Caterpillar TH62, TH63, TH82, TH83, TH103, TH255(C), TH336(C), TH337(C), TH406(C), TH407(C), TH414(C), TH417(C), TH514(C) Tele-handler Factory Service & Shop Manual
Catalog:
Model:
Complete workshop repair service manual with electrical wiring diagrams for Caterpillar TH62, TH63, TH82, TH83, TH103, TH255, TH255C, TH336, TH336C, TH337, TH337C, TH406, TH406C, TH407, TH407C, TH414, TH414C, TH417, TH417C, TH514, TH514C. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.
Caterpillar Caterpillar TH62, TH63, TH82, TH83, TH103, TH255, TH255C, TH336, TH336C, TH337, TH337C, TH406, TH406C, TH407, TH407C, TH414, TH414C, TH417, TH417C, TH514, TH514C manuals (including maintenance, overhaul, disassembling, and assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.
31200362 - Operation & Maintenance Manual (Model TH255)
31200363 - Parts Manual (Model TH255)
31200364 - Service Manual (Model TH255)
31200368 - Operation & Maintenance Manual (Model TH336, TH337, TH406, TH407, TH414, TH514, TH417)
31200369 - Parts Manual (Models TH336, TH337, TH406, TH407)
31200370 - Service Manual (Models TH336, TH337, TH406, TH407, TH414, TH514, TH417)
31200425 - Manuel d'utilisation et de maintenance (Modèles TH336, TH337, TH406, TH407, TH414, TH514, TH417)
31200426 - Manual del operador y de mantenimiento (Modelos TH336, TH337, TH406, TH407, TH414, TH514, TH417)
31200451 - Service Manual Axle (Models TH255, TH255C)
31200453 (UENR6252) - Disassembly & Assembly Manual Axle (Models TH336, TH337, TH406, TH407, TH414, TH336C, TH337C, TH406C, TH407C, TH414C)
31200455 (UENR6253) - Disassembly & Assembly Manual Axle (Models TH514, TH417, TH514C, TH417C)
31200459 - Manuel d'utilisation et de maintenance (Modèle TH255)
31200460 - Manual del operador y de mantenimiento (Modelo TH255)
31200483 - Electrical Schematic (Models TH336, TH337, TH406, TH407, TH414, TH514,TH417)
31200484 - Electrical Schematic (Models TH336, TH337, TH406, TH407, TH414, TH514,TH417)
31200488 - Parts Manual (Models TH414, TH514, TH417)
31200493 - Parts Manual PowerSynchro Transmission (Models TH336, TH337, TH406, TH407, TH414, TH514, TH417)
31200562 - Systems Operation_Testing & Adjusting PowerSynchro Transmission (Models TH336, TH337, TH406, TH407, TH414, TH514, TH417)
31200563 - Disassembly & Assembly PowerSynchro Transmission (Models TH336, TH337, TH406, TH407, TH414, TH514, TH417)
31200720 - Electrical Schematic (Models TH336, TH337, TH406,TH407, TH414, TH514, TH417)
31200721 - Parts Manual (Model TH255C)
31200729 - Parts Manual (Models TH414C, TH514C, TH417C)
31200730 - Parts Manual (Models TH336C, TH337C, TH406C, TH407C)
31200746 (SEBU9291) - Operation & Maintenance Manual (Model TH255C)
31200752 (SEBU9285) - Operation & Maintenance Manual (Models TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C)
31200799 (UENR6251) - Service Manual (Models TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C)
31200807 (SFBU9285) - Manuel d’utilisation et de maintenance (Modèles TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C)
31200808 (SSBU9285) - Manual del operador y de mantenimiento (Modelos TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C)
31200831 - Electrical Schematic (Models TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C)
31200832 - Electrical Schematic (Models TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C)
31200872 (SFBU9291) - Manuel d’utilisation et de maintenance (Modèle TH255C)
31200873 (SSBU9291) - Manual del operador y de mantenimiento (Modelo TH255C)
31200927 - Service Manual (Model TH255C)
31200928 - Electrical Schematic (Models TH336, TH337, TH406, TH407, TH414, TH514,TH417)
31200929 - Electrical Schematic (Models TH336, TH337, TH406, TH407, TH414, TH514,TH417)
31200934 - Engine Parts Manual (Model TH255C)
31200980 - Engine Service Manual (Model TH255C)
31211008 - Axle Service Manual (Models TH255, TH255C)
Deutz TCD2.9 Engine (TH255C) Training
TEJB9602 - Product Bulletin (Work Tools for Cat Tele-handlers)
RENR1377 - Systems Operation (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)
Abbreviations and Symbols
ETR Component Descriptions
ETR Introduction
ETR Junction Box-Switchgear Not Required (OP,WT)
ETR Junction Box-Switchgear Not Required (OP,WT,OS)
ETR Junction Box-Switchgear Required (OP,WT,OS)
Junction Box and Enclosure Group
RENR1377 - Testing & Adjusting (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)
Crank Terminate Speed Calibration
Diode Test
Electric Protection System Functional Test
