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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