-59].
Installation: The servo arm (Item 1) [Figure 30-40-59]

must be carefully aligned with the slot and threaded holes
in the swash plate while installing, and must be pressed
completely into the swash plate slot.
Tighten the swash plate guide bolt and servo arm bolt to
24 ft.-lbs. (32 Nm) torque.
Figure 30-40-60
Inspect the swash plate guide (Item 1) [Figure 30-40-58]

for wear. Replace as needed.
Installation: Tighten the bolt to 24 ft.-lbs. (32 Nm)

torque.
The threaded holes (Item 1) [Figure 30-40-60] in the

swash plate must be cleaned prior to assembly.
V518 VersaHANDLER
Inspection (Cont'd)
Figure 30-40-61
Check the swash plate bearings (Item 1) [Figure 30-40-

63] for wear and damage. Replace as needed.
Figure 30-40-64
Figure 30-40-62

Check each piston (Item 1) [Figure 30-40-64] and piston
If the headed roll pin and flat washer (Item 1) [Figure 30- shoe (Item 2) [Figure 30-40-64] for wear or scratches.
40-61] must be installed in the swash plate, the distance
between the washer and the side of the swash plate must
be .21 inch (5,33 mm) [Figure 30-40-62].
V518 VersaHANDLER
Inspection (Cont'd)
Figure 30-40-65
Inspect the shaft seal (Item 1) [Figure 30-40-67].

Replace if needed.

Check the cylinder block bores for wear or scratches 67].
[Figure 30-40-65].
Inspect the multi-function valve cartridge for damage to

If there is any defect in the cylinder block or pistons, the parts or O-rings.
complete rotating group must be replaced.
Figure 30-40-68
Figure 30-40-66
Replace O-rings as needed [Figure 30-40-68].

Check the shaft for wear or damage in the spline and
bearing areas [Figure 30-40-66].
Check the bearing for correct operation. Remove the

race (Item 1) [Figure 30-40-66] from the shaft only if it is
necessary to replace the bearing.
V518 VersaHANDLER
Assembly
IMPORTANT
damage the system.
I-2003-0888
Prior to assembly
Clean and lightly oil all parts prior to assembly. Apply LOCTITE #242 to four NEW retainer bolts (Item 1)
[Figure 30-40-71]. Install the slipper guide bearings
Figure 30-40-69 (Item 2) [Figure 30-40-71] and spacers (Item 3) [Figure
30-40-71].
Tighten the four bolts to 10 ft.-lbs. (13,5 Nm) torque.

NOTE: Always use NEW retainer bolts with proper
locking compound.
NOTE: The slipper guides and piston slippers must

slide freely on the swash plate.
Figure 30-40-72
Put the piston assemblies into the slipper guide [Figure

30-40-69].
Figure 30-40-70
Lubricate the pistons and cylinder block bores. Install the

assembled swash plate and pistons into the cylinder
block [Figure 30-40-72].
NOTE: The pistons and bores are not selectively

fitted.
Lubricate the slipper running surface on the swash plate,

center the piston and guide on the swash plate [Figure
30-40-70].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-73
Install the bronze slider block (Item 1) [Figure 30-40-75]

on the swash plate servo arm.
Figure 30-40-76
Install the swash plate bearing races (Item 1) [Figure 30-
40-73] into the housing. Note the locating pins are offset
in the housing to assure proper assembly.

Figure 30-40-74
Carefully lower the cylinder block and swash plate

assembly into the housing [Figure 30-40-76].
Assemble and lubricate the bearing cage (Item 1)

[Figure 30-40-74], and install it on the bearing races.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-77
Install new O-rings (Item 1) [Figure 30-40-79] on the

servo end cap.
Lightly lubricate the O-rings and the inner surface of the

Holding the cylinder block and swash plate assembly end cap.
approximately 1/2" (12 mm) above the bearings. Position
the servo piston (Item 1) [Figure 30-40-77] on the bronze Figure 30-40-80

slider block (Item 2) [Figure 30-40-77]. Take care not to
wedge the block, the parts should slide freely.
Figure 30-40-78
Hold the servo piston in position and install the servo end
cap [Figure 30-40-80].
Lower the cylinder block and swash plate assembly until

the swash plate is properly located on the bearings
[Figure 30-40-78].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-81
Align the slot in the swash plate bearing cage (Item 1)

[Figure 30-40-83] with the pin (Item 2) [Figure 30-40-83]
in the swash plate and the pin hole (Item 3) [Figure 30-
40-83] in the housing.
Install the three end cap mounting bolts (Item 1) [Figure
30-40-81]. Tighten to 10 ft.-lbs. (13,5 Nm) torque. Figure 30-40-84

Lightly lubricate the O-rings and inner surface of the
adjustment cover.
Figure 30-40-82
Hook the cage locator link (Item 1) [Figure 30-40-84]

over the pin (Item 2) [Figure 30-40-84] between the
swash plate and washer. Rotate the link into the slot in
the bearing cage.
Install the servo adjustment cover over the servo piston Install the anchor pin (Item 3) [Figure 30-40-84] through
until the piston adjustment screw touches the cover. the locator link and into the housing.
Using a hex wrench, turn the adjustment screw
counterclockwise while holding the cover until it is in
position [Figure 30-40-82].
NOTE: Do not install the bolts at this time.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-85
Install the two guide post bolts (Item 1) [Figure 30-40-87]

through the leveler and inserts. Install the sealing nuts
and tighten to 17 ft.-lbs. (23 Nm) torque.
Push the swashplate assembly toward the servo piston Install a new O-ring (Item 2) [Figure 30-40-87] on the
until the swash plate guide contacts the bearing races. cover.
Check for clearance between the servo arm and the

slider block [Figure 30-40-85]. If no clearance is present, Figure 30-40-88
recheck the assembly of the bearing cage and races.
Figure 30-40-86
Lift the swash plate leveler and install the side cover
[Figure 30-40-88].
Position the two side cover inserts (Item 1) [Figure 30-

40-86] and swashplate leveler (Item 2) [Figure 30-40-86]
on the side cover. Note the orientation of the leveler and
the notch (Item 3) [Figure 30-40-86] in the cover.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-89
Rotate the side cover [Figure 30-40-91] (which will also

rotate the leveler and swash plate) until the zero angle
position is established, as determined by a second depth
measurement.
Install the two side cover bolts (Item 1) [Figure 30-40-89]
finger tight. Figure 30-40-92

Apply a force of 5 - 10 ft.-lbs. (22 - 44 Nm) to the swash
plate leveler to make sure both lever arms contact the
swash plate.
Make sure the swash plate assembly is seated correctly

on the bearings.
Figure 30-40-90
After the zero angle position has been established,

tighten the two side cover bolts (Item 1) [Figure 30-40-
92].
Use a depth micrometer to measure the distance from

the end cap to the swash plate surface (Item 1) [Figure
30-40-90]. Take a second measurement at a point 90°
(Item 2) [Figure 30-40-90] from the first point of
measurement. These measurements must not vary more
than .001 inches (.025 mm).
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-93
Turn the adjustment screw on the servo, which will rotate

the swash plate assembly until a zero angle position is
established [Figure 30-40-95].
Install the four remaining side cover bolts, apply Figure 30-40-96
LOCTITE #242 to the threads of the "thru" bolts (Item 1)
[Figure 30-40-93].

First tighten the four side cover bolts (Item 2) [Figure 30-
40-93] to 24 ft.-lbs. (32,5 Nm) torque. Tighten the two
remaining side cover bolts (Item 1) [Figure 30-40-93] to
18.5 ft.-lbs. (25 Nm) torque.
Figure 30-40-94
Use a depth micrometer to measure the distance from

the end cap to the swash plate surface [Figure 30-40-
96]. Take a second measurement at a point 180° from
the first point of measurement. These measurements
must not vary more than .001 inch (.025 mm).
Install the three servo adjustment cover mounting bolts

(Item 1) [Figure 30-40-94]. Tighten to 10 ft.-lbs. (13,5
Nm) torque.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-97
Lightly lubricate both solenoid spools and install into the

manifold housing and retain with the four screws (Item 1)
[Figure 30-40-99].
Without turning the servo adjustment screw, install the Figure 30-40-100
sealed nut (Item 1) [Figure 30-40-97] and tighten.

Figure 30-40-98
Apply assembly lube on the gasket (Item 1) [Figure 30-

40-100] and install on the manifold housing.
Install new O-rings (Item 1) [Figure 30-40-98] on the

solenoid spool.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-101
Install the spring seats (Item 1) [Figure 30-40-103] on

the leveler arms.
Figure 30-40-104
Install the manifold assembly (Item 1) [Figure 30-40-101]
on the pump with the six screws (Item 2) [Figure 30-40-
101].

Figure 30-40-102
Install both springs (Item 1) [Figure 30-40-104] on the

leveler spring seats.
Lubricate the running surface of the cylinder (Item 2)

[Figure 30-40-104].
Install the spring (Item 1) [Figure 30-40-102] on the
servo arm link.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-105
Lubricate the end cap journal bearing (Item 1) [Figure

30-40-107]. Install the hardened shims (Item 2) [Figure
30-40-107] in the charge pump pockets for the swash
plate leveler springs. Retain the shims with assembly
Install the valve plate (Item 1) [Figure 30-40-105] on the lube.
alignment pins.
Turn the charge pump housing over.

NOTE: The direction of the arrow cut outs (Item 2)
[Figure 30-40-105] in the valve plate. Figure 30-40-108
Figure 30-40-106
Lightly lubricate the alignment pin (Item 1) [Figure 30-40-

108] and install into the charge pump housing, in the
Install a new gasket (Item 1) [Figure 30-40-106] on the position marked at time of disassembly. This will properly
housing. align the wear plate and eccentric ring.
Install a new O-ring (Item 2) [Figure 30-40-108].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-109
Apply assembly lube and install the charge pump gears

(Item 1) [Figure 30-40-111], charge pump shaft (Item 2)
[Figure 30-40-111] and key (Item 3) [Figure 30-40-111]
into the pump.
Lubricate both sides of the wear plate (Item 1) [Figure
30-40-109] and install in the charge pump. Align the wear Figure 30-40-112
plate with the alignment pin (Item 2) [Figure 30-40-109].

Figure 30-40-110
Install the coupler (Item 1) [Figure 30-40-112].
Install the eccentric ring (Item 1) [Figure 30-40-110] in

the charge pump and align with the alignment pin (Item
2) [Figure 30-40-110].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-113
Lower the charge pump onto the pump housing while

positioning the three springs in their pockets [Figure 30-
40-115].
Install the charge pump cover (Item 1) [Figure 30-40- When properly installed, the charge pump will engage
113]. the alignment pins, but the springs will hold the charge
pump housing 1/8 to 1/4 (3 to 8 mm) away from the pump

Rotate until pin hole in cover aligns with the pin. housing.
Figure 30-40-114 Figure 30-40-116
Install the retaining plate cover (Item 1) [Figure 30-40- Install the flange adapter (Item 1) [Figure 30-40-116] and
114] and six bolts (Item 2) [Figure 30-40-114]. Tighten four bolts (Item 2) [Figure 30-40-116]. Tighten the bolts
the bolts to 10 ft.-lbs. (13,5 Nm) torque. to 90 ft.-lbs. (122 Nm) torque.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-117
Install the plug with lock nut (Item 1) [Figure 30-40-119],

align the marks made at disassembly. Tighten the lock
nut to 38 ft.-lbs. (52 Nm) torque.
Install the two mounting bolts (Item 1) [Figure 30-40-117] Figure 30-40-120

NOTE: Install the lifting bracket (Item 2) [Figure 30-
40-117].
Figure 30-40-118
Lightly lubricate and install both multi-function valve

assemblies (Item 1) [Figure 30-40-120] in the charge
pump. Tighten to 66 ft.-lbs. (89 Nm) torque.
Install the spring and relief poppet into the charge pump
[Figure 30-40-118].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-121
Install a new O-ring (Item 1) [Figure 30-40-123].
Lubricate the seal with assembly lube and install the seal
assembly on the drive shaft and in the housing [Figure
Install the bearing (Item 1) [Figure 30-40-121], the 30-40-122].
spacer washer (Item 2) [Figure 30-40-121] and the snap
ring (Item 3) [Figure 30-40-121] on the drive shaft. Figure 30-40-124

Position the pump on the charge pump end.
Figure 30-40-122
Install the retainer plate (Item 1) [Figure 30-40-124] and

three bolts (Item 2) [Figure 30-40-124]. Tighten the bolts
in a sequenced pattern to 12 ft.-lbs. (16 Nm) torque.
Install the shaft and bearing assembly, aligning the shaft

spline with the cylinder block spline. Continue to lower
the shaft and align with the charge pump journal bearing
and charge pump coupler [Figure 30-40-122].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-125
Install the coupler gear (Item 1) [Figure 30-40-127] on

the shaft and install the bolt (Item 2) [Figure 30-40-127].
Figure 30-40-128
Install the filter head (Item 1) [Figure 30-40-125] on the
pump.

Tighten to 90 ft.-lbs. (122 Nm) torque.
Figure 30-40-126
NOTE: When installing the coupler, maintain a .0625

inch (1,59 mm) gap from the pump mount
flange to the coupler [Figure 30-40-127] &
[Figure 30-40-128].
Remove the case plug (Item 3) [Figure 30-40-127] and

Install a new filter (Item 1) [Figure 30-40-126] on the fill with clean hydraulic fluid prior to start up.
pump.
Rotate the pump shaft with a torque wrench to assure
correct assembly. The torque required to turn the shaft
(after "break away") should be within:
MINIMUM MAXIMUM
4 ft.-lbs. (5,4 Nm) 9 ft.-lbs. (12,2 Nm)
V518 VersaHANDLER
DRIVE SYSTEM
AXLE AND DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Axle Housing/Drive Axle Assembly . . . . . . . . . . . . . . . . . 40-20-52
Axle Housing/Drive Axle Disassembly . . . . . . . . . . . . . . . 40-20-13
Axle Housing/Drive Axle Parts Identification . . . . . . . . . . 40-20-12
Brake Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-42
Brake Group Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 40-20-18
Brake Group Parts Identification . . . . . . . . . . . . . . . . . . . 40-20-18
Brake Housing Inspection . . . . . . . . . . . . . . . . . . . . . . . . 40-20-24
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-39
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-25
Differential Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-28
DIFFERENTIAL Parts Identification. . . . . . . . . . . . . . . . . 40-20-25
Planetary Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . 40-20-2
Planetary Carrier Inspection . . . . . . . . . . . . . . . . . . . . . . . 40-20-4
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Pinion Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-33
Pinion Group Disassembly. . . . . . . . . . . . . . . . . . . . . . . . 40-20-30
Pinion Group Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-32
Pinion Group Parts Identification . . . . . . . . . . . . . . . . . . . 40-10-29

Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . 40-20-62
Planetary Carrier Parts Identification . . . . . . . . . . . . . . . . . 40-20-1
Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . 40-20-57
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . 40-20-10
Steering Knuckle Parts Identification . . . . . . . . . . . . . . . . . 40-20-9
Wheel Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-6
Wheel Hub Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-9
Wheel Hub Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-60
Wheel Hub Parts Identification. . . . . . . . . . . . . . . . . . . . . . 40-20-5
AXLE TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-7
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

Re-Activating The Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-2
Releasing The Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
STEERING ANGLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 40-60-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
V518 VersaHANDLER
V518 VersaHANDLER
TROUBLESHOOTING
Chart
The following Troubleshooting Chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Pinion or Ring gear tooth broken 1, 2, 3, 4, 5, 6
Pinion teeth pitted 5, 11
Axle housing bent 12, 13
Worn or pitted bearings 3, 5, 6, 8, 11, 14
Oil leakage 6, 9, 10, 14, 15
Excessive wear on input shaft splines 3, 16, 17, 19
Pinion teeth fatigue 7, 12, 17, 19
Side gear spline worn 17, 19
Thrust washer surface worn 5, 6, 7
Inner diameter of tapered roller bearing worn 5, 6, 18, 19
Bent or broken half shaft 19
Half shaft broken at wheel side 20, 21

KEY TO CORRECT THE CAUSE
1. Excessive gear load
2. Incorrect gear adjustment (excessive play)
3. Pinion nut loose
4. Incorrect gear adjustment (insufficient play)
5. Insufficient lubrication
6. Contaminated oil
7. Incorrect lubrication
8. Worn bearings
9. Operation at high temperature
10. Low oil level
11. Excessive use
12. Overloaded
13. Accident
14. Normal Wear
15. Lip seal damaged
16. Pinion axle play
17. Continuous overload
18. Excessive pinion axle play
19. Vehicle intensively operated or overloaded
20. Wheel loose
21. Beam housing bent
V518 VersaHANDLER
V518 VersaHANDLER
AXLE AND DIFFERENTIAL The rear axle is the same as the front axle, except that it
is NOT equipped with brakes.
General Information
Axle removal. (See Removal on Page 40-30-1.)
For photo clarity, the following axle procedures are done
with the complete axle assembly removed from the Drive motor removal. (See Removal And Installation on
machine, although the planetary carrier, wheel hub, Page 30-30-1.)
steering knuckle and drive axle procedures may be done
with the axle assembly installed in the machine. For Drive box removal. (See DRIVE BOX on Page 20-70-1.)
complete axle repair, the following must be done.
Steering cylinder removal. (See Removal And Installation
on Page 20-60-1.)
Planetary Carrier Parts Identification
V158 VarsaHANDLER
AXLE AND DIFFERENTIAL (CONT'D) Figure 40-20-3
Planetary Carrier Disassembly
IMPORTANT
damage the system.
I-2003-0888
Figure 40-20-1
Remove the planetary carrier (Item 1) [Figure 40-20-3]
from the axle.
Figure 40-20-4

With the drain plug (Item 1) [Figure 40-20-1] in the
position shown, place a drain pan under the hub and
remove the plug.
Figure 40-20-2 Remove and discard the O-ring (Item 1) [Figure 40-20-4]
from the planetary carrier.
Remove the two screws (Item 1) [Figure 40-20-2] from

the planetary carrier.
V158 VarsaHANDLER
Planetary Carrier Disassembly (Cont'd)
Figure 40-20-5
Remove the three gears (Item 1) [Figure 40-20-7] with

needle bearings from each gear shaft.
NOTE: Mark the gear location for correct assembly.

Remove the three snap rings (Item 1) [Figure 40-20-5].
Figure 40-20-8
Figure 40-20-6

Remove the thrust washers (Item 1) [Figure 40-20-8]
Remove the thrust plate (Item 1) [Figure 40-20-6]. from each shaft.
V158 VarsaHANDLER
Planetary Carrier Inspection
Figure 40-20-9
If any of the bearing shafts (Item 1) [Figure 40-20-10] are

damaged, replace all bearing shafts.
If the thrust pin (Item 2) [Figure 40-20-10] is worn,

Inspect the planetary gears (Item 1) [Figure 40-20-9] for replace the entire planetary carrier.
worn or cracked teeth.

If any of the planetary gears are damaged, replace all the
planetary gears and drive axle end of the drive axle
assembly. One damaged gear can cause a microscopic
fatigue crack in mating teeth and cause premature failure
after servicing.
V158 VarsaHANDLER
AXLE AND DIFFERENTIAL (CONT'D)
Wheel Hub Parts Identification
V158 VarsaHANDLER
Wheel Hub Disassembly
Figure 40-20-11
Remove the six ring gear mounting bolts (Item 1) [Figure

40-20-13].
Figure 40-20-14
Figure 40-20-12

Install two bolts (Item 1) [Figure 40-20-14] into the ring
gear as shown, and tighten equally pushing the ring gear
assembly (Item 2) [Figure 40-20-14] from the shaft.
Remove the thrust washer (Item 1) [Figure 40-20-12]
and spacer (Item 2) [Figure 40-20-12].
V158 VarsaHANDLER
Wheel Hub Disassembly (Cont'd)
Figure 40-20-15
Remove the inner bearing (Item 1) [Figure 40-20-17]

from the swivel housing.
Figure 40-20-18
Remove the ring gear assembly [Figure 40-20-15].
Figure 40-20-16

Remove the retainer ring (Item 1) [Figure 40-20-18] from
the ring gear assembly.
Remove the outer bearing and hub assembly from the

axle [Figure 40-20-16].
NOTE: Use care while removing, as assembly may

remove easy.
V158 VarsaHANDLER
Wheel Hub Disassembly (Cont'd)
Figure 40-20-19

hub.
Figure 40-20-22
Remove the gear (Item 1) [Figure 40-20-19] from the
ring gear (Item 2) [Figure 40-20-19].

Figure 40-20-20
Using a brass drift remove both bearing races (Item 1)

[Figure 40-20-22] from the hub.
Remove the six bushings (Item 1) [Figure 40-20-20]

from the gear if damaged or worn.
V158 VarsaHANDLER
AXLE AND DIFFERENTIAL (CONT'D) Inspect the ring gear (Item 1) [Figure 40-20-23] and
inner gear (Item 2) [Figure 40-20-23] for broken or
Wheel Hub Inspection damaged teeth.
Figure 40-20-23 Replace both parts if needed.
Steering Knuckle Parts Identification
V158 VarsaHANDLER
Steering Knuckle Disassembly
Figure 40-20-24
Lift and remove the knuckle assembly from the axle

[Figure 40-20-26].
Figure 40-20-27
king pin (Item 2) [Figure 40-20-24] from the bottom of
the knuckle.

Figure 40-20-25
Remove the Belleville washers (Item 1) [Figure 40-20-

27] from the top and bottom of the axle.
NOTE: The bottom Belleville washer is smaller than

the top Belleville washer.
Remove the two bolts (Item 1) [Figure 40-20-25] and
king pin (Item 2) [Figure 40-20-25] from the top of the
knuckle.
V158 VarsaHANDLER
Steering Knuckle Disassembly (Cont'd)
Figure 40-20-28
Using a puller, remove the top and bottom bushings from

the axle [Figure 40-20-29] & [Figure 40-20-30].
Figure 40-20-31
Remove the spacer washer (Item 1) [Figure 40-20-28]
from the top of the axle.

Figure 40-20-29

knuckle assembly.
V158 VarsaHANDLER
Steering Knuckle Disassembly (Cont'd)
Figure 40-20-32
Remove the ball type bearing (Item 1) [Figure 40-20-33]

from the lower king pin.
NOTE: Removal procedure will destroy the ball

Remove the bushing (Item 1) [Figure 40-20-32] from the bearing.
knuckle assembly.

Axle Housing/Drive Axle Parts Identification
V158 VarsaHANDLER
Axle Housing/Drive Axle Disassembly
Figure 40-20-34
Remove the two snap rings (Item 1) [Figure 40-20-36]

across from each other.
Figure 40-20-37
Remove the drive axle from the axle housing [Figure 40-
20-34].

Figure 40-20-35
Drive the upper bearing cup down to push the opposite

bearing cup partially through the yoke [Figure 40-20-37].
NOTE: The bottom bearing cup will not be completely

Remove the seal (Item 1) [Figure 40-20-35] and bushing removed.
(Item 2) [Figure 40-20-35] from the axle end housing.
V158 VarsaHANDLER
Axle Housing/Drive Axle Disassembly (Cont'd)
Figure 40-20-38
Turn the shaft over and remove the bearing cup (Item 1)
[Figure 40-20-40]. Remove the drive shaft (Item 2)
[Figure 40-20-40] from the yoke.
Turn the shaft over and remove the bearing cup (Item 1) Figure 40-20-41
[Figure 40-20-38].

Figure 40-20-39
Remove the two snap rings (Item 1) [Figure 40-20-41]

from the yoke.
Drive the cross (Item 1) [Figure 40-20-39] down to push

the opposite bearing cup through the yoke.
NOTE: Drive shaft end (Item 2) [Figure 40-20-39] may

fall out of the yoke.
V158 VarsaHANDLER
Figure 40-20-42
Press the second bearing cup through the yoke [Figure

40-20-44].
Figure 40-20-45
Using two different size sockets and a vice, press one
bearing cup into the yoke while pushing the opposite
bearing cup through the yoke [Figure 40-20-42].

Figure 40-20-43
Remove the bearing cup (Item 1) [Figure 40-20-45] and

cross (Item 2) [Figure 40-20-45] from the yoke.
Remove the bearing cup (Item 1) [Figure 40-20-43].
V158 VarsaHANDLER
Figure 40-20-46
Remove the nut (Item 1) [Figure 40-20-48] from the

bottom of the housing.
Figure 40-20-49
With the axle supported on a secure work surface or floor
mark the axle housing to the center housing for correct

Figure 40-20-47
Remove the remaining mounting bolts (Item 1) [Figure

40-20-49].
Remove the two axle housing mounting bolts and install

two alignment bolts (Item 1) [Figure 40-20-47].
V158 VarsaHANDLER
Figure 40-20-50

axle housing.
Separate the axle housing from the brake housing

[Figure 40-20-50].

Remove the axle housing.
V158 VarsaHANDLER
Brake Group Parts Identification

Brake Group Disassembly Figure 40-20-53
Figure 40-20-52
Remove the tube lines (Item 1) [Figure 40-20-53].
Remove the brake separator plates, friction plates and NOTE: Mark the tube lines for correct installation.
coupler from the brake housing [Figure 40-20-52].
NOTE: For friction plate replacement do not remove

the brake housing.
V158 VarsaHANDLER
Brake Group Disassembly (Cont'd)
Figure 40-20-54
Separate and remove the brake housing from the center

Figure 40-20-57
Remove the stud bolt (Item 1) [Figure 40-20-54] from the
housing.

Figure 40-20-55

57] from the center housing.
Remove the upper mounting bolt (Item 1) [Figure 40-20-

V158 VarsaHANDLER
Figure 40-20-58
Remove and discard the two O-rings (Item 1) [Figure 40-

20-60] from the piston.
Figure 40-20-61
the brake housing.

NOTE: There are six bevel washers nested in
opposing direction on each bolt.
Figure 40-20-59
Turn the three brake adjusting screws (Item 1) [Figure

40-20-61] out (counterclockwise) equally.

61].

brake housing.
V158 VarsaHANDLER
Figure 40-20-62
Remove the split ring retainer (Item 1) [Figure 40-20-64].
Figure 40-20-65
Using a 6-1/2 inch O.D. tube and suitable press, apply

enough downward pressure on the Belleville springs
allowing the split ring retainer ring to drop down [Figure

40-20-62].
Figure 40-20-63
Remove the two Belleville springs (Item 1) [Figure 40-

20-65].
With the split ring retainer ring (Item 1) [Figure 40-20-63]

in the down position, remove the split ring (Item 2)
[Figure 40-20-63].
Carefully release the pressure and remove the brake

housing from the press.
V158 VarsaHANDLER
Figure 40-20-66
Remove and discard the two O-rings (Item 1) [Figure 40-

20-68] from the pins.
Figure 40-20-69
Remove the three snap rings (Item 1) [Figure 40-20-66]
from the pins.

Figure 40-20-67
Remove the brake plate (Item 1) [Figure 40-20-69] from

the brake housing.
Push the three pins (Item 1) [Figure 40-20-67] from the

brake plate.
V158 VarsaHANDLER
Figure 40-20-70

72] from the adjusting screw.
Figure 40-20-73
Remove the two O-rings (Item 1) [Figure 40-20-70] from
the brake plate.

Figure 40-20-71
Turn the brake housing over and remove the lock nut
retainer (Item 1) [Figure 40-20-73] and bolt (Item 2)
[Figure 40-20-73].
Remove the jam nut (Item 1) [Figure 40-20-71] adjusting

screw (Item 2) [Figure 40-20-71] and wedge (Item 3)
[Figure 40-20-71] from the brake housing.
V158 VarsaHANDLER
AXLE AND DIFFERENTIAL (CONT'D) Brake Housing Inspection
Brake Group Disassembly (Cont'd) Figure 40-20-76
Figure 40-20-74
Inspect the friction plates (Item 1) [Figure 40-20-76] for

wear. Replace all friction plates at the same time.
Remove the internal nut (Item 1) [Figure 40-20-74] from
the brake housing by rotating counterclockwise using Figure 40-20-77
special tool CA119030.

Figure 40-20-75
Inspect the internal and external splines on the coupler

for damage or wear [Figure 40-20-77].
Remove the race by gently taping out of the brake

V158 VarsaHANDLER
DIFFERENTIAL Parts Identification

Differential Disassembly Figure 40-20-79
Figure 40-20-78
Mark the housing for correct assembly [Figure 40-20-

79].
Remove the differential assembly (Item 1) [Figure 40-20-
78] from the axle housing.
V158 VarsaHANDLER
Differential Disassembly (Cont'd)
Figure 40-20-80
Remove the discs and spacers (Item 1) [Figure 40-20-

82] from the pinion gear.
Figure 40-20-83
Support the differential assembly in a vise. Remove the
twelve bolts (Item 1) [Figure 40-20-80] and ring gear
(Item 2) [Figure 40-20-80].

Figure 40-20-81
Remove the pinion gear (Item 1) [Figure 40-20-83].
Separate the housings [Figure 40-20-81].
V158 VarsaHANDLER
Differential Disassembly (Cont'd)
Figure 40-20-84
Remove the gear (Item 1) [Figure 40-20-86] and cup

washer (Item 2) [Figure 40-20-86] from the spindle (Item
3) [Figure 40-20-86].
Remove the spindle/gear assemblies (Item 1) [Figure

40-20-84].

Figure 40-20-85
Remove the bearing from the housing [Figure 40-20-85].
V158 VarsaHANDLER
Differential Inspection
Figure 40-20-87
Inspect the cup washers (Item 1) [Figure 40-20-89] for

damage or wear. Replace as needed.
Figure 40-20-88

Inspect the pinion gear [Figure 40-20-87] & [Figure 40-
20-88] for broken or damaged teeth.
Replace both parts if needed.
V158 VarsaHANDLER
Pinion Group Parts Identification
V158 VarsaHANDLER
Pinion Group Disassembly
Figure 40-20-90
Free the pinion from the housing using a soft hammer

[Figure 40-20-92].
Figure 40-20-93
Pry up the peened notch (Item 1) [Figure 40-20-90] in
the nut.

Loosen the nut using special tools CA119099 and
CA715022.
Figure 40-20-91
Remove the nut (Item 1) [Figure 40-20-91] and washer

(Item 2) [Figure 40-20-91].
V158 VarsaHANDLER
Pinion Group Disassembly (Cont'd)
Figure 40-20-94
Remove the two washers (Item 1) [Figure 40-20-96] and

spacer (Item 2) [Figure 40-20-96] from the pinion shaft.
Figure 40-20-97
Remove the pinion shaft from the housing [Figure 40-20-
94].

Figure 40-20-95
Remove the bearing from the pinion shaft [Figure 40-20-

97].
Remove the outer bearing (Item 1) [Figure 40-20-95].
V158 VarsaHANDLER
AXLE AND DIFFERENTIAL (CONT'D) Pinion Group Inspection
Pinion Group Disassembly (Cont'd) Figure 40-20-100
Figure 40-20-98
Inspect the pinion gear (Item 1) [Figure 40-20-100] and

shaft splines (Item 2) [Figure 40-20-100] for broken or
Remove the inner race from the housing [Figure 40-20- damaged teeth.
98].

Figure 40-20-99
Remove the outer race from the housing [Figure 40-20-

99].
V158 VarsaHANDLER
Pinion Group Assembly
IMPORTANT
damage the system.
I-2003-0888
Figure 40-20-101
Install the bearing (Item 1) [Figure 40-20-103] onto the
dummy pinion tool CA715040.
Figure 40-20-104

Install the outer race [Figure 40-20-101].
Figure 40-20-102
Install the dummy pinion and bearing into the center

housing and install the outer bearing and lock nut [Figure
40-20-104].
Tighten the lock nut to eliminate any bearing end play.

DO NOT overtighten the nut.
Install the inner race [Figure 40-20-102].
Prior to assembly, clean and lightly oil all parts.
V158 VarsaHANDLER
Pinion Group Assembly (Cont'd)
Figure 40-20-105
Insert the dummy differential tool CA715041 into the

brake housings [Figure 40-20-107].
Figure 40-20-106

Install both brake housings (Item 1) [Figure 40-20-105]
onto the center housing. Install and tighten the bolt (Item
1) [Figure 40-20-106].
V158 VarsaHANDLER
Figure 40-20-108
To determine the thickness of the shim to be installed

between the pinion and bearing, subtract the value
stamped on the end of the pinion (Item 1) [Figure 40-20-
110] from the value X (above).
Figure 40-20-109
Figure 40-20-111

Using a depth gauge (Item 1) [Figure 40-20-108] &
[Figure 40-20-109] measure thru the reference hole in Select the shim [Figure 40-20-111] from the chart below:
the dummy pinion.
SHIM THICKNESS RANGE
X = (distance to be measured)
A = (measured value) Thick 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
B = (given value) = 100 ± 0,01 mm Qty. - - - - - - - - - -
C = (given value) = 45 mm
(A + C) - B = X
V158 VarsaHANDLER
Figure 40-20-112
Remove the dummy pinion tool (Item 1) [Figure 40-20-

Figure 40-20-115
Remove the dummy differential tool [Figure 40-20-112].
Figure 40-20-113

Remove the bearing (Item 1) [Figure 40-20-115] from
the dummy pinion.
Remove both brake housings (Item 1) [Figure 40-20-

V158 VarsaHANDLER
Figure 40-20-116
Install the two washers (Item 1) [Figure 40-20-118] and

collapsible spacer (Item 2) [Figure 40-20-118] onto the
shaft.
Install the shims selected (Item 1) [Figure 40-20-116] Figure 40-20-119

onto the pinion shaft.

NOTE: The beveled edge must go towards the gear.
Figure 40-20-117
Install the pinion gear assembly into the center housing

and install the outer bearing [Figure 40-20-119].
NOTE: Drive the outer bearing onto the shaft, have an

assistant place a second hammer on the
Install the bearing (Item 1) [Figure 40-20-117] onto the pinion head to absorb the impact.
pinion shaft until it is fully seated.
V158 VarsaHANDLER
Figure 40-20-120
Install the special tool CA715116 (Item 1) [Figure 40-20-

122] onto the pinion shaft.
Figure 40-20-123
Install the backing washer (Item 1) [Figure 40-20-120]
and nut (Item 2) [Figure 40-20-120].

Tighten the nut using the special tools CA119099 and
CA715022.
NOTE: The tightening torque is determined by

measuring the force required to rotate the
pinion (preload of bearings).
Figure 40-20-121
Attach one end of a light rope to the special tool [Figure

40-20-123]. Make 2 or 3 complete wraps around the tool.
Attach the spring scale perpendicular to the housing to
measure the rolling torque on the bearings. Tighten (or
loosen) the nut (Item 1) [Figure 40-20-121] until 2-3 lb
(.9 - 1.4 Kg) of smooth and continuous rolling torque is
measured on the spring scale.
SEE STEP BELOW. Tighten the nut in incremental steps.

If overtightened (preload to high) the collapsed spacer
must be replaced and the procedure repeated [Figure
40-20-121].
V158 VarsaHANDLER
Differential Assembly
Figure 40-20-124
Install the remaining discs (Item 1) [Figure 40-20-126]

onto the shaft, alternating between steel and friction.
Figure 40-20-127
Install the bearing (Item 1) [Figure 40-20-124] onto each
housing.

Figure 40-20-125
Install the gear/disc assembly into the housing [Figure

40-20-127].
NOTE: Make sure the disc remains in correct position.

Install the disc (Item 1) [Figure 40-20-125] that is one
half friction and the other half metal onto the gear splines.
NOTE: The metal side must be next to the gear.
V158 VarsaHANDLER
Differential Assembly (Cont'd)
Figure 40-20-128
Set the gear/discs assembly (Item 1) [Figure 40-20-130]

onto the spindle gears.
Figure 40-20-131
Install the gear (Item 1) [Figure 40-20-128] cup washer
(Item 2) [Figure 40-20-128] onto the spindle (Item 3)
[Figure 40-20-128].

Figure 40-20-129
Install the housing (Item 1) [Figure 40-20-131] onto the

housing/gear assembly (Item 2) [Figure 40-20-131].
Make sure to align the reference marks made earlier.
Install the spindle/gear assemblies (Item 1) [Figure 40-

20-129] into the housing.
V158 VarsaHANDLER
Differential Assembly (Cont'd)
Figure 40-20-132
Apply LOCTITE #270 to the end of the mounting bolts

[Figure 40-20-133].
Install the ring gear (Item 1) [Figure 40-20-132] and

twelve bolts (Item 2) [Figure 40-20-132]. Tighten the
bolts to 58 ft.-lbs. (78 Nm) torque.
V158 VarsaHANDLER
Brake Group Assembly
Figure 40-20-134
Lightly lubricate and install two new O-rings (Item 1)

[Figure 40-20-136] onto the brake plate.
Figure 40-20-137
Install the bearing race into the housing until it is flush
with center surface (Item 1) [Figure 40-20-134].

Figure 40-20-135
Lightly lubricate and install new O-rings (Item 1) [Figure

40-20-137] onto the pins.
Install the internal adjusting nut (Item 1) [Figure 40-20-

135] into the brake housing by rotating clockwise until it
is tight against the bearing race.
V158 VarsaHANDLER
Brake Group Assembly (Cont'd)
Figure 40-20-138
Install the three wedges (Item 1) [Figure 40-20-140] into

the brake housing as shown.
Figure 40-20-141
Install the three pins into the brake plate and retain with
the snap rings (Item 1) [Figure 40-20-138].

Figure 40-20-139
Lubricate and install a new O-ring (Item 1) [Figure 40-20-

141] onto the adjusting screw.
Install the adjusting screw (Item 2) [Figure 40-20-141]

Align the holes in the brake housing with the pins (Item 1) and jam nut (Item 3) [Figure 40-20-141] into the housing.
[Figure 40-20-139] and install the brake plate into the
brake housing until it is fully seated.
Turn the brake housing over.
V158 VarsaHANDLER
Figure 40-20-142
Using a 6-1/2 inch O.D. tube and suitable press, apply

enough downward pressure on the Belleville springs
allowing the split ring retainer to drop down [Figure 40-
20-144].
Install the Belleville springs (Item 1) [Figure 40-20-142]
into the brake housing. NOTE: Make sure the Belleville springs are centered
in the housing.

NOTE: The inner edges of the Belleville springs must
touch for correct installation. Figure 40-20-145
Figure 40-20-143
With the split ring retainer (Item 1) [Figure 40-20-145] in

the down position, install the split ring (Item 2) [Figure
Temporarily place the spring ring retainer ring (Item 1) 40-20-145] into the groove in the brake housing.
[Figure 40-20-143] on the Belleville springs.
Carefully release press pressure making sure that the
split ring is fully seating the housing groove and the
retainer ring secures the split ring.
Remove the housing from the press.
V158 VarsaHANDLER
Figure 40-20-146
Align the holes in the piston and the threaded holes in the
housing and install the piston into the housing [Figure
40-20-148].
Install a new O-ring (Item 1) [Figure 40-20-146] on the Figure 40-20-149

housing.

Turn the three brake adjusting screws (Item 2) [Figure
40-20-146] in (clockwise) equally.
Figure 40-20-147
Be sure that the bolt assembly is in the arrangement

shown [Figure 40-20-149].
Lightly lubricate and install two new O-rings (Item 1)

[Figure 40-20-147] onto the piston.
V158 VarsaHANDLER
Figure 40-20-150
Set the pinion assembly (Item 1) [Figure 40-20-152] in

the center housing as shown. Install the two guide bolts
(Item 2) [Figure 40-20-152].
Install the bolt assembly (Item 1) [Figure 40-20-150] into Figure 40-20-153
the brake housing and tighten washer to 7 ft.-lbs. (10
Nm) torque.

Figure 40-20-151
Install the brake housing and two bolts (Item 1) [Figure

40-20-153].
NOTE: Be sure the bearing (Item 2) [Figure 40-20-153]

Install a new O-ring (Item 1) [Figure 40-20-151] onto the on the pinion gear is aligned with the brake
center housing. housing race.
V158 VarsaHANDLER
Figure 40-20-154
Install the tool CA715055 (Item 1) [Figure 40-20-156] on

the pinion shaft [Figure 40-20-156].
Figure 40-20-157
Install the two guide bolts (Item 1) [Figure 40-20-154].
Figure 40-20-155

Using a dial gauge, move the pinion shaft back and forth
and make a note of the backlash between the pinion and
ring gear [Figure 40-20-157].
Install the brake housing and two bolts (Item 1) [Figure
40-20-155]. Check that the backlash is within the allowed margins of
0.007 - 0.009 inches (0.18 - 0.23 mm).
NOTE: Be sure the bearing on the pinion gear is
aligned with the brake housing race.
Tighten the upper bolt to 59 ft.-lbs. (80 Nm) and the

bottom to 88 ft.-lbs. (120 Nm) torque.
V158 VarsaHANDLER
Figure 40-20-158
Attach one end of a light rope to the special tool and

make 2 or 3 wraps around the tool. Attach the spring
scale to the opposite end of the rope. Pull the scale
perpendicular to the housing to measure the rolling
Adjusting the lock nuts [Figure 40-20-158]: torque on the bearings. The value is 2 - 3 lbs. (0.9 to 1.4
- If the backlash measured is under the permissible range, Kg) [Figure 40-20-160].
tighten the lock nut on the side opposite the crown wheel

and unscrew the lock nut on the other side by the same - If the total preload is under the permissible range, tighten
amount. the two lock nuts by same amount, retaining the value of
- If the backlash is above the permissible range, tighten the pinion ring gear backlash.
the lock nut on the side of the crown wheel and loosen the -If the total preload is above the permissible range,
lock nut on the other side by the same amount. slacken the two lock nuts by the same amount, retaining
Once the pinion and ring gear adjustment has been the value of the pinion ring gear backlash.
carried out, check that there is at least a minimal preload Figure 40-20-161
on the differential cage bearings. If necessary, repeat the
steps if backlash is still outside the permissible ranges.
Once the pinion/ring gear backlash has been determined,

the total preload of the pinion ring gear wheel bearings
must be measured, to verify that if falls within the
permissible limits.
Figure 40-20-159
Stake the lock nut (Item 1) [Figure 40-20-161] on the

pinion.
Install the special tool CA715116 (Item 1) [Figure 40-20-

159] onto the pinion shaft.
V158 VarsaHANDLER
Figure 40-20-162
Temporarily install the brake housing and bolts (Item 1)

[Figure 40-20-164].
Figure 40-20-165
Temporarily remove the brake housing bolts (Item 1)
[Figure 40-20-162] opposite from the ring gear. Remove
the brake housing.