Engine Oil Pressure Switch Test
General Testing and Adjusting Information
General Troubleshooting Information
Magnetic Pickup Test
Oil Step Speed Calibration
Overspeed Calibration
Overspeed Verification Test
Slave Relay Test
Troubleshooting the ETR Full Protective System (OP, WT, OS)
Troubleshooting the ETR Partial Protection System (OP, WT)
Water Temperature Contactor Switch Test
RENR3404 - Schematic (TH62, TH63, TH82 & TH83 Electrical System)
Collage Schematic
Main Schematic
RENR3405 - Schematic (TH103 Electrical System)
Collage Schematic
Main Schematic
RENR3407 - Schematic (TH62, TH63, TH82 & TH83 Telehandler Electrical System)
Collage Schematic
Main Schematic
RENR3413 - Schematic (TH103 Telehandler Electrical System)
Collage Schematic
Main Schematic
RENR3415 - Schematic (TH62, TH63, TH82 & TH83 Telehandler Electrical System)
Collage Schematic
Main Schematic
RENR3416 - Schematic (TH103 Telehandler Electrical System)
Collage Schematic
Main Schematic
RENR3436 - Disassembly & Assembly (TH62, TH63, TH82, TH83 & TH103 Telehandlers Power Train)
Axle Shaft - Install 1
Axle Shaft - Install 2
Axle Shaft - Remove 1
Axle Shaft - Remove 2
Axle Trunnion (Front and Rear) - Remove and Install
Differential and Bevel Gear (Front) - Assemble
Differential and Bevel Gear (Front) - Disassemble
Differential and Bevel Gear (Front) - Install
Differential and Bevel Gear (Front) - Remove
Differential and Bevel Gear (Rear) - Assemble
Differential and Bevel Gear (Rear) - Disassemble
Differential and Bevel Gear (Rear) - Install
Differential and Bevel Gear (Rear) - Remove
Differential and Bevel Gear - Assemble
Differential and Bevel Gear - Disassemble
Differential and Bevel Gear - Install
Differential and Bevel Gear - Remove
Drive Shaft - Remove and Install
Engine, Torque Converter and Transmission - Connect
Engine, Torque Converter and Transmission - Install
Engine, Torque Converter and Transmission - Remove
Engine, Torque Converter and Transmission - Separate
Final Drive and Wheel - Assemble 1
Final Drive and Wheel - Assemble 2
Final Drive and Wheel - Disassemble 1
Final Drive and Wheel - Disassemble 2
Final Drive and Wheel - Install 1
Final Drive and Wheel - Install 2
Final Drive and Wheel - Remove 1
Final Drive and Wheel - Remove 2
Front Axle (Fixed) - Install
Front Axle (Fixed) - Remove
Front Axle (Oscillating) - Install 1
Front Axle (Oscillating) - Install 2
Front Axle (Oscillating) - Remove 1
Front Axle (Oscillating) - Remove 2
Parking Brake - Assemble
Parking Brake - Disassemble
Parking Brake - Install
Parking Brake - Remove
Rear Axle (Oscillating) - Install 1
Rear Axle (Oscillating) - Install 2
Rear Axle (Oscillating) - Remove 1
Rear Axle (Oscillating) - Remove 2
Service Brake - Assemble
Service Brake - Disassemble
Service Brake - Install
Service Brake - Remove
Service and Parking Brake - Assemble
Service and Parking Brake - Disassemble
Service and Parking Brake - Install
Service and Parking Brake - Remove 1
Torque Converter - Assemble 1
Torque Converter - Assemble 2
Torque Converter - Disassemble 1
Torque Converter - Disassemble 2
Transfer Gear Mount - Remove and Install
Transfer Gears - Assemble
Transfer Gears - Disassemble
Transfer Gears - Install
Transfer Gears - Remove
Transmission - Assemble 1
Transmission - Assemble 2
Transmission - Disassemble 1
Transmission - Disassemble 2
Wheel Stud Bolts - Remove and Install 1
Wheel Stud Bolts - Remove and Install 2
Wheel and Tire - Remove and Install
RENR3437 - Disassembly & Assembly (TH62, TH63, TH82, TH83 & TH103 Telehandlers Machine Systems)
Bank Valve - Assemble 1
Bank Valve - Assemble 2
Bank Valve - Assemble 3
Bank Valve - Disassemble 1
Bank Valve - Disassemble 2
Bank Valve - Disassemble 3
Bank Valve - Install
Bank Valve - Remove
Boom - Assemble 1
Boom - Assemble 2
Boom - Disassemble 1
Boom - Disassemble 2
Boom - Install
Boom - Remove
Boom Cylinder - Remove and Install
Cab - Install
Cab - Remove
Cab Heater - Install
Cab Heater - Remove
Compensating Cylinder - Remove and Install
Control Valve (Compensating Cylinder) - Remove and Install
Control Valve (Trailer and Towing Hitch) - Assemble
Control Valve (Trailer and Towing Hitch) - Disassemble
Counterweight - Remove and Install
Diverter Valve (Boom Head) - Remove and Install
Fender - Remove and Install 1
Fender - Remove and Install 2
Frame Leveling Cylinder - Remove and Install
Fuel Tank - Install
Fuel Tank - Remove
Hitch Cylinder - Remove and Install
Hydraulic Oil Lines (Boom) - Install
Hydraulic Oil Lines (Boom) - Remove
