Bobcat v623 Service Manual

VersaHANDLER
V623
Service
Manual
Dealer Copy -- Not for Resale

(S/N 367111001 - 367113000)
(S/N 367211001 - 367213000)
6901675 (3-06) Printed in U.S.A. © Bobcat Company 2006
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6901675 (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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ALPHABETICAL INDEX
AIR CLEANER ........................................................ 70-01 HYDRAULIC CONNECTION SPECIFICATION SPEC-01

AIR CLEANER SERVICE ....................................... 10-01 HYDRAULIC CONTROL VALVE .............................20-01
AIR CONDITIONING SERVICE.............................. 80-01 HYDRAULIC/HYDROSTATIC FLUID
AIR CONDITIONING SYSTEM FLOW ................... 80-01 SPECIFICATIONS ........................................... SPEC-01
ALTERNATOR ........................................................ 60-01 HYDRAULIC/HYDROSTATIC SYSTEM..................10-01
AXLE AND DIFFERENTIAL.................................... 40-01 HYDRAULIC RESERVOIR......................................20-01
AXLE PIVOT FRAME ............................................. 40-01 HYDRAULIC SYSTEM INFORMATION ..................20-01
AXLES (FRONT AND REAR) ................................. 10-01 HYDROSTATIC DRIVE MOTOR .............................30-01
AXLE TOE-IN.......................................................... 40-01 HYDROSTATIC PUMP ............................................30-01
HYDROSTATIC SYSTEM INFORMATION..............30-01
BASIC TROUBLESHOOTING ................................ 80-01
BATTERY................................................................ 60-01 INCHING SWITCH ..................................................60-01
BOOM ASSEMBLY ................................................. 50-01 INNER BOOM .........................................................50-01
BOOM STOP .......................................................... 10-01 INSTRUMENT PANEL.............................................60-01
BRAKE LIGHT SWITCH ......................................... 60-01
BRAKE VALVE........................................................ 20-01 JOYSTICK ....................................................20-01, 60-01
BUCKET POSITIONING CYLINDER...................... 20-01 JOYSTICK PANEL...................................................60-01
COMPONENTS ...................................................... 80-01 LIFT CYLINDER ......................................................20-01

COMPRESSOR ...................................................... 80-01 LIFTING AND BLOCKING THE VersaHANDLER ...10-01
CONDENSER ......................................................... 80-01 LIGHTS....................................................................60-01
CONVERSIONS ................................................SPEC-01 LUBRICATION.........................................................10-01

DASH COVERING/STEERING COLUMN COVER 60-01 MACHINE TORQUE SPECIFICATIONS ........... SPEC-01
DRIVE BOX ............................................................ 20-01 MAIN RELIEF VALVE ..............................................20-01
DRIVE SHAFT ........................................................ 40-01 MUFFLER................................................................70-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01 OIL COOLER...........................................................30-01

ENGINE AND ENGINE MOUNTS .......................... 70-01 OPERATOR CAB .........................................10-01, 50-01
ENGINE COOLING SYSTEM ................................. 10-01 OPERATOR SEAT...................................................50-01
ENGINE COMPONENTS AND TESTING .............. 70-01
ENGINE COVER ......................................... 10-01, 50-01 PARKING BRAKE....................................................40-01
ENGINE/HYDROSTAT ASSEMBLY ....................... 70-01 PEDAL ASSEMBLY.................................................60-01
ENGINE LUBRICATION SYSTEM.......................... 10-01 PIVOT LINK .............................................................50-01
ENGINE SPECIFICATIONS...............................SPEC-01 PRESSURE SWITCH..............................................80-01
ENGINE SPEED CONTROL .................................. 70-01
EVAPORATOR/BLOWER UNIT.............................. 80-01 QUICK TACH...........................................................50-01
EXPANSION VALVE ............................................... 80-01 QUICK TACH CYLINDER........................................20-01
EXTENSION CYLINDER ........................................ 20-01
RADIATOR ..............................................................70-01
REAR WEIGHTS .....................................................50-01
FAN MOTOR........................................................... 20-01 REAR WIPER MOTOR............................................60-01
FENDER ................................................................. 50-01 RECEIVER/DRIER ..................................................80-01
FLYWHEEL AND HOUSING................................... 70-01 RECONDITIONING THE ENGINE ..........................70-01
FRAME LEVELING CYLINDER.............................. 20-01 REGULAR MAINTENANCE ....................................80-01
FRONT AXLE ......................................................... 40-01
FRONT AXLE WITH FRAME LEVELING ............... 40-01 SAFETY...................................................................80-01
FRONT WIPER MOTOR......................................... 60-01 SERVICE SCHEDULE ............................................10-01
FUEL SYSTEM ....................................................... 10-01 SPARK ARRESTOR MUFFLER..............................10-01
FUEL TANK............................................................. 50-01 STARTER ................................................................60-01
STEERING ANGLE ADJUSTMENTS .....................40-01
GEAR PUMP .......................................................... 20-01 STEERING CYLINDER ...........................................20-01
GENERAL AIR CONDITIONING SERVICE STEERING MODE VALVE BLOCK .........................20-01
GUIDELINES ........................................................ 80-01 STEERING VALVE ..................................................20-01
SWITCH PANEL ......................................................60-01
HEATER ASSEMBLY.............................................. 80-01 SYSTEM CHARGING & RECLAMATION ...............80-01
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ALPHABETICAL INDEX (CONT’D)
SYSTEM TROUBLESHOOTING.............................80-01
TEMPERATURE/PRESSURE .............................80-01
TIRE MAINTENANCE .............................................10-01
TILT CYLINDER ......................................................20-01
TOP WIPER MOTOR ..............................................60-01
TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01
TOWING THE VersaHANDLER ..............................10-01
TRANSPORTING THE VersaHANDLER.................10-01
TRAVEL/SIGNAL LEVER ........................................60-01
TROUBLESHOOTING..................................40-01, 70-01
VersaHANDLER SPECIFICATIONS.................. SPEC-01
WEAR PADS (FRONT)............................................50-01

WEAR PADS (REAR) ..............................................50-01
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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 . . . . . . . . . . . . . . . . X
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
V623 VersaHANDLER
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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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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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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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V623 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.
V623 VersaHANDLER
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DELIVERY REPORT Figure 4
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].
B-16315
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
LIGHTS
on top of frame) at correct pressure)
BUCKET MIRROR
ATTACHMENT
ENGINE B-15886
COVER B-19821
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SAFETY &
SAFETY AND MAINTENANCE 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) . . . . . . . . . . . . . . . . . . . . 10-110-2
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
V623 VersaHANDLER
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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
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Tire Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
TOWING THE VERSAHANDLER . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TRANSPORTING THE VERSAHANDLER . . . . . . . . . . . . . . . 10-30-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
V623 VersaHANDLER
LIFTING AND BLOCKING THE VERSAHANDLER Figure 10-10-2
Procedure
Always park the machine on a level surface.
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].

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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V623 VersaHANDLER
OPERATOR CAB Cab Door Window
Emergency Exit Figure 10-20-3
The left door and rear window provide exits.
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
P-34374 P-34373 engages onto the door post (Item 1) [Figure 10-20-3] to
hold the window in the open position.

Turn the handle (Inset) and push the rear window open.
Figure 10-20-4
Exit through the rear window opening [Figure 10-20-1].
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.
V623 VersaHANDLER
V623 VersaHANDLER
TRANSPORTING THE VersaHANDLER
Procedure
Always drive the VersaHANDLER backwards (heavy end

up) onto the transport vehicle.
Figure 10-30-1
1
4 3
B-21967

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 VERSAHANDLER
SPECIFICATIONS on Page SPEC-10-1.
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
V623 VersaHANDLER
V623 VersaHANDLER
TOWING THE VersaHANDLER Figure 10-40-1
Procedure
The VersaHANDLER can be towed a short distance such

as removing it from mud or loading onto a transport
vehicle.
Releasing Brake Disks: To release the brake disks, turn

each of the six (6) screws (Item 1) [Figure 10-40-1] in
only one half turn at a time; then repeat until all six
screws are 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.
V623 VersaHANDLER
V623 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
machine. Follow warnings and instructions in the manuals when making
WARNING 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 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. Replace if
Mirrors damaged or worn.
Fuel Filter Clean the sediment bowl/water trap.
Nut & 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.
King Pins, U-Joints, Axle Oscillation Lubricate with multi-purpose lithium based grease.
(Front & Rear). Attach. Frame
Pivot(s), Tilt & Lift Cyl., Boom Pivot,
Leveling Cyl. (If equipped)
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 and Check condition of hoses, tubelines and connectors. Repair or replace as
Connections. 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 Belt Check belt tension and adjust as needed. ●
Engine Oil and Filter Replace the engine oil and filter. See Specifications Content Page SPEC- ●
01 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 Specifications Contents
Page SPEC-01for correct capacity. Use a genuine Bobcat filter.
Front & Rear Axle Fluid Replace the axle fluid. See Specifications Contents Page SPEC-01for ▼ ^
correct capacity.
Engine Coolant Check freeze protection of antifreeze -34°F (-30°C). Flush cooling system
and replace coolant with premixed 53% propylene glycol and 47% water.
✵ 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.
V623 VersaHANDLER
27 of 784 10-50--1 Service Manual
V623 VersaHANDLER
28 of 784 10-50--2 Service Manual
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.
V623 VersaHANDLER
V623 VersaHANDLER
ENGINE COOLING SYSTEM Checking The Coolant Level
Cleaning The Cooling System Open the engine cover.

Check the cooling system every day to prevent over-
heating, loss of performance or engine damage. Check the coolant level in the coolant recovery tank.
Figure 10-70-3
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 10-70-1
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.
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
Open the engine cover (Item 1) [Figure 10-70-1]. damage.
Too little antifreeze reduces the additives which
Figure 10-70-2
protect the internal engine compo nents; reduces the
boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength
concentrated coolant can cause serious premature
engine damage.
I-2124-0497
Use low air pressure or water pressure to clean the

radiator and oil cooler [Figure 10-70-2].
Check cooling system for leaks.
V623 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. P-24141
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine Remove the engine block drain plug (Item 1) [Figure 10-
damage. 70-5].
Too little antifreeze reduces the additives which
Open the radiator drain valve located on the back side

protect the internal engine compo nents; reduces the and bottom of the radiator and drain all of the coolant into
boiling point and freeze protection of the system. a container. Dispose of used coolant in an
Always add a premixed solution. Adding full strength environmentally safe manner.
concentrated coolant can cause seri ous premature
engine damage. Close the drain valve and install the engine drain plug.
I-2124-0497
Mix the coolant in a separate container.
Open the engine cover. NOTE: The loader is factory filled with propylene
glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.
Figure 10-70-4
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-
70-4] on the coolant recovery tank.
Run the engine until it is at operating temperature.
Remove the cap (Item 1) [Figure 10-70-4] from the Stop the engine.
coolant recovery tank.
Check the coolant level in the recovery tank when cool.
Remove fan shield. Add coolant to the recovery tank as needed.
V623 VersaHANDLER
FUEL SYSTEM Fuel Filter
Fuel Specifications See SERVICE SCHEDULE on Page 10-50-1 for the

service interval when to clean the sediment bowl.
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1. Figure 10-80-2
The following is one suggested blending guideline which

should prevent fuel gelling problems in cold
temperatures:
TEMP. F° (C°) NO. 2 NO. 1

+15° (9°) 100% 0%
Down to -20° (-29°) 50% 50%
Below -20° (-29°) 0% 100%
See your fuel supplier for local recommendations.
Filling The Fuel Tank
Remove and clean the sediment bowl (Item 1) [Figure
WARNING 10-80-2]. Install and tighten the sediment bowl.

See SERVICE SCHEDULE on Page 10-50-1 for the
Stop and cool the engine before adding fuel. NO service interval when to replace the fuel filter.
SMOKING! Failure to obey warnings can cause an
explosion or fire. Remove the filter element (Item 2) [Figure 10-80-2].
W-2063-0887
Clean the area around the filter housing.
Figure 10-80-1
Put oil on the seal of the new filter element.
Install the fuel filter, and hand tighten.
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
explosion or fire which can result in injury or death.
W-2103-1285
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].
V623 VersaHANDLER
V623 VersaHANDLER
ENGINE LUBRICATION SYSTEM Oil Chart
Checking Engine Oil
WARNING
W-2103-1285
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.
Run the engine until it is at operating temperature. Stop

the engine.
Open the engine cover.
Remove the shield.
Remove the oil filter (Item 2) [Figure 10-90-1].
Clean the filter housing surface.

Open the engine cover and remove the dipstick (Item 1)
[Figure 10-90-1]. Put clean oil on the new oil filter gasket.
Keep the oil level between the marks on the dipstick Install the filter and hand tighten.
(INSET) [Figure 10-90-1].
Use a good quality motor oil that meets API Service

Classification of CD or better. (See Oil Chart below.)
V623 VersaHANDLER
ENGINE LUBRICATION SYSTEM (CONT'D) Figure 10-90-3
Replacing Oil And Filter (Cont'd)
Figure 10-90-2
Remove the filler cap (Item 1) [Figure 10-90-3].

Put oil in the engine. (See Capacities on Page SPEC-10-
2 for Capacity).
Remove the access panel at the rear of the engine
compartment. Remove the cap and install the drain hose Install fill cap.
(Item 1) [Figure 10-90-2].
Start the engine and let it run for several minutes.
Drain the oil into a container and recycle or dispose of
used oil in an environmentally safe manner. Stop the engine.
Remove drain hose and install cap. 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.
WARNING
W-2103-1285
V623 VersaHANDLER
HYDRAULIC/HYDROSTATIC SYSTEM Replacing Hydraulic/Hydrostatic Filter
Checking And Adding Fluid See SERVICE SCHEDULE on Page 10-50-1 for the
correct service intervals.

WARNING Remove the belt shield.
Figure 10-100-2
explosion or fire which can result in serious injury or
death.
W-2103-1285
Use only recommended fluid in the hydraulic system.

(See HYDRAULIC/HYDROSTATIC FLUID
SPECIFICATIONS on Page SPEC-60-1.)
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].
Clean the surface of the filter housing where the seal

contacts the housing.
Put clean oil on the seal of the new filter element.
Install and hand tighten the filter element.
Close the engine cover before operating.
Check the fluid level at the sight gauge (Item 1) [Figure

10-100-1].
Remove the fill cap (Item 2) [Figure 10-100-1].

WARNING
Add the fluid as needed until visible in the center of the Diesel fuel or hydraulic fluid under pressure can
sight gauge [Figure 10-100-1]. penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Install the fill cap. Use a piece of cardboard or wood to find leaks. Do
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.
W-2072-0496
V623 VersaHANDLER
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D) Figure 10-100-4
Replacing Hydraulic Fluid
Figure 10-100-3

Remove the reservoir drain plug (Item 1) [Figure 10-100-
Remove the fill cap (Item 1) [Figure 10-100-3]. 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 is visible in the center of the sight gauge

(Item 2) [Figure 10-100-3].
Install the fill cap.
Close the engine cover.
V623 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 Capacities on Page SPEC-10-2 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 Capacities on Page SPEC-10-2
for capacity and type.)
Repeat the procedure for the other side.
Install and tighten the plug.
Repeat the procedure for the other side.
V623 VersaHANDLER
AXLES (FRONT AND REAR) (CONT'D) Checking Oil Level (Front Differential)
Checking Oil Level (Rear Differential) Figure 10-110-5
Figure 10-110-3
Put the machine on a level surface with the plugs

positioned as shown (Item 1) [Figure 10-110-5].
With the machine on a level surface, remove the plug
(Item 1) [Figure 10-110-3]. The oil level should be at the Remove the plugs (Item 1) [Figure 10-110-5]. The oil
bottom edge of the plug hole. level should be at the bottom edge of the plug hole.

Add oil through the hole if the oil level is below the hole. Add oil through the hole if the oil level is below the hole.
(See Capacities on Page SPEC-10-2 for capacity and (See Capacities on Page SPEC-10-2 for capacity and
type.) type.)
Install and tighten the plug. Install and tighten the plug.
Draining Oil (Rear Differential) Draining Oil (Front Differential)
See SERVICE SCHEDULE on Page 10-50-1 for the See SERVICE SCHEDULE on Page 10-50-1 for the
correct service interval. correct service interval.
Figure 10-110-4 Figure 10-110-6
With the machine on a level surface remove the plug With the machine on a level surface, remove the plug
(Item 1) [Figure 10-110-4] and drain into a container. (Item 1) [Figure 10-110-6] and drain into a container.
Recycle or dispose of the used lubricant in an Recycle or dispose of the used lubricant in an
environmentally safe manner. environmentally safe manner.
V623 VersaHANDLER
LUBRICATION Figure 10-120-3
Procedure
Lubricate as specified in the SERVICE SCHEDULE, See

SERVICE SCHEDULE on Page 10-50-1 for the best
performance of the machine.
1
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
P-24167
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].
FRONT REAR
P-25906 P-25915
2. Universal Joints - Front and Rear (Item 1) [Figure 10-

120-2].
V623 VersaHANDLER
LUBRICATION (CONT'D) Figure 10-120-7
Procedure (Cont’d)
Figure 10-120-5
7. Main Pivot Link (Item 1) [Figure 10-120-7].
Figure 10-120-8
5. Lower Pivot Link (Item 1) [Figure 10-120-5].
Figure 10-120-6

8. Extension Cylinder Rod End (Item 1) [Figure 10-120-
8].
6. Remove the two cover bolts (Item 1) and cover (Item

2) [Figure 10-120-6].
V623 VersaHANDLER
Figure 10-120-9
P-42286
11. Base End Slave Cylinder (Item 1) [Figure 10-120-11].
NOTE: The rear cover must be removed.

NOTE: Raise the boom and install the boom stop (See
Boom Stop Intallation Page 10-150-1) before Figure 10-120-12
lubricating the boom cylinder.

9. Lift Cylinder Rod End (Item 1) [Figure 10-120-9].
Figure 10-120-10
12. Slave Cylinder Pivot Bracket (Item 1) [Figure 10-120-

12].
P-42285 NOTE: The rear cover must be removed.
10. Lift Cylinder Base End (Item 1) [Figure 10-120-10].
NOTE: The rear cover must be removed.
V623 VersaHANDLER
Figure 10-120-13
15. Boom Slide [Figure 10-120-15] (Four Places).
Figure 10-120-16
13. Boom Pivot (Item 1) [Figure 10-120-13] (Four

Places).

Figure 10-120-14
P-34461
16. Axle Oscillation - Front Axle (Item 1) [Figure 10-120-

16] (V623 with frame leveling only)
14. Cab Door Hinges (Item 1) [Figure 10-120-14] (three

Places).
V623 VersaHANDLER
LUBRICATION (CONT’D)
Figure 10-120-17
P-34455
17. Axle Oscillation - Front Axle (Item 1) [Figure 10-120-

17] (V623 with frame leveling only)
V623 VersaHANDLER
V623 VersaHANDLER
TIRE MAINTENANCE Tire Rotation
Wheel Nuts Check the tires regularly for wear, damage and pressure.
(See Tires on Page SPEC-10-2 for the correct tire
Figure 10-130-1 pressure.)
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 217 ft.-lbs. (159 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.
V623 VersaHANDLER
V623 VersaHANDLER
SPARK ARRESTOR MUFFLER

service interval for cleaning the spark arrestor muffler. IMPORTANT
Do not operate the machine with a defective exhaust This loader is factory equipped with a U.S.A..
system. Forestry Service approved spark arrestor muffler. It
is necessary to do maintenance on this spark
Stop the engine. arrestor muffler to keep it in working condition. The
spark arrestor muffler must be serviced by dumping
Figure 10-140-1 the spark chamber every 100 hours of operation.
If this machine is operated on flammable forest,
brush or grass covered land, it must be equipped
with a spark arrestor attached to the exhaust system
and maintained in working order. Failure to do so will
be in violation of California State Law, Section 4442
PRC.
Make reference to local laws and regulations for
spark arrestor requirements.
I-2022-0595

Remove the plug (Item 1) [Figure 10-140-1] from the
bottom of the muffler.
WARNING
When the engine is running during service, the Travel
Direction Lever must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
death.
W-2397-0301
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 clean out

hole.
Stop the engine.
Install and tighten the plug.
V623 VersaHANDLER
V623 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 [Figure 10-150-2].
• Install the pins and secure the 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
V623 VersaHANDLER
V623 VersaHANDLER
ENGINE COVER Adjusting The Latch
Opening And Closing The Engine Cover Figure 10-160-2
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
Release the latch (Item 1) [Figure 10-160-1] and raise latch.
the engine cover.
Close the engine cover before operating the

VersaHANDLER.
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
V623 VersaHANDLER
V623 VersaHANDLER
HYDRAULIC SYSTEM
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
HYDRAULIC
BUCKET POSITIONING CYLINDER . . . . . . . . . . . . . . . . . . . 20-30-1 SYSTEM
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-9
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
DRIVE BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

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

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7

FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . 20-140-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-3
FRAME LEVELING CYLINDER . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-9
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
GEAR PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 20-130-5
V623 VersaHANDLER
HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE (S/N 367111001-367112500 AND

367211001-367212500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1
Auxiliary Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-10
Frame Leveling Valve Section (Optional). . . . . . . . . . . . . 20-170-5
Inlet/Outlet Valve Section . . . . . . . . . . . . . . . . . . . . . . . . 20-170-28
Lifting Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-22
Telescoping Valve Section . . . . . . . . . . . . . . . . . . . . . . . 20-170-15
Tilting Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-16
HYDRAULIC CONTROL VALVE (S/N 367112501-367113000 AND

367212501-367213000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-171-1
Auxiliary Valve Section Disassembly And Assembly . . . 20-171-30
End Housing Disassembly And Assembly . . . . . . . . . . . . 20-171-6
Frame Leveling Valve Section Disassembly And Assembly (If
Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-171-40

Inlet-Outlet Valve Section Disassembly And Assembly . 20-171-51
Lifting Valve Section Disassembly And Assembly . . . . . . 20-171-7
Telescoping Valve Section Disassembly And Assembly 20-171-17
Tilting Valve Section Disassembly And Assembly . . . . . 20-171-12
HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . 20-10-1

Tightening Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-4
JOYSTICK (S/N 367112501-367113000 AND 367212501-

367213000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-1
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . 20-180-1
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . 20-180-2
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
V623 VersaHANDLER
HYDRAULIC SYSTEM (CONT’D)
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2
Testing And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
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
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-5
STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1

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

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
V623 VersaHANDLER
V623 VersaHANDLER
HYDRAULIC/HYDROSTATIC SCHEMATIC
V623 (S/N 367111001 - 367112500)
(S/N 367211001 - 367212500)
Printable Version Click Here (Printed September 2004)
V623-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 (3000 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. V623-VersaHle (9-1-4)

59 of 784
HYDRAULIC/HYDROSTATIC
SCHEMATIC
V623 (S/N 367111001 - TELESCOPIC CYLINDER
367112500) 46 46
AND (S/N 367211001 -
367212500) 5
4
(PRINTED SEPTEMBER 2004)

MS-1329
5
Printable Version Click Here 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 10 22 SPOOL
EVP2
15 A 24
3
B 44
9 B1 A1
M4 EV2 BOOM
M5 23 CYLINDER
M1 19 SPOOL
0°
U
13 EVP1
M2
Dealer Copy -- Not for Resale L2 HYD.
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 12 27
FRONT AXLE 43 XB 30
B
S A
38
37
16 EV3
A
XA S GEAR
16
PUMP (2) 29 1
17
B
L1 M2 M3 M4 CE
18
CF
HYDRAULIC MOTOR
38 LS
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
ACCUM.
60 of 784
HYDRAULIC SYSTEM INFORMATION
mc-2340
V623 VersaHANDLER
20-10-1 Service Manual
61 of 784
HYDRAULIC SYSTEM INFORMATION (CONT’D)
mc-2340-
2
V623 VersaHANDLER
62 of 784
mc-2340-
3
V623 VersaHANDLER
63 of 784
HYDRAULIC SYSTEM INFORMATION
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 6
The hydraulic oil temperature warning light comes ON when hydraulics are operating. 1, 2
Slow hydraulic system action. 1, 2, 4, 8
Hydraulic action is not smooth. 1, 3, 4, 5
Boom goes up slowly at full engine RPM. 1, 2, 4, 5, 6, 7
The boom comes down with the lever in neutral position. 7, 8, 9

KEY TO CORRECT THE CAUSE
1. The fluid level is not correct..
2. The hydraulic pump has damage.
3. Relief valve is not at the correct pressure.
4. Suction leak on the inlet side of the hydraulic pump.
5. Fluid is cold. Wrong viscosity fluid. (See Section SPEC-01.)
6. Using the machine for more than its rated capacity.
7. Internal leak in the lift cylinder.
8. External leak from the cylinder(s).
9. Damaged lift spool.
V623 VersaHANDLER
64 of 784
Tightening Procedures
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.
I-2003-0888
To tighten the hydraulic fittings, tubelines etc. See Spec

Section - Hydraulic Connection Specifications, for the
correct procedure and torque.
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
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
V623 VersaHANDLER
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V623 VersaHANDLER
66 of 784
LIFT CYLINDER Figure 20-20-3
Removal And Installation
Figure 20-20-1
Place a wood block (Item 1) [Figure 20-20-3] under the

lift cylinder.
Figure 20-20-4
Lower the boom onto adequate stands or blocks as
shown [Figure 20-20-1].

Figure 20-20-2
Remove the pivot pin retainer bolt (Item 1) [Figure 20-

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

the machine.
V623 VersaHANDLER
LIFT CYLINDER (CONT'D) Figure 20-20-7
Removal And Installation (Cont'd)
Figure 20-20-5
2. The side window (Item 1) and frame opening (Item 2)

[Figure 20-20-7] must be protected from sparks.
Figure 20-20-8
Remove the upper pivot pin using a pin removal tool
(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.
V623 VersaHANDLER
LIFT CYLINDER (CONT'D)

IMPORTANT
Figure 20-20-9
damage the system.
I-2003-0888
Figure 20-20-11
After the upper pivot pin has been removed, the rod end
of the cylinder should be lowered onto the center frame
with a pipe (Item 1) [Figure 20-20-9] positioned as

shown.
Figure 20-20-10
Remove the base end pivot pin retainer bolt (Item 1)

[Figure 20-20-11].
Figure 20-20-12
Remove the two hoses (Item 1) [Figure 20-20-10] from

the lift lock on the lift cylinder.
NOTE: Mark all hoses for correct installation.
Lift and support the base end of the cylinder [Figure 20-
20-12].
V623 VersaHANDLER
Figure 20-20-13
Lift and remove the cylinder [Figure 20-20-14].
Remove the base end pivot pin (Item 1) [Figure 20-20-

13].
V623 VersaHANDLER
Parts Identification
V623 VersaHANDLER
Disassembly
Figure 20-20-15
Carefully peen the lock ring from the head gland [Figure
20-20-17].
Figure 20-20-18
Use the following tools to disassemble the cylinders:
MEL1354-Spanner Wrench

MEL1076-Cylinder Wrench
Put the cylinder in a vise [Figure 20-20-15].
Figure 20-20-16
Use a spanner wrench to loosen the head gland [Figure

20-20-18].
Remove the four bolts (Item 1) and remove the lift lock
(Item 2) [Figure 20-20-16].
V623 VersaHANDLER
Disassembly (Cont'd)
Figure 20-20-19
Support the cylinder rod on a wood block [Figure 20-20-

21].
Figure 20-20-22
Remove the rod assembly (Item 1) [Figure 20-20-19]
from the housing.

Figure 20-20-20
Carefully peen the lock ring tab (Item 1) [Figure 20-20-

22] up and out of the lock nut groove.
Put the rod end of the cylinder in a vise [Figure 20-20-

20].
V623 VersaHANDLER
Figure 20-20-23
Remove the piston (Item 1) [Figure 20-20-25] from the

rod.
Figure 20-20-26
Remove the lock nut from the cylinder rod [Figure 20-20-
23] using a cylinder wrench.

Figure 20-20-24
Remove the two wear rings (Item 1) and seal (Item 2)

[Figure 20-20-26] from the piston.
Remove the lock ring (Item 1) [Figure 20-20-24].
V623 VersaHANDLER
Figure 20-20-27
Remove the head gland (Item 1) [Figure 20-20-29] from

the rod.
Figure 20-20-30
Remove the expander O-ring (Item 1) [Figure 20-20-27].
Figure 20-20-28

Remove the two O-rings (Item 1) [Figure 20-20-30] from
the head gland.
Remove the O-ring (Item 1) [Figure 20-20-28] from the

piston.
V623 VersaHANDLER
Figure 20-20-31
Remove the wear ring (Item 1) [Figure 20-20-31].
Figure 20-20-32

Remove seal (Item 1) wear ring (Item 2) and wiper (Item
3) [Figure 20-20-32] from the head gland.
V623 VersaHANDLER
Assembly
Use the following tools to disassemble the cylinders:
MEL1033-Rod Seal Installation Tool
Wash the cylinder parts in solvent and dry with

compressed air.
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 center seal (Item 1) [Figure 20-20-35].
Figure 20-20-33 NOTE: The groove in the seal must point away from
the wiper seal (Item 1) [Figure 20-20-33].
Figure 20-20-36

Always use new O-rings and seals. Install the wiper (Item
1) and wear ring (Item 2) [Figure 20-20-33] in the head
gland.
Install the two O-rings (Item 1) [Figure 20-20-36].
Figure 20-20-34
Install the wear ring (Item 1) [Figure 20-20-34].
V623 VersaHANDLER
Assembly (Cont'd)
Figure 20-20-37
Install the expander O-ring (Item 1) [Figure 20-20-39] on

the piston.
Figure 20-20-40
Install the head gland (Item 1) [Figure 20-20-37] onto the
rod.

Figure 20-20-38
Install the two wear rings (Item 1) and seal (Item 2)

[Figure 20-20-40] onto the piston.
Install the O-ring (Item 1) [Figure 20-20-38] in the piston.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 20-20-41
Install the lock ring (Item 1) [Figure 20-20-43].
Figure 20-20-44
Clean off any old residue, and apply LOCTITE 242 or

equivalent to the threads on the rod [Figure 20-20-41].

Figure 20-20-42
Use the cylinder wrench to install the lock nut (Item 1)

[Figure 20-20-44] and tighten.
Install the piston (Item 1) [Figure 20-20-42] on the rod.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 20-20-45
Use the spanner wrench to tighten the head gland

[Figure 20-20-47].
Figure 20-20-48
Peen the lock ring tab (Item 1) [Figure 20-20-45] into the
groove in the lock nut.

Figure 20-20-46
Peen the lock ring into the groove in the head gland
[Figure 20-20-48].
Install the rod assembly (Item 1) [Figure 20-20-46] into

the housing.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 20-20-49
Install the lift lock (Item 1) onto the cylinder and tighten
the four bolts (Item 2) [Figure 20-20-49].
V623 VersaHANDLER
V623 VersaHANDLER
BUCKET POSITIONING CYLINDER Figure 20-30-3
Figure 20-30-1
Remove the upper hose (Item 1) [Figure 20-30-3] from

the cylinder.

Raise the boom and install the boom stop (Item 1)
[Figure 20-30-1].

Figure 20-30-2
IMPORTANT
damage the system.
I-2003-0888
Figure 20-30-4

the machine.
Remove the lower hose (Item 1) [Figure 20-30-4] from

the cylinder.
V623 VersaHANDLER
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-7
Figure 20-30-5
Remove the upper pivot pin using a pin removal tool

[Figure 20-30-7].
NOTE: Secure the top of the cylinder from falling

Remove the nut (Item 1) [Figure 20-30-5] from the upper forward and causing damage to the cylinder
retainer bolt. rod when the pivot pin is removed.

Figure 20-30-6 Figure 20-30-8
Remove the upper retainer bolt (Item 1) [Figure 20-30-6] Remove the lower pivot pin retainer bolt (Item 1) [Figure
from the top pivot pin. 20-30-8].
V623 VersaHANDLER
Figure 20-30-9
Have an assistant tilt the cylinder forward while removing

the cylinder out the back [Figure 20-30-10].
Remove the lower pivot pin (Item 1) [Figure 20-30-9].
V623 VersaHANDLER
BUCKET POSITIONING CYLINDER (CONT'D)
V623 VersaHANDLER
Disassembly
Use the following tools to disassemble the cylinder:
Figure 20-30-11
Use a spanner wrench to remove the head gland [Figure

20-30-13].
Figure 20-30-14

Figure 20-30-12

from the housing.
20-30-12].
V623 VersaHANDLER
Figure 20-30-15
Remove the piston assembly (Item 1) [Figure 20-30-17]

from the rod.
Figure 20-30-18
15].