Figure 40-20-163
Turn the pinion using the special tool CA715022 several

turns [Figure 40-20-165].
Remove the brake housing [Figure 40-20-162].
Use colored lead and brush to paint 3 or 4 teeth of the

ring gear in three opposite places [Figure 40-20-163].
V158 VarsaHANDLER
Check the wear pattern of the pinion/ring gear teeth.
Figure 40-20-166
Excessive contact on flank of tooth - adjust the backlash

[Figure 40-20-168].
Figure 40-20-169
Correct Pattern - If pinion/ring gear has been properly

adjusted, wear pattern (contact) should be shown
[Figure 40-20-166].
Figure 40-20-167
Once the wear pattern is correct, install the lock nut

retainer (Item 1) [Figure 40-20-169] and bolt (Item 2)
[Figure 40-20-169] tighten the bolt to 10 ft.-lbs. (13 Nm)
torque.
Excessive contact on tooth edge - adjust the backlash

[Figure 40-20-167].
V158 VarsaHANDLER
Figure 40-20-170
Install the coupler (Item 1) [Figure 40-20-172] in the

friction plate.
Figure 40-20-173
Install the two tubelines (Item 1) [Figure 40-20-170].
Figure 40-20-171

Note the position of the groove (Item 2) [Figure 40-20-
173] in the coupler.
Install the thick spacer plate into the grooves in the brake Install the second friction plate (Item 1) [Figure 40-20-
housing followed by a friction plate and a thin spacer 173] onto the coupler (Item 2) [Figure 40-20-173].
plate [Figure 40-20-171].
V158 VarsaHANDLER
Figure 40-20-174
Install the axle housing onto the brake housing by sliding

on the alignment pins [Figure 40-20-176].
Figure 40-20-177
Install the second thick spacer plate followed by the thin
spacer plate [Figure 40-20-174].

Axle Housing/Drive Axle Assembly
Figure 40-20-175
Install and tighten the mounting bolts (Item 1) [Figure 40-

20-177].
Install a new O-ring (Item 1) [Figure 40-20-175] on the

axle housing.
V158 VarsaHANDLER
Axle Housing/Drive Axle Assembly (Cont'd)
Figure 40-20-178
Remove the two alignment bolts (Item 1) [Figure 40-20-

179], install the two remaining bolts, tighten all bolts to
236 ft.-lbs. (320 Nm) torque.
Install the nut (Item 1) [Figure 40-20-178] to the stud on

the bottom of the housing. Tighten to 140 ft.-lbs. (190
Nm) torque.
V158 VarsaHANDLER
Figure 40-20-180
Press the bearing cup into the yoke [Figure 40-20-182].
Figure 40-20-183
Partially install a new bearing cup (Item 1) [Figure 40-20-

180] into the yoke.

Figure 40-20-181
Install the second bearing cup into the yoke and press
onto the cross [Figure 40-20-183].
NOTE: Use care not to lose or drop any needle

bearings out of position.
Install the cross (Item 1) [Figure 40-20-181] into the
bearing cup.
V158 VarsaHANDLER
Figure 40-20-184
Partially install a new bearing cup (Item 1) [Figure 40-20-

186] into the yoke.
Figure 40-20-187
Fully press the two bearing cups into the drive shaft yoke
[Figure 40-20-184].

Figure 40-20-185
Install the cross/shaft assembly into the bearing cup

[Figure 40-20-187].
Install the two snap rings (Item 1) [Figure 40-20-185].
V158 VarsaHANDLER
Figure 40-20-188
Install a new bushing (Item 1) [Figure 40-20-190] and

seal (Item 2) [Figure 40-20-190] into the axle housing.
Lightly lubricate the new seal and bushing.

Install the second bearing cup into the yoke and press
onto the cross [Figure 40-20-188]. Install the drive axle into the axle housing aligning the
shaft with the splines.

NOTE: Use care not to lose or drop any needle
bearings out of position. NOTE: Use care not to damage the seal.
Figure 40-20-189 Figure 40-20-191
Make sure the bearing cups are fully seated and install
both snap rings [Figure 40-20-189].
V158 VarsaHANDLER
Steering Knuckle Assembly
Figure 40-20-192
Figure 40-20-195
Install the bushing (Item 1) [Figure 40-20-192] into the

knuckle housing.

Figure 40-20-193
Install the bushings into the top and bottom of the axle
[Figure 40-20-194] & [Figure 40-20-195].
NOTE: The cupped bushing goes on the bottom.
Install a new seal (Item 1) [Figure 40-20-193] into the

knuckle housing.
V158 VarsaHANDLER
Steering Knuckle Assembly (Cont'd)
Figure 40-20-196
Install the knuckle assembly onto the axle [Figure 40-20-

198].
Figure 40-20-199
Install the spacer washer (Item 1) [Figure 40-20-196] on
the top bushing.

Figure 40-20-197
Install the upper king pin (Item 1) [Figure 40-20-199] and

two bolts (Item 2) [Figure 40-20-199]. Tighten to 140 ft.-
lbs. (190 Nm) torque.
Install the Belleville washers (Item 1) [Figure 40-20-197]

on the top and bottom bushing.
NOTE: The larger Belleville washer is on top.
V158 VarsaHANDLER
Steering Knuckle Assembly (Cont'd)
Figure 40-20-200
Install the lower king pin (Item 1) [Figure 40-20-201] and

three bolts (Item 2) [Figure 40-20-201]. Tighten to 140
Place the lower king pin in a vise or press and install the Lubricate the upper and lower king pins.
ball bearing (Item 1) [Figure 40-20-200] onto the king pin
shaft until it is fully seated.
V158 VarsaHANDLER
Wheel Hub Assembly
Figure 40-20-202
Install the six bushings (Item 1) [Figure 40-20-204] into

the gear.
Figure 40-20-205
Install both bearing races (Item 1) [Figure 40-20-202]
into the hub.

Figure 40-20-203
Install the gear (Item 1) [Figure 40-20-205] into the ring

gear (Item 2) [Figure 40-20-205].
Install the retainer ring (Item 3) [Figure 40-20-205] into

Lightly lubricate the seal (Item 1) [Figure 40-20-203] and the groove in the ring gear.
install into the hub.
V158 VarsaHANDLER
Wheel Hub Assembly (Cont'd)
Figure 40-20-206
Install the ring gear assembly (Item 1) [Figure 40-20-

208] onto the steering knuckle. Install the six mounting
bolts (Item 2) [Figure 40-20-208] and tighten to 88 ft.-lbs.
(120 Nm) torque.
Install the inner bearing (Item 1) [Figure 40-20-206] onto
the steering knuckle. Figure 40-20-209

Figure 40-20-207
Install the spacer (Item 1) [Figure 40-20-209] and thrust

washer (Item 2) [Figure 40-20-209] on the axle shaft.
Install the hub assembly (Item 1) [Figure 40-20-207] and
outer bearing (Item 2) [Figure 40-20-207] onto the
steering knuckle.
V158 VarsaHANDLER
Wheel Hub Assembly (Cont'd)
Figure 40-20-210
Using grease to hold the needle bearings in position,

install the gears onto the shaft [Figure 40-20-212].
Figure 40-20-213
Install the snap ring (Item 1) [Figure 40-20-210] onto the
axle shaft.

Planetary Carrier Assembly
Figure 40-20-211
Install the thrust plate (Item 1) [Figure 40-20-213] and

snap rings (Item 2) [Figure 40-20-210].
Install the thrust washers (Item 1) [Figure 40-20-211]

onto the shafts.
V158 VarsaHANDLER
Planetary Carrier Assembly (Cont'd)
Figure 40-20-214
Install the two screws (Item 1) [Figure 40-20-216] and

Figure 40-20-217
planetary carrier.

Figure 40-20-215

drain plug.
See AXLES (FRONT AND REAR) on Page 10-110-1 for

Install the planetary carrier (Item 1) [Figure 40-20-215]. filling the axle assembly with fluid.
V158 VarsaHANDLER
V158 VarsaHANDLER
FRONT AXLE Figure 40-30-3
Removal
Figure 40-30-1
Remove the hose (Item 1) [Figure 40-30-3] from the right

side of the drive motor.
NOTE: Mark all hoses for correct installation.

NOTE: Removal and installation of the rear axle will
be the same as the front axle, although
several steps are not required.
IMPORTANT

Fully retract the telescoping boom and raise enough to
allow the front axle to be removed from under the frame.
Rotate the battery disconnect switch (Item 1) [Figure 40- clean the work area before disassembly and keep all
30-1] to the right, to disconnect the power supply from parts clean. Always use caps and plugs on hoses,
the battery. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Drain the hydraulic reservoir. (See Replacing Hydraulic I-2003-0888
Fluid on Page 10-100-2.)
Figure 40-30-4
Figure 40-30-2
Remove the hose (Item 1) [Figure 40-30-4] from the left

Remove the four driveshaft mounting bolts (Item 1) side of the drive motor.
[Figure 40-30-2]. Lower the driveshaft.
V518 VersaHANDLER
FRONT AXLE (CONT'D) Figure 40-30-7
Removal (Cont'd)
Figure 40-30-5
Remove the brake tube line (Item 1) [Figure 40-30-7]

from the left side of the axle.
Figure 40-30-8
Remove the lower four bolt flange hose (Item 1) [Figure
40-30-5].

Figure 40-30-6
Remove the brake hose (Item 1) [Figure 40-30-8] from

the right side of the axle.

drive motor.
V518 VersaHANDLER
Removal (Cont'd)
Figure 40-30-9

the steering cylinder.
Figure 40-30-12
Unplug the two head light electrical connectors (Item 1)
[Figure 40-30-9] from the main harness.

NOTE: Mark all connectors for correct assembly.
Figure 40-30-10
Remove the tie straps (Item 1) [Figure 40-30-12] from

the brake hose and tube line.
Reposition all hoses and wires to the left side.
Unplug the electrical connector (Item 1) [Figure 40-30-

10] and remove the tie straps (Item 2) [Figure 40-30-10].
V518 VersaHANDLER
Removal (Cont'd)
Figure 40-30-13
Remove the electrical plug retainer bolt (Item 1) [Figure

40-30-15]. Remove the electrical plug (Item 2) [Figure
40-30-15].
Remove the upper four bolt flange hose (Item 1) [Figure Figure 40-30-16
40-30-13].

Figure 40-30-14
Remove the two mounting plate bolts (Item 1) [Figure

40-30-16] from both sides.

drive motor.
V518 VersaHANDLER
Removal (Cont'd)
Figure 40-30-17
Remove the bolt (Item 1) [Figure 40-30-19] and remove

the front fenders.
Figure 40-30-20
Lift the front of the machine and place jack stands under
the frame as shown [Figure 40-30-17].

Place a block in front and behind the rear wheel.
Figure 40-30-18
Re-route the head light harness (Item 1) [Figure 40-30-

20] out from under the frame. Remove the two light bar
mounting bolts (Item 2) [Figure 40-30-20] and remove
the light bar.
Remove the eight lug nuts and washers (Item 1) [Figure

40-30-18] from each front tire.
Remove both front tires.
V518 VersaHANDLER
Removal (Cont'd)
Figure 40-30-21
Have an assistant balance the axle on the floor jack and

lower the floor jack slowly. Roll the axle out from under
the frame [Figure 40-30-23].
Using a floor jack, apply upward pressure to lift and

support the front axle [Figure 40-30-21].

Figure 40-30-22
Remove the two axle mounting bolts (Item 1) [Figure 40-

30-22] and mounting plates (Item 2) [Figure 40-30-22]
from each side of the axle.
V518 VersaHANDLER
Installation
Figure 40-30-24
Install the bottom plate (Item 1) [Figure 40-30-26] and

mounting bolts and nuts (Item 2) [Figure 40-30-26].
Tighten to 275-300 ft.-lbs. (370-410 Nm) torque.
Have an assistant balance the axle on the floor jack and Figure 40-30-27
roll the axle under the frame [Figure 40-30-24].

Figure 40-30-25
Route the head light harness (Item 1) [Figure 40-30-27]

through the bracket and under the frame. Install the two
mounting bolts and nuts (Item 2) [Figure 40-30-27] and
Raise the floor jack, lifting the axle upward and into tighten to 275-300 ft.-lbs. (370-410 Nm) torque.
V518 VersaHANDLER
Installation (Cont'd)
Figure 40-30-28
Raise the machine and remove the two jack stands (Item
1) [Figure 40-30-30].
Lower the jack.

Install the front fender using the bolt (Item 1) [Figure 40-
30-28]. Tighten to 90-100 ft.-lbs. (125-140 Nm) torque. Figure 40-30-31

Figure 40-30-29
Install the two bottom plate mounting bolts (Item 1)

[Figure 40-30-31]. Tighten to 275-300 ft.-lbs. (370-410
Install both front tires, tighten the nuts (Item 1) [Figure Nm) torque.
40-30-29] to 217 ft.-lbs. (159 Nm) torque.
V518 VersaHANDLER
Figure 40-30-32
Install the upper four bolt flange hose (Item 1) [Figure

40-30-34] to the drive motor.
Figure 40-30-35
Plug the electrical plug (Item 1) [Figure 40-30-32] into
the axle and install the retainer bolt (Item 2) [Figure 40-
30-32].

Figure 40-30-33
Route the brake hose (Item 1) [Figure 40-30-35] next to

the tube line and install tie straps (Item 2) [Figure 40-30-
35].
Install the hose (Item 1) [Figure 40-30-33].
V518 VersaHANDLER
Figure 40-30-36
Plug in the two head light electrical connectors (Item 1)

[Figure 40-30-38].
Figure 40-30-39
Install the two steering hoses (Item 1) [Figure 40-30-36]
to the steering cylinder.

Figure 40-30-37
Install the brake hose (Item 1) [Figure 40-30-39] to the

right side of the axle.
Plug the electrical connector (Item 1) [Figure 40-30-37]

into the axle solenoid. Secure the electrical harness (Item
2) [Figure 40-30-37] to the steering hoses with tie straps
(Item 3) [Figure 40-30-37].
V518 VersaHANDLER
Figure 40-30-40
Install the lower four bolt flange hose (Item 1) [Figure 40-
30-42].
Figure 40-30-43
Install the brake tube line (Item 1) [Figure 40-30-40] to
the left side of the axle.

Figure 40-30-41
Install the hose (Item 1) [Figure 40-30-43] to the left side

of the drive motor.
Install the hose (Item 1) [Figure 40-30-41] to the drive

motor.
V518 VersaHANDLER
Figure 40-30-44
Install the drive shaft using the four mounting bolts (Item
1) [Figure 40-30-45].
Fill the hydraulic reservoir.

Install the hose (Item 1) [Figure 40-30-44] to the right
side of the drive motor.
V518 VersaHANDLER
AXLE TOE-IN Figure 40-40-3
Adjustment
The axle is removed from the machine for photo clarity,

but this procedure may be completed with the axle
installed in the machine.
Turn the steering wheel until the steering cylinder rod is

positioned in the center. Measure the exposed part of the
cylinder rod on each side of the cylinder housing making
sure they are the same length.
Figure 40-40-1
If measurement is not the same, adjust both tie rod ends

(Item 1) [Figure 40-40-3] by loosening or tightening the
track rods (Item 2) [Figure 40-40-3] of both tie rods until
the measurement is the same.
Tighten nut (Item 3) [Figure 40-40-3] to 221 ft.-lbs. (300

Nm) torque.

Install two identical, straight bars (Item 1) [Figure 40-40-
1] onto the wheel hub and secure them using lug nuts.
NOTE: The two bars must be perpendicular to the

ground.
Figure 40-40-2
Measure the distance between the ends of the two bars

[Figure 40-40-2]. The measurement must be equal.
V518 VersaHANDLER
V518 VersaHANDLER
PARKING BRAKE Figure 40-50-2
Releasing The Brake
Figure 40-50-1
Locate the tow valve (Item 1) [Figure 40-50-2], turn

counterclockwise 90° to the towing position.
The machine is now ready to be towed.
Block all four wheels to prevent the machine from moving

once the parking brake is disabled.
Locate the six brake release bolts (three per side) on the
front axle.
Alternately turn the brake release bolts (Item 1, 2 & 3)

[Figure 40-50-1] "IN" (clockwise) 1/2 turn each until you
feel resistance. Continue to turn each release bolt in
equally 1/2 turn for a total of approximately 5 complete
turns.
V518 VersaHANDLER
PARKING BRAKE (CONT'D) Figure 40-50-4
Re-Activating The Brake
Figure 40-50-3
Locate the tow valve (Item 1) [Figure 40-50-4] under the

hood, turn clockwise 90° to the run position.
The parking brake is now re-activated.
Block all four wheels to prevent the machine from

moving.
Locate the six brake release bolts (three per side) on the
front axle.
Alternately turn the brake release bolts (Item 1, 2 & 3)
[Figure 40-50-3] "OUT" (counterclockwise) 1/2 turn until
the torque drops off sharply. Continue to turn each
release bolt out equally 1/2 turn until the brake release
bolt presses against the bolt housing. After the brake
release bolt is touching the bolt housing turn each brake
release bolt "IN" (clockwise) a1/4 turn.
V518 VersaHANDLER
STEERING ANGLE ADJUSTMENT Figure 40-60-3
Adjustment
Figure 40-60-1
Using an angle gauge, adjust the bolt (Item 1) [Figure

40-60-3] to obtain a reading of between 32-35 degrees
[Figure 40-60-2].
The axle is removed from the machine for photo clarity, Adjust the stop (Item 1) [Figure 40-60-3] as needed.
but this procedure may be completed with the axle Tighten the lock nut to 110 ft.-lbs. (150 Nm) torque.
installed in the machine.

Figure 40-60-4
Install the identical, straight bars (Item 1) [Figure 40-60-
1] onto the wheel hub and secure them using lug nuts.
Turn the steering wheel completely to one side. Place a
straight bar (Item 2) [Figure 40-60-1] on the pinion shaft.
Figure 40-60-2
Turn the steering wheel completely to the other side

[Figure 40-60-4] and repeat above procedure.
V518 VersaHANDLER
V518 VersaHANDLER
DRIVESHAFT Figure 40-70-2
Figure 40-70-1
Remove the drive shaft out the rear of the machine

[Figure 40-70-2].
Remove the eight drive shaft mounting bolts (Item 1)

[Figure 40-70-1] from each end of the drive shaft.
V518 VersaHANDLER
V518 VersaHANDLER
MAIN FRAME
BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

ENGINE HOOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . 50-70-1
FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

INNER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1


OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
QUICK TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

REAR WEIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

WEAR PADS (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

WEAR PADS (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
V518 VersaHANDLER
V518 VersaHANDLER
OPERATOR CAB Remove the two bolts (Item 1) [Figure 50-10-2] and
retainer bracket (Item 2) [Figure 50-10-2].
Figure 50-10-3
Figure 50-10-1
Unplug the three connectors (Item 1) [Figure 50-10-3]

Raise the boom and install the boom stop (Item 1) and remove the accompanying ground wires (Item 2)
[Figure 50-10-1]. [Figure 50-10-3] from the bolt.

Remove the battery. (See Removal And Installation on NOTE: Mark all wires for correct installation.
Page 60-20-1.)
Figure 50-10-4
Remove the dash cover/steering column. (See Removal
Remove the joystick panel. (See Removal And

Remove the operator seat. (See Removal And

Drain the radiator. (See Replacing The Coolant on Page

10-70-2.)
Remove the refrigerant from the A/C system. (See

Reclamation Procedure on Page 80-100-1.)
Figure 50-10-2
Unplug the two connectors (Item 1) [Figure 50-10-4] and
remove the accompanying ground wires (Item 2) [Figure
50-10-4] from the bolt.
V518 VersaHANDLER
OPERATOR CAB (CONT'D) Figure 50-10-7
Figure 50-10-5
For photo clarity the connector is shown in the locked

Figure 50-10-8
Unplug the connector (Item 1) [Figure 50-10-5] below
the joystick.

Figure 50-10-6
For photo clarity the connector is shown in the unlocked

Slide the connector lock (Item 1) [Figure 50-10-6]

forward, unplug the connector (Item 2) [Figure 50-10-6].
Remove any accompanying ground wires.
V518 VersaHANDLER
Figure 50-10-9
Locate and unplug the connector (Item 1) [Figure 50-10-

11] from the red switch.
Unplug the harness (Item 1) [Figure 50-10-9] from the

controller.

Figure 50-10-10
Unplug the connector (Item 1) [Figure 50-10-10] from

the joystick. Remove any accompanying ground wires
(Item 2) [Figure 50-10-10].
V518 VersaHANDLER
IMPORTANT
damage the system.
I-2003-0888
Figure 50-10-12
Carefully pull the accelerator cable (Item 1) [Figure 50-
10-14] through the cab and out the battery box.
Figure 50-10-15

Remove all wire harnesses (Item 1) [Figure 50-10-12]
from the cab by carefully pulling through the floor plate
and out the battery box.
Remove the floor mat and insulation from the cab.

Remove the three hoses (Item 1) [Figure 50-10-15]
Figure 50-10-13 inside the battery box.
Remove the accelerator cable (Item 1) [Figure 50-10-13]

from the pedal and mounting bracket (Item 2) [Figure 50-
10-13].
V518 VersaHANDLER
Figure 50-10-16
Separate the heater hoses (Item 1) [Figure 50-10-18]

and pull through the floor plate.
Figure 50-10-19
Remove the seven hoses on the right side of the cab
[Figure 50-10-16].

Figure 50-10-17
Remove the four connectors (Item 1) [Figure 50-10-19].
NOTE: Mark all connectors for correct assembly.
Temporarily remove the two washer tubes (Item 1)

[Figure 50-10-17] from the harness conduit.
V518 VersaHANDLER
Figure 50-10-20
Remove the bolt (Item 1) [Figure 50-10-22] and plate

(Item 2) [Figure 50-10-22]. Remove the two A/C hoses.
NOTE: Plug the A/C hoses to avoid contamination.

Remove the rear panel (Item 1) [Figure 50-10-20].
Figure 50-10-23
Figure 50-10-21

Remove the A/C hoses (Item 1) [Figure 50-10-23] from
Temporarily remove the foam covering (Item 1) [Figure the rear cab panel and pull through the floor plate.
50-10-21] from the A/C hoses.
V518 VersaHANDLER
Figure 50-10-24
Remove the four bolts (Item 1) [Figure 50-10-26] from

the bottom of the cab.
Figure 50-10-27
Install a hoist to lift and support the cab [Figure 50-10-
24].

Figure 50-10-25
Remove the cab mount bolt (Item 1) [Figure 50-10-27]

from the front of the cab.
Remove the two bolts (Item 1) [Figure 50-10-25] from

the floor plate.
V518 VersaHANDLER
Figure 50-10-28
Lift and remove cab [Figure 50-10-29].
Remove the grounding strap (Item 1) [Figure 50-10-28]

and rear mounting bolt (Item 2) [Figure 50-10-28].
V518 VersaHANDLER
OPERATOR SEAT
Remove the battery. (See Removal And Installation on

Page 60-20-1.)
Figure 50-20-1

Remove the four bolts (Item 1) [Figure 50-20-1] from the
bottom of the cab.
Lift and remove the seat.
V518 VersaHANDLER
448 of 724
BOOM ASSEMBLY Figure 50-30-3
Figure 50-30-1
Place a wood block (Item 1) [Figure 50-30-3] under the

lift cylinder/bucket positioning cylinder.
Figure 50-30-4
Lower the boom onto adequate stands or blocks as
shown [Figure 50-30-1].

Figure 50-30-2
Remove the pivot pin retainer pin (Item 1) [Figure 50-30-

4] from the lift cylinder/bucket positioning cylinder.

the machine.
V518 VersaHANDLER
BOOM ASSEMBLY (CONT'D) Figure 50-30-7
Figure 50-30-5

(Item 2) [Figure 50-30-7].
Support both cylinders using a cinch strap (Item 1) Figure 50-30-8

[Figure 50-30-5].

Figure 50-30-6

50-30-8].
Remove the lift cylinder pivot pin using a pin removal tool
(Item 1) [Figure 50-30-6].
NOTE: See Page 20-20-2 for additional information.
V518 VersaHANDLER
IMPORTANT
damage the system.
I-2003-0888
Figure 50-30-9
Disconnect the six hydraulic hoses (Item 1) [Figure 50-
30-11] from the tubelines.
Figure 50-30-12

Disconnect the secondary auxiliary harness connector
(Item 1) [Figure 50-30-9].
Figure 50-30-10
Install a lifting chain (Item 1) [Figure 50-30-12] on the

front of the boom.
Disconnect the light harness connector (Item 1) [Figure

50-30-10].
V518 VersaHANDLER
Figure 50-30-13
Remove the boom pin [Figure 50-30-15].
Figure 50-30-16
Install a lifting chain (Item 1) [Figure 50-30-13] at the

rear of the boom.

Figure 50-30-14
Lift and remove the boom assembly [Figure 50-30-16].
Remove the bolt (Item 1) [Figure 50-30-14] and washer

(Item 2) [Figure 50-30-14] from the boom pin.
V518 VersaHANDLER
INNER BOOM Figure 50-40-3
Removal
Figure 50-40-1
Disconnect the light harness connector (Item 1) [Figure

50-40-3].
Remove the front wear pads. (See Removal And IMPORTANT

Figure 50-40-2 clean the work area before disassembly and keep all
damage the system.
I-2003-0888
Figure 50-40-4
Disconnect the secondary auxiliary harness connector

(Item 1) [Figure 50-40-2].
Disconnect the six hydraulic hoses (Item 1) [Figure 50-

40-4] from the tubelines.
V518 VersaHANDLER
INNER BOOM (CONT'D) Figure 50-40-6
Removal (Cont'd)
Figure 50-40-5
Begin sliding the inner boom from the main boom. Before
the inner boom is completely removed, position a hoist
and lifting strap on the inner boom. Carefully continue to
remove the inner boom completely [Figure 50-40-6].
Place a wood block (Item 1) [Figure 50-40-5] under the
cylinder for support. Remove the bolt (Item 2) [Figure 50-
40-5] from the cylinder.

Loosen the rear wear pad adjusting bolts (Item 3) [Figure
50-40-5].
V518 VersaHANDLER
Installation
Figure 50-40-7
Install the bolt (Item 1) [Figure 50-40-9] through the

support pin and into the cylinder. Tighten the bolt to 221
Apply grease to the inside top and bottom corners of the Remove the wood block (Item 2) [Figure 50-40-9].
main boom [Figure 50-40-7].
Figure 50-40-10

Figure 50-40-8
Reconnect the six hoses (Item 1) [Figure 50-40-10] to

Install the end of the inner boom (Item 1) [Figure 50-40- the tubelines.
8] into the main boom approximately 2 ft. (610 mm).
Install the front wear pads. (See Removal And Installation

on Page 50-50-1.)
Remove the lifting strap and slide the inner boom fully
into the main boom (Item 2) [Figure 50-40-8].
V518 VersaHANDLER
Figure 50-40-11
Install the rear cover (Item 1) [Figure 50-40-13].
Reconnect the light harness connector (Item 1) [Figure

50-40-11].

Figure 50-40-12
Reconnect the front auxiliary harness connector (Item 1)

[Figure 50-40-12].
Adjust the wear pads. (See Content Page 50-01.)
V518 VersaHANDLER
WEAR PADS (FRONT) Figure 50-50-3
Figure 50-50-1
Remove the wear pad (Item 1) [Figure 50-50-3] and

inner support (Item 2) [Figure 50-50-3].
With both upper wear pads removed, use a hoist and

Extend the inner boom approximately 2 ft. (610 mm) and lifting strap at the end of the boom, apply upwards
mark the location of the inner supports and wear pads pressure, lifting the inner boom off the bottom wear pads.
(Item 1) [Figure 50-50-1].

Figure 50-50-4
Figure 50-50-2
Remove the bottom wear pads (Item 1) [Figure 50-50-4].

Remove the four bolts (Item 1) [Figure 50-50-2] and two
blocks (Item 2) [Figure 50-50-2] from the boom.
Installation: Tighten the bolts to 58 ft.-lbs. (43 Nm).
V518 VersaHANDLER
V518 VersaHANDLER
WEAR PADS (REAR) Figure 50-60-3
Removal
Remove the inner boom. (See Removal on Page 50-40-

1.)
Figure 50-60-1
Install the new wear pad (Item 1) [Figure 50-60-3].
Figure 50-60-4

With the inner boom supported, remove the wear pad
(Item 1) [Figure 50-60-1].
NOTE: Grease was removed for photo clarity.
Installation
Figure 50-60-2
Apply grease to the wear pads [Figure 50-60-4].
Install the inner boom. (See Installation on Page 50-40-

3.) DO NOT hook up hoses at this time.
Loosen the adjustment screw (Item 1) [Figure 50-60-2]

until the adjusting plate (Item 2) [Figure 50-60-2] is flush
with the wear pad retainer (Item 3) [Figure 50-60-2].
V518 VersaHANDLER
WEAR PADS (REAR) (CONT'D) Figure 50-60-7
Figure 50-60-5
Connect the secondary auxiliary harness (Item 1)

[Figure 50-60-7].
Figure 50-60-8
Turn the adjusting bolts (Item 1) [Figure 50-60-5]
equally, centering the inner boom inside the main boom.
Tighten adjusting bolts to 29 ft.-lbs. (39 Nm) torque.

Figure 50-60-6
Connect the light harness connector (Item 1) [Figure 50-

60-8].
Install the rear cover.
Reconnect the hoses (Item 1) [Figure 50-60-6] to the

tubelines.
V518 VersaHANDLER
ENGINE HOOD Removal And Installation
Gas Cylinder Removal And Installation Figure 50-70-2
Figure 50-70-1
Remove the gas cylinder.
Lift the engine hood [Figure 50-70-1]. Add a support to Lower the hood.
prevent the hood from closing when the gas cylinder is
removed. Remove the plastic cap (Item 1) [Figure 50-70-2] cotter

pin (Item 2) [Figure 50-70-2] and washer (Item 3)
Remove the retainer clips (Item 1) [Figure 50-70-1] at [Figure 50-70-2] from both ends of the pivot pin.
both of the ball joints ends. Remove the ball joints from
the ends. Figure 50-70-3
Remove the gas cylinder.
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288
Remove the hood pivot pin (Item 1) [Figure 50-70-3].
Remove the hood.
V518 VersaHANDLER
V518 VersaHANDLER
FUEL TANK Figure 50-80-3
Figure 50-80-1
Remove the two wires (Item 1) [Figure 50-80-3] from the

fuel sending unit.
NOTE: Mark for correct assembly.

Remove both rear weights. (See Removal And
Installation on Page 50-100-1.) Figure 50-80-4

Remove the plug (Item 1) [Figure 50-80-1] and drain.
Figure 50-80-2
Position a hoist as shown to lift and support the fuel tank

[Figure 50-80-4]. Remove the mounting bolts (Item 1)
[Figure 50-80-4].
Remove both fuel lines (Item 1) [Figure 50-80-2] from Remove the fuel tank.
the fuel tank.
NOTE: Mark for correct assembly.
V518 VersaHANDLER
V518 VersaHANDLER
QUICK TACH Figure 50-90-3
Figure 50-90-1
Remove the pivot pin [Figure 50-90-3].
Start the engine and retract the tilt cylinder by moving the
joystick to the right.
Lower the boom onto a wood block and put a chain (Item
1) [Figure 50-90-1] around the quick tach and boom to Figure 50-90-4
keep the quick tach from rotating forward.

Figure 50-90-2
Remove the pivot pin retainer bolt (Item 1) [Figure 50-

90-2].
V518 VersaHANDER
QUICK TACH (CONT'D) Figure 50-90-7
Figure 50-90-5
Remove the quick tach pivot pin retainer bolt (Item 1)

[Figure 50-90-7].
Figure 50-90-8
Using a hoist, lower the quick tach onto the wood blocks
[Figure 50-90-5].

Figure 50-90-6
Remove the quick tach pivot pin (Item 1) [Figure 50-90-

8].
Raise the boom and remove the quick tach.

Disconnect the secondary auxiliary couplers (Item 1)
[Figure 50-90-6].
V518 VersaHANDER
REAR WEIGHTS Figure 50-100-3
Figure 50-100-1
Remove the tail light harness (Item 1) [Figure 50-100-3]

from the frame.
Figure 50-100-4
Figure 50-100-2

Position a hoist as shown to lift and support the rear
weight [Figure 50-100-4].
Disconnect the tail light harness connector (Item 1)

V518 VersaHANDLER
REAR WEIGHTS (CONT'D) Figure 50-100-7
Figure 50-100-5
Slide the weight forward to release it from the mounting

pin [Figure 50-100-7].
Figure 50-100-8
Figure 50-100-6

Lift and remove the weight [Figure 50-100-8].
5] & [Figure 50-100-6].
V518 VersaHANDLER
FENDER
Figure 50-110-1
Remove the fender mount bolt (Item 1) [Figure 50-110-

1]. Remove the fender.

Installation: Tighten the bolt to 90-100 ft.-lbs. (125-140
Nm) torque.
V518 VersaHANDLER
V518 VersaHANDLER
ELECTRICAL SYSTEM AND ANALYSIS
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . 60-20-3
BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
DASH COVER/STEERING COLUMN COVER. . . . . . . . . . . 60-100-1

FRONT WIPER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

INCHING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

JOYSTICK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
JOYSTICK PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-60-2
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-60-1
PEDAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

REAR WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

V518 VersaHANDLER
ELECTRICAL SYSTEM AND ANALYSIS (CONT’D)
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-10
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-7
SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

TOP WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

TRAVEL/SIGNAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

V518 VersaHANDLER
473 of 724
L
B
A
H
C
G
MS-1304
Y
E
BATTERY 12V
W
367012500)
SHEET 1 of 8
GRE
WHITE
YELLO
ORAN G
MASTER DISCONNECT
-
60A-Z-N
+
DARK BLUE
WIRING SCHEMATIC
LIGHT B L U E
V518 (S/N 367011001 -
TO + WAR N IN G
[A] SEE PAGE 3 OF 8
PRINTED SEPTEMBER 2004
Z
V
S
R
N
M
+ BATTERY
N
D
N
GROUND 0V
R E
PINK
BROW
GREE
BLACK
VIOL E T
R 70 A
R
38-R 38-R
27-B 27-B
30
M
87
X50 20/30 A
STARTER MOTOR
53-B/N
85
9
86
37-B
X58
30
62-N
87a 8 7
- STARTER RELAY
R R
85
86
37-B
Example : A/B
Example : A-B
Light Blue
Light Blue
\
+ BATTERY
62.5-S-N E9 STARTER
[D] SEE PAGE 5 OF 8 FORWARD
W T O R E V E R S \TOOL CONTIN U OU S OFF
76.A-G/N
[B] SEE PAGE 2 OF 8

ODOMOTER E
TO LOCKING MECHANISM
D +
37-B
TO C H AR GIN G TELL TALE [C] SEE PAGE 2 OF 8
White
R
White
B + R
50A
40A
B
R R
-
ALTERNATOR
R R
38-R
76.A-G/N
4
70 A
X88
PRE-HEATER
-
38-R 38-R
X19
-
57-M
X18
30
87
X52
62-N
X50
57.B-M 57.B-M
-
85
1
86
STARTER SWITCH
37-B
6 2 - N : W I R E N °6 2 B L A C K
30
PRE-HEATER RELAY
17
A : ST O P P O S I T I O N
58
50a
88:N° THE CONNECTOR
4: P OS I TI ON OF THE W I R E
6 8 . 0 - R : W I R E N °6 8 . 0 R E D
B : ON POSITION
C : PRE-HEAT ER PO SI T I O N P
D
D : ST AR T P O S I T I O N
4 9 . A -V -N : W I R E N °4 9 . A G R E E N - B L A C K
19
C 15/54
B
MOD U L
62-N E 57.A-M
B6
57.B-M 57.B-M
86 30
70 A
85 87
CONTACT RELAY
MOD U L
E
GROUND 0V
B2
84A-H -R 84A-H -R
+ BATTERY
SPEED REGULATOR
F19
X50
040-A 040-A 7,5 A
2
1
EV8
D
2
84.C-A -B
SPEE
84A-H -R
20/30 A
R
040-A
X87
N
84-A-B
- -
30
62-N
F
14
87a 8 7
76.A-G/N
62-N
+ CONTACT
6
1
84B-A/B H
20/30 A
85
37-B
76-G/R
G F-N-R SWI T C H
86
F27
2
76B-H -G
7,5 A
(53a)
15
E11 SPEED R ELAY

30
87a 8 7
M /N
B-V 76B-H -G
5
R
85
Z
86
76-G/R
74-M /N
3
N
E8 SECU FR ON T
15
L
TO 86-E 1 3 MAIN BRAKE
1
33.A-G-R
REVERSE LIGH T R ELAY L-G

4
GROUND 0V
[E] SEE PAGE 3 OF 8

74-M /N
75-A/V
3
X88
WATER TEMP. NEAR

040-A
IN JEC T I O N
4
[F] SEE PAGE 2 OF 8
REGU LATO
X88
HAND BRAKE
RU M
P
TO D I O D E D 1 2
P
0V
START E
R
X50 F22
62-N 40-L 40-L 40-L
7,5 A
2
5
400-A-G
3
MOD U L
4
E
1
B3
2
ELECTRO. G.O.
74-M /N
75-A/V
X88
400-A-G
6
33.E C/B
X88
E10 PASSIVE BR A K E HYDROSTATIC

5
X88
33M -G-B
F21
400-A-G
P
7,5 A
7
28
TRANSMISSION CONT.
24
X87 400-A-G
62-N 33M-G- B
42
+ BATTERY
13
V
2
20
33N -R /N
M
3
T
21
47-Z/B 47-Z/B
7
B
POR
478-L/N 478-L/N
13
GROUND 0V
G
8
9
478-L/N
R S 232 D I A G N O S T I C
EV2-AR
+ CONTACT
FORWARD DRIVE SOLENOID

G
1
EV1-AV
0
96607.7
478-L/N
1
48-V/N 48-V/N
5
6
1
01-H-N
X88
02-S-G
4
2
1
16
15
29
14
31
62-N
G
REVERSE DRIVE SOLEN OID

62-N
62-N
04-M
05-L
08-G-V
06-G-V
SPEED SENSOR
- - -
ECO
X27
07-M G
524005+------
GROUND 0V
-
X27
P P
08-G-V
-
+ BATTERY
09-L
MODE SWITCH
62-N
62-N
62-N
YELLO YELLO
X28 06-G-V
W R:5 1 0 R W
C
GREE G R E E X28
N N 04-M
R:5 1 0 R
A
R E X28
D 05-L
B
IN C H IN G
LINEAR DETECTOR
WIRING SCHEMATIC
V518 (S/N 367011001 -
367012500)
SHEET 2 of 8 + BATTERY + BATTERY + BATTERY + BATTERY

MS-1305
+ CONTACT + CONTACT + CONTACT
6V FORWARD ARM
DIRECTION
DASHBOAR
FROM 7 C D E ELEC TR IC AL BOX
7,5 A
HEATE
10 A
10 A
20 A
R
D
F13 F25 F26 F28
[G] SEE PAGE 5 OF 8
40.A-R
[J] SEE PAGE 3 OF 8
900-R -G
77A-C-L
X-CEC
405-B-C EUROP 67-G-N TO NIGHT LIGH T
10 E TELL TALE
TO CEC
408-G
402-B/R 402-B/R X-CEC
62-N
10
900-R -G
MO D U L
MO D U L
408-G
D4
B1
E
E
OPTION
- B
402-B/R
[H] SEE PAGE 5 OF 8
96604.4 5
FROM FU SE F32
- - - -
GREE
N 3 C H
M L
2 1 0
77A-C-L
1
0
1
524005 + 5 9 6 6 5 0
91-C-B
90-L-R
62-N
- + P 1/2
0 1
911-C
96593.9 O i l
408-G
CRAB 2WD 4WD