Hydraulic System Pressure - Release
Hydraulic Tank - Install
Hydraulic Tank - Remove
Load Control Valve (Boom Cylinder) - Remove and Install
Load Control Valve (Frame Leveling Cylinder) - Remove and Install
Load Control Valve (Stabilizer Cylinder) - Remove and Install
Load Control Valve (Telescoping Cylinder) - Remove and Install
Load Control Valve (Tilt Cylinder) - Remove and Install
Metering Pump (Steering) - Install
Metering Pump (Steering) - Remove
Piston Pump (Implement and Steering) - Assemble
Piston Pump (Implement and Steering) - Disassemble
Piston Pump (Implement and Steering) - Install
Piston Pump (Implement and Steering) - Remove
Piston Pump (Steering) - Assemble
Piston Pump (Steering) - Disassemble
Quick Coupler - Assemble
Quick Coupler - Disassemble
Quick Coupler - Install
Quick Coupler - Remove
Seat - Remove and Install
Selector Valve (Steering Mode) - Remove and Install
Solenoid Valve - Remove and Install
Stabilizer - Install
Stabilizer - Remove
Stabilizer Control Valve - Remove and Install
Stabilizer Cylinder - Remove and Install
Steering Cylinder - Remove and Install 1
Steering Cylinder - Remove and Install 2
Steering Wheel - Remove and Install
Telescoping Cylinder - Remove and Install 1
Telescoping Cylinder - Remove and Install 2
Tilt Cylinder - Remove and Install
Window Wiper and Wiper Motor (Front) - Remove and Install
Window Wiper and Wiper Motor (Roof) - Remove and Install
RENR3443 - Schematic (TH62, TH63, TH82 & TH83 Telehandler Hydraulic System for Type 1, Type 3 or Type A Control Arrangements)
Main Schematic
RENR3444 - Schematic (TH62, TH63, TH82 & TH83 Telehandler Hydraulic System for Type 2, Type 4 or Type B Control Arrangements)
Main Schematic
RENR3445 - Schematic (TH103 Telehandler Hydraulic System)
Main Schematic
RENR3453 - Disassembly & Assembly (TH62, TH63, TH82, TH83 & TH103 Telehandlers Engine Supplement)
Air Cleaner - Install
Air Cleaner - Remove
Alternator - Remove and Install
Battery - Remove and Install
Electric Starting Motor - Remove and Install
Engine Enclosure - Remove and Install
Engine Mount (Front) - Install
Engine Mount (Front) - Remove
Engine Mount (Rear) - Install
Engine Mount (Rear) - Remove
Expansion Tank - Remove and Install
Fan Guard - Remove and Install
Muffler - Remove and Install
Precleaner - Remove and Install
Radiator - Assemble
Radiator - Disassemble
Radiator - Install
Radiator - Remove
Transmission Oil Cooler - Install
Transmission Oil Cooler - Remove
RENR3455 - Systems Operation (TH62, TH63, TH82 & TH83 Telehandlers Steering System)
General Information
Manifold Valve
Metering Pump (Steering)
Piston Pump (Implement and Steering)
Position Sensor (Steering)
Selector Valve (Steering Mode)
Steering System
RENR3455 - Testing & Adjusting (TH62, TH63, TH82 & TH83 Telehandlers Steering System)
General Information Table
Hydraulic Oil Contamination - Test
Machine Preparation for Troubleshooting
Position Sensor (Steering) - Adjust
Pump Flow - Test
Signal Resolver Network - Test
Solenoid Valve - Test
Steering System Pressures - Test and Adjust
Steering System Troubleshooting
Visual Inspection
Wheel Alignment - Check and Adjust
RENR3458 - Schematic (TH62, TH63, TH82 & TH83 Telehandler Hydraulic System for Type 'A' Control Arrangement)
Main Schematic
RENR3460 - Systems Operation (TH103, TH62, TH63, TH82 & TH83 Telehandlers Longitudinal Stability Indicator)
Display Module
General Information
Sensor
Switch (Boom)
RENR3460 - Testing & Adjusting (TH103, TH62, TH63, TH82 & TH83 Telehandlers Longitudinal Stability Indicator)
Calibration
Display Module - Replace
Machine Preparation for Troubleshooting
Operational Checks
Sensor - Test
Switch (Boom) - Adjust 1
Switch (Boom) - Adjust 2
Visual Inspection
RENR3462 - Specifications (TH62, TH63, TH82 & TH83 Telehandlers Steering and Hydraulic System)
Bank Valve (Directional Control) 1
Bank Valve (Directional Control) 2
Boom Cylinder (Raise_Lower) 1
Boom Cylinder (Raise_Lower) 2
Boom Cylinder (Raise_Lower) 3
Control Valve (Compensating Cylinder) 1
Control Valve (Compensating Cylinder) 2
Coupler Cylinder
Frame Leveling Cylinder
Hydraulic Tank
Load Control Valve (Boom Cylinder)
Load Control Valve (Stabilizer Cylinder)
Metering Pump (Steering)
Piston Pump (Implement and Steering)
Solenoid Valve (Pilot Selector) 1
Solenoid Valve (Pilot Selector) 2
Stabilizer Cylinder
Telescoping Cylinder 1
Telescoping Cylinder 2
RENR3463 - Specifications (TH103 Telehandler Steering & Hydraulic System)
Bank Valve (Directional Control) 1