Figure 20-30-16

Support the cylinder rod on a wood block and remove the

set screw (Item 1) [Figure 20-30-16] from the piston.
V623 VersaHANDLER
Figure 20-30-19

the rod.
Figure 20-30-22
Figure 20-30-20

Remove the center seal (Item 1) and outer wear ring
(Item 2) [Figure 20-30-22].

piston.
V623 VersaHANDLER
Figure 20-30-23
Remove any residue from the threads on the cylinder rod

[Figure 20-30-25].
Remove the outer wear ring (Item 1) and wiper (Item 2)

[Figure 20-30-23].

Figure 20-30-24
Remove the two O-rings (Item 1) [Figure 20-30-24].
V623 VersaHANDLER
BUCKET POSITIONING CYLINDER (CONT'D) Install the wiper (Item 1) and wear ring (Item 2) [Figure
20-30-27].
Assembly
Figure 20-30-28
Use the following tools to assemble the cylinder:

compressed air.


installation.
Always use new O-rings and seals.
Figure 20-30-26 Install the wear ring (Item 1) [Figure 20-30-28].
Figure 20-30-29

Install the two O-rings (Item 1) [Figure 20-30-26] onto
the head gland.
Install the center seal (Item 1) [Figure 20-30-29].
Figure 20-30-27
NOTE: The groove in the seal must point away from
V623 VersaHANDLER
Assembly (Cont'd)
Figure 20-30-30
Install the expander O-ring (Item 1) [Figure 20-30-32]

onto the piston.
Figure 20-30-33
rod.

Figure 20-30-31

[Figure 20-30-33].
V623 VersaHANDLER
Assembly (Cont'd)
Figure 20-30-34
Align the hole (Item 1) [Figure 20-30-36] in the piston

with the hole in the end of the cylinder rod.
Figure 20-30-37
Apply LOCTITE 242 or equivalent to the threads on the
rod [Figure 20-30-34].

Figure 20-30-35
Apply LOCTITE 242 or equivalent to the set screw (Item

1) [Figure 20-30-37].
Install the piston (Item 1) [Figure 20-30-35] onto the rod.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 20-30-38

[Figure 20-30-40].
Figure 20-30-41
Install the set screw (Item 1) [Figure 20-30-38] into the
piston and tighten.

Figure 20-30-39
Carefully peen the lock ring over and into the nut [Figure
20-30-41].

the housing.
V623 VersaHANDLER
EXTENSION CYLINDER Figure 20-40-3
Remove the inner boom. (See Removal on Page 50-40-

1.)
Remove the tilt cylinder. (See Removal And Installation

on Page 20-50-1.)
NOTE: The tilt cylinder may be removed from the

machine either before or after the inner boom
is removed.
Figure 20-40-1
Remove any tie straps (Item 1) [Figure 20-40-3].
Figure 20-40-4

Remove the electrical connector (Item 1) [Figure 20-40-
1] from the auxiliary valve.
Figure 20-40-2
Remove the two tubelines (Item 1) [Figure 20-40-4] from

the bulkhead fittings.
Remove the harness (Item 1) from the connector (Item 2)

[Figure 20-40-2].
NOTE: Mark the harness connector for correct

installation.
V623 VersaHANDLER
EXTENSION CYLINDER (CONT'D) Figure 20-40-7
Figure 20-40-5
Remove the two bolts (Item 1) [Figure 20-40-7] from the

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

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

Figure 20-40-6
Remove the extension cylinder assembly from the boom

Pull the two bulkhead fittings (Item 1) and electrical [Figure 20-40-8].
harness (Item 2) [Figure 20-40-6] into the boom.
NOTE: Install caps and plugs after the bulkhead

fittings are pulled into the boom.
V623 VersaHANDLER
Figure 20-40-9
Remove the bolt (Item 1) [Figure 20-40-11] from the

tubeline bracket on the top of the rod end of the cylinder.
Move the tubeline and bracket assembly over the rod end
Mark the location of the tubelines in reference to the as far as possible.
bracket for proper assembly [Figure 20-40-9].
Figure 20-40-12

Figure 20-40-10
Remove the three clamps (Item 1) [Figure 20-40-12]

Remove the bolt (Item 1) and remove the bracket (Item 2) from the base end of the cylinder.
[Figure 20-40-10] from the rod end of the cylinder.
NOTE: Mark the location of the tubelines for ease of
assembly.
V623 VersaHANDLER
Figure 20-40-13
Install a hoist to lift and support the cylinder [Figure 20-

40-15].
Figure 20-40-16
Remove the bracket (Item 1) [Figure 20-40-13] from the
base end of the cylinder.

Figure 20-40-14

bracket on the rod end of the cylinder.
Remove the two tubelines (Item 1) [Figure 20-40-14]

from the cylinder lift lock valve.
V623 VersaHANDLER
Figure 20-40-17
Lift and remove the extension cylinder from the tubelines

and tray assembly [Figure 20-40-19].

bracket on the base end of the cylinder.

Figure 20-40-18
Carefully separate the tubelines at the base end of the

cylinder [Figure 20-40-18].
V623 VersaHANDLER
EXTENSION CYLINDER (CONT'D)
V623 VersaHANDLER
Disassembly
Use the following tool to disassemble the cylinder:
Figure 20-40-20
Carefully peen the lock ring from the groove in the head
gland [Figure 20-40-22].
Figure 20-40-23

Figure 20-40-21
Use the spanner wrench to loosen the head gland

[Figure 20-40-23].
Remove the two fittings (Item 1) and relief cartridges

(Item 2) [Figure 20-40-21].
V623 VersaHANDLER
Figure 20-40-24

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

Figure 20-40-25
Carefully peen the lock ring tab (Item 1) [Figure 20-40-

27] up and out of the lock nut groove.

25].
V623 VersaHANDLER
Figure 20-40-28

rod.
Figure 20-40-31
Use the cylinder wrench to remove the lock nut from the
cylinder rod [Figure 20-40-28].

Figure 20-40-29

V623 VersaHANDLER
Figure 20-40-32

the rod.
Figure 20-40-35
Figure 20-40-33

the head gland.

piston.
V623 VersaHANDLER
Figure 20-40-36
Remove the wear ring (Item 1) [Figure 20-40-36].
Figure 20-40-37

Remove seal (Item 1) wear ring (Item 2) and wiper (Item
3) [Figure 20-40-37] from the head gland.
V623 VersaHANDLER
Assembly

compressed air.


installation. Install the center seal (Item 1) [Figure 20-40-40].
Figure 20-40-38 NOTE: The groove in the seal must point away from
Figure 20-40-41

Install the wiper (Item 1) and wear ring (Item 2) [Figure
20-40-38] in the head gland.
Figure 20-40-39 Install the two O-rings (Item 1) [Figure 20-40-41].
V623 VersaHANDLER
Assembly (Cont'd)
Figure 20-40-42
Install the expander O-ring (Item 1) [Figure 20-40-44] on

the piston.
Figure 20-40-45
rod.

Figure 20-40-43

V623 VersaHANDLER
Assembly (Cont'd)
Figure 20-40-46
Figure 20-40-49


Figure 20-40-47
Use the cylinder wrench to install the lock nut (Item 1)

[Figure 20-40-49] and tighten.
V623 VersaHANDLER
EXTENSION (CONT'D) Figure 20-40-52
Assembly (Cont'd)
Figure 20-40-50

[Figure 20-40-52].
Figure 20-40-53
Peen the lock ring tab (Item 1) [Figure 20-40-50] into the
groove in the lock nut.

Figure 20-40-51
Peen the lock ring into the groove in the head gland
[Figure 20-40-53].

the housing.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 20-40-54
Install the two fittings (Item 1) and two relief cartridges

(Item 2) [Figure 20-40-54].
V623 VersaHANDLER
TILT CYLINDER Figure 20-50-3
Figure 20-50-1
Remove the bolt (Item 1) and bushing (Item 2) [Figure

20-50-3] from each side of the boom.
Installation: Tighten the bolt to 188-210 ft.-lbs. (255-285

Remove the four bolts [Figure 20-50-1]. Extend the inner Nm) torque.
boom out approximately 36 inches (914 mm) .
Figure 20-50-4

Remove the Pivot Link. (See Removal And Installation on
Page 50-120-1.)
Figure 20-50-2
Remove the tilt cylinder from the end of the boom as


the tubelines.
NOTE: Mark the hoses for correct assembly.
V623 VersaHANDLER
TILT CYLINDER (CONT'D)
V623 VersaHANDLER
TILT CYLINDER (CONT'D) Figure 20-50-7
Disassembly
MEL1075-Adjustable Gland Wrench
Figure 20-50-5
Remove the relief cartridge (Item 1) [Figure 20-50-7].
Figure 20-50-8

Figure 20-50-6
Remove the set screw (Item 1) [Figure 20-50-8].

the cylinder.
V623 VersaHANDLER
Figure 20-50-9

11].
Figure 20-50-12
Use the adjustable gland wrench to loosen the head

Figure 20-50-10

12].
Remove the rod assembly (Item 1) [Figure 20-50-10].
V623 VersaHANDLER
Figure 20-50-13

Figure 20-50-16
Figure 20-50-14


rod.
V623 VersaHANDLER
Figure 20-50-17

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

Figure 20-50-18
Remove the seal (Item 1) wear ring (Item 2) and wiper

(Item 3) [Figure 20-50-20].

the rod.
V623 VersaHANDLER
Assembly

MEL1075-Adjustable Gland Nut Wrench

compressed air.
Inspect the cylinder parts for damage. Replace any

damaged parts.

installation. Always use new O-rings and seals.
Figure 20-50-21
rod.
Figure 20-50-24

Install the wiper (Item 1) wear ring (Item 2) and seal (Item
3) [Figure 20-50-21].

the wiper seal (Item 1) [Figure 20-50-21]. Install the O-ring (Item 1) [Figure 20-50-24] on the inside
of the piston.
Figure 20-50-22
Install the O-ring (Item 1) [Figure 20-50-22] on to the

head.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 20-50-25

Figure 20-50-28
onto the piston.

Figure 20-50-26
Install the piston (Item 1) [Figure 20-50-28] onto the rod

and tighten.

[Figure 20-50-26].
V623 VersaHANDLER
Assembly (Cont'd)
Figure 20-50-29
Use the adjustable gland wrench to tighten the head

Figure 20-50-32
Figure 20-50-30

1) [Figure 20-50-32].
Install the piston/rod assembly (Item 1) [Figure 20-50-

30] into the housing.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 20-50-33
Install the two hoses (Item 1) [Figure 20-50-35].
Install the set screw (Item 1) [Figure 20-50-33] and

tighten.

Figure 20-50-34
Install the relief cartridge (Item 1) [Figure 20-50-34].
V623 VersaHANDLER
STEERING CYLINDER Figure 20-60-3
Remove the axle. (See Removal on Page 40-30-1.)
Figure 20-60-1
Remove the tie rod end from the axle [Figure 20-60-3].
Figure 20-60-4
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.
V623 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) and remove the centering tighten to 88 ft.-lbs. (120 Nm) torque.
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.
V623 VersaHANDLER
STEERING CYLINDER (CONT'D)
V623 VersaHANDLER
Disassembly
Figure 20-60-9
Drive the head gland (Item 1) inwards. Remove the

internal snap ring (Item 2) [Figure 20-60-11].
Figure 20-60-12
Put the cylinder in a vise and remove the tie rod swivel
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) 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.
V623 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) and spacer (Item 2)

[Figure 20-60-13] from the rod.

Figure 20-60-14
Remove the backup ring (Item 1) 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.
V623 VersaHANDLER
Figure 20-60-17
Figure 20-60-20
Remove the wear ring (Item 1) 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].
V623 VersaHANDLER
Figure 20-60-21

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

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].
V623 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) 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.
V623 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) and wiper seal (Item 2)

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

(Item 2) [Figure 20-60-30].
V623 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) and head (Item 2) onto the

machined end (Item 3) [Figure 20-60-34] of the cylinder
rod.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 20-60-37
Install the tie rod swivel ends (Item 1) [Figure 20-60-38]

onto the cylinder rod. Tighten to 406 ft.-lbs. (300 Nm)
torque.
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].
V623 VersaHANDLER
V623 VersaHANDLER
DRIVE BOX
V623 VersaHANDLER
DRIVE BOX 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].
V623 VersaHANDLER
DRIVE BOX (CONT'D) Figure 20-70-6
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].
V623 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].
V623 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].
V623 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.
V623 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.
V623 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].
V623 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.
V623 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.
V623 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.
V623 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].
V623 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.
V623 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) 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.
V623 VersaHANDLER
MAIN RELIEF VALVE Figure 20-80-2
Testing And Adjustment
The following tool will be needed to do the following

procedure:
MEL10003-Hydraulic Tester
Figure 20-80-1
2 2 1
5 P-25421
3
Start the engine and run at low idle RPM. Push the
4
detent rocker switch (Item 1) and front auxiliary rocker
switch (Item 2) [Figure 20-80-2]. Make sure the tester is
connected correctly. If no flow is indicated on the tester,
the hoses are connected wrong. with the hoses
connected correctly, increase the engine speed to 2200

1 P-32247 RPM.
Warm the fluid to 140° F (60° C) by turning the restrictor

Connect the inlet hose (Item 1) from the tester to the control (Item 5) [Figure 20-80-1] on the tester to about
front coupler (Item 2) [Figure 20-80-1]. 1000 psi (6895 Kgm). DO NOT exceed system relief
pressure. Open the restrictor control knob and record the
Connect the outlet hose (Item 3) from the tester to the free flow (GPM) at 2200 RPM.
rear coupler (Item 4) [Figure 20-80-1].
There should be 14.5 GPM (55 L/min) free flow. Turn the
restrictor control (Item 5) [Figure 20-80-1] on the tester
until the main relief opens. The correct pressure should
IMPORTANT be 3600 PSI (24822 kPa).
If adjustment is needed, remove the rear cover. (See

The hydraulic tester must be in the fully open
Page 60-01.).
position before you start the engine.
I-2024-0284
V623 VersaHANDLER
MAIN RELIEF VALVE (CONT’D) Removal and Installation
Testing And Adjustment (Cont’d)
Figure 20-80-3
IMPORTANT
1 tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Remove the rear cover. (See Page 60-01.)
Figure 20-80-5
P-32249
Remove the tamper proof cap (Item 1) [Figure 20-80-3].

1

Figure 20-80-4
1 P-32249
Clean the area around the control valve.
Remove the main relief valve (Item 1) [Figure 20-80-5]
P-32266
Turn the adjustment screw (Item 1) [Figure 20-80-4]

clockwise to increase pressure or counterclockwise to
decrease the pressure.
NOTE: A 1/4 of a turn = 600 psi (4137 kPa).
Retest the main relief valve after adjustment.
V623 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 the floor
[Figure 20-90-1].

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

the cylinder.
V623 VersaHANDLER
QUICK TACH CYLINDER (CONT'D) Figure 20-90-7
Figure 20-90-5
Remove the roll pin (Item 1) and remove the extension

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

Remove the cylinder (Item 1) [Figure 20-90-8].
Remove the washer (Item 1) and spring (Item 2) [Figure

20-90-6] from the cylinder rod extension.
V623 VersaHANDLER
QUICK TACH CYLINDER (CONT'D)
1. Cylinder Housing
2. Extension
3. Wiper
4. Seal
5. O-ring
6. Head Gland
7. Rod
8. Piston
9. Wear Ring
V623 VersaHANDLER
Disassembly
Figure 20-90-9
Use the cylinder wrench to loosen the head gland

[Figure 20-90-11].
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].
V623 VersaHANDLER
Figure 20-90-13
Remove the head (Item 1) [Figure 20-90-15] from each

rod.
Figure 20-90-16
Use the cylinder wrench to 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.
V623 VersaHANDLER
Figure 20-90-17
Remove the expander O-ring (Item 1) [Figure 20-90-19]

from each piston.
Remove the seal (Item 1) and wiper (Item 2) [Figure 20-

90-17] from each head gland.

Figure 20-90-18
Remove the wear ring (Item 1) and seal (Item 2) [Figure

20-90-18] from each piston.
V623 VersaHANDLER
Assembly

compressed air.


installation.
Always use new O-rings and seals. Install the wiper (Item 1) and seal (Item 2) [Figure 20-90-
22] in each head gland.
Figure 20-90-20
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) and wear ring (Item 2) [Figure

20-90-21] on each piston.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 20-90-24
Use the cylinder wrench to 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.
V623 VersaHANDLER
FRAME LEVELING CYLINDER Figure 20-100-2
Figure 20-100- 1
1 1
P-40479
Remove the two hoses (Item 10 [Figure 20-100-2].

P-40482
Install caps and plugs.
Install jack stands under the frame to prevent the frame Figure 20-100-3
from tilting during cylinder removal [Figure 20-100- 1].

2
Relieve hydraulic pressure.
WARNING
penetrating the skin. This can cause serious injury 1
immediately.
W-2145-0290 P-40481
Remove the snap ring (Item 1) and washer (Item 2)

[Figure 20-100-3].
IMPORTANT
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
V623 VersaHANDLER
157 of 784
FRAME LEVELING CYLINDER (CONT’D)
Removal And Installation (Cont’d)
Figure 20-100-4
P-40480
Remove the pivot pin (Item 1) [Figure 20-100-4].

Figure 20-100-5
P-40483
Remove the four mounting bolts (Item 1) [Figure 20-100-

5].
Remove the frame leveling cylinder.
V623 VersaHANDLER
158 of 784
1. Relief Cartridge
2. Tube
3. Wear Ring
4. Seal
5. Set Screw
6. Piston
7. O-ring
8. Sleeve
9. Head Gland
10. Wiper
11. Bushing
12. Rod
13. Grease Fitting

2 4
5
1
3
6
7
1 8
7
4
10
13
7
9
3
11
12
b-19814
V623 VersaHANDLER
159 of 784
FRAME LEVELING CYLINDER (CONT’D) Figure 20-100-8
Disassembly
2
1
MEL1353 - Cylinder Gland Nut Wrench
Figure 20-100-6
2
P-40486
1 Remove the two relief cartridges (Item 1) and two fittings

1 (Item 2) [Figure 20-100-8].
Figure 20-100-9
P-40484

Remove the mounting blocks (Item 1) [Figure 20-100-6].
Figure 20-100-7
P-40487
P-40485
Remove the bushing (Item 1) [Figure 20-100-7] from

both mounting blocks.
V623 VersaHANDLER
160 of 784
Disassembly (Cont’d)
Figure 20-100-10 1
P-40492

P-29868 from the housing.
Figure 20-100-13
20-100-10].

Figure 20-100-11
P-40493

P-40489 13].
Remove the head gland [Figure 20-100-11].
V623 VersaHANDLER
161 of 784
Figure 20-100-14
1
P-29879
Remove the expander O-ring (Item 1) [Figure 20-100-

P-40494 16].
Figure 20-100-17
Remove the set screw (Item 1) [Figure 20-100-14] from
the piston.

Remove the piston assembly (Item 2) [Figure 20-100-14]
from the rod.
Figure 20-100-15
1
1
1 P-29880

piston.
2
P-29877

V623 VersaHANDLER
162 of 784
Figure 20-100-18 1
P-40497
Remove the head gland (Item 1) [Figure 20-100-20]

P-40496 from the rod.
Figure 20-100-21
Remove the sleeve (Item 1) [Figure 20-100-18] from the
rod.

Figure 20-100-19
1 2
P-29883
Remove the center seal (Item 1) and outer wear ring

P-40501 (Item 2) [Figure 20-100-21] from the head gland.

sleeve.
V623 VersaHANDLER
163 of 784
Figure 20-100-22
1
P-40509
Remove the bushing (Item 1) [Figure 20-100-24] from

P-29884 the rod end.
Remove the outer wear ring (Item 1) and wiper (Item 2)

[Figure 20-100-22]

Figure 20-100-23
P-29882
Remove the rod from the vise.
V623 VersaHANDLER
164 of 784
Assembly
1
MEL1353 - Cylinder Gland Nut Wrench

compressed air.
2
Always use new O-rings and seals. Lubricate all O-rings

and seals with hydraulic oil during installation, P-29884
Figure 20-100-25
Install the wiper (Item 1) and wear ring (Item 2) [Figure
20-100-27].
1
Figure 20-100-28

1
P-40509
Install the bushing (Item 1) [Figure 20-100-25] in the rod

end. P-29883
Figure 20-100-26
P-29882

the head gland.
V623 VersaHANDLER
165 of 784
Assembly (Cont’d)
Figure 20-100-29
1
P-40501
Install the O-ring (Item 1) [Figure 20-100-31] in the

P-29885 sleeve.
Figure 20-100-32
Install the center seal (Item 1) [Figure 20-100-29].

Figure 20-100-30
P-40496
Install the sleeve (Item 1) [Figure 20-100-32] on the rod.
P-40497
Put the rod end in a vise. Use care not to damage the
rod.
Install the head gland (Item 1) [Figure 20-100-30] onto

the rod.
V623 VersaHANDLER
166 of 784
Assembly (Cont’d)
Figure 20-100-33
1 1
1 2
P-29877

P-29880 [Figure 20-100-35].
Figure 20-100-36
Install the O-ring (Item 1) [Figure 20-100-33] in the
piston.

Figure 20-100-34
P-40508
1
Clean the threads and apply LOCTITE 242 or equivalent
P-29879 to the threads on the rod [Figure 20-100-36].

onto the piston.
V623 VersaHANDLER
167 of 784
Assembly (Cont’d)
Figure 20-100-37
P-29887

P-40493 1) [Figure 20-100-39].
Figure 20-100-40

Figure 20-100-38
1
P-40494
P-29888 Install the set screw (Item 1) [Figure 20-100-40] into the
piston and tighten.
Align the hole (Item 1) [Figure 20-100-38] in the piston

with the hole in the end of the cylinder rod.
V623 VersaHANDLER
168 of 784
Assembly (Cont’d)
Figure 20-100-41
P-40491
Carefully peen the lock ring over and into the nut [Figure
P-40492 20-100-43].
Remove the cylinder from the vise.

Put the housing in a vise. Use care not to damage the
housing. Figure 20-100-44

the housing. 2
Figure 20-100-42 1
2
P-40486
Install the two relief valve cartridges (Item 1) and two

fittings (Item 2) [Figure 20-100-44].
P-40490
Tighten the head gland [Figure 20-100-42].
V623 VersaHANDLER
169 of 784
Assembly (Cont’d)
Figure 20-100-45
P-40485
Install the bushing (Item 1) [Figure 20-100-45] on both

mounting blocks.

Figure 20-100-46
P-40484
Install the two mounting blocks (Item 1) [Figure 20-100-

46].
V623 VersaHANDLER
170 of 784
STEERING MODE VALVE BLOCK

IMPORTANT
Figure 20-110-1
damage the system.
I-2003-0888
Figure 20-110-3
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.
Figure 20-110-2 Remove the hoses (Item 1) [Figure 20-110-3].
NOTE: Mark the location of the hoses.
Figure 20-110-4
Remove the four solenoid mounting bolts (Item 1)

[Figure 20-110-2].
NOTE: Mark the location of the solenoids on the

block. Remove the four mounting bolts (Item 1) [Figure 20-110-
4]. Remove the block.
Remove the solenoids from the block.
V623 VersaHANDLER
STEERING MODE VALVE BLOCK (CONT'D)
V623 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.
V623 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), pin (Item 2), spring
(Item 3) 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.
V623 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].
V623 VersaHANDLER
STEERING MODE BLOCK (CONT'D) Figure 20-110-19
Assembly (Cont'd)
Figure 20-110-17
Install each coil (Item 1) onto the solenoid shaft, install

and tighten the nuts (Item 2) [Figure 20-110-19].
Figure 20-110-20
Install the spring retainer (Item 1), spring (Item 2), pin
(Item 3) 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.
V623 VersaHANDLER
BRAKE VALVE

IMPORTANT
Remove the dash cover/column cover. (See Removal
And Installation on Page 60-100-1.) When repairing hydrostatic and hydraulic systems,
damage the system.
I-2003-0888
Figure 20-120-2

Remove the three hoses (Item 1) [Figure 20-120-1] from
the brake valve.
NOTE: Mark hoses for correct assembly.
Remove the two Allen head screws (Item 1) [Figure 20-

120-2] and remove the brake valve.
V623 VersaHANDLER
V623 VersaHANDLER
GEAR PUMP Remove the tee fitting (Item 1) [Figure 20-130-2] and
two hoses from the filter head.
Figure 20-130-3
Remove the fuel tank. (See Removal And Installation on
Page 50-80-1.)
Drain the hydraulic reservoir.
IMPORTANT
damage the system.
I-2003-0888
Figure 20-130-1 Remove the three hoses (Item 1) [Figure 20-130-3].
Figure 20-130-4

Remove the hose (Item 1) [Figure 20-130-1].

Loosen the two hose clamps (Item 1) and remove the
Figure 20-130-2 hose (Item 2) [Figure 20-130-4].
V623 VersaHANDLER
GEAR PUMP (CONT'D) Figure 20-130-7
Figure 20-130-5

the flow divider valve.
Figure 20-130-8
Loosen the two hose clamps (Item 1) and remove the
hose (Item 2) [Figure 20-130-5].

Figure 20-130-6
Remove the hose (Item 1) [Figure 20-130-8] from the

gear pump.
Remove the hose (Item 1) and harness (Item 2) [Figure

20-130-6].
V623 VersaHANDLER
Figure 20-130-9
Remove the gear pump [Figure 20-130-10].
Install a chain hoist and lifting strap to lift and support the
gear pump [Figure 20-130-9].

Remove the two mounting bolts (Item 1) [Figure 20-130-
9] from the gear pump.
Assembly: Tighten the mounting bolts to 52 - 59 ft. lbs.

(50 - 80 Nm) torque.
V623 VersaHANDLER
GEAR PUMP (CONT'D)
V623 VersaHANDLER
Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
Figure 20-130-11
Remove the flow divider from the housing [Figure 20-
130-13].
Figure 20-130-14

Mark the pump housing for correct assembly and remove
the fittings (Item 1) [Figure 20-130-11].
Figure 20-130-12
Remove the fitting (Item 1), O-ring (Item 2), spring (Item
3), spring seat (Item 4) and spool (Item 5) from the
housing (Item 6) [Figure 20-130-14].
NOTE: Always use new O-rings.
Remove the four bolts (Item 1) [Figure 20-130-12].
Assembly: Tighten the bolts to 25 ft.-lbs. (33 Nm) torque.
V623 VersaHANDLER
Disassembly And Assembly (Cont'd)
Figure 20-130-15
To remove the orifice assembly (Item 1) [Figure 20-130-

17] 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) and O-ring (Item 2) [Figure 20- hardwood. Drill a 0.550 inch (14 mm) hole in the center of
130-15] from the housing. the hardwood block. Cut the block lengthwise [Figure
20-130-16].

Figure 20-130-16
Place both halves of the hardwood block around the
spool. Clamp the blocks in a vise [Figure 20-130-17].
NOTE: Do not use anything other than hardwood

blocks to grip the spool, or the spool will be
damaged.
Figure 20-130-18
Remove the screen (Item 1) from the orifice (Item 2)

[Figure 20-130-18] and clean.
V623 VersaHANDLER
Figure 20-130-19
Remove both O-rings (Item 1) [Figure 20-130-21] from

the housing.
Figure 20-130-22
Remove the housing/gear assembly (Item 1) [Figure 20-
130-19] from the main housing.

Figure 20-130-20
Remove the backup ring (Item 1) and seal ring (Item 2)

[Figure 20-130-22] from the gear holder.
Assembly: The seal ring (Item 2) [Figure 20-130-22] is

Remove the housing (Item 1) from the gear assembly installed onto the gear holder first followed by the backup
(Item 2) [Figure 20-130-20]. ring.
Assembly: The position of the small opening (Item 3) on

the gear holders will point towards the port (Item 4)
[Figure 20-130-20] on the housing.
V623 VersaHANDLER
Figure 20-130-23
Turn the housing over and remove the mount plate

[Figure 20-130-25].
Figure 20-130-26
23] from the flange.

Figure 20-130-24
Remove the snap ring (Item 1) [Figure 20-130-26].
Remove the four bolts (Item 1) and drive shaft (Item 2)

[Figure 20-130-24].
Assembly: Tighten the bolts to 25 ft.-lbs. (33 Nm) torque.
V623 VersaHANDLER
Figure 20-130-27
Remove the two thrust plates (Item 1), seal ring (Item 2)
and backup ring (Item 3) [Figure 20-130-29] from the
gears.
Remove the shaft seal (Item 1) [Figure 20-130-27]. Assembly: The seal ring (Item 2) will be installed on the
thrust plate (Item 1) first followed by the backup ring
Figure 20-130-28 (Item 3) [Figure 20-130-29].

Remove the O-ring (Item 1) and gear assembly (Item 2)
[Figure 20-130-28] from the housing.
Assembly: The position of the V portion (Item 3) on the

thrust plate must point towards the larger port (Item 4)
[Figure 20-130-28] on the housing.
V623 VersaHANDLER
V623 VersaHANDLER
FAN MOTOR Figure 20-140-3
Open the hood.
Figure 20-140-1
Remove the lower hose (Item 1) [Figure 20-140-3] from

the cooling fan motor.
Figure 20-140-4
Remove the three mounting bolts (Item 1) [Figure 20-

140-1] and remove the safety shield.
IMPORTANT
damage the system.
I-2003-0888
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.
V623 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
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.
V623 VersaHANDLER
FAN MOTOR (CONT'D)
V623 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 Remove and discard the O-ring (Item 1) [Figure 20-140-
procedure is the same. 11].
Remove the four nuts (Item 1) [Figure 20-140-9] from Assembly: Always use new O-rings.
the pump stud bolts.
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.
V623 VersaHANDLER
Figure 20-140-12
Remove the thrust plate (Item 1) [Figure 20-140-14].
Assembly: The thrust plate opening (Item 2) [Figure 20-

Remove the spacers and O-rings (Item 1) [Figure 20- 140-14] must be installed toward the pressure side of the
140-12] from the pump. pump.
Figure 20-140-13 Figure 20-140-15

Remove the O-ring (Item 1) [Figure 20-140-13] from the Remove the pump housing (Item 1) [Figure 20-140-15]
spacer (Item 2) [Figure 20-140-13] and discard. from the end plate (Item 2) [Figure 20-140-15].
Assembly: Always use new O-rings.
V623 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].
V623 VersaHANDLER
HYDRAULIC RESERVOIR Figure 20-150-3
Remove the engine/hydrostat assembly. (See Removal

And Installation on Page 70-80-1.)
Remove the air cleaner housing. (See Housing Removal

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

150-3].
Remove the reservoir.

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

150-2]. Lower the filter.
V623 VersaHANDLER
V623 VersaHANDLER
STEERING VALVE

IMPORTANT
And Installation on Page 60-100-1.) When repairing hydrostatic and hydraulic systems,
damage the system.
I-2003-0888
Figure 20-160-2

Remove the five hoses (Item 1) [Figure 20-160-1] from
the steering valve.
Remove the four bolts (Item 1) [Figure 20-160-2] and

remove the steering valve.
V623 VersaHANDLER
STEERING VALVE (CONT'D)
V623 VersaHANDLER
STEERING VALVE (CONT'D) Figure 20-160-5
Disassembly
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].

IMPORTANT
damage the system.
I-2003-0888
Figure 20-160-4
Remove the end cap (Item 1) [Figure 20-160-6].
Remove the fittings (Item 1) from the steering valve

[Figure 20-160-4].
V623 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].
V623 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].
V623 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.
V623 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) 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].
V623 VersaHANDLER
Figure 20-160-23
Remove the spool (Item 1) 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) from within each other freely or in the housing,
the metering end of the housing (Item 2) [Figure 20-160- they must be replaced.
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].
V623 VersaHANDLER
STEERING VALVE (CONT'D) Inspection
Disassembly (Cont'd) Figure 20-160-29
Figure 20-160-27
Inspect the spool (Item 1) and sleeve (Item 2) [Figure

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

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), spring (Item 2)

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

assembly.
V623 VersaHANDLER
Assembly
IMPORTANT
damage the system.
I-2003-0888
Prior to assembly, clean and lightly oil all parts.