- - -
3 Water
194.0-Z/B
194.0-Z/B
C7
C5
C6
C3
C4
D5
B7
MO D U L
MO D U L
MO D U L
MO D U L
MO D U L
MO D U L
MO D U L
S
1 7
4 9 - V - BE
E
1 2
0
524149 + 5 9 6 8 0 2
191-L-G
190-C-N
50-B
408-G
51-H-R
54-S
33.B-G-R
78-Z-N
77-L/B
62-N
404-A-G
1 3
6V
77-L/B
A2
A1
D1
MO D U L
MO D U L
MO D U L
78-Z-N
INVER SE FAN
E
E
E
2 4 5
96596.2
51.A-L/G
- - - 5
- 49.A -V -N 49.A -V -N
402-B/R
62-N
194-Z-G
X8 7
51.A-L/G
15
X5 0
X5 0
X5 0
X8 7
X8 7
5
11
6
12
1
7
0 1
X5 0
X5 0
524010 + 5 9 3 2 9 0
594785 X8 7
12
62-N
8
402-B/R
62-N
10
49.A -V -N
-
402-B/R
190-C-N
402-B/R
49-V-B
50-B
55-Z
191-L-G
ENGINE OIL PR ESSU R E
51.A-L/G
62-N
62-N
WATER TEMPERATURE
51-H-R
594784
rev/min
77-L/B
T P
193-C-B
X5 5
4
h
X8 7
HYDRAULIC OIL TEMPERATU R E

6
X2 9
X4 0
X2 2
C
C
B
A
X5 5
X5 5
1
3
33.B-G-R
X8 7
(S) N
(S) N
FRONT AXLE D IR EC TION
X5 5
7
2
C
REAR AXLE D IR EC TION

X8 7
- L
- L
+ M
+ M
9
X5 0
FU EL LEVE L
N
194-Z-G
X5 0
4
10
D2
MO D U L
D6
MO D U L
HEATER
X15 1
4
2ND FUNCTION AR M
54-S
MOTO
E
E
R
INVER SE FAN
X10 3
TO ALTERNATOR D + TER MIN AL

M
1
4 WH EEL D R I V E
77-L/B
OPTION
78-Z-N
CRA
OPTION
33-A-R
85-S-N
B
D25
[C] SEE PAGE 1 OF 8

X8 7
33.A-G-R
D26 18
HAND BRAKE
TO SECURE FRONT RELAY
X5 0
[F] SEE PAGE 1 OF 8 P
3
TO ALTERNATOR W TERMINAL
EV51 EV52 EV6 EV7
62-N
62-N
X15 1
62-N
62-N
[B] SEE PAGE 1 OF 8
X10 3
62-N
C
62-N
62-N
62-N
62-G-V
(CAB L E ) GROUND 0V GROUND 0V GROUND 0V GROUND 0V GROUND 0V
Example : A- B
BROW Light Blue White
A LIG H T BL U E M 4 9 . A - V - N : W I R E N °4 9 . A G R E E N - B L A C K
N
B WHITE N BLACK 6 2 - N : W I R E N °6 2 B L A C K
ORANG R E
C R Example : A/B 6 8 . 0 - R : W I R E N °6 8 . 0 R E D
EELLO
Y D Light Blue White
G W
S PINK X88 88:N° THE CONNE CTOR
GRE GREE
H V 4 4: P OS I TI ON OF T H E W I R E
Y N
L DARK BLUE Z VIO L ET
474 of 724
WIRING SCHEMATIC
V518 (S/N 367011001 -
367012500)
SHEET 3 of 8 [A] SEE PAGE 1 OF 8
+ BATTERY (BEFORE BATTERY MASTER DISCONNECT) X1 9 0
PRINTED SEPTEMBER 2004 4

60A-Z-N
MS-1306 + BATTERY + BATTERY + BATTERY + BATTERY

+ CONTACT + CONTACT + CONTACT + CONTACT + CONTACT
67.0-G-N 67.0-G-N
WINDSHIELD WIPER
64.0-A
HIGH BEAMS
ROAD LIGHTS
CAB SIR E N
[K] SEE PAGE 4 OF 8
HEADLIGHTS
A-F8
A-F9
LEFT NIGHT LIGH T
RT. NIGH T L I G H T
7,5 A
TO INTER W ORKING BEACON
15 A
15 A
15 A
10 A
TURN SIGNAL
64-G
WARN I N
7,5 A
7,5 A
7,5 A
7,5 A
64-G
G
F5 F20 F4 F6 F3
96600. 2
3 6 8
F24 F10
70.0-R
F8 F9
38-S-N
67-G-N 67-G-N
67-G-N
1 - - -
71.A-A-N
2
650-H-R
64-G
60-B-R
2 1 0
52413 8 + 5 9 5 1 0 5
64-G
67-G-N
38-R REAR BRAKE LIGHT SW IT CH [J] SEE PAGE 2 OF 8
38-S-N
42.0-C-B
71.A-A-N 38-R 65-L-N 029-R 67-G-N

42.0-C-B
700-L-C 65-L-N 66-A TO B1
29 FROM FUSE F18
700-L-C
MODUL
68.0-R
52419 4 + 5 9 6 1 9 1
700-L-C
[L] SEE PAGE 4 OF 8
SIDE MARKER LIG H T S

X9 0
66-A
7
A4
15 1 5 3 8 2 0 1
X251(6V) / X254(8V) X251(6V) / X254(8V) 5/6V 2/6V
E
N-L
N-Z
Z-B
B- G
- -
29-R -N
38-S OU 38-S-N
15
56 15/1 49a
5 1 6 4 96590. 5
63-L
62-N
62-N
651-R -V
63-L
65-L-N
1
I I
J 0
31
I
G
53b
651-R -V
65-L-N
53 J
[M] SEE PAGE 4 OF 8

62-N
0I 0I 53c H L R
N-L/B
31b
TO FU S E F 2 9
N-L/G
0
N-L/M
56b 56a L R
WASCHE
67-G-N
HUP
M-L
N-G
M-G
X251
Z-R
Z-V
68.0-R
49a
X251(6V) / X254(8V)
E
3/6V
6
4/6V 1/6V 8 3 2 4 6/6V 6 7
42.0-C-B
65-L-N
R
022-B
70.1-H-N
6
68.1 -V-N
49
66-A
72-A-G
711-A-R
721-A-B
66-A
42.1-C 42.1-C
63-L
Dealer Copy -- Not for Resale 63-L
C3
89-L-B
70.1-H-N
20/30 A
86 68.1 -V-N
5 C
30
C2
2
E3 S I R E N
68.0-R
70.0-R
022-B
[E] SEE PAGE 1 OF 8
E7 HIG H BEAM S
20/30 A
30-V-M
30 86
301-A-V
96597. 0
74-M/N REAR WORKING
E13 REVERSE LIG HT

E6 HEADLIG HTS
87a 8 7 85
20/30 A
30 86
20/30 A
MODUL
30 86
700-L-C
62-N
71.A-A-N
42-C -N
A3
87a 8 7 85
67-G-N
87a 8 7 85 62-N
1
68.A-V
MODUL
5
38-S OU 38-S-N
65798. 1
87a 8 7 85
A5
66-A
62-N
42-C -N
62-N
22-M/N
710-B-N
38-S OU 38-S-N
62-N
62-N
X8 9
X8 7
2
16
52400 5 + 5 9 6 6 2 6
68-V
68-V
X8 9
X8 7
5
64-G
67-G-N
711-A-R
72-A-G
71.A-A-N
8
- - -
66-A
62-N
721-A-B
62-N
X8 9
X8 9
X8 9
12
70-H
11
4
70.A-H
RADIO
X8 9
70-H
70-H
X5 6
3
INTERI O R L I G H T
66-A
X8 9
63-L
67-G-N
X5 6
X5 6
29-R -N
X8 9
1
8
64-G
X5 6
X8 9
1
X5 6
X1 5 3
X8 9
3
X3 4
X3 4
X3 4
X3 4
1
5
63-L
MODUL
62-N
6
89-L-B
710-B-N
X8 9
62-N 29-R -N 22-M/N 22-M/N
42-C -N
A7
E
7
H
64-G
L-B
L-N
63-L
N
X3 3
X3 3
X3 3
3
5
67-G-N
7 0 - H X3 3
66-A
2
70-H
68-V
66-A
X3 8
1
63-L 63-L 29-R -N
L
64-G
68-V
42-C
63-L
X--
X--
62-N
64-G
FRO N
2
X3 5 X3 9
5
5
3
4
W INDSHIELD T
W ASHE W INDSHIELD
HEADLIGHT
SIGNAL
BEAM
LIG H T
LIG H T
BRAK
SIGNAL
FOG LIG HT
LIG H T
BRAK
LIG H T
NIGHT
67-G-N
WIPER MOTOR
LIG H T
TUR
EAM
R
NIGHT
BHIGH
SIGNAL
HEA
SIGNAL
HIGH
1-L
TUR
TUR
NIGHT
FLUID MOTOR STO

LIG H T
TUR
M STO
2-54G
P
LIG H T
NIGHT
BACKU
N
X3 6 6-54
S
E
M
D
E
P
N
64-G
LIG H T
N
S
62-N
7-58L R
HOR
64-G
3-31 5-58R
P
N
4-R
RE V E R S
66-A
EA L A R
TRAILER PLUG
X9 0
M
4
X1 5 3
LICENSE PLAT E L I G H T
FRONT LEFT HEADLIG HT REAR LEFT LIG H T REAR RIG HT LIG HT FRONT RIGHT HEADLIGHT
1
1
62-N
62-N
62-N
X3 3
X3 6
X3 8
X3 4
1
1
GROUN GROUN GROUN GROUN
GROUND 0V
D D D D
Exam ple : A-B

BROW Light Blue White
A LI G H T B L U E M N 4 9 . A - V - N : W I R E N °4 9 . A G R E E N - B L A C K
ORAN G R E
C R Example : A/B 6 8 . 0 - R : W I R E N °6 8 . 0 R E D
E
YELLO D Light Blue White
G S PIN K X88 88:N° T HE CONNEC T O R
W
GRE GREE
H Y
V N 4 4: PO SIT IO N O F T H E W I R E
475 of 724 L DARK BLUE Z VI O L E T

476 of 724
MS-1307
367021500)
SHEET 4 of 8

WIRING SCHEMATIC
V518 (S/N 367011001 -
L
B
A
H
C
G
W O R K I N G
F2
B E A C O N
Y
E
W
BLUE HEADLIGHT OPTION 2501- G - R
15 A
X10 7 25.6-B X10 6 X8 9
GRE
WHITE
2 1 14
YELLO
ORA N G
25.6-B 20/30 A
DARK BLUE
LIGHT BLUE
BLUE HEADLIGHT OPTION
2501- G - R
X10 6 25.6-B X10 7 X8 9 25.6-B
30
2 1 13
87a 87
Z
V
S
R
N
M
62-N
[K] SEE PAGE 3 OF 8
25.5-B
85
N
D
N
86
OPTION
R E
IN T E R IO R N IG H T L IG H T
PIN K
BROW
GREE
BLACK
E4 BLUE HEADLIGHTS
VIOLET
96601.0
W O R K I N G
64.A-G
B E A C O N
8
1
5
FRONT LEFT CAB 25.1- G- V

20/30 A
25- G- V
W O R K I N G
B E A C O N 2501- G - R
X9 0
2
25- G- V 25- G- V
30
1
87a 87
ORIGINAL INTERIOR
1
FRONT RIGHT CAB 62-N

79923.9
0
- - -
85
86
Example : A/B
O
Example : A-B
25.5-B
52400 5 + 5 9 6 4 7 3
Light Blue
Light Blue
1
25.1- G- V
E2 WORKING BEACON U
W O R K I N G
3
B E A C O N X9 0 64.A-G
25.B-G
5
White
White
INTERIOR W I T H B L U E O P T I O N
25.1- G- V
REAR LEFT CAB

62-N
25.1- G- V
20/30 A
25.B-G
W O R K I N G
X3 0
B E A C O N X3 0 X8 9
25.C- G- V 25.C- G- V
30
4
2 1 10
87a 87
A R
X8 8
66501.8
62-N
M
51103 1 + 5 9 6 4 7 3
85
86
W O R K I N G
F1
B E A C O N
25.0-G- R 25.0-G- R 15 A
E1 WORKING BEACON
1
6 2 - N : W I R E N °6 2 B L A C K
96591.3
ROTATING BEACON
4 :POSIT ION OF T H E W IR E
6 8 . 0 - R : W I R E N °6 8 . 0 R E D
+ BATTERY
M
+ CONTACT
ROTATING BEACON
GROUND 0V
1
F17
X9 0
4 9 . A - V - N : W I R E N °4 9 . A G R E E N - B L A C K
79-Z 79-Z 79-Z 79.A-S- N 79.A-S- N 7,5 A
6
62-N
66500.0
X--
+ CONTACT
52400 5 + 5 9 6 4 2 6
+
CIGARETTE LIGHTER
GROUND 0V
F7
X--
038- R
LIGHTER
10 A
CIGARETTE
REAR HOOK
X15 0 62-N 187-H- N
1
8
0
L O W E R
96598.8
H O O K
2
EV11
X15 0 X8 7
1
187-H- N
3 3
7
3
X15 0 X8 7
186-R- N
+ CONTACT
192-A/N
4 4
2
RAISE HOOK
192-A/N
EV12
X15 0
62-N 186-R- N
8
4
62-N
176-L/B
GROUND 0V
REAR OPTIONS
- - -
EV13
[L] SEE PAGE 3 OF 8
X15 0 X15 0 X8 7
52405 8 + 5 9 6 3 0 1
62-N 176-L/B 176-L/B

10 5 5
TO BRAKE LIGHT CONTACT
- - -
52405 8 + 5 9 6 1 5 4
176-L/B
192-A/N
62-N
X15 0
62-N 188-S- G
7
4
REAR HYDRAULI C S ( + )
029- R
EV10
X15 0 X8 7
188-S- G
3
2 2
192-A/N
OPTION REAR
X15 0 X8 7
189- R- V
F18
192-A/N
10 A
1
1 1
BRAKE LI G H T
REAR H Y D R A U L I C S ( - )
GROUND 0V
EV9
2
X15 0
0
62-N 189- R- V
REAR HYDRAULIC PLUG
6
96599.6
721T - H - N
- - -
52402 4 + 5 9 6 3 0 7
62-N
TO 30-E13 REVERSE LIGHT RELAY
X2 1 X9 0 [M] SEE PAGE 3 OF 8 022-B

7
R 71-L-B 71T-L- B 71T-L- B

5
2 5 WINDSHIELD WIPER
X2 1 X9 0
1
F29
V 72-L 72T- L- G
F
721.T-H-N 721.T-H-N 10 A
X2 1 3 9
G 721-H- N 7 2 1 . T - A - NX9 0 721T - H - N
ROO
REVERSE LIGHT
GROUND 0V
0
1 X2 1 8
N 62-N 62-N
WIPER MOTOR
4
1
96603.6
72T- L- G
72T- L- G
+ CONTACT
62-N
721T - H - N
2
1
0
96602.8
REAR WINDSHIELD
WIPER
F30
72 1 A R - A 72 1 A R - A
5
X2 0 X9 0 7,5 A
40- A 73A R - L 73A R - L
- 10
X9 0
N 72 1 A R - A
7
11
X9 0
4
REA
72.AR- V 89 A R - B
M
3
W INDSHIELD
WIPER MOTOR
X2 0 62-N 62-N
-
62-N
- - -
X-- X8 7
89 A R - B
+ 17
52411 5 + 5 9 4 7 6 9
72 1 A R - A
M
MOTO
X--
72.AR- V
W INDSHIELD
W ASHER FLUID
-
62-N
WIRING SCHEMATIC
V623 (S/N 367111001 -
367112500)
AND (S/N 367211001 -
367212500)
SHEET 5 of 8 + BATTERY + BATTERY + BATTERY + BATTERY + BATTERY

MS-1308A
INV.VENTIL.
CDE MANIP
7,5 A
7,5 A
DUM
C E
883-Z-N
P
INV. VENTI L .
TOO
F16
A-F16
[H] SEE PAGE 2 OF 8 L
F23 F32
3 A
MODU L
404-A-G
B4
403-R-C
E
96606. 9
- - - 6 5
524110+596 6 5 3
3,5%
62-N
YELLO
536-R-G
- -
W
DUM
517-C
8 2 7 1 1
0
[G] SEE PAGE 2 OF 8 524110+594 4 1 1 P
TO 86 E12 6 V
8
43-M-B
2
6
177-B-N CONTINUOUS TOOL 43-M-B
7
62-N
43.B-M - B
5
1
524276+------
0 1
BUZ Z ER L IM IT E D
OK OF 3 X C E C
BLUE 8 2 7 1
96592. 1
0
EURO P
EURO P
Prop 1
Prop 2
Prop 3
Prop 4
TELESCOPIC RETRACT
1
TOOL 1 / T O O L 2
TELESCOPIC EXTEND
-INV
-INV
-INV
-INV
INTER. OUTPUT O F
E
N-INV
N-INV
N-INV
N-INV
Prop 1
- - - 6 4 5 3
(-) DIRECTION
(+) DIRE C T I O N
96605. 1
INTER.DI R . 1 A
INTER.DI R . 1 B
62-N
LOA
FOR ANY A X I S
UNLOA
H / S INTER.DI R . 1 A
M / V INTER.DI R . 1 B
G/M I N T E R . D I R . 2 A
B / G INTER.DI R . 2 B
H INTER.DI R . 3 A
S INTER.DI R . 3 B
R INTER.DI R . 4 A
Z INTER.DI R . 4 B
883-Z-N
D
POSITION
RAISE
LOW E
NEUTRAL
MODU L
B BUTTON 5
X-CEC
X-CEC
D
536-R-G
C2
177-B-N
R
1220-R
1210-L
E
62.5-S-N
BLUE
1-LIFTING TILT 3-TEL ESCOPIC 4- TOOL
R/L
U-
194.0 Z/B
B/V
Udc
H/M
U+
195-L-R
G
N
B/H
L
R E
532-L/G
887-L-C
518-R/N
43.B-M - B
D
511-M
OF 85 REL.E9
62-N
[D] SEE PAGE
X210
X210
X210
X210
X210
X210
X210
X210
X210
X210
X210
X210
X210
X210
X210
X210
X210
X183
X183
X183
X183
X183
X183
X183
1 OF 8
18
13
12
11
14
16
15
10
17
9
2
X250
X250
X250
X250
X250
X250
X250
X250
X250
X250
X250
X250
X250
10
12
13
11
7
6
12 V +DE V .
D27
MANIP
D28
2 4 5
+ DUMP
K22
1 3
K12
CONTINUOUS TOOL
3 1 1 3
470Ù
K11 BIS
470Ù
CONTACTS"OR"
5 4 1
SECURITY
5 4 1
LOC K10
XXX
K6
K 5 4 2 2 4 5 LS A ND
3 2
D A N F O S S 1 KÙ
3 2 P O W E R
MULTIMETER
MEASUREMENT POINT
AXE1 AXE2 AXE3 AXE4 EV3 AXE5
D22
D23
D26
D25
D24
D21
X184
X184
X184
X184
X184
X184
X184
X184
X184
X184
X184
X184
X184
X184
X184
X184
X184
X184
10
11
12
13
14
15
16
17
18
1
9
9
18
4
17
12
6
2
1
15
10
11
16
SHIELDING
5
SHIELDING
14
1 S
(+)
ELECTRO LS
1 S (+) 1S (+) 1 S (+) 1S (+) 2

2 2 2 2
( - ) 3
( - ) 3 ( - ) 3 ( - ) 3 ( - ) 3
PVEK DANFOSS PVEK DANFOSS PVEK DANFOSS PVEK DANFOSS

EVP1
PVEK DANFOSS EV3 EVP5 DUM
EVP2 EVP3 EVP4 P
LIFT TILT TELESCOPIC TOOL
Example : A-B
Light Blue White
BROW
A LIGHT B L U E M N 4 9 . A- V - N : W I R E N °4 9 . A G R E E N - B L A C K
ORAN G R E
C E
R D Example : A/B 6 8 . 0 - R : W I R E N °6 8 . 0 R E D
YELLO Light Blue White
G W
S P IN K X8 8 88:N° THE CONNECTOR
GRE GREE
H Y
V N 4 4 :POSIT ION OF T H E W IR E
L DARK BLUE Z VIOLE T
477 of 724
WIRING SCHEMATIC
V518 (S/N 367011001 -
367012500)
SHEET 6 of 8
PRINTED SEPTEMBER 2004 Printable Version Click Here
MS-1309
+ BATTERY + BATTERY
+ CONTACT + CONTACT
X2 2 1
X2 2 1
1
2
-H-R-
VENTIL.C L I M .
COMPRESSO
7,5 A
20 A
R
F02 F01
-R-
-R-
-H-R-
E17 VENTIL. CLI M.

20/30 A
30 86
87a 87 85
-N-
-H-
- B
3 C H
M L
2 1 0
-R-
-C-
-B-
-G-
-G-V- -G-V-
E16 COMPRES.
20/30 A
30 86
-B-
-C-
-G-
87a 87 85
-L-
-V-
X2 2 2
X2 2 2
1
3
X2 2 2
X2 2 2
5
2
-L-
THERMOSTAT ANTI-ICING
T ( x °)
-V-
3C
MOTO
R
-V-N-
VENTIL.C LIM .
M
COMPRESSO
CLUTCH
- V - N - X2 2 2
4
R
PRESSURE CONTOLLER
-N-
1 3
2 4
-N-
-N-
GROUND 0V GROUND 0V
478 of 724
96616.8
SPAR E R ELA Y
WIRING SCHEMATIC 2V
7,5 A 28
?
1A 12
X2 7 NOT USED
7,5 A 32
16
V518 (S/N 367011001 - 17 16
7,5 A 27 14 7 1A 11 P
7,5 A 02
01
EV2-AR
3 A
R
367012500)
20 A
20 A 26 7,5 A 10
SPARE
SPARE
FUSE
FUSE
13 6
SHEET 7 of 8 10 A 25
SPAR E R ELA Y
7,5 A 9
EV1-A V
31
7,5 A 15
7,5 A 24 7,5 A 8
NOT USED
12 5 15
10 A
7,5 A 23
MS-1310
10 A 7
BLUE
BLEU
SPARE
7,5 A 22 15 A 6
FUSE
Printable Version Click Here 11 4
7,5 A 21 AUT 7,5 A 5
7,5 A 30
14
O
15 A
15 A 20 15 A 4
10 3
7,5 A 19 10 A 3
START
YELLOW-GREEN C B
GRE R STO
P
Y 10 A 18 9 2 15 A 2
ORA NG
29
13
H L WHITE
70 71 73 E
M
7,5 A 17 P 15 A 1
10 A
10 A
YELLO
W
OPT IO N V Rx x x
X1 8 3 8 1
T O W A R D S 9V X1 8 4 18V X2 2 2
R O L L E R
TO DISTRIBUTOR 6V
X2 1 0 X2 5 0
X9 0
25V
11V
3 13V X8 7 11
X8 8
7V X8 9
21V
X2 X5 0
C 21 17V TO FRONT OF MACHINE
TI
OS 2V 13V
A GN X1 9 0 TO FRONT LIGHTS
DI
4V
X2 2 0 X2 0
3V DealerTOCopy
FRONT OF -- Not for Resale
MOTOR 4V
X2 8
RA
3V T O FR O N T C L IM. DI
14 X2 1
O
4V
X5 6
6V
N° # PINS CONNECTIONS X X YY LOCATION
X20 4 W AY 11/RE A R W IP E R CAB ROOF
X21 4 W AY 11/ROOF W IP E R CAB ROOF
MOTO
X27 2 W AY 3/SPEED SENSOR
R
X5 5 X28 3 W AY 3/14 CAB.AXE PEDA L
4V X50 13 W A Y 1/6 BELOW FUSE BOX
* *
BOARD LAYOUT X55 4 W AY 1/HEATE R BELOW FRONT CONSOLE
X56 6 W AY 1/W INDS HIE LD W IP E R BELOW FRONT CONSOLE
X87 21 W A Y 1/5 BELOW FUSE BOX
1/ 2
* *
3,5% P X88
- +
ROUGE
O R AN G
0 1
7 W AY 1/3 FRONT OF FUSE B OX
GRE E E
BLUE YELLOW R E
N D
X89 17 W A Y 1/4 BELOW FUSE BOX
S
X90 11 W A Y 1/11 CA B S IDE FUS E B O X
rev/min
X183 9 W AY 70/CDE DUMP CAB CENTER
* *
X184 18 W A Y 62/70 CAB CENTER
O i l
h * *
Water
X190 4 W AY 1/6 S IDE FUS E B O X
* *
X210 25 W A Y 7 0 / MA N I P CAB CENTER
* *
* *
X222 6 W AY 71/73 COTE CL I M.
X250 13 W A Y 1/70 CAB CENTER
BLE U
E C VERT
O 6V
479 of 724
WIRING SCHEMATIC
V518 (S/N 367011001 - X3 9
367012500) 6V
SHEET 8 of 8
MS-1311
X3 8
Printable Version Click Here 2V
9
52
X3 5
6V
4
X3 6 2 V
3V
X3 0 X1 0 3
2V
X2 9
X1 5 0
EV13
3V 12V
EV52
OP
TIO 5
N
X1 5 2
3V
EV12
IN NO
V. N
VE UT
NT X1 5 1 IL EV11
IL IS
. 2V E
72
6 5 EV10
4
X2 2 3 EV9
53 2V 2
1 16
EV8
EV7

8 62 EV6
X4 0
15
3V
57
2V 70 18V
1
X1 0 7
6V X184
X3 4 X87
2V
X1 0 6
56
X1 5 3 X89
21V
X3 3
2V
2EME END ARM 6V X50 17V
OPTION
N° # PINS CONNECTIONS XX YY LOCATION
7 X190
4V
13V
X22 2 W AY 6/HYD. OIL PROBE HYDRAULIC RESERVOIR

X29 3 W AY 5/REAR AXLE SENSOR FRONT AXLE EXTERIOR
71
X30 2 W AY 4/15 LEFT REAR EXTERIO R X220
EV51
X33 6 W AY 4/7 FRONT AXLE EXTERIOR 3V
X34 6 W AY 4/8 FRONT AXLE EXTERIOR
X35 6 W AY 4/LEFT REAR LIGHT LEFT REAR EXTERIO R CABIN * *
X36 2 W AY 4/9 LEFT REAR EXTERIO R
X38 2 W AY 4/REVERSE ALARM RIGHT REAR EXTERIOR
X39 6 W AY 4 / R IG H T R E A R L I G H T RIGHT REAR EXTERIOR
X40 3 W AY 5/FRONT AXLE SENSOR FRONT AXLE EXTERIOR
X50 13 W AY 1/6 UNDER FUSE BOX
* *
* *
* *
X1 0 3 3 W AY 5/52 REAR OF ARM
X1 0 6 2 W AY 55/56 FRONT AXLE EXTERIOR
X1 5 0 12 W AY 5/16 RE AR S ID E D IS TR IB U TIO N O P TIO N
X1 5 1 2 W AY 6/53 OPTION INV.VE N TIL .
X1 5 2 3 W AY 6 / - MOTO R , N O T U TIL IZ E D
X1 8 3 9 W AY 70/CDE DUMP CAB CENTER
* *
X1 8 4 18 W AY 62/70 CAB CENTER
* *
X1 9 0 4 W AY 1/6 SIDE F U S E B O X
* *
X2 2 0 3 W AY 71/72 SIDE F U S E B O X
* *
480 of 724
38-R
ELECTRICAL SCHEMATIC + BATTERY

40A
X190B + BATTERY + BATTERY + BATTERY
V518 (S/N 367012501 - 367013000) 1
R
(Printed September 2004) 70 A
V-0598 X190A
Sheet 1 of 8 50A + CONTACT + CONTACT
30
1
87
400-A-G
85
SPEED REGULATOR
86
TRANSMISSION
HYDROSTATIC
F-N-R SWITCH
STARTER
XXXXX.X
7,5 A
7,5 A
7,5 A
7,5 A
5 ---
CONTACT RELAY
38-R
R
CREEP
F22
A
F19 F27 F21
58 1
R
38-R
R
1 0
15/54
524005+------
76B-H-G
62-N
30 400-A-G
40-L
11-G-R
19 76-G/R
400-A-G
76B-H-G
37-B 50a
C
96607.7 CREEP
5 ---
57.B-M
17
POTENTIOMETER
37-B
84A-H-R
MODE
E8 SECU FRONT
D
30 86 Work
20/30 A
MAIN BRAKE
RS 232 SWITCH
040-A
57.A-M
R:1K
C : PRE-HEAT
76.A-G/N
KEY SWITCH
DIAGNOSTIC PORT 1
D : START
1
A : STOP
0
REVERSE / AUX. NOT CONTINUOS
B : RUN
37-B
524005+------
2 3 5 9
62-N
STARTER / FORWARD
87a 87 85
XM-AB
30 86
20/30 A
+ BATTERY
11
76.A-G/N
TO DIODE D12
10-L
HAND BRAKE
37-B 33.A-G-R
[G] See page 2 of 8
G
MASTER DISCONNECT
G G
R:68R
R:68R
87a 87 85
76-G/R
400-A-G
02-S-G
62-N
DIRECTIONAL CONTROL LEVER
M
V
B
1
R
28 42 20 21 13 4
X28B
X28B
R
X28B
A
C
B
X50
37-B
62.5-S-N
9
M/N 15
-- 15
(53a)
[D] See page 5 of 8
53-B/N
1 10-L
To LOCKING MECHANISM
32
38-R
06-G-V
04-M
2 R 5 11-G-R
STARTER RELAY
86 F
70 A
30 N
57.B-M
1 2 R N F
05-L
400-A-G
400-A-G
400-A-G
31
M
V N
V
C
L
M
L
04-M
G
S
1
6 2 5 3 4
06-G-V
87 85
57.B-M
14
X50
27-B
75-A/V 75-A/V
[A] See page 3 of 8
2
2 62-N
29
62-N
74-M/N 15
60A-Z-N
040-A
74-M/N 3
X50
TO WARNING
R R [F] See page 3 of 8

1
33N-R/N
24 08-G-V
16
62-N
76.A-G/N
X87
19
3 1
E10 PASSIVE
20
X87
BRAKE
040-A 040-A
X87
40-L
5 4 2 7 8 6
[E] See page 3 of 8

X58
21
-
84B-A/B
74-M/N
06-G-V
84A-H-R
478-L/N
47-Z/B
48-V/N
04-M
+
08-G-V
05-L
[C] See page 2 of 8
R
[B] See page 2 of 8
X190C
07-M
33M-G-B
1
57.B-M
To Battery Lamp
38-R
27-B
JAUNE X28A
VERT X28A
X28A
C
B
To Odometer
X27
84A-H-R
-
BATTERY 12V
X87
22
33.E C/B
PRE-HEAT RELAY
86
70 A
30
X27
24
X87
-
30 86
20/30 A
XM-AB
E11 SPEED
T
9
R
R
R:510R
R:510R
33M-G-B
X87
23
87 85
87a 87 85
62-N
SPEED SENSER
D+
478-L/N
W
62-N
84.C-A-B
B+
ROUGE
-
JAUNE
VERT
PPU
WATER
XM-AB
X52
47-Z/B
TEMPERATURE
-
SWITCH
8
DETECTEUR LINEAIRE
40-L
EV1-AR
EV2-AV
X87
14
STARTER
MOTOR
478-L/N
478-L/N
ALTERNATOR
57-M
48-V/N
23
22
M G
84-A-B
1 2 2 1
PRE-HEATER
B- EV8 INCHING
24
23
22
FORWARD DRIVE REVERSE DRIVE
ELECTRO. G.O.
SPEED SOLENOID SOLENOID
62-N
62-N
62-N
62-N
62-N
62-N
- GROUND - GROUND - GROUND 0V - GROUND - GROUND
Example : A-B
Light Blue White
A LIGHT BLUE M BROWN 49.A-V-N : WIRE N°49.A GREEN BLACK
B WHITE N BLACK 62-N : WIRE N°62 BLACK
C ORANGE R RED Example : A/B 68.0-R : WIRE N°68.0 RED
G YELLOW S PINK Light Blue White
X88 88:N° THE CONNECTOR
H GREY V GREEN 4 4:POSITION OF THE WIRE
V-0598 9/1/04
L DARK BLUE Z VIOLET
481 of 724
ELECTRICAL SCHEMATIC
V518 (S/N 367012501 - 367013000)
+ BATTERY + BATTERY + BATTERY + BATTERY
V-0599
Sheet 2 of 8

6V AV-BRAS
DIRECTION
HEATER
7,5 A
DASH
10 A
10 A
20 A
F13 F25 F26 F28
40.A-R
94-H-R
900-R-G
77A-C-L
[K] See page 6 of 8 X-CEC
405-B-C 67-G-N
EUROPE [M] See page 3 of 8
10
408-G TOCEC
402-B/R 402-B/R X-CEC
402-B/R
62-N
10
900-R-G
MODULE
XM-CD
408-G
B1
9
OPTION
- B
402-B/R
96604.4 5 ----
VERT
3 C H
M L
2 1 0
1
0
77A-C-L
1
524005+596650
[H] See page 5 of 8
62-N
91-C-B
90-L-R
- + P 1/2
STEERING SELECTOR SWITCH
0 1
Fuel
[J] See page 5 of 8
911-C
96593.9
--- Oil
408-G
3 Water
194.0-Z/B
10
12
6
3
XM-CD
XM-CD
XM-AB
XM-CD
XM-CD
XM-CD
XM-CD
S
194.0-Z/B
1 2 1 7
0
408-G 524149+596802
50-B
190-C-N
191-L-G
51-H-R
54-S
33.B-G-R
49-V-B
78-Z-N
77-L/B
62-N
404-A-G
1 3
2
XM-AB
1
7
77-L/B
XM-AB
XM-CD
E12
78-Z-N
2 4 5
REVERSIBLE FAN
96596.2
--- 5
51.A-L/G
49.A-V-N 49.A-V-N
-
62-N
402-B/R
194-Z-G
402-B/R
X87
51.A-L/G
15
X50
X50
X50
5
X87
12
6
11
X87
1
7
0 1
524010+593290
X50
X50
594785 X87
12
402-B/R
8
62-N
62-N
X87 13
-
49.A-V-N
402-B/R
10
50-B
190-C-N
49-V-B
402-B/R
55-Z
191-L-G
ENGINE OIL PRESSURE
62-N
WATER TEMPERATURE
62-N
51.A-L/G
RPM
51-H-R
594784 77-L/B
T P
X55
193-C-B
h
X87
X29
X40
C
C
B
X22
TEMPERATURE D'HUILE HYD.

2
1
X55
X55
3
1
X87
33.B-G-R
X55
7
(S) N
(S) N
X87
FRONT AXLE DIRECTION

T
9
+M
+M
REAR AXLE DIRECTION
-L
-L
X50
FUEL LEVEL
N
R
X50
G
4
194-Z-G
10
8
11
XM-CD
XM-CD
HEATER
X151
MOTOR
54-S
2nd FUNCTION ARM
X103
M
REVERSIBLE FAN
ALL WHEEL STEER

1
CRAB STEER
24
OPTION
77-L/B
OPTION
78-Z-N
[C] See page 1 of 8

33-A-R
D11
85-S-N
33.A-G-R
[G] See page 1 of 8 D12
HAND BRAKE
X50
3
P
W
[B] See page 1 of 8
33-A-R
[L] See page 5 of 8
EV51 EV52 EV6 EV7
X103
62-N
62-N
X151
62-N
62-N
C
62-N
62-G-V
62-N
62-N
62-N
- GROUND - GROUND - GROUND - GROUND - GROUND

Example : A-B
Light Blue White
G YELLOW S PINK Light Blue White V-0599 9/1/04
482 of 724
ELECTRICAL SCHEMATIC [A] See page 1 of 8
X190C
60A-Z-N
2
V518 (S/N 367012501 - 367013000)
+ BATTERY + BATTERY + BATTERY + BATTERY
V-0600
Sheet 3 of 8

67.0-G-N 67.0-G-N
64.0-A
ROAD LIGHTS
HIGH BEAMS
HEADLIGHTS
A-F8
A-F9
WIPER
15 A
15 A
15 A
10 A
64-G
CLIGNOTANT
[N] See page 4 of 8
WARNING
LIGHTS
LIGHTS
64-G
7,5 A
7,5 A
7,5 A
7,5 A
F20 F4 F6 F3
96600.2
3 6 8
F8 F24 F10 F9
71.A-A-N
70.0-R
64-G 67-G-N 67-G-N
67-G-N
1 2 ---
68.0-R
650-H-R
2 1 0
60-B-R
524138+595105
REAR BRAKE
64-G
38-R
67-G-N
LIGHT SWITCH
029-R
71.A-A-N 38-R 65-L-N [P] See page 4 of 8
66-A
LIGHT & HORN
700-L-C 67-G-N
66-A [M See page 2 of 8
29
7,5 A
700-L-C
524194+596191
8
XM-AB
7 66-A
66-A
3 8 2 0 1
R
4
4 7 10
B-G
N-Z
Z-B
L
--
F5
29-R-N
S
R
H
5 1 6 4 96590.5
38-S-N 56 15/1 49a
63-L
62-N
62-N
651-R-V
63-L
65-L-N
65-L-N
1
II
J 0
38-S-N
31
G
53b
31b
65-L-N
42.0-C-B
M 53c
62-N
651-R-V
53 J
H
0I 0 I L R
0
M
56b
N
R
C
56a L
V
R-N
WASCHER
HUPE
67-G-N
R-B
Z
G
B
N-L/G
49a
X90
[R] See page 4 of 8

N-L/B
7
6
M-G
Z-N
G
Z
N
L
42.0-C-B
49
1/2V 2/2V 1 2 12 6 X251 (2V) + X254 (12V) 5 3 9 11
66-A
38-S OU 38-S-N
42.1-C 63-L
63-L
70.1-H-N 63-L 74-M/N

[E] See page 1 of 8
C3
86 68.1 -V-N
30
5C
89-L-B
C2
20/30 A
HORN RELAY
70.1-H-N
2
721-A-B
68.0-R 68.0-R
711-A-R
72-A-G

71.A-A-N
022-B
70.0-R
E7 HIGH BEAMS
30 86
30-V-M
20/30 A
301-A-V [F] See page 1 of 8
74-M/N
96597.0
1
87a 87 85
E6 HEADLIGHTS
30 86
20/30 A
0
30 86
XM-AB
20/30 A
LIGHT / ALARM
62-N
700-L-C
42-C-N
BACK-UP
3
87a 87 85
62-N
87a 87 85 68.A-V
67-G-N
1
5
XM-AB
65798.1
87a 87 85
38-S OU 38-S-N
5
62-N
66-A
42-C-N
62-N
62-N
22-M/N
710-B-N
62-N
X89
2
38-S OU 38-S-N
68-V
X89
524005+596626
68-V
5
X87
64-G
8
711-A-R
72-A-G
66-A
71.A-A-N
---
71.A-A-N
62-N
62-N
67-G-N
X89
721-A-B
X89
12
70-H
X89
11
70.A-H
RADIO
X89 4
70-H
70-H
X56
3
X56
X89
66-A
X89
6
15
63-L
X56
X89
8
1
67-G-N
64-G
29-R-N
INTERIOR LIGHT
X56
X89 1
X56
X153
22-M/N
X89
3
X34
X34
X34
X34
63-L
1
5
6
XM-AB
62-N
62-N 29-R-N X89

89-L-B
710-B-N 22-M/N
6
42-C-N
7
67-G-N
L-N
64-G
L-B
63-L
X33
X33
X33
66-A
5
X33
66-A
67-G-N
70-H
68-V
63-L
66-A
29-R-N
X38
63-L 29-R-N
1
L
64-G
68-V
67-G-N
70-H
42-C
63-L
X--
X--
64-G
62-N
FRONT
2
2
X35 X39
5
5
HEAD LIGHTS 2
HIGH 3
4
WINDSHIELD WINDSHIELD
WIPER MOTOR
BEAMS
HEADLIGHTS
TAIL LIGHTS
TURN SIGNAL
TURN SIGNAL
TURN SIGNAL
BACKUP LIGHT
BACKUP LIGHT
TAIL LIGHTS
HIGH BEAMS
TURN SIGNAL
WASHER
RUNNING LIGHTS
RUNNING LIGHTS
STOP
STOP
FLUID MOTOR STOP 1-L STOP
M X36
64-G 2-54G 6-54
BACK-UP ALARM
M R
62-N
7-58L
HORN
1
3-31
64-G
5-58R
4-R
66-A
66-A
X90
X153
FRONT LEFT HEAD LIGHTS REAR LEFT TAIL LIGHTS TRAILOR PLUG
1
1
REAR RIGHT TAIL LIGHT FRONT RIGHT HEAD LIGHT
62-N
62-N
LICENSE
62-N
X33
X36
X38
X34
PLATE LIGHT
1
1
- GROUND - GROUND - GROUND - GROUND - GROUND
Example : A-B
Light Blue White
V-0600 9/1/04
483 of 724
OPTION BLUE HEAD LIGHTS 2501-G-R 15 A
X107 X106 X89
F2
25.6-B
2 1 14
BEACON
25.6-B 20/30 A
L
B
A
H
C
G
484 of 724
OPTION BLUE HEAD LIGHTS 2501-G-R
87a
X106 X107 X89
25.6-B 25.6-B
30
2 1 13
87
GREY
62-N
WHITE
25.5-B
YELLOW
ORANGE
85
86
OPTION
DARK BLUE
LIGHT BLUE
V-0601
1
Sheet 4 of 8
E4 BLUE HEAD LIGHTS