Bank Valve (Directional Control) 2
Boom Cylinder (Raise_Lower)
Control Valve (Compensating Cylinder)
Coupler Cylinder
Frame Leveling Cylinder
Hydraulic Tank
Load Control Valve (Boom Cylinder)
Load Control Valve (Stabilizer Cylinder)
Metering Pump (Steering)
Piston Pump (Implement and Steering)
Solenoid Valve (Pilot Selector)
Stabilizer Cylinder
Telescoping Cylinder
RENR3473 - Schematic (TH62, TH63, TH82 & TH83 Telehandler Hydraulic System for Type 'B' Control Arrangemen)
Main Schematic
RENR3475 - Systems Operation (TH103 Telehandler Steering System)
General Information
Metering Pump (Steering) 1
Metering Pump (Steering) 2
Piston Pump (Implement and Steering)
Position Sensor (Steering) 1
Position Sensor (Steering) 2
Selector Valve (Steering Mode)
Steering System 1
Steering System 2
RENR3475 - Testing & Adjusting (TH103 Telehandler Steering System)
General Information Table
Hydraulic Oil Contamination - Test
Machine Preparation for Troubleshooting
Position Sensor (Steering) - Adjust 1
Position Sensor (Steering) - Adjust 2
Pump Flow - Test
Signal Resolver Network - Test 1
Signal Resolver Network - Test 2
Solenoid Valve - Test
Steering System Pressures - Test and Adjust 1
Steering System Pressures - Test and Adjust 2
Steering System Troubleshooting
Visual Inspection
Wheel Alignment - Check and Adjust 1
Wheel Alignment - Check and Adjust 2
RENR3476 - Systems Operation (TH103 Telehandler Hydraulic System)
Access Platform System
Auxiliary System
Bank Valve
Boom Hydraulic System
Compensating System
Control Valve (Compensating Cylinder)
Diverter Valve
Frame Leveling System
General Information
Joystick Control
Load Control Valve (Boom Cylinder)
Load Control Valve (Frame Leveling) - If Equipped
Load Control Valve (Stabilizer Cylinder) - If Equipped
Load Control Valve (Telescoping Cylinder)
Load Control Valve (Tilt Cylinder)
Main Hydraulic System
Pilot Hydraulic System
Quick Coupler System
Stabilizer System
Telescoping Boom and Boom Chain
Telescoping Cylinder
Tilt System
RENR3476 - Testing & Adjusting (TH103 Telehandler Hydraulic System)
Access Platform - Test and Adjust
Boom Chain - Clean_Inspect_Lubricate
General Troubleshooting Information
Hydraulic Oil Contamination - Test
Hydraulic System Pressure - Release
Hydraulic System Troubleshooting
Machine Preparation for Troubleshooting
Operational Checks
Pilot Pressure - Test
Pressure for Pump and Relief Valve (Main) - Test and Adjust
Pressure for Relief Valve (Auxiliary) - Test and Adjust
Visual Inspection
RENR3478 - Schematic (TH103 Telehandler Hydraulic System)
Main Schematic
RENR3491 - Systems Operation (TH103 Telehandler Hydraulic System)
Access Platform System
Auxiliary System
Bank Valve
Boom Hydraulic System
Compensating System
Control Valve (Compensating Cylinder)
Diverter Valve
Frame Leveling System
General Information
Joystick Control
Load Control Valve (Boom Cylinder)
Load Control Valve (Frame Leveling)
Load Control Valve (Stabilizer Cylinder)
Load Control Valve (Telescoping Cylinder)
Load Control Valve (Tilt Cylinder)
Main Hydraulic System
Pilot Hydraulic System
Quick Coupler System
Stabilizer System
Telescoping Boom and Boom Chain
Telescoping Cylinder
Tilt System
RENR3491 - Testing & Adjusting (TH103 Telehandler Hydraulic System)
Access Platform - Test and Adjust
Boom Chain - Clean_Inspect_Lubricate
General Troubleshooting Information
Hydraulic Oil Contamination - Test
Hydraulic System Pressure - Release
Hydraulic System Troubleshooting
Machine Preparation for Troubleshooting
Operational Checks
Pilot Pressure - Test
Pressure for Pump and Relief Valve (Main) - Test and Adjust
Pressure for Relief Valve (Auxiliary) - Test and Adjust
Visual Inspection
RENR3492 - Schematic (TH103 Telehandler Hydraulic System)
Collage Schematic
Main Schematic
RENR5105 - Specifications (TH103 Telehandler Braking System)
Brake Cylinder (Boost)
Brake Cylinder (Master)
Parking Brake
RENR5105 - Systems Operation (TH103 Telehandler Braking System)
Brake Cylinder (Master) 1
Brake Cylinder (Master) 2
Brakes 1
Brakes 2
General Information 1
General Information 2
Parking Brake 1
Parking Brake 2
Service Brake 1
Service Brake 2
RENR5105 - Testing & Adjusting (TH103 Telehandler Braking System)
Brake Cylinder (Master) - Test and Adjust
Braking System Troubleshooting 1
Braking System Troubleshooting 2
General Information
Machine Preparation for Troubleshooting
Operation Checks
Parking Brake Control Cable - Adjust 1
Parking Brake Control Cable - Adjust 2
Service Brake - Adjust