Install the check ball (Item 1), ball seat (Item 2), spring
Figure 20-160-31 (Item 3) and plug (Item 4) [Figure 20-160-33] into the
correct port marked earlier.
Turn each of the port plugs (Item 3) 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
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), spring (Item 2) and plug (Item
3) [Figure 20-160-32] into the correct port marked
earlier.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 20-160-35
Install the control spool/sleeve assembly (Item 1) into the

metering end of the housing (Item 2) [Figure 20-160-37].
NOTE: When installing the spool assembly keep the

Install the spool (Item 1) into the sleeve (Item 2) [Figure drive pin (Item 3) [Figure 20-160-37]
20-160-35]. horizontal. If the pin becomes vertical it may
drop from the spool and get caught in an oil

NOTE: The spool should turn freely inside the sleeve. 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) and thrust bearing
(Item 2) [Figure 20-160-38] on the spool.
V623 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].
V623 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).
V623 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) in the drive shaft with the drive
pin (Item 2) [Figure 20-160-48] and install the drive
shaft.
V623 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.
V623 VersaHANDLER
V623 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367111001- Figure 20-170-2
367112500 AND 367211001-367212500)
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 ten hoses from the top of the control valve
[Figure 20-170-1].
NOTE: On machines equipped with the optional frame Remove the four connectors (Item 1) by sliding the lock
leveling control section remove two (Item 2) [Figure 20-170-3] forward and lifting on the
additional hoses. connector.
NOTE: Mark the hoses for correct installation. NOTE: On machines equipped with the optional frame
leveling control section remove two
additional hoses.
NOTE: Mark the location of the connectors for correct

assembly.
V623 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367111001-
367112500 AND 367211001-367212500) (CONT’D)
Figure 20-170-4
Remove the four valve mounting bolts (Item 1) [Figure

20-170-4].

Remove the valve assembly.
V623 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367111001-367112500 AND 367211001-367212500) (CONT'D)
V623 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367111001- Assembly: Tighten the thru-bolt nuts (Item 1) [Figure
367112500 AND 367211001-367212500) (CONT'D) 20-170-6] to 16-19 ft.-lbs. (22-26 Nm) torque.
Disassembly And Assembly NOTE: Control valve shown with optional frame
leveling valve section (Item 1) [Figure 20-170-
5].
IMPORTANT Figure 20-170-7

damage the system.
I-2003-0888
Figure 20-170-5

Remove the end housing (Item 1) [Figure 20-170-7] from
the control valve.
Figure 20-170-8
P-40257
Mark all of the sections of the control valve for proper

installation [Figure 20-170-5].
Remove all hydraulic fittings.
Figure 20-170-6
Remove the five O-rings (Item 1) [Figure 20-170-8] from

the end housing.
Remove the thru-bolt nuts (Item 1) [Figure 20-170-6]

and washers.
V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Frame Leveling Valve Section (Optional)
Figure 20-170-9
Remove the four controller mounting screws (Item 1)

[Figure 20-170-11].
Assembly: Tighten the screws to 70 in.-lbs. (0.8 Nm)

torque.
Remove the frame leveling valve section (Item 1) [Figure
20-170-9]. Remove the controller from the frame leveling valve

section.
Figure 20-170-10
Figure 20-170-12
Remove the seven O-rings (Item 1) [Figure 20-170-10]

from the valve section. Remove the five O-rings (Item 1) [Figure 20-170-12]
from the controller.
V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Frame Leveling Valve Section (Optional) (Cont'd)
Figure 20-170-13
Carefully remove the filter (Item 1) [Figure 20-170-15]

Figure 20-170-16
Remove the three orifices (Item 1) [Figure 20-170-13]


NOTE: Mark the location of the orifices for correct
assembly.
Figure 20-170-14
Clean and inspect the filter (Item 1) [Figure 20-170-16]

for wear or damage.
Check the O-ring (Item 1) [Figure 20-170-14] on each

orifice removed, and replace as needed.
V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Figure 20-170-17
Remove the three O-rings (Item 1) [Figure 20-170-19]

from the control box.
Figure 20-170-20
Measure and record the distance from the control box

housing to the end of the adjusting screws (Item 1)

[Figure 20-170-17]. Loosen the adjusting screws to allow
the control box to be removed.
Remove the four mounting screws (Item 2) [Figure 20-

170-17] from the control box.

torque.
Figure 20-170-18
Remove the spool assembly (Item 1) [Figure 20-170-20]

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

170-18] from the frame leveling valve section.
V623 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367111001- Assembly: Tighten the actuator to 6 ft.-lbs. (0.8 Nm)
367112500 AND 367211001-367212500) (CONT'D) torque.
Frame Leveling Valve Section (Optional) (Cont'd) Figure 20-170-23
Figure 20-170-21
Remove the actuator (Item 1), O-ring (Item 2), spring

retainer (Item 3 and spring (Item 4) [Figure 20-170-23].
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 20-170-24
long) piece of hardwood. Drill a 0.6250 inch (15 mm) hole
in the center of the hardwood block. Cut the block
lengthwise [Figure 20-170-21].
Figure 20-170-22

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 20-170-22].

damaged.
Remove the actuator (Item 1) [Figure 20-170-22] from

the end of the spool.
V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Figure 20-170-25
Check the spool (Item 1) [Figure 20-170-26] for

scratches, or wear. Replace as needed.
Check the O-ring (Item 1) [Figure 20-170-25] on the

plug. Replace as needed.
V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Auxiliary Valve Section
Figure 20-170-27

[Figure 20-170-29].

torque.
Remove the auxiliary valve section (Item 1) [Figure 20-
170-27]. Remove the controller from the telescoping valve section.

Figure 20-170-28 Figure 20-170-30
Remove the seven O-rings (Item 1) [Figure 20-170-28] Remove the five O-rings (Item 1) [Figure 20-170-30]
from the valve section. from the controller.
V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Auxiliary Valve Section (Cont'd)
Figure 20-170-31

Figure 20-170-34


assembly.
Figure 20-170-32

for wear or damage.

V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Figure 20-170-35

Figure 20-170-38


torque.
Figure 20-170-36

from the telescoping valve section.

170-36] from the telescoping valve section.
V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D) torque.
Auxiliary Valve Section (Cont'd) Figure 20-170-41
Figure 20-170-39

retainer (Item 3) and spring (Item 4) [Figure 20-170-41]

Figure 20-170-40

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

[Figure 20-170-40].

damaged.

V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Figure 20-170-43

valve section.
Figure 20-170-46


Figure 20-170-44


V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Telescoping Valve Section
Figure 20-170-47

valve section.
Replace the O-ring on the plug.
Remove the spring/check valve (Item 1) [Figure 20-170- Figure 20-170-50

47] from the valve section.

Figure 20-170-48
Remove the spring/check valve (Item 1) [Figure 20-170-

Check the check valve for damage or wear. Replace as

needed [Figure 20-170-48].
V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Tilting Valve Section
Figure 20-170-51

[Figure 20-170-53].

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

Figure 20-170-52 Figure 20-170-54
V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Tilting Valve Section (Cont'd)
Figure 20-170-55

Figure 20-170-58


assembly.
Figure 20-170-56

for wear or damage.

V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Figure 20-170-59

Figure 20-170-62


torque.
Figure 20-170-60

from the telescoping valve section.

170-60] from the telescoping valve section.
V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D) torque.
Tilting Valve Section (Cont'd) Figure 20-170-65
Figure 20-170-63


Figure 20-170-64

end of the spool.

[Figure 20-170-64].

damaged.

V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Figure 20-170-67

valve section.
Figure 20-170-70


Figure 20-170-68


V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Figure 20-170-71
Remove the spring/poppet assembly (Item 1) [Figure 20-

170-73] from the valve section.
Figure 20-170-74


Figure 20-170-72
Check the spring/poppet assembly for damage or wear

[Figure 20-170-74].

valve section.
V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Lifting Valve Section
Figure 20-170-75

[Figure 20-170-77].

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

Figure 20-170-76 Figure 20-170-78
V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Lifting Valve Section (Cont'd)
Figure 20-170-79

Figure 20-170-82


assembly.
Figure 20-170-80

for wear or damage.

V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Figure 20-170-83

Figure 20-170-86


torque.
Figure 20-170-84

from the lifting valve section.

170-84] from the lifting valve section.
V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D) torque.
Lifting Valve Section (Cont'd) Figure 20-170-89
Figure 20-170-87


Figure 20-170-88

end of the spool.

[Figure 20-170-88].

damaged.

V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Figure 20-170-91

valve section.
Figure 20-170-94


Figure 20-170-92


V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Figure 20-170-95

Figure 20-170-98


Figure 20-170-96
Check the spring/poppet assembly for damage or wear

[Figure 20-170-98].

valve section.
V623 VersaHANDLER
367112500 AND 367211001-367212500) (CONT'D)
Inlet/Outlet Valve Section
Figure 20-170-99
Remove the spool (Item 1) and spring (Item 2) [Figure

20-170-101] from the valve.
Assembly: The rounded part of the spring (Item 3)

[Figure 20-170-101] must go next to the spoo
valve.

Figure 20-170-100
Remove the O-ring (Item 1) [Figure 20-170-100] from

the plug. Replace as needed.
V623 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367112501- NOTE: Mark all hoses and tubelines for correct
367113000 AND 367212501-367213000) installation.
Removal And Installation Figure 20-171-2
Relieve hydraulic pressure. Drain the hydraulic reservoir.

(See HYDRAULIC RESERVOIR on Page 20-150-1.)
WARNING
2
sufficient force to enter a person’s body by 1
immediately.
W-2145-0290 P-42969
Remove the tubeline (Item 1) and hose (Item 2) [Figure

20-171-2].
IMPORTANT

Figure 20-171-3
damage the system.
I-2056-0793
1
Figure 20-171-1
P-42970
Remove the two hoses (Item 1) [Figure 20-171-3].
P-44523
Remove the rear cover (Item 1) [Figure 20-171-1].
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)
Figure 20-171-4
1 2
1
4
P-42973
1 2 1
Unplug the two wire connectors (Item 1) [Figure 20-171-
6] from the main wire harness.
P-42971
NOTE: On models with frame leveling unplug an
additional wire connector (Item 2) [Figure 20-
Remove the five hoses (Item 1) [Figure 20-171-4] from 171-6].
the control valve.

NOTE: Mark the location of the connectors for correct
NOTE: On models with frame leveling remove an installation.
additional hose (Item 2) [Figure 20-171-4].
Remove the tubeline (Item 3) and hose (Item 4) [Figure
Figure 20-171-5 20-171-6].
Figure 20-171-7
1
1
1 1 2
P-42972
P-42974
Remove the six hoses (Item 1) [Figure 20-171-5] from
the control valve.
NOTE: On models with frame leveling remove an
additional hose (Item 2) [Figure 20-171-5].
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)
Figure 20-171-8
1 1
P-42976

10] from the control valve.
P-42977
Figure 20-171-11

control valve.

Figure 20-171-9 1
P-42978
Install a hoist and lift strap (Item 1) [Figure 20-171-11]

on the control valve.
P-42975
Use care not to damage the tubelines or fittings.
Remove the mounting bolt (Item 1) [Figure 20-171-9]

from the front of the control valve.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)
Figure 20-171-12
P-42979
Raise the hoist and remove the control valve [Figure 20-
171-12].
V623 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367112501-367113000 AND 367212501-367213000) (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
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)
IMPORTANT
damage the system. 1
I-2056-0793
P-42982
Figure 20-171-13
Remove the three nuts (Item 1) [Figure 20-171-15] from
the tie rod bolts.
Assembly: Tighten the nuts to 26 ft.-lbs. (35 Nm) torque.
End Housing Disassembly And Assembly

Figure 20-171-16
1
P-42980
Remove the tubeline (Item 1) [Figure 20-171-13].
Figure 20-171-14
P-42983
Remove the end housing (Item 1) [Figure 20-171-16].
P-42981
Remove all hydraulic fittings. Mark the valve sections for

proper assembly [Figure 20-171-14].
V623 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367112501- Lifting Valve Section Disassembly And Assembly
367113000 AND 367212501-367213000) (CONT’D)
Figure 20-171-19
End Housing Disassembly And Assembly (Cont’d)
Figure 20-171-17
1
1
2
P-42986
P-42984 Remove the lifting valve section (Item 1) [Figure 20-171-

19].
Remove the dust cap (Item 1) and plug (Item 2) [Figure Figure 20-171-20
20-171-17] from the end housing.

Figure 20-171-18
1
P-42987
P-42985 Remove the four O-rings (Item 1) [Figure 20-171-20]

from the valve section.

plug.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)
Lifting Valve Section Disassembly And Assembly

(Cont’d)
Figure 20-171-21
1 1
P-42991
Loosen the four screws (Item 1) [Figure 20-171-23].
Assembly: Tighten the screws to 7 ft,-lbs. (10 Nm)

P-42989 torque.
Figure 20-171-24

valve section.
Figure 20-171-22
1 1
2
1
P-42992
Remove the four screws (Item 1) and cover (Item 2)

P-42990 [Figure 20-171-24].
Remove the two O-rings (Item 1) and backup ring (Item

2) [Figure 20-171-22] from the plug.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

(Cont’d)
Figure 20-171-25
1
1
P-42996
Remove the relief valve (Item 1) [Figure 20-171-27] from

the valve section.
P-42993 Assembly: Tighten the relief valve to 33 ft.-lbs. (45 Nm)

torque.

Figure 20-171-28
cover.
Figure 20-171-26
1
2
P-42988
2
1
P-42995 Remove the two O-rings (Item 1) and backup ring (Item
2) [Figure 20-171-28] from the relief valve.
Remove the spring (Item 1) and spring retainer (Item 2)

[Figure 20-171-26] from the spool.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

(Cont’d)
Figure 20-171-29
1
P-42993
1
Remove the O-ring (item 1) [Figure 20-171-31] from the

cover.
P-42997 Figure 20-171-32

Assembly: Tighten the screws to 7 ft.-lbs. (10 Nm)
torque.
Figure 20-171-30 2
1
1 P-42999

P-42998

[Figure 20-171-30] from the valve section.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

(Cont’d)
2
Figure 20-171-33 1
P-44276
Remove the spring (Item 1) and poppet (Item 2) [Figure

20-171-35] from the plugs.
P-44000 Figure 20-171-36
Remove the spool (Item 1) [Figure 20-171-33] from the

valve section.
Figure 20-171-34 1
P-44277
1
plugs.
P-44275
Remove the two plugs (Item 1) [Figure 20-171-34] from

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

torque.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

(Cont’d)
Figure 20-171-37
1
P-44280

plug.
P-44278 Tilting Valve Section Disassembly And Assembly
Figure 20-171-40
Loosen the plug (Item 1) [Figure 20-171-37].

Assembly: Tighten the plug to 40-49 ft.-lbs. (54-66 Nm) 1
torque.
Figure 20-171-38
3 P-44001
2
Remove the tilting valve section (Item 1) [Figure 20-171-
1 40]
P-44279
Remove the plug (Item 1) poppet (Item 2) and guide

(Item 3) [Figure 20-171-38] from the valve section.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)
Tilting Valve Section Disassembly And Assembly

(Cont’d)
1
Figure 20-171-41 2
P-42988

1 2) [Figure 20-171-43] from the relief valve.
P-44002 Figure 20-171-44
Remove the four O-rings (Item 1) [Figure 20-171-41]

Figure 20-171-42
1
1
P-44004
Loosen the four screws (Item 1) [Figure 20-171-44] on

the cover.
P-44003 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.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

(Cont’d)
Figure 20-171-45
2
1
1
P-44006

P-44005 Figure 20-171-48

Figure 20-171-46 1
P-44007

the valve section.

torque.

cover.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

(Cont’d)
Figure 20-171-49
2
1
1
2
P-44009

P-42988 Figure 20-171-52

Figure 20-171-50
2
1
P-44010
1
P-44008

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

torque.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

(Cont’d)
2
Figure 20-171-53 1
P-44276

P-44011 Figure 20-171-56

valve section.
1
Figure 20-171-54
P-44277
1
plugs.
P-44275

the valve section.

torque.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

(Cont’d)
Figure 20-171-57
P-44280

plug.
P-44278 Telescoping Valve Section Disassembly And

Assembly

Figure 20-171-60
Assembly: Tighten the plug to 40-49 ft.-lbs. (54-66 Nm)

torque. 1
Figure 20-171-58
3
P-44012
2
Remove the telescoping valve section (Item 1) [Figure
1
20-171-60].
P-44279

V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)
Telescoping Valve Section Disassembly And

Assembly (Cont’d)
Figure 20-171-61
1
P-44015
1
Remove the controller assembly (Item 1) [Figure 20-171-
P-44013 Figure 20-171-64

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

controller assembly.
P-44014
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.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-65
1 P-44019

the controller assembly.
P-44017 Assembly: Tighten the screws to 2-3 ft.-lbs. (3-3,5 Nm)

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

Figure 20-171-68
Figure 20-171-66
2
1
1
P-44020
P-44018 Remove the four screws (Item 1) and cover (Item 2)

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

from the couplers.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-69
1
P-44023
1
plug.
P-44021 Figure 20-171-72
Remove the seal (Item 1) [Figure 20-171-69] from the

cover.
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.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Assembly (Cont’d)
1
Figure 20-171-73 2
1 P-44027

20-171-75] from the port valve.
P-44025 Figure 20-171-76

plunger.
1
Figure 20-171-74
P-44028

from the port valve.
P-44026
Remove the port valve (Item 1) [Figure 20-171-74] from

the controller.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-77
1 1
P-44031
Remove the cover (Item 1) [Figure 20-171-79] from the

port block.
P-44029 Figure 20-171-80
Remove the spacer (Item 1) [Figure 20-171-77] from the

actuator.
Figure 20-171-78 1
P-44032
Remove the poppet (Item 1) [Figure 20-171-80] from the

cover.
P-44030

V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Assembly (Cont’d)
1
Figure 20-171-81
P-44035

from the positioning valve.
1
P-44033 Figure 20-171-84
Remove the positioning valve (Item 1) [Figure 20-171-

81] from the port block.
Figure 20-171-82 1
P-44036

the valve section.
P-44034 Assembly: Tighten the valve to 33 ft.-lbs. (45 Nm)

torque.

from the positioning valve.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-85
1
2
1 2
1
P-44038
Remove the screw (Item 1) and piston (Item 2) [Figure

20-171-87] from the adapter.
P-42988 Figure 20-171-88

Figure 20-171-86
P-44039
1
from the piston.
P-44037
Loosen the screw (Item 1) [Figure 20-171-86] on the

piston.
Assembly: Tighten the screw to 7 ft.-lbs. (10 Nm) torque.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-89
1
1
P-44041
Loosen the two screws (item 1) [Figure 20-171-91] on

the cover.

torque.

Figure 20-171-92
valve section.
Figure 20-171-90
1 2
2 1
P-44042
P-42990 Remove the two screws (Item 1) and cover (Item 2)


2) [Figure 20-171-90] from the plug.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-93
P-44046
Remove the adapter (Item 1) [Figure 20-171-95] from

the spool.
1
P-44044 Figure 20-171-96
Install a hex wrench in the screw (Item 1) [Figure 20-

171-93] on the end of the spool.
Figure 20-171-94 1
P-44047
Remove the O-ring (Item 1)[Figure 20-171-96] from the

adapter.
P-44045
Loosen the adapter (Item 1) [Figure 20-171-94].
Assembly: Tighten the adapter to 7-8 ft.-lbs. (9-11 Nm)

torque.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-97
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 20-171-97] from the

valve section. Figure 20-171-100
Figure 20-171-98
3
2
1
P-44051
P-44049
Remove the O-ring (Item 1) seal (Item 2) and retainer
(Item 3) [Figure 20-171-100] from the spool.
Assembly: Install the countersunk side of the washer
(Item 1) [Figure 20-171-98] into the valve section.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-101
2
1 1
P-33886
Using the wood blocks clamp the spool (Item 1) [Figure

20-171-103] 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-

101] fits inside the retainer (Item 3) [Figure 20-171-100]. Loosen the screw (Item 2) [Figure 20-171-103]].
Figure 20-171-102 Assembly: Tighten the screw to 7 ft.-lbs. (10 Nm) torque.
Cut Figure 20-171-104
0.710” 2.0”
1
1.500” 4
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 171-104] from the spool.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-105 1
P-44277
1
the plugs.
P-44275 Figure 20-171-108

the valve section;
1
torque.
Figure 20-171-106
2
1
P-44278

torque.
P-44276

V623 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367112501- Auxiliary Valve Section Disassembly And Assembly
367113000 AND 367212501-367213000) (CONT’D)
Figure 20-171-111
Assembly (Cont’d)
Figure 20-171-109 1
P-44054
2
1 Remove the auxiliary valve section (Item 1) [Figure 20-

P-44279 171-111].
Figure 20-171-112

Figure 20-171-110
1
1
P-44055

P-44280 from the valve section.

the plug.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)
Auxiliary Valve Section Disassembly And Assembly

(Cont’d)
Figure 20-171-113
P-44058
1
P-44056 Figure 20-171-116
Remove the two screws (Item 1) [Figure 20-171-113]]


Nm) torque.
Figure 20-171-114 1
P-44059
Remove the two couplers (Item 1) [Figure 20-171-116]

1
P-44057

V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

(Cont’d)
Figure 20-171-117
2
1
P-44061

P-44018 Figure 20-171-120

from the couplers.
Figure 20-171-118
P-44021

1 cover.
P-44060
Assembly: Tighten the screws to 2-3 ft.-lbs. (3-3,5 Nm)

torque.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

(Cont’d)
Figure 20-171-121
2
1
P-44062
1
Remove the controller (Item 1) from the port block (Item
2) [Figure 20-171-123].
P-44022 Figure 20-171-124

cover.
Figure 20-171-122
1
1
1
P-44063
Remove the two port valves (Item 1) [Figure 20-171-

124] from the controller.
P-44023

the plug.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

(Cont’d)
Figure 20-171-125
1 1
2
P-44066
Remove the two poppets (Item 1) [Figure 20-171-127]

P-44064 Figure 20-171-128

20-171-125] from the port valves.
Figure 20-171-126
1
1
P-44067

P-44065

from the port valves.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

(Cont’d)
Figure 20-171-129
2
1
P-44070
1

20-171-131] from the adapter.
P-44068 Figure 20-171-132

the port block.
Figure 20-171-130
P-44071
Loosen the two screws (Item 1) [Figure 20-171-132] on

the cover.
1
torque.

piston.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

(Cont’d)
Figure 20-171-133
1
P-44074
Loosen the adapter (Item 1) [Figure 20-171-135].

P-44072 torque.
Figure 20-171-136
Remove the two screws (Item 1) and cover (Item 2)

Figure 20-171-134
P-44077
1
Remove the adapter (Item 1) and washer (Item 2)
P-44073 [Figure 20-171-136] from the valve section.

171-134].
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

(Cont’d)
Figure 20-171-137
1
P-44078

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

interchange spools and valve blocks.

(Item 1) [Figure 20-171-137] into the valve section. Figure 20-171-140
Figure 20-171-138
3
2
1
P-44051
P-44047
Remove the O-ring (Item 1), seal (Item 2) and retainer
the adapter.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

(Cont’d)
Figure 20-171-141
2
1
1
P-33886

20-171-143] in a vise.
P-44053 NOTE: Do not use anything other than hardwood

damaged.

141] fits inside the retainer. Loosen the screw (Item 2) [Figure 20-171-143].
Figure 20-171-142 Assembly: Tighten the screw to 7 ft.-lbs. (10 Nm) torque.
Cut Figure 20-171-144
0.710” 2.0”
1 4
1.500”
0.750”
B-14674
3
2
P-44052
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 171-144] from the spool.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

(Cont’d)
Figure 20-171-145 1
P-44277
1
the plugs.
P-44281 Figure 20-171-148

the valve section. 1

torque.
Figure 20-171-146
2
1
P-44282
Assembly: Tighten the plug to 40-49 ft.lbs. (54-66 Nm)

torque.
P-44276

V623 VersaHANDLER
HYDRAULIC CONTROL VALVE (S/N 367112501- Frame Leveling Valve Section Disassembly And
367113000 AND 367212501-367213000) (CONT’D) Assembly (If Equipped)
Auxiliary Valve Section Disassembly And Assembly Figure 20-171-151

(Cont’d)
Figure 20-171-149 1
2 P-44079
1
P-44283 Remove the frame leveling valve section (Item 1) [Figure
20-171-151].
Remove the plug (Item 1), poppet (Item 2) and guide

Figure 20-171-152
Figure 20-171-150
P-44080
P-44280 Remove the four O-rings (Item 1) [Figure 20-171-152]


the plug.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)
Frame Leveling Valve Section Disassembly And

Assembly (If Equipped) (Cont’d)
Figure 20-171-153
P-44083
1
P-44081 Figure 20-171-156
Remove the two screws (Item 1) [Figure 20-171-153]


Nm) torque.
Figure 20-171-154
P-44084
Assembly: Tighten the screws to 2-3 ft.-lbs. (3-3,5 Nm)

torque.
1
P-44082

V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Figure 20-171-157
1
2
1
P-44022
Remove the plug (Item 1) [Figure 20-171-159]] from the

cover.
P-44085 Figure 20-171-160

Figure 20-171-158
1
P-44023

the plug.
P-44021

cover.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Figure 20-171-161
P-44088
Remove the two caps (Item 1) [Figure 20-171-163] from

the port block.
2
1
P-44086 Figure 20-171-164
Remove the controller (Item 1) from the port block (Item

2) [Figure 20-171-161].
Figure 20-171-162 1
P-44089
Remove the poppet (Item 1) [Figure 20-171-164] from

the caps.
P-44087

the plunger.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

1
Figure 20-171-165
1 P-44035

from the positioning valves.
P-44090 Figure 20-171-168
Remove the two positioning valves (Item 1) [Figure 20-

171-165] from the port block.
Figure 20-171-166
1
1
P-44091

the connecting flange.
P-44034 Assembly: Tighten the screws to 7-8 ft.-lbs. (9-11 Nm)

torque.

from the positioning valves.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Figure 20-171-169
1 P-44094

piston.
P-44092 Assembly: Tighten the screw to 7 ft.-lbs. (10 Nm) torque.
Figure 20-171-172
Remove the two screws (Item 1) and connecting flange

(Item 2) [Figure 20-171-169].
Figure 20-171-170
2
1
1
P-44096

P-44093 20-171-172] from the adapter.

from the connecting flange.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Figure 20-171-173
P-44099

1 171-175].
P-44097 Figure 20-171-176

the cover.
Assembly: Tighten the screws to 7 ft.-lbs. (10 Nm) 1

torque.
Figure 20-171-174
P-44100
2
1 Loosen the adapter (Item 1) [Figure 20-171-176].

torque.
P-44098
Remove the two screws (Item 1) and cover (Item 2)

V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Figure 20-171-177
1
1
P-44102
Remove the washer (Item 1) [Figure 20-171-179] from

the valve section.
P-44101 Figure 20-171-180
Remove the adapter (Item 1) [Figure 20-171-177] from

the spool.
Figure 20-171-178
P-44049

(Item 1) [Figure 20-171-180] into the valve section.
P-44047

the adapter.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

1
Figure 20-171-181
P-44053

183] fits inside the retainer.
P-44103 Figure 20-171-184
Remove the spool (Item 1) [Figure 20-171-181] from the Cut

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

interchange spools and valve blocks. 2.0”
0.710”
Figure 20-171-182
3
1.500”
2 0.750”
B-14674
1

inch wide x 2.0 inch long (19 mm thick x 38 mm wide x 51
mm long) piece of hardwood. Drill a 0.710 inch (18 mm)
hole in the center of the hardwood block. Cut the block
P-44051
Remove the O-ring (Item 1), seal (Item 2) and retainer

V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Figure 20-171-185
2 P-44281
1
the valve section.
P-33886 Assembly: Tighten the plugs to 20-24 ft.-lbs. (27-33 Nm)

torque.

Figure 20-171-188
20-171-185] in a vise.

blocks to grip the spool, or the spool will be 2
damaged.
1
Loosen the screw (Item 2) [Figure 20-171-185].
Figure 20-171-186
P-44276

4
1
3
2
P-44052
Remove the screw (Item 1), spring retainer (Item 2),

spring (Item 3) and spring retainer (Item 4) [Figure 20-
171-186] from the spool.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Figure 20-171-189
3
1
2
1
P-44283
Remove the plug (Item 1), poppet (Item 2 ) and guide

P-44277 Figure 20-171-192

the plugs.
Figure 20-171-190
1
P-44280

the plug.
P-44282

torque.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)
Inlet-Outlet Valve Section Disassembly And

Assembly
1
Figure 20-171-193
1
P-44106

the plug.
P-44104 Figure 20-171-196

1
Figure 20-171-194
P-44107
Remove the spring (Item 1) [Figure 20-171-196] from

the valve section.
P-44105

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

torque.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-197 1
P-44110
Remove the relief valve (Item 1) [Figure 20-171-199]


torque.

Figure 20-171-200
valve section.
Assembly: Tighten the plug to 15 ft.-lbs. (20 Nm) torque.
Figure 20-171-198
2
1
P-44111

P-44109

the plug.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-201 1
1 P-44268

the plug.
P-44112 Figure 20-171-204
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 20-171-202
4
P-44269
3
2 1
Remove the screen (Item 1) [Figure 20-171-204] from
the valve.
P-44265
Remove the plug (Item 1), shim (Item 2), spring (Item 3)
and spool (Item 4) [Figure 20-171-202] from the valve.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-205
1
P-44115
1 2
the test fitting.
P-44267 Figure 20-171-208

2) [Figure 20-171-205] from the flow regulator valve.
Figure 20-171-206 1
P-44116
Remove the cap (Item 1) [Figure 20-171-208] from the

test fitting.
P-44114
Remove the test fitting (Item 1) [Figure 20-171-206] from

the valve section.
V623 VersaHANDLER
367113000 AND 367212501-367213000) (CONT’D)

Assembly (Cont’d)
Figure 20-171-209
P-44117

the test fitting.
V623 VersaHANDLER
V623 VersaHANDLER
JOYSTICK (S/N 367112501-367113000 AND Figure 20-180-3
367212501-367213000)
Handle Removal And Installation
Remove the dash cover/steering column cover. (See 1

Removal And Installation on Page 60-100-1.)
1
Remove the joystick panel. (See JOYSTICK PANEL 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].
V623 VersaHANDLER
367212501-367213000) (CONT’D)
Handle Removal And Installation (Cont’d)
Figure 20-180-5
1
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.

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

1
Remove the dash cover/steering column cover. (See 1
2
Page 60-50-1.)
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.
WARNING
P-47776
immediately.
Disconnect the electrical connector (Item 1) [Figure 20- W-2145-0290
180-6].
V623 VersaHANDLER
367212501-367213000) (CONT’D)
Joystick Removal And Installation (Cont’d)
1
IMPORTANT
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.
V623 VersaHANDLER
JOYSTICK (S/N 367112501-367113000 AND 367212501-367213000) (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
V623 VersaHANDLER
367212501-367213000) (CONT’D)

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
Remove the swivel joint (Item 1) [Figure 20-180-14].

2
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.
V623 VersaHANDLER
367212501-367213000) (CONT’D)
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

housing.
P-42901
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.
V623 VersaHANDLER
367212501-367213000) (CONT’D)
Disassembly And Assembly (Cont’d)

1
Figure 20-180-19
3
1
2
P-42907

rod.
P-42905
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
NOTE: Install the spool assemblies in the same bore
the spools were removed from.
inside of the plunger body.
V623 VersaHANDLER
367212501-367213000) (CONT’D)

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

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

(Item 2) [Figure 20-180-23].

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

(Item 3) and shims (Item 4) from the spool (Item 5)
[Figure 20-180-24].
V623 VersaHANDLER
367212501-367213000) (CONT’D)

1
Figure 20-180-27
P-42918

from the housing,
P-42915
Clean all parts in solvent and dry with compressed air.
Inspect the push rod crown for wear. Replace all
Remove the O-ring (Item 1) [Figure 20-180-27] from the components showing excessive wear.
bolt.