96601.0
Z
V
S
R
N
M
WORKING FLASHERS
8
64.A-G
[N] See page 3 of 8
RED
1
5
PINK
FRONT LEFT CAB 25.1-G-V
BLACK
VIOLET
GREEN
BROWN
25-G-V
20/30 A
WORKING FLASHERS 2501-G-R
87a
X90
V518 (S/N 367012501 - 367013000)
25-G-V 25-G-V
30
1
87
INTER D'ORIGINE
1
FRONT RIGHT CAB 62-N
79923.9
---
85
25.5-B
86
524005+596473
25.1-G-V
OU
1
E2 WORKING FLASHERS
3
WORKING FLASHERS
X90 64.A-G
Example : A/B
25.B-G
Example : A-B
5
25.1-G-V
Light Blue
2
Light Blue
INTER AVEC OPTION PH BLEU
REAR LEFT CAB
25.1-G-V
62-N
25.B-G
20/30 A
WORKING FLASHERS
87a
X30 X30 X89
25.C-G-V 25.C-G-V
White
30
White
2 1 10
87
66501.8
ARM 62-N
511031+596473
85
86
WORKING FLASHER
F1
25.0-G-R 25.0-G-R 15 A
E1 WORKING FLASHERS
4
X88
1
96591.3
0
ROTATING BEACON
M
+ BATTERY
- GROUND
62-N : WIRE N°62 BLACK

ROTATING BEACON
F17
1
+ CONTACT
X90
79-Z 79-Z 79-Z 79.A-S-N 79.A-S-N
68.0-R : WIRE N°68.0 RED

7,5 A
4:POSITION OF THE WIRE

6
62-N
49.A-V-N : WIRE N°49.A GREEN BLACK

62-N
66500.0
XALCIG
524005+596426
- GROUND
+ CONTACT
POWER PLUG
F7
PLUG
XALCIG
038-R 10 A
12 V POWER
1
(OPTIONAL)
TRAILER HYDRAULIC
X150 CONNECTOR
62-N 187-H-N
1
8
0
96598.8
LOWER TRAILER PIN

2
EV11
X150 X87
1
187-H-N
3 3
7
X150 X87
3
186-R-N
192-A/N
4 4
2
192-A/N
+ CONTACT
RAISE TRAILER PIN
EV12
X150 62-N 186-R-N
8
4
62-N
176-L/B
- GROUND
---
REAR OPTIONS
EV13
524058+596301
X150 X150 X87

62-N 176-L/B 176-L/B
10 5 5
---
176-L/B
524058+596154
192-A/N
62-N
X150 62-N 188-S-G

[P] See page 3 of 8
7
4
REAR HYDRAULICS
2
EV10
X150 X87 188-S-G

029-R

192-A/N
2 2
F18
X150 X87
189-R-V 192-A/N 10 A
1
1 1
- GROUND
REAR HYDRAULICS
EV9
2
(OPTIONAL) (OPTIONAL)
X150 REAR BRAKE LIGHT
62-N 189-R-V
0
REAR HYDRAULICS
6
96599.6
721T-H-N
---
524024+596307
62-N
X21 X90 022-B

7
R 71-L-B 71T-L-B 71T-L-B [R] See page 3 of 8

5
2 5
X21 X90
F29
V 72-L 72T-L-G
721.T-H-N 721.T-H-N 10 A
X21 3 X90 9
G 721-H-N 721.T-A-N 721T-H-N
- GROUND
M
CAB ROOF
0
1 X21 8
N 62-N 62-N
WIPER MOTOR
4 WINDSHIELD WIPER
96603.6
BACK-UP LIGHT
1
72T-L-G
72T-L-G
62-N
+ CONTACT
721T-H-N
2
1
0
96602.8
F30
721AR-A 721AR-A 7,5 A

X20 X90
5
40-A 73AR-L 73AR-L

- 10
N X90 721AR-A
7
11 REAR WIPER\WASHER MOTOR

X90
4
72.AR-V 89AR-B
M
3
X20
WIPER MOTOR
REAR WINDOW
62-N 62-N
-
62-N
V-0601 9/1/04
---
X--
89AR-B
524115+594769
+
721AR-A
M
MOTOR
WASHER
WINDOW
X--
72.AR-V
-
62-N
V518 (S/N 367012501 - 367013000)
V-0602
Sheet 5 of 8
Printable Version Click Here 883-Z-N
F16
A-F16 OUTIL
CDE MANIP
INV.VENTIL.
43A-B-N
DEVERS
3A
7,5 A
7,5 A
CEC
96606.9
--- 6 5
F23 F32
177-B-N
TELESCOPING SWITCH AUXILIARY SWITCH 404-A-G
[J] See page 2 of 8 1
403-R-C
HALL 8 2 7 0 1
RESTRAINT BAR SESOR

524110+594411
524110+596653
62-N
536-R-G
43-M-B
--
43-M-B
517-C
43C-H-L
POUSSOIR 7
POUSSOIR 8
PNP
NPN
(BAS)
62-N
8
HALL
CONTINUOS TOOL
L
R
G
V
SIGNAL BLANC
2
SIGNAL BLANC
6
524276+------
de 0.5V a 4.5V
ROUGE 5V
ROUGE 5V
0V MASSE
de 0.5V a 4.5V
BLEU
BLEU
177-B-N BLEU 8 2 7 1 0 1
7
5
[L] See page 2 of 8
1
X231
X231
X231
X231
X231
X231
X231
X231
[H] See page 2 of 8

8
7
1
9
--- 6 4 5 3 96605.1
62-N
0
X241
X241
62.5-S-N
96592.1
883-Z-N
1
43C-H-L
XM-CD
43.B-M-B
1
[D] See page 1 of 8

536-R-G
195-H-N
62-N
1220-R
177-B-N
1210-L
BLEU
33-A-R
X252
X252
X252
X252
8
6
X251
X251
X251
X251
X251
X251
X251
X251
1
7
6
7
4
B
G-V
V
1 2 3 4 5 6 7
RESTRAINT BAR
ON & OFF
+DEV
12V D28
CONTINUOS TOOL
D27
3 1
470Ù
470Ù
SECURITY
K10 MANIP
CONTACTS"OR"
5 4 1
K11 BIS
LOCK
5 4 1
SECURITES
K12
5 4 2
3 2 1 KÙ
3 2 MULTIPLIER
MEASUREMENT POINT
AXE3 AXE4 EV3

D23
D25
D24
X184
X184
X184
X184
X184
X184
X184
X184
X184
X184
X184
10
11
12
13
14
15
1
2
9
12
15
10
11
7
8
1
14
4 3 4 3
S (+) 5V (+)
5V S
1 1
(-) 2 (-) 2
CONTROL VALVE
CONTROL VALVE EV3
TELESCOPING VALVE EVP3 AUXILIARY VALVE EVP4
SECTION SECTION
LOAD SENSE
ACTIVATION VALVE
Example : A-B
Light Blue White
G S Light Blue White
YELLOW PINK X88 88:N° THE CONNECTOR V-0602 9/1/04
485 of 724
+ BATTERY + BATTERY
V518 (S/N 367012501 - 367013000)

+ CONTACT + CONTACT
V-0603
Sheet 6 of 8
056-R
94-H-R
[K] See page 2 of 8
X221
X221
2
-H-R-
COMPRESSOR
7,5 A
HVAC
20 A
F02 F01
-R-
-R-
-H-R-
30 86
20/30 A
E17 HVAC
87a 87 85
-N-
-H-
- B
3 C H
M L
2 1 0
-R-
-C-
-B-
-G-
-G-V- -G-V-

E16 COMPRESSOR
30 86
20/30 A
-B-
-C-
-G-
87a 87 85
-L-
-V-
X222
X222
1
3
X222
X222
5
2
-L-
THERMOSTAT ANTIGIVRAGE
4
T(x°)
-V-
3C
X220
MOTOR
2
HVAC
(IF EQUIPPED)
-V-N-
M
COMPRESSOR
CLUTCH
X222
4
-V-N-
X220
-N-
1
PRESSURE SWITCH
1 3
2 4
-N- X220
-N-
3
- GROUND - GROUND
Example : A-B
Light Blue White
A LIGHT BLUE M BROWN 49.A-V-N : WIRE N°49.A GREEN BLACK V-0603 9/1/04
486 of 724
ELECTRICAL SCHEMATIC XX
N° PIN NO. YY LOCATION
V518 (S/N 367012501 - 367013000) X20
CONNECTIONS
11/REAR WIPER CAB ROOF 96616.8
4v
(Printed September 2004) X21 4v 11/ROOF WIPER CAB ROOF ? SPARE RELAY
7,5 A 28 1A 12
V-0604 X28A 3v 1/14 CAB AXE PEDAL
Sheet 7 of 8 1/ CREEP OPTION NOT USED
32
16
X28B 3v CONSOLE
12 v 17 16
7,5 A 27 14 7 1A 11 P
Printable Version Click Here X50 1/6 BELOW FUSE BOX
02
01
**
7,5 A
3A
X55 4v 1/HEATER BELOW FRONT CONSOLE
R
7,5 A
20 A 26 7,5 A 10
20 A
X56 6v 1/WINDSHIELD WIPER BELOW FRONT CONSOLE
1/5
SPARE
24 v BELOW FUSE BOX
SPARE
X87
FUSE
** 13 6
FUSE
24 v 1/4 10 A 25 7,5 A 9
X89 BELOW FUSE BOX **
X90 11 v 1/11 CAB SIDE FUSE BOX
SPARE RELAY
VERT
31
15
7,5 A 24 7,5 A 8
6V
X184 18 v 62/70 CAB CENTER ** NOT USED
X190A 1v 1/6 CAB CENTER 12 5 15
**
7,5 A
10 A
X190B 1v 1/6 CAB CENTER 7,5 A 23 10 A 7
** BLUE
X190C 2v 1/6 CAB CENTER ** BLEU
BLEU
SPARE
X220 3v 71/72 SIDE FUSE BOX 7,5 A 22 15 A 6
FUSE
**
11 4
X221 2v 1/71 SIDE FUSE BOX
X222 6v 71/73 REAR OF CAB 7,5 A 21 7,5 A 5
AUTO
30
14
X231 12 v 70/JOYSTICK SIDE FUSE BOX
X233 4v 70/CDE DEVERS
7,5 A
SIDE FUSE BOX
15 A
15 A 20 10 3 15 A 4
X241 2v LEFT SIDE OF CAB
Work
ROUGE
X251 8v 1/70 CAB CENTER 7,5 A 19 10 A 3

X252 8v 1/70 CAB CENTER START
YELLOW-GREEN C B GREY
R STOP
9 2
10 A 18 15 A 2
ORANGE H WHITE
29
13
L
M
7,5 A 17 P 15 A 1
10 A
10 A
YELLOW
8 1
71
X233 4V 70 73
CDE DEVERS
X222
MOLETTE DEVERS
6V
VERS CAPTEUR EFFET HALL 2V X241 Dealer Copy -- Not for Resale
(UNIQUEMENT SUR CANOPY)
P
8V
1
X252
X231
Teau
X90
12V X251
1
8V 11V
OPTION CREEPER
3 X87 18V 11
1/2
X28B
X89 X184
S
3V 24V
0
VERS DISTRIBUTEUR
X2
UE
ROUGE
21 24V VERS FAISCEAU MACHINE

TIQ X1
OS 2V X1 90A X50
tr/min
N
AG X1 90C 12V VERS FAISCEAU ECLAIRAGE
DI
h
90 1V
ORANGE
B
3,5%
JAUNE
2V
1V
X20
VERT
X220 4V
VERS FAISCEAU MOTEUR
X28A 3V AU
TO
3V VERS FAISCEAU CLIM. RA
14 DI
BLEU
X21 O
4V
X241
Thuile
2V
+
-
73
X56
6V
VERS BOITIER DE CONTROLE

X55
(UNIQUEMENT SUR CANOPY)
4V
V-0604 9/1/04
487 of 724
CONNECTOR
NO. # of Pins CONNECTIONS XX YY LOCATION
X22 2V 6/HYD. OIL PRESSURE HYDRAULIC RESERVOIR
ELECTRICAL SCHEMATIC X27 2V 3/SPEED SENSOR MOTOR
V518 (S/N 367012501 - 367013000) X29 3V 5/REAR AXLE SENSOR REAR AXLE
X30 2V 4/15 LEFT REAR EXTERIOR
(Printed September 2004) X33 6V 4/7 FRONT OF MACHINE BY AXLE
V-0605
X34 6V 4/8 FRONT OF MACHINE BY AXLE
Sheet 8 of 8
X35 6V 4/FEU AR GAUCHE LEFT REAR OF MACHINE
Printable Version Click Here X36 2V 4/9 LEFT REAR OF MACHINE
X38 2V 4/AVERTISSEUR DE RECUL RIGHT REAR OF MACHINE
X39 6V 4/FEU AR DROIT RIGHT REAR OF MACHINE
X40 3V 5/CAPTEUR PONT AV FRONT OF MACHINE BY AXLE
X50 12V 1/6 UNDER FUSE BOX **
X87 24V 1/5 UNDER FUSE BOX **
X89 24V 1/4 UNDER FUSE BOX ** X39
X103 3V 5/52 REAR OF ARM 6V
X150 12V 5/16 REAR OF MACHINE
X151 2V 6/53 (IF EQUIPPED) HVAC CAB
X152 3V 6/- NOT USED
X153 2V 5/8 FRONT OF MACHINE BY AXLE 9
X184 18V 62/70 CENTER OF CAB X38 2V
**
X190A 1V 1/6 CENTER OF CAB EV6
**
X190B 1V 1/6 CENTER OF CAB **
X190C 2V 1/6 CENTER OF CAB
**
X220 3V 71/72 SIDE FUSE BOX X35
X221 2V 71/1 SIDE FUSE BOX

4 6V
EV7 X36 2V
52
2V
X30
X29
72 3V
X103 3V
EV52 6
X150 EV13
X152 12V
3V
NO
TU
SE
X151 D
2V 2V
EV12
X27
5
EV2-AR Dealer Copy -- Not for Resale 4
EV11
53 X22 3
2V EV10
EV1-AV 62 EV9
EV8
16
5
8
X40
15
3V
57
2V 70 1 X184
X107
18V
6V
1V X190A
X34
2V
X106
56 2V X190C
X87
X153 1V X190B
24V
X33
2V
6V X2 X89
2EME FCT BOUT BRAS 21
OPTION 24V
7 2V X50
12V
X220
3V
EV51 71
CAB CONNECTIONS
V-0605 9/1/04
488 of 724
BATTERY Figure 60-20-2
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.In case of acid
contact, wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. Always disconnect the negative cable (Item 1) [Figure
W-2065-1296 60-20-2] first to prevent sparks.
Remove the positive battery cable (Item 2) [Figure 60-

Figure 60-20-1 20-2].
Figure 60-20-3

the battery access door (Item 2) [Figure 60-20-1].
Remove the battery hold down bolt and nut (Item 1)
[Figure 60-20-3].
Remove the hold down.
Remove the battery.
V518 VersaHANDLER
BATTERY (CONT'D) Figure 60-20-5
Servicing
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.In case of acid
contact, wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. Always clean the terminals and cable ends when
W-2065-1296 installing a new battery [Figure 60-20-4] and [Figure 60-
20-5].
Figure 60-20-4 When installing the battery in the loader, do not touch any
metal parts with the battery terminal posts.

Connect and tighten the battery cables. Connect the
negative (-) cable last to prevent sparks.
Figure 60-20-6
The battery cables must be clean and the connections

tight. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate (baking soda) and
water solution [Figure 60-20-6].
Clean the electrolyte level in the battery. Add distilled

water as needed.
Put Battery Saver (P/N 6664458) or grease on the

battery terminals and cable ends to prevent corrosion.
V518 VersaHANDLER
BATTERY (CONT'D) Figure 60-20-7
Using A Booster Battery (Jump Starting)
WARNING
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at engine frame.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F. (16°C.) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.
W-2066-1296 Connect the end of the first cable to the positive (+)
terminal of the booster battery. Connect the other end of
the same cable to the positive terminal (Item 1) [Figure
60-20-7] on the VersaHANDLER battery.
IMPORTANT Connect the end of the second cable to the negative (-)
terminal of the booster battery. Connect the other end of

the same cable to the VersaHANDLER where the
Damage to the alternator can occur if:
negative cable connects to the frame (Item 2) [Figure 60-
• Engine is operated with battery cables
20-7].
disconnected.
• Battery cables are connected when using a fast
Keep cables away from moving parts. Start the engine.
charger or when welding on the loader. (Remove
both cables from the battery.)
After the engine has started, remove the ground (-) cable
• Extra battery cables (booster cables) are
(Item 2) [Figure 60-20-7] first.
connected wrong.
I-2023-1285
Remove the cable from the positive terminal (Item 1)
[Figure 60-20-7].
If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the
operator's seat and one person to connect and
disconnect the battery cables.
The key switch must be OFF. The booster battery must

be 12 volt.
NOTE: The battery compartment is located in front of

the left rear tire, on the back side of the cab.
V518 VersaHANDLER
V518 VersaHANDLER
ALTERNATOR Figure 60-30-3
Figure 60-30-1
Loosen and remove the alternator adjusting bolt (Item 1)

[Figure 60-30-3].
Figure 60-30-4
Open the hood.
Remove the three belt shield mounting bolts (Item 1)

[Figure 60-30-1].
Figure 60-30-2
Loosen and remove both mounting bolts (Item 1) [Figure

60-30-4].
Remove the alternator.
Remove the three connectors (Item 1) [Figure 60-30-2]

from the back of the alternator.
V518 VersaHANDLER
V518 VersaHANDLER
STARTER Figure 60-40-3
Figure 60-40-1
Remove the wires (Item 1) [Figure 60-40-3] from the

starter.
Figure 60-40-4
Rotate the battery disconnect switch (Item 1) [Figure 60-
40-1] to the right, to disconnect the power supply from
the battery.

Figure 60-40-2
Remove the three nuts and bolts (Item 1) [Figure 60-40-

4] and remove the starter.
Installation: Tighten to 40-45 ft.-lbs. (54-61 Nm) torque.
Remove the access cover mounting bolt (Item 1) [Figure

60-40-2]. Remove the access cover (Item 2) [Figure 60-
40-2].
V518 VersaHANDLER
STARTER (CONT'D)
V518 VersaHANDLER
STARTER (CONT'D) Figure 60-40-7
Disassembly
Figure 60-40-5

the brush cover.
Figure 60-40-8
Mark the frame and magnetic switch (Item 1) [Figure 60-
40-5] for ease of assembly.

Remove the cable (Item 2) [Figure 60-40-5] from the
magnetic switch and frame.
Figure 60-40-6
Remove both thru bolts (Item 1) [Figure 60-40-8].
Mark the frame and housing for ease of assembly

[Figure 60-40-6].
V518 VersaHANDLER
Figure 60-40-9
Mark the location of the adjustment screw (Item 1)

[Figure 60-40-11] for ease of assembly.
Remove the adjustment screw.

Remove the cover (Item 1) [Figure 60-40-9].
Figure 60-40-12
Figure 60-40-10

Separate the frame from the housing, the fork (Item 1)
Remove the split bushing (Item 1) [Figure 60-40-10] and [Figure 60-40-12] will slide free from the pinion gear.
washers (Item 2) [Figure 60-40-10] from the cover.
V518 VersaHANDLER
Figure 60-40-13
Remove the armature (Item 1) [Figure 60-40-15] from

the frame.
Figure 60-40-16
Remove the two nuts and washers (Item 1) [Figure 60-
40-13] from the magnetic switch.

Remove the magnetic switch assembly from the housing.
Figure 60-40-14
Press the collar (Item 1) [Figure 60-40-16] down to gain

access to the snap ring.
Remove the fork assembly (Item 1) [Figure 60-40-14]

and gasket (Item 2) [Figure 60-40-14] from the switch
assembly (Item 3) [Figure 60-40-14].
V518 VersaHANDLER
Figure 60-40-17
Remove the end cover (Item 1) [Figure 60-40-19] from

the armature.
Figure 60-40-20
Remove the snap ring (Item 1) [Figure 60-40-17] from
the shaft.

Figure 60-40-18
Using a needle nose pliers, pull the brush springs (Item

1) [Figure 60-40-20] back and remove the brushes (Item
2) [Figure 60-40-20].
Remove the collar (Item 1) [Figure 60-40-18] and pinion

(Item 2) [Figure 60-40-18] from the shaft.
V518 VersaHANDLER
Inspection And Repair
Figure 60-40-21
Check the pinion gear teeth for wear or damage [Figure

60-40-23].
Figure 60-40-24
Inspect the brush cover bushing (Item 1) [Figure 60-40-
21], washers (Item 2) [Figure 60-40-21] and split bearing
(Item 3) [Figure 60-40-21]. Replace parts as needed. If

there is any discoloration on the brush cover, that
indicates the starter has been overheated.
Figure 60-40-22
Check the pinion gear shaft splines for wear or damage

[Figure 60-40-24].
Check the bushing (Item 1) [Figure 60-40-22] for

damage or wear. Replace if needed.
V518 VersaHANDLER
Inspection And Repair (Cont'd)
Figure 60-40-25
Armature Winding Ground Test: Use a circuit tester,

touch one probe to a commutator segment and the other
probe to the armature core [Figure 60-40-27]. There
should be no continuity. If there is continuity, the
Check the cover bushing (Item 1) [Figure 60-40-25] and armature is grounded and must be replaced.
seal (Item 2) [Figure 60-40-25]. Replace as needed.
Figure 60-40-28

Figure 60-40-26
Armature Winding Continuity Test: Use a circuit tester,

Armature short-Circuit Test: Use a growler tester, put the touch the probes to two commutator segments [Figure
armature on the growler and hold a hack saw blade 60-40-28]. There must be continuity at any point. If there
against the armature core while slowly rotating the is no continuity, the winding is open-circuited, replace the
armature [Figure 60-40-26]. A short circuited armature armature.
causes the blade to vibrate and be attracted to the core.
An armature which is short-circuited must be replaced.
V518 VersaHANDLER
Inspection And Repair (Cont'd)
Figure 60-40-29
Field Windings Continuity Test: Use a circuit tester, touch

one probe to the wire and the other probe to the brush
[Figure 60-40-31]. There must be continuity. If there is
no continuity, the field windings are open-circuited.
Commutator Run-Out Test: Check the commutator run- Replace the yoke if the field windings have an open
out as shown in [Figure 60-40-29]. circuit.

If the commutator exceeds the service limit, repair as Inspect the brushes for wear and damage.
needed.
Replace the brush holder or yoke assembly if the
Check the field windings for wear and damage. brushes are worn or damaged.
Check all the connections for clean and tight solder Check brush springs, for damage or rust. Replace as
joints. needed.
Figure 60-40-30 Figure 60-40-32
Field Winding Ground Test: Use a circuit tester, touch Brush Holder Insulation Test: Use a circuit tester, touch
one probe to the field winding end of the brush and the one probe to the positive brush holder plate and the other
other probe to the surface of the frame [Figure 60-40- probe to the holder plate [Figure 60-40-32]. There
30]. There should be no continuity. If there is continuity, should be no continuity. If there is continuity, replace or
the field windings are grounded. repair.
Replace the field windings.
V518 VersaHANDLER
Assembly
Figure 60-40-33
Assemble the magnetic switch (Item 1) [Figure 60-40-

35] and install the assembly into the housing. Install the
two washers and nuts (Item 2) [Figure 60-40-35]. Do not
tighten at this time.
Install the end cover (Item 1) [Figure 60-40-33], pinion
gear assembly (Item 2) [Figure 60-40-33] and collar Install the foam gasket (Item 3) [Figure 60-40-35].
(Item 3) [Figure 60-40-33] on the shaft.

Figure 60-40-36
Install the snap ring (Item 4) [Figure 60-40-33].
Figure 60-40-34
Install the armature assembly into the housing making

sure the magnetic switch fork (Item 1) [Figure 60-40-36]
is in line with the pinion groove.
Pull the collar (Item 1) [Figure 60-40-34] over the snap
ring. Align the dowel (Item 2) [Figure 60-40-36] with the pin
hole in the end cover.
Slide assembly together.
V518 VersaHANDLER
Assembly (Cont'd)
Figure 60-40-37
Align the pin (Item 1) [Figure 60-40-39] with the two end
cap mounting bolt holes (Item 2) [Figure 60-40-39] and
dowel pin hole (Item 3) [Figure 60-40-39].
Align the magnetic switch fork hole with the hole in the Figure 60-40-40
housing [Figure 60-40-37]. Install the adjustment screw.

Install the frame over the armature.
Figure 60-40-38
Align the slots (Item 1) [Figure 60-40-40] in the split

bearing with the two holes (Item 2) [Figure 60-40-40] in
the cover.
Install the brush holder (Item 1) [Figure 60-40-38] over

the armature.
Use a needle nose plier, pull the spring (Item 2) [Figure

60-40-38] back and install the brushes (Item 3) [Figure
60-40-38].
V518 VersaHANDLER
Assembly (Cont'd)
Figure 60-40-41
Install and tighten the two brush cover bolts (Item 1)

[Figure 60-40-43].
Figure 60-40-44
Align the pin (Item 1) [Figure 60-40-41] in the shaft with
the split bearing (Item 2) [Figure 60-40-41] in the end
cap. Align the pin (Item 3) [Figure 60-40-41] and pin hole

(Item 4) [Figure 60-40-41]. Install the end cap.
Figure 60-40-42
Install the cable (Item 1) [Figure 60-40-44] on the

terminal and magnetic switch. Tighten both nuts.
Install and tighten the thru bolts (Item 1) [Figure 60-40-

42].
V518 VersaHANDLER
JOYSTICK PANEL Figure 60-50-2
Remove the travel/signal levers. (See Removal And

Remove the instrument panel. (See Removal And

Remove the switch panel. (See Removal And Installation

on Page 60-90-1.)

Removal And Installation on Page 60-100-1.)
Figure 60-50-1
Disconnect the lighter connector (Item 1) [Figure 60-50-

2] and remove the joystick panel.

Remove the fuse box cover (Item 1) [Figure 60-50-1]
and side cover (Item 2) [Figure 60-50-1].
V518 VersaHANDLER
V518 VersaHANDLER
LIGHTS Figure 60-60-3
Rear Removal And Installation
Figure 60-60-1
Remove the two lens retainer screws (Item 1) [Figure

60-60-3].
Figure 60-60-4
Remove the four rear cover mounting bolts (Item 1)
[Figure 60-60-1]. Remove the cover.

Figure 60-60-2
Remove the two light mounting bolts (Item 1) [Figure 60-

60-4].
Remove the light assembly.

Unplug the light harness connector (Item 1) [Figure 60-
60-2] from the main harness.
V518 VersaHANDLER
LIGHTS (CONT'D) Figure 60-60-6
Front Removal And Installation
Figure 60-60-5

remove the light.
Unplug the harness (Item 1) [Figure 60-60-5] from the

light.
V518 VersaHANDLER
TRAVEL/SIGNAL LEVER Figure 60-70-3
Figure 60-70-1
Remove the two mounting screws (Item 1) [Figure 60-

70-3].
Figure 60-70-4
Reposition the rubber boot (Item 1) [Figure 60-70-1] and
remove the screw (Item 2) [Figure 60-70-1] from the
Travel Lever.

Figure 60-70-2
Remove the lever assembly [Figure 60-70-4].
Installation: Make sure the pin (Item 1) [Figure 60-70-4]

is installed in the hole (Item 2) [Figure 60-70-4] in the
steering column.
Remove the cover (Item 1) [Figure 60-70-2].
V518 VersaHANDLER
511 of 724 60-70-1 Service Manua
TRAVEL/SIGNAL LEVER (CONT'D)
Figure 60-70-5
Tilt the steering wheel up completely and carefully pull

the harness connector (Item 1) [Figure 60-70-5] from the
column housing and disconnect.
V518 VersaHANDLER
INSTRUMENT PANEL Figure 60-80-3
Figure 60-80-1
Remove the five instrument panel mounting bolts (Item 1)

[Figure 60-80-3].
Figure 60-80-4
Remove the temperature control knob (Item 1) [Figure
60-80-1].

Figure 60-80-2
Tilt the instrument panel forward and unplug all

connectors [Figure 60-80-4]. Remove the instrument
panel.
Remove the nut (Item 1) [Figure 60-80-2] letting the NOTE: Mark the connectors for correct installation.
temperature controller fall inward.
V518 VersaHANDLER
V518 VersaHANDLER
SWITCH PANEL Figure 60-90-3
Figure 60-90-1
Remove the switch panel [Figure 60-90-3].
Remove the five screws (Item 1) [Figure 60-90-1].
Figure 60-90-2

Unplug the harness connectors from the back of the
switch panel [Figure 60-90-2].
NOTE: Mark all connectors for ease of assembly.
V518 VersaHANDLER
V518 VersaHANDLER
DASH COVER/STEERING COLUMN COVER Figure 60-100-3
Remove the Travel/Signal Levers. (See Removal And



on Page 60-90-1.)
Figure 60-100-1

the left side of the dash.
Figure 60-100-4

Remove the two bolts (Item 1) [Figure 60-100-1].
Figure 60-100-2
Remove the three screws (Item 1) [Figure 60-100-4]

from the right side column.
Remove the three dash mounting screws (Item 1)

[Figure 60-100-2].
V518 VersaHANDLER
DASH COVER/STEERING COLUMN COVER (CONT'D) Figure 60-100-7
Figure 60-100-5

vent.
Figure 60-100-8
the center.

Figure 60-100-6
Remove the steering column cover [Figure 60-100-8].
Lift and remove the dash [Figure 60-100-6].
V518 VersaHANDLER
FRONT WIPER MOTOR Figure 60-110-3
Figure 60-110-1
Remove the two mounting bracket bolts (Item 1) [Figure

60-110-3].
Reposition the steering column assembly (as shown).

Remove the dash cover/steering column cover. See
Removal And Installation on Page 60-100-1.) Figure 60-110-4

Remove the four lower mounting bracket bolts (Item 1)
[Figure 60-110-1].
Figure 60-110-2
Disconnect the front wiper connector (Item 1) [Figure 60-

110-2] from the main harness.
Reposition the main wire harness to the right side of the

cab.
V518 VersaHANDLER
FRONT WIPER MOTOR (CONT'D) Figure 60-110-7
Removal and Installation (Cont'd)
Figure 60-110-5
Remove the wiper arms from the wiper motor shafts

[Figure 60-110-7].
Figure 60-110-8
Remove the spray tube (Item 1) [Figure 60-110-5].
Figure 60-110-6

Remove both outer nuts (Item 1) [Figure 60-110-8].
Flip open the wiper covers and remove the two nuts (Item
1) [Figure 60-110-6].
V518 VersaHANDLER
FRONT WIPER MOTOR (CONT'D) Figure 60-110-10
Figure 60-110-9
Remove the wiper motor from inside the cab [Figure 60-
110-10].
Remove both inner nuts and washers (Item 1) [Figure

60-110-9].
V518 VersaHANDLER
V518 VersaHANDLER
TOP WIPER MOTOR Figure 60-120-3
Figure 60-120-1
Unplug the wiper motor connector (Item 1) [Figure 60-

120-3] from the harness.
Figure 60-120-4
the upper panel.

Figure 60-120-2
Remove the squirter tube (Item 1) [Figure 60-120-4].
Slide the upper panel forward on the support rails

[Figure 60-120-2].
Lower the panel.
V518 VersaHANDLER
TOP WIPER MOTOR (CONT'D) Figure 60-120-7
Figure 60-120-5
Remove the plastic nut (Item 1) [Figure 60-120-7] and

extension post (Item 2) [Figure 60-120-7].
Figure 60-120-8
Flip open the wiper covers and remove the nut (Item 1)
[Figure 60-120-5] and clip (Item 2) [Figure 60-120-5].

Figure 60-120-6
While supporting the wiper motor inside the cab, have an

assistant remove the two nuts (Item 1) [Figure 60-120-
8].
Remove the wiper arms from the wiper shafts [Figure Remove the wiper motor.
60-120-6].
V518 VersaHANDLER
REAR WIPER MOTOR Figure 60-130-3
Figure 60-130-1
Flip open the wiper cover and remove the nut (Item 1)
[Figure 60-130-3].
Figure 60-130-4
the upper panel and slide the upper panel forward.

Figure 60-130-2
Remove the wiper arm [Figure 60-130-4].
Unplug the rear wiper motor connector (Item 1) [Figure

60-130-2] from the harness.
V518 VersaHANDLER
REAR WIPER MOTOR (CONT'D) Figure 60-130-6
Figure 60-130-5
Remove the plastic cover (Item 1) [Figure 60-130-6] and

two nuts (Item 2) [Figure 60-130-6].
Remove the wiper motor.

Have an assistant support the wiper motor [Figure 60-
130-5].
V518 VersaHANDLER
PEDAL ASSEMBLY Figure 60-140-3

Figure 60-140-1

the brake valve.
IMPORTANT

Unplug the two connectors (Item 1) [Figure 60-140-1].
Figure 60-140-2
damage the system.
I-2003-0888
Figure 60-140-4
Remove the accelerator cable (Item 1) [Figure 60-140-2]

from the pedal and mounting bracket (Item 2) [Figure 60-
140-2].
Remove the mounting bolts (Item 1) [Figure 60-140-4].
Remove the pedal assembly.
V518 VersaHANDLER
V518 VersaHANDLER
BRAKE LIGHT SWITCH Figure60-150-3

Figure 60-150-1
Loosen the nut (Item 1) [Figure60-150-3].
With the brake pedal at rest, turn the adjustment bolt

(Item 2) [Figure60-150-3] until it touches the brake light
switch plug.
Tighten the nut (Item 1) [Figure60-150-3].

Unplug the switch connector (Item 1) [Figure 60-150-1]
from the harness.
Figure60-150-2
Loosen the nut (Item 1) [Figure60-150-2]. Remove the

switch.
Adjustment

V518 VersaHANDLER
V518 VersaHANDLER
INCHING SWITCH Adjustment
Figure 60-160-1


Unplug the switch connector (Item 1) [Figure 60-160-1]
from the harness.
Figure 60-160-2

With the brake pedal in the rest position, turn the

adjustment bolt (Item 1) [Figure 60-160-3] so that it is
0.31 in. (8 mm) away from the switch body (Item 2)
[Figure 60-160-3].
Check that the potentiometer rod (Item 3) [Figure 60-

160-3] is in contact with the center of the adjusting bolt.
Remove the two mounting bolts and nuts (Item 1)
[Figure 60-160-2]. When adjustment is complete, tighten the nut (Item 4)
[Figure 60-160-3] without turning the adjusting bolt.
Installation: Be sure the switch is on the front side of the
mounting bracket.
Remove the switch.
V518 VersaHANDLER
V518 VersaHANDLER
JOYSTICK Figure 60-180-2

Remove the joystick panel. (See Removal And

Figure 60-180-1
Remove the four joystick mounting bolts (Item 1) [Figure

60-180-2]. Remove the joystick.

Loosen both harness retainers (Item 1) [Figure 60-180-
1]. Unplug the harness.
V518 VersaHANDLER
V518 VersaHANDLER
ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . 70-40-1
ENGINE AND ENGINE MOUNTS. . . . . . . . . . . . . . . . . . . . . . 70-60-1

ENGINE COMPONENTS AND TESTING. . . . . . . . . . . . . . . . 70-70-1

Checking The Fuel Lift Pump. . . . . . . . . . . . . . . . . . . . . . . 70-70-8
Fuel Injection Pump Removal And Installation . . . . . . . . . 70-70-1
Fuel Injector Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-7
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . 70-70-4
Fuel Lift Pump Removal And Installation . . . . . . . . . . . . . . 70-70-8
ENGINE/HYDROSTAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . 70-80-1

ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1


FLYWHEEL AND HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Ring Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-4
Ring Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-4
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 70-50-4
V518 VersaHANDLER
ENGINE SERVICE (CONT’D)
RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . 70-100-1

Camshaft And Tappets Installation . . . . . . . . . . . . . . . . 70-100-22
Camshaft And Tappets Removal . . . . . . . . . . . . . . . . . . 70-100-21
Checking Crankshaft End Play . . . . . . . . . . . . . . . . . . . 70-100-35
Checking Piston Height . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-29
Changing Valve Springs (With Cylinder Head Installed) 70-100-14
Cutting A Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-12
Connecting Rod Bushing Replacement . . . . . . . . . . . . . 70-100-27
Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . 70-100-27
Cooling System Description. . . . . . . . . . . . . . . . . . . . . . 70-100-36
Crankshaft And Bearings Description . . . . . . . . . . . . . . 70-100-30
Crankshaft And Bearings Installation. . . . . . . . . . . . . . . 70-100-32
Crankshaft And Bearings Removal . . . . . . . . . . . . . . . . 70-100-30
Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . 70-100-3
Cylinder Head Inspection. . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-4
Cylinder Liner Inspection . . . . . . . . . . . . . . . . . . . . . . . . 70-100-46
Cylinder Liner Installation. . . . . . . . . . . . . . . . . . . . . . . . 70-100-48

Cylinder Liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-47
Engine Block Description . . . . . . . . . . . . . . . . . . . . . . . . 70-100-44
Engine Block Disassembly And Assembly. . . . . . . . . . . 70-100-44
Engine Lubrication System Description . . . . . . . . . . . . . 70-100-39
Front Oil Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . 70-100-18
Exhaust Manifold Removal and Installation . . . . . . . . . . . 70-100-2
Front Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-18
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-45
Inspection Of Crankshaft And Bearings. . . . . . . . . . . . . 70-100-32
Intake Manifold Removal and Installation . . . . . . . . . . . . 70-100-1
Oil Filter Adapter Removal. . . . . . . . . . . . . . . . . . . . . . . 70-100-40
Oil Filter Adapter Installation . . . . . . . . . . . . . . . . . . . . . 70-100-40
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . 70-100-40
Oil Pressure Relief Valve Disassembly And Assembly . 70-100-43
Oil Pump Disassembly And Assembly. . . . . . . . . . . . . . 70-100-43
Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-42
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-41
Oil Screen And Pick-up Tube. . . . . . . . . . . . . . . . . . . . . 70-100-41
V518 VersaHANDLER
ENGINE SERVICE (CONT’D)
RECONDITIONING THE ENGINE (CONT'D) . . . . . . . . . . . . 70-100-2

Piston Cooling Jet Alignment . . . . . . . . . . . . . . . . . . . . . 70-100-45
Piston Cooling Jet Installation . . . . . . . . . . . . . . . . . . . . 70-100-45
Piston Cooling Jet Removal. . . . . . . . . . . . . . . . . . . . . . 70-100-45
Piston And Connecting Rod Assembly . . . . . . . . . . . . . 70-100-27
Pistons And Connecting Rods Description . . . . . . . . . . 70-100-23
Pistons And Connecting Rods Disassembly . . . . . . . . . 70-100-25
Piston And Connecting Rod Installation. . . . . . . . . . . . . 70-100-27
Pistons And Connecting Rods Removal . . . . . . . . . . . . 70-100-23
Piston Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-25
Piston Ring Groove Clearance . . . . . . . . . . . . . . . . . . . 70-100-26
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-25
Rear Oil Seal Housing Positioning. . . . . . . . . . . . . . . . . 70-100-34
Rear Oil Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-100-34
Rear Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-34
Rocker Shaft Disassembly And Assembly. . . . . . . . . . . . 70-100-8
Thermostat Removal and Installation . . . . . . . . . . . . . . 70-100-37
Thermostat Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-37
Timing Case And Drive Assembly Description . . . . . . . 70-100-16

Timing Case And Gear Installation . . . . . . . . . . . . . . . . 70-100-19
Timing Case And Gear Removal . . . . . . . . . . . . . . . . . . 70-100-18
Timing Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-100-17
Timing Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-16
Turbo Charger Description. . . . . . . . . . . . . . . . . . . . . . . 70-100-50
Turbo Charger Removal and Installation . . . . . . . . . . . . 70-100-50
Valves Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-12
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . 70-100-15
Valve Depth Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-10
Valve Guides Checking . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-10
Valve Guide Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-11
Valve Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-11
Valve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-9
Valve Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-13
Valve Springs Checking. . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-9
Water Pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . 70-100-38
Water Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-38
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
V518 VersaHANDLER
V518 VersaHANDLER
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for assistance in location and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start (cold). 2, 5, 6, 7
Engine will not start. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10
Difficult to start. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19 20, 21
No power for engine. 9, 11, 15, 16, 17, 18, 19, 21, 22, 25, 26, 27
Engine is mis-firing. 11, 15, 16, 17, 18, 19, 20 ,21, 22, 23, 24
Too much fuel consumption. 7, 16, 17, 18, 20 ,21, 22, 28, 29, 30
Black exhaust. 16, 17, 18, 19 20, 22, 25, 27
Blue/white exhaust. 4, 7, 16, 18, 19, 22, 31, 32
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 48, 51
Engine knocking. 4, 5, 17, 18, 19 ,20, 23, 34, 35, 36, 37, 38
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 14, 20, 21, 22, 25, 26, 27, 28, 29, 40, 52

Vibration 16, 30, 50, 51, 52
High oil pressure warning. 4, 33, 36
Overheating. 18, 19, 20, 22, 25, 31, 33, 46, 47, 48, 49
Too much crankcase pressure. 25, 35, 36, 42
Poor compression. 17, 18, 22, 23, 30, 32, 34, 35, 36, 44
Start and stop. 9, 11, 13, 15, 17, 22, 23, 30
Excessive oil consumption 4, 22, 32, 36, 40, 41, 42, 43, 44, 45
V518 VersaHANDLER
TROUBLESHOOTING (CONT'D)
Chart (Cont'd)

1. Battery capacity low. 27. Poor boost pressure.
2. Bad electrical connections 28. Fuel leak.
3. Faulty starter motor. 29. Lubrication oil diluted by fuel.
4. Incorrect grade of oil. 30. Sticking valves.
5. Incorrect grade of fuel. 31. Leaking head gasket.
6. Incorrect use of cold starting equipment. 32. Worn valve guides/stems.
7. Faulty cold starting equipment. 33. Faulty thermostat.
8. Insufficient fuel in tank. 34. Incorrect piston height.
9. Faulty stop control. 35. Broken/worn piston rings.
10. Broken fuel injection pump drive. 36. Worn cylinder liners.
11. Air in the fuel system 37. Worn wrist pins.
12. Restricted fuel feed. 38. Excessive camshaft end play.
13. Fuel tank vent blocked. 39. Excessive timing gear backlash.
14. Plugged fuel filters. 40. Oil leaks.