Service Brake Air - Purge 1
Service Brake Air - Purge 2
Service Brake Discs - Check 1
Service Brake Discs - Check 2
Visual Inspection
RENR5106 - Specifications (TH62, TH63, TH82 & TH83 Telehandlers Braking System)
Brake Cylinder (Boost)
Brake Cylinder (Master)
RENR5106 - Systems Operation (TH62, TH63, TH82 & TH83 Telehandlers Braking System)
Brake Cylinder (Boost)
Brake Cylinder (Master)
Brakes
General Information
Parking Brake
Service Brake
RENR5106 - Testing & Adjusting (TH62, TH63, TH82 & TH83 Telehandlers Braking System)
Brake Cylinder (Master) - Test and Adjust
Braking System Troubleshooting
General Information
Machine Preparation for Troubleshooting
Operation Checks
Parking Brake Control Cable - Adjust
Service Brake - Adjust
Service Brake Air - Purge
Service Brake Discs - Check
Visual Inspection
SEBF9050 - Applied Failure Analysis - Engine Valve Failure Modes{1100, 1105}
SEBU6875 - Owner's Manual (Caterpillar Driver Information Display)
SEGV3008 - Systems Operation (Fundamentals Electrical System for All Caterpillar Products)
Basic Circuit Theory
Basic Electrical Components
Battery
Charging System
Circuit Voltage
Electrical Measurement
Electrical Schematic
Electricity - How It Works
Magnetism
Ohms Law
Solid State Electrical Components
Starting System
SENR1234 - Specifications (TH103 Telehandler Power Train)
Differential
Front Axle
Main Drive Shaft
Rear Axle
Torque Converter
Transmission
SENR1234 - Systems Operation (TH103 Telehandler Power Train)
Differential Lock Control
Differential and Bevel Gear 1
Differential and Bevel Gear 2
Front Axle and Rear Axle 1
Front Axle and Rear Axle 2
General Information
Solenoid Valve (Transmission Clutch)
Torque Converter
Transfer Gears
Transmission Control (Shift Lever)
Transmission Hydraulic System
Transmission Power Flow
Transmission
SENR1234 - Testing & Adjusting (TH103 Telehandler Power Train)
Axle Housing and Bearing Preload - Adjust 1
Axle Housing and Bearing Preload - Adjust 2
Differential Backlash and Bearings - Adjust 1
Differential Backlash and Bearings - Adjust 2
Differential Lock - Adjust
Differential Pinion Bearing - Adjust 1
Differential Pinion Bearing - Adjust 2
Differential and Final Drive Troubleshooting
General Troubleshooting Information
Machine Preparation for Troubleshooting
Operational Checks
Torque Converter Stall - Test
Torque Converter Troubleshooting
Transmission Pressures - Test and Adjust
Transmission Troubleshooting
Visual Inspection
Wheel Bearings - Adjust
SENR1235 - Disassembly & Assembly (TH103 Telehandler Power Train)
Assemble Transfer Gearbox 139-8306
Axle Front
Axle Shaft
Differential
Engine and Transmission
Final Drive
Hub
Rear Axle
Transfer Gearbox
Transmission
SENR1236 - Specifications (TH103 Telehandler Steering & Hydraulic System)
Attachment Coupler Tilt Cylinder (8I6089)
Boom Extend Cylinder (8I6092)
Boom Raise Cylinder (8I6093)
Compensating Cylinder (8I6090)
Directional Control Valve (129-6209)
Frame Level Cylinder (8I6091)
Hand Metering Unit (9T8012)
Hydraulic Pump (134-2947)
Stabilizer Cylinder (8I6467)
SENR1237 - Systems Operation (TH103 Telehandler Steering System)
SENR1237 - Testing & Adjusting (TH103 Telehandler Steering System)
SENR1238 - Systems Operation (TH103 Telehandler Brake System)
SENR1238 - Testing & Adjusting (TH103 Telehandler Brake System)
SENR1239 - Systems Operation (TH103 Telehandler Hydraulic System)
Access Platform
Auxiliary System
Bank Valve
Boom Hydraulic System
Compensating System
Control Valve (Compensating Cylinder)
Diverter Valve - If Equipped
Frame Leveling System
Joystick Control
Load Control Valve (Boom Cylinder)
Load Control Valve (Frame Leveling)
Load Control Valve (Stabilizer Cylinder)
Load Control Valve (Telescoping Cylinder)
Load Control Valve (Tilt Cylinder)
Main Hydraulic System
Pilot Hydraulic System
Stabilizer System
Telescoping Boom and Boom Chain
Telescoping Cylinder
Tilt System
SENR1239 - Testing & Adjusting (TH103 Telehandler Hydraulic System)
Access Platform - Test and Adjust
Boom Chain - Clean_Inspect_Lubricate
General Troubleshooting Information
Hydraulic Oil Contamination - Test
Hydraulic System Pressure - Release
Hydraulic System Troubleshooting
Machine Preparation for Troubleshooting
Pilot Pressure - Test
Pressure for Pump and Relief Valve (Main) - Test and Adjust
Pressure for Relief Valve (Auxiliary) - Test and Adjust
Visual Inspection
SENR1240 - Schematic (TH103 Telehandler Hydraulic System)
SENR1241 - Disassembly & Assembly (TH103 Machine Systems Disassembly & Assembly)