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

[Figure 20-180-28].
V623 VersaHANDLER
V623 VersaHANDLER
HYDROSTATIC SYSTEM
HYDROSTATIC DRIVE MOTOR. . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-22
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-5
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-20
HYDROSTATIC
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1 SYSTEM
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-26
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-9
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-22
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . 30-10-1

Replenishing The Valve Function . . . . . . . . . . . . . . . . . . . 30-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

V623 VersaHANDLER
V623 VersaHANDLER
HYDROSTATIC SYSTEM INFORMATION
WARNING
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
The VersaHANDLER does not move 1, 2
The VersaHANDLER does not move in a straight line. 3, 4
The hydrostatic system is overheating. 5, 6, 7, 8
Warning light comes ON. 5, 8, 9, 10, 11

1. The hydrostatic pump has damage.
2. The hydrostatic motor has damage.

3. The tires do not have the correct tire pressure.
4. The tires are not the same size.
5. The hydrostatic fluid is not at the correct level.
6. The oil cooler has a restriction.
7. The temperature sending switch is not operating correctly.
8. The VersaHANDLER is not being operated at the correct RPM.
9. The sender is defective.
10. Pump is defective or worn hydrostatics
11. Hydraulic filter is plugged.
V623 VersaHANDLER
309 of 784
HYDROSTATIC SYSTEM INFORMATION (CONT’D)
Replenishing The Valve Function

IMPORTANT
Figure 30-10-1
damage the system.
I-2003-0888
The functions of the replentishing valves are:
1. To give replacement fluid to the low pressure side of

the hydrostatic circuit. Replacement fluid is needed
because of normal internal leakage and the controlled
Function 1 Valve Moves For flow to the oil cooler for cooling; Function 1 [Figure
Charge Oil 30-10-1].
Replacement
2. To keep high pressure fluid out of the low pressure
side of the hydrostatic circuitry; Function 2 [Figure
30-10-1].

Valve Stays on Seat
to Hold High
Pressure for
Drive
Function 2 B-2804
V623 VersaHANDLER
310 of 784
OIL COOLER Figure 30-20-3
IMPORTANT
damage the system.
I-2003-0888
OPEN THE ENGINE COVER

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.
V623 VersaHANDLER
V623 VersaHANDLER
HYDROSTATIC DRIVE MOTOR
Figure 30-30-1

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.
V623 VersaHANDLER
HYDROSTATIC DRIVE MOTOR (CONT'D)
V623 VersaHANDLER
Parts Identification (Cont’d)
V623 VersaHANDLER
V623 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 four bolts (Item 1) [Figure 30-30-3] and

remove the solenoid housing.
V623 VersaHANDLER
Figure 30-30-6
Remove the solenoid shaft (Item 1) and O-ring (Item 2

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

Figure 30-30-7
Remove the O-ring (Item 1) and pin (Item 2) from the

solenoid shaft (Item 3) [Figure 30-30-9].

housing.
V623 VersaHANDLER
Figure 30-30-10
Remove the pin (Item 1) [Figure 30-30-12] from the

housing.
Figure 30-30-13
housing.

Figure 30-30-11
Remove the fitting (Item 1) [Figure 30-30-13].

11] from the plug.
V623 VersaHANDLER
Figure 30-30-14
Remove the eight bolts (Item 1) [Figure 30-30-16] from

the end cap.
Figure 30-30-17
housing.

Figure 30-30-15
Lift and remove the end cap (Item 1) [Figure 30-30-17]

from the housing.
Remove and discard the seven O-rings (Item 1) [Figure

30-30-15] from the housing.
V623 VersaHANDLER
Figure 30-30-18
Remove the orifice (Item 1) [Figure 30-30-20].
NOTE: Mark the orifice location for correct assembly.
Remove the gasket (Item 1) [Figure 30-30-18] from the Figure 30-30-21
end cap.

Figure 30-30-19
Remove the spool (Item 1) [Figure 30-30-21].
Remove the plug (Item 1) [Figure 30-30-19].
V623 VersaHANDLER
Figure 30-30-22
Remove the two orifices (Item 1) [Figure 30-30-24] from

the spool.
NOTE: Mark the orifice location for correct assembly.

Remove the servo control spool (Item 1) [Figure 30-30-
22] from the housing. Figure 30-30-25

Figure 30-30-23
Remove the two spring seats and spring (Item 1) from the
servo spool hole (Item 2) [Figure 30-30-25].
the servo control spool.
V623 VersaHANDLER
Figure 30-30-26

28].
Figure 30-30-29
Loosen the large nut (Item 1) [Figure 30-30-26] on the
adjustment screw.

NOTE: Do not change the adjustment.
Figure 30-30-27
Remove the four bolts (Item 1) and remove the end cap
(Item 2) [Figure 30-30-29].
Remove the adjustment screw (Item 1) [Figure 30-30-27]

from the housing.
V623 VersaHANDLER
Figure 30-30-30
Remove the inner set screw the servo piston [Figure 30-
30-32].
Figure 30-30-33
Figure 30-30-31

Remove the feedback lug (Item 1) [Figure 30-30-33]
from the servo piston.
Remove the outer set screw from the servo piston

[Figure 30-30-31].
V623 VersaHANDLER
Figure 30-30-34
Remove the two plugs (item 1) [Figure 30-30-36] from

the housing.
Figure 30-30-37
Remove the servo piston (Item 1) [Figure 30-30-34].
Figure 30-30-35

the housing by loosening the larger nut.
Remove the two seals (Item 1) [Figure 30-30-35] from

the servo piston.
V623 VersaHANDLER
Figure 30-30-38
Remove the plug (Item 1), spring (Item 2), spring seat
(Item 3) and spool (Item 4) [Figure 30-30-40] from the
housing.
Remove the plug (Item 1), O-rings (Item 2), spring (Item Figure 30-30-41
3) and poppet (Item 4) from the relief valve housing (Item
5) [Figure 30-30-38].

Figure 30-30-39
V623 VersaHANDLER
Figure 30-30-42
Figure 30-30-45
Remove the plug (Item 1), spring (Item 2) and spring seat
(Item 3) [Figure 30-30-42] from the housing.

Figure 30-30-43
NOTE: Mark the location of the orifice for correct

assembly.

43] from the plug.
V623 VersaHANDLER
Figure 30-30-46
Remove the valve segment (Item 1) [Figure 30-30-48]

from the cylinder.
Figure 30-30-49
Figure 30-30-47

Remove and discard the O-ring (Item 1). Remove the
eight mounting bolts (Item 2) [Figure 30-30-49] from the
mounting plate.
NOTE: Mark the location of the orifice for correct

assembly.
V623 VersaHANDLER
Figure 30-30-50
Remove the cylinder block (Item 1) and synchronizing

shaft assembly (Item 2) [Figure 30-30-52] from the
housing.
Remove the mounting plate (Item 1) [Figure 30-30-50] NOTE: It is not important that the pistons are installed
using a suitable puller. in their original position.

Figure 30-30-51 Figure 30-30-53
Remove and discard the seal (Item 1) [Figure 30-30-51] Remove the bearing plate (Item 1) [Figure 30-30-53]
from the mounting plate. from the cylinder block.
V623 VersaHANDLER
Figure 30-30-54
Press the piston/shaft assembly from the housing

[Figure 30-30-56].
DO NOT damage the pistons.

Remove the bearing from the cylinder block [Figure 30-
30-54]. Figure 30-30-57

DO NOT damage the bearing plate surface of the
cylinder block.
Figure 30-30-55
Pry up the peened notch (Item 1) [Figure 30-30-57] in

the ring nut.

housing.
V623 VersaHANDLER
Figure 30-30-58
Using a clamp, compress the spring seat and spring, and

drive the pin (Item 1) [Figure 30-30-60] inwards. Release
the clamp.
Remove the ring nut (Item 1) [Figure 30-30-58] from the Figure 30-30-61
shaft.

Figure 30-30-59
Remove the pin (Item 1), spring (Item 2) and spring seat
(Item 3) [Figure 30-30-61] from the shaft assembly.
Remove the large bearing and race (Item 1), small

bearing and race (Item 2) and spacer (Item 3) [Figure
30-30-59] from the shaft.
V623 VersaHANDLER
HYDROSTATIC DRIVE MOTOR (CONT'D) Inspection
Disassembly (Cont'd) Clean all parts in solvent and use air pressure to dry
them. DO NOT use cloth or paper as small pieces of
Figure 30-30-62 material can get into the system and cause damage.
Figure 30-30-63
Remove the piston rings (Item 1) [Figure 30-30-62] from

the pistons.
Inspect the running (bronze) surface of the bearing plate

NOTE: If any portion of the shaft assembly, bearings (Item 1) and locating pin holes (Item 2) [Figure 30-30-63]
or races must be replaced, the complete shaft/ for wear. Replace if damaged or worn.
bearing assembly must be ordered. The only
serviceable part is the piston rings (Item 1) Figure 30-30-64
[Figure 30-30-62].
Inspect the cylinder block assembly for wear or damage.

The piston bores (Item 1) must be smooth. The races for
the synchronizing shaft rollers (Item 2) [Figure 30-30-64]
must not be worn.
If there is any defect in the cylinder block or pistons, the

complete rotating group must be replaced.
V623 VersaHANDLER
Inspection (Cont'd)
Figure 30-30-65
Inspect the valve segment for damage or wear on the

sealing surface (Item 1) [Figure 30-30-67].
Check that the spindle is located correctly in the valve

Inspect the piston (Item 1) [Figure 30-30-65] for wear or segment by measuring distance "A" [Figure 30-30-67]. 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 30-30-66
Inspect the swash plate running surface (Item 1) [Figure

30-30-66] in the end cap for wear or damage.
V623 VersaHANDLER
Assembly
IMPORTANT
damage the system.
I-2003-0888
Prior to assembly
Install the pin (Item 1) [Figure 30-30-70] as shown.
Clean and lightly oil all parts prior to assembly.
NOTE: Clamp is removed for photo clarity.
Figure 30-30-68
Figure 30-30-71

Install the spring (Item 1) and spring seat (Item 2) into the
shaft assembly (Item 3) [Figure 30-30-68].
Support the shaft assembly in a press without causing
Figure 30-30-69 damage to the pistons, install the large bearing and race
(Item 1), spacer (Item 2) and small bearing and race
(Item 3) [Figure 30-30-71] 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 30-30-69].
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-72
Press the piston/shaft assembly into the housing [Figure

30-30-74].
DO NOT DAMAGE THE PISTONS.

Install the ring nut (Item 1) [Figure 30-30-72] onto the
shaft. Figure 30-30-75

NOTE: Do not over tighten the ring nut and that there
is no noticeable looseness in the bearing.
Figure 30-30-73
Install a new seal (Item 1) [Figure 30-30-75] into the

mounting plate until it is fully seated.
Using a punch seat the ring nut into the groove in the
shaft. [Figure 30-30-73].
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-76

mounting plate.
Figure 30-30-79
housing. Figure 30-30-80

Figure 30-30-77
0.53 to 0.55”
(13.5 to 14.0 mm)
B-15933
Press a new bearing into the cylinder block until it is

Install the mounting plate onto the housing, install the located 0.53 to 0.55 inch (13.5 to 14.0 mm) below the
eight mounting bolts (Item 1) [Figure 30-30-77] and bearing plate surface [Figure 30-30-79].
tighten to 46 ft.-lbs. (63 Nm) torque.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-81
Install the bearing plate (Item 1) [Figure 30-30-83] with

the bronze surface facing up onto the cylinder block.
Figure 30-30-84
Figure 30-30-82

Position the housing on end, tip the three pistons (Item 1)
Install new piston rings (Item 1) [Figure 30-30-81] onto [Figure 30-30-84] closest to the minimum angle stop out
the pistons, make sure the spherical surface (Item 1) toward the housing.
[Figure 30-30-82] conforms to the shape of the piston.
An identification mark (Item 2) [Figure 30-30-81] &

[Figure 30-30-82] is on the "outer" side of the piston ring.
The ends of the piston rings must NOT overlap each

other.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-85
NOTE: The recess (Item 1) [Figure 30-30-87] on each

roller MUST face the synchronizing shaft.
Figure 30-30-88
Install the synchronizing shaft support pin (Item 1)
[Figure 30-30-85] into the cylinder block and retain with
grease.

Figure 30-30-86
Install the synchronizing shaft support pin (Item 1)

[Figure 30-30-88] into the motor shaft assembly and
retain with grease.
Install the six synchronizing shaft rollers (Item 1) [Figure

30-30-86] onto the synchronizing shaft and retain with
grease.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-89
If the cylinder block (Item 1) [Figure 30-30-91] 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) NOTE: A brass rod may be used to guide the pistons
[Figure 30-30-89] into the motor shaft races. When into their bores.
properly 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 30-30-92
Figure 30-30-90
Install a new gasket (Item 1) [Figure 30-30-92] onto the

housing.
When installing the cylinder block, the races (Item 1)
[Figure 30-30-90] in the cylinder block must be Install the valve segment (Item 2) [Figure 30-30-92] onto
positioned so the synchronizing shaft rollers (Item 2) the cylinder block and retain with heavy grease.
[Figure 30-30-89] and pistons (Item 3) [Figure 30-30-89]
and their bores (Item 2) [Figure 30-30-90] are aligned.
NOTE: The hole (Item 3) in the valve segment should
Install the six pistons (Item 3) [Figure 30-30-89] into the be next to the minimum displacement
cylinder bores, tilt the block so the synchronizing shaft adjustment screw (Item 4) [Figure 30-30-92].
rollers enter their races in the block and the support pin
(Item 3) [Figure 30-30-90] enter the recess.
Lift the cylinder block slightly and guide the three

remaining pistons in position.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-93
Install the orifice (Item 1) [Figure 30-30-95] and tighten

to 4 ft.-lbs. (5 Nm) torque.
Figure 30-30-96
Install the orifice (Item 1) [Figure 30-30-93] and tighten

Figure 30-30-94
Install the plug (Item 1) [Figure 30-30-96] and tighten to

4 ft.-lbs. (5 Nm) torque.

V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-97

plug.
Figure 30-30-100
plug.

Figure 30-30-98
Install the spring seat (Item 1), spring (Item 2) and plug
(Item 3) [Figure 30-30-100] into the housing and tighten
Install the spool (Item 1), spring seat (Item 2), spring
(Item 3) and plug (Item 4) [Figure 30-30-98] into the
housing and tighten to 30 ft.-lbs. (41 Nm) torque.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-101
Install the two plugs (Item 1) [Figure 30-30-103] and

Figure 30-30-104
Assemble the poppet (Item 1) and spring (Item 2) into the
relief valve housing (Item 3) using new O-ring (Item 4)
and plug (Item 5) [Figure 30-30-101].

Figure 30-30-102
Install the two seals (Item 1) [Figure 30-30-104] onto the

servo piston.
Install the relief valve (Item 1) [Figure 30-30-102] into the

V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-105
While holding the feedback lug, install the pointed set

screw into the groove int he feedback lug [Figure 30-30-
107].
Install the servo piston (Item 1) into the housing, make Do not tighten at this time.
sure the hole (Item 2) [Figure 30-30-105] is in the
position shown when the piston is fully installed. Figure 30-30-108

Figure 30-30-106
Install the two O-rings (Item 1) [Figure 30-30-108].
Install the feed back lug (Item 1) [Figure 30-30-106] into

the servo piston.
NOTE: The position of the flat side of the feed back

lug (Item 2) [Figure 30-30-106].
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-109
Install the adjustment rod (Item 1) [Figure 30-30-111]

into the housing and through the feed back lug. Tighten
the large nut to 15 ft.-lbs. (20 Nm) torque.
Install the end cap and tighten the four bolts (Item 1) Figure 30-30-112
[Figure 30-30-109] to 58 ft.-lbs. (78 Nm) torque.

Figure 30-30-110
Tighten the pointed set screw at this time [Figure 30-30-

112].

adjustment rod.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-113
Install the two orifices (Item 1) [Figure 30-30-115] into

the spool and tighten to 18 lbs (2 Nm) torque.
Figure 30-30-116
Install the second set screw and tighten [Figure 30-30-
113].

Figure 30-30-114

the spool.
Install the two spring seats and spring (Item 1) into the
servo piston hole (Item 2) [Figure 30-30-114].
NOTE: Apply assembly lube to help hold into correct

position.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-117
Install the orifice (Item 1) [Figure 30-30-119] into the

Figure 30-30-120
Install the servo control spool (Item 1) [Figure 30-30-

Figure 30-30-118

Install the inner spool (Item 1) [Figure 30-30-118].
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-121
Install the end cap housing and tighten the eight bolts
(Item 1) [Figure 30-30-123] to 85 ft.-lbs. (115 Nm)
torque.
Install a new gasket (Item 1) [Figure 30-30-121] onto the Figure 30-30-124
end cap.

Figure 30-30-122
Install the seven O-rings (Item 1) [Figure 30-30-124].
Align the feed back lug (Item 1) and the valve segment
(Item 2) [Figure 30-30-122].
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-125
Install the pin into the housing as shown [Figure 30-30-

127].
Figure 30-30-128
Install the spool (Item 1) [Figure 30-30-125] into the
housing.

NOTE: The position of the groove (Item 2) [Figure 30-
30-125].
Figure 30-30-126

plug.
Install the fitting (Item 1) [Figure 30-30-126].
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-129
Install a new O-ring (Item 1) and solenoid shaft assembly

(Item 2) [Figure 30-30-131] into the housing.
Figure 30-30-132

Figure 30-30-130
Install the spool (Item 1) [Figure 30-30-132] into the

housing.

solenoid shaft.
Lightly lubricate the pin (Item 2) [Figure 30-30-130] and

install into the solenoid shaft.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-30-133
Install the solenoid nut (Item 1) [Figure 30-30-135] and

hand tighten.
Figure 30-30-136
solenoid.

Figure 30-30-134
Install the solenoid housing assembly (Item 1) [Figure

30-30-136]. Tighten the bolts to 58 ft.-lbs. (78 Nm)
torque.
Install the solenoid (Item 1) [Figure 30-30-134].
V623 VersaHANDLER
HYDROSTATIC PUMP Remove the two hoses (Item 1) [Figure 30-40-2].
Remove the gear pump. (See Removal And Installation

on Page 20-130-1.)
IMPORTANT
damage the system.
I-2003-0888
Figure 30-40-1 Remove the two fittings (Item 1) [Figure 30-40-3] from
the pump housing.
Figure 30-40-4

Remove the four bolt flange hose (Item 1) [Figure 30-40-
1] from the hydrostatic pump.
NOTE: Mark all hoses for correct assembly. Remove the four bolt flange hose (Item 1) [Figure 30-40-
4] from the backside of the pump.
Figure 30-40-2
V623 VersaHANDLER
HYDROSTATIC PUMP (CONT'D) Figure 30-40-7
Figure 30-40-5
Remove the two wires (Item 1) [Figure 30-40-7] from the

solenoids.
Remove the two hoses (Item 1) [Figure 30-40-5]. pump.
Figure 30-40-6 Figure 30-40-8

Remove the hose (Item 1) [Figure 30-40-6] from the Remove the four mounting bolts (Item 1) [Figure 30-40-
hydrostatic pump. 8].
V623 VersaHANDLER
HYDROSTATIC PUMP (CONT'D)
Figure 30-40-9
Lift and remove the hydrostatic pump [Figure 30-40-9].
V623 VersaHANDLER
V623 VersaHANDLER
V623 VersaHANDLER
V623 VersaHANDLER
V623 VersaHANDLER
V623 VersaHANDLER
Disassembly
IMPORTANT
damage the system.
I-2003-0888
Figure 30-40-10
Remove the retainer bolt (Item 1). Remove the coupler
gear (Item 2) [Figure 30-40-12] from the shaft.
Figure 30-40-13

Remove and discard the filter (Item 1) [Figure 30-40-10].
Figure 30-40-11
Remove the three bolts (Item 1) [Figure 30-40-13].
Remove the retainer plate (Item 2) [Figure 30-40-13]

from the pump housing.
Remove the filter head (Item 1) [Figure 30-40-11] from

the pump housing.
V623 VersaHANDLER
Figure 30-40-14
Remove the snap ring (Item 1) and spacer washer (Item

2) [Figure 30-40-16] from the shaft.
Figure 30-40-17
Remove the shaft and bearing assembly from the
housing [Figure 30-40-14].

NOTE: If the shaft or bearing assembly become stuck
in the housing, lightly tap on the shaft.
Figure 30-40-15
Remove the bearing (Item 1) [Figure 30-40-17] from the

shaft.
Remove the shaft seal (Item 1) [Figure 30-40-15] from

the shaft.
V623 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 30-40-18

20].
NOTE: Remove the lifting bracket (Item 2) [Figure 30-

40-20] from the pump.
Figure 30-40-21

Remove the relief valve lock nut (Item 1) and the plug
(Item 2) [Figure 30-40-18].
Figure 30-40-19

21] from the flange adapter.
Remove the flange adapter (Item 2) [Figure 30-40-21].
Remove the spring and relief poppet from the charge

pump housing [Figure 30-40-19].
V623 VersaHANDLER
Figure 30-40-22
Remove the charge pump cover (Item 1) [Figure 30-40-

24].
Figure 30-40-25
Lift and remove the charge pump (Item 1) [Figure 30-40-
22] from the pump housing.

Figure 30-40-23
Only if wear marks are present, remove the bushing (Item

1) from the charge pump cover (Item 2) [Figure 30-40-
25].
Remove the six bolts (Item 1) and remove the retaining

plate (Item 2) [Figure 30-40-23] from the charge pump.
V623 VersaHANDLER
Figure 30-40-26
Remove the charge pump gears (Item 1) [Figure 30-40-

28].
Figure 30-40-29
Remove the coupler (Item 1) [Figure 30-40-26].
Figure 30-40-27

Remove the eccentric ring (Item 1) and alignment pin
(Item 2) [Figure 30-40-29] from the pump.
Remove the charge pump shaft (Item 1) and key (Item 2) Note the position of the alignment pin.
[Figure 30-40-27] from the pump.
V623 VersaHANDLER
Figure 30-40-30
For proper operation, if the plugs (Item 1) & (Item 2)

[Figure 30-40-32] are removed from the housing they
must be returned to their original position.
Remove the charge pump wear plate (Item 1) [Figure 30- Installation: Tighten the servo relief valve plug (Item 1)
40-30]. to 9 ft.-lbs. (12 Nm) torque. Tighten the rotation pipe
plugs (Item 2) [Figure 30-40-32] to 4 ft.-lbs. (5.4 Nm)

Remove the O-ring (Item 2) [Figure 30-40-30]. torque.
Figure 30-40-31 Figure 30-40-33
Remove the swash plate leveler spring shims (Item 1) Remove the multi-function valve assemblies (Item 1)
[Figure 30-40-31] from the spring pockets. [Figure 30-40-33] from the housing.
Inspect the journal bearing (Item 2) [Figure 30-40-31].

Replace as needed.
V623 VersaHANDLER
Figure 30-40-34
Remove both spring seats (Item 1) [Figure 30-40-36]

from the swash plate leveler.
Figure 30-40-37
Remove the gasket (Item 1) and the valve plate (Item 2)
from the housing. Note the direction of the arrows (Item
3) [Figure 30-40-34] on the valve plate for proper

assembly.
Figure 30-40-35
Remove the swash plate hold down spring (Item 1)

[Figure 30-40-37].
Remove the two leveler springs (Item 1) [Figure 30-40-

35].
V623 VersaHANDLER
Mark the position of the side cover.
Figure 30-40-38
Remove and discard the O-ring (Item 1). Loosen and

remove both guide posts (Item 2) [Figure 30-40-40].
Figure 30-40-41
Remove the six bolts (Item 1) [Figure 30-40-38] from the

side cover.
Figure 30-40-39
Remove the leveler (Item 1) and slide inserts (Item 2)

[Figure 30-40-41] from the side cover.
Inspect the slide inserts for wear or damage.
Replace if needed.
Remove the side cover/swash plate leveler assembly
from the housing [Figure 30-40-39].
V623 VersaHANDLER
Figure 30-40-42
Remove the four solenoid mounting bolts (Item 1)

[Figure 30-40-44].
Figure 30-40-45
Remove the six solenoid manifold mounting bolts (Item
1). Remove the manifold (Item 2) [Figure 30-40-42].

Figure 30-40-43
Remove the solenoids (Item 1) [Figure 30-40-45] from

the manifold.
Remove the gasket (Item 1) [Figure 30-40-43] from the

manifold.
V623 VersaHANDLER
Figure 30-40-46
Remove the cage locator link (Item 1) [Figure 30-40-48]

from the swash plate.
Figure 30-40-49
Remove and discard the three O-rings (Item 1) [Figure
30-40-46] from the solenoid.

Figure 30-40-47
Remove the cylinder block (Item 1) [Figure 30-40-49]

through the housing end opening. The swash plate and
piston assembly will remain in the housing.
Remove the anchor pin (Item 1) [Figure 30-40-47].
V623 VersaHANDLER
Figure 30-40-50
Remove the swash plate bearings (Item 1) [Figure 30-

Figure 30-40-53
Remove the swash plate/piston assembly (Item 1)
[Figure 30-40-50] from the pump housing.

Figure 30-40-51
Remove the swash plate bearing races (Item 1) [Figure

30-40-53] from the housing.
Remove the four slipper guide bearing retainer bolts

(Item 1) [Figure 30-40-51].
V623 VersaHANDLER
Figure 30-40-54
Remove the three bolts (Item 1) [Figure 30-40-56] and

remove the servo adjustment cover.
Figure 30-40-57
Remove the bronze slider block (Item 1) [Figure 30-40-
54] from the servo piston.

Mark the position of the servo end covers.
Figure 30-40-55
Measure and record the adjustment setting for

approximate installation adjustment [Figure 30-40-57].
Remove the three bolts and remove the servo end cover.
Remove and discard both O-rings (Item 1) [Figure 30-
40-55].
V623 VersaHANDLER
Figure 30-40-58
Remove the servo piston (Item 1) from the housing (Item

2) [Figure 30-40-58].

58].
V623 VersaHANDLER
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 30-40-59
Inspect the servo piston and seal rings (Item 1) [Figure

30-40-61] for wear. If worn, remove the seal rings and
expander O-rings from the piston.
Install new expander O-rings into the grooves in the

servo piston. Carefully install the piston seal rings over
the expander rings. Do not overstretch the piston seal

rings.
Check the wear plate (Item 1) and charge pump gears
(Item 2) [Figure 30-40-59] for damage or wear. Figure 30-40-62
Figure 30-40-60
Lubricate the seal rings and carefully slide the servo

piston (Item 1) into the cylinder (Item 2) [Figure 30-40-
Check the valve plate [Figure 30-40-60], the surface 62]. Allow the assembly to set for 5 minutes to allow the
must be smooth and free of scratches. If scratches can seal rings to return to their original size.
be felt with a finger nail, replace the part.
V623 VersaHANDLER
Inspection (Cont'd)
Figure 30-40-63
Servo arm (Item 1) [Figure 30-40-65] 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 30-40-63]. Remove the swash plate guide bolt (Item 2) and the
servo arm mounting bolt (Item 3) [Figure 30-40-65].

Figure 30-40-64
Installation: The servo arm (Item 1) [Figure 30-40-65]
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
Figure 30-40-66
Inspect the swash plate guide (Item 1) [Figure 30-40-64]

for wear. Replace as needed.
Installation: Tighten the bolt to 24 ft.-lbs. (32 Nm)

torque.
The threaded holes (Item 1) [Figure 30-40-66] in the

swash plate must be cleaned prior to assembly.
V623 VersaHANDLER
Inspection (Cont'd)
Figure 30-40-67
Check the swash plate bearings (Item 1) [Figure 30-40-

69] for wear and damage. Replace as needed.
Figure 30-40-70
Figure 30-40-68

Check each piston (Item 1) and piston shoe (Item 2)
If the headed roll pin and flat washer (Item 1) must be [Figure 30-40-70] for wear or scratches.
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 30-40-68].
V623 VersaHANDLER
Inspection (Cont'd)
Figure 30-40-71
Inspect the shaft seal (Item 1) [Figure 30-40-73].

Replace if needed.

Check the cylinder block bores for wear or scratches 73].
[Figure 30-40-71].
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 30-40-74
Figure 30-40-72
Replace O-rings as needed [Figure 30-40-74].

Check the shaft for wear or damage in the spline and
bearing areas [Figure 30-40-72].
Check the bearing for correct operation. Remove the race

(Item 1) [Figure 30-40-72] from the shaft only if it is
necessary to replace the bearing.
V623 VersaHANDLER
Assembly
IMPORTANT
damage the system.
I-2003-0888
Prior to assembly
Apply LOCTITE #242 to four NEW retainer bolts (Item 1).
Clean and lightly oil all parts prior to assembly. Install the slipper guide bearings (Item 2) and spacers
(Item 3) and bolts (Item 1) [Figure 30-40-77].
Figure 30-40-75
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 30-40-78
Put the piston assemblies into the slipper guide [Figure

30-40-75].
Figure 30-40-76
Lubricate the pistons and cylinder block bores. Install the

assembled swash plate and pistons into the cylinder
block [Figure 30-40-78].
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
30-40-76].
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-79
Install the bronze slider block (Item 1) [Figure 30-40-81]

on the swash plate servo arm.
Figure 30-40-82
Install the swash plate bearing races (Item 1) [Figure 30-
40-79] into the housing. Note the locating pins are offset
in the housing to assure proper assembly.

Figure 30-40-80
Carefully lower the cylinder block and swash plate

assembly into the housing [Figure 30-40-82].
Assemble and lubricate the bearing cage (Item 1)

[Figure 30-40-80], and install it on the bearing races.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-83
Install new O-rings (Item 1) [Figure 30-40-85] 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) on the bronze slider block (Item Figure 30-40-86

2) [Figure 30-40-83]. Take care not to wedge the block,
the parts should slide freely.
Figure 30-40-84
Hold the servo piston in position and install the servo end
cap [Figure 30-40-86].
Lower the cylinder block and swash plate assembly until

the swash plate is properly located on the bearings
[Figure 30-40-84].
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-87
Align the slot in the swash plate bearing cage (Item 1)

with the pin (Item 2) in the swash plate and the pin hole
(Item 3) [Figure 30-40-89] in the housing.
Install the three end cap mounting bolts (Item 1) [Figure Figure 30-40-90
30-40-87]. Tighten to 10 ft.-lbs. (13,5 Nm) torque.

Lightly lubricate the O-rings and inner surface of the
adjustment cover.
Figure 30-40-88
Hook the cage locator link (Item 1) over the pin (Item 2)
[Figure 30-40-90] between the swash plate and washer.
Rotate the link into the slot in the bearing cage.
Install the anchor pin (Item 3) [Figure 30-40-90] through

the locator link and into the housing.
Install the servo adjustment cover over the servo piston
until the piston adjustment screw touches the cover.
Using a hex wrench, turn the adjustment screw
counterclockwise while holding the cover until it is in
position [Figure 30-40-88].
NOTE: Do not install the bolts at this time.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-91
Install the two guide post bolts (Item 1) [Figure 30-40-93]

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 30-40-93] on the
until the swash plate guide contacts the bearing races. cover.
Check for clearance between the servo arm and the

slider block [Figure 30-40-91]. If no clearance is present, Figure 30-40-94
recheck the assembly of the bearing cage and races.
Figure 30-40-92
Lift the swash plate leveler and install the side cover
[Figure 30-40-94].
Position the two side cover inserts (Item 1) and

swashplate leveler (Item 2) on the side cover. Note the
orientation of the leveler and the notch (Item 3) [Figure
30-40-92] in the cover.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-95
Rotate the side cover [Figure 30-40-97] (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 30-40-95]
finger tight. Figure 30-40-98

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 30-40-96
After the zero angle position has been established,

tighten the two side cover bolts (Item 1) [Figure 30-40-
98].
Use a depth micrometer to measure the distance from

the end cap to the swash plate surface (Item 1). Take a
second measurement at a point 90° (Item 2) [Figure 30-
40-96] from the first point of measurement. These
measurements must not vary more than .001 inches
(.025 mm).
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-99
Turn the adjustment screw on the servo, which will rotate

the swash plate assembly until a zero angle position is
established [Figure 30-40-101].
Install the four remaining side cover bolts, apply Figure 30-40-102
LOCTITE #242 to the threads of the "thru" bolts (Item 1)
[Figure 30-40-99].