15. Faulty fuel pump. 41. New or rebuilt engine not broken in.
16. Low compression. 42. Plugged breather pipe.
17. Incorrect valve clearance. 43. Glazed cylinder liners.
18. Incorrect valve timing. 44. Worn pistons.
19. Incorrect fuel pump timing. 45. Worn valve stem seals.
20. Faulty injectors. 46. Coolant level low.
21. Faulty fuel injection pump. 47. Faulty water pump.
22. Plugged air filter. 48. Loose or broken blower fan belt.
23. Broken or weak valve springs. 49. Radiator cooling fins plugged.
24. Overheating. 50. Damaged blower fan.
25. Restricted exhaust system. 51. Loose flywheel.
26. Water in fuel. 52. Broken engine mounts.
V518 VersaHANDLER
ENGINE SPEED CONTROL Figure 70-20-3
Figure 70-20-1
Open the hood
Remove the engine speed control cable (Item 1) [Figure

70-20-3] from the linkage.
Remove the floor mat and insulation from the cab floor.
Remove the engine speed control cable from the
Remove the speed control cable (Item 1) [Figure 70-20- mounting bracket (Item 2) [Figure 70-20-3].

1] from the pedal and mounting bracket (Item 2) [Figure
70-20-1]. Remove any necessary cable ties, carefully remove the
speed control cable.
Remove the battery box cover.
Figure 70-20-2
Carefully pull the speed control cable (Item 1) [Figure

70-20-2] through the cab and into the battery box.
V518 VersaHANDLER
V518 VersaHANDLER
MUFFLER Figure 70-30-2
Figure 70-30-1
Remove the four muffler mounting bolts (Item 1) [Figure

70-30-2].
Remove the muffler.

Remove the three exhaust mounting bolts (Item 1)
[Figure 70-30-1].
V518 VersaHANDLER
V518 VersaHANDLER
AIR CLEANER Figure 70-40-2
Housing Removal And Installation
Figure 70-40-1
Remove both mounting bolts (Item 1) [Figure 70-40-2].
Remove the air cleaner housing assembly.
Open the hood.
Loosen the clamp (Item 1) [Figure 70-40-1] and remove

the hose from the air cleaner.
V518 VersaHANDLER
V518 VersaHANDLER
RADIATOR Figure 70-50-3
Figure 70-50-1
Remove the hose clamp bolt (Item 1) [Figure 70-50-3]

and hose (Item 2) [Figure 70-50-3] from the engine
block.
Remove the hood. (See Removal And Installation on Figure 70-50-4

Page 50-70-1.)
Remove the air cleaner housing. (See Housing Removal

Open the drain valve (Item 1) [Figure 70-50-1] and drain

the coolant into a container.
Remove the oil cooler. (See Removal And Installation on

Page 30-20-1.)
Installation: Fill the coolant recovery tank with premixed

coolant. (See Capacities on Page SPEC-10-2) for correct
capacity.
Figure 70-50-2
Remove the three mounting bolts (Item 1) [Figure 70-50-

4] and remove the cooling fan safety shield.
Remove the hoses (Item 1) [Figure 70-50-2] from the

overflow tank.
V518 VersaHANDLER
RADIATOR (CONT'D) Figure 70-50-7
Figure 70-50-5
Remove the radiator support bracket (Item 1) [Figure 70-

50-7].
Remove the lower radiator hose (Item 1) [Figure 70-50-

5] from the water pump.
IMPORTANT

Route the lower radiator hose and overflow tank hose
through the center support (Item 2) [Figure 70-50-5]. When repairing hydrostatic and hydraulic systems,
Figure 70-50-6 parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
Figure 70-50-8
Remove the upper radiator hose (Item 1) [Figure 70-50-

6] from the radiator.
Remove both hoses (Item 1) [Figure 70-50-8] from the

cooling fan motor.
Install caps and plugs on the fittings.
V518 VersaHANDLER
Figure 70-50-9
Lift and remove the radiator assembly [Figure 70-50-11].
Remove the air intake tube mounting bolt (Item 1)

[Figure 70-50-9].

Slide the intake tube rearward.
Figure 70-50-10
Remove both radiator mounting bolts (Item 1) [Figure

70-50-10] from the bottom of the engine pan.
V518 VersaHANDLER
Figure 70-50-12
Remove the four fan shroud mounting bolts (Item 1)

[Figure 70-50-14].
Remove the fan shroud.

Lay the radiator assembly on a work surface, with the fan
in the upright position. Figure 70-50-15

remove the mounting bracket (Item 2) [Figure 70-50-12]
on both sides.
Figure 70-50-13
Lift and remove the upper and lower plates (Item 1)

[Figure 70-50-15] from the radiator.
Remove the two cooling fan mount bolts (Item 1) [Figure

70-50-13].
Remove the cooling fan assembly.
V518 VersaHANDLER
Disassembly and Assembly (Cont'd)
Figure 70-50-16
Remove the side cover (Item 1) [Figure 70-50-18].
Remove the four bolts (Item 1) [Figure 70-50-16].
Figure 70-50-17

Stand the radiator on its side and remove the two
mounting bolts (Item 1) [Figure 70-50-17].
V518 VersaHANDLER
V518 VersaHANDLER
ENGINE AND ENGINE MOUNTS Figure 70-60-3

NOTE: Set the engine/hydrostat assembly on blocks,

to allow access to remove the motor mount
bolts.
Remove the hydrostatic pump. (See Removal And

Remove the flywheel and housing. (See Removal And

If equipped with air conditioning, remove the hoses from

the compressor. (See COMPRESSOR on Page 80-110-1.) Remove the three mounting bolts (Item 1) [Figure 70-60-
3] and remove the cooling fan safety shield.
Figure 70-60-1
Figure 70-60-4

overflow tank.
Remove the radiator hose (Item 1) [Figure 70-60-4] from
the water pump.
Figure 70-60-2
Remove the hose clamp bolt (Item 1) [Figure 70-60-2]

and hose (Item 2) [Figure 70-60-2] from the engine
block.
V518 VersaHANDLER
ENGINE AND ENGINE MOUNTS (CONT'D) Figure 70-60-7
Figure 70-60-5
Install lifting brackets (Item 1) [Figure 70-60-6] and (Item

1) [Figure 70-60-7] to the engine block.
Figure 70-60-8
Remove the intake hose (Item 1) [Figure 70-60-5] from
the tube.

Figure 70-60-6
Install a hoist and chain to the lifting brackets [Figure 70-

60-8].
V518 VersaHANDLER
ENGINE AND ENGINE MOUNTS (CONT'D)
Figure 70-60-9
Remove both front engine mount bolts (Item 1) [Figure

70-60-9].

Installation: Tighten the engine mount bolts to 185-200
ft.-lbs. (250-271 Nm) torque.
Lift and remove the engine.
V518 VersaHANDLER
V518 VersaHANDLER
ENGINE COMPONENTS AND TESTING Figure 70-70-3
Fuel Injection Pump Removal And Installation
The tool listed will be needed to do the following

procedure:
MEL1540 - Timing Tool
Figure 70-70-1
Remove the mounting bolts (Item 1) [Figure 70-70-3]

from the front side of the water pump.

torque.
Remove the water pump from the engine.

Figure 70-70-4
Remove the tubeline (Item 1) [Figure 70-70-1] and
clamps (Item 2) [Figure 70-70-1] from the oil cooler to
the water pump.
NOTE: Coolant may come out when tube is removed.
Figure 70-70-2
Turn the crankshaft over slowly until the hole (Item 1)

[Figure 70-70-4] in the fuel injection pump gear, timing
plate and the hole in the hub, align with a hole in the body
of the fuel injection pump.
NOTE: Do not loosen the nut (Item 2) [Figure 70-70-4]

from the fuel injection pump. The timing of the
Remove the bolts (Item 1) [Figure 70-70-2] from the fuel injection pump comes set from the
water pump. factory.
Installation: Tighten the nuts to 16 ft.-lbs. (22 Nm)

torque.
V518 VersaHANDLER
ENGINE COMPONENTS AND TESTING (CONT'D)

(Cont'd)
WARNING
Figure 70-70-5 Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
W-2072-0496
Figure 70-70-7
Insert a timing pin (Item 1) [Figure 70-70-5] into the

aligned holes.

NOTE: The dimensions of the timing pin are 8 mm
O.D. x 127 mm long.
Figure 70-70-6
Disconnect the injector tubelines (Item 1) [Figure 70-70-

7] from the injector pump.
Installation: Tighten the tubeline fittings to 16 ft.-lbs. (22

Nm) torque.
Disconnect the two tubelines (Item 1) [Figure 70-70-6]

from the top of the fuel injector pump.
Disconnect the tubeline (Item 2) [Figure 70-70-6] from

the injector pump.
Remove the six tubelines (Item 3) [Figure 70-70-6] from

the top side of the secondary fuel filter.

from the fuel filter mounting bracket.
Remove the fuel filter mounting bracket and fuel filter

from the engine.
V518 VersaHANDLER
ENGINE COMPONENTS AND TESTING (CONT'D) Figure 70-70-9

(Cont'd)
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Figure 70-70-8
Remove the return spring (Item 1) [Figure 70-70-9].

the pump.
Disconnect the electrical connections (Item 3) [Figure

70-70-9] from the injection pump.

Remove the mounting nuts (Item 4) [Figure 70-70-9]
from the injection pump.

torque.
Disconnect the injector tubelines (Item 1) [Figure 70-70- Figure 70-70-10

8] from the injectors.

Nm) torque.
Remove the fuel tubeline (Item 2) [Figure 70-70-8].
Remove the breather hose (Item 3) [Figure 70-70-8].

from the fuel injection pump gear.

torque.
Remove the fuel pump and timing pin from the engine.
V518 VersaHANDLER
Fuel Injector Removal And Installation
WARNING
Diesel fuel or hydraulic fluid under pressure can
W-2072-0496

Figure 70-70-11 12] from the injector pump.

Nm) torque.
Figure 70-70-13

Disconnect the two tubelines (Item 1) [Figure 70-70-11]
from the top of the fuel injection pump.

the injector pump.
Remove the tubelines (Item 3) [Figure 70-70-11] from 13] from the injectors.
the fuel filter housing.
Remove the mounting bolts (Item 4) [Figure 70-70-11] Nm) torque.
Remove the fuel tubeline (Item 2) [Figure 70-70-13].
from the engine. Remove the breather hose (Item 3) [Figure 70-70-13].
Remove the injector tubelines from the engine.
V518 VersaHANDLER
Fuel Injector Removal And Installation (Cont'd)
IMPORTANT
I-2029-0289
Figure 70-70-14
Loosen the nut (Item 1) [Figure 70-70-16] at the fuel

injector and remove it from the cylinder head.
Installation:Tighten the nut to 23 ft.-lbs. (30 Nm) torque.
Figure 70-70-17

Disconnect the fuel return tubeline (Item 1) [Figure 70-
70-14] at the fuel injectors.
Remove the fuel return tubeline (Item 2) [Figure 70-70-

14] from the engine.
Figure 70-70-15
Installation: Always replace the copper washer (Item 1)

[Figure 70-70-17] at the nozzle.
Installation: Always replace the copper gaskets (Item 1)

[Figure 70-70-15] at the fuel return tubeline.
V518 VersaHANDLER
ENGINE COMPONENTS AND TESTING (CONT'D)
Fuel Injector Removal And Installation (Cont'd)
Figure 70-70-18
Installation: Make sure the ball (Item 1) [Figure 70-70-

18] , in the injector body, is aligned with the notch (Item
2) [Figure 70-70-18] in the cylinder head when the fuel

injector is installed.
V518 VersaHANDLER
Fuel Injector Checking
IMPORTANT
Do not disassemble or test the fuel injector nozzles
unless you have the correct service and testing
tools.
I-2027-0284
WARNING Check the nozzle spray pattern [Figure 70-70-20].

The spray pattern must be uniform from the nozzle.
The nozzles are dirty or defective:
If the spray pattern is not uniform.
If the fuel drips from the end of the nozzle.

If the spray is solid stream instead of a mist.
W-2072-0496
The tools listed will be needed to do the following

procedure;
OEM1064 - Injection Nozzle Tester OEM 1065 -

Accessory Set
Figure 70-70-19
Connect the nozzle to the test pump, in a down position

[Figure 70-70-19].
Operate the test pump until the nozzle valve opens:
Injection Working Pressure

4263 PSI (29393 kPa)
V518 VersaHANDLER
Checking The Fuel Lift Pump
Install a gauge to the outlet side of the lift pump. Turn the
engine for 10 seconds.
Standard Pressure 6-10 PSI (41-70 kPa) Minimum

Pressure 3.75 PSI (25 kPa)
Fuel Lift Pump Removal And Installation
Figure 70-70-21
Disconnect the fuel in-let hose (Item 1) [Figure 70-70-22]

from the lift pump.
Disconnect the fuel tubeline (Item 2) [Figure 70-70-22]

going to the primary fuel filter.

22].

torque.
Remove the hose clamp (Item 1) [Figure 70-70-21] from Remove the fuel lift pump.
the turbocharger air inlet hose (Item 2) [Figure 70-70-
21].
Remove the air inlet hose from the turbocharger.
V518 VersaHANDLER
ENGINE/HYDROSTAT ASSEMBLY NOTE: Mark all hoses and electrical connectors for
correct installation.
Figure 70-80-3
Raise the boom and install the boom support device.
(See Installing Boom Stop on Page 10-150-1.)
Remove the hood. (See Removal And Installation on

Page 50-70-1.)
Drain the hydraulic reservoir. (See Replacing Hydraulic

Fluid on Page 10-100-2.)
Remove the battery. (See Removal And Installation on

Page 60-20-1.)
If equipped with air conditioning, remove the compressor.

(See Removal And Installation on Page 80-110-1.)
Figure 70-80-1
Remove both fuel lines (Item 1) [Figure 70-80-3] from

the engine.
Figure 70-80-4

Remove the upper radiator hose (Item 1) [Figure 70-80-
1] from the thermostat housing.
NOTE: Engine coolant may come out when hose is

removed.
Figure 70-80-2
Remove the engine speed control cable (Item 1) [Figure
70-80-4] from the linkage.
Remove the engine speed control cable from the

mounting bracket (Item 2) [Figure 70-80-4].
Remove both heater hoses (Item 1) [Figure 70-80-2]

from the engine.
V518 VersaHANDLER
ENGINE/HYDROSTAT ASSEMBLY (CONT'D) Figure 70-80-7
Figure 70-80-5
Remove the temperature connector (Item 1) [Figure 70-

80-7].
Figure 70-80-8
Remove the two electrical connectors (Item 1) [Figure
70-80-5] from the injection pump.

Figure 70-80-6
Remove the three mounting bolts (Item 1) [Figure 70-80-

8].
Remove the cooling fan safety shield.

Remove the oil pressure connector (Item 1) [Figure 70-
80-6] from the lower right side of the block.
V518 VersaHANDLER
Figure 70-80-9
Remove the connector (Item 1) [Figure 70-80-11] from

the turbo.
Figure 70-80-12
Remove the hydraulic oil temperature sensor connector
(Item 1) [Figure 70-80-9].

Figure 70-80-10

70-80-12]. Remove the access cover (Item 2) [Figure
70-80-12].
Remove the two connectors (Item 1) [Figure 70-80-10]

from the back of the alternator.
V518 VersaHANDLER
Figure 70-80-13
Remove the two bolts (Item 1) [Figure 70-80-15]

securing both relays.
Figure 70-80-16
Remove the wires (Item 1) [Figure 70-80-13] from the
starter.

Figure 70-80-14
Remove the fuse covers (Item 1) [Figure 70-80-16],

fuses (Item 2) [Figure 70-80-16] and relays (Item 3)
[Figure 70-80-16] from the harness.
Remove the bolt (Item 1) [Figure 70-80-14]. Remove the NOTE: Mark the location of the fuses and relays for
relay cover (Item 2) [Figure 70-80-14]. correct installation.
Installation: Fuse holder R1 uses a 50 amp fuse and

fuse holder F2 uses a 40 amp fuse.
V518 VersaHANDLER
Figure 70-80-17
Relay housing marked R1: [Figure 70-80-19]

1 - terminal - Red
2 - terminal - Small Brown
3 - terminal - Large Brown
Using a pointed tool, press down on the tab (Item 1) 4 - terminal - 2 Black
[Figure 70-80-17] and remove the relay housing (Item 2)
[Figure 70-80-17] from the fuse holder (Item 3) [Figure Figure 70-80-20

70-80-17].
Mark the wires and relay housing for correct installation.
Figure 70-80-18
Relay housing marked R2: [Figure 70-80-20]

1 - terminal - Red
2 - terminal - Black
3 - terminal - White
4 - terminal - White/Black
Using a pointed tool, press down on the tab for each wire
and pull the wire from the connector [Figure 70-80-18].
Installation: Install the wires into the relay housing as

listed below.
V518 VersaHANDLER
Figure 70-80-21
Loosen and remove both alternator mounting bolts (Item

1) [Figure 70-80-23].
Remove the alternator belt.

remove the belt shield (Item 2) [Figure 70-80-21]. Remove the electrical harness from behind the alternator.

Figure 70-80-22 Remove any tie straps securing the electrical harness to
the engine.
Figure 70-80-24
Loosen the alternator adjusting bolt (Item 1) [Figure 70-

80-22].
Remove the electrical harness, heater hoses, fuel lines

and speed control cable from the engine compartment
and route through the access hole [Figure 70-80-24].
Remove the ground strap mounting bolt (Item 1) [Figure

70-80-24].
V518 VersaHANDLER
Figure 70-80-25
Remove the eight drive shaft mounting bolts (Item 1)

[Figure 70-80-27].
Figure 70-80-28
Remove the three exhaust mounting bolts (Item 1)
[Figure 70-80-25].

Figure 70-80-26
Remove the drive shaft out the rear of the machine

[Figure 70-80-28].
Disconnect the engine speed sensor connector (Item 1)

[Figure 70-80-26].
V518 VersaHANDLER
IMPORTANT
damage the system.
I-2003-0888
Figure 70-80-29
Disconnect the hydraulic hose (Item 1) [Figure 70-80-31]
on the drive motor.
Figure 70-80-32

Disconnect the three hydraulic hoses (Item 1) [Figure
70-80-29] that go from the rear of the hydrostatic pump
forward to the drive motor.
NOTE: Mark all hydraulic hoses for correct

installation.
from the hydraulic filter
Figure 70-80-30
Disconnect both electrical connectors (Item 1) [Figure

70-80-30] from the hydrostatic solenoids.
V518 VersaHANDLER
Figure 70-80-33
Disconnect the three hoses (Item 1) [Figure 70-80-35]

from the flow divider valve.
Figure 70-80-36
Disconnect the two hydraulic hoses (Item 1) [Figure 70-
80-33] from the hydraulic reservoir.

Figure 70-80-34

from the inner gear pump that goes to the pressure side
of the control valve.

that goes to the drive motor.
V518 VersaHANDLER
Figure 70-80-37
Install a chain hoist to lift and secure the engine

Figure 70-80-40
from the outer gear pump going to the control valve.

Figure 70-80-38
Remove the engine assembly mounting bolt (Item 1)

[Figure 70-80-40] located by the turbo.

from the inner gear pump going to the park brake.
V518 VersaHANDLER
Figure 70-80-41
Lift the engine assembly up approximately one inch (25

mm) and pull the engine assembly away from the
machine about ten inches (250 mm) [Figure 70-80-43].
Remove the engine assembly mounting bolt (Item 1) Figure 70-80-44

[Figure 70-80-41] located by the fuel filter.

Figure 70-80-42
Disconnect the hydraulic hoses (Item 1) [Figure 70-80-

44] from the hydrostatic filter.
Remove the engine assembly mounting bolt (Item 1) Disconnect the hydraulic hose (Item 2) [Figure 70-80-44]
[Figure 70-80-42] located by the air filter. from the hydrostat.
Disconnect the four bolt flange hydraulic hose (Item 3)

[Figure 70-80-44] from the hydrostat.
Remove the engine assembly.
V518 VersaHANDLER
V518 VersaHANDLER
FLYWHEEL AND HOUSING Figure 70-90-3

NOTE: Set the engine/hydrostat assembly on blocks,

to allow access to remove the motor mount
bolts.
Remove the hydrostatic pump. (See Removal And

Remove the starter. (See Removal And Installation on

Page 60-40-1.)
Figure 70-90-1
Remove both rear engine mounting bolts [Figure 70-90-
2] & [Figure 70-90-3].
Installation: Tighten engine mounting bolts to 185-200

ft.-lbs. (250-271 Nm) torque.
Figure 70-90-4

Install lifting brackets and hoist on the housing to lift and
support [Figure 70-90-1].
Figure 70-90-2
Lifting from the housing assembly, raise the engine

slightly and place support blocks under the oil pan
[Figure 70-90-4].
Lower the engine assembly on the support blocks.
V518 VersaHANDLER
FLYWHEEL AND HOUSING (CONT'D) Figure 70-90-7
Figure 70-90-5
Remove the six coupler mounting bolts (Item 1) [Figure

70-90-7]. Remove the coupler.

Loosen and remove the ten flywheel housing mount bolts
(Item 1) [Figure 70-90-5]. Figure 70-90-8

Figure 70-90-6
Remove two of the flywheel mount bolts and install two

guide studs (Item 1) [Figure 70-90-8] in the flywheel to
prevent the fly wheel from falling.
Remove the flywheel housing from the engine [Figure

70-90-6].
V518 VersaHANDLER
Figure 70-90-9
If removing the backing plate (Item 1) [Figure 70-90-10]

is required, loosen and remove the eight mounting bolts
(Item 2) [Figure 70-90-10].
Install a chain hoist (Item 1) [Figure 70-90-9]. Installation: Tighten the bolts to 52 ft.-lbs. (70 Nm)
torque.
Remove the remainder of the bolts (Item 2) [Figure 70-

90-9]. Remove the flywheel by sliding outward over the Check the flywheel and ring gear for wear or damage.
guide studs. Replace as needed.
Installation: Tighten the flywheel bolts to 77 ft.-lbs. (105

Nm) torque.
V518 VersaHANDLER
Figure 70-90-11
Check the alignment of the flywheel face [Figure 70-90-

12].
The misalignment must not be more than 0.001 inch

Install a dial indicator to check the flywheel run out (0,03 mm) total indicator reading for every 1.0 inch (25
[Figure 70-90-11]. mm) of the flywheel radius from the crankshaft axis to the
dial gauge plunger.

Flywheel run out must be less than 0.012 inch (0,30 mm).
Example: The misalignment must not be greater than
0.008 inch (0,203 mm) at 8 inches. (203 mm) from the
centerline of the crankshaft towards the outside of the
flywheel.
During this check keep the crankshaft pressed toward

the front so crankshaft end play will not affect the
reading.
Ring Gear Removal
Before the ring gear is removed note the position of the

chamfer on the teeth.
Heat the ring gear enough to expand it and hit it with a

hammer evenly to remove it.
Be careful not to damage the flywheel during this

operation.
Ring Gear Installation
The ring gear is a heat expansion fit on the flywheel.
Do not heat the ring gear to a temperature greater than

480° F (250° C) make sure the ring gear chamfer is in the
correct position.
V518 VersaHANDLER
RECONDITIONING THE ENGINE Figure 70-100-3
Intake Manifold Removal and Installation
Figure 70-100-1
Remove the mounting bolt (Item 1) [Figure 70-100-3]

from the inside of the intake manifold.
Remove all the mounting bolts from the intake manifold

Remove the turbocharger. (See Turbo Charger Removal (Item 2) [Figure 70-100-3].
and Installation on Page 70-100-50.)
Installation: Tighten the mounting bolts to 24 ft.-lbs. (33

Disconnect the tubeline (Item 1) [Figure 70-100-1] from Nm) torque.
the intake manifold.
Figure 70-100-4
Figure 70-100-2
Remove the intake manifold from the cylinder [Figure

Disconnect the tubeline (Item 1) [Figure 70-100-2] from 70-100-4].
the intake manifold.
Installation: Always replace the intake manifold gasket.
2] from the intake manifold housing.
Installation: Tighten the mounting bolts to 24 ft.-lbs. (33

Nm) torque.
V518 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D)
Exhaust Manifold Removal and Installation
Remove the turbocharger. (See Turbo Charger Removal

Remove the intake manifold. (See Intake Manifold

Removal and Installation on Page 70-100-1.)
Figure 70-100-5

Remove all the nuts from the exhaust manifold (Item 1)
[Figure 70-100-5].

torque.
V518 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-7
Cylinder Head Disassembly
IMPORTANT
I-2029-0289
Remove the turbo charger. (See Turbo Charger Removal

Remove the oil cooler. (See Removal And Installation on

Page 30-20-1.) Disconnect the injector tubelines (Item 1) [Figure 70-
100-7] from the injector pump.
Remove the intake manifold. (See Intake Manifold
Removal and Installation on Page 70-100-1.) Figure 70-100-8
Remove the exhaust manifold. (See Exhaust Manifold

Removal and Installation on Page 70-100-2.)

Figure 70-100-6
Remove the breather hose (Item 1) [Figure 70-100-8].
Remove the dipstick mount bolt (Item 2) [Figure 70-100-

8].
Disconnect the tubelines (Item 1) [Figure 70-100-6] from Disconnect the injector tubelines (Item 3) [Figure 70-
the top of the fuel injector pump. 100-8] from the injectors.
Disconnect the tubeline (Item 2) [Figure 70-100-6] from Disconnect the fuel tubeline (Item 4) [Figure 70-100-8]
the injector pump. and remove the tubeline.
Disconnect the six tubelines (Item 3) [Figure 70-100-6] Remove the injector tube lines from the engine.
from the top side of the fuel filter.
Remove the fuel injectors. (See Fuel Injector Removal
Remove the mounting bolts (Item 4) [Figure 70-100-6] And Installation on Page 70-70-4.)

from the engine.
V518 VersaHANDLER
Cylinder Head Removal
Figure 70-100-9
Remove the push rods [Figure 70-100-11].
Figure 70-100-12
Remove the three rocker cover retaining nuts (Item 1)

[Figure 70-100-9].

Figure 70-100-10
Starting with bolt (number 22) [Figure 70-100-12] and

working down, remove the head bolts.
NOTE: There are three different length head bolts.

[Figure 70-100-12] shows the three different
Remove the four nuts (Item 1) [Figure 70-100-10] and bolt lengths: S short; M medium & L long
remove the rocker shaft assembly [Figure 70-100-10]. bolts.
(See Rocker Shaft Disassembly And Assembly on Page
70-100-8) for disassembly and assembly of the rocker Check the head bolts for distortion and damage. Replace
shaft assembly.) as needed.
Lift off the cylinder head and clean the bottom face.
Remove the valves from the cylinder head. (See Valve

Removal on Page 70-100-9.)
V518 VersaHANDLER
Cylinder Head Inspection
Figure 70-100-13
NOTE: The locating pins (Item 1) [Figure 70-100-14]

are pressed in the engine block so the head
gasket (Item 2) [Figure 70-100-14] can be
positioned correctly.
Put a straight edge on the cylinder head as shown in
[Figure 70-100-13]. The head gasket is installed with no sealer.

Using a feeler gauge between the straight edge and Place the head gasket in position with the Front Top (Item
head, check for warpage. 2) [Figure 70-100-14] marks in the correct position.
Maximum allowed (Item 1) [Figure 70-100-13] is 0.003 Lower the cylinder head in position.
inches (0,08 mm), (Item 2) [Figure 70-100-13] is 0.006
inches (0,15 mm) and (Item 3) [Figure 70-100-13] is Figure 70-100-15
0.006 inches (0,15 mm).
The head may be machined removing only a minimum

amount. Head thickness must not be less than 4.035
inches (102,5 mm).
Completely clean the rest of the head.
Check for cracks or other damage.
Cylinder Head Installation
Make sure the mating surfaces of the head and block are
clean.
Clean the engine block bolt bores with the correct size
tap to ensure correct torque for the cylinder head bolts. [Figure 70-100-15] shows the three different bolt
lengths: S-short; M-medium and L-long.
Clean any debris out of the cylinder bores.
Install all the cylinder head bolts in the correct location
[Figure 70-100-15].
Follow the bolt tightening sequence shown in [Figure 70-

100-15]. Tighten all cylinder head bolts to 80 ft.-lbs. (108
Nm) torque.
V518 VersaHANDLER
Cylinder Head Installation (Cont'd)
Figure 70-100-16
Tighten short bolts 2.5 flats, medium bolts 3 flats, and

long bolts 3.5 flats in the same sequence as shown in
[Figure 70-100-18].
Additional tightening of the head bolts requires the use of Figure 70-100-19
a torque angle gauge (Item 1) [Figure 70-100-16].
Tighten the short bolts 150°, medium bolts 180° and long

bolts 210°, in the same sequence as shown in [Figure
70-100-16].
Figure 70-100-17
Install the push rods [Figure 70-100-19].
Make sure the push rods seat in the tappet sockets.
If no angle gauge is available make a suitable mark on

the head bolt corner. Make another mark on the cylinder
head the correct number of flats away [Figure 70-100-
17]. Turn the head bolt until the lines match.
V518 VersaHANDLER
Cylinder Head Installation (Cont'd)
Figure 70-100-20
Install the fuel injectors. (See Fuel Injector Removal And

Install the injector tubelines on the engine.

Install the rocker arm shaft. Tighten the rocker arm nuts
(Item 1) [Figure 70-100-20] to 55 ft.-lbs. (75 Nm) torque. Connect the fuel tubelines (Item 1) [Figure 70-100-21].

NOTE: Make sure the oil feed line seal (Item 2) [Figure Tighten tubeline fittings to 16 ft.-lbs. (22 Nm) torque.
70-100-20] is correctly positioned in the
cylinder head. Connect the injector tubeline (Item 2) [Figure 70-100-
21].
The valve lash adjustment must be checked after the
cylinder head is installed. (See Valve Clearance Install the breather hose (Item 3) [Figure 70-100-21].
Adjustment on Page 70-100-15.)
Figure 70-100-22
IMPORTANT
I-2029-0289
Connect the injector tubelines (Item 1) [Figure 70-100-

22] to the injection pump.
V518 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Rocker Shaft Disassembly And Assembly
Cylinder Head Installation (Cont'd) Figure 70-100-24
Figure 70-100-23
Remove the clips (Item 1) [Figure 70-100-24] from both

ends of the shaft.
Install the fuel filter mounting bracket and fuel filter using
the mounting bolts (Item 1) [Figure 70-100-23]. Remove the location screw (Item 2) [Figure 70-100-24]
for the oil supply connection.

Connect the six tubelines (Items 2) [Figure 70-100-23] to
the filter housing. Remove the rocker arm (Item 3) [Figure 70-100-24],
mount bracket (Item 4) [Figure 70-100-24], rocker arm
Connect the tubeline (Item 3) [Figure 70-100-23] to the (Item 3) [Figure 70-100-24] and spring (Item 5) [Figure
injection pump. 70-100-24].
Connect the tubeline (Item 4) [Figure 70-100-23] to the Continue to disassemble the rocker shaft.
top of the injection pump.
Clean and inspect all components for damage and wear.
Install the exhaust manifold. (See Exhaust Manifold
Removal and Installation on Page 70-100-2.) Check the clearance between the rocker arms and shaft.
Install the intake manifold. (See Intake Manifold Removal Using a press and adapter, remove the old bushing and
and Installation on Page 70-100-1.) press in the new one making sure the oil holes line up.
Install the turbocharger. (See Turbo Charger Removal Shaft O.D. 0.7485-0.7495 inch (19,01-
and Installation on Page 70-100-50.) 19,04 mm)
Rocker Arm Bushing Bore 0.8751-0.8763 inch (22,23-
Dia. 22,26 mm)
O.D. of Bushing 0.8771-0.8783 inch (22,28-
22,31 mm)
Rocker Arm Bushing 0.0008-0.0035 inch (0,020-
Clearance 0,089 mm)
I.D. of Reamed Rocker 0.7503-0.7520 inch (19,06-
Bushing 19,10 mm)
Clearance Between Rocker 0.001-0.0035 inch (0,03-
Arm Bushing & Shaft 0,09 mm)
If the clearance is more than 0.005 inch (0.13 mm)

replace the bushing(s).
V518 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Valve Springs Checking
Valve Removal Figure 70-100-26
Figure 70-100-25
Use the following chart [Figure 70-100-26]:
NOTE: Mark all components so they can be returned Valve Springs (Outer):
to the same position.
Compressed Height 1.41 inch (35,8 mm)

Using a valve spring compressor compress the springs Installed Pressure 39.5-43.7 lbs. (176-195 N)
and remove the retainers (Item 1) [Figure 70-100-25].
Valve Springs (Inner):
Release the compressor and remove the valve spring
Compressed Height 1.34 inch (34,0 mm)
cap (Item 2) [Figure 70-100-25], outer spring (Item 3)
[Figure 70-100-25] inner spring (Item 4) [Figure 70-100- Installed Pressure 20-23 lbs. (89-104 Nm)
25], valve seal (Item 5) [Figure 70-100-25], valve seat
washer (Item 6) [Figure 70-100-25] and the valve (Item
7) [Figure 70-100-25].
Clean and inspect all components.
V518 VersaHANDLER
Valve Depth Checking
Figure 70-100-27
The valve guides can be checked for wear with either of

the operations listed in [Figure 70-100-28] or [Figure 70-
100-29].
Check the valve depth as shown in [Figure 70-100-27]. Use the following chart to check valve guides.
The maximum depth is 0.073 inch (1,85 mm) for both Inside Diameter

intake and exhaust valves.
(Item 1) [Figure 70-100-28] 0.3744-0.3764 inch (9,51-
If the valve is below the limits, install a new valve and 9,56 mm)
recheck the valve depth. If it is still below limits a new
valve seat insert must be installed. Outside Diameter
(Item 2) [Figure 70-100-28] 0.6260-0.6264 inch (15,90-
When the depth is less than 0.050-0.063 inch (1,27-1,60 15,91 mm)
mm) the seat may be ground to lower the valve depth.
Interference fit of valve guide to cylinder head:
Valve Guides Checking 0.0018-0.0027 inch (0,047-0,007 mm)
Figure 70-100-28 Overall Length: (Item 3) [Figure 70-100-28]

Intake 2.281 inch (57,94 mm)
Exhaust 2.406 inch (61,10 mm)
Protrusion from bottom recess for valve spring:

(Item 4) [Figure 70-100-28] 0.585-0.596 inch (14,85-
15,15 mm)
Valve Guide Bore 0.6248-0.6256 inch (15,87-

15,89 mm)
To check the valve guides for wear using a valve.

Set up dial indicator gauge (Item 1) [Figure 70-100-29]
as shown.
Lift the valve (Item 2) [Figure 70-100-29] 0.60 inches

(15,0 mm) and move the valve in and away from the
gauge (Item 1) [Figure 70-100-29]. Record this reading.
If the clearance exceeds 0.002-0.007 inches (0,25-0,069

mm) for intake or 0.004-0.008 inches (0,40-0,084 mm)
for exhaust (Item 3) [Figure 70-100-29] the valve guide
needs to be replaced.
V518 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Valve Guide Installation
Valve Guide Removal Figure 70-100-31
Figure 70-100-30

Clean the guide bore in the head.
Install a valve guide removal/installation tool (Item 1) Lubricate the outer surface of the new guide (Item 1)
[Figure 70-100-30] on the valve guide (Item 2) [Figure [Figure 70-100-31] with engine oil.
70-100-30].
Put the guide in position on the valve guide removal/
Pull the guide (Item 2) [Figure 70-100-30] out of the installation tool (Item 2) [Figure 70-100-31].
cylinder head.
Pull the guide into the cylinder head.
When correctly positioned the top of the guide should

extend 0.594 inch (15,1 mm) above the valve spring seat.
(As Shown On Page 70-100-10 [Figure 70-100-31].)
V518 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Cutting A Valve Seat
Valves Checking Before any work is done the valve guides must meet
specifications or have been replaced.
NOTE: If the valves do not meet specifications they
need to be replaced. They cannot be ground. Install the pilot in the valve guide.
Figure 70-100-32 Select the correct size cutter.
Valve Seat Angle 46°
Figure 70-100-33

Use the following chart [Figure 70-100-32] to check the
valve dimensions:
REF. VALVE SPECIFICATIONS

1. Intake 4.829-4.854 inch (122,66-123,30 Carefully turn the cutter in a clockwise direction using
mm) even downward pressure. Keep the valve seat as narrow
as possible [Figure 70-100-33].
Exhaust 4.829-4.854 inch (122,66-123,30
mm) Remove any cutting debris.
2. Intake 0.3725-0.3536 inch (8,95-8,98 mm)
Exhaust 0.3519-0.3528 inch (8,93-8,96 mm) Install the valve and lightly tap.
3. Intake 1.688-1.698 inch (42,88-43,12 mm) Check the valve depth to make sure that it is within limits.
Exhaust 1.609-1.619 inch (40,88-41,12 mm) (See Valve Depth Checking on Page 70-100-10.)
4. Int./Exh. 0.055-0.07 inch (1,40-1,70 mm)
(Production) NOTE: If the valve seat is worn or damaged, a new
valve seat insert can be installed.
Int./Exh. 0.077 inch (1,95 mm)
(Service
Max.)
Intake/ 45°
Exhaust
Valve Face
Angle
V518 VersaHANDLER
Valve Seat Assembly
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285
Figure 70-100-34

Lubricate the valve stems (Item 1) [Figure 70-100-34]
with clean engine oil and install them in the respective
guides.
Install the spring seat washers (Item 2) [Figure 70-100-

34].
Install new valve seals (Item 3) [Figure 70-100-34].
Install the inner and outer springs (Items 4 & 5) [Figure

70-100-34] on the washers with dampener coils (Item 6)
[Figure 70-100-34] toward the cylinder head.
Place the valve caps on the springs (Item 7) [Figure 70-

100-34].
Using a valve spring compressor compress the springs

and install the retainers (Item 8) [Figure 70-100-34].
V518 VersaHANDLER
Changing Valve Springs (With Cylinder Head

Installed)
Figure 70-100-35
Install the valve spring compressor and adaptor [Figure

70-100-36].
Compress the valve springs and remove the retainers.
Remove the rocker cover. NOTE: Do not rotate the crankshaft while the valve
springs are removed.

Rotate the crankshaft clockwise until the intake valve has
opened and the exhaust valve has not fully closed. In this Release the compressor and remove the valve spring(s).
position the piston (Item 1) [Figure 70-100-35] will be at
approximately T.D.C. Place the new valve springs in position.
Remove the rocker shaft assembly. Compress the valve springs and install the retainers.
V518 VersaHANDLER
Valve Clearance Adjustment
Figure 70-100-37
Figure 70-100-39
Adjust the valve clearance as follows:
Loosen the lock nut (Item 1) [Figure 70-100-37].