Attachment Coupler Cylinder Lock Valve
Attachment Coupler Cylinder
Boom Extend Cylinder Lock Valve
Boom Extend Cylinder
Boom Hoses
Boom Raise Cylinder Lock Valve
Boom Raise Cylinder
Boom
Brake Unit
Cab
Compensating Cylinder
Compensating Valve
Counterweight
Directional Control Valve
Frame Level Control Valve
Frame Level Cylinder Lock Valve
Frame Level Cylinder
Fuel Tank Gauge Sender Unit
Fuel Tank
Hydraulic Pump
Hydraulic Tank
Outrigger Assembly
Outrigger Cylinder Lock Valve
Outrigger Cylinder
Seat
Steering Console
Steering Control Valve
Steering Cylinder
Steering Hand Metering Unit (HMU)
Steering Pivot
Steering Tie Rod
SENR1242 - Disassembly & Assembly (TH103 Telehandler Transmission)
Torque Converter - Assemble
Torque Converter - Disassemble
Transmission - Assemble
Transmission - Disassemble
SENR1244 - Systems Operation (TH103 Telehandler Transmission)
SENR1244 - Specifications (TH103 Telehandler Transmission)
Identification Of The Unit
Servicing Machine After Components Overhaul
Transmission (HR Model without Internal Disconnect)
SENR1244 - Testing & Adjusting (TH103 Telehandler Transmission)
SENR2995 - Product Safety
SENR3130 - Specifications (Torque Specifications for All Caterpillar Products)
SENR3130 - Torque Specifications
Air Brake Fittings
Air Conditioning Fittings
Bulkhead Nuts
English (SAE) Fasteners
Flare Fittings
General Information
Ground Engaging Tool (G.E.T.) Fasteners
Hose Clamps
Installation of Fittings
Metric (ISO) Fasteners
Miscellaneous Fittings
O-Ring Face Seal Fittings
Plugs
Straight Thread O-Ring Fittings
Tapered Pipe Thread Fittings
SENR3685 - Disassembly & Assembly (Alternator - Bosch K1_N1)
Alternator - Assemble
Alternator - Disassemble
SENR3685 - Specifications (Alternator - Bosch K1_N1)
Alternator
SENR3685 - Systems Operation (Alternator - Bosch K1_N1)
Component Description
General Information
Normal Operation
SENR3685 - Testing & Adjusting (Alternator - Bosch K1_N1)
Alternator Output - Test
Brush Assembly - Test
Brush Length - Check
Capacitor - Test
Diode Assembly - Test
Diode Trio - Test
Field Winding - Test
Insulated Screw - Check
Rectifier - Test
Regulator - Test
Residual Magnetism - Restore
Stator - Test
SENR3685 - Troubleshooting (Alternator - Bosch K1_N1)
Alternator Charge Rate Is High
Alternator Charge Rate Is Low
Alternator Is Noisy
Alternator Will Not Charge
General Information
Service Tools
SENR3828 - Disassembly & Assembly (RA1.2, R1.4, R2.0, R2.2, R2.5, R2.7, R3.0, R4.5 and R5.5 Series Reduction Starting Motors)
General Information
Starting Motor - Assemble
Starting Motor - Disassemble
SENR3828 - Specifications (RA1.2, R1.4, R2.0, R2.2, R2.5, R2.7, R3.0, R4.5 and R5.5 Series Reduction Starting Motors)
Electric Starting Motor
SENR3828 - Systems Operation (RA1.2, R1.4, R2.0, R2.2, R2.5, R2.7, R3.0, R4.5 and R5.5 Series Reduction Starting Motors)
Component Description
General Information
Normal Operation
SENR3828 - Testing & Adjusting (RA1.2, R1.4, R2.0, R2.2, R2.5, R2.7, R3.0, R4.5 and R5.5 Series Reduction Starting Motors)
Component - Test
Initial Troubleshooting Procedure
No Load - Test
Starting Motor - Troubleshoot
SENR3981 - Schematic - Fluid Power & Electrical Graphic Symbols
Electrical Power Graphic Symbols
Fluid Power Graphic Symbols
SENR5815 - Specifications (3054 Engine for Caterpillar Built Machines)
Alternator and Regulator
Belt Tension Chart
Camshaft
Connecting Rod
Crankcase Breather
Crankshaft Seals
Crankshaft
Cylinder Block
Cylinder Head Valves
Cylinder Head
Electric Starting Motor
Engine Design
Engine Oil Filter Base
Engine Oil Pan
Engine Oil Pressure
Engine Oil Pump
Engine Oil Relief Valve
Exhaust Manifold
Fan Drive
Flywheel and Flywheel Housing Runout
Fuel Injection Nozzles
Fuel Injection Pump
Fuel Transfer Pump
Gear Group (Front)
Housing (Front)
Muffler
Piston and Rings
Rocker Shaft
Turbocharger
Valve Mechanism Cover
Water Pump
Water Temperature Regulator
SENR5816 - Systems Operation (3054 Engine for Built Machines)
Air Inlet and Exhaust System
Basic Engine
Cooling System
Electrical System
Engine Design
Fuel System
General Information
Lubrication System
SENR5816 - Troubleshooting (3054 Engine for Built Machines)
Air Inlet Heater - Test
Air Inlet and Exhaust System - Inspect
Air in Fuel - Test
Alternator - Test
Automatic Timing Advance Unit - Test
Battery - Test
Belt Tension Chart
Charging System - Test
Compression - Test
Connecting Rod - Inspect
Cooling System - Check
Cooling System - Inspect
Cooling System - Test
Cylinder Block - Inspect