First tighten the four side cover bolts (Item 2) to 24 ft.-lbs.
(32,5 Nm) torque. Tighten the two remaining side cover
bolts (Item 1) [Figure 30-40-99] to 18.5 ft.-lbs. (25 Nm)
torque.
Figure 30-40-100
Use a depth micrometer to measure the distance from

the end cap to the swash plate surface [Figure 30-40-
102]. 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 30-40-100]. Tighten to 10 ft.-lbs. (13,5
Nm) torque.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-103
Lightly lubricate both solenoid spools and install into the

manifold housing and retain with the four screws (Item 1)
[Figure 30-40-105].
Without turning the servo adjustment screw, install the Figure 30-40-106
sealed nut (Item 1) [Figure 30-40-103] and tighten.

Figure 30-40-104
Apply assembly lube on the gasket (Item 1) [Figure 30-

40-106] and install on the manifold housing.
Install new O-rings (Item 1) [Figure 30-40-104] on the

solenoid spool.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-107
Install the spring seats (Item 1) [Figure 30-40-109] on

the leveler arms.
Figure 30-40-110
Install the manifold assembly (Item 1) on the pump with
the six screws (Item 2) [Figure 30-40-107].

Figure 30-40-108
Install both springs (Item 1) [Figure 30-40-110] on the

leveler spring seats.
Lubricate the running surface of the cylinder (Item 2)

Install the spring (Item 1) [Figure 30-40-108] on the [Figure 30-40-110].
servo arm link.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-111
Lubricate the end cap journal bearing (Item 1). Install the
hardened shims (Item 2) [Figure 30-40-113] in the
charge pump pockets for the swash plate leveler springs.
Retain the shims with assembly lube.
Install the valve plate (Item 1) [Figure 30-40-111] on the
alignment pins. Turn the charge pump housing over.

NOTE: Ensure the direction of the arrow cut outs Figure 30-40-114
(Item 2) [Figure 30-40-111] in the valve plate
are positioned as shown.
Figure 30-40-112
Lightly lubricate the alignment pin (Item 1) [Figure 30-40-

114] and install into the charge pump housing, in the
position marked at time of disassembly. This will properly
align the wear plate and eccentric ring.
Install a new gasket (Item 1) [Figure 30-40-112] on the
housing. Install a new O-ring (Item 2) [Figure 30-40-114].
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-115
Apply assembly lube and install the charge pump gears

(Item 1), charge pump shaft (Item 2) and key (Item 3)
[Figure 30-40-117] into the pump.
Lubricate both sides of the wear plate (Item 1) and install Figure 30-40-118
in the charge pump. Align the wear plate with the
alignment pin (Item 2) [Figure 30-40-115].

Figure 30-40-116
Install the coupler (Item 1) [Figure 30-40-118].
Install the eccentric ring (Item 1) in the charge pump and

align with the alignment pin (Item 2) [Figure 30-40-116].
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-119
Lower the charge pump onto the pump housing while

positioning the three springs in their pockets [Figure 30-
40-121].
Install the charge pump cover (Item 1) [Figure 30-40- When properly installed, the charge pump will engage
119]. 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 30-40-120 Figure 30-40-122
Install the retaining plate cover (Item 1) and six bolts Install the flange adapter (Item 1) and four bolts (Item 2)
(Item 2) [Figure 30-40-120]. Tighten the bolts to 10 ft.- [Figure 30-40-122]. Tighten the bolts to 90 ft.-lbs. (122
lbs. (13,5 Nm) torque. Nm) torque.
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-123
Install the plug with lock nut (Item 1) [Figure 30-40-125],

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- Figure 30-40-126
123] and tighten to 28 ft.-lbs. (38 Nm) torque.

NOTE: Install the lifting bracket (Item 2) [Figure 30-40-
123].
Figure 30-40-124
Lightly lubricate and install both multi-function valve

assemblies (Item 1) [Figure 30-40-126] in the charge
pump. Tighten to 66 ft.-lbs. (89 Nm) torque.
Install the spring and relief poppet into the charge pump
[Figure 30-40-124].
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-127
Install a new O-ring (Item 1) [Figure 30-40-129].
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), the spacer washer (Item 2) 30-40-128].
and the snap ring (Item 3) [Figure 30-40-127] on the
drive shaft. Figure 30-40-130

Position the pump on the charge pump end.
Figure 30-40-128
Install the retainer plate (Item 1) and three bolts (Item 2)

[Figure 30-40-130]. 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 30-40-128].
V623 VersaHANDLER
Assembly (Cont'd)
Figure 30-40-131
Install the coupler gear (Item 1) [Figure 30-40-133] on

the shaft and install the bolt (Item 2) [Figure 30-40-133].
Figure 30-40-134
Install the filter head (Item 1) [Figure 30-40-131] on the
pump.

Tighten to 90 ft.-lbs. (122 Nm) torque.
Figure 30-40-132
.0625”
(1.59 mm)
B-15045
NOTE: When installing the coupler, maintain a .0625

inch (1,59 mm) gap from the pump mount
flange to the coupler [Figure 30-40-133] &
[Figure 30-40-134].
Install a new filter (Item 1) [Figure 30-40-132] on the Remove the case plug (Item 3) [Figure 30-40-133] and
pump. fill with clean hydraulic fluid prior to start up.
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)
V623 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 DRIVE
Differential Parts Identification . . . . . . . . . . . . . . . . . . . . . 40-20-25 SYSTEM
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 . . . . . . . . . . . . . . . . . . . 40-20-29
Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . 40-20-62
Planetary Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . 40-20-2

Planetary Carrier Inspection . . . . . . . . . . . . . . . . . . . . . . . 40-20-4
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 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-60
Wheel Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-6
Wheel Hub Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-9
Wheel Hub Parts Identification. . . . . . . . . . . . . . . . . . . . . . 40-20-5
AXLE PIVOT FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-32-1

Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . 40-32-2
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
FRONT AXLE WITH FRAME LEVELING . . . . . . . . . . . . . . . . 40-31-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-31-6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-31-1
V623 VersaHANDLER
DRIVE SYSTEM (CONT’D)
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

Re-Activating The Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-2
Releasing The Brake For Towing. . . . . . . . . . . . . . . . . . . . 40-50-1
STEERING ANGLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 40-60-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
V623 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

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
V623 VersaHANDLER
V623 VersaHANDLER
AXLE AND DIFFERENTIAL Axle removal. (See Removal on Page 40-30-1.)
General Information Drive motor removal. (See Removal And Installation on

Page 30-30-1.)
For photo clarity, the following axle procedures are done
with the complete axle assembly removed from the Drive box removal. (See DRIVE BOX on Page 20-70-1.)
machine, although the planetary carrier, wheel hub,
steering knuckle and drive axle procedures may be done Steering cylinder removal. (See Removal And Installation
with the axle assembly installed in the machine. For on Page 20-110-1.)
complete axle repair, the following must be done.
Frame leveling cylinder removal (If equipped). (See
The rear axle is the same as the front axle, except that it Removal And Installation on Page -1.)
is NOT equipped with brakes or frame leveling.
Planetary Carrier Parts Identification
V623 VersaHANDLER
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.
V623 VersaHANDLER
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.
V623 VersaHANDLER
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.
V623 VersaHANDLER
AXLE AND DIFFERENTIAL (CONT'D)
Wheel Hub Parts Identification
V623 VersaHANDLER
Wheel Hub Disassembly
Figure 40-20-11
Remove the six ring gear mounting bolts (Item 1) [Figure

40-20-13].
Figure 40-20-14
Remove the snap ring (Item 1) [Figure 40-20-11].
Figure 40-20-12

Install two bolts (Item 1) 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) and spacer (Item 2)
[Figure 40-20-12].
V623 VersaHANDLER
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.
V623 VersaHANDLER
Wheel Hub Disassembly (Cont'd)
Figure 40-20-19

hub.
Figure 40-20-22
Remove the gear (Item 1) 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.
V623 VersaHANDLER
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 If the ring gear or innergear are damaged, replace both
parts.
Steering Knuckle Parts Identification
V623 VersaHANDLER
Steering Knuckle Disassembly
Figure 40-20-24
Lift and remove the knuckle assembly from the axle

[Figure 40-20-26].
Figure 40-20-27
Remove the three bolts (Item 1) and 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

Remove the two bolts (Item 1) and king pin (Item 2) the top Belleville washer.
[Figure 40-20-25] from the top of the knuckle.
V623 VersaHANDLER
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.
V623 VersaHANDLER
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
V623 VersaHANDLER
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) and bushing (Item 2) [Figure removed.
40-20-35] from the axle end housing.
V623 VersaHANDLER
Axle Housing/Drive Axle Disassembly (Cont'd)
Figure 40-20-38
Turn the shaft over and remove the bearing cup (Item 1).
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.
V623 VersaHANDLER
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) and cross (Item 2)

[Figure 40-20-45] from the yoke.
Remove the bearing cup (Item 1) [Figure 40-20-43].
V623 VersaHANDLER
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
assembly [Figure 40-20-46].

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 studs (Item 1) [Figure 40-20-47].
V623 VersaHANDLER
Figure 40-20-50

axle housing.
Separate the axle housing from the brake housing

[Figure 40-20-50].

Remove the axle housing.
V623 VersaHANDLER
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.
V623 VersaHANDLER
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-

V623 VersaHANDLER
Figure 40-20-58
Remove and discard the two O-rings (Item 1) [Figure 40-

20-60] from the piston.
Figure 40-20-61
Remove the three bolts (Item 1) [Figure 40-20-58] from
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.
V623 VersaHANDLER
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) 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.
V623 VersaHANDLER
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.
V623 VersaHANDLER
Figure 40-20-70

72] from the adjusting screw.
Figure 40-20-73
the brake plate.

Figure 40-20-71
Turn the brake housing over and remove the lock nut
retainer (Item 1) and bolt (Item 2) [Figure 40-20-73].
Remove the jam nut (Item 1) adjusting screw (Item 2) and

wedge (Item 3) [Figure 40-20-71] from the brake
housing.
V623 VersaHANDLER
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

V623 VersaHANDLER
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.
V623 VersaHANDLER
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) 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].
V623 VersaHANDLER
Differential Disassembly (Cont'd)
Figure 40-20-84
Remove the gear (Item 1) and cup washer (Item 2) 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].
V623 VersaHANDLER
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.
If either gear is damaged, replace both gears.
V623 VersaHANDLER
AXLE AND DIFFERENTIAL (CONT’D)
Pinion Group Parts Identification
V623 VersaHANDLER
Pinion Group Disassembly
Figure 40-20-90
Remove the nut (Item 1) and washer (Item 2) [Figure 40-

20-92].
Figure 40-20-93
Pry up the peened notch (Item 1) [Figure 40-20-90] in
the nut.

Figure 40-20-91
Free the pinion from the housing using a soft faced

hammer [Figure 40-20-93].
Loosen the nut using special tools CA119099 and

CA715022 [Figure 40-20-91].
V623 VersaHANDLER
Pinion Group Disassembly (Cont'd)
Figure 40-20-94
Remove the two washers (Item 1) 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].
V623 VersaHANDLER
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) and shaft splines (Item 2)

[Figure 40-20-100] for broken or damaged teeth.
Remove the inner race from the housing [Figure 40-20-
98].

Figure 40-20-99
Remove the outer race from the housing [Figure 40-20-

99].
V623 VersaHANDLER
Pinion Group Assembly
1
IMPORTANT
damage the system.
I-2003-0888
Prior to assembly, clean and lightly oil all parts.

Figure 40-20-101 dummy pinion tool CA715040.
Figure 40-20-104

1
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 (Item
1) [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].
V623 VersaHANDLER
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].
V623 VersaHANDLER
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.
Figure 40-20-109
Figure 40-20-111

1
Using a depth gauge (Item 1) [Figure 40-20-108] &

[Figure 40-20-109] measure thru the reference hole in Select the correct shim [Figure 40-20-111] from the chart
the dummy pinion. below:
X = (distance to be measured)
SHIM THICKNESS RANGE
A = (measured value)
B = (given value) = 100 ± 0,01 mm Thick 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
C = (given value) = 45 mm Qty. - - - - - - - - - -
(A + C) - B = X
V623 VersaHANDLER
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-

V623 VersaHANDLER
Figure 40-20-116
Install the two washers (Item 1) and collapsible spacer

(Item 2) [Figure 40-20-118] onto the shaft.
Figure 40-20-119
Install the shims selected (Item 1) [Figure 40-20-116]
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
pinion head to absorb the impact.
pinion shaft until it is fully seated.
V623 VersaHANDLER
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].

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.
P-25712 Attach the spring scale perpendicular to the housing to
measure the rolling torque on the bearings. Tighten (or
loosen) the nut [Figure 40-20-121] until 2-3 lb (.9 - 1.4
Gradually tighten the nut (See Figure 122 & 123 for the
Kg) of smooth and continuous rolling torque is measured
proper procedure) using the special tools CA119099 and
on the spring scale.
CA715022 (Item 1) [Figure 40-20-121].
NOTE: The tightening torque is determined by

measuring the force required to rotate the
pinion (preload of bearings).
SEE Figure 122 & 123. Tighten the nut in incremental

steps. If overtightened (preload too high) the collapsible
spacer (Item 2) [Figure 40-20-118] must be replaced and
the procedure repeated [Figure 40-20-121].
V623 VersaHANDLER
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.
V623 VersaHANDLER
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) cup washer (Item 2) onto the
spindle (Item 3) [Figure 40-20-128].

Figure 40-20-129
Install the housing (Item 1) 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.
V623 VersaHANDLER
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) and twelve bolts (Item 2)

[Figure 40-20-132]. Tighten the bolts to 58 ft.-lbs. (78
Nm) torque.
V623 VersaHANDLER
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 the 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.
V623 VersaHANDLER
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) and jam nut (Item 3)

Align the holes in the brake housing with the pins (Item 1) [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.
V623 VersaHANDLER
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) in the down position,

install the split ring (Item 2) [Figure 40-20-145] into the
Temporarily place the spring ring retainer ring (Item 1) 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.
V623 VersaHANDLER
Figure 40-20-146
Align the holes in the piston and the threaded holes in the
housing and install the piston (Item 1) [Figure 40-20-
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

Lightly lubricate and install two new O-rings (Item 1)

V623 VersaHANDLER
Figure 40-20-150
Set the pinion assembly (Item 1) 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.
V623 VersaHANDLER
Figure 40-20-154
Install the tool CA715055 (Item 1) on the pinion shaft

[Figure 40-20-156].
Figure 40-20-157
Install the two guide studs (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 permissible range 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.
V623 VersaHANDLER
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,
amount. tighten the two lock nuts by same amount, retaining the
- If the backlash is above the permissible range, tighten value of the pinion ring gear backlash. -If the total preload
the lock nut on the side of the crown wheel and loosen the is above the permissible range, slacken the two lock nuts
lock nut on the other side by the same amount. by the same amount, retaining the value of the pinion ring
Once the pinion and ring gear adjustment has been gear backlash.
carried out, check that there is at least a minimal preload
on the differential cage bearings. If necessary, repeat the Figure 40-20-161
steps if backlash is still outside the permissible range.
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 it falls
within the permissible range.
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.
V623 VersaHANDLER
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].
P-25716 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].
V623 VersaHANDLER
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 as shown
[Figure 40-20-166].
Figure 40-20-167
Once the wear pattern is correct, install the lock nut

retainer (Item 1) 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].
V623 VersaHANDLER
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) onto the coupler
housing followed by a friction plate and a thin spacer (Item 2) [Figure 40-20-173].
plate [Figure 40-20-171].
V623 VersaHANDLER
Figure 40-20-174
Install the axle housing onto the brake housing by sliding

on the alignment studs [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].

axle housing.
V623 VersaHANDLER
Axle Housing/Drive Axle Assembly (Cont'd)
Figure 40-20-178
Remove the two alignment studs (Item 1) [Figure 40-20-

179], install the two remaining bolts, tighten all bolts to
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.
V623 VersaHANDLER
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.
V623 VersaHANDLER
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].
V623 VersaHANDLER
Figure 40-20-188
Install a new bushing (Item 1) 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]. Figure 40-20-191

NOTE: Use care not to lose or drop any needle
bearings out of position.
Figure 40-20-189
Install the drive axle into the axle housing aligning the
shaft with the splines [Figure 40-20-191].
NOTE: Use care not to damage the seal.
Make sure the bearing cups are fully seated and install
both snap rings (Item 1) [Figure 40-20-189].
V623 VersaHANDLER
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.
V623 VersaHANDLER
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) 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.
V623 VersaHANDLER
Steering Knuckle Assembly (Cont'd)
Figure 40-20-200
Install the lower king pin (Item 1) and three bolts (Item 2)
[Figure 40-20-201]. Tighten to 140 ft.-lbs. (190 Nm)
torque.
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.
V623 VersaHANDLER
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) 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.
V623 VersaHANDLER
Wheel Hub Assembly (Cont'd)
Figure 40-20-206
Install the ring gear assembly (Item 1) 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 Figure 40-20-209
the steering knuckle.

Figure 40-20-207
Install the spacer (Item 1) and thrust washer (Item 2)

[Figure 40-20-209] on the axle shaft.
Install the hub assembly (Item 1) and outer bearing (Item

2) [Figure 40-20-207] onto the steering knuckle.
V623 VersaHANDLER
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) and snap rings (Item 2)

[Figure 40-20-213].
Install the thrust washers (Item 1) [Figure 40-20-211]

onto the shafts.
V623 VersaHANDLER
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 Checking Oil Level (Planetary Carrier) on Page 10-

Install the planetary carrier (Item 1) [Figure 40-20-215]. 110-1 for filling the axle assembly with fluid.
V623 VersaHANDLER
V623 VersaHANDLER
FRONT AXLE Figure 40-30-2
Removal
Figure 40-30-1
Rotate the battery disconnect switch (Item 1) [Figure 40-

30-2] to the right, to disconnect the power supply from
the battery.
Raise the boom and install the boom stop (Item 1) Drain the hydraulic reservoir. (See HYDRAULIC
[Figure 40-30-1]. RESERVOIR on Page 20-150-1.)

Relieve hydraulic pressure. Figure 40-30-3
WARNING
immediately.
W-2145-0290
Remove the access panel (Item 1) [Figure 40-30-3].
V623 VersaHANDLER
FRONT AXLE (CONT'D) Figure 40-30-6
Removal (Cont'd)
Figure 40-30-4
Remove the lower four bolt flange hose (Item 1) [Figure

40-30-6].
Figure 40-30-7
the drive motor. Install caps and plugs.

IMPORTANT
damage the system.
I-2003-0888
Remove the electrical plug (Item 1) [Figure 40-30-7].

Figure 40-30-5
Figure 40-30-8
Remove the upper four bolt flange hose (Item 1) [Figure

40-30-5]. Remove the return hose (Item 1) [Figure 40-30-8] from
the side of the drive motor.
V623 VersaHANDLER
Removal (Cont'd)
Figure 40-30-9
Unplug the electrical connector (Item 1) [Figure 40-30-

11] from each side of the drive motor.
Figure 40-30-12
Remove the four driveshaft mounting bolts (Item 1)
[Figure 40-30-9]. Lower the driveshaft.

Figure 40-30-10
Remove the brake tubeline (Item 1) [Figure 40-30-12]

from the left side of the axle.

the bottom of the drive motor.
V623 VersaHANDLER
Removal (Cont'd)
Figure 40-30-13
Unplug the electrical connector (Item 1) [Figure 40-30-

15].
Figure 40-30-16
Remove the brake hose (Item 1) [Figure 40-30-13] from
the right side of the axle.

Figure 40-30-14
Remove the three mounting plate bolts (Item 1) [Figure

40-30-16] from both sides.

the steering cylinder.
V623 VersaHANDLER
Removal (Cont'd)
Figure 40-30-17
P-44143
Remove the two bolts (Item 1) [Figure 40-30-19] and

P-44142 remove the front fenders.
Figure 40-30-20
Lift the front of the machine and place jackstands under
the frame as shown.

Place a block in front and behind the rear wheel [Figure
40-30-17].
Figure 40-30-18
Using a floor jack, apply upward pressure to lift and

support the front axle [Figure 40-30-20].
Remove the eight lug nuts and washers (Item 1) [Figure

40-30-18] from each front tire.
Remove both front tires.
V623 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 40-30-22].
Remove the six axle mounting bolts (Item 1) [Figure 40-

30-21] and lower mounting plates from each side of the
axle.
V623 VersaHANDLER
Installation
Figure 40-30-23
Install the bottom plate and mounting bolts (Item 1)

[Figure 40-30-25]. Tighten to 275-300 ft.-lbs. (370-410
Nm) torque.
Have an assistant balance the axle on the floor jack and Figure 40-30-26
roll the axle under the frame [Figure 40-30-23].

Figure 40-30-24
P-44143
Install the front fenders using the two bolts (Item 1)

Raise the floor jack, lifting the axle upward and into Nm) torque.
V623 VersaHANDLER
Installation (Cont'd)
Figure 40-30-27
Install the three bottom plate mounting bolts (Item 1)

Nm) torque.
Install both front tires, tighten the nuts (Item 1) [Figure Figure 40-30-30
40-30-27] to 217 ft.-lbs. (159 Nm) torque.

Figure 40-30-28
Plug the electrical connector (Item 1) [Figure 40-30-30]

P-44142 into the axle solenoid.
Raise the machine and remove the two jackstands (Item

1) [Figure 40-30-28].
Lower the machine.
V623 VersaHANDLER
Figure 40-30-31
Install the brake tubeline (Item 1) [Figure 40-30-33] on

the left side of the axle.
Figure 40-30-34
Install the two steering hoses (Item 1) [Figure 40-30-31]
to the steering cylinders.

Figure 40-30-32
Plug in the electrical connector (Item 1) [Figure 40-30-

34] on both sides of the drive motor.
Install the brake hose (Item 1) [Figure 40-30-32] to the

right side of the axle.
V623 VersaHANDLER
Figure 40-30-35
Install the hose (Item 1) [Figure 40-30-37] on the side of

the drive motor.
Figure 40-30-38
Install the two hoses (Item 1) [Figure 40-30-35] on the
bottom of the drive motor.

Figure 40-30-36
Plug in the electrical connector (Item 1) [Figure 40-30-

38].
Install the driveshaft using the four mounting bolts (Item

1) [Figure 40-30-36].
V623 VersaHANDLER
Figure 40-30-39
Install the two hoses (Item 1) [Figure 40-30-41].
Figure 40-30-42
Install the lower four bolt flange hose (Item 1) [Figure 40-
30-39].

Figure 40-30-40
Install the access cover (Item 1) [Figure 40-30-42].
Install the upper four bolt flange hose (Item 1) [Figure

40-30-40].
V623 VersaHANDLER
Fill the hydraulic reservoir to the correct level. (See

Checking And Adding Fluid on Page 10-100-1.)
Figure 40-30-43
Raise the boom and remove the boom stop (Item 1)

[Figure 40-30-44].

30-43] to the left, to restore the power supply from the
battery.
V623 VersaHANDLER
FRONT AXLE WITH FRAME LEVELING Figure 40-31-2
Removal
Fully retract the telescoping boom. Raise the boom and

install the boom stop. (See Installing Boom Stop on Page 1
10-150-1.)
Figure 40-31-1
1
2
1
P-40277
Remove the two bolts (Item 1) from the cover (Item 2)

[Figure 40-31-2]. Remove the cover.
P18440
IMPORTANT

Rotate the battery disconnect switch (Item 1) [Figure 40- When making repairs on hydraulic system, clean the
31-1] to the right, to disconnect the power supply from work area before disassemble and keep all parts
the battery. clean. Always use caps and plugs on hoses,
damage the system.
I-2056-0793
WARNING Figure 40-31-3

physician familiar with this injury is not received 1
immediately.
W-2145-0290
1
Relieve hydraulic pressure.
Drain the hydraulic reservoir. (See HYDRAULIC

RESERVOIR on Page 20-150-1.)
P-40278
Remove the two 4 bolt flange hoses (Item 1) [Figure 40-

31-3].
Mark the location of the hoses for correct assembly.
V623 VersaHANDLER
FRONT AXLE (WITH FRAME LEVELING) (CONT’D) Figure 40-31-6
Removal (Cont’d)
2
Figure 40-31-4
P-40280
Remove the hose (Item 1) and disconnect the wire

P-40279 harness (Item 2) [Figure 40-31-6] from the right side of
the drive motor.
Remove the hose (Item 1) [Figure 40-31-4] from the top Figure 40-31-7
of the drive motor.

Figure 40-31-5
1
2
1
P-40293
P-40292 Remove the nut (Item 1) and coil (Item 2) [Figure 40-31-
7] from the right side of the drive motor.
Remove the hose (Item 1) [Figure 40-31-5] from the top

right side of the drive motor.
V623 VersaHANDLER
Removal (Cont’d)
Figure 40-31-8
P-40282

P-40281 the left side of the axle.
Figure 40-31-11

Figure 40-31-9
P-40283

P-40284 the right side of the axle.

V623 VersaHANDLER
Removal (Cont’d)
Figure 40-31-12
P18476
Remove the four driveshaft mounting bolts (Item 1)

1 [Figure 40-31-14] and nuts.
P-40286
Figure 40-31-15
Lift the front of the machine and place jack stands (Item
1) [Figure 40-31-12] under the frame as shown.

1
Place a block in front and behind one of the rear wheels.
Figure 40-31-13
P-22280
Remove the eight lug nuts and washers (Item 1) [Figure

40-31-15] from each front tire.
P-42458 Remove both front tires.
Remove the two bolts (Item 1) from both front fender

mount brackets (Item 2) [Figure 40-31-13].
Remove the front fenders.
V623 VersaHANDLER
Removal (Cont’d)
2
Figure 40-31-16
P-40291
Remove the six mounting bolts (Item 1), gauge (Item 2)

P-40289 and mounting plate (Item 3) [Figure 40-31-18] from the
left side of the axle.
Using a jack, apply upward pressure to lift and support Figure 40-31-19
the front axle [Figure 40-31-16].

Figure 40-31-17
1 1
P-40308
2
P-40290 Lower the jack approximately 4 inches (100 mm) and
remove the two steering cylinder hoses (Item 1) [Figure
40-31-19].
Remove the six mounting bolts (Item 1) and mounting
plate (Item 2) [Figure 40-31-17] from the right side of the
axle,
V623 VersaHANDLER
FRONT AXLE (WITH FRAME LEVELING) (CONT’D) Installation
Removal (Cont’d) Figure 40-31-21
Figure 40-31-20
P-40307
P-40307
Have an assistant balance the axle on the jack and roll
the axle under the frame [Figure 40-31-21].
Have an assistant balance the axle on the jack and lower
the jack slowly. Roll the axle out from under the frame Figure 40-31-22

[Figure 40-31-20].
P-40308
Raise the jack, lifting the axle upward to within 4 inches

(102 mm) of the frame (Item 1) [Figure 40-31-22].
Install the hoses (Item 2) [Figure 40-31-22] on the

steering cylinder.
V623 VersaHANDLER
Installation (Cont’d)
Figure 40-31-23
3
3
P18476
1
Install the driveshaft using the four mounting bolts (Item
P-40309 1) [Figure 40-31-25].
Figure 40-31-26
Raise the jack, lifting the axle upward into position and
install the bottom plate (Item 1), gauge (Item 2) and

mounting bolts and nuts (Item 3) [Figure 40-31-23] on
the left side of the axle.
1
NOTE: Do not tighten the bolts at this time.
1
Figure 40-31-24
1 P-40289
1
Tighten the axle mounting bolts (Item 1) [Figure 40-31-
26] on both sides of the axle to 275-300 ft.-lbs. (370-410
Nm) torque.
P-40310
Install the bottom plate (Item 1) and mounting bolts and

nuts (Item 2) [Figure 40-31-24] on the right side of the
axle.
NOTE: Do not tighten the bolts at this time.
V623 VersaHANDLER
Figure 40-31-27
1
1
P-40286
Raise the machine and remove the two jack stands (Item
P-22280 10 [Figure 40-31-29].
Lower the machine.

Install both front tires, tighten the nuts (Item 1) [Figure
40-31-27] to 159 ft.-lbs. (217 Nm) torque. Figure 40-31-30

Figure 40-31-28
1
1
P-40283
P-42458
Install the brake hose (Item 1) [Figure 40-31-30] on the
right side of the axle.
Install the front fenders using the two bolts (Item 1)
[Figure 40-31-28].
Tighten the bolts to 90-100 ft.-lbs. (125-140 Nm) torque.
V623 VersaHANDLER
Figure 40-31-31
P-40281
Install the hose (Item 1) [Figure 40-31-33] on the bottom

P-40282 of the drive motor.
Figure 40-31-34
Install the brake hose (Item 1) [Figure 40-31-31] on the
left side of the axle.

Figure 40-31-32
1
P-40284
1 2
Install the hose (Item 1) [Figure 40-31-34] on the bottom
P-40293 of the drive motor.
Install the coil (Item 1) and nut (Item 2) [Figure 40-31-

32]. Hand tighten the nut.
NOTE: Do not overtighten the nut.
V623 VersaHANDLER
Figure 40-31-35
2 1
P-40279
1
Install the hose (Item 1) [Figure 40-31-37] on the top of
P-40280 the drive motor.
Figure 40-31-38
Install the hose (Item 1) and connect the wire harness
(Item 2) [Figure 40-31-35] on the right side of the drive 1

motor.
Figure 40-31-36
P-40278
Install the two 4-bolt flange hoses (Item 1) [Figure 40-31-

38].
P-40292
Install the hose (Item 1) [Figure 40-31-36] on the top

right side of the drive motor.
V623 VersaHANDLER
FRONT AXLE (WITH FRAME LEVELING) (CONT’D)
Figure 40-31-39
1 2
P-40277
Install the cover (Item 10 with two bolts (Item 2) [Figure

40-31-39].

Fill the hydraulic reservoir. (See HYDRAULIC
Figure 40-31-40
P18440
Rotate the battery switch (Item 1) [Figure 40-31-40] to

the left to reconnect the power supply from the battery.
V623 VersaHANDLER
V623 VersaHANDLER
AXLE PIVOT FRAME Figure 40-32-3
Figure 40-32-1
1
P-40303
Remove the bolt (Item 1) and nut from the pivot pin (Item
2) [Figure 40-32-3]. Remove the pivot pin.
P-40300 Figure 40-32-4

Support the pivot with blocks and a jack [Figure 40-32-
1].
Figure 40-32-2
2 P-40305
Slowly lower the jack and remove the pivot frame out
1
from under the frame [Figure 40-32-4].
P-40301
Remove the snap ring (Item 1) and washer from the rod
end pivot pin (Item 2) [Figure 40-32-2] of the leveling
cylinder.
Remove the pivot pin.
V623 VersaHANDLER
483 of 784
AXLE PIVOT FRAME (CONT’D)
Bushing Removal And Installation
Figure 40-32-5
P-40306
Remove the bushings (Item 1) [Figure 40-32-5]. (Front

And Rear)

Installation: Install the bushings flush with the outside of
the frame.
V623 VersaHANDLER
484 of 784
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.
V623 VersaHANDLER
V623 VersaHANDLER
PARKING BRAKE Alternately turn the brake release bolts (Item 1, 2 & 3)
[Figure 40-50-1] "IN" (clockwise) 1/2 turn each until you
Releasing The Brake For Towing feel resistance. Continue to turn each release bolt in
equally 1/2 turn for a total of approximately 5 complete
Block all four wheels to prevent the machine from moving turns.
once the parking brake is released.
Figure 40-50-2
Locate the six brake release bolts (three per side) on the
front axle.
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.
V623 VersaHANDLER
PARKING BRAKE (CONT'D) the torque drops off sharply. Continue to turn each
release bolt out equally 1/2 turn until the brake release
Re-Activating The Brake bolt presses against the bolt housing. After the brake
release bolt is touching the bolt housing turn each brake
Block all four wheels to prevent the machine from release bolt "IN" (clockwise) a1/4 turn.
moving.
Figure 40-50-4
Locate the six brake release bolts (three per side) on the
front axle.
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.
Alternately turn the brake release bolts (Item 1, 2 & 3)

[Figure 40-50-3] "OUT" (counterclockwise) 1/2 turn until
V623 VersaHANDLER
STEERING ANGLE ADJUSTMENT Figure 40-60-3
Adjustment
The axle is removed from the machine for photo clarity,

but this procedure may be completed with the axle
installed in the machine.
Figure 40-60-1
Using an angle gauge, adjust the bolt (Item 1) [Figure

40-60-3] to obtain a reading of 32-35 degrees [Figure
40-60-2].
Adjust the stop (Item 1) [Figure 40-60-3] as needed.