Turn the adjustment screw (Item 2) [Figure 70-100-37]
until the correct clearance is obtained.
NOTE: The clearance is measured between the

rocker arm and valve stem tip (Item 3) [Figure
70-100-37].
Adjust the valve clearance as follows:
0.008 inch (0,20 mm) Intake Use the following sequence to set the valves [Figure 70-
0.018 inch (0,45 mm) Exhaust 100-38] & [Figure 70-100-39]:
a. With the rocker arm rocking (valves 7 & 8) on No. 4

cylinder set clearance at No. 1 cylinder (valves 1 & 2).
b. With the rocker arm rocking (valves 3 & 4) on No. 2

c. With the rocker arm rocking (valves 1 & 2) on No. 1

d. With the rocker arm rocking (valves 5 & 6) on No. 3

V518 VersaHANDLER
Timing Case And Drive Assembly Description
The timing case and cover are made of aluminum and in

most applications, the timing gears are made of steel.
The drive from the crankshaft passes to the idler gear, to
the camshaft gear, to the gear on the fuel injection pump
and to the water pump.
The camshaft and fuel injection pump run at half the

speed of the crankshaft.
Timing Cover Removal
Figure 70-100-40
Remove the cover (Item 1) [Figure 70-100-42] and

gasket.

Remove the crankshaft pulley (Item 1) [Figure 70-100-
40].
Remove the water pump. (See Water Pump Removal on

Page 70-100-38.)
Figure 70-100-41
Remove the timing cover bolts (Item 1) [Figure 70-100-

41].
V518 VersaHANDLER
Timing Cover Installation

procedure:
MEL1537 - Timing Cover Centralizing Tool
To install the timing cover, the tool will be needed to

center the timing cover around the crankshaft.
NOTE: If the cover is not centered correctly the

backlash between the injection pump gear
and water pump gear will be affected. This can
cause seizure of the injection pump.
Clean the gasket mating surfaces. Install the crankshaft pulley (Item 1) [Figure 70-100-44].
Place the gasket and timing cover on the engine. Tighten the crankshaft pulley bolts (Item 2) [Figure 70-
100-44] to 85 ft.-lbs. (115 Nm) torque.
Hold the timing cover in position and install two bolts that
are on opposite sides of the cover. Do not tighten the
bolts.

Figure 70-100-43
Install the tool (Item 1) [Figure 70-100-43] in the oil seal

housing.
Using the special washer (Item 2) [Figure 70-100-43],

install the crankshaft pulley bolts (Item 3) [Figure 70-
100-43] and tighten evenly to center the cover.
Install the remainder of the cover bolts, tighten the bolts

to 16 ft.-lbs. (22 Nm) torque.
Remove the tool.
Install the water pump. (See Water Pump Removal on

Page 70-100-38.)
V518 VersaHANDLER
Front Oil Seal Removal
Remove the crankshaft pulley.
Remove the oil seal using a seal removal tool.
Do not damage the edge of the seal housing.
Front Oil Seal Installation
Clean the oil seal housing.
Lubricate and place the new seal in the housing. Make

sure the spring loaded lip faces toward the engine.
Figure 70-100-45 Rotate the crank shaft until the timing marks (Item 1)
[Figure 70-100-46] are lined up.
Remove the fuel injection pump gear (Item 2) [Figure 70-

100-46].

the idler gear (Item 4) [Figure 70-100-46].
Remove the idler gear (Item 4) [Figure 70-100-46].
NOTE: Do not turn the crankshaft with the idler gear

removed.
Remove the cam gear retaining bolt (Item 5) [Figure 70-

100-46].
Place the seal tool (Item 1) [Figure 70-100-45] against Figure 70-100-47
the seal.
Using the three hole washer (Item 2) [Figure 70-100-45],

install the crankshaft bolts and tighten evenly until the
face of the seal tool is against the face of the seal
housing.
NOTE: The standard seal is installed to a depth of

0.266/0.285 inch (6,75/7,25 mm) from the front
face of the oil seal housing. If there is wear on
the seal surface of the crankshaft pulley the
seal can be installed to a depth of 0.366 inch
(9,3 mm)
Clean and lubricate the seal surface of the crankshaft

pulley before installing.
Remove the cam gear (Item 1) [Figure 70-100-47].
Timing Case And Gear Removal
Remove the timing cover. (See Timing Cover Removal

on Page 70-100-16.)
V518 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Timing Case And Gear Installation
Timing Case And Gear Removal (Cont'd) Clean the mating surfaces. If the oil pan was not
removed trim the oil gasket flush with the block.
Figure 70-100-48
Using the three idler gear bolts, position the idler hub
(Item 3) [Figure 70-100-49] with the lubrication hole on
top. Press the hub on by tightening the bolts evenly.
Install the camshaft thrust washer (Item 4) [Figure 70-

100-49].
Install the case cover gasket (Item 2) [Figure 70-100-49]

and trim the bottom to fit. Apply sealant to the bottom
ends of the gasket.
Place the timing case (Item 1) [Figure 70-100-49] in

position. Make sure it's positioned correctly against the
block.
Tighten the eight millimeter bolts to 16 ft.-lbs. (22 Nm)

Remove all the timing case bolts [Figure 70-100-48]. torque.
Remove the two bolts (Item 1) [Figure 70-100-48] from Tighten the ten millimeter bolts to 33 ft.-lbs. (44 Nm)

the front of the oil pan. torque.
Figure 70-100-49 Tighten the two oil pan bolts (Item 1) [Figure 70-100-48]
to 16 ft.-lbs. (22 Nm) torque.
Figure 70-100-50
Remove the timing case (Item 1) [Figure 70-100-49] and

gasket (Item 2) [Figure 70-100-49] from the engine. Do
not allow the idler gear hub (Item 3) [Figure 70-100-49]
and camshaft thrust washer (Item 4) [Figure 70-100-49] Install the cam gear (Item 1) [Figure 70-100-50].
to fall.
V518 VersaHANDLER
Timing Case And Gear Removal (Cont'd)
Figure 70-100-51
Install the cam gear retaining bolt (Item 1) [Figure 70-

100-51]. Tighten to 58 ft.-lbs. (78 Nm) torque.

Install the idler gear (Item 2) [Figure 70-100-51].
Install the idler gear retaining bolts (Item 3) [Figure 70-

100-51]. Tighten to 33 ft.-lbs. (44 Nm) torque.
Place the fuel injection pump gear (Item 4) [Figure 70-

100-51] in the case.
NOTE: Make sure all the timing marks (Item 5) [Figure

70-100-51] are in correct alignment.
Install the timing case cover. (See Timing Cover

V518 VersaHANDLER
Camshaft And Tappets Removal
Remove the timing case cover. (See Timing Cover

Remove the fuel injection pump. (See Fuel Injection

Pump Removal And Installation on Page 70-70-1.)
Remove the timing case. (See Timing Case And Gear

Remove the rocker cover, rocker assembly and push

rods. (See Cylinder Head Removal on Page 70-100-4.)
Remove the fuel pump and gasket.

Remove the camshaft thrust washer (Item 1) [Figure 70-
Figure 70-100-52 100-53].
Figure 70-100-54

Turn the engine over and remove the oil pan mounting
bolts [Figure 70-100-52].
Carefully remove the camshaft (Item 1) [Figure 70-100-
Remove the oil pan and gasket. 54].
Installation: Tighten the oil pan mounting bolts to 16 ft- Figure 70-100-55
.lbs. (22 Nm) torque.
Remove the tappets (Item1) [Figure 70-100-55] from the

block.
V518 VersaHANDLER
Camshaft And Tappets Installation
Figure 70-100-56
Install the camshaft thrust washer (Item 1) [Figure 70-

100-58]. Make sure that the dowel pin (Item 2) [Figure
70-100-58] lines up with the hole in the thrust washer.
Install the timing case. (See Timing Case And Gear

Clean and inspect the camshaft and tappets for Installation on Page 70-100-19.)
excessive wear and damage.
Check camshaft end play. The end play for a new engine
is 0.004 - 0.016 inch (0,10 - 0,41 mm), service limits

Inspect the camshaft bushing for excessive wear and 0.021 inch (0,53 mm).
damage.
Figure 70-100-59
NOTE: Only the front camshaft journal bore has a
bushing.
Clearance between the camshaft journals, the bushing

and camshaft bore is 0.0025-0.0055 inch (0,06-0,14
mm).
Make sure all components are clean and lubricated with

clean engine oil.
Install the tappets (Item 1) [Figure 70-100-56].
Figure 70-100-57
Install the fuel pump and gasket. Tighten the bolts (Item
1) [Figure 70-100-59] to 16 ft.-lbs. (22 Nm) torque.
Install the timing gears. (See Timing Case And Gear

Install the injection pump. (See Fuel Injection Pump

Install the push rods and rocker assembly. (See Cylinder

Head Installation on Page 70-100-5.)
Install the timing cover. (See Timing Cover Installation on

Page 70-100-17.)
Carefully install the camshaft (Item 1) [Figure 70-100- Install the oil pan. (See Oil Pan Removal And Installation
on Page 70-100-40.)
57].
V518 VersaHANDLER
Pistons And Connecting Rods Description
The pistons have a Quadram combustion chamber. They

have two compression rings and one oil control ring. The
top ring groove has a hard metal insert to reduce wear.
Full floating piston pins are used and are retained by
snap rings.
Controlled expansion pistons have a steel insert ring in

the piston skirt. The connecting rods are molybdenum
steel. The connecting rods on the turbocharged engines
have wedge shaped small ends. The location of the
bearing caps to the connecting rods is made by
serrations and the cap is retained by two bolts.
The pistons used in the 1000 series engines have two Mark and remove the connecting rod caps (Item 1)
compression rings and one oil control ring. All the rings [Figure 70-100-61].
are above the piston pin. Each of the three piston rings
have different design features. Always use the engine NOTE: Do not allow the connecting rods to hit the
identification number to order new parts. cooling jets.
Pistons And Connecting Rods Removal Figure 70-100-62

Figure 70-100-60
Turn the connecting rods 90° to prevent contact with the

piston cooling jets (Item 1) [Figure 70-100-62]. Push the
Remove the cylinder head. (See Cylinder Head Removal piston and rod assemblies out the top of the cylinder.
on Page 70-100-4.)
Remove all the carbon from the top of the cylinder liners.
Remove the oil pan. (See Oil Pan Removal And

Remove the oil pick up screen and tube (Item 1) [Figure

70-100-60].
V518 VersaHANDLER
Pistons And Connecting Rods Removal (Cont’d)
Figure 70-100-63
Inspect the crankshaft journals (Item 1) [Figure 70-100-

63] for wear or damage.

NOTE: Keep all parts together so they can be
replaced in their original position.
NOTE: Before installing the pistons check cylinder

bore for wear or damage. (See Cylinder Liner
Inspection on Page 70-100-46.)
V518 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Piston Ring End Gap
Pistons And Connecting Rods Disassembly Figure 70-100-66
Figure 70-100-64
Place the piston rings in the upper part of the cylinder to

check the end gap [Figure 70-100-66].
Mark the piston to indicate the cylinder number (Item 1)
[Figure 70-100-64] as shown on the connecting rod. Top Ring End Gap 0.014-0.028 inch (0,35-
0,70 mm)

Figure 70-100-65
Second Ring End Gap 0.012-0.030 inch (0,30-
0,76 mm)
Third Ring End Gap 0.010-0.031 inch (0,25-
0,75 mm)
Piston Ring Installation
Figure 70-100-67
Remove the piston rings (Item 1) [Figure 70-100-65] with

a ring expander.
Remove the snap rings (Item 2) [Figure 70-100-65]

which retain the piston pin.
Push the piston pin (Item 3) [Figure 70-100-65] out by

hand. If the pin doesn't push out easily, heat the piston to
100°-120° F (40°-50° C) for easier removal. Install the spring of the oil control ring in the bottom
groove with the latch pin inside both ends of the spring
Remove the connecting rod (Item 4) [Figure 70-100-65]. [Figure 70-100-67].
V518 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Piston Ring Groove Clearance
Piston Ring Installation (Cont'd) Figure 70-100-69
Use a ring expander to install the piston rings.
Install the oil spring on the bottom groove of the piston

with the latch pin inside both ends of the spring.
Figure 70-100-68
With the piston rings installed, check the groove

clearance [Figure 70-100-69].
Top Ring Wedge

Second Ring Side 0.003 - 0.004 inch (0,07 -

Clearance 0,10 mm)
Install the oil control ring over the spring (Item 1) [Figure Third Ring Side Clearance 0.002 - 0.003 inch (0,05 -
70-100-68]. 0,07 mm)
Make sure the ring gap is 180° from the latch pin.
Install the cast iron ring with the tapered face (Item 2)
[Figure 70-100-68] in the second groove with the word
TOP or symbol facing the top of the piston.
New second rings have a green identification mark,

which must be on the left of the ring gap after the ring is
installed and the piston is upright.
The second ring has an external step at the bottom of the

tapered face.
Place the chromium ring (Item 3) [Figure 70-100-68] with

the symbol or word TOP up when installed on the piston.
The top ring (Item 3) [Figure 70-100-68] has an internal

step.
New top rings have a red or blue identification mark,

which must be on the left of the ring gap after the ring is
installed and the piston is uptight.
Make sure the ring gaps are 120° apart.
V518 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Piston And Connecting Rod Assembly
Connecting Rod Inspection Figure 70-100-71
Figure 70-100-70
Install the connecting rod (Item 1) [Figure 70-100-71],

piston pin (Item 2) [Figure 70-100-71] and two snap
Checking the connecting rod for distortion [Figure 70- rings (Item 3) [Figure 70-100-71] in the piston.
100-70].
Piston And Connecting Rod Installation

NOTE: The large and small end bores must be square
and parallel within the limits of ± 0.010 inch Apply a light coat of oil to the piston and piston rings.
(0,25 mm).
NOTE: Make sure the piston ring end gaps are 120°
Measure this 5.0 inch (127 mm) on each side of the apart.
connecting rod axis on a test fixture.
Figure 70-100-72
With the piston pin bushing installed the limit is reduced
to ± 0.0025 inch (0,06 mm).
Check the pin bushing for wear or damage. Replace as

needed.
Connecting Rod Bushing Replacement
Press out the old bushing. Clean the bore and remove
any burrs.
Press in the new bushing making sure the oil feed holes
line up.
Ream the bushing to get the proper clearance of 0.0008 -

0.0017 inch (0,02 - 0,043 mm) between the small end
bushing and piston pin. Install the ring compressor over the piston rings [Figure
70-100-72].
Carefully place the connecting rod in the cylinder and

using a hammer handle, push the piston in the bore.
V518 VersaHANDLER
Piston And Connecting Rod Installation (Cont'd)
Figure 70-100-73
Install the upper and lower bearing shells in position

making sure the locating tang (Item 1) [Figure 70-100-
75] is in the correct position.
When the piston has cleared the cooling jet, rotate the NOTE: New connecting rod nuts must be installed
piston assembly so that the arrow or FRONT mark is each time the rod caps are removed.
toward the front of the engine [Figure 70-100-73].

Figure 70-100-76
Figure 70-100-74
Install the caps (Item 1) [Figure 70-100-76] and nuts.

Clean the bearing surfaces and crank pin. Lubricate the Gradually tighten the nuts to 45 ft.-lbs. (61 Nm) torque.
crank pin (Item 1) [Figure 70-100-74] with clean engine Tighten to a final torque of 92 ft.-lbs. (125 Nm).
oil.
Rotate the crankshaft. The crankshaft must rotate
smoothly.
V518 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) NOTE: Two Quadram piston heights can be used. In
the factory H - high or L - low. In service only
Piston And Connecting Rod Installation (Cont'd) L pistons are supplied.
Figure 70-100-77 If a L piston is used in place of an H piston the

height may be up to 0.0075 inch (0,19 mm)
below the bottom limit. The top of the piston
can not be machined.
If the original piston is being reused, install

the piston with the original connecting rod in
the cylinder bore that it was removed from.
Install the cylinder head. (See Cylinder Head Installation

on Page 70-100-5.)
Install the oil pick up tube and screen (Item 1) [Figure

70-100-77].

Install the oil pan. (See Oil Pan Removal And Installation
on Page 70-100-40.)
Checking Piston Height
Rotate the crankshaft until the piston is approximately at

top dead center (T.D.C.).
Using a dial indication gauge, pre-load the plunger on the

top surface of the block and zero the gauge.
Carefully move the dial gauge so that the plunger is on

top of the piston above the axis of the piston pin.
Rotate the crankshaft to bring the piston to it's highest

point. Record this gauge reading.
When installed, the top surface of the piston is slightly

above the surface of the cylinder block.
For the Quadram piston engines, the height above the

surface of the block should be 0.005 to 0.014 inch (0,14
to 0,36 mm).
V518 VersaHANDLER
Crankshaft And Bearings Description
The crankshaft is a chrome-moly forging which has five

main journals. End play is controlled by two half thrust
washers on both sides of the center main bearing.
The main bearings have steel backs with a aluminium/ tin

bearing material. The main bearing caps are made of
cast iron.
The front and rear oil seals are viton lip seals with a dust
lip to the outside of the main lip.
Crankshaft And Bearings Removal
Figure 70-100-78 Remove the two bolts (Item 1) [Figure 70-100-79]

retaining the bridge piece.
Remove the bridge piece.
Figure 70-100-80

Remove the water pump. (See Water Pump Removal on
Page 70-100-38.)
Remove timing case cover. (See Timing Cover Removal

on Page 70-100-16.)
Mark the main bearing caps (Item 1) [Figure 70-100-80]
Remove the fuel injection pump. (See Fuel Injection for correct installation.
Pump Removal And Installation on Page 70-70-1.)
Remove the main bearing cap bolts.
Remove the timing gears and timing case. (See Timing
Case And Gear Removal on Page 70-100-18.)
Remove the flywheel. (See Removal And Installation on

Page 70-90-1.)
Remove the pistons and connecting rods (See Pistons

And Connecting Rods Removal on Page 70-100-23),
keeping them in order.
Remove the rear oil seal housing (Item 1) [Figure 70-

100-78].
V518 VersaHANDLER
Crankshaft And Bearings Removal (Cont'd)
Figure 70-100-81
Remove the crankshaft [Figure 70-100-83].
Figure 70-100-84
Remove the main bearing caps (Item 1) [Figure 70-100-

81].

Figure 70-100-82
Remove the crankshaft bearings from the engine block

[Figure 70-100-84].
Keep the bearings with their respective caps for

installation.
Remove the thrust washers from the sides of the center
main bearing bore [Figure 70-100-82].
V518 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Crankshaft And Bearings Installation
Inspection Of Crankshaft And Bearings Figure 70-100-86
Figure 70-100-85
Clean the main bearing bores and install the upper

bearing shells in position. Lubricate the bearings with
Check the crankshaft for wear [Figure 70-100-85]. The clean engine oil [Figure 70-100-86].
maximum wear and out of round of the crank journals is
0.0016 inch (0,04 mm). NOTE: Only the upper half of the bearings has oil

lubrication holes and must be installed in the
The main journals and the crank pins of standard size cylinder block.
can be machined 0.010 inch (0,25 mm) 0.020 inch (0,50
mm) or 0.030 inch (0,75 mm). Figure 70-100-87
NOTE: See ENGINE SPECIFICATIONS on Page

SPEC-20-1 for more crankshaft
specifications.
Check the oil clearance of the bearings.
All Main Bearings 0.0022 - 0.0046 inch (0,057

- 0,117 mm)
Thrust Washer Thickness

Standard 0.089 - 0.091 inch (2,26 -
2,31 mm)
Oversize 0.096 - 0.098 inch (2,45 -
2,50 mm)
Make sure the main journals are clean and install the
crankshaft in the block [Figure 70-100-87].
Make sure the locating pins for the main caps are in
position.
V518 VersaHANDLER
Crankshaft And Bearings Installation (Cont'd)
Figure 70-100-88
Install the bridge piece, and using a straight edge, align

the bridge with the cylinder block [Figure 70-100-89].
Tighten the bridge retaining bolts to 12 ft.-lbs. (16 Nm)
torque.
Clean and install the upper and lower thrust bearings on
each side of the center main bearing [Figure 70-100-88]. Figure 70-100-90

Clean the main caps and install the bearings.
Lubricate the bearings with clean engine oil.
Install the main cap bolts and torque in steps working

from the center outward.
Step 1 65 ft.-lbs. (88 Nm)

Step 2 125 ft.-lbs. (170 Nm)
Step 3 185 ft.-lbs. (250 Nm)
Clean the bridge piece and apply a bead of LOCTITE

#518 in the corners and around the thread holes on the
block.
Inject LOCTITE #518 into the groove (Item 1) [Figure 70-
100-90] at each end of the bridge piece. Continue to
inject sealant until it leaves the lower groove (Item 2)
[Figure 70-100-90] at the front and rear of the piece.
V518 VersaHANDLER
Rear Oil Seal Removal
Remove the bolts that retain the seal housing. Remove

the housing.
Inspect the seal for wear or damage. Replace even if

there is only a small nick or scratch.
Inspect the crankshaft flange for damage.
Clean the block, seal housing, and crankshaft.
Rear Oil Seal Housing Positioning

procedure; Install the seal in the seal housing using the seal
installation tool. Seat the seal to the correct depth
MEL1532 - Rear Crankshaft Seal Installation Tool [Figure 70-100-92].
Figure 70-100-91 Rear Oil Seal Installation
Install the new seal in the housing.

Figure 70-100-93
The seal can be installed from flush with the housing face
(Item 1) [Figure 70-100-91] to 0.27 inch (6,86 mm) (Item
2) [Figure 70-100-91] back from the housing face. Install
seal so that the seal lip does not line up with any worn
areas on the crankshaft. Make sure the dowels (Item 1) [Figure 70-100-93] are in
the block correctly.
Install the new gasket (Item 2) [Figure 70-100-93] on the

housing (Item 3) [Figure 70-100-93].
Install the seal replacer tool (PD145-3) (Item 4) [Figure

70-100-93] on the crankshaft.
Lubricate the seal, tool, and crankshaft with clean engine

oil.
Carefully push the seal and housing (Item 3) [Figure 70-

100-93] over the tool and crankshaft and into position on
the dowels. Remove the tool.
V518 VersaHANDLER
Rear Oil Seal Installation (Cont'd)
Figure 70-100-94
Remove the pry bar and record the dial indicator reading
[Figure 70-100-96].
The end play specification is 0.0075 inch (0,019 mm)

Tighten the bolts (Item 1) [Figure 70-100-94] to 16 ft.-lbs. maximum.
(22 Nm) torque.
If end play is excessive there is over size thrust washers

Checking Crankshaft End Play available to reduce movement.
The axial movement of the crankshaft is controlled by two Figure 70-100-97

half thrust washers placed on both sides of the center
main bearing.
Figure 70-100-95
The end play can also be checked using a feeler gauge

[Figure 70-100-97].
Pry the crankshaft to the rear of the cylinder block and

Install a dial indicator on the end of the crankshaft measure the distance between the thrust washer and
[Figure 70-100-95]. crankshaft.
Pry the crankshaft to the rear of the cylinder block and

set the dial indicator to zero.
V518 VersaHANDLER
Cooling System Description
Figure 70-100-98
The coolant then passes around the cylinders and in the

cylinder head. The coolant leaves the cylinder head at
the front and passes into the thermostat housing (Item 1)
[Figure 70-100-100].
Coolant from the radiator passes through the centrifugal
water pump (Item 1) [Figure 70-100-98], to assist the If the thermostat is closed, the coolant goes directly
flow of the coolant through the system. through a by-pass to the inlet side of the water pump. If

the thermostat is open, the thermostat closes the by-pass
The water pump is gear driven from the gear off the fuel and the coolant passes to the radiator.
injection pump.
From the water pump, the coolant passes through a

passage in the timing case.
The coolant passes through a passage in the left side of

the cylinder block to the rear of the cylinder block.
Figure 70-100-99
The oil cooler (Item 1) [Figure 70-100-99] is installed on

the left side of the engine. Coolant from the by-pass
connection at the rear of the coolant pump passes
through a pipe to the oil cooler.
V518 VersaHANDLER
Thermostat Removal and Installation
Drain the engine coolant until it is below the thermostat

level.
Figure 70-100-101
Remove the six mounting bolts at the coolant housing

(Item 1) [Figure 70-100-103].
Figure 70-100-104

Remove the bolts (Item 1) [Figure 70-100-101] and
thermostat housing.
Installation: Make sure all gasket surfaces are clean.

Replace the gasket before installing the thermostat
housing.
Figure 70-100-102
Remove coolant housing (Item 1) [Figure 70-100-104]

from the engine block.
Thermostat Testing
Hang the thermostats in a suitable container filled with

coolant.
Heat the coolant gradually. Use a thermometer to check

the temperature when it starts to open and when it's fully
open.
Remove the housing and thermostat (Item 1) [Figure 70-
100-102]. If the thermostats do not operate correctly they must be
replaced.
NOTE: Identify thermostat temperature by the

stamping on the by-pass valve.
V518 VersaHANDLER
Water Pump Removal
Figure 70-100-105
Loosen the hose clamp (Item 1) [Figure 70-100-107].
Remove the water pump.
Remove the coolant from the cooling system. Water Pump Installation
Remove the nuts (Item 1) [Figure 70-100-105]. Clean the gasket surfaces and replace the O-ring.

Figure 70-100-106 Install the water pump in the timing cover. The pump is a
tighten fit in the cover and is pulled into position by
tightening the bolts evenly.
Pipe thread sealant must be applied to the pump

mounting bolts before installation.
Install the water pump bolts (Item 1) [Figure 70-100-106]

Install the two nuts (Item 1) [Figure 70-100-105] and

Tighten the hose clamp (Item 1) [Figure 70-100-107].

from the water pump.
V518 VersaHANDLER
Engine Lubrication System Description
Figure 70-100-108
The engine oil passes from the filter (Item 1) [Figure 70-
100-110] to the cylinder block.
The oil passes to the main bearings of the crankshaft and
through passages in the crankshaft to the big end
Pressure lubrication is supplied by a rotor type pump bearings. The pistons and the cylinder bores are
lubricated by splash and oil mist.
(Item 1) [Figure 70-100-108] which is driven through an
idler gear from the crankshaft gear. Engine oil passes from the main bearings through

passages in the cylinder block to the journals of the
camshaft. Engine oil passes from the center journal of
Engine oil from the oil pan sump passes through a the camshaft through a passage in the cylinder block and
strainer (Item 2) [Figure 70-100-108] and pipe to the cylinder head to a restriction in the pedestal of the rocker
suction side of the pump. shaft, at a reduced pressure, to feed the rocker bushing.
The oil passes through a passage in the rocker shaft to
the bearings of the rocker levers. The valve stems, valve
The engine oil passes from the outlet side of the pump springs and the tappets are lubricated by splash and oil
through a pipe to a relief valve (Item 3) [Figure 70-100- mist.
108], which is installed in the bottom left side of the
cylinder block. The relief valves opens if the oil pressure The hub of the idler gear is lubricated by oil from the
cylinder block and the timing gears are splash lubricated.
is too high; this allows some of the engine oil to return to
the sump. The turbocharger is lubricated by oil after the filter. Oil is
supplied from a connection on the right side of the
cylinder block through an external pipe to the
Figure 70-100-109 turbocharger. The oil passes through the turbocharger
and returns through a pipe to the oil pan sump.
Figure 70-100-111
From the relief valve, engine oil passes to a plate type oil
cooler (Item 1) [Figure 70-100-109].
Turbocharged engines have piston cooling jets (Item 1)
Oil flows through the oil tubes (Item 2) [Figure 70-100- [Figure 70-100-111]. These jets are connected to the oil
109] to the filter. pressure rail and spray lubricating oil inside the pistons to
keep them cool.
V518 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Oil Pan Removal And Installation
Oil Filter Adapter Removal Figure 70-100-114
Figure 70-100-112
Remove the oil pan retaining bolts [Figure 70-100-114].
Remove the oil filter. Remove the pan and gasket.
Remove the oil cooler tube (Item 1) [Figure 70-100-112] Clean the pan in solvent and dry with compressed air.

from the filter pump.
Remove the four bolts (Item 2) [Figure 70-100-112] and Clean the block surface.
the filter adapter (Item 3) [Figure 70-100-112].
Installation: Place a new gasket on the oil pan. Place
Oil Filter Adapter Installation two bolts on each side to position the oil pan correctly.
Install the remaining bolts. Tighten the bolts to 16 ft.-lbs.
Figure 70-100-113 (22 Nm) torque [Figure 70-100-114].
Clean the filter adapter (Item 1) [Figure 70-100-113] and

the block mounting surfaces (Item 2) [Figure 70-100-
113].
Using a new gasket, install the adapter (Item 1) [Figure

70-100-113] on the block.
Connect the turbocharger oil supply line.
Connect the oil cooler lines to the filter adapter.
Install the oil filter.
V518 VersaHANDLER
Oil Screen And Pick-up Tube
Figure 70-100-115
Remove the oil pressure relief valve (Item 1) [Figure 70-

100-116].
Remove the oil screen and pick-up tube.

Remove the bolt (Item 1) [Figure 70-100-115] that holds
the bracket (Item 2) [Figure 70-100-115] to the main The oil pump is installed on the number 1 main bearing
bearing cap. cap.

Remove the bolts (Item 3) [Figure 70-100-115] from the
pick-up tube flange. NOTE: The pump can be removed with the main
bearing cap if a spanner wrench is available
Remove the pick-up tube (Item 4) [Figure 70-100-115] that will allow the torque to be applied directly
and gasket. to the main cap bolts.
Wash the assembly in solvent and dry with compressed If there is no spanner wrench, the front timing case cover
air. must be removed. (See Timing Cover Removal on Page
70-100-16.)
Check the tube and strainer for cracks or other damage.
Replace as necessary. Figure 70-100-117
Loosely assemble the bracket (Item 2) [Figure 70-100-
115] with the pick-up tube to the main bearing cap.
Install the pick up tube gasket and mounting bolts (Item

3) [Figure 70-100-115].
Tighten the mounting bolts to 16 ft.-lbs. (22 Nm) torque.
Tighten the bolt (Item 1) [Figure 70-100-115] for the pick-

up tube bracket.
Tighten the bolt to 16 ft.-lbs. (22 Nm) torque.
Oil Pump Removal
NOTE: The oil pump has a channel in the body of the

pump. Oil from the front main bearing passes
down the channel of the pump to an oil hole in Remove the snap ring (Item 1) [Figure 70-100-117], idler
the idler shaft for lubrication of the idler shaft gear (Item 2) [Figure 70-100-117], and washer.
bushing.
Remove the bolts and oil pump.
Remove the oil pan. (See Oil Pan Removal And
V518 VersaHANDLER
Oil Pump Installation
Figure 70-100-118
Check that there is a minimum of 0.003 inch (0,076 mm)

backlash between the idler gear and oil pump gear
[Figure 70-100-119].
Fill the pump with engine oil. End play for the idler gear should be 0.0005/0.0253 inch
(0,012/0,643 mm).
If the number one main cap was removed, reinstall and

tighten to 185 ft.-lbs. (250 Nm) torque. Install the oil screen and pick-up tube. (See Oil Screen
And Pick-up Tube on Page 70-100-41.)
Install the pump on the main cap and tighten to 16 ft.-lbs.
(22 Nm) torque. Install the pressure relief valve.
Check the idler gear and bushing for wear. Install the oil pan. (See Oil Pan Removal And Installation
on Page 70-100-40.)
Lubricate with clean engine oil and install the washer,
idler gear (Item 1) [Figure 70-100-118] and snap ring
(Item 2) [Figure 70-100-118].
Check the backlash between oil pump and idler gears.
There must be a minimum of 0.003 inch (0,076 mm).
V518 VersaHANDLER
Oil Pump Disassembly And Assembly
Figure 70-100-120
Check the rotor end play [Figure 70-100-122].
Rotor end play must be 0.001-0.004 inch (0,03-0,10

mm).
NOTE: If any part is worn enough to effect
performance replace the complete oil pump. Install the cover and tighten the bolts to 16 ft.-lbs. (22
Nm) torque.

Remove the cover of the oil pump.
Oil Pressure Relief Valve Disassembly And Assembly
Remove the outer rotor and thoroughly clean. Check for
cracks or other damage. Figure 70-100-123
Install the outer rotor and check the outer rotor to body
clearance [Figure 70-100-120].
Clearance between the outer rotor and body must be

0.006-0.013 inch (0,15-0,34 mm).
Figure 70-100-121
Press the end plate (Item 1) [Figure 70-100-123] in the

valve body (Item 2) [Figure 70-100-123] and remove the
snap ring (Item 3) [Figure 70-100-123].
Remove the end plate (Item 1) [Figure 70-100-123],

spring (Item 4) [Figure 70-100-123], and plunger (Item 5)
[Figure 70-100-123] from the body (Item 2) [Figure 70-
100-123].
Check the inner rotor to outer rotor clearance [Figure 70-
Clean the parts in solvent and dry with compressed air.
100-121].
Lubricate the bore of the valve body (Item 2) [Figure 70-
Clearance between the inner rotor and outer rotor must 100-123], plunger (Item 5) [Figure 70-100-123] and the
be 0.0015 - 0.005 inch (0,04-0,13 mm). end plate (Item 1) [Figure 70-100-123] with clean engine
oil before assembly.
V518 VersaHANDLER
Engine Block Description
Figure 70-100-124
A bushing (Item 1) [Figure 70-100-125] is installed in the

cylinder block for the front camshaft journal while the
other camshaft journals run directly in the block.
Engine Block Disassembly And Assembly

The cylinder block is made of cast iron and provides full
length support for the dry liners. Remove the water pump. (See Water Pump Removal on
Page 70-100-38.)

The liners (Item 1) [Figure 70-100-124] are made of cast Remove the fuel injection pump. (See Fuel Injection
iron. Production liners are a press fit and service liners Pump Removal And Installation on Page 70-70-1.)
are a transion fit. Both types of liners are honed with
silicon carbide tools to a specially controlled finish to Remove the oil cooler. (See Removal And Installation on
ensure long engine life and low oil consumption. Page 30-20-1.)
Remove the oil filter and oil pan. (See Oil Pan Removal
Remove the turbocharger. (See Turbo Charger Removal
Remove the lift fuel pump. (See Fuel Lift Pump Removal
Remove the starter. (See Removal And Installation on

Page 60-40-1.)
Remove the cylinder head. (See Cylinder Head Removal
on Page 70-100-4.)
Remove the timing case and gears. (See Timing Case

And Gear Removal on Page 70-100-18.)
Remove the piston and connecting rod assemblies. (See

Pistons And Connecting Rods Removal on Page 70-100-
23.)
Remove the camshaft and tappets. (See Camshaft And

Tappets Removal on Page 70-100-21.)
Remove the engine mounting bracket and flywheel. (See

Remove the rear oil seal and the crankshaft. (See

Crankshaft And Bearings Removal on Page 70-100-30.)
V518 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Piston Cooling Jet Alignment
Piston Cooling Jet Removal Figure 70-100-128
Figure 70-100-126
Insert a 0.067 inch (1,70 mm) diameter rod of suitable

length, in the jet.
Remove the piston cooling jet assembly (Item 1) [Figure
70-100-126] from the engine block. The tip of the rod must extend out the top of the cylinder
in an area 1.30 inch (33 mm) in height and 0.8 inch (21

Figure 70-100-127 mm) of width to provide proper cooling jet alignment to
cool the pistons [Figure 70-100-128].
Inspection
Clean all passages of coolant and oil.
Check the block for cracks or other damage.
NOTE: The top face of the block must not be

machined. This will affect liner flange depth
and piston height above the top face of the
cylinder block.
Check the camshaft bushing for wear. If the bushing

needs to be replaced, press out old one. Press a new
one in, insuring that the oil holes line up.
Inspect the jet tube (Item 1) [Figure 70-100-127], mount
bolt (Item 2) [Figure 70-100-127] and alignment pin
(Item 3) [Figure 70-100-127] for damage. Replace as
needed.
Piston Cooling Jet Installation
Clean all parts in solvent and dry with compressed air.
Install the cooling jet (Item 1) [Figure 70-100-127] being

sure it is seated correctly on the dowel (Item 3) [Figure
70-100-127] in the block.
Install the mounting bolt (Item 2) [Figure 70-100-127]

V518 VersaHANDLER
Cylinder Liner Inspection
Figure 70-100-129
Check the cylinder liner bore for out of round or wear

beyond service limits [Figure 70-100-130]. The inside
diameter of the service liner should be 3.937-3.939 inch
(100,00-100,06 mm).
The condition of a cylinder liner is decided by:
A flex type hone may be used to clean up small scoring
• The amount and location of polished areas. or pitting.

• Wear. Damaged or worn liners must be replaced.
• Damage to the liner wall.
NOTE: It is not necessary to replace the liners if: The

honed finish can be clearly seen. Engine
performance and oil consumption is
acceptable.
Examine the liner surface (Item 1) [Figure 70-100-129]

for cracks, deep scratches and polished areas where the
honed finish is worn away.
V518 VersaHANDLER
Cylinder Liner Removal
Figure 70-100-131

NOTE: Where several liners are to be removed or a
very tight production liner is found, a press
should be used.
When one liner is replaced, a hand tool is available and

the following procedure can be done with the crank shaft
installed.
Rotate the crankshaft (if installed) to provide access to

the liner and protect the crank pin from damage.
Place the tool (Item 1) [Figure 70-100-131] over the

center of the liner (Item 2) [Figure 70-100-131]. Make
sure the flat bearing race (Item 3) [Figure 70-100-131] is
against the bottom of the recess.
Install the rod (Item 4) [Figure 70-100-131] through the

handle (Item 5) [Figure 70-100-131].
Place the adapter (Item 6) [Figure 70-100-131] under

the cylinder liner. Tighten the nut and washer. Turn the
handle and pull out the old liner.
V518 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Place the threaded rod (Item 4) [Figure 70-100-132]
through the handle (Item 5) [Figure 70-100-132] and
Cylinder Liner Installation liner (Item 1) [Figure 70-100-132].
Adjust the rod until it is below the bottom of the block

surface.
IMPORTANT Install the adapter (Item 6) [Figure 70-100-132] on the
rod. Center the adapter against the bottom of the block.
For the first five hours after the new liners have been
installed: Tighten the nut and washer.
• Do not operate at full load.
• Do not operate at high speed. Turn the handle and press the liner in the bore, stopping
• Do not allow engine to idle for extended periods. when approximately 2 inch (50 mm) remain. Apply
I-2117-1196
LOCTITE #603 to the outer surface below the flange and
to the flange recess.
Figure 70-100-132
Continue to press the liner into position. Remove the tool.
NOTE: Do Not hit the cylinder liners with a hammer.