Cylinder Head - Inspect
Cylinder Liner Projection - Inspect
Electric Starting System - Test
Engine Oil Pressure - Test
Engine Oil Pump - Inspect
Engine Valve Lash - Inspect_Adjust
Excessive Bearing Wear - Inspect
Excessive Engine Oil Consumption - Inspect
Exhaust Temperature - Test
Finding Top Center Position for No. 1 Piston
Flywheel - Inspect
Flywheel Housing - Inspect
Fuel Injection Nozzle - Test
Fuel Quality - Test
Fuel System - Inspect
Fuel System - Prime
Fuel System Pressure - Test
Gear Group (Front) - Time
High Idle RPM - Adjust
Increased Engine Oil Temperature - Inspect
Low Idle RPM - Adjust
Piston Height - Inspect
Troubleshooting
Turbocharger - Inspect
Valve Depth - Inspect
Valve Guide - Inspect
Water Temperature Regulator - Test
SENR5840 - Disassembly & Assembly (TH62, TH63, TH82 & TH83 TELEHANDLERS POWER TRAIN)
Axle Shaft
Differential
Drive Shafts
Engine and Transmission
Final Drive
Front Axle (Fixed Frame)
Front Axle (With Frame Level)
Hub
Rear Axle
Torque Converter
Transfer Gearbox
Transmission
Wheel
SENR5841 - Disassembly & Assembly (G3B, K3A & L3A Denso Alternators)
Alternator - Assemble
Alternator - Disassemble
SENR5841 - Specifications (G3B, K3A & L3A Denso Alternators)
Alternator
SENR5841 - Systems Operation (G3B, K3A & L3A Denso Alternators)
Component Description
General Information
Normal Operation
SENR5841 - Testing & Adjusting (G3B, K3A & L3A Denso Alternators)
Component - Test
General Information
Initial Troubleshooting Procedure
T1 Alternator Output - Test
T2 Electrical System Current - Test
T3 Charging System - Test
T4 Alternator Drive System - Check
T5 Alternator Current - Test
T7 Identifying Source of Current Draw - Test
T8 Alternator Overcharging - Test
SENR5844 - Systems Operation (TH62, TH63, TH82 & TH83 Telehandlers Braking System)
Brake Cylinder (Boost)
Brake Cylinder (Master)
Brakes
General Information
Parking Brake
Service Brake
SENR5844 - Testing & Adjusting (TH62, TH63, TH82 & TH83 Telehandlers Braking System)
Brake Cylinder (Master) - Test and Adjust
Braking System Troubleshooting
General Information
Machine Preparation for Troubleshooting
Operation Checks
Parking Brake Control Cable - Adjust
Service Brake - Adjust
Service Brake Air - Purge
Service Brake Discs - Check
Visual Inspection
SENR5845 - Schematic (TH62, TH63, TH82 & TH83 Telehandlers Hydraulic System)
SENR5846 - Disassembly and Assembly (TH62, TH63 TH82 & TH83 Telehandlers Machine Systems)
Attachment Carriage
Auxilliary Hydraulic Hose
Auxilliary Selector Valve
Boom Assembly (Three Section'
Boom Assembly (Two Section)
Boom Extend Cylinder (Three Section Boom)
Boom Extend Cylinder Lock Valve (Three Section Boom)
Boom Extend Cylinder. (Two Section Boom)
Boom Raise Cylinder Lock Valve
Boom Raise Cylinder
Brake Master Cylinder
Cab
Compensating Cylinder
Compensating Valve (TH62 and TH82)
Compensating Valve (TH63 and TH83)
Counterweight
Disc Brake
FRAME LEVEL CYLINDER LOCK VALVE
Fork Tilt Cylinder Lock Valve
Fork Tilt Cylinder
Forks
Frame Level Control Valve
Frame Level Cylinder
Fuel Tank Sender Unit
Fuel Tank
Hydraulic Pump
Hydraulic Tank
Outrigger Assembly
Outrigger Cylinder Lock Valve
Outrigger Cylinder
Parkbrake Assembly And Cable
Pilot Selector and Differential Lock Control Valve
Seat
Steering Console
Steering Control Valve
Steering Cylinder
Steering Pivot
Steering Tie Rod
Steering Valve (HMU)
SENR5847 - Schematic (TH62, TH63, TH82, TH83 & TH103 Telehandler Electrical System)
Collage Schematic
Main Schematic
SENR5851 - Disassembly & Assembly (TH62, TH63, TH82 & TH83 Telehandlers Engine Supplement)
AIR CLEANER ASSEMBLY
ALTERNATOR
EXHAUST SYSTEM
RADIATOR
STARTER MOTOR
SENR5857 - Specifications (TH62, TH63, TH82 & TH83 Telehandlers Steering & Hydraulic)
Boom Extend Cylinder (8I3467)
Boom Extend Cylinder 8I4366
Boom Raise Cylinder (1181943)
Boom Raise Cylinder (8I6043)
Boom Raise Cylinder 8I5486
Compensating Cylinder 8I5488
Compensating Cylinder 8I6159
Directional Control Valve 1229703
Directional Control Valve 8I6425
Directional Control Valve 8I6426
Fork Level (Tilt) Cylinder
Frame Level Cylinder 8I3276
Hand Metering Unit
Hydraulic Pump
Stabilizer Cylinder
SENR6241 - Disassembly & Assembly (3054 Engine for Caterpillar Built Machines)
Alternator - Remove and Install 1
Alternator - Remove and Install 2
Bearing Clearance - Check
Camshaft - Remove and Install
Camshaft Bearings - Remove and Install
Camshaft Gear - Remove and Install
Connecting Rod Bearings - Install
Connecting Rod Bearings - Remove