Tighten the lock nut to 110 ft.-lbs. (150 Nm) torque.

Figure 40-60-4
Install a straight bar (Item 1) [Figure 40-60-1] onto the
wheel hub and secure 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.
V623 VersaHANDLER
V623 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 four drive shaft mounting bolts (Item 1)

[Figure 40-70-1] from each end of the drive shaft.
V623 VersaHANDLER
V623 VersaHANDLER
MAIN FRAME
BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

ENGINE COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . 50-70-1
FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

INNER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1 MAIN FRAME
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1


OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
PIVOT LINK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

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
V623 VersaHANDLER
V623 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 DASH
COVER/STEERING COLUMN COVER on Page 60-100-
1.)
Remove the joy stick panel. (See JOYSTICK PANEL on

Page 60-50-1.)
Remove the operator seat. (See OPERATOR SEAT on

Page 50-20-1.)
Drain the radiator. (See RADIATOR on Page 70-50-1.)
Remove the fuel tank. (See FUEL TANK on Page 50-80-

1.)
Remove the refrigerant from the A/C system. (See

Component Replacement And Refrigeration Leaks on
Page 80-60-2.)
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.
V623 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.
V623 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].
V623 VersaHANDLER
Figure 50-10-12
Carefully pull the accelerator cable (Item 1) [Figure 50-

10-14] through the cab.
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.
Figure 50-10-13

the brake valve.
Remove the accelerator cable (Item 1) [Figure 50-10-13]

from the pedal and mounting bracket (Item 2) [Figure 50- IMPORTANT
10-13].
damage the system.
I-2003-0888
V623 VersaHANDLER
Figure 50-10-16
Remove the four connectors (Item 1) [Figure 50-10-18].
NOTE: Mark all connectors for correct assembly.
Remove the seven hoses on the right side of the cab Figure 50-10-19
[Figure 50-10-16].

Figure 50-10-17
Separate the heater hoses (Item 1) [Figure 50-10-19]

and pull through the floor plate.
Temporarily remove the two washer tubes (Item 1)

[Figure 50-10-17] from the harness conduit.
V623 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.
V623 VersaHANDLER
Figure 50-10-24
Remove the grounding strap (Item 1) [Figure 50-10-26]

and rear mounting bolt (Item 2) [Figure 50-10-26].
Figure 50-10-27
Install a hoist to lift and support the cab [Figure 50-10-
24].

Figure 50-10-25
Lift and remove cab [Figure 50-10-27].
Remove the cab mount bolt (Item 1) [Figure 50-10-25]

from the front of the cab.
V623 VersaHANDLER
V623 VersaHANDLER
OPERATOR SEAT
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.
NOTE: Fuel tank is removed for photo clarity.
V623 VersaHANDLER
V623 VersaHANDLER
BOOM ASSEMBLY Figure 50-30-3
Remove the bucket positioning cylinder. (See Removal

Figure 50-30-1
Place a wood block (Item 1) [Figure 50-30-3] under the

lift cylinder.
Figure 50-30-4

Lower the boom onto adequate stands or blocks as
Figure 50-30-2
Remove the pivot pin retainer bolt (Item 1) [Figure 50-30-

4] from the lift cylinder.

the machine.
V623 VersaHANDLER
BOOM ASSEMBLY (CONT'D) Figure 50-30-7
Figure 50-30-5
Disconnect the light harness connector (Item 1) [Figure

50-30-7].
Remove the lift cylinder pivot pin using a pin removal tool
(Item 1) [Figure 50-30-5]. Lower cylinder onto the block.
IMPORTANT

NOTE: See LIFT CYLINDER Removal And Installation
on Page 20-20-1 for additional information. When repairing hydrostatic and hydraulic systems,
damage the system.
I-2003-0888
Figure 50-30-8
Disconnect the secondary auxiliary harness connector

(Item 1) [Figure 50-30-6].
Disconnect the six hydraulic hoses (Item 1) [Figure 50-

30-8] from the tubelines.
NOTE: Mark the hoses for correct installation.
V623 VersaHANDLER
BOOM ASSEMBLY (CONT'D) Figure 50-30-11
Figure 50-30-9
Remove the bolt (Item 1) [Figure 50-30-11] and washer

(Item 2) [Figure 50-30-11] from the boom pin.
Figure 50-30-12
Install a lifting chain (Item 1) [Figure 50-30-9] on the
front of the boom.

Figure 50-30-10
Remove the boom pin [Figure 50-30-12].
Install a lifting chain (Item 1) [Figure 50-30-10] at the

rear of the boom.
V623 VersaHANDLER
BOOM ASSEMBLY (CONT'D)
Figure 50-30-13
Lift and remove the boom assembly [Figure 50-30-13].
V623 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

Installation on Page 50-50-1.)
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.
V623 VersaHANDLER
INNER BOOM (CONT'D) Figure 50-40-7
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 50-40-7].
cylinder.

Loosen the rear wear pad adjusting bolts (Item 2) [Figure
50-40-5].
Figure 50-40-6
Remove the extension cylinder mounting block (Item 1)

[Figure 50-40-6].
V623 VersaHANDLER
Installation
Figure 50-40-8
Install the extension cylinder mounting block (Item 1)

[Figure 50-40-10].
Figure 50-40-11
Apply grease to the inside top and bottom corners of the
main boom [Figure 50-40-8].

Figure 50-40-9
Apply LOCTITE 242 to the bolt and install the bolt (Item
1) [Figure 50-40-11] through the support pin and into the
cylinder. Tighten the bolt to 221 ft.-lbs. (300 Nm) torque.
Install the end of the inner boom (Item 1) [Figure 50-40-

9] 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 50-40-9].
V623 VersaHANDLER
Figure 50-40-12
Reconnect the front auxiliary harness connector (Item 1)

[Figure 50-40-14].
Adjust the wear pads. (See Removal And Installation on

Reconnect the six hoses (Item 1) [Figure 50-40-12] to Page 50-50-1.)
the tubelines.
Figure 50-40-15

Figure 50-40-13
Install the rear cover (Item 1) [Figure 50-40-15].

Reconnect the light harness connector (Item 1) [Figure
50-40-13].
V623 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).
V623 VersaHANDLER
V623 VersaHANDLER
WEAR PADS (REAR) Figure 50-60-3
Removal
Figure 50-60-1
Install the new wear pad (Item 1) [Figure 50-60-3].
Figure 50-60-4
Remove the inner boom. (See Removal on Page 50-40-

1.)

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].
V623 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.
V623 VersaHANDLER
ENGINE COVER Removal And Installation
Gas Cylinder Removal And Installation Figure 50-70-2
Figure 50-70-1
Remove the gas cylinder.
Lift the engine cover [Figure 50-70-1]. Add a support to Lower the engine cover.
prevent the cover from closing when the gas cylinder is
removed. Remove the plastic cap (Item 1) cotter pin (Item 2) and

washer (Item 3) [Figure 50-70-2] from both ends of the
Remove the retainer clips (Item 1) [Figure 50-70-1] at 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 engine cover pivot pin (Item 1) [Figure 50-

70-3].
Remove the engine cover.
V623 VersaHANDLER
V623 VersaHANDLER
FUEL TANK Figure 50-80-3
Figure 50-80-1
Drain the fuel from the fuel tank by removing the plug
(Item 1) [Figure 50-80-3].
Figure 50-80-4
Raise the boom and install the boom stop (Item 1)
[Figure 50-80-1].

Page 60-20-1.)
Figure 50-80-2
Remove the two bolts (Item 1) [Figure 50-80-4] from the

cab spring.
Install a hoist to lift and support the cab [Figure 50-80-2].
V623 VersaHANDLER
FUEL TANK (CONT'D) Figure 50-80-7
Figure 50-80-5
Support the fuel tank using a forklift or jack [Figure 50-

80-7].
Figure 50-80-8
Remove the two wires (Item 1) [Figure 50-80-5] from the
fuel sending unit.

NOTE: Mark the wires for correct assembly.
Figure 50-80-6

the fuel tank.
V623 VersaHANDLER
FUEL TANK (CONT'D) Figure 50-80-11
Figure 50-80-9
Remove the mounting bolts (Item 1) [Figure 50-80-10] &

[Figure 50-80-11] from the rear of the fuel tank.
Figure 50-80-12
Remove the two mounting bolts (Item 1) [Figure 50-80-9]
from the front of the fuel tank.

Figure 50-80-10
Carefully lower and remove the fuel tank [Figure 50-80-

12].
V623 VersaHANDLER
V623 VersaHANDLER
QUICK TACH Figure 50-90-3
Figure 50-90-1
Remove the pivot pin [Figure 50-90-3].
Figure 50-90-4
Rotate the quick tach forward fully.
Disconnect the couplers (Item 1) [Figure 50-90-1].

Figure 50-90-2

2].
V623 VersaHANDLER
QUICK TACH (CONT'D) Figure 50-90-7
Figure 50-90-5
Remove the pivot pin [Figure 50-90-7].
Support the link as shown [Figure 50-90-5].
Figure 50-90-6

6].
V623 VersaHANDLER
REAR WEIGHTS Figure 50-100-3
Figure 50-100-1
Position a hoist as shown to lift and support the rear

weight [Figure 50-100-3].
Figure 50-100-4
Figure 50-100-2

Remove the three weight mounting bolts (Item 1) [Figure
50-100-4].
Unplug the tail light connector (Item 1) [Figure 50-100-2] Remove the weight.
from the main harness.
V623 VersaHANDLER
V623 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.
V623 VersaHANDLER
V623 VersaHANDLER
PIVOT LINK Figure 50-120-3
Rotate the quick tach back fully.
Figure 50-120-1
Rotate the quick tach forward until it is on the ground

[Figure 50-120-3].
Figure 50-120-4

120-1] from the pivot.
Figure 50-120-2

3] and cover (Item 2) [Figure 50-120-4].
Remove the pivot pin (Item 1) [Figure 50-120-2] and

lower the link (Item 2) [Figure 50-120-2].
V623 VersaHANDLER
PIVOT LINK (CONT'D) Figure 50-120-7
Figure 50-120-5
Place a floor jack under the pivot link [Figure 50-120-7].
Figure 50-120-8

120-5].

Figure 50-120-6

120-8].
Remove the pivot pin (Item 1) [Figure 50-120-6] from the

tilt cylinder.
V623 VersaHANDLER
PIVOT LINK (CONT'D) Figure 50-120-10
Figure 50-120-9
Lower the floor jack and remove the pivot link [Figure 50-
120-10].
Remove the pivot pin (Item 1) [Figure 50-120-9].
V623 VersaHANDLER
V623 VersaHANDLER
ELECTRICAL SYSTEM AND ANALYSIS
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
DASH COVER/STEERING COLUMN COVER. . . . . . . . . . . . . . . 60-100-1

ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Fuses, Diodes & Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

ELECTRICAL
SYSTEM &
FRONT WIPER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1 ANALYSIS
INCHING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

JOYSTICK (S/N 367111001-367112500 AND 367211001-367212500) . .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

V623 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

V623 VersaHANDLER
38-R
WIRING SCHEMATIC + BATTERY

40A
X18 + BATTERY + BATTERY + BATTERY
-
V623 (S/N 367111001 -
R
367112500) X19
70 A
+ CONTACT + CONTACT
AND (S/N 367211001 - 50A
30
-
87
367212500)
85
TRANSMISSION CONT.
D
RE G U L A T O R
86
F-N-R SWITCH
HYDROSTATI
E
SHEET 1 of 8
38-R
ST AR T E
7,5 A
7,5 A
7,5 A
7,5 A
E
CONTACT RELAY
38-R
P
PRINTED SEPTEMBER 2004
R
R
C
S
F22
A
F19 F27 F21
MS-1304A 58
R
R
15/54
76B-H - G 01-H -N
40-L
R
400-A -G
19
76B-H - G
76-G/R
37-B 50a
C
96607.7
57.B-M
5 - - -
17
84A- H - R
37-B E C M O D E
E8 SECU FRONT
D
20/30 A
30 86
MAIN BRAKE
040-A
RS 232 DIAGN OSTIC S W I T C H
O
57.A-M
C : PRE-HEATERPOSITION
76.A-G/N POR
1
T 1 0
37-B
D : STAR T PO SI T I O N
X88
STARTER SWITCH
A : ST O P PO SI T I O N
7
\TOOL CONTINUOUS OFF
524005+- - - - - -
E9 STARTER F O R W A R
62-N
2 3 5 9
B : O N PO SI T I O N
87a 87 85
MODUL
20/30 A
86
X88
30
5
+ BATTERY
76.A-G/N
B6
D
E
\
33.A-G-R TO DIOD E D 12
HAND BRAKE
X88
2
37-B
G
MASTER DISCONNECT
[F] SEE PAGE 2 OF 8 G G

87a 87 85
76-G/R
400-A -G
02-S-G
400-A -G
62-N
REVER S
M
V
B
1
L
E
28 42 20 21 13 4
62.5-S-N
X50
37-B
9
15
M/N
- - 15
(53a)
53-B/N
1
38-R
G
2 R
STARTER RELAY
F
70 A
TO LOCKING MECHANISM
30 86 N
57.B-M
1 R N F
400-A -G
2 05-L
31
B-V
L-G
G
H
Z
[D] SEE PAGE 5 OF 8
1 04- M
6 2 5 3 4
57.B-M
87 85 14 06-G-V
X50
X88
27-B
2
75-A/V 75-A/V 2
4 29 62-N
Dealer Copy -- Not for Resale X88 62-N

[A] SEE PAGE 3 OF 8
15
040-A
74-M /N 74-M /N 3
R R
X50
3
TO + WARNING
1
X88 33N - R / N
24
60A-Z-N
6 16 08-G-V
62-N
E10 PASSIVE BRAKE

76.A-G/N
[C] SEE PAGE 2 OF 8
[B] SEE PAGE 2 OF 8
3 1
040-A 040-A
40-L
5 4 2
7 8 6
84B-A/B
X58
74-M /N
-
REVERSE LIGHT RELAY

84A- H - R
06-G-V
478-L/N
47-Z/B
48-V/N
08-G-V
04 - M
05-L
+
TO 86-E13
07 - M
09-L
R
[E] SEE PAGE 3 OF 8
X50
TO CHARGING TELL TALE
2
57.B-M
33M -G-B
O
ODOMOTE R
38-R
27-B
X28
G R E E X28
X28
C
B
X27
BATTERY 12V
478-L/N
PRE-HEATER RELAY
84A- H - R
-
33.E C/B
X87
70 A
X27
YELLO
30 86
13
-
E11 SPEED RELAY
20/30 A
WATER TEMP. NEAR

86
MODUL
30
N
T
W
B3
E
R
R :510 R
R :510 R
R
R
33M-G-B
REGULATO
INJECTION
87 85
62-N
87a 87 85
S P E E D
S E N S O R
RU M
B +
D +
62-N
W
84.C-A-B
P
P
YELLO
- P P
GRE E
R E
U
MODUL
D
W
N
X52
B2
E
EV1- A V
EV2-AR
X87
40-L
LINEAR DETECTOR
14
478-L/N
478-L/N
S T A R T E R ALTERNATO
48-V/N
47-Z/B
57 - M
M O T O R R
M G
84-A-B
P
1 2 2 1
PRE-HEATER
B - EV8 INCHING
FORWARD DRIVE SOLENOID REVERSE DRIVE SOLENOID

SPEE ELEC TR O. G.O .
D
62-N
62-N
62-N
62-N
62-N
62-N
GROUND GROUND GROUND GROUND GROUND
0 V 0 V 0V 0 V
0 V 0 V
Example : A-B
Light Blue White
BROW
A LIGHT BLUE M 49.A-V-N : W IRE N °4 9 . A G R E E N -B L A C K
N
BLAC
B WHITE N K E
6 2 -N : W IR E N °6 2 B L A C K
ORANG R
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 PINK X88 88:N° THE CONNECTOR
WR E
G GREE
H Y
V N 4 4:POSITION OF THE W IRE
L DARK BLUE Z VIOLET
535 of 784
WIRING SCHEMATIC
V623 (S/N 367111001 -
367112500)
AND (S/N 367211001 -
367212500) + BATTERY + BATTERY + BATTERY + BATTERY
SHEET 2 of 8
MS-1305A + CONTACT + CONTACT + CONTACT
Printable Version Click Here
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 H
C 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
524010 + 5 9 3 2 9 0
X5 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
C
X2 2
B
A
X5 5
X5 5
1
3
33.B-G-R
X8 7
(S) N
FRONT AXLE D IR EC TION
(S) N
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 EM N 4 9 . A - V - N : W I R E N °4 9 . A G R E E N - B L A C K
B WHITE N BLACK 6 2 - N : W I R E N °6 2 B L A C K
ORANG R E
E
YELLO D Light Blue White
G S PINK X88 88:N° THE CONNE CTOR
W
GRE GREE
H V 4 4: P OS I TI ON OF T H E W I R E
Y N
L 536
DARK of 784 Z
BLUE VIO L ET
WIRING SCHEMATIC
V623 (S/N 367111001 -
367112500)
AND (S/N 367211001 -
367212500) [A] SEE PAGE 1 OF 8
+ BATTERY (BEFORE BATTERY MASTER DISCONNECT) X1 9 0
SHEET 3 of 8 4
60A-Z-N

+ BATTERY + BATTERY + BATTERY + BATTERY
MS-1306A
+ 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
LEFT NIGHT LIGH T
A-F8
A-F9
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
Dealer Copy -- Not for Resale 63-L
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
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
70-H
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
E HT
LIG H T
BRAK
BRAK
SIGNAL
FOG LIG HT
LIG H T
NIGHT
LIG H T
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
LIG
M STO
2-54G
P
LIG H T
NIGHT
X3 6
BACKU
N
6-54
S
E
M
D
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

Light Blue White
BROW
A LI G H T B L 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
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 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
537 of 784 L DARK BLUE Z VI O L E T

538 of 784
MS-1307A
367212500)
367112500)
SHEET 4 of 8

WIRING SCHEMATIC
AND (S/N 367211001 -

V623 (S/N 367111001 -
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 X10 6 X8 9
25.6-B
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 X10 7 X8 9
25.6-B 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
88:N° THE CONNECTOR
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
X15 0
62-N EV12 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 40- A X9 0 73A R - L 73A R - L 7,5 A

- 10
N X9 0 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
+ CONTACT + CONTACT + CONTACT + CONTACT + CONTACT
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
K11 BIS
470Ù
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
E
YELLO D Light Blue
G S P IN K White
X8 8 88:N° THE CONNECTOR
W
GRE GREE
H Y
V N 4 4 :POSIT ION OF T H E W IR E
L DARK BLUE Z VIOLE T
539 of 784
WIRING SCHEMATIC
V623 (S/N 367111001 -
367112500)
AND (S/N 367211001 -
367212500)
SHEET 6 of 8
MS-1309A + 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
540 of 784
WIRING SCHEMATIC 96616.8
? SPAR E R ELA Y
V623 (S/N 367111001 - X2 7
2V
7,5 A 28
NOT USED
1A 12
7,5 A 32
16
P
367112500) 17 16
7,5 A 27 14 7 1A 11
7,5 A 02
01
EV2-AR
3 A
R
20 A
20 A 26 7,5 A 10
AND (S/N 367211001 -
SPARE
SPARE
FUSE
FUSE
13 6
10 A 25 7,5 A 9
367212500) EV1-A V
SPAR E R ELA Y
31
7,5 A 15
7,5 A 24 7,5 A 8
NOT USED
SHEET 7 of 8 12 5 15
10 A
7,5 A 23 10 A 7
BLUE
PRINTED SEPTEMBER 2004 BLEU
SPARE
7,5 A 22 15 A 6
FUSE
MS-1310A 7,5 A 21 AUT
11 4
7,5 A 5
7,5 A 30
14
Printable Version Click Here O
15 A
15 A 20 15 A 4
10 3
7,5 A 19 10 A 3
START
B
GRE R STO
YELLOW-GREEN C 10 A 18 P 9 2 15 A 2
Y
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 TO FRONT OF MOTOR 4V
X2 8
3V
14 Dealer
T O FR O N TCopy
C L IM. -- Not for Resale
X2 1
RA
DI
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 ROUGE
X88 7 W AY 1/3
- +
O R AN G
0 1
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
541 of 784
WIRING SCHEMATIC
V623 (S/N 367111001 -
367112500)
AND (S/N 367211001 - X3 9
6V
367212500)
SHEET 8 of 8
MS-1311A X3 8 2V
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
TI O 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
* *
542 of4784
X1 9 0 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
* *
ELECTRICAL SYSTEM INFORMATION
WARNING
assistance in locating and correcting problems which are Instructions are necessary before operating or
most common. Many of the recommended procedures servicing machine. Read and understand the
must be done by authorized Bobcat Service Personnel Operation & Maintenance Manual, Handbook and
only. 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-2003-0199
PROBLEM CAUSE
Battery will not take charge. 1, 2, 3, 4, 5
Alternator will not charge.. 1, 2, 5

Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.
V623 VersaHANDLER
543 of 784
ELECTRICAL SYSTEM INFORMATION (CONT’D) Fuses, Diodes & Relays
Description Figure 60-10-2

Diode
Diod tab
Figure 60-10-1 Diode
1 Diode tab
toward front
of machine
P-26904
P-26461
P-24156
The electrical system is protexted by fuses, diodes and
relays.
The VersaHANDLER has a 12 volt, negative ground
alternator charging system. The electrical system is Remove the console cover (Item 1) [Figure 60-10-1].

protected by fuses located in the cab in the right console
(Item 1) [Figure 60-10-1]. Remove the cover(s) from the rows of fuses/relays/
diodes (Item 1) [Figure 60-10-2] to check or replace
The fuses will protect the electrical system when there is fuses, diodes or relays.
an electrical overload. The reason of the overload must
be found before starting the engine again. Two relays and two fuses are located in the rear of the
engine compartment. See page 60-10-4.
V623 VersaHANDLER
544 of 784
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Fuses, Diodes & Relays (Cont’d)
Figure 60-10-3
* 11 12
28
12
27 14
32 7 11 12
26 16
13 6
10
02 25
17 16 31 9
24 12 5 15
01 8
23
22
11 4 7
6
21 10 3
30
20 14 5
19 9 2 4
29 18 3
8 13
1 2
17
1
1
18

P-26461
P-26904
The locations and description are shown below and

[Figure 60-10-3].
FUSES & DIODES RELAYS

Ref. Description Amps Ref. Description Amps Ref. Description
1 Rear Work Lights 15 20 Front Wiper 15 1 Rear Work Lights

2 Front Work Lights 15 21 Travel Controller 7.5 2 Front Work Lights
3 Headlights 10 22 Fuel Pump 7.5 3 Horn
4 Low Beam Headlights 15 23 Joystick 7.5 4 NOT USED
5 Horn & Cab Light 7.5 24 Directional Signal 7.5 5 NOT USED
6 High Beam Headlights 15 25 Steering Mode Valve 10 6 Low Beam Headlights
7 12V Accessory Plug 10 26 Heater Fan 20 7 High Beam Headlights
8 Left Park Lights 7.5 27 Travel Direction 7.5 8 Transmission/Parking Brake
9 Right Park Lights 7.5 28 Control Panel 7.5 9 Neutral Start
10 Hazard Lights 7.5 29 Top Wiper & Rear Travel 10 10 Brake Control System
11 Parking Brake D* Light 11 Low Travel Speed
12 Trans.Parking Brake D* 30 Rear Wiper, Rear & Top 7.5 12 Auxiliary Hydraulics
13 2nd Auxiliary Hyd. 10 Wiper 13 Backup Lights/Backup Alarm
14 Spare Fuse 15 31 Spare Fuse 10 14 NOT USED
15 Spare Fuse 7.5 32 Reverse Cooling Fan 7.5 15 Switched Power Relay
(Optional) 16 Air Conditioner Compressor
16 Front Auxiliary Hyd. 3
17 Rotating Beacon 7.5 17 Air Conditioner Fan
01 Air Cond. Compressor 7.5 18 Direction Signal
18 Brake Lights 10
02 Air Cond. Fan 20
19 Low Travel Speed 7.5
*D Diodes (Items 11 & 12) inserted with the tab toward the front of the machine (Inset) [Figure 60-10-3].
V623 VersaHANDLER
545 of 784
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Fuses, Diodes & Relays (Cont’d)
Figure 60-10-4
1
4
P18473
Remove the access panel at the rear of the engine

compartment. The relay/fuse receptacles are located

under the air conditioning compressor [Figure 60-10-4].
FUSES
Ref. Description Amps

1 Unswitched Power Fuse 40
2 Switched Power Fuse 50
RELAYS
Ref. Description
1 Starting Motor Relay
2 Preheat Relay
V623 VersaHANDLER
546 of 784
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

Remove the battery access door (Item 1) [Figure 60-20-
1].
Remove the two battery hold down clamps (Item 1)
[Figure 60-20-3].
Remove the battery.
V623 VersaHANDLER
BATTERY (CONT'D)
Servicing
WARNING
Figure 60-20-4
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.
W-2065-1296
Figure 60-20-6
Figure 60-20-5

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].
Always clean the terminals and cable ends when
installing a new battery [Figure 60-20-4] and [Figure 60- Clean the electrolyte level in the battery. Add distilled
20-5]. water as needed.
When installing the battery in the loader, do not touch any Put Battery Saver (P/N 6664458) or grease on the
metal parts with the battery terminal posts. battery terminals and cable ends to prevent corrosion.
Connect and tighten the battery cables. Connect the

negative (-) cable last to prevent sparks.
V623 VersaHANDLER
BATTERY (CONT'D) Figure 60-20-7
Using A Booster Battery (Jump Starting)
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.
WARNING Connect the end of the first cable to the positive (+)
terminal of the booster battery. Connect the other end of
Keep arcs, sparks, flames and lighted tobacco away the same cable to the positive terminal (Item 1) [Figure
from batteries. When jumping from booster battery 60-20-7] on the VersaHANDLER battery.
make final connection (negative) at engine frame.
Do not jump start or charge a frozen or damaged Connect the end of the second cable to the negative (-)
battery. Warm battery to 60°F. (16°C.) before terminal of the booster battery. Connect the other end of

connecting to a charger. Unplug charger before the same cable to the negative terminal (Item 2) [Figure
connecting or disconnecting cables to battery. Never 60-20-7] on the VersaHANDLER battery.
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury. Keep cables away from moving parts. Start the engine.
W-2066-1296
After the engine has started, remove the ground (-) cable
(Item 2) [Figure 60-20-7] first.
Remove the cable from the positive terminal (Item 1)

IMPORTANT [Figure 60-20-7].
Damage to the alternator can occur if:

• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
V623 VersaHANDLER
V623 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.
V623 VersaHANDLER
V623 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
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].
V623 VersaHANDLER
STARTER (CONT'D)
V623 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].
V623 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.
V623 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].
V623 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.
V623 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.
V623 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.
V623 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 joints. Check brush springs, for damage or rust. Replace as
needed.
Figure 60-40-30
Figure 60-40-32
Field Winding Ground Test: Use a circuit tester, touch

one probe to the field winding end of the brush and the Brush Holder Insulation Test: Use a circuit tester, touch
other probe to the surface of the frame [Figure 60-40- one probe to the positive brush holder plate and the other
30]. There should be no continuity. If there is continuity, probe to the holder plate [Figure 60-40-32]. There
the field windings are grounded. should be no continuity. If there is continuity, replace or
repair.
Replace the field windings.
V623 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.
V623 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].
V623 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].
V623 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.)
Remove the dash cover/steering column cover. (See

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].
V623 VersaHANDLER
V623 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 two 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.
V623 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.
V623 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].
V623 VersaHANDLER
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.
V623 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.
V623 VersaHANDLER
571 of 784 60-80-1 Servi ce Manual
V623 VersaHANDLER
572 of 784 60-80-2 Servi ce Manual
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.
V623 VersaHANDLER
V623 VersaHANDLER
DASH COVER/STEERING COLUMN COVER Figure 60-100-3
Remove the travel/signal Levers. (See Removal And



on Page 60-90-11.)
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].
V623 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].
V623 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).

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.
V623 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].
V623 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].
V623 VersaHANDLER
V623 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.
V623 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].
V623 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.
V623 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].
V623 VersaHANDLER
PEDAL ASSEMBLY Figure 60-140-3
Figure 60-140-1

the brake valve.


Unplug the two connectors (Item 1) [Figure 60-140-1].
IMPORTANT
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.
V623 VersaHANDLER
V623 VersaHANDLER
BRAKE LIGHT SWITCH Adjustment
Figure 60-150-1

And Installation on Page 60-100-1.) Loosen the nut (Item 1) [Figure 60-150-3].