They will be damaged.
Figure 70-100-133

Check liner protrusion with a dial gauge [Figure 70-100-
133].
The liner may have 0.004 inch (0,10 mm) protrusion or

recession from the block face.
Allow 15 minutes before measuring the bore. The liner

will take six hours to reach full strength.
Clean the cylinder bore and the outside of the liner. The inside diameter of the service liner should be 3.937-
3.939 in. (100,00- 100,06 mm).
Lubricate the cylinder bore with engine oil.
New piston rings must be used when the cylinder liners
Start the liner (Item 1) [Figure 70-100-132] in the bore. have been replaced.
Make sure it is started straight.
The measurement must be from the flange (Item 1)
With the adapter (Item 2) [Figure 70-100-132] on the top [Figure 70-100-133] of the cylinder liner, not the top of
of the liner, place the bearing (Item 3) [Figure 70-100- the flame ring (Item 2) [Figure 70-100-133].
132] in the recess at the top.
V518 VersaHANDLER
Turbo Charger Troubleshooting
The chart below is given to assist in the correct diagnosis of turbocharger faults.
If the inside of the intake manifold is wet, check that there is not a fuel leak from the starting aid.
PROBLEM CAUSE
Not enough power 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28
Black Smoke 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28
Blue Smoke 1, 2, 4, 6, 8, 9, 17, 19, 20, 21, 22, 30, 31, 32
High Lubricating Oil Consumption 2, 8, 15, 17, 19, 20, 28, 29, 31, 32
Two Much Lubricating Oil At Turbine End 2, 7, 8, 17, 19, 20, 22, 28, 30, 31, 32
Two Much Lubricating Oil At Compressor End 1, 2, 4, 5, 6, 8, 19, 20, 21, 28, 31, 32
Not Enough Lubrication 8, 12, 14, 15, 16, 23, 24, 29, 32, 33, 34, 35
Lubricating Oil In The Exhaust Manifold 2, 7, 17, 18, 19, 20, 22, 28, 31, 32
Inside The Induction Manifold Wet 1, 2, 3, 4, 5, 6, 8, 10, 11, 17, 18, 19, 20, 21, 28, 32, 36, 37
Damaged Compressor Impeller 3, 4, 6, 8, 12, 15, 16, 20, 21, 23, 24, 29, 32, 33, 35, 36
Damaged Turbine Rotor 7, 8, 12, 13, 14, 15, 16, 18, 20, 22, 23, 24, 25, 27, 29, 29, 32, 33, 34,
35
Rotating Assembly Does Not Turn Freely 3, 6, 7, 8, 12, 13, 14, 15, 16, 18, 20, 21, 22, 23, 24, 29, 32, 33, 34, 35

Worn Bearings, Bearing Bores, Journals 6, 7, 8, 12, 13, 14, 15, 16, 23, 24, 29, 33, 34, 35
Noise From Turbocharger 1, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 20, 21, 22, 23,
24, 29, 32, 33, 34, 35
Sludge or Carbon Deposit In Bearing Housing 2, 11, 13, 14, 15, 17, 18, 24, 29, 33, 34, 35

1. Air filter element dirty. 17. Restricted lubricating oil drain pipe.
2. Restricted crankcase breather. 18. Turbine housing damage or restricted.
3. Air filter element missing, leaking or not sealing 19. Leakage from turbocharger seals.
correctly. Loose connection to turbocharger.
4. Internal distortion or restriction in pipe from air filter to 20. Worn turbocharger bearings.
turbocharger.
5. Damaged/restricted crossover pipe, turbocharger to 21. Excessive dirt in turbocharger housing.
induction manifold.
6. Restriction between air filter and turbocharger. 22. Excessive carbon behind turbine rotor.
7. Restriction in exhaust system. 23. Engine speed raised too rapidly at initial start.
8. Turbocharger loose or clamps/setscrews loose. 24. Insufficient engine idle period.
9. Induction manifold cracked or loose, flanges distorted. 25. Faulty fuel injection pump.
10. Exhaust manifold cracked or loose. 26. Worn or damaged fuel injectors.
11. Restricted exhaust system. 27. Valves burned.
12. Delay of lubricating oil to turbocharger at engine start. 28. Worn piston rings. flanges distorted.
13. Insufficient lubrication. 29. Lubricating oil leakage from supply pipe.
14. Dirty lubricating oil. 30. Excessive starting fluid (on initial engine start).
15. Incorrect lubricating oil. 31. Excessive engine idle period.
16. Restricted lubricating oil supply pipe. 32. Restriction in turbocharger bearing housing.
33. Restriction in lubricating oil filter.
34. Engine stopped too soon from high load.
35. Insufficient lubricating oil.
36. Fuel leakage from fuelled starting aid.
37. Crack in back plate of compressor.
V518 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Turbo Charger Removal and Installation
Turbo Charger Description Remove the three nuts (Item 2) [Figure 70-100-134] that
mount the extension tube to the turbo.
Figure 70-100-135
WARNING
Turbochargers operate at high speed and high
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196
Figure 70-100-134
Remove the bolts (Item 1) [Figure 70-100-135] from the

extension tube and muffler.

Remove the extension tube [Figure 70-100-135].
Figure 70-100-136
The turbocharger (Item 1) [Figure 70-100-134] is placed

between the exhaust and intake manifolds. It is driven by
hot exhaust gases and supplies air at more than
atmospheric pressure to the intake. It is lubricated by oil
from the main gallery.
The oil flows from the filter adapter through the bearing
housing and returns to the engine block.
The turbocharger should only be serviced by an

authorized dealer or repair shop.
Disconnect the air cleaner hose (Item 1) [Figure 70-100-

136] from the turbocharger.
V518 VersaHANDLER
Turbo Charger Removal and Installation (Cont'd)
Figure 70-100-137
Remove the oil return line (Item 1) [Figure 70-100-139].
Figure 70-100-140
Thoroughly clean the turbocharger.
Loosen the hose clamps at the compressor outlet hose

(Item 1) [Figure 70-100-137].
Figure 70-100-138
Remove the four nuts (Item 1) [Figure 70-100-140] for

the turbocharger to exhaust manifold flange.
Installation: Apply anti-seize compound to the mounting

studs. Tighten the nuts to 33 ft.-lbs. (44 Nm) torque.
Remove the turbocharger and gasket from the exhaust

Disconnect the oil supply tubeline (Item 1) [Figure 70- manifold.
100-138].
The turbocharger must only be serviced by an authorized
Installation: Fill the bearing housing with clean oil repair shop.
through the oil supply port.
Before starting the engine, disconnect the electrical stop
control. Crank the engine until oil pressure is obtained.
Stop cranking and reconnect the stop control.
V518 VersaHANDLER
V518 VersaHANDLER
HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SERVICE . . . . . . . . . . . . . . . . . . . . . . . 80-90-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . 80-10-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
Principals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1

Checking The Electrical System . . . . . . . . . . . . . . . . . . . . 80-50-2
Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . 80-50-1
Poor A/C Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1
Compressor Clutch Disassembly. . . . . . . . . . . . . . . . . . . 80-110-2

CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1
EVAPORATOR/BLOWER UNIT . . . . . . . . . . . . . . . . . . . . . . 80-150-1

EXPANSION VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-160-1

GENERAL AIR CONDITIONING SERVICE GUIDELINES . . . 80-60-1

Component Replacement And Refrigeration Leaks. . . . . . 80-60-3
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
Compressor Oil Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
HEATER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1

Core Removal And Installation . . . . . . . . . . . . . . . . . . . . 80-170-2
Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . 80-170-2
PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1

RECEIVER/DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1
V518 VersaHANDLER
HEATING, VENTILATION, AIR CONDITIONING (CONT’D)
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-2
Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . 80-40-2
Filter Element Removal And Installation . . . . . . . . . . . . . . 80-40-1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . 80-100-1

Charging Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-6
Charging Procedure With A Manifold Gauge Set . . . . . . 80-100-4
Reclamation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1
SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . 80-70-1
TEMPERATURE/PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
V518 VersaHANDLER
AIR CONDITIONING SYSTEM FLOW
Principals
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) (See Chart on Page 80-10-2) takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) (See Chart on Page 80-10-2).
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver/drier (Item 3) (See Chart on Page 80-10-2) where impurities such as
moisture and dirt are filtered out. The receiver/drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) (See Chart on Page 80-10-2).
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) (See Chart on Page 80-10-2). As
the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan
(Item 6) (See Chart on Page 80-10-2). Since the refrigerant is colder than the air, it absorbs the heat from the air and
produces cooled air, which is pushed into the cab by the fan. The moisture in the air condenses on the evaporator coil and

drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.
V518VersaHANDLER
AIR CONDITIONING SYSTEM FLOW (CONT'D)
Chart
V518VersaHANDLER
COMPONENTS Figure 80-20-3
Identification
Figure 80-20-1
Receiver/Drier: The receiver/drier (Item 1) [Figure 80-20-

3] is the unit that receives the liquid refrigerant from the
condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 80-20-1] extra liquid refrigerant until it is needed by the evaporator.
is the pump that circulates the refrigerant throughout the
system. It raises the pressure of the refrigerant for heat Figure 80-20-4

transfer through the condenser and evaporator.
NOTE: The A/C System (compressor) is

recommended to be turned on for at least 5
minutes weekly throughout the year to
lubricate the internal components.
Figure 80-20-2
Pressure Switch: The pressure switch (Item 1) [Figure

80-20-4] is located on the receiver/drier assembly (Item
2) [Figure 80-20-3]. It will disengage the compressor
clutch if the pressure readings are too low or too high,
which indicates loss of refrigerant.
Condenser: The condenser (Item 1) [Figure 80-20-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.
V518 VersaHANDLER
COMPONENTS (CONT'D) Figure 80-20-7
Identification (Cont'd)
Figure 80-20-5
Fan Switch: This is a three position switch (Item 1)

[Figure 80-20-7]. When the fan switch is in the OFF
position the A/C will not engage.
Evaporator Unit: The evaporator unit (Item 1) [Figure 80-

20-5] is located behind the operator seat inside the cab.
The unit delivers the cold air for the A/C into the cab. The

unit also contains the blower, evaporator coil and
thermostat which are not serviceable.
Figure 80-20-6
Expansion Valve: The expansion valve (Item 1) [Figure

80-20-6] controls the amount of refrigerant entering the
evaporator coil.
V518 VersaHANDLER
SAFETY Figure 80-30-8
Safety Equipment
WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
WARNING In servicing A/C and heater systems you will be exposed

to high pressures, temperatures and several chemical
HFC 134A refrigerant can be dangerous if not hazards. Moving belts and pulleys are normal shop
properly handled. Liquid 134A may cause blindness hazards.
if it contacts the eyes and may cause serious
frostbite if it contacts the skin. In addition to exercising caution in your work, DO WEAR
• Gaseous 134A becomes lethal (phosgene) gas SAFETY GLASSES OR A FACE SHIELD [Figure 80-30-

when it contacts open flame or very hot 8] when you are using R-134a or a leak detector,
substances. adjusting service valves or the manifold gage set
• NEVER SMOKE when there is the possibility of connectors. Safety glasses or a transparent face shield
even small amounts of 134A in the air. are practical safety items and one or the other is
Any servicing work that involves release or addition absolutely required.
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment, Figure 80-30-9
knowledge, and experience to service refrigeration
equipment.
W-2373-0500
R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO 21.6 F DEGREES
"INSTANTLY". If it spills on your skin or in your eyes you
should flood the area with cool water and SEEK
MEDICAL ATTENTION FAST! It is a good idea to wear
gloves [Figure 80-30-9] to prevent frost bite if you should
get refrigerant on your hands.
V518 VersaHANDLER
V518 VersaHANDLER
REGULAR MAINTENANCE Figure 80-40-3
Filter Element Removal And Installation
Figure 80-40-1
Remove the filter (Item 1) [Figure 80-40-3] and backup

screen (Item 2) [Figure 80-40-3].
Figure 80-40-4
Remove the four mount bolts (Item 1) [Figure 80-40-1]
from the fresh air filter cover at the front of the cab.

Figure 80-40-2
The fresh air filter [Figure 80-40-4] is made of open cell

foam and should be cleaned with water. A mild detergent
may also be used.
Remove the three filter mount bolts (Item 1) [Figure 80-

40-2].
V518 VersaHANDLER
REGULAR MAINTENANCE (CONT'D) Cleaning The Condenser
Compressor Drive Belt Inspection Figure 80-40-6
Figure 80-40-5
Open the hood.
It is a good rule to regularly inspect (weekly) the Temporarily remove the air cleaner. (See Housing
compressor drive belt for tension and wear. Removal And Installation on Page 70-40-1.)
Clean the condenser (Item 1) [Figure 80-40-6] using

Open the hood.
water or air pressure.
Remove the drive belt cover.
NOTE: Clean between the oil cooler and condenser.
Check the tension on the compressor belt (Item 1)
[Figure 80-40-5].
V518 VersaHANDLER
BASIC TROUBLESHOOTING Inspect the sight glass located on the receiver/drier for air
bubbles. (See Content Page 80-01.)
Poor A/C Performance
Compressor Drive Belt Inspection
Start the VersaHANDLER, engage the parking brake.
Engage the A/C system with the blower fan on high. Run
the VersaHANDLER at full RPM for approximately 15 Figure 80-50-3
minutes, with the cab door closed.
Figure 80-50-1
Regularly inspect (weekly) the compressor drive belt for

wear.

Figure 80-50-2
Open the hood.
Remove the belt cover.
Check the tension on the compressor belt (Item 1)

[Figure 80-50-3].
Check the temperature at the louvers (Item 1) [Figure

80-50-1] with a thermometer [Figure 80-50-2].
The louver temperature should be between 36-53°.F
(2.2-11,6° C) depending on the amount of humidity in the
air.
If the louver temperature is too high. (See SYSTEM
TROUBLESHOOTING CHART on Page 80-70-1.)
Check the blower fan for proper operation or noise, and

replace if necessary. (See Removal And Installation on
Page 80-150-1.)
Check the belt tension on the A/C compressor. (See

Compressor Drive Belt Inspection on Page 80-40-2.)
Check the A/C condenser for dirt or mud, and clean if

necessary. (See Cleaning The Condenser on Page 80-
40-2.)
V518 VersaHANDLER
BASIC TROUBLESHOOTING (CONT'D) Figure 80-50-6
Checking The Electrical System
Figure 80-50-4
If the compressor clutch does not engage, check the fuse

(Item 1) [Figure 80-50-6]. Replace the fuse if needed.
Figure 80-50-7
Check to see if the compressor clutch (Item 1) [Figure
80-50-4] is engaging.

Turn the ignition key switch to the RUN position without
starting the machine.
Figure 80-50-5
Unplug the connector (Item 1) [Figure 80-50-7] from the

compressor.
Turn the blower fan switch (Item 1) [Figure 80-50-5] to

the first on position, the compressor clutch should make
a click sound, which indicates the clutch is engaging.
V518 VersaHANDLER
Checking The Electrical System (Cont'd)
Figure 80-50-8
Disconnect the machine harness (Item 1) [Figure 80-50-

10] from the pressure switch.
Figure 80-50-11
With a multimeter check the resistance to the
compressor clutch connector (Item 1) [Figure 80-50-8].

If there is no resistance value replace the compressor
clutch. (See Removal And Installation on Page 80-110-
1.)
Figure 80-50-9
With the key switch to the run position (engine off) and
the fan switch on the first position. Use a multimeter to
check the machine harness (Item 1) [Figure 80-50-11]
for voltage.
There should be around 12 volts. If there is no voltage,

check the harness for broken wires.
With a multimeter, check the voltage to the compressor
clutch at the main harness (Item 1) [Figure 80-50-9].
If there is no power at the clutch, check the wiring

harness for broken wires.
If there is no power at the clutch, reconnect the wiring

harness to the compressor clutch.
V518 VersaHANDLER
Figure 80-50-12
Check the main harness (Item 1) [Figure 80-50-14] for

voltage. The voltage should be 12 volts. If there is no
voltage, check the harness for broken wires.
If there is voltage at the harness, check the resistance at Figure 80-50-15

the pressure switch (Item 1) [Figure 80-50-12].

If there is no resistance value, check for a low refrigerant
level. (See Content Page 80-01.)
If good resistance value is observed, the pressure switch

is good.
Reconnect the main harness to the pressure switch.
Figure 80-50-13
If there is voltage at the wiring harness, check the

thermostat wire (green) for resistance. The resistance
value should be 10 ohms at 68° F (20 ° C) [Figure 80-50-
15].
If there is no resistance, replace the entire blower unit.
Disconnect the thermostat wiring connector (Item 1)

V518 VersaHANDLER
Figure 80-50-16
Check the main harness (Item 1) [Figure 80-50-18] for

voltage. The voltage should be 12 volts if there is no
voltage check the harness for broken wires.
Figure 80-50-19
Remove the fuse box cover (Item 1) [Figure 80-50-16].
Figure 80-50-17

If there is voltage at the main harness check the blower
switch [Figure 80-50-19] for resistance.
Disconnect the main wire harness connectors (Item 1) With the switch in the OFF position, there should be zero
[Figure 80-50-17] from the switch. resistance between all terminals.
With the switch in the 1 position, there should be

NOTE: Mark the wires for correct assembly. resistance between C terminal and the B terminal. And
also between the C terminal and the L terminal frame
[Figure 80-50-19].

resistance between C terminal and the B terminal. And
also between the C terminal and the M terminal frame
[Figure 80-50-19].

resistance between C terminal and the B terminal. And
also between the C terminal and the H terminal frame
[Figure 80-50-19].
If any of the above resistance tests fail, replace the

blower switch.
V518 VersaHANDLER
V518 VersaHANDLER
GENERAL AIR CONDITIONING SERVICE Compressor Oil Check
GUIDELINES
The compressor oil should be checked as follows when
Compressor Oil oil is being added to an in service loader.
Figure 80-60-1 There is a close affinity between oil and refrigerant.

During normal operation, part of the oil circulates with the
refrigerant in the system. therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run-in advance to
insure return of oil to the compressor.
If the amount of refrigerant in the system has decreased,

charge the system. (See SYSTEM CHARGING AND
RECLAMATION on Page 80-100-1.)
Open the cab door and windows.
Run the blower at maximum speed.
Run the compressor for at least 20 minutes at 800-1200

RPM.
The compressor (Item 1) [Figure 80-60-1] is factory filled
with 150-170 cc's of PAG oil (Poly Alkelene Glycol). Remove the compressor from the machine. (See

Unlike engine oil, it is not necessary to frequently check
or change the compressor oil.
It is necessary to check, replenish or replace the

compressor oil in the following cases:
1. When the evaporator, condenser or receiver-drier is

replaced.
2. When refrigerant has leaked from the system.
3. When refrigerant is suddenly released from the

cooling cycle.
4. When any related problems occur in the cooling cycle.
When one of the components (the evaporator, condenser

or receiver-drier) is replaced, one ounce (30 cc's) of
PAG oil should be added for each component replaced.
If the A/C compressor is changed, no oil should be added

to the system, because the compressor comes factory
filled with oil.
NOTE: Only PAG oil should be used. Never mix R-12

and R-134a Oils.
V518 VersaHANDLER
GENERAL AIR CONDITIONING SERVICE Figure 80-60-4
GUIDELINES (CONT'D)
Compressor Oil Check (Cont'd)
Figure 80-60-2
NOTE: After draining the oil through the drain hole

and the connectors, extract the remaining oil
through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-60-
4] several times by hand.
Figure 80-60-3
Measure the drained oil in a measuring cylinder.

Check the oil for contamination, dirt, metal shavings, or
varnish color, discard the oil if contaminated.
NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.
Figure 80-60-5
Remove the oil drain plug (Item 1) [Figure 80-60-2] and

drain the oil through the connectors and the oil drain hole
(Item 1) [Figure 80-60-3].
Installation: Tighten the oil drain plug to 9.4-10.8 ft.-lbs.

(13-15 Nm) torque.
Add new compressor oil through the suction side

connector (Item 1) [Figure 80-60-5].
Installation: Add 150-170 cc's of PAG oil.
NOTE: The suction port on the compressor is marked

with an S and is the large port on the
compressor.
V518 VersaHANDLER
GENERAL AIR CONDITIONING SERVICE
GUIDELINES (CONT'D)
Component Replacement And Refrigeration Leaks
Figure 80-60-6
Whenever the A/C system is opened to the atmosphere

or there has been a leak in the system, the receiver/drier

(Item 1) [Figure 80-60-6] must be changed.
Never leave hose fittings, compressor fittings or

components uncapped while working on the A/C system.
V518 VersaHANDLER
V518 VersaHANDLER
SYSTEM TROUBLESHOOTING CHART
Blower motor does not operate
POSSIBLE CAUSE INSPECTION SOLUTION

1. Blown Fuse. Inspect the fuse/wiring. Replace fuse/repair wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or connector.
connection.
3. Fan motor Check the lead wires from the motor with a circuit tester. Replace Evaporator/Blower
malfunction. Unit.
4. Fan motor switch Check power into and out of the fan switch. Replace Fan Switch.
malfunction.
Blower motor operates normally, but air flow is insufficient
Possible Cause Inspection Solution

1. Evaporator inlet Check evaporator for plugging. Remove obstruction and clean
obstruction evaporator fins with air or
water.
2. Defective thermo. Check thermostat using a circuit tester. Replace Evaporator/Blower
switch (frozen unit.

evaporator).
Insufficient cooling although air flow and compressor operation are normal

1. System low on The high side pressure will be low and bubbles may be present Repair any leaks and recharge
refrigerant. in sight glass on receive drier. the refrigerant to the correct
level.
2. Excessive The high pressure side pressure will be high. Use refrigerant recovery
refrigerant. equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
The compressor does not operate at all, or operates improperly

1. Loose drive belt. The belt is vibrating or oscillating. Adjust tension.
2. Internal compressor The compressor is locked up and the belt slips. Replace compressor.
malfunction.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
5. Oil on the clutch Clutch slips. Replace or clean the clutch
surface. surface.
6. Open coil. Clutch does not engage and there is not reading when a circuit Replace clutch.
tester is connected between the coil and terminals.
7. Broken wiring or poor Clutch will not engage. Inspect the ground and connections. Repair.
ground.
8. Wiring harness Test the conductance of the pressure switch, thermostat, Check operation.
components. Relay, etc.
V518 VersaHANDLER
SYSTEM TROUBLESHOOTING CHART (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86-96 degrees F
(30-38 degrees C) and compressor speed of approximately 2000 RPM are:
High pressure side pressure: 210-265 PSI

Low pressure side pressure: 15-33 PSI
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.

Low pressure side The low pressure side pressure normally becomes too high
Too high. when the high pressure side pressure is too high. As this is
explained below, the following inspection is only used when
the low pressure side is too high.
1. Expansion valve Frost is present on the suction hose. Replace expansion valve
opens too far.
2. Defective The high and low pressure side gauge pressures equalize Replace compressor.
compressor when the magnetic clutch is disengaged.
Low pressure side
Too low.
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge present in sight glass on receiver drier. the refrigerant to the correct

level.
2. Clogged or closed The expansion valve's inlet side is frosted. Moisture or other Clean or replace the expansion
expansion valve. Contaminants can be the cause. Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading may be shown.
valve.
4. Thermostat The evaporator is frozen. Replace Evaporator/Blower unit.
malfunction.
High pressure side
Too high.
1. Poor condenser Dirty or clogged condenser fins. Condenser fans not Clean fins, and/or repair the fan.
performance. Operating.
2. Excessive The high pressure side pressure will be high. Use refrigerant recovery
refrigerant. equipment to capture excess
refrigerant. Charge to the correct
refrigerant level.
3. Excessive oil The high pressure side will be high. Evacuate system. Remove oil
charge from condenser and compressor.
Measure oil from compressor and
add correct oil charge back into
compressor. Flush system with
nitrogen. Replace drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
Refrigerant.
5. Restriction in High pressure side will be high, and low pressure side will be Evacuate and flush system
drier,condenser or low. replacing defective parts.
high pressure line.
High pressure side
Too low.
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge. present in sight glass on receiver drier. the refrigerant to the correct
level.
V518 VersaHANDLER
SYSTEM TROUBLESHOOTING CHART (CONT'D)
Gauge Pressure Related Troubleshooting (Cont'd)

System pressures
Equal
1. Clutch not operating See magnetic clutch related topics above.
2. Compressor not Equal high and low pressures. Replace compressor.
pumping.
V518 VersaHANDLER
V518 VersaHANDLER
TEMPERATURE/PRESSURE
NORMAL CONDENSER RANGE
Chart TEMP F. PSIG
93 110.20
NORMAL EVAPORATOR RANGE
94 112.10
TEMP F. PSIG
95 114.10
16 15.69 100 124.30
18 17.04 102 128.50
20 18.43 104 132.90
22 19.87 106 137.30
24 21.35 108 141.90
26 22.88 110 146.50
28 24.47 112 151.30
30 26.10 114 156.10
32 27.79 116 161.10
34 29.52 118 166.10
36 31.32 120 171.30
38 33.17 122 176.60
40 35.07

124 182.00
42 37.03 126 187.50
44 39.05 128 193.10
45 40.09 130 198.90
50 45.48 135 213.70
55 51.27 140 229.40
60 57.47 145 245.80
65 64.10 150 263.00
70 71.19 155 281.10
75 78.75 160 300.10
80 86.80 165 320.10
85 95.40 170 340.80
90 104.40
91 106.30
92 108.20
Evaporator
Pressures represent gas temperatures inside the coil. not the coil surface. For an estimate of the temperature of the air
coming off the coil add 8-10 degrees F. to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 40 degrees F. to the ambient temperature
to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient
temperature.
Conditions and pressures will vary from system to system.
V518 VersaHANDLER
V518 VersaHANDLER
AIR CONDITIONING SERVICE
Chart
Service Company/Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
Explain services required:

Post Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
V518 VersaHANDLER
V518 VersaHANDLER
SYSTEM CHARGING AND RECLAMATION NOTE: This test is run with the loader engine OFF,
and the A/C switch in the OFF position.
Reclamation Procedure
Figure 80-100-3
WARNING
a toxic gas.
W-2371-0500
Figure 80-100-1
NOTE: Before reclaiming a refrigeration system, it is

recommended to identify the type of
refrigerant that is in the A/C system and if it is
pure enough to use. The tool MEL 1592,

Refrigerant Identifier (Item 1) [Figure 80-100-3]
will determine, the kind of refrigerant and any
possible harmful or dangerous substances
that may be present in the system. Thus
preventing mixing of dangerous material with
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems
that are reclaimed and charged from your
Open the hood. MEL 1581 Recovery/Recycling/Recharging
Machine.
80-100-1]. Remove the access cover (Item 2) [Figure Remove the protective cap and connect the refrigerant
80-100-1]. identifier to the low pressure hose (Item 1) [Figure 80-
100-2].
Figure 80-100-2
Connect the refrigerant identifier to its power source.
Locate the low pressure port (Item 1) [Figure 80-100-2]

and high pressure port (Item 2) [Figure 80-100-2] on the
back side of the compressor.
V518 VersaHANDLER
SYSTEM CHARGING AND RECLAMATION (CONT'D)
Reclamation Procedure (Cont'd)

WARNING
Figure 80-100-4
HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious
frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
equipment.
W-2373-0500
Follow the steps displayed on the refrigerant identifier Figure 80-100-5

screen [Figure 80-100-4].

Allow two minutes for the refrigerant identifier to display
the type of refrigerant and air content. An alarm will
sound if potentially flammable hydrocarbons are present
and will also indicate on the visual display.
Disconnect the refrigerant identifier from the loader A/C.
If the refrigerant is dangerous or flammable, it must be

evacuated from the A/C system into a separate container
and properly and safety disposed of.
If R134a is found, evacuate the system.
Important: Only A/C trained technicians should

perform the reclaiming and recharging Use an approved recovery/charging unit [Figure 80-100-
procedure. 5] to evacuate the system.
Connect the reclaimer to the loader A/C charge ports.
V518 VersaHANDLER
SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-100-8
Reclamation Procedure (Cont'd)
Figure 80-100-6
NOTE: The reclaimer unit, has a complete step by

step set of instructions [Figure 80-100-8] to
follow for reclamation and recharging of the
A/C system. a trained technician should
Connect the Red hose (Item 1) [Figure 80-100-6] to the follow these instructions as they may very
high pressure port and open the valve. slightly depending on the model and brand of
reclaimer used.

Connect the Blue hose (Item 2) [Figure 80-100-6] to the
low pressure port and open the valve.
Figure 80-100-7
Turn the reclaimer unit [Figure 80-100-7] to the ON

position and follow the on screen instructions.
V518 VersaHANDLER
Charging Procedure With A Manifold Gauge Set
WARNING
a toxic gas.
W-2371-0500
Figure 80-100-9
Connect the Red hose (Item 1) [Figure 80-100-10] to the

high pressure port and open the valve.
Connect the Blue hose (Item 2) [Figure 80-100-10] to the

low pressure port and open the valve.
Figure 80-100-11

Open the hood.
Check to see that the hand valves (Item 1) [Figure 80-

100-9] are closed on the manifold gauge set.
If there is any refrigerant in the A/C system, it must be

recovered by an approved A/C reclamation procedure.
(See Reclamation Procedure on Page 80-100-1.)
Connect the Yellow hose (Item 1) [Figure 80-100-11] to
Connect the gauges to the loader A/C charge ports. the vacuum pump.
V518 VersaHANDLER
SYSTEM CHARGING AND RECLAMATION (CONT'D)
Charging Procedure With A Manifold Gauge Set

(Cont’d)
Figure 80-100-12
Start the vacuum pump and open ISO-valve (Item 1)

[Figure 80-100-12] on the vacuum pump.

Run the vacuum pump for at least 5-10 minutes to insure
that a vacuum has been pulled on the system.
Close the ISO-valve (Item 1) [Figure 80-100-12] (which

isolates the vacuum pump from the A/C system) and turn
OFF the vacuum pump.
V518 VersaHANDLER
SYSTEM CHARGING AND RECLAMATION (CONT'D) Be sure that both hand valves, and both charge port
valves are open.
Charging Procedure
Run the vacuum pump for at least 45 minutes to insure
Figure 80-100-13 that all the moisture is boiled out of the system.
Stop the vacuum pump and close the ISO-valve on the

vacuum pump.
Close both hand valves on the manifold gauge set and

remove the yellow hose from the vacuum pump that goes
to the manifold gauge set.
Remove the vacuum pump and thermistor vacuum

gauge.
Figure 80-100-15
Note vacuum pressure indicated on the low pressure

(Blue) gauge (Item 1) [Figure 80-100-13]. Let stand for
5-10 minutes and recheck the pressure for changes.

If the pressure drops, this may be an indication of a leak
in the A/C system.
Determine the problem with the A/C system and repair it.
Figure 80-100-14
Place a refrigerant container with R134a (Item 1) [Figure

80-100-15] on a charging scale (Item 2) [Figure 80-100-
15] and zero out the scale.
Connect the yellow hose (Item 3) [Figure 80-100-15]

from the manifold gauge set to the valve on the
refrigerant tank.
A thermistor vacuum gauge (Item 1) [Figure 80-100-14]

can be used to determine the critical vacuum level during
evacuation. It is a solid state instrument that constantly
monitors and visually indicates the vacuum level.
The thermistor vacuum gauge is used with the vacuum

pump [Figure 80-100-14].
Start the vacuum pump and open ISO-valve on the

vacuum pump.
V518 VersaHANDLER
Charging Procedure (Cont'd)
Figure 80-100-16
Turn the A/C fan switch (Item 1) [Figure 80-100-17] to

HIGH position.
Start the machine, and run at medium speed.

Open the valve on the refrigerant container (Item 1)
[Figure 80-100-16] and open the low pressure hand Watch the scale and run system until the predetermined
valve (Blue) (Item 2) [Figure 80-100-16] on the manifold amount of refrigerant is added to the A/C system.

gauge set. Allow the vacuum to pull in the refrigerant until
the pressure stabilizes. The A/C system holds 1.76 lbs (0,800 Kg) of refrigerant.
Turn off the valve on the refrigerant container, and hand

valves on the manifold gauge set.
Turn off the engine and remove the A/C charging

equipment from the machine.
Install access cover.
Close the hood.
V518 VersaHANDLER
V518 VersaHANDLER
COMPRESSOR

WARNING
Evacuate the A/C system. (See Reclamation Procedure
on Page 80-100-1.) In the event of a leakage, wear safety goggles.
Remove the alternator. (See Removal And Installation on eyes. In contact with a flame, R134a refrigerant gives
Page 60-30-1.) a toxic gas.
W-2371-0500
Remove the compressor belt.
Figure 80-110-3
Figure 80-110-1

Remove the compressor hoses (Item 1) [Figure 80-110-
Remove the two tensioner pulley mount belts (Item 1)
3].
[Figure 80-110-1]. Remove the pulley assembly.
Installation: Tighten the hoses to 22 ft.-lbs. (29,8 Nm)
Figure 80-110-2
torque.
Cap and plug the hoses and fittings with the proper A/C
caps and plugs.
Figure 80-110-4
Unplug the connector (Item 1) [Figure 80-110-2] from the

compressor.
Mark the compressor hoses for correct installation.
Remove the mount bolts (Item 1) [Figure 80-110-4].
Remove the compressor.
V518 VersaHANDLER
COMPRESSOR (CONT'D) Figure 80-110-7
Compressor Clutch Disassembly
Figure 80-110-5
The armature plate puller (Item 1) [Figure 80-110-7] can

be constructed by drilling three 8 mm holes in a flat
circular plate, located 1.25 inches apart.
Remove the center armature nut (Item 1) [Figure 80- Figure 80-110-8
110-5].

Installation: Tighten the armature nut to 8 ft.-lbs. (12
Nm).
Figure 80-110-6
Attach the armature puller plate (Item 1) [Figure 80-110-

8] to the armature plate using the three bolts (Item 2)
[Figure 80-110-8].
To remove the armature plate (Item 1) [Figure 80-110-6]

from the clutch face you must make an armature plate
puller.
V518 VersaHANDLER
Compressor Clutch Disassembly (Cont'd)
Figure 80-110-9

the pulley assembly.
Figure 80-110-12
Attach a slide hammer puller to the armature puller tool
[Figure 80-110-9].

Figure 80-110-10
Remove the pulley from the compressor [Figure 80-110-

12].
Remove the armature plate (Item 1) [Figure 80-110-10]

from the compressor clutch.
Remove the shims (Item 2) [Figure 80-110-10] from the

armature shaft or armature plate.
Installation: Insure that the clutch has the correct

clearance by adding the shims (Item 2) [Figure 80-110-
10].
The specified clearance for the clutch is 0.01-0.02 in.

(0.3-0.6 mm) adjusting shims are available in the
following thicknesses.
0.0039 in. (0.1 mm)

0.0118 in. (0.3 mm)
0.0197 in. ().5 mm)
V518 VersaHANDLER
Figure 80-110-13
Remove the harness retainer screw assembly (Item 1)

[Figure 80-110-15].
Figure 80-110-16
The pulley assembly and bearing [Figure 80-110-13]
must be replaced as a complete unit.

Figure 80-110-14

the coil.
Remove the lock (Item 1) [Figure 80-110-14] and

connector (Item 2) [Figure 80-110-14] from the
compressor harness.
V518 VersaHANDLER
COMPRESSOR (CONT'D)
Figure 80-110-17
Remove the coil from the compressor [Figure 80-110-

17].

Figure 80-110-18
The compressor [Figure 80-110-18] must be replaced as

a complete unit.
V518 VersaHANDLER
V518 VersaHANDLER
CONDENSER Figure 80-120-2

Remove the air cleaner. (See Housing Removal And

Remove the receiver/drier. (See Removal And

WARNING
Escaping refrigerant can cause severe injuries to Remove the A/C hose (Item 1) [Figure 80-120-2] from
eyes. In contact with a flame, R134a refrigerant gives the condenser.
a toxic gas.
W-2371-0500 Figure 80-120-3
Figure 80-120-1

Remove the two nuts (Item 1) [Figure 80-120-3] from
each side of the condenser.
Remove the hose (Item 1) [Figure 80-120-1] from the oil Figure 80-120-4
cooler.
NOTE: Install caps and plugs on all fittings.
Remove the condenser [Figure 80-120-4].
V518 VersaHANDLER
V518 VersaHANDLER
RECEIVER/DRIER Figure 80-130-2
Open The Hood

Remove the air cleaner. (See Housing Removal And

WARNING
Escaping refrigerant can cause severe injuries to Remove the two hoses (Item 1) [Figure 80-130-2] from
eyes. In contact with a flame, R134a refrigerant gives the Receiver/Drier.
a toxic gas.
W-2371-0500 NOTE: Mark the hoses for correct installation.
Figure 80-130-1 NOTE: Install caps and plugs on all fittings.

Figure 80-130-3
NOTE: Locate the sight glass (Item 2) [Figure 80-130-

1].
Loosen the bolt (Item 1) [Figure 80-130-3] on the
Unplug the connector (Item 1) [Figure 80-130-1] from mounting bracket.
the pressure switch.
V518 VersaHANDLER
RECEIVER/DRIER (CONT'D) Figure 80-130-5
Figure 80-130-4
Remove the two mounting bracket bolts (Item 1) [Figure

80-130-5].
Remove the mounting bracket.

Lift and remove the Receiver/Drier unit [Figure 80-130-
4].
V518 VersaHANDLER
PRESSURE SWITCH Remove the pressure relief switch (Item 1) [Figure 80-
140-2] from the Receiver/Drier assembly.
WARNING
a toxic gas.
W-2371-0500
Figure 80-140-1

Open the hood.

Unplug the connector (Item 1) [Figure 80-140-1] from

the pressure relief switch (Item 2) [Figure 80-140-1].
Figure 80-140-2
V518 VersaHANDLER
V518 VersaHANDLER
EVAPORATOR/BLOWER UNIT Figure 80-150-3
WARNING
a toxic gas.
W-2371-0500
Figure 80-150-1
Temporarily remove the covering (Item 1) [Figure 80-

150-3] from the A/C hoses and expansion valve.
Figure 80-150-4

Figure 80-150-2 Remove the bolt (Item 1) [Figure 80-150-4] and plate
(Item 2) [Figure 80-150-4]. Remove both A/C hoses.
V518 VersaHANDLER
EVAPORATOR/BLOWER UNIT (CONT'D) Figure 80-150-3
Figure 80-150-1
Remove the front mounting bolt (Item 1) [Figure 80-150-

3].
Lay the evaporator/blower unit on the seat.

Unplug the thermostat wiring connector (Item 1) [Figure
80-150-1]. Figure 80-150-4

Figure 80-150-2
Remove the drain hose (Item 1) [Figure 80-150-4].
Remove the three mount bolts (Item 1) [Figure 80-150-2] Remove the evaporator/blower unit from the machine.
and ground wire (Item 2) [Figure 80-150-2] from the
back of the evaporator unit.
V518 VersaHANDLER
EXPANSION VALVE Figure 80-160-3
WARNING
a toxic gas.
W-2371-0500
Figure 80-160-1
Temporarily remove the covering (Item 1) [Figure 80-

160-3] from the A/C hoses and expansion valve.
Figure 80-160-4

Figure 80-160-2 Remove the bolt (Item 1) [Figure 80-160-4] and plate
(Item 2) [Figure 80-160-4]. Remove both A/C hoses.
V518 VersaHANDLER
EXPANSION VALVE (CONT'D) Figure 80-160-6
Figure 80-160-5
The expansion valve (Item 1) [Figure 80-160-6] is

replaced as a complete unit.
Remove the two mount bolts (Item 1) [Figure 80-160-5].
Remove the expansion valve.
V518 VersaHANDLER
HEATER ASSEMBLY Figure 80-170-3
Remove the travel/signal levers. (See Removal And



on Page 60-90-1.)

Figure 80-170-1
Clamp the heater hoses [Figure 80-170-3].
Figure 80-170-4

Unplug the connector (Item 1) [Figure 80-170-1].
Figure 80-170-2
Remove the heater hoses (Item 1) [Figure 80-170-4]

from the heater assembly.
Remove the vent hoses (Item 1) [Figure 80-170-2] from

the top of the assembly.
V518 VersaHANDLER
HEATER ASSEMBLY (CONT'D) Figure 80-170-7
Figure 80-170-5
Remove the blower fan mounting bolts (Item 1) [Figure

80-170-7] and remove the blower fan.
Core Removal And Installation

and remove the heater assembly. Figure 80-170-8

Fan Removal And Installation
Figure 80-170-6
Remove the two flange mounting nuts (Item 1) [Figure

80-170-8].
Carefully remove the clip (Item 1) [Figure 80-170-6] and

cable (Item 2) [Figure 80-170-6].
V518 VersaHANDLER
Figure 80-170-9
Remove the four screws (Item 1) [Figure 80-170-11]

from the vent bracket.
Figure 80-170-12
Remove the flange/linkage assembly (Item 1) [Figure
80-170-9] from assembly.