Crankshaft - Install
Crankshaft - Remove
Crankshaft Front Seal - Install
Crankshaft Front Seal - Remove
Crankshaft Gear - Remove and Install
Crankshaft Main Bearings - Install
Crankshaft Main Bearings - Remove
Crankshaft Pulley - Remove and Install
Crankshaft Rear Seal - Install
Crankshaft Rear Seal - Remove
Cylinder Head - Install
Cylinder Head - Remove
Cylinder Liner - Install
Cylinder Liner - Remove
Electric Starting Motor - Remove and Install 1
Electric Starting Motor - Remove and Install 2
Engine Design
Engine Oil Filter Base - Assemble
Engine Oil Filter Base - Disassemble
Engine Oil Filter Base - Install
Engine Oil Filter Base - Remove
Engine Oil Pan - Remove and Install
Engine Oil Pump - Install
Engine Oil Pump - Remove
Engine Oil Relief Valve - Remove and Install
Exhaust Manifold - Remove and Install - Type 1 Engines and 9RM Engines
Exhaust Manifold - Remove and Install - Type 2 Engines and 7BJ Engines
Fan - Remove and Install
Fan Drive - Install
Fan Drive - Remove
Flywheel - Install
Flywheel - Remove
Flywheel Housing - Remove and Install
Front Cover - Install
Front Cover - Remove
Fuel Filter Base - Remove and Install
Fuel Injection Lines - Remove and Install
Fuel Injection Nozzles - Install - Type 1 Engines and 9RM Engines
Fuel Injection Nozzles - Install
Fuel Injection Nozzles - Remove - Type 1 Engines and 9RM Engines
Fuel Injection Nozzles - Remove
Fuel Injection Pump - Install - Type 1 Engines and 9RM Engines
Fuel Injection Pump - Install - Type 2 Engines and 7BJ Engines
Fuel Injection Pump - Remove - Type 1 Engines and 9RM Engines
Fuel Injection Pump - Remove - Type 2 Engines and 7BJ Engines
Fuel Transfer Pump - Assemble
Fuel Transfer Pump - Disassemble
Fuel Transfer Pump - Install
Fuel Transfer Pump - Remove
Gear Group (Front) - Install
Gear Group (Front) - Remove
Housing (Front) - Install
Housing (Front) - Remove
Inlet Manifold - Install - Type 1 Engines and 9RM Engines
Inlet Manifold - Install - Type 2 Engines and 7BJ Engines
Inlet Manifold - Remove - Type 1 Engines and 9RM Engines
Inlet Manifold - Remove - Type 2 Engines and 7BJ Engines
Inlet and Exhaust Valve Guides - Remove and Install
Inlet and Exhaust Valve Seat Inserts - Remove and Install
Inlet and Exhaust Valve Springs - Remove and Install
Inlet and Exhaust Valves - Remove and Install
Lifter Group - Remove and Install
Piston Cooling Jets - Remove and Install
Pistons and Connecting Rods - Assemble
Pistons and Connecting Rods - Disassemble
Pistons and Connecting Rods - Install
Pistons and Connecting Rods - Remove
Rocker Shaft - Assemble
Rocker Shaft - Disassemble
Rocker Shaft and Pushrod - Install
Rocker Shaft and Pushrod - Remove
Turbocharger - Assemble
Turbocharger - Disassemble
Turbocharger - Install
Turbocharger - Remove
V-Belts - Remove and Install
Valve Mechanism Cover - Remove and Install
Water Outlet Manifold - Install
Water Outlet Manifold - Remove
Water Pump - Assemble - Type 1 Engines and 9RM Engines
Water Pump - Disassemble - Type 1 Engines and 9RM Engines
Water Pump - Install
Water Pump - Remove
Water Temperature Regulator - Remove and Install
UENR3262 - Disassembly & Assembly - Seal Installation
Duo-Cone Seals - Install
Lip Type Seals - Install
O-Ring Seals - Install - RADIAL, FITTING ASSEMBLY O-RINGS & OTHER O-RING APPLICATIONS
…
EXCERPT:
Engine and Transmission
Remove Engine and Transmission.
Start By:
a. Remove battery. b. Remove radiator.
SENR58400001
1. Remove four nuts (1), bolts (2) and washers (3) and remove hood and hood support (4).
2. Disconnect electrical cables (5) from alternator.
3. Remove three nuts (6), washers (7) and disconnect exhaust pipe (8).
4. Disconnect electrical cables (9) from starter motor solenoid. Remove nut (10) and disconnect earth cable (11).
5. Disconnect air intake hose (12) from beneath air cleaner assembly.
6. Remove bolt (13), washer (14) and clip (15) and detach battery cables from transmission.
…
Bank Valve - Assemble
SMCS - 5051-016 S/N - 3JN1510-UP S/N - 3RN4015-UP S/N - 5WM6021-UP
Assembly Procedure
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. All disassembly and all assembly procedures must be performed on a clean work surface and in a clean hydraulic area. Keep cleaned parts covered and protected at all times.
Note: O-rings, gaskets, and seals should always be replaced. A used O-ring may not have the same sealing properties as a new O-ring. Use 1U-6396 O-Ring Assembly Compound during the assembly procedure.
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