Unplug the switch connector (Item 1) [Figure 60-150-1] With the brake pedal at rest, turn the adjustment bolt
from the harness. (Item 2) [Figure 60-150-3] until it touches the brake light
switch plug.
Figure 60-150-2
Tighten the nut (Item 1) [Figure 60-150-3].
Loosen the nut (Item 1) [Figure 60-150-2]. Remove the

switch.
V623 VersaHANDLER
V623 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.
V623 VersaHANDLER
V623 VersaHANDLER
367211001-367212500)


Page 60-50-1.)
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.
V623 VersaHANDLER
V623 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 SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
ENGINE/HYDROSTAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . 70-80-1


FLYWHEEL AND HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Ring Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-4
Ring Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-4 ENGINE
SERVICE
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 70-50-4
RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . 70-100-1

Camshaft And Tappets Installation . . . . . . . . . . . . . . . . 70-100-24
Camshaft And Tappets Removal . . . . . . . . . . . . . . . . . . 70-100-23
Changing Valve Springs (With Cylinder Head Installed) 70-100-16
Checking Crankshaft End Play . . . . . . . . . . . . . . . . . . . 70-100-38
Checking Piston Height . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-32
Connecting Rod Bushing Replacement . . . . . . . . . . . . . 70-100-30
Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . 70-100-30
Cooling System Description. . . . . . . . . . . . . . . . . . . . . . 70-100-39
Crankshaft And Bearings Description . . . . . . . . . . . . . . 70-100-33
Crankshaft And Bearings Installation. . . . . . . . . . . . . . . 70-100-35
Crankshaft And Bearings Removal . . . . . . . . . . . . . . . . 70-100-33
Cutting A Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-14
V623 VersaHANDLER
ENGINE SERVICE (CONT’D)
RECONDITIONING THE ENGINE (CONT'D) . . . . . . . . . . . . 70-100-2

Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . 70-100-3
Cylinder Head Inspection. . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6
Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-100-7
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Cylinder Liner Inspection . . . . . . . . . . . . . . . . . . . . . . . . 70-100-51
Cylinder Liner Installation. . . . . . . . . . . . . . . . . . . . . . . . 70-100-53
Cylinder Liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-52
Engine Block Description . . . . . . . . . . . . . . . . . . . . . . . . 70-100-48
Engine Block Disassembly And Assembly. . . . . . . . . . . 70-100-48
Engine Lubrication System Description . . . . . . . . . . . . . 70-100-42
Exhaust Manifold Removal and Installation . . . . . . . . . . . 70-100-2
Front Oil Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-100-20
Front Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-20
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-50
Inspection Of Crankshaft And Bearings . . . . . . . . . . . . . 70-100-35
Intake Manifold Removal and Installation . . . . . . . . . . . . 70-100-1
Oil Filter Adapter Installation . . . . . . . . . . . . . . . . . . . . . 70-100-43
Oil Filter Adapter Removal. . . . . . . . . . . . . . . . . . . . . . . 70-100-43

Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . 70-100-44
Oil Pressure Relief Valve Disassembly And Assembly . 70-100-47
Oil Pump Disassembly And Assembly. . . . . . . . . . . . . . 70-100-47
Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-46
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-45
Oil Screen And Pick-up Tube. . . . . . . . . . . . . . . . . . . . . 70-100-44
Piston And Connecting Rod Assembly . . . . . . . . . . . . . 70-100-30
Pistons And Connecting Rods Description . . . . . . . . . . 70-100-26
Pistons And Connecting Rods Disassembly . . . . . . . . . 70-100-28
Piston And Connecting Rod Installation. . . . . . . . . . . . . 70-100-30
Pistons And Connecting Rods Removal . . . . . . . . . . . . 70-100-26
Piston Cooling Jet Alignment . . . . . . . . . . . . . . . . . . . . . 70-100-50
Piston Cooling Jet Installation . . . . . . . . . . . . . . . . . . . . 70-100-50
Piston Cooling Jet Removal. . . . . . . . . . . . . . . . . . . . . . 70-100-50
Piston Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-28
Piston Ring Groove Clearance . . . . . . . . . . . . . . . . . . . 70-100-29
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-28
Rear Oil Seal Housing Positioning. . . . . . . . . . . . . . . . . 70-100-37
Rear Oil Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-100-37
Rear Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-37
Rocker Shaft Disassembly And Assembly . . . . . . . . . . . 70-100-10
V623 VersaHANDLER
ENGINE SERVICE (CONT’D)
RECONDITIONING THE ENGINE (CONT'D) . . . . . . . . . . . . 70-100-2

Thermostat Removal and Installation . . . . . . . . . . . . . . 70-100-40
Thermostat Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-40
Timing Case And Drive Assembly Description . . . . . . . 70-100-18
Timing Case And Gear Removal . . . . . . . . . . . . . . . . . . 70-100-20
Timing Case And Gear Installation . . . . . . . . . . . . . . . . 70-100-21
Timing Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-100-19
Timing Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-18
Valves Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-14
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . 70-100-17
Valve Depth Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-12
Valve Guide Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-13
Valve Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-13
Valve Guides Checking . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-12
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-11
Valve Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-15
Valve Springs Checking . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-11
Water Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-41
Water Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-41

Turbo Charger Description. . . . . . . . . . . . . . . . . . . . . . . 70-100-56
Turbo Charger Removal and Installation . . . . . . . . . . . . 70-100-56
Turbo Charger Troubleshooting . . . . . . . . . . . . . . . . . . . 70-100-54
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
V623 VersaHANDLER
V623 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
V623 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.
V623 VersaHANDLER
ENGINE SPEED CONTROL Open the engine cover.
Remove the floor mat and insulation from the cab floor.
Figure 70-20-1
Remove the engine speed control cable (Item 1) [Figure

70-20-3] from the linkage.
Remove the engine speed control cable from the

Remove the speed control cable (Item 1) from the pedal mounting bracket (Item 2) [Figure 70-20-3].

and mounting bracket (Item 2) [Figure 70-20-1].
Remove any necessary cable ties, carefully remove the
Remove the battery box cover. speed control cable.
Figure 70-20-2 Adjustment
Install an engine tachometer.
NOTE: See the instructions supplied with the

tachometer for proper installation.
With the aid of an assistant in the cab/canopy start the

engine and run until the engine reaches normal operating
temperature.
With the engine at low idle, normal operating temperature

and no load on the engine the tachometer should read
between 775 and 825 RPM.
Carefully pull the speed control cable (Item 1) [Figure

70-20-2] through the cab and into the battery box.
V623 VersaHANDLER
ENGINE SPEED CONTROL (CONT’D) Figure 70-20-6
Adjustment (Cont’d)
Figure 70-20-4
P-44167
2
If engine RPM is too low ensure the throttle plate (Item 1)
P-44165 is contacting the high idle adjusting bolt (Item 2) [Figure
70-20-6].
If engine RPM is too high ensure the throttle plate (Item Figure 70-20-7
1) is contacting the low idle adjusting bolt (Item 2)

[Figure 70-20-4].
Figure 70-20-5
1
2
1
2
P-44168
If the throttle plate is not contacting the adjusting bolt,

P-44168 loosen the nut (Item 1) on the front of the cable mounting
bracket and turn the nut (Item 2) on the back of the cable
mounting bracket counterclockwise until the throttle plate
If the throttle plate is not contacting the adjusting bolt, contacts the adjusting bolt. Tighten the nuts (Item 1) &
loosen the nut (Item 1) [Figure 70-20-5] on the front of (Item 2) [Figure 70-20-7].
the cable mounting bracket.
If both high and low dile speed RPM’s cannot be correctly
Turn the nut (Item 2) on the back of the cable mounting adjusted repair or replace the fule injector pump
bracket clockwise until the throttle plate contacts the
adjusting bolt. Tighten the nuts (Item 1) & (Item 2)
[Figure 70-20-5].
Run the engine at high idle (full throttle). With the engine
at high idle, normal operating temperature and no load
the tachometer should read between 2320 and 2420
RPM.
V623 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].
V623 VersaHANDLER
V623 VersaHANDLER
AIR CLEANER Figure 70-40-2
Housing Removal And Installation
Open the hood.
Figure 70-40-1
Remove both mounting bolts (Item 1) [Figure 70-40-2].
Remove the air cleaner housing assembly. (See Housing

Loosen the clamp (Item 1) [Figure 70-40-1] and remove

the hose from the air cleaner.
V623 VersaHANDLER
V623 VersaHANDLER
RADIATOR Remove the hoses (Item 1) [Figure 70-50-2] from the
overflow tank.
Figure 70-50-3
Remove the hood. (See ENGINE COVER on Page 50-
70-1.)
If equipped with air conditioning, remove the condenser.

(See Removal And Installation on Page 80-120-1.)
Remove the air cleaner housing. (See Housing Removal

Figure 70-50-1
Remove the hose clamp bolt (Item 1) and hose (Item 2)

[Figure 70-50-3] from the engine block.
Figure 70-50-4

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.
V623 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,
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.
V623 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.
V623 VersaHANDLER
Lay the radiator assembly on a work surface, with the fan

in the upright position.
Figure 70-50-12
Remove the four fan shroud mounting bolts (Item 1)

[Figure 70-50-14].
Remove the fan shroud.
Figure 70-50-15

Remove the two bolts (Item 1) and 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.
V623 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].
V623 VersaHANDLER
V623 VersaHANDLER
ENGINE AND ENGINE MOUNTS Figure 70-60-2

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 Remove the hose clamp bolt (Item 1) and hose (Item 2)
the compressor. (See Removal And Installation on Page [Figure 70-60-2] from the engine block.
80-110-1.)
Figure 70-60-3
Figure 70-60-1

Remove the three mounting bolts (Item 1) [Figure 70-60-
Remove the hose (Item 1) [Figure 70-60-1] from the 3] and remove the cooling fan safety shield.
overflow tank.
Figure 70-60-4
Remove the radiator hose (Item 1) [Figure 70-60-4] from

the water pump.
V623 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].
V623 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.
V623 VersaHANDLER
V623 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) 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]

Remove the bolts (Item 1) [Figure 70-70-2] from the from the fuel injection pump. The timing of the
water pump. fuel injection pump comes set from the
factory.
Installation: Tighten the nuts to 16 ft.-lbs. (22 Nm)
torque.
V623 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
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.
V623 VersaHANDLER
ENGINE COMPONENTS AND TESTING (CONT'D) Figure 70-70-9

(Cont'd)
Figure 70-70-8
Remove the return spring (Item 1) [Figure 70-70-9].

the pump.
Disconnect the injector tubelines (Item 1) [Figure 70-70- Disconnect the electrical connections (Item 3) [Figure
8] from the injectors. 70-70-9] from the injection pump.

Installation: Tighten the tubeline fittings to 16 ft.-lbs. (22 Remove the mounting nuts (Item 4) [Figure 70-70-9]
Nm) torque. from the injection pump.
Remove the fuel tubeline (Item 2) [Figure 70-70-8]. Installation: Tighten the nuts to 16 ft.-lbs. (22 Nm)
torque.
Remove the breather hose (Item 3) [Figure 70-70-8].
Figure 70-70-10
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289

from the fuel injection pump gear.

torque.
Remove the fuel pump and timing pin from the engine.
V623 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.
V623 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.
V623 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.
V623 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
The tools listed will be needed to do the following

procedure;
OEM1064 - Injection Nozzle Tester Check the nozzle spray pattern [Figure 70-70-20].
OEM 1065 - Accessory Set
Figure 70-70-19 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.
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)
WARNING
W-2072-0496
V623 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 fuel lift pump.

Remove the hose clamp (Item 1) from the turbocharger
air inlet hose (Item 2) [Figure 70-70-21].
Remove the air inlet hose from the turbocharger.
V623 VersaHANDLER
ENGINE/HYDROSTAT ASSEMBLY Remove both heater hoses (Item 1) [Figure 70-80-2]
from the engine.
NOTE: Mark all hoses and electrical connectors for
Raise the boom and install the boom support device. correct installation.
(See BOOM STOP on Page 10-150-1.)
Figure 70-80-3
Remove the hood. (See ENGINE COVER on Page 50-
70-1.)
If equipped with air conditioning, remove the compressor.

(See Removal And Installation on Page 80-110-1.)
Drain the hydraulic reservoir. (See HYDRAULIC


Page 60-20-11.)
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].
V623 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.
V623 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
Remove the access cover mounting bolt (Item 1).

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.
V623 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), fuses (Item 2) and

relays (Item 3) [Figure 70-80-16] from the harness.
NOTE: Mark the location of the fuses and relays for

Remove the bolt (Item 1). Remove the relay cover (Item correct installation.
2) [Figure 70-80-14].
Installation: Fuse holder R1 uses a 50 amp fuse and
fuse holder F2 uses a 40 amp fuse.
V623 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) and 4 - terminal - 2 Black
remove the relay housing (Item 2) from the fuse holder
(Item 3) [Figure 70-80-17]. Figure 70-80-20

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
Using a pointed tool, press down on the tab for each wire 3 - terminal - White
and pull the wire from the connector [Figure 70-80-18]. 4 - terminal - White/Black
Installation: Install the wires into the relay housing as

listed below.
V623 VersaHANDLER
Figure 70-80-21
Loosen and remove both alternator mounting bolts (Item

1) [Figure 70-80-23].
Remove the alternator belt.

Remove the three bolts (Item 1) and 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].
V623 VersaHANDLER
Figure 70-80-25

the tow valve.
Figure 70-80-28
Remove the three exhaust mounting bolts (Item 1)
[Figure 70-80-25].

Figure 70-80-26
Disconnect the hydraulic hose (Item 1) [Figure 70-80-28]

from the hydraulic filter.
Disconnect the engine speed sensor connector (Item 1)

[Figure 70-80-26] located on the backside of the engine
on the flywheel housing.
IMPORTANT
damage the system.
I-2003-0888
V623 VersaHANDLER
IMPORTANT
damage the system.
I-2003-0888
Figure 70-80-29
Remove the three hoses (Item 1) [Figure 70-80-31].
Figure 70-80-32

Remove the hose (Item 1) [Figure 70-80-29].

Remove the three hoses (Item 1) and harness (Item 2)
Figure 70-80-30 [Figure 70-80-32].
Remove the tee fitting (Item 1) [Figure 70-80-30] and

two hoses from the filter head.
V623 VersaHANDLER
Figure 70-80-33

hydrostatic pump.
Figure 70-80-36
Remove the hose (Item 1) from the gear pump and the
four bolt flange hose (Item 2) [Figure 70-80-33] from the
backside of the pump.

Figure 70-80-34
Remove the two wires (Item 1) [Figure 70-80-36] from

the solenoids.
V623 VersaHANDLER
Figure 70-80-37
Figure 70-80-40
Remove the four bolt flange hose (Item 1) [Figure 70-80-

37] from the hydrostatic pump.

Figure 70-80-38

the hydraulic reservoir.
V623 VersaHANDLER
Figure 70-80-41
Remove the engine assembly mounting bolt (Item 1)

[Figure 70-80-43] located by the air filter.
Figure 70-80-44
Install a chain hoist to lift and secure the engine
assembly [Figure 70-80-41].

Figure 70-80-42
Lift the engine assembly up approximately one inch (25

mm) and pull the engine assembly away from the
machine [Figure 70-80-44].
Remove the two engine assembly mounting bolts (Item

1) [Figure 70-80-42].
V623 VersaHANDLER
V623 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.
V623 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].
V623 VersaHANDLER
Figure 70-90-9
If removing the backing plate (Item 1) 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.
V623 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.
V623 VersaHANDLER
RECONDITIONING THE ENGINE Figure 70-100-3
Intake Manifold Removal and Installation
Remove the turbocharger.
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

(Item 2) [Figure 70-100-3].
Disconnect the tubeline (Item 1) [Figure 70-100-1] from Installation: Tighten the mounting bolts to 24 ft.-lbs. (33

the intake manifold. Nm) torque.
Figure 70-100-2 Figure 70-100-4
Disconnect the tubeline (Item 1) [Figure 70-100-2] from Remove the intake manifold from the cylinder [Figure
the intake manifold. 70-100-4].
Remove the four mounting bolts (Item 2) [Figure 70-100- 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.
V623 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D)
Exhaust Manifold Removal and Installation
Figure 70-100-5
Remove the intake manifold.

Remove all the nuts from the exhaust manifold (Item 1)
[Figure 70-100-5].
Installation: Tighten the nuts to 24 ft.-lbs. (33 Nm)

torque.
V623 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-7
Cylinder Head Disassembly
Remove the oil cooler. (See Removal And Installation on

Page 30-20-1.)
Remove the intake manifold.
Remove the exhaust manifold.
Figure 70-100-6
Disconnect the injector tubelines (Item 1) [Figure 70-

100-7] from the injector pump.
IMPORTANT

I-2029-0289
Figure 70-100-8
Disconnect the tubelines (Item 1) [Figure 70-100-6] from
the top of the fuel injector pump.

the injector pump.
Disconnect the six tubelines (Item 3) [Figure 70-100-6]

from the top side of the fuel filter.


from the engine.
Remove the breather hose (Item 1) [Figure 70-100-8].
Remove the dipstick mount bolt (Item 2) [Figure 70-100-

8].
Disconnect the injector tubelines (Item 3) [Figure 70-

100-8] from the injectors.
Disconnect the fuel tubeline (Item 4) [Figure 70-100-8]

and remove the tubeline.
Remove the injector tube lines from the engine.
Remove the fuel injectors. (See Fuel Injector Removal

V623 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) and remove the rocker bolt lengths: S short; M medium & L long
shaft assembly [Figure 70-100-10]. for disassembly and bolts.
assembly of the rocker shaft assembly.)
Check the head bolts for distortion and damage. Replace
as needed.
Lift off the cylinder head and clean the bottom face.
Remove the valves from the cylinder head. See Page -

70-100-11
V623 VersaHANDLER
Cylinder Head Inspection
Figure 70-100-13
Put a straight edge on the cylinder head as shown in

[Figure 70-100-13].

Using a feeler gauge between the straight edge and
head, check for warpage.
Maximum allowed (Item 1) is 0.003 inches (0,08 mm),

(Item 2) is 0.006 inches (0,15 mm) and (Item 3) [Figure
70-100-13] is 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.
V623 VersaHANDLER
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.
Clean any debris out of the cylinder bores.
Figure 70-100-14
[Figure 70-100-15] shows the three different bolt

lengths: S-short; M-medium and L-long.
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.
Figure 70-100-16
NOTE: The locating pins (Item 1) are pressed in the

engine block so the head gasket (Item 2)
[Figure 70-100-14] can be positioned
correctly.
The head gasket is installed with no sealer.
Place the head gasket in position with the Front Top (Item
2) [Figure 70-100-14] marks in the correct position.
Lower the cylinder head in position.
Additional tightening of the head bolts requires the use of

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].
V623 VersaHANDLER
Cylinder Head Installation (Cont’d)
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 Figure 70-100-20

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.
Figure 70-100-18
Install the rocker arm shaft. Tighten the rocker arm nuts
(Item 1) [Figure 70-100-20] to 55 ft.-lbs. (75 Nm) torque.
NOTE: Make sure the oil feed line seal (Item 2) [Figure
70-100-20] is correctly positioned in the
Tighten short bolts 2.5 flats, medium bolts 3 flats, and cylinder head.
long bolts 3.5 flats in the same sequence as shown in
[Figure 70-100-18]. The valve lash adjustment must be checked after the
cylinder head is installed. See Page -70-100-17
V623 VersaHANDLER
Cylinder Head Installation (Cont'd)
Install the fuel injectors. (See Fuel Injector Removal And

IMPORTANT
I-2029-0289
Install the injector tubelines on the engine.

Connect the injector tubelines (Item 1) [Figure 70-100-
Figure 70-100-21 22] to the injection pump.
Figure 70-100-23

Connect the fuel tubelines (Item 1) [Figure 70-100-21].
Tighten tubeline fittings to 16 ft.-lbs. (22 Nm) torque. Install the fuel filter mounting bracket and fuel filter using
the mounting bolts (Item 1) [Figure 70-100-23].
Connect the injector tubeline (Item 2) [Figure 70-100-
21]. Connect the six tubelines (Items 2) [Figure 70-100-23] to
the filter housing.
Install the breather hose (Item 3) [Figure 70-100-21].
Connect the tubeline (Item 3) [Figure 70-100-23] to the
injection pump.
Connect the tubeline (Item 4) [Figure 70-100-23] to the

top of the injection pump.
Install the exhaust manifold. See Page -70-100-2
Install the intake manifold. See Page -70-100-1
Install the turbocharger. See Page -70-100-54
V623 VersaHANDLER
Rocker Shaft Disassembly And Assembly
Figure 70-100-24
Remove the clips (Item 1) [Figure 70-100-24] from both

ends of the shaft.

Remove the location screw (Item 2) [Figure 70-100-24]
for the oil supply connection.
Remove the rocker arm (Item 3), mount bracket (Item 4),
rocker arm (Item 3) and spring (Item 5) [Figure 70-100-
24].
Continue to disassemble the rocker shaft.
Clean and inspect all components for damage and wear.
Check the clearance between the rocker arms and shaft.
Using a press and adapter, remove the old bushing and

press in the new one making sure the oil holes line up.
Shaft O.D. 0.7485-0.7495 inch (19,01-

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).
V623 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Valve Springs Checking
Valve Removal Figure 70-100-26
NOTE: Mark all components so they can be returned

to the same position.
Figure 70-100-25
Use the following chart [Figure 70-100-26]:
Valve Springs (Outer):

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), outer spring (Item 3) inner spring (Item 4), Installed Pressure 20-23 lbs. (89-104 Nm)
valve seal (Item 5), valve seat washer (Item 6) and the
valve (Item 7) [Figure 70-100-25].
Clean and inspect all components.
V623 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 Outside Diameter
valve seat insert must be installed. (Item 2) [Figure 70-100-28] 0.6260-0.6264 inch (15,90-
15,91 mm)
When the depth is less than 0.050-0.063 inch (1,27-1,60
mm) the seat may be ground to lower the valve depth. Interference fit of valve 0.0018-0.0027 inch (0,047-
guide to cylinder head: 0,007 mm)
Valve Guides Checking Overall Length: (Item 3) [Figure 70-100-28]
Intake 2.281 inch (57,94 mm)
Figure 70-100-28
Exhaust 2.406 inch (61,10 mm)
Protrusion from bottom 0.585-0.596 inch (14,85-
recess for valve spring: 15,15 mm)
(Item 4) [Figure 70-100-28]
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) 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.
V623 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) on Lubricate the outer surface of the new guide (Item 1)
the valve guide (Item 2) [Figure 70-100-30]. [Figure 70-100-31] with engine oil.
Pull the guide (Item 2) [Figure 70-100-30] out of the Put the guide in position on the valve guide removal/
cylinder head. installation tool (Item 2) [Figure 70-100-31].
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].)
V623 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 Carefully turn the cutter in a clockwise direction using
(122,66-123,30 even downward pressure. Keep the valve seat as narrow
mm) as possible [Figure 70-100-33].
Exhaust 4.829-4.854 inch Remove any cutting debris.

(122,66-123,30
mm) Install the valve and lightly tap.
2. Intake 0.3725-0.3536 inch
(8,95-8,98 mm) Check the valve depth to make sure that it is within limits.
Exhaust 0.3519-0.3528 inch See Page -70-100-12
(8,93-8,96 mm)
NOTE: If the valve seat is worn or damaged, a new
3. Intake 1.688-1.698 inch valve seat insert can be installed.
(42,88-43,12 mm)
Exhaust 1.609-1.619 inch
(40,88-41,12 mm)
4. Int./Exh. (Production) 0.055-0.07 inch
(1,40-1,70 mm)
Int./Exh. (Service Max.) 0.077 inch (1,95
mm)
Intake/Exhaust Valve Face Angle 45°
V623 VersaHANDLER
Valve Seat Assembly
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) 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].
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
V623 VersaHANDLER
Changing Valve Springs (With Cylinder Head

Installed)
Remove the rocker cover.
Figure 70-100-35
Install the valve spring compressor and adaptor [Figure

70-100-36].
Compress the valve springs and remove the retainers.
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.
V623 VersaHANDLER
Valve Clearance Adjustment
Adjust the valve clearance as follows:
Figure 70-100-37
Figure 70-100-39
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

V623 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 Page -70-100-41
Figure 70-100-41
Remove the timing cover bolts (Item 1) [Figure 70-100-

41].
V623 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), 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

Remove the tool.
Install the water pump. See Page -70-100-41
V623 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Timing Case And Gear Removal
Front Oil Seal Removal Remove the timing cover. See Page -70-100-18
Remove the crankshaft pulley. Figure 70-100-46
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].
Remove the three bolts (Item 3) from 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.
Place the seal tool (Item 1) [Figure 70-100-45] against
the seal. Remove the cam gear retaining bolt (Item 5) [Figure 70-
100-46].
Using the three hole washer (Item 2) [Figure 70-100-45],
install the crankshaft bolts and tighten evenly until the Figure 70-100-47
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].
V623 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 70-100-49]
Remove the timing case (Item 1) and gasket (Item 2)

from the engine. Do not allow the idler gear hub (Item 3)
and camshaft thrust washer (Item 4) [Figure 70-100-49]
to fall.
V623 VersaHANDLER
Timing Case And Gear Removal (Cont'd)
Figure 70-100-50
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 cam gear (Item 1) [Figure 70-100-50].
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 Page -70-100-19
V623 VersaHANDLER
Camshaft And Tappets Removal
Remove the timing case cover. See Page -70-100-18
Remove the fuel injection pump. (See Fuel Injection

Pump Removal And Installation on Page 70-70-1.)
Remove the timing case. See Page -70-100-18
Remove the rocker cover, rocker assembly and push

rods. See Page -70-100-5
Remove the fuel pump and gasket.
Figure 70-100-52
Remove the camshaft thrust washer (Item 1) [Figure 70-
100-53].
Figure 70-100-54

Turn the engine over and remove the oil pan mounting
bolts [Figure 70-100-52].
Remove the oil pan and gasket.

Carefully remove the camshaft (Item 1) [Figure 70-100-
54].
Installation: Tighten the oil pan mounting bolts to 16 ft-
.lbs. (22 Nm) torque.
Figure 70-100-55
Remove the tappets (Item1) [Figure 70-100-55] from the

block.
V623 VersaHANDLER
Camshaft And Tappets Installation
Clean and inspect the camshaft and tappets for

excessive wear and damage.
Inspect the camshaft bushing for excessive wear and

damage.
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 Install the camshaft thrust washer (Item 1). Make sure
clean engine oil. that the dowel pin (Item 2) [Figure 70-100-58] lines up
with the hole in the thrust washer.
Figure 70-100-56
Install the timing case. See Page -70-100-21
Check camshaft end play. The end play for a new engine

is 0.004 - 0.016 inch (0,10 - 0,41 mm), service limits
0.021 inch (0,53 mm).
Figure 70-100-59
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 70-100-7.)
Install the timing cover. (See Timing Cover Installation on

Carefully install the camshaft (Item 1) [Figure 70-100- Page 70-100-19.)
57].
Install the oil pan. See Page -70-100-44
V623 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Pistons And Connecting Rods Removal
Pistons And Connecting Rods Description Remove the cylinder head. See Page -70-100-5
The pistons have a Quadram combustion chamber. They Remove all the carbon from the top of the cylinder liners.
have two compression rings and one oil control ring. The
top ring groove has a hard metal insert to reduce wear. Remove the oil pan. See Page -70-100-44
Full floating piston pins are used and are retained by
snap rings. Figure 70-100-60
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

compression rings and one oil control ring. All the rings
are above the piston pin. Each of the three piston rings
have different design features. Always use the engine
identification number to order new parts.

Remove the oil pick up screen and tube (Item 1) [Figure
70-100-60].
Figure 70-100-61
Mark and remove the connecting rod caps (Item 1)

[Figure 70-100-61].
NOTE: Do not allow the connecting rods to hit the

cooling jets.
V623 VersaHANDLER
Pistons And Connecting Rods Removal (Cont’d)
Figure 70-100-62
Inspect the crankshaft journals (Item 1) [Figure 70-100-

63] for wear or damage.
NOTE: Keep all parts together so they can be

Turn the connecting rods 90° to prevent contact with the replaced in their original position.
piston cooling jets (Item 1) [Figure 70-100-62]. Push the
piston and rod assemblies out the top of the cylinder. NOTE: Before installing the pistons check cylinder

bore for wear or damage. See Page -70-100-50
V623 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].
V623 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.
V623 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), piston pin (Item 2) and
two snap rings (Item 3) [Figure 70-100-71] in the piston.
Checking the connecting rod for distortion [Figure 70-
100-70]. Piston And Connecting Rod Installation

NOTE: The large and small end bores must be square Apply a light coat of oil to the piston and piston rings.
and parallel within the limits of ± 0.010 inch
(0,25 mm). NOTE: Make sure the piston ring end gaps are 120°
apart.
Measure this 5.0 inch (127 mm) on each side of the
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 Install the ring compressor over the piston rings [Figure
bushing and piston pin. 70-100-72].
Carefully place the connecting rod in the cylinder and

using a hammer handle, push the piston in the bore.
V623 VersaHANDLER
Piston And Connecting Rod Assembly (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.
V623 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Checking Piston Height
Piston And Connecting Rod Installation (Cont'd) Rotate the crankshaft until the piston is approximately at
top dead center (T.D.C.).
Figure 70-100-77
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).
Install the oil pick up tube and screen (Item 1) [Figure NOTE: Two Quadram piston heights can be used. In
70-100-77]. the factory H - high or L - low. In service only
L pistons are supplied.

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 Page -70-100-7
V623 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
Remove the water pump. (See Water Pump Removal on Remove the two bolts (Item 1) [Figure 70-100-79]
Page 70-100-41.) retaining the bridge piece.
Remove timing case cover. (See Timing Cover Removal Remove the bridge piece.
on Page 70-100-18.)
Figure 70-100-80

Remove the timing gears and timing case. (See Timing

Case And Gear Removal on Page 70-100-20.)
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 70-100-26,
keeping them in order.
Figure 70-100-78
Mark the main bearing caps (Item 1) [Figure 70-100-80]

for correct installation.
Remove the main bearing cap bolts.
Remove the rear oil seal housing (Item 1) [Figure 70-

100-78].
V623 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].
V623 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 SPECIFICATIONS Section, 20-01 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.
V623 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) 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.
V623 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) 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) 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.
V623 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.
V623 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.
V623 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.
V623 VersaHANDLER
Water Pump Removal
Remove the coolant from the cooling system.
Figure 70-100-105
Loosen the hose clamp (Item 1) [Figure 70-100-107].
Remove the water pump.
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 70-100-6]

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.
V623 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

Pressure lubrication is supplied by a rotor type pump through passages in the crankshaft to the big end
(Item 1) [Figure 70-100-108] which is driven through an bearings. The pistons and the cylinder bores are
idler gear from the crankshaft gear. lubricated by splash and oil mist.

Engine oil from the oil pan sump passes through a Engine oil passes from the main bearings through
strainer (Item 2) [Figure 70-100-108] and pipe to the passages in the cylinder block to the journals of the
suction side of the pump. camshaft. Engine oil passes from the center journal of
the camshaft through a passage in the cylinder block and
The engine oil passes from the outlet side of the pump cylinder head to a restriction in the pedestal of the rocker
through a pipe to a relief valve (Item 3) [Figure 70-100- shaft, at a reduced pressure, to feed the rocker bushing.
108], which is installed in the bottom left side of the The oil passes through a passage in the rocker shaft to
cylinder block. The relief valves opens if the oil pressure the bearings of the rocker levers. The valve stems, valve
is too high; this allows some of the engine oil to return to springs and the tappets are lubricated by splash and oil
the sump. mist.
Figure 70-100-109 The hub of the idler gear is lubricated by oil from the
cylinder block and the timing gears are splash lubricated.
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
turbocharger. The oil passes through the turbocharger
and returns through a pipe to the oil pan sump.
From the relief valve, engine oil passes to a plate type oil
cooler (Item 1) [Figure 70-100-109].
Oil flows through the oil tubes (Item 2) [Figure 70-100-

109] to the filter.
V623 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Oil Filter Adapter Installation
Engine Lubrication System Description (Cont’d) Figure 70-100-113
Figure 70-100-111
Clean the filter adapter (Item 1) and the block mounting

surfaces (Item 2) [Figure 70-100-113].
Turbocharged engines have piston cooling jets (Item 1)
[Figure 70-100-111]. These jets are connected to the oil Using a new gasket, install the adapter (Item 1) [Figure
pressure rail and spray lubricating oil inside the pistons to 70-100-113] on the block.

keep them cool.
Connect the turbocharger oil supply line.
Oil Filter Adapter Removal
Connect the oil cooler lines to the filter adapter.
Remove the oil filter.
Install the oil filter.
Figure 70-100-112
Remove the oil cooler tube (Item 1) [Figure 70-100-112]

from the filter pump.
Remove the four bolts (Item 2) and the filter adapter (Item
3) [Figure 70-100-112].
V623 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Oil Screen And Pick-up Tube
Oil Pan Removal And Installation Figure 70-100-115
Figure 70-100-114
Remove the bolt (Item 1) that holds the bracket (Item 2)

[Figure 70-100-115] to the main bearing cap.
Remove the oil pan retaining bolts [Figure 70-100-114].
Remove the bolts (Item 3) [Figure 70-100-115] from the
Remove the pan and gasket. pick-up tube flange.

Clean the pan in solvent and dry with compressed air. Remove the pick-up tube (Item 4) [Figure 70-100-115]
and gasket.
Clean the block surface.
Wash the assembly in solvent and dry with compressed
Installation: Place a new gasket on the oil pan. Place air.
two bolts on each side to position the oil pan correctly.
Install the remaining bolts. Tighten the bolts to 16 ft.-lbs. Check the tube and strainer for cracks or other damage.
(22 Nm) torque [Figure 70-100-114]. Replace as necessary.
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.
V623 VersaHANDLER
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
the idler shaft for lubrication of the idler shaft
bushing.
Remove the oil pan. See Page -70-100-44
Figure 70-100-116
Remove the snap ring (Item 1), idler gear (Item 2)

[Figure 70-100-117], and washer.
Remove the bolts and oil pump.

Remove the oil pressure relief valve (Item 1) [Figure 70-
100-116].
Remove the oil screen and pick-up tube.
The oil pump is installed on the number 1 main bearing

cap.
NOTE: The pump can be removed with the main

bearing cap if a spanner wrench is available
that will allow the torque to be applied directly
to the main cap bolts.
If there is no spanner wrench, the front timing case cover

must be removed. See Page -70-100-18
V623 VersaHANDLER
Oil Pump Installation
Fill the pump with engine oil.
If the number one main cap was removed, reinstall and

Install the pump on the main cap and tighten to 16 ft.-lbs.

(22 Nm) torque.
Check the idler gear and bushing for wear.
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].
End play for the idler gear should be 0.0005/0.0253 inch

(0,012/0,643 mm).

Install the oil screen and pick-up tube. See Page -70-
100-44
Install the pressure relief valve.
Lubricate with clean engine oil and install the washer,

idler gear (Item 1) 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).
V623 VersaHANDLER
Oil Pump Disassembly And Assembly
NOTE: If any part is worn enough to effect

performance replace the complete oil pump.
Remove the cover of the oil pump.
Remove the outer rotor and thoroughly clean. Check for

cracks or other damage.
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).
Install the cover and tighten the bolts to 16 ft.-lbs. (22

Nm) torque.