Figure 80-170-10
Remove the end bracket (Item 1) [Figure 80-170-12] and

spacer (Item 2) [Figure 80-170-12] from the assembly.

save for later use.
V518 VersaHANDLER
Figure 80-170-13
Slide the core from the housing [Figure 80-170-14].
Be sure to separate the bracket (Item 1) [Figure 80-170-

13] and tab (Item 2) [Figure 80-170-13].
V518 VersaHANDLER
SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-70-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . SPEC-70-1
U.S. To Metric Conversion. . . . . . . . . . . . . . . . . . . . . . SPEC-70-2
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1

Camshaft And Thrust Washer . . . . . . . . . . . . . . . . . . . SPEC-20-6
Connecting Rods And Bearings. . . . . . . . . . . . . . . . . . SPEC-20-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Crankshaft Re-Grind Data . . . . . . . . . . . . . . . . . . . . . . SPEC-20-5
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-7
Engine Torque Component . . . . . . . . . . . . . . . . . . . . SPEC-20-11
Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-9
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-7
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-7
Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-7

Intake Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6
Oil Pump, Gear And Relief Valve. . . . . . . . . . . . . . . . . SPEC-20-9
Pistons And Piston Rings. . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Rocker Shaft, Rockers And Bushings . . . . . . . . . . . . . SPEC-20-3
Thrust Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6
Timing Case And Timing Gears. . . . . . . . . . . . . . . . . . SPEC-20-8
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-9
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Valve Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Water Pump And Thermostat . . . . . . . . . . . . . . . . . . SPEC-20-10
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . SPEC-50-1

Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-2
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . SPEC-50-1
O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-3
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-5
Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . SPEC-50-1
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS SPEC-60-1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
LOADER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
V518 VersaHANDLER
689 of 724 SPEC-01 Service Manual
SPECIFICATIONS (CONT’D)
TORQUE SPECIFICATIONS FOR BOLTS. . . . . . . . . . . . SPEC-40-1

Torque For General Metric Bolts . . . . . . . . . . . . . . . . . SPEC-40-2
Torque for General SAE Bolts . . . . . . . . . . . . . . . . . . . SPEC-40-1
VERSAHANDLER SPECIFICATIONS . . . . . . . . . . . . . . . SPEC-10-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Performance Specifications . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
V518 VersaHANDLER
690 of 724 SPEC-02 Service Manual
VERSAHANDLER SPECIFICATIONS
Each attachment and each VersaHANDLER TTC have different Load

Capacity Charts. For example: An 84 inch bucket used on a V518 will have
WARNING its own chart; that same 84 inch bucket when used on a V623 will have a
different chart. Be sure you use the correct chart for your attachment and
VersaHANDLER TTC combination. W-2395-0301
• All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
• Where applicable, specifications conform to SAE, ASME or ISO standards and are subject to change without notice.
Dimensional Specifications

Performance Specifications Controls
Operating Weight 10846 lbs. (4920 kg) Steering Steering Wheel w/ 3 Mode
Maximum Rated Capacity *5500 lbs. (2495 kg) *6500 Selections (2-Wheel, 4-Wheel)
lbs. (2948 kg) Hydraulics Joystick w/ switches
Auxiliary Hydraulics Electrical Switches on Joystick
* Rated Load Capacity can change depending on which
Parking Brake Hand Operated Lever
approved attachment is used.
Engine
Mak/Model PERKINS 1004-40T

(Turbocharged)
Fuel/Cooling Diesel/Liquid
Horsepower (SAE net) 105 HP (79 kW)
Number of Cylinders Four
Lubrication Pressure System W/Filter
Air Cleaner Dry replaceable cartridge w/
safety element
V518 VersaHANDLER
691 of 724 SPEC-10-1 Service Manual
VERSAHANDLER SPECIFICATIONS (CONT’D)
Drive System
Main Drive Hydrostatic 4 wheel drive

Transmission Infinitely variable hydrostatic piston
pump, driving 1 fully reversing
hydrostatic motor
Final Drive Front Differential w/ reduction gearbox,
Rear Differential, Planetary Axles with
Oil Lubrication
Travel Speed
Low Range 0-4.7 mph (7,6 km/hr.)
High Range 0-18.4 mph (29,6 km/hr)
Tires
Standard Tires Dunlop 400/70x20-44 PSI (3 BAR)
Hydraulic System
Hydraulic Pump Engine driven, 24 GPM (91 L/min)

Hydraulic Pressure 3191 PSI (220 BAR)
Electrical System
Alternator 12-Volt, 90 amp open, neg. ground

Battery 12 Volt - 900 CCA @ 0° F (-18° C)
Instrument Panel
Full compliment of instrumentation for engine, hydraulic

and vehicle functions.
Capacities
Fuel Tank 31.7 gals. (120 L) Type:

Diesel #2 or #1
Eng. Cooling 19 qts. (17 L) Antifreeze mixture
System Premix 50%
Ethylene Glycol /
50% Water
Engine Oil Chage 7 qts (6,5 L)
w/ Filter
Hyd./Hydros. 19 gals. (72 L)
System
Front Axle 11.1 qts (10,5 L)
Rear Axle 11 qts. (10 L)
Front Reduction 0.85 qts. (0,8 L)
Gearbox
V518 VersaHANDLER
ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
General
Number Of Cylinders 4
Cylinder Arrangement In-line
Cycle 4 Stroke
Direction Of Rotation Clockwise From The Front
Intake System Turbocharged
Combustion System Direct Injection
Nominal Bore 3.937 (100)
Stroke 5.000 (127)
Compression Ratio 17.25:1
Displacement 243 C.I. (4 liters)
Firing Order 1-3-4-2
Cylinder Head

Head Thickness 4.047 - 4.078 (102,8 - 103,6)
Head Thickness After Machining (Minimum) 4.035 (102,5)
Leak Test Pressure 29 PSI (200 kPa)
Valve Guides
Inside Diameter 0.3744-0.3764 (9,51-9,56)

Outside Diameter 0.6260-0.6264 (15,90-15,91)
Valve Guide Bore 0.6248-0.6256 (15,87-15,89)
Valve Guide Clearance In The Cylinder Head 0.0018-0.0027 (0,047-0,007)
(Interference)
Overall Length:
Intake 2.281 (57,94)
Exhaust 2.406 (61,10)
Protrusion From Bottom 0.585-0.596 (14,85-15,15)
V518 VersaHANDLER
ENGINE SPECIFICATIONS (CONT'D)
parentheses.
Exhaust Valves
Valve Stem Diameter 0.3515-0.3 528(8,93-8,96)

Valve Guide Clearance 0.0016-0.0033 (0,040-0,84)
Maximum 0.0041 (0,104)
Valve Head Diameter 1.609-1.619 (40,88-41,12)
Valve Face Angle 45°
Overall Length 4.829-4.854 (122,66-123,30)
Seal Type Positive
Valve Clearance 0.018 (0,45)
Exhaust Depth (Production) 0.055-0.067 (1,40-1,70)
Exhaust Depth (Service) 0.077 (1,95)
Intake Valves

Valve Stem Diameter 0.3525-0.3535 (8,95-8,98)
Valve Guide Clearance 0.0010-0.0027 (0,025-0,069)
Maximum 0.005 (0,13)
Valve Head Diameter 1.688-1.698 (42,88-43,12)
Valve Face Angle 45°
Overall Length 4.829-4.854 (122,66-123,30)
Seal Type Positive
Valve Clearance 0.008 (0,20)
Intake Depth (Production) 0.050-0.068 (1,27-1,60)
Intake Depth (Service) 0.077 (1,85)
Valve Springs
Double Valve Springs (Outer)

Installed Height 1.41 (35,8)
Installed Height Pressure 39.5-43.7 lbs. (176-195 N)
Double Valve Springs (Inner)
Installed Height 1.34 (34,0)
Installed Height Pressure 20-23 lbs. (89-104 N)
V518 VersaHANDLER
parentheses.
Rocker Shaft, Rockers And Bushings
Shaft Outside Diameter 0.748-0.750(19,01-19,04 )

Rocker Arm Bushing Bore Diameter 0.875-0.876 (22,23-22,26 )
Outside Diameter of the Bushing 0.877-0.8783(22,28-22,31 )
Rocker Arm Bushing Clearance 0.0008-0.0035 (0,020-0,089 )
Inside Diameter of Reamed Rocker Bushing 0.750-0.752 (19,06-19,10)
Clearance Between Rocker Arm Bushing and Shaft 0.001-0.0035 (0,03-0,09)
Maximum 0.005 (0,13)
Pistons And Piston Rings
Type Fastram combustion bowl inserted top ring groove,

graphite skirt
Piston Pin Bore Diameter 1.5001-1.5004 (38,103-38,109 )
Piston Projection Above the Block Deck 0.006-0.014 (0,14-0,36)

Top Ring Groove Width Tapered
Second Ring Groove Width 0.1008-0.1016 (2,56-2,58)
Third Ring Groove Width 0.1591-0.1598 (4,04-4,06)
Top Ring Barrel Face, Molybdenum insert, Wedge
Second Ring Taper Face, Cast Iron, Outside Bottom Step
Oil Control Ring Coil Spring Loaded, Chromium Face
Top Ring Width Tapered
Second Ring Width 0.097-0.098 (2,48-2,49)
Third Ring Width 0.1366-0.1374 (3,47-3,49)
Top Ring Side Clearance Wedge
Second Ring Side Clearance 0.003-0.004 (0,07-0,10)
Third Ring Side Clearance 0.002-0.003 (0,05-0,07)
Top Ring End Gap 0.011-0.025 (0,28-0,63)
Top Ring End Gap (With Internal Step) 0.014-0.028 (0,35-0,70)
Second Ring End Gap 0.012-0.030 (0,30-0,76)
Second Ring End Gap (With External Step) 0.016-0.034 (0,40-0,85)
Third Ring End Gap 0.010-0.031 (0,25-0,75)
Piston Pin Type Full Floating
Piston Pin Outside Diameter 1.5628-1.5630 (39,694-39,700)
Piston Boss Clearance 0.0001-0.0006 (0,003-0,015)
Bushing Type Steel Back, Lead Bronze Tin Bearing Material
Bushing Outside Diameter 1.6972-1.6988 (43,11-43,15)
Bushing Inside Diameter (Reamed) 1.5638-1.5645 (39,723-39,738)
Piston Pin Bushing Clearance 0.0009-0.0017 (0,023-0,044)
V518 VersaHANDLER
parentheses.
Connecting Rods And Bearings
Connecting Rod Type H Section, Wedge Shape Small End

Connecting Rod Cap Location Flat joint face with dowels
Crank Pin End Diameter 2.6460-2.6465 (67,21-67,22 )
Piston Pin End 1.656-1.657 (42,07-42,09)
Length Between Centers 8.624-8.626 (219,05-219,10)
Bearing Type Steel Back, Lead Bronze Bearing Material with Lead Finish
Bearing Width 1.242-1.255 (31,55-31,88)
Bearing Thickness At The Center 0.0723-0.0726 (1,835-1,844)
Bearing Clearance 0.0012-0.0032 (0,03-0,081)
Bearing Undersize Available -0.010 (-0,25), -0.020 (-0,51), -0.030 (-0,76)
Crankshaft
Main Journals 2.998-2.999 (76,16-76,18)

Maximum Wear And Out Of Round Of The Journals And 0.0016 (0,04)
Crank Pins
Width Of Front Journal 1.454-1.484 (36,93-37,69)
Width Of Center Journal 1.738-1.741 (44,15-44,22)
Width Of Other Journals 1.545-1.549 (39,24-39,35)
Crank Pin Diameters 2.499-2.500 (63,47-63,49)
Width Of Crank Pins 1.589-1.591 (40,35-40,42)
Crankshaft End Play 0.00075 (0,019)
Thrust Washer Thickness: Std. 0.090-0.091 (2,26-2,31)
Oversize 0.096-0.098 (2,24-2,50)
Main Bearing Oil Clearance 0.0022-0.0046 (0,057-0,117)
V518 VersaHANDLER
parentheses.
Crankshaft (Cont'd)
Undersize Journals And Crank Pins 0.010 (0,25), 0.020 (0,51), 0.030 (0,76)
With the crankshaft on V-blocks check the maximum run-out of the journals. They must not exceed these specifications
below and the difference in run-out between journals must not exceed 0.004 (0,10)
Journal #1 Mounting
Journal #2 0.003 (0,08)
Journal #3 0.006 (0,15)
Journal #4 0.003 (0,08)
Journal #5 Mounting
Crankshaft Re-Grind Data

The finished sizes for crankshaft journals which have been ground undersize are given in the table below:
ITEM 0.010 (0,25) 0.020 (0,51) 0.030 (0,76)

1 2.9884-2.9892 2.9784-2.96792 2.9684-2.9692
(75.905-75.926) (75,651-75,672) (75,397-75,418)
2 2.488-2.4896 2.4788-2.4796 2.4688-2.4696
(63,216-63,236) (62,962-62,982) (62,708-62,728)
3 1.554 (39,47) maximum - -
4 1.489 (37,82) maximum - -
5 1.759 (44,68) maximum - -
6 1.596 (40,55) maximum - -
7 5.243 (133,17) maximum - -
8 Do not machine this diameter - -
9 0.145-0.156 (3,68-3,96) - -
Crankshaft Heat Treatment: 60 Hour Nitride
NOTE: Crankshafts that have been nitrided for 60 hours can be machined 0.010 (0,25) without the need to harden
again. Check the crankshaft for cracks before and after machining. Demagnetize the crankshaft after it
has been checked for cracks. Remove any sharp corners from the oil holes. Surface finish and fillet radii
must be maintained.
V518 VersaHANDLER
parentheses.
Main Bearings
Type Steel Back, 20% Tin Aluminium

Center Bearing Width 1.430-1.445 (36,32-36,70)
All Others 1.245-1.255 (31,62-31,88)
Bearing Thickness (center) 0.0820-0.0823 (2,083-2,089)
Bearing Clearance 0.0022-0.0046 (0,057-0,117)
Thrust Washers
Type Steel back, Lead Bronze

Position Each Side Of Center Main Bearing
Standard 0.089-0.091 (2,26-2,31 )
Oversize 0.096-0.098 (2,45-2,50 )
Camshaft And Thrust Washer

Journal #1 Diameter 1.997-1.998 (50,71-50,74)
Clearance On All Journals 0.0024-0.0055 (0,06-0,14)
Cam Lift (Intake) 0.2999-0.3027 (7,62-7,69)
Cam Lift (Exhaust) 0.3035-0.3066 (7,71-7,79)
Maximum Wear And Out Of Round 0.002 (0,05)
Camshaft End Play 0.004-0.016 (0,10-0,41)
Service Limits 0.021 (0,53)
Thrust Washer Type 360°
Thrust Washer Thickness 0.216-0.218 (5,49-5,54)
Thrust Washer Recess Depth 0.215-0.218 (5,46-5,54)
Bore #1 2.187-2.189 (55,56-55,59)
Bore #2 1.990-1.992 (50,55-50,60)
Bore #3 1.970-1.972 (50,04-50,09)
Cylinder Block
Cylinder Bore Diameter 4.103-4.104 (104,20-104,23 )

Cylinder Liner Flange Recess 0.150-0.154 (3.81-3.91)
Cylinder Liner Flange Recess Diameter 4.245-4.250 (107,82-107,95)
Main Bearing Bore Diameter 3.166-3.167 (80,416-80,442)
V518 VersaHANDLER
parentheses.
Cylinder Liners
Production Dry, Interference Fit, Flanged, With Flame Ring

Service Dry, Interference Fit, Flanged, With Flame Ring
Production Liner Outside Diameter 4.105-4.106 (104,25-104,28)
Production Liner Clearance 0.001-0.003 (0,03-0,08)
Production Liner Inside Diameter 3.937-3.938 (100,00-100,03)
Service Liner Clearance ±0.001 ( ±0,03)
Inside Diameter Of Service Liner With Flame Ring 3.937-3.961 (100,0-100,63)
(Installed)
Maximum 0.010 (0,25)
Flange Thickness 0.150-0.152 (3,81-3,86)
Liner Projection From Deck Surface 0.004 (0,10) Above or 0.004 (0,10) Below
Hose Angle 30/35°
Piston Cooling Jets 20 ft.lbs. (27 Nm)

Fuel Injection Pump
Type Stanadyne DB4, Pin Timed

Number 1 Cylinder Outlet 8 O'clock Position Viewed From The Rear
Rotation From Drive End Clockwise
Fuel System Self Vent
Fuel Injectors
Working Pressure 4263 PSI (29393 kPa)
Fuel Lift Pump
Type A.C. Delco, Type XD

Method of Drive Camshaft
Standard Pressure 6-10 PSI (42-70 kPa)
Minimum Pressure 3.75 PSI (25 kPa)
V518 VersaHANDLER
parentheses.
Timing Case And Timing Gears
Camshaft Gear Number Of Teeth 56

Camshaft Gear Bore Diameter 1.375-1.376 (34,93-34,95)
Camshaft Hub Outside Diameter 1.374-1.375 (34,90-34,92)
Camshaft Gear Hub Gear Clearance 0.0003-0.0019 (0,008-0,048)
Fuel Pump Gear Number Of Teeth 56
Fuel Pump Gear Bore 1.417-1.420 (36,00-36,06)
Crankshaft Gear Number Of Teeth 28
Crankshaft Gear Bore Diameter 1.875-1.8760 (47,625-47,650)
Crankshaft Gear Hub Diameter 1.875-1.8758 (47,625-47,645)
Crankshaft Gear Clearance -0.0008 - +0.0010 (-0,020 - +0,048)
Idler Gear Number Of Teeth 63
Idler Gear Bore Diameter 2.250-2.251 (57,14-57,18)
(With Needle Bearings) 2.717-2.718 (69,01-69,03)

Width Of Idler Gear And Bushing Assembly 1.186-1.187 (30,14-30,16)
Flanged Bushing Inside Diameter 1.999-2.000 (50,78-50,80)
Idler Gear Hub Outside Diameter 1.996-1.998 (50,70-50,74)
Idler Gear Hub Bushing Clearance 0.0016-0.0039 (0,04-0,10)
Gear End Play 0.004-0.008 (0,10-0,20)
Service Limit 0.015 (0,38)
Backlash For All Gears 0.003 (0,08) Minimum
V518 VersaHANDLER
parentheses.
Oil Pump, Gear And Relief Valve
Type of Oil Pump Gear Driven, Differential Rotor

Number Of Lobes Inner 6, Outer 7
Clearance Of Outer Rotor To Body 0.006-0.013 (0,15-0,34)
Inner To Outer Rotor Clearance 0.0015-0.0050 (0,04-0,13)
End Play 0.001-0.004 (0,03-0,10)
Oil Pump Idler Gear Bushing I.D. 0.875-0.876 (22,23-22,26)
Idler Shaft O.D. 0.873-0.874 (22,19-22,21)
Idler Gear Shaft Bushing Clearance 0.0008-0.0026 (0,020-0,066)
Oil Pump Idler Gear End Play 0.0005-0.0253 (0,012-0,643)
Relief Valve Plunger Bore Diameter 0.718-0.719 (18,24-18,27)
Relief Valve Plunger Outside Diameter 0.715-0.716 (18,16-18,18)
Clearance 0.002-0.004 (0,06-0,11)
Length Of The Spring (Installed) 2.35 (59,8)

Load On The Spring (Installed) 3.6-5.2 PSI (15,9-23,1 Nm)
Pressure To Open Pressure Relief Valve 60-68 PSI (415-470 kPa)
Oil Filter Type Full Flow Screw-on Type Canister
Pressure To Open By-pass Valve In Oil Filter 8-12 PSI (55-83 kPa)
Pressure To Open By-pass Valve In Oil Cooler 25 PSI (172 kPa)
Minimum Engine Oil Pressure At Maximum Speed 40 PSI (280 kPa)
Oil Pump Gear and Idler Gear Backlash 0.003 (0,076)
Turbocharger
Type Garrett T20
Flywheel
Run-Out Less than 0.012 (0,30)

Misalignment 0.008 (0,203) @ 8 (203)
V518 VersaHANDLER
parentheses.
Water Pump And Thermostat
Type Centrifugal, Gear Drive

Shaft Outside Diameter 0.746-0.747 (18,95-18,96)
Drive Gear Bore Diameter 0.744-0.750 (18,90-18,92)
Drive Gear Shaft Clearance 0.0012-0.0024 (0,03-0,06)
Impeller Bore Diameter 0.625-0.626 (15,87-15,89)
Impeller Shaft Outside Diameter 0.626-0.627 (15,91-15,92)
Impeller Clearance On Shaft 0.0007-0.002 (0,02-0,05)
Bearing Bore Diameter 1.498-1.499 (38,06-38,08)
Bearing Diameter 1.499-1.500 (38,09-38,10)
Bearing Clearance In Pump Body 0.0004-0.0016 (0,01-0,04)
Thermostat Type Wax Pellet, By-pass Blanking
NOMINAL TEMPERATURE

STAMPED ON START TO OPEN FULLY OPEN MINIMUM VALVE LIFT,
THERMOSTAT BY-PASS TEMPERATURE TEMPERATURE FULLY OPEN
VALVE
180° F (82° C) 170°/185° F (77°/85° C) 198°/208° F (92°/98° C) 0.35 (9,0)
160° F (71° C) 153°/167° F (67°/75° C) 185°/190° F (85°/88° C) 0.35 (9,0)
V518 VersaHANDLER
Engine Torque Component
COMPONENT FT.-LBS. NM
Bridge Piece To Block 12 16
Camshaft Gear Bolt 58 78
Camshaft Gear Bolts (45 mm long) 74 100
Connecting Rod Nuts
Step 1 45 61
Final 92 125
Crank Pulley Bolts 85 115
Cylinder Head Bolt
Step One 80 108
Step Two - Short Bolts 150°
Step Two - Medium Bolts 180°
Step Two - Large Bolts 210°
Engine Mounting Bridge To Frame 200 271
Exhaust Manifold Nuts 24 33
Flywheel Cover To Housing 45 61
Flywheel Housing To Cylinder Block 52 70
Flywheel To Crankshaft Bolts 77 105
Fuel Injector Nut 23 30

Fuel Injection Pump Gear Mounting Bolts 20 28
Fuel Injection Pump Gear Nut 59 80
Fuel Injection Pump Flange Nuts 16 22
Fuel Lift Pump Bolts 16 22
High Pressure Fuel Lines Fittings 16 22
Idler Gear Hub Bolts 33 44
Intake Manifold Bolts 24 33
Main Bearing Bolts
Step 1 65 88
Step 2 125 170
Step 3 185 250
Oil Pan Bolts 16 22
Oil Pan Plug 25 34
Oil Pump Cover 21 28
Oil Pump To Front Main Cap 16 22
Oil Transfer Plate Bolts 22 30
Piston Cooling Jets 15 20
Rear Oil Seal Housing Bolts 16 22
Rear Oil Seal Housing Bolts (Torx) 16 22
Rear Oil Seal Housing To Bridge Piece (Torx also) 13 18
Rear Oil Seal Housing To Bridge Piece (Thread Size M6) 10 13
Rocker Cover Nuts (With Shim Washer) 22 30
Rocker Cover Nuts 15 20
Rocker Shaft Bracket Nuts 55 75
Timing Case To Block (M8 Bolts) 16 22
Timing Case To Block (M10 Bolts) 33 44
Timing Case Cover To Timing Case Bolts 16 22
Timing Case Cover To Timing Case Nuts 16 22
Turbocharger To Manifold Nuts 33 44
Water Pump To Timing Case Bolts & Nuts 16 22
V518 VersaHANDLER
V518 VersaHANDLER
LOADER TORQUE
Specifications
AXLE
FT.-LBS. NM
Axle To Frame Mounting Bolts 275-300 370-410
Brake Housing Hex Bolt 59 80
Brake Housing Spring Bolts 7 10
Brake Housing Stud 88 120
Differential Lock Retainer Bolt 10 13
Fender Mount Bolt 90-100 125-140
Housing Bolt 236 320
Housing Nut 140 190
King Pin Mount Bolts 140 190
Pinion Ring Gear Bolts 10 13
Planetary Cover Bolts 18 25
Planetary Gear Mount Bolts 88 120
Steering Cylinder Bolts 88 120
Tie Rod Jam Nut 185 250

Tie Rod Nut 160 220
Tie Rod Swivel End 300 406
Turn Stop Adjust Jam Nut 110 150
Wheel Nuts 221 300
BOOM
Extension Cylinder Base End 133 180

Extension Cylinder Rod End 188-210 255-285
Wear Pads Front 43 58
Wear Pads Rear 29 39
DRIVE BOX
Cover Bolts 44 60
Inner Housing Bolts 88 120
Mounting Flange Bolts 44 60
DRIVE MOTOR
End Cap Bolts 85 115

Mounting Bolts 155 210
Mounting Plate Bolts 46 63
ENGINE
A/C Compressor Mount Bolts 88 120

Alternator Mount Bolts 45 54
Starter Mount Bolts 45 54
V518 VersaHANDLER
LOADER TORQUE SPECIFICATION (CONT'D)
Specifications (Cont’d)
HYDRAULIC PUMP
FT.-LBS. NM
Filter Head 90 122
Flange Adapter 90 122
Guide Post Bolts 17 23
Mounting Bolts 78 106
Retaining Plate 10 13
Servo End Cap 10 13
Side Cover Bolts 24 32
V518 VersaHANDLER
TORQUE SPECIFICATIONS FOR BOLTS
Torque for General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Melroe that have zinc phosphate coating are specified by the letter H following the part number.
THREAD SIZE SAE GRADE 5 SAE GRADE 8

INCH. LBS.(Nm) .250 80-90 (9,0-10,2) 110-120 (12,4-13,6)
.3125 180-200 (20,3-22,6) 215-240 (24,2-27,1)
FOOT LBS.(Nm) .375 25-28 (34-38) 35-40 (47-54)
.4375 40-45 (54-61) 60-65 (81-88)
.500 65-70 (88-95) 90-100 (122-136)
.5625 90-100 (122-136) 125-140 (170-190)
.625 125-140 (170-190) 175-190 (240-260)
.750 220-245 (300-330) 300-330 (410-450)
.875 330-360 (450-490) 475-525 (645-710)
1.000 475-525 (645-710) 725-800 (985-1085)
1.125 650-720 (880-975) 1050-1175 (1425-1600)
1.250 900-1000 (1200-1360) 1475-1625 (2000-2200)

1.375 1200-1350 (1630-1830) 2000-2200 (2720-2980)
1.500 1500-1650 (2040-2240) 2600-2850 (3530-3870)
1.625 2000-2800 (2720-2980) 3450-3800 (4680-5150)
1.750 2500-2750 (3390-3730) 4300-4800 (5830-6500)
1.875 3150-3500 (4270-4750) 5500-6100 (5830-6500)
2.000 3800-4200 (5150-5700) 6500-7200 (8800-9800)
V518 VersaHANDLER
TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
THREAD SIZE MATERIAL

(DIA. X PITCH) HEAD MARK 4 HEAD MARK 7 HEAD MARK 10
M 5 x 0.8 3-4 ft.-lbs. (4-5 Nm)
M 6 x 1.0 6-7 ft.-lbs. (8-9 Nm) 6-9 ft.-lbs. (8-12
Nm)
M 8 x 1.25 6-9 ft.-lbs. (8-12 11-16 ft.-lbs. (15-22 18-25 ft.-lbs. (24-34
Nm) Nm) Nm)
M 10 x 1.25 13-18 ft.-lbs. (18-24 22-30 ft.-lbs. (30-41 36-50 ft.-lbs. (49-68
Nm) Nm) Nm)
M 12 x 1.25 22-30 ft.-lbs. (30-41 40-54 ft.-lbs. (54-73 69-87 ft.-lbs. (94-
Nm) Nm) 118 Nm)
M 14 x 1.5 36-50 ft.-lbs. (49-68 58-80 ft.-lbs. (79- 116-137 ft.-lbs.
Nm) 108 Nm) (157-186 Nm)
V518 VersaHANDLER
HYDRAULIC CONNECTION SPECIFICATIONS Straight Thread O-ring Fitting
O-ring Face Seal Connection Figure Spec-50-2
IMPORTANT
damage the system.
I-2003-0888
Figure Spec-50-1
Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [Figure Spec-50-
2].

Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will

restrict flow, which will slow hydraulic action and cause
heat.
Replace hoses which show signs of wear, damage or

weather cracked rubber.
When the fitting is tightened, you can feel when the fitting Always use two wrenches when loosening and tightening
is tight to eliminate leakage caused by under or over hose or tubeline fittings.
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
Spec-50-1].
V518 VersaHANDLER
HYDRAULIC CONNECTION SPECIFICATIONS Use the following procedure to tighten the flare fitting:
(CONT'D)
Tighten the nut until it makes contact with the seat. Make
Flare Fitting a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure Spec-50-3].
Figure Spec-50-3
Use the chart below to find the correct tightness needed
(Item 2) [Figure Spec-50-3]. If the fitting leaks after
tightening, disconnect it and inspect the seat area for
damage.
FLARE FITTING TIGHTENING TORQUE

TUBELINE NEW ROTATE RE-ASSEMBLY
TORQUE FT.-
WRENCH SIZE OUTSIDE THREAD SIZE NO. OF HEX ROTATE NO. OF
LBS. (NM)
DIAMETER FLATS HEX FLATS
5/8" 5/16" 1/2" - 20 17 (23) 2-1/2 1
11/16" 3/8" 9/16" - 18 22 (30) 2 1
7/8" 1/2" 3/4" - 16 40 (54) 2 1
1" 5/8" 7/8" - 14 60 (81) 1-1/2 1
1-1/4" 3/4" 1-1/16" - 12 84 (114) 1 3/4
1-3/8" 1" 1-5/16" - 12 118 (160) 3/4 3/4
V518 VersaHANDLER
HYDRAULIC CONNECTION SPECIFICATIONS Use the following procedure to tighten the O-ring flare
(CONT'D) fitting.
O-ring Flare Fitting Figure Spec-50-5
Figure Spec-50-4
Tighten the nut until it contacts with the seat. Make a

mark across the flats of both the male and female parts of
The flare is the primary seal, the O-ring is the secondary the connection (Item 1) [Figure Spec-50-5].
seal and helps absorb vibration and pressure pulses at

the connection [Figure Spec-50-4]. Use the chart below to find the correct tightness needed
(Item 2) [Figure Spec-50-5]. If the fitting leaks after
If necessary, the O-ring-flare fitting can be used without tightening, disconnect it and inspect the seat area for
an O-ring. damage.
FLARE FITTING TIGHTENING TORQUE

** ***
TUBELINE *
NEW ROTATE RE-ASSEMBLY
WRENCH SIZE OUTSIDE THREAD SIZE TORQUE FT.-
NO. OF HEX ROTATE NO. OF
DIAMETER LBS. (NM)
FLATS HEX FLATS
5/8" 5/16" 1/2" - 20 17 (23) 2-1/2 1
11/16" 3/8" 9/16" - 18 22 (30) 2 1
7/8" 1/2" 3/4" - 16 40 (54) 2 1
1" 5/8" 7/8" - 14 60 (81) 1-1/2 1
1-1/4" 3/4" 1-1/16" - 12 84 (114) 1 3/4
1-3/8" 1" 1-5/16" - 12 118 (160) 3/4 3/4
* If a torque wrench is used to tighten a new fitting to a used hose/tubeline.

* If a torque wrench is used to tighten a used fitting to a new hose/tubeline.
* If a torque wrench is used to tighten a new fitting to a new hose/tubeline.
** If using the hex flat tightening method to tighten a new fitting to a new hose/tubeline.
** If using the hex flat tightening method to tighten a new fitting to a used hose/tubeline.
*** If using the hex flat tightening method to tighten a used fitting to a new hose/tubeline.
V518 VersaHANDLER
HYDRAULIC CONNECTION SPECIFICATIONS Figure Spec-50-7
(CONT'D)
O-ring Flare Fitting (Cont'd)
Figure Spec-50-6
Always remove the O-ring (Item 1) [Figure Spec-50-7]

from the flare face as shown.
An O-ring (Item 2) [Figure Spec-50-7] is added to the flat

boss of the fitting to seal the connection in this
NOTE: O-ring flare fittings are not recommended in application.
all applications. Use the standard flare fittings

in these applications.
Do not use a O-ring flare fitting when a copper bonnet

orifice is used. When tightened the connection at the
bonnet may distort the flare face and prevent it from
sealing.
Use a standard flare fitting (Item 1) [Figure Spec-50-6]

as shown.
When a O-ring flare fitting is used as a straight thread

port adapter the O-ring flare face is not used to seal. The
O-ring may come off the fitting and enter the system.
V518 VersaHANDLER
HYDRAULIC CONNECTION SPECIFICATIONS NOTE: If a torque wrench cannot be used, use the
(CONT'D) hex flat tightening method as an approximate
guideline.
Port Seal Fitting
NOTE: Port seal fittings are not recommended in all
Figure Spec-50-8 applications. Use O-ring boss fittings in these
applications.
Figure Spec-50-9

Do not use port seal fittings when a thread in orifice (Item
1) [Figure Spec-50-9] is used in the port. The orifice may
interfere with the fitting and prevent it from sealing.
Use an O-ring boss fitting (Item 1) [Figure Spec-50-9] as

shown.
PORT SEAL AND O-RING BOSS TIGHTENING

TORQUE
FITTING NUT TORQUE

THREAD SIZE
WRENCH SIZE FT.LBS. (NM)
The nut is the primary seal, the O-ring is the secondary
seal and helps absorb vibration and pressure pulses at 11/16" 9/16" - 18 22 (30)
the connection [Figure Spec-50-8]. 15/16" 3/4" - 16 40 (54)
1 - 1/8" 7/8" - 14 60 (81)
The hex portion of the nut does not contact the surface of
the component when the nut is tight. 1 - 1/4" 1 - 1/16" - 12 84 (114)
1 - 1/2" 1 - 5/16" - 12 118 (160)
Use the following procedure to tighten the port seal
fitting:
Port seal and nut, washer and O-ring (O-ring Boss)

fittings use the same tightening torque valve chart.
If a torque wrench cannot be used, use the following

method.
Tighten the nut until it just makes metal to metal contact,

you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat
maximum.
Do not over tighten the port seal fitting.
V518 VersaHANDLER
V518 VersaHANDLER
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS When temperatures below zero degree F (-18°C) are
common, the machine must be kept in a warm building.
Specifications Extra warm-up time must be used each time the machine
is started during cold temperature conditions. Cold fluid
Use Bobcat axle fluid (P/N 100032-06A), for the transfer will not flow easily and it makes action on the hydraulic
case, planetarys and axle housing. function slower. Loss of fluid flow to the hydrostatic
transmission pump (indicated by TRANS light ON) can
Use Bobcat hydraulic/hydrostatic transmission fluid (P/N cause transmission damage in less than 60 seconds.
6563328). If this fluid is not available, use 10W-30 or
10W-40 SAE Motor Oil (5W-30 for 0°F [-18°C] and
Below).
DO NOT use automatic transmission fluids in the loader

WARNING
or permanent damage to the transmission will result.
During cold weather (32°F [0°C] and below), do not
operate machine until the engine has run for at least
five minutes at less than half throttle. This warm-up
WARNING period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
penetrate skin or eyes, causing serious injury or When temperatures are below -20°F (-30°C), the
death. Fluid leaks under pressure may not be visible. hydrostatic oil must be heated or kept warm. The
Use a piece of cardboard or wood to find leaks. Do hydrostatic system will not get enough oil at low
not use your bare hand. Wear safety goggles. If fluid temperatures. Park the machine in an area where the

enters skin or eyes, get immediate medical attention temperature will be above 0°F (-18°C) if possible.
from a physician familiar with this injury. W-2027-1285
W-2072-0496
V518 VersaHANDLER
V518 VersaHANDLER
CONVERSIONS
Decimal And Millimeter Equivalents
FRACTIONS DECIMALS MM FRACTIONS DECIMALS MM

1/64 0.015625 0.397 33/64 0.515625 13.097
1/32 0.03125 0.794 17/32 0.53125 13.494
3/64 0.046875 1.191 35/64 0.546875 13.891
1/16 0.0625 1.588 9/16 0.5625 14.288
5/64 0.078125 1.984 37/64 0.578125 14.684
3/32 0.09375 2.381 19/32 0.59375 15.081
7/64 0.109375 2.778 39/64 0.609375 15.478
1/8 0.1250 3.175 5/8 0.6250 15.875
9/64 0.140625 3.572 41/64 0.640625 16.272
5/32 0.15625 3.969 21/32 0.65625 16.669
11/64 0.171875 4.366 43/64 0.671875 17.066
3/16 0.1876 4.762 11/16 0.6875 17.462
13/64 0.203125 5.159 45/64 0.703125 17.859
7/32 0.21875 5.556 23/32 0.71875 18.256

15/64 0.234375 5.953 47/64 0.734375 18.653
1/4 0.2500 6.350 3/4 0.7500 19.050
17/64 0.265625 6.747 49/64 0.765625 19.447
9/32 0.28125 7.144 25/32 0.78125 19.844
19/64 0.296875 7.541 51/64 0.796875 20.241
5/16 0.3125 7.938 13/16 0.8125 20.638
21/64 0.328125 8.334 53/64 0.828125 21.034
11/32 0.34375 8.731 27/32 0.84375 21.431
23/64 0.359375 9.128 55/64 0.859375 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.390625 9.922 57/64 0.890625 22.622
13/32 0.40625 10.319 29/32 0.90625 23.019
27/64 0.421875 10.716 59/64 0.921875 23.416
7/16 0.4375 11.112 15/16 0.9375 23.812
29/64 0.453125 11.509 61/64 0.953125 24.209
15/32 0.46875 11.906 31/32 0.96875 24.606
31/64 0.484375 12.303 63/64 0.984375 25.003
1/2 0.5000 12.700 1 1.000 25.400
1 mm = 0.001" =
0.03937" 0.0254 mm
V518 VersaHANDLER
CONVERSION (CONT’D)
U.S. To Metric Conversion
TO CONVERT INTO MULTIPLY BY

LINEAR MEASUREMENT Miles Kilometers 1.609
Yards Meters 0.9144
Feet Meters 0.3048
Feet Centimeters 30.48
Inches Meters 0.0254
Inches Centimeters 2.54
Inches Millimeters 25.4
AREA Square Miles Square Kilometers 2.59
Square Feet Square Meters 0.0929
Square Inches Square Centimeters 6.452
Acre Hectare 0.4047
VOLUME Cubic Yards Cubic Meters 0.7646
Cubic Feet Cubic Meters 0.02832
Cubic Inches Cubic Centimeters 16.39

WEIGHT Tons (Short) Metric Tons 0.9078
Pounds Kilograms 0.4536
Ounces (Avdp.) Grams 28.3495
PRESSURE Pounds/Sq. In. Kilopascal 6.895
WORK Foot-Pounds Newton-Metre 1.356
LIQUID VOLUME Quarts Liters 0.9463
Gallons Liters 3.785
LIQUID FLOW Gallons/Minute Liters/Minute 3.785
TEMPERATURE Fahrenheit Celsius 1.Subtract 32°
2. Multiply by 5/9
V518 VersaHANDLER
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: V518-1

Date: 13 February 2002
Product: Bobcat VersaHANDLER
Model: V518
Manual No: 6901769 (1-02)
The following pages are a revision to the above Service Manual.
Take out existing pages and put in the new pages as listed below:
TAKE OUT PUT IN REVISION DECRIPTION

20-01, 20-02 20-01, 20-02 Revised contents page
20-20-1 thru 20-20-14 Added lift cylinder removal and installation
20-30-1 thru 20-30-14 Added bucket positioning cylinder removal and installation
20-50-1 thru 20-50-14 Added tuft cylinder removal and installation
20-90-1 thru 20-90-8 Added quick tach cylinder removal and installation
20-130-1, 20-130-2 20-130-1, 20-130-2 Revised text
50-01, 50-02 50-01, 50-02 Revised contents page
50-30-1 thru 50-30-4 Added boom assembly removal and installation
50-90-1, 5 0-90-2 Added quick tach
Printed in U.S.A.
719 of 724
720 of 724
ROUTE TO
ATTENTION
PARTS MANAGER
Revision No: V518-2

Date: 1 September 2004
Product: VersaHANDLER
Model: V518
Manual No: 6901769 (1-02)
The following pages are a revision to the above Service Manual.
Take out existing pages and put in the new pages as listed below:

TAKE OUT PUT IN REVISION DECRIPTION
Cover Cover Revised Serial Numbers
10-130 10-130 Revised Text
All Hydraulic Schematics All Hydraulic Schematics Revised Serial Numbers and Added New Schematics
Printed January 2002 Printed September 2004
20-01 20-01 Revised text

20-170 20-170 Revised text
20-171 Added text
20-180 Added text
Spec-30 Spec-30 Revised Text
All Electrical Schematics All Electrical Schematics Revised Serial Numbers and Added New Schematics
Printed January 2002 Printed September 2004
Printed in U.S.A.
721 of 724
722 of 724
ROUTE TO
ATTENTION
PARTS MANAGER
Revision No: V518-3

Date: 24 March 2006
Product: VersaHANDLER
Model: V518
Manual No: 6901769 (1-02)
V518 Service Manual (P/N 6901769) Dated (3-06) contains updated service information which
replaces the previous V518 Service Manual (P/N 6901769) Dated (1-02)
Printed in U.S.A.
723 of 724
724 of 724
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VersaHANDLER

Dealer Copy -- Not for Resale

6901769 (3-06) Printed in U.S.A. © Bobcat Company 2006

Safety Alert Symbol: This symbol with a warning statement,

CORRECT WRONG WRONG

Dealer Copy -- Not for Resale

WRONG WRONG WRONG

B-16081 B-16078 B-6589

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X HYDROSTATIC

SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE

HYDROSTATIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

Dealer Copy -- Not for Resale

2. Check that ROPS mounting 10. Attachment locking pins must

3. The seat belt must be 11. Safety treads must be in good

Dealer Copy -- Not for Resale

4. Check boom support device, 12. Check for correct function of

5. Machine signs must be 13. Check hydraulic fluid level,

7. Check for correct function of 15. Lubricatethe VersaHANDLER.

8. The parking brake must 16. Check the condition of the

19. Inspect for loosen or broken 22. Recommend to the owner

Dealer Copy -- Not for Resale

Dealer Copy -- Not for Resale

• The VersaHANDLER Operator Training Course is

The dealer and owner/operator review the recommended

Dealer Copy -- Not for Resale

Flammable debris (leaves, straw, etc.) must be removed

The spark arrestor muffler is designed to control the

• Do not use the machine where exhaust, arcs, sparks

Dealer Copy -- Not for Resale

• The operator cab, engine compartment, and engine

• Check all electrical wiring and connections for

• Check fuel and hydraulic tubes, hoses and fittings for

• Do not use ether or starting fluids on any engine

• Always clean the machine, disconnect the battery,

• Stop the engine and let it cool before adding fuel. NO

Always use the serial number of the VersaHANDLER Figure 3

VersaHANDLER Serial Number

Dealer Copy -- Not for Resale

The front, on the right side of the chassis [Figure 2].

The engine serial number is stamped on a plate near the

Other Serial Numbers

Some components may also have serial numbers.

The Delivery Report must be filled out by the dealer and

Dealer Copy -- Not for Resale

BOOM MIRROR OPERATOR HANDBOOK &

Dealer Copy -- Not for Resale

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

AXLES (FRONT AND REAR) . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

BOOM STOP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Dealer Copy -- Not for Resale

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . 10-90-1

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-100-1

LIFTING AND BLOCKING THE VERSAHANDLER . . . . . . . . 10-10-1

Continued On Next Page

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1