Oil Pressure Relief Valve Disassembly And Assembly
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) in the valve body (Item 2)

and remove the snap ring (Item 3) [Figure 70-100-123].
Remove the end plate (Item 1), spring (Item 4), and
plunger (Item 5) from the body (Item 2) [Figure 70-100-
123].
Clean the parts in solvent and dry with compressed air.
Lubricate the bore of the valve body (Item 2), plunger

Check the inner rotor to outer rotor clearance [Figure 70- (Item 5) and the end plate (Item 1) [Figure 70-100-123]
100-121]. with clean engine oil before assembly.
Clearance between the inner rotor and outer rotor must

be 0.0015 - 0.005 inch (0,04-0,13 mm).
V623 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Remove the oil cooler. (See Removal And Installation on
Page 30-20-1.)
Engine Block Description
Remove the oil filter and oil pan. (See Oil Filter Adapter
The cylinder block is made of cast iron and provides full Removal on Page 70-100-43.)
length support for the dry liners.
Remove the turbocharger. (See Turbo Charger Removal
Figure 70-100-124 and Installation on Page 70-100-54.)
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 70-100-5.)
Remove the timing case and gears. (See Timing Case

And Gear Removal on Page 70-100-20.)
Remove the piston and connecting rod assemblies. (See

Pistons And Connecting Rods Removal on Page 70-100-
26.)

The liners (Item 1) [Figure 70-100-124] are made of cast
iron. Production liners are a press fit and service liners Remove the camshaft and tappets. (See Camshaft And
are a transion fit. Both types of liners are honed with Tappets Removal on Page 70-100-23.)
silicon carbide tools to a specially controlled finish to
ensure long engine life and low oil consumption. Remove the engine mounting bracket and flywheel. (See
Figure 70-100-125
Remove the rear oil seal and the crankshaft. (See
Crankshaft And Bearings Removal on Page 70-100-33.)
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
Remove the water pump. (See Water Pump Removal on

Page 70-100-41.)

V623 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) Piston Cooling Jet Alignment
Piston Cooling Jet Removal Insert a 0.067 inch (1,70 mm) diameter rod of suitable
length, in the jet.
Figure 70-100-126
Figure 70-100-128
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), mount bolt (Item 2) 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) 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]

V623 VersaHANDLER
Cylinder Liner Inspection
The condition of a cylinder liner is decided by:
• The amount and location of polished areas.
• Wear.
• 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.
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).
A flex type hone may be used to clean up small scoring

or pitting.

Damaged or worn liners must be replaced.
Examine the liner surface (Item 1) [Figure 70-100-129]

for cracks, deep scratches and polished areas where the
honed finish is worn away.
V623 VersaHANDLER
Cylinder Liner Removal
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.
Figure 70-100-131

Place the tool (Item 1) over the center of the liner (Item
2). Make sure the flat bearing race (Item 3) [Figure 70-
100-131] is against the bottom of the recess.
Install the rod (Item 4) 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.
V623 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.
Clean the cylinder bore and the outside of the liner.
Continue to press the liner into position. Remove the tool.
Lubricate the cylinder bore with engine oil.
NOTE: Do Not hit the cylinder liners with a hammer.
Figure 70-100-132 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.
The inside diameter of the service liner should be 3.937-

3.939 in. (100,00- 100,06 mm).
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) of the
With the adapter (Item 2) on the top of the liner, place the cylinder liner, not the top of the flame ring (Item 2)
bearing (Item 3) [Figure 70-100-132] in the recess at the [Figure 70-100-133].
top.
V623 VersaHANDLER
RECONDITIONING THE ENGINE (CONT'D) The chart below is given to assist in the correct diagnosis
of turbocharger faults.
Turbo Charger Troubleshooting
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. 20. Worn turbocharger bearings.
2. Restricted crankcase breather. 21. Excessive dirt in turbocharger housing.
3. Air filter element missing, leaking or not sealing correctly. Loose 22. Excessive carbon behind turbine rotor.
connection to turbocharger.
4. Internal distortion or restriction in pipe from air filter to 23. Engine speed raised too rapidly at initial start.
turbocharger.
5. Damaged/restricted crossover pipe, turbocharger . to induction 24. Insufficient engine idle period.
manifold.
6. Restriction between air filter and turbocharge. 25. Faulty fuel injection pump.
7. Restriction in exhaust system. 26. Worn or damaged fuel injectors.
8. Turbocharger loose or clamps/setscrews loose. 27. Valves burned.
9. Induction manifold cracked or loose, flanges distorted. 28. Worn piston rings.
10. Exhaust manifold cracked or loose, flanges distoted. 29. Lubricating oil leakage from supply pipe.
11. Restricted exhaust system. 30. Excessive starting fluid (on initial engine start).
12. Delay of lubricating oil to turbocharge at engine start. 31. Excessive engine idle period.
13. Insufficient lubrication. 32. Restriction in turbocharger bearing housing.
14. Dirty lubricating oil. 33. Restriction in lubricating oil filter.
15. Incorrect lubricating oil. 34. Engine stopped too soon from high load.
16. Restricted lubricating oil supply pipe. 35. Insufficient lubricating oil.
17. Restricted lubricating oil drain pipe. 36. Fuel leakage from fuelled starting aid.
18. Turbine housing damage or restricted. 37. Crack in back plate of compressor.
19. Leakage from turbocharger seals.
V623 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.
V623 VersaHANDLER
Turbo Charger Removal and Installation (Cont'd)
Thoroughly clean the turbocharger.
Figure 70-100-137
Remove the oil return line (Item 1) [Figure 70-100-139].
Figure 70-100-140
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.
V623 VersaHANDLER
V623 VersaHANDLER
HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SERVICE . . . . . . . . . . . . . . . . . . . . . . . 80-90-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . 80-10-3

Principals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
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 HVAC
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
V623 VersaHANDLER
HEATING, VENTILATION, AIR CONDITIONING (CONT’D)
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-5
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
V623 VersaHANDLER
V623 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) 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) .
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) 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) .
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) . 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) . 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.
V623 VersaHANDLER
AIR CONDITIONING SYSTEM FLOW (CONT'D)
Chart
V623 VersaHANDLER
V623 VersaHANDLER
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.
V623 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.
V623 VersaHANDLER
SAFETY Figure 80-30-2
Safety Equipment
In servicing A/C and heater systems you will be exposed

to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
Figure 80-30-1
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 80-30-2] to prevent frost bite if you should

get refrigerant on your hands.
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-30-
1] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gage set
WARNING
connectors. Safety glasses or a transparent face shield
are practical safety items and one or the other is HFC 134A refrigerant can be dangerous if not
absolutely required. 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
WARNING when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
In the event of a leakage, wear safety goggles. even small amounts of 134A in the air.
Escaping refrigerant can cause severe injuries to Any servicing work that involves release or addition
eyes. In contact with a flame, R134a refrigerant gives of 134A to the system must be done by a competent
a toxic gas. refrigeration dealer who has the proper equipment,
W-2371-0500 knowledge, and experience to service refrigeration
equipment.
W-2373-0500
V623 VersaHANDLER
V623 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].
V623 VersaHANDLER
REGULAR MAINTENANCE (CONT'D) Cleaning The Condenser
Compressor Drive Belt Inspection Open the hood.
It is a good rule to regularly inspect (weekly) the Temporarily remove the air cleaner. (See AIR CLEANER
compressor drive belt for tension and wear. on Page 70-40-1.)
Open the hood. Figure 80-40-6
Remove the drive belt cover.
Figure 80-40-5

Clean the condenser (Item 1) [Figure 80-40-6] using
water or air pressure.
NOTE: Clean between the oil cooler and condenser.

Check the tension on the compressor belt (Item 1)
[Figure 80-40-5].
V623 VersaHANDLER
BASIC TROUBLESHOOTING Check the belt tension on the A/C compressor.(See
Poor A/C Performance
Check the A/C condenser for dirt or mud, and clean if
Start the VersaHANDLER, engage the parking brake. necessary. (See Cleaning The Condenser on Page 80-
Engage the A/C system with the blower fan on high. Run 40-2.)
the VersaHANDLER at full RPM for approximately 15
minutes, with the cab door closed. Inspect the sight glass located on the receiver/drier for air
bubbles. (See SYSTEM TROUBLESHOOTING CHART
Figure 80-50-1 on Page 80-70-1.)
Compressor Drive Belt Inspection
Regularly inspect (weekly) the compressor drive belt for

wear.
Open the hood.
Remove the belt cover.
Figure 80-50-3

Figure 80-50-2
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 EVAPORATOR/BLOWER
UNIT on Page 80-150-1.)
V623 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.
V623 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.
V623 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 Component Replacement And Refrigeration
Leaks on Page 80-60-31.)
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)

[Figure 80-50-13] from the main harness.
V623 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.
Remove the fuse box cover (Item 1) [Figure 80-50-16]. Figure 80-50-19
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)
[Figure 80-50-17] from the switch. With the switch in the OFF position, there should be zero
resistance between all terminals.
NOTE: Mark the wires for correct assembly. With the switch in the 1 position, there should be
resistance between C terminal and the B terminal. And
also between the C terminal and the L terminal frame
[Figure 80-50-19].
With the switch in the 2 position, there should be

also between the C terminal and the M terminal frame
[Figure 80-50-19].
With the switch in the 3 position, there should be

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.
V623 VersaHANDLER
V623 VersaHANDLER
GENERAL AIR CONDITIONING SERVICE There is a close affinity between oil and refrigerant.
GUIDELINES During normal operation, part of the oil circulates with the
refrigerant in the system. therefore, when checking the
Compressor Oil amount of oil in the system or replacing any system
component, the compressor must be run-in advance to
Figure 80-60-1 insure return of oil to the compressor.
If the amount of refrigerant in the system has decreased,

charge the system. (See Charging Procedure on Page
80-100-5.)
Open the cab door and windows.
Run the blower at maximum speed.
Run the compressor for at least 20 minutes at 800-1200

RPM.
Remove the compressor from the machine. (See

Figure 80-60-2
The compressor (Item 1) [Figure 80-60-1] is factory filled

with 150-170 cc's of PAG oil (Poly Alkelene Glycol).

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. Figure 80-60-3
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) 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.
Compressor Oil Check
The compressor oil should be checked as follows when Remove the oil drain plug (Item 1) [Figure 80-60-2] and
drain the oil through the connectors and the oil drain hole
oil is being added to an in service loader. (Item 1) [Figure 80-60-3].
Installation: Tighten the oil drain plug to 9.4-10.8 ft.-lbs.

(13-15 Nm) torque.
V623 VersaHANDLER
GENERAL AIR CONDITIONING SERVICE Figure 80-60-5
GUIDELINES (CONT'D)
Compressor Oil Check (Cont'd)
Figure 80-60-4
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: After draining the oil through the drain hole NOTE: The suction port on the compressor is marked
and the connectors, extract the remaining oil with an S and is the large port on the

through the discharge-side connector by compressor.
rotating the drive pulley (Item 1) [Figure 80-60-
4] several times by hand. Component Replacement And Refrigeration Leaks
Measure the drained oil in a measuring cylinder. Figure 80-60-6
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.
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.
V623 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
connection. connector.
3. Fan motor malfunction. Check the lead wires from the motor with a circuit tester. Replace Evaporator/Blower
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

1. Evaporator inlet Check evaporator for plugging. Remove obstruction and
obstruction clean 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
refrigerant. in sight glass on receive drier. recharge the refrigerant to
the correct level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
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
surface. clutch 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.
V623 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 charge The high pressure side will be high. Evacuate system. Remove oil
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.
V623 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.
V623 VersaHANDLER
V623 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 18.43 104 137.30
22 19.87 106 132.90
24 21.35 108 146.50
26 22.88 110 141.90
28 24.47 112 151.30
30 26.10 114 161.10
32 27.79 116 156.10
34 29.52 118 166.10
36 31.32 120 176.60
38 33.17 122 171.30
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 45.48 135 229.40
55 51.27 140 213.70
60 57.47 145 245.80
65 64.10 150 263.00
70 71.19 155 300.10
75 78.75 160 281.10
80 86.80 1665 320.10
85 95.40 170 340.80
90 104.40
91 108.20
92 106.30
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.
Example: Ambient Temperature=90 degrees F.

90 degrees F.
+40 degrees F.
130 degrees F. condenser temperature=200 psig
Conditions and pressures will vary from system to system.
V623 VersaHANDLER
V623 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:
V623 VersaHANDLER
V623 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
Figure 80-100-1
NOTE: Before reclaiming a refrigeration system, it is

Open the hood. recommended to identify the type of
refrigerant that is in the A/C system and if it is
Remove the access cover mounting bolt (Item 1) [Figure pure enough to use. The tool MEL 1592,

80-100-1]. Remove the access cover (Item 2) [Figure 80- Refrigerant Identifier (Item 1) [Figure 80-100-3]
100-1]. will determine, the kind of refrigerant and any
possible harmful or dangerous substances
Figure 80-100-2 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
MEL 1581 Recovery/Recycling/Recharging
Machine.
Remove the protective cap and connect the refrigerant

identifier to the low pressure hose (Item 1) [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.
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
V623 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.
V623 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.
V623 VersaHANDLER
Charging Procedure With A Manifold Gauge Set
Open the hood.
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

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.
V623 VersaHANDLER
Charging Procedure With A Manifold Gauge Set

(Cont’d)
Figure 80-100-12
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.
Start the vacuum pump and open ISO-valve (Item 1) The thermistor vacuum gauge is used with the vacuum
[Figure 80-100-12] on the vacuum pump. pump [Figure 80-100-14].

Run the vacuum pump for at least 5-10 minutes to insure Start the vacuum pump and open ISO-valve on the
that a vacuum has been pulled on the system. vacuum pump.
Close the ISO-valve (Item 1) [Figure 80-100-12] (which
Be sure that both hand valves, and both charge port
isolates the vacuum pump from the A/C system) and turn
valves are open.
OFF the vacuum pump.
Run the vacuum pump for at least 45 minutes to insure
Charging Procedure
that all the moisture is boiled out of the system.
Figure 80-100-13
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.
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.
V623 VersaHANDLER
Charging Procedure (Cont’d)
Figure 80-100-15
Turn the A/C fan switch (Item 1) [Figure 80-100-17] to

HIGH position.
Start the machine, and run at medium speed.

Place a refrigerant container with R134a (Item 1) [Figure
80-100-15] on a charging scale (Item 2) [Figure 80-100- Watch the scale and run system until the predetermined
15] and zero out the scale. amount of refrigerant is added to the A/C system.

Connect the yellow hose (Item 3) [Figure 80-100-15] The A/C system holds 1.76 lbs (0,800 Kg) of refrigerant.
from the manifold gauge set to the valve on the
refrigerant tank. Turn off the valve on the refrigerant container, and hand
valves on the manifold gauge set.
Figure 80-100-16
Turn off the engine and remove the A/C charging
equipment from the machine.
Install access cover.
Close the hood.
Open the valve on the refrigerant container (Item 1)

[Figure 80-100-16] and open the low pressure hand
valve (Blue) (Item 2) [Figure 80-100-16] on the manifold
gauge set. Allow the vacuum to pull in the refrigerant until
the pressure stabilizes.
V623 VersaHANDLER
COMPRESSOR

WARNING
Evacuate the A/C system. (See SYSTEM CHARGING
AND RECLAMATION 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.
V623 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.
V623 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. (0.5 mm)
V623 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.
V623 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.
V623 VersaHANDLER
V623 VersaHANDLER
CONDENSER Figure 80-120-2

Page 80-60-3.)
Remove the air cleaner. (See AIR CLEANER on Page

70-40-1.)
Remove the receiver/drier. (See RECEIVER/DRIER on

Page 80-130-1.)
WARNING Remove the A/C hose (Item 1) [Figure 80-120-2] from

In the event of a leakage, wear safety goggles. the condenser.
eyes. In contact with a flame, R134a refrigerant gives Figure 80-120-3
a toxic gas.
W-2371-0500

Figure 80-120-1
Remove the two nuts (Item 1) [Figure 80-120-3] from

each side of the condenser.
Figure 80-120-4
Remove the hose (Item 1) [Figure 80-120-1] from the oil

cooler.
NOTE: Install caps and plugs on all fittings.
Remove the condenser [Figure 80-120-4].
V623 VersaHANDLER
V623 VersaHANDLER
RECEIVER/DRIER Figure 80-130-2
Open The Hood

Page 80-60-3.)
Remove the air cleaner. (See AIR CLEANER on Page

70-40-1.)
WARNING
In the event of a leakage, wear safety goggles. Remove the two hoses (Item 1) [Figure 80-130-2] from
Escaping refrigerant can cause severe injuries to the Receiver/Drier.
a toxic gas. NOTE: Mark the hoses for correct installation.
W-2371-0500
NOTE: Install caps and plugs on all fittings.

Figure 80-130-1 Figure 80-130-3
NOTE: Locate the sight glass (Item 2) [Figure 80-130- Loosen the bolt (Item 1) [Figure 80-130-3] on the
1]. mounting bracket.

the pressure switch.
V623 VersaHANDLR
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].
V623 VersaHANDLER
PRESSURE SWITCH Figure 80-140-2
Open the hood.

Page 80-60-3.)
WARNING
a toxic gas. Remove the pressure relief switch (Item 1) [Figure 80-
W-2371-0500 140-2] from the Receiver/Drier assembly.
Figure 80-140-1

the pressure relief switch (Item 2) [Figure 80-140-1].
V623 VersaHANDLER
V623 VersaHANDLER
EVAPORATOR/BLOWER UNIT Figure 80-150-3

Page 80-60-3.)
WARNING
a toxic gas.
W-2371-0500
Temporarily remove the covering (Item 1) [Figure 80-
150-3] from the A/C hoses and expansion valve.
Figure 80-150-1
Figure 80-150-4

Remove the fuse box cover (Item 1) [Figure 80-150-1].
Figure 80-150-2 (Item 2) [Figure 80-150-4]. Remove both A/C hoses.
V623 VersaHANDLER
EVAPORATOR/BLOWER UNIT (CONT'D) Figure 80-150-7
Figure 80-150-5
Remove the front mounting bolt (Item 1) [Figure 80-150-

7].
Lay the evaporator/blower unit on the seat.

Unplug the thermostat wiring connector (Item 1) [Figure
80-150-5]. Figure 80-150-8

Figure 80-150-6
Remove the drain hose (Item 1) [Figure 80-150-8].
Remove the three mount bolts (Item 1) [Figure 80-150-6] Remove the evaporator/blower unit from the machine.
and ground wire (Item 2) [Figure 80-150-6] from the
back of the evaporator unit.
V623 VersaHANDLER
EXPANSION VALVE Figure 80-160-3

Page 80-60-3.)
WARNING
a toxic gas.
W-2371-0500
Temporarily remove the covering (Item 1) [Figure 80-
160-3] from the A/C hoses and expansion valve.
Figure 80-160-1
Figure 80-160-4

Remove the fuse box cover (Item 1) [Figure 80-160-1].
Figure 80-160-2 (Item 2) [Figure 80-160-4]. Remove both A/C hoses.
V623 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.
V623 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.
V623 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].
V623 VersaHANDLER
HEATER ASSEMBLY (CONT'D) Figure 80-170-11
Core Removal And Installation (Cont'd)
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.
V623 VersaHANDLER
HEATER ASSEMBLY (CONT'D)
Core Removal And Installation (Cont'd)
Figure 80-170-13
Be sure to separate the bracket (Item 1) [Figure 80-170-

13] and tab (Item 2) [Figure 80-170-13].

Figure 80-170-14
Slide the core from the housing [Figure 80-170-14].
V623 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
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-11
Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-9
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-7
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-7
Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1

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 SPECIFICATIONS
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . SPEC-50-1
O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-3
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-5
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . SPEC-50-1
Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS . SPEC-60-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . SPEC-40-1

Torque For General Metric Bolts . . . . . . . . . . . . . . . . . SPEC-40-2
Torque for General SAE Bolts . . . . . . . . . . . . . . . . . . . SPEC-40-1
V623 VersaHANDLER
747 of 784 SPEC-01 Service Manual
SPECIFICATIONS (CONT’D)
LOADER TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . SPEC-30-1

Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
Drive Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-2
VERSAHANDLER SPECIFICATIONS . . . . . . . . . . . . . . . SPEC-10-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Dimensional Specifications . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
V623 VersaHANDLER
748 of 784 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 14550 lbs. (6600 kg) Steering Steering Wheel w/ 3 Mode
Maximum Rated Capacity *6500 lbs. (2948 kg) Selections (2-Wheel, 4-Wheel,
Crab)
*Rated Load Capacity can change depending on which Hydraulics Joystick w/ switches
approved attachment is used. Auxiliary Hydraulics Electric Switches on Joystick
Parking Brake Hand Operated Lever
Engine
Drive System
Make/Model PERKINS 1004-40T
(Turbocharged)
Main Drive Hydrostatic 4 wheel drive
Fuel/Cooling Diesel/Liquid
Transmission Infinitely variable hydrostatic piston pump,
Horsepower (SAE Net) 105 HP (79 kW) driving 1 fully reversing hydrostatic motor
Number of Cylinders Four Final Drive Front Differential w/ reduction gearbox,
Lubrication Pressure System W/Filter Rear Differential, Planetary Axles with Oil
Air Cleaner Dry replaceable cartridge w/ Lubrication.
safety element Travel Speed
Engine RPM (No load) Low Idle - 775-825 RPM Low Range 0-4.4 mph (7,1 km/hr.)
High Idle - 2320-2420 RPM High Range 0-18.7 mph (30,1 km/hr)
V623 VersaHANDLER
749 of 784 SPEC-10-1 Service Manual
VERSAHANDLER SPECIFICATIONS (CONT’D)
Tires
Standard Tires Dunlop 400/80x24-62 PSI

(4.25 BAR)
Dunlop 400/70 x 20 - 44
PSI (3 Bar)
Continental 15.5/55 x 17-51
PSI (3.5 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 @ 05 F

(-185 C)
Instrument Panel
Full compliment of instrumentation for engine, hydraulic

and vehicle functions.
Capacities
Fuel Tank 38.3 gals. (145 L) Type: Diesel #2

or #1
Eng. Cooling 19 qts. (17 L) Type: Antifreeze
System mixture Premix
50% Ethylene
Glycol / 50%
Water
Engine Oil 7 qts (6,5 L)
Change w/Filter
Hyd./Hydros. 22.2 gals. (84 L)
System
Front axle 11.1 qts (10,5 L)
Rear Axle 11qts. (10 L)
Front Reduction 0.85 qts. (0,8 L)
Gearbox
V623 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 (Interference) 0.0018-0.0027 (0,047-0,007)
Overall Length:
Intake 2.281 (57,94)
Exhaust 2.406 (61,10)
Protrusion From Bottom 0.585-0.596 (14,85-15,15)
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)
V623 VersaHANDLER
ENGINE SPECIFICATIONS (CONT'D)
parentheses.
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)
V623 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, graphiti

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)
V623 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)
V623 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 0.020 (0,51) 0.030 (0,76)

0.010 (0,25)
1 2.9884-2.9892 (75,905-75,926) 2.9784-2.9792 (75,651- 2.9684-2.9692 (75,397-
75,672) 75,418)
2 2.4888-2.4896 (63,216-63,236) 1.554 (39,47) maximum 2.4788-2.4796 (62,962- 2.4688-2.4696 (62,708-
62,982) - 62,728) -
3 1.554 (39,7) 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.
V623 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)
V623 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)
V623 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
V623 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)
V623 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)
V623 VersaHANDLER
Engine Torque
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
V623 VersaHANDLER
V623 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 159 217
Boom
Ft.-Lbs. Nm
Extension Cylinder Base End 221 300
Extension Cylinder Rod End 188-210 255-285
Wear Pads Front 43 58
Wear Pads Rear 29 39
Drive Box
Ft.-Lbs. Nm
Cover Bolts 44 60
Inner Housing Bolts 88 120
Mounting Flange Bolts 44 60
Drive Motor
Ft.-Lbs. Nm
End Cap Bolts 85 115
Mounting Bolts 155 210
Mounting Plate Bolts 46 63
Engine
Ft.-Lbs. Nm
A/C Compressor Mount Bolts 88 120
Alternator Mount Bolts 45 54
Starter Mount Bolts 45 54
V623 VersaHANDLER
LOADER TORQUE SPECIFICATION (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
V623 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. .250 80-90 (9,0-10,2) 110-120 (12,4-13,6)
LBS.(Nm) .3125 180-200 (20,3-22,6) 215-240 (24,2-27,1)
FOOT .375 25-28 (34-38) 35-40 (47-54)
LBS.(Nm) .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)
V623 VersaHANDLER
TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
Thread Size (Dia. x Material

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. 6-9 ft.-lbs.
(8-9 Nm) (8-12 Nm)
M 8 x 1.25 6-9 ft.-lbs. 11-16 ft.-lbs. 18-25 ft.-lbs.
(8-12 Nm) (15-22 Nm) (24-34 Nm)
(18-24 Nm) (30-41 Nm) (49-68 Nm)
(30-41 Nm) (54-73 Nm) (94-118 Nm)
(49-68 Nm) (79-108 Nm) (157-186 Nm)
V623 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].
V623 VersaHANDLER
HYDRAULIC CONNECTION SPECIFICATIONS Tighten the nut until it makes contact with the seat. Make
(CONT'D) a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure SPEC-50-3].
Flare Fitting
Use the chart below to find the correct tightness needed
Use the following procedure to tighten the flare fitting: (Item 2) [Figure SPEC-50-3]. If the fitting leaks after
tightening, disconnect it and inspect the seat area for
Figure SPEC-50-3 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
V623 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
The flare is the primary seal, the O-ring is the secondary of 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.
V623 VersaHANDLER
HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-50-7
(CONT'D)
O-ring Flare Fitting (Cont'd)
NOTE: O-ring flare fittings are not recommended in 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.
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
application.

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.
V623 VersaHANDLER
HYDRAULIC CONNECTION SPECIFICATIONS Do not over tighten the port seal fitting.
(CONT'D)
NOTE: If a torque wrench cannot be used, use the hex
Port Seal Fitting flat tightening method as an approximate
guideline.
Figure SPEC-50-8
NOTE: Port seal fittings are not recommended in all
applications. Use O-ring boss fittings in these
applications.
PORT SEAL AND O-RING BOSS TIGHTENING

TORQUE
FITTING NUT TORQUE FT.-

THREAD SIZE
WRENCH SIZE LBS. (NM)
11/16" 9/16" - 18 22 (30)
15/16" 3/4" - 16 40 (54)
1-1/8" 7/8" - 14 60 (81)
1-1/4" 1-1/16" - 12 84 (114)
1-1/2" 1-5/16" - 12 118 (160)
Figure SPEC-50-9

The nut is the primary seal, the O-ring is the secondary
seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-50-8].
Do not use port seal fittings when a thread in orifice (Item
The hex portion of the nut does not contact the surface of 1) [Figure SPEC-50-9] is used in the port. The orifice
the component when the nut is tight. may interfere with the fitting and prevent it from sealing.
Use the following procedure to tighten the port seal Use an O-ring boss fitting (Item 1) [Figure SPEC-50-9]
fitting: as shown.
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.
V623 VersaHANDLER
V623 VersaHANDLER
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS When temperatures below zero degree F (-18°C) are
common, the loader must be kept in a warm building.
Specifications Extra warm-up time must be used each time the loader is
started during cold temperature conditions. Cold fluid will
Use Bobcat axle fluid (P/N 100032-06A), for the trasver 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 Melroe 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

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
V623 VersaHANDLER
V623 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
V623 VersaHANDLER
CONVERSIONS (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
V623 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: V623-1

Date: 5 December 2001
Product: VersaHANDLER
Model: V623
Manual No: 6901675 (11-01)
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

10-01, 10-02 Added contents page
10-10-1, 10-10-2 Added lifting and blocking the VersaHANDLER
10-20-1, 10-20-2 Added operator cab
10-30-1, 10-30-2 Added transporting the VersaHANDLER
10-40-1,10-40-2 Added towing the VersaHANDLER
10-50-1, 10-50-2 Added service schedule
10-60-1, 10-60-2 Added Air Cleaner
10-70-1, 10-70-2 Added engine cooling system
10-80-1, 10-80-2 Added fuel system
10-90-1, 10-90-2 Added engine lubrication
10-100-1, 10-100-2 Added hydraulic and hydrostatic system
10-110-1, 10-110-2 Added axles (front and rear)
10-120-1 thru 10-120-4 Added Lubrication
10-130-1, 10-130-2 Added tire maintenance
10-140-1, 10-140-2 Added spark arrestor muffler
10-150-1, 10-150-2 Added boom stop
10-160-1, 10-160-2 Added engine cover
20-01, 20-02 20-01, 20-02 Revised contents page
Hydraulic/Hydrostatic Added hydraulic/hydrostatic legend and schematic
Schematic V623 (S/N
367111001 & Above) Dec.
2001
20-20-1 thru 20-20-4 Added lift cylinder removal and installation
20-30-1 thru 20-30-12 Added bucket positioning cylinder removal and installation
30-30-1 thru 30-30-38 Added hydrostatic drive motor
40-30-01 thru 40-30-12 40-30-1 thru 40-30-12 Revised front axle removal and installation
50-30-1 thru 50-30-4 Added boom assembly removal and installation
Printed in U.S.A.
777 of 784
778 of 784
ROUTE TO
ATTENTION
PARTS MANAGER
Revision No: V623-2

Date: 15 February 2002
Model: V623
Manual No: 6901675 (11-01)

10-01, 10-02 10-01, 10-02 Added contents page
20-20-5 thru 20-20-16 Added lift cylinder disassembly and assembly
20-40-1 thru 20-40-16 Added extension cylinder
20-50-1 thru 20-50-10 Added tilt cylinder
20-90-1 thru 20-90-8 Added quick tach cylinder
50-40-1 thru 50-40-4 50-40-1 thru 50-40-4 Revised inner boom
50-80-1, 50-80-2 50-80-1, 50-80-2 Revised fuel tank
50-90-1, 50-90-2 Added quick tach
50-100-1, 50-1000-2 Added rear weights removal and installation
50-120-1 thru 50-120-4 Added pivot link removal and installation
779 of 784
780 of 784
ROUTE TO
ATTENTION
PARTS MANAGER
Revision No: V623-3

Date: 15 April 2003
Model: V623
Manual No: 6901675 (11-01)
Please discard your old V623 Service Manual (P/N 6901675) dated 11-01 and replace it with the revised V623 Service
Manual (P/N 6901675) dated 4-03.

This Service manual is in a new format with added updates.
781 of 784
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ROUTE TO
ATTENTION
PARTS MANAGER
Revision No: V623-4

Date: 1 September 2004
Model: V623
Manual No: 6901675 (4-03)

Cover Cover Revised Serial Numbers
Alpha Index Alpha Index Revised Text
All Hydraulic Schematics All Hydraulic Schematics Revised Serial Numbers and Added New Schematics
Printed April 2003 Printed September 2004
20-01 20-01 Revised text

20-171 Added text
20-180 Added text
All Electrical Schematics All Electrical Schematics Revised Serial Numbers and Added New Schematics
Printed April 2003 Printed September 2004
Printed in U.S.A.
783 of 784
784 of 784

Bobcat v623 Service Manual

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VersaHANDLER

Dealer Copy -- Not for Resale

6901675 (3-06) Printed in U.S.A. © Bobcat Company 2006

6901675 (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

AIR CLEANER ........................................................ 70-01 HYDRAULIC CONNECTION SPECIFICATION SPEC-01

COMPONENTS ...................................................... 80-01 LIFT CYLINDER ......................................................20-01

Dealer Copy -- Not for Resale

ELECTRICAL SYSTEM INFORMATION ................ 60-01 OIL COOLER...........................................................30-01

VersaHANDLER SPECIFICATIONS.................. SPEC-01

WEAR PADS (FRONT)............................................50-01

Dealer Copy -- Not for Resale

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

BOBCAT VersaHANDLER IDENTIFICATION

BOOM MIRROR OPERATOR HANDBOOK &

Dealer Copy -- Not for Resale

SAFETY TREAD TIRES

AXLES (FRONT AND REAR) . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

BOOM STOP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1