A Service Manual (sometimes referred to as a Repair, Technical, Workshop
or Shop Manual) is often
large and broken down in to sections for different parts of your equipment.
Service
manuals cover absolutely every aspect of your machine unless mentioned
otherwise. Sometimes, the
engine is covered in a separate service manual that is written specifically for
the
engine. Most of the time though, it’s included in the main service manual. A
service manual will
arm you with the same exact information that your local service center has and
includes
electrical and hydraulic diagrams and which are usually color and or large
foldout pages.
Most OEM service manuals will also include troubleshooting flow charts, error
codes and
exploded views of components which are a great help for disassembly and
re-assembly.

An Operator’s Manual typically describes basic equipment operation and
maintenance. This
is the manual distributed with your equipment at the time of purchase from the
dealer.

• MAINTENANCE SAFETY
• CONTENTS
• FOREWORD
• FOREWORD
• SAFETY INSTRUCTIONS
• FIRE PREVENTION
• Maintenance
• Operation
• Electrical
• Hydraulic System
• Fueling
• Starting
• Spark Arrester Exhaust System
• Welding And Grinding
• Fire Extinguishers
• SERIAL NUMBER LOCATION
• Telescopic Handler Serial Number
• Engine Serial Number
• Other Serial Numbers
• DELIVERY REPORT
• IDENTIFICATION OF THE TELESCOPIC HANDLER
• SAFETY AND MAINTENANCE
• LIFTING AND BLOCKING THE TELESCOPIC HANDLER
• Procedure
• OPERATOR CAB
• Emergency Exit
• Cab Door
• Cab Door Window
• TRANSPORTING THE TELESCOPIC HANDLER
• Loading And Unloading
• Fastening
• TOWING THE TELESCOPIC HANDLER
• Procedure
• SERVICE SCHEDULE
• AIR CLEANER SERVICE
• Replacing Filter Element
• ENGINE COOLING SYSTEM
• Cleaning The Cooling System
• Checking The Coolant Level
• Replacing The Coolant
• FUEL SYSTEM
• Fuel Specifications
• Filling The Fuel Tank
• Fuel Filter
• ENGINE LUBRICATION SYSTEM
• Checking Engine Oil
• Oil Chart
• Replacing Oil And Filter
• HYDRAULIC / HYDROSTATIC SYSTEM
• Checking And Adding Fluid
• Replacing Hydraulic / Hydrostatic Filter
• Replacing Hydraulic Fluid
• AXLES (FRONT AND REAR)
• Checking Oil Level (Planetary Carrier)
• Draining Oil (Planetary Carrier)
• Checking Oil Level (Rear Differential)
• Draining Oil (Rear Differential)
• Checking Oil Level (Front Differential)
• Draining Oil (Front Differential)
• Checking Oil (Drive Box)
• Draining Oil (Drive Box)
• LUBRICATION
• Procedure
• ATTACHMENT FRAME
• Inspection And Maintenance
• TYRE MAINTENANCE
• Wheel Nuts
• Tyre Mounting
• Tyre Rotation
• SPARK ARRESTER MUFFLER
• Cleaning
• APPROVED BOOM STOP
• Installing The Approved Boom Stop
• Removing The Approved Boom Stop
• ENGINE COVER
• Opening And Closing The Engine Cover
• HYDRAULIC SYSTEM
• HYDRAULIC SYSTEM INFORMATION
• Troubleshooting Chart
• HYDRAULIC SCHEMATICS
• Tightening Procedures
• LIFT CYLINDER
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• BUCKET POSITIONING CYLINDER
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• EXTENSION CYLINDER
• Cylinder Group Removal And Installation
• Upper Tubeline Removal
• Upper Tubeline Installation
• Extension Cylinder Removal And Installation
• Tubeline Tray Disassembly
• Tubeline Tray Assembly
• Parts Identification
• Disassembly
• Assembly
• TILT CYLINDER
• Removal And Installation
• TILT CYLINDER
• Parts Identification
• Disassembly
• Assembly
• STEERING CYLINDER (FRONT)
• Removing The Steering Cylinder
• Installing The Steering Cylinder
• Disassembling The Steering Cylinder
• Assembling The Steering Cylinder
• STEERING CYLINDER (REAR)
• Removing The Steering Cylinder
• Installing The Steering Cylinder
• Disassembling The Steering Cylinder
• Assembling The Steering Cylinder
• DRIVE BOX
• Parts Identification
• Disassembly
• Assembly
• Special Tools
• MAIN RELIEF VALVE
• Testing And Adjustment
• Removal And Installation
• QUICK TACH CYLINDER
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• PORT RELIEF VALVES
• Adjustment Procedure
• STEERING MODE VALVE BLOCK
• Removal And Installation
• Parts Identification
• Disassembly
• Solenoid Testing
• Assembly
• BRAKE VALVE
• Removal And Installation
• Disassembly And Assembly
• GEAR PUMP
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• FAN MOTOR
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• HYDRAULIC RESERVOIR
• Removal And Installation
• STEERING VALVE
• Removal And Installation
• Parts Identification
• Disassembly
• Inspection
• Assembly
• HYDRAULIC CONTROL VALVE
• Troubleshooting Chart (Controllers)
• Telescoping Valve Section Troubleshooting
• Auxiliary Valve Section Troubleshooting
• Troubleshooting Chart (Control Valve)
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• End Housing Disassembly And Assembly
• Lifting Valve Section Disassembly And Assembly
• Tilting Valve Section Disassembly And Assembly
• Telescoping Valve Section Disassembly And Assembly
• Auxiliary Valve Section Disassembly And Assembly
• Inlet-Outlet Valve Section Disassembly And Assembly
• JOYSTICK
• Removal And Installation
• PARKING BRAKE
• Parking Brake Valve Removal And Installation
• Parking Brake Valve Disassembly And Assembly
• PILOT PRESSURE LOCK OUT VALVE
• Testing
• Removal And Installation
• Disassembly And Assembly
• ACCUMULATOR
• Removal And Installation
• TOW VALVE
• Removal And Installation
• Disassembly And Assembly
• FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE
• Removal And Installation
• Disassembly And Assembly
• FLOW CONTROL VALVE
• Removal And Installation
• HYDROSTATIC SYSTEM
• HYDROSTATIC SYSTEM INFORMATION
• Troubleshooting Chart
• Replenishing Valve Function
• OIL COOLER
• Description
• HYDROSTATIC DRIVE MOTOR
• Removal And Installation
• Parts Identification
• Disassembly
• Inspection
• Assembly
• HYDROSTATIC PUMP
• Removal And Installation
• Parts Identification
• Disassembly
• Inspection
• Assembly
• Charge pressure checking procedure
• Charge pressure adjusting procedure
• DRIVE SYSTEM
• TROUBLESHOOTING
• Chart
• AXLE AND DIFFERENTIAL (FRONT)
• General Information
• Planetary Carrier And Wheel Hub Parts Identification
• Planetary Carrier Disassembly And Assembly
• Wheel Hub Disassembly And Assembly
• Steering Knuckle Disassembly And Assembly
• Axle Housing / Drive Axle Disassembly
• Brake Group Parts Identification
• Brake Group Disassembly
• Differential Parts Identification
• Differential Disassembly And Assembly
• Pinion Group Parts Identification
• Pinion Group Disassembly
• Pinion Group Assembly
• Brake Group Assembly
• Axle Housing / Drive Axle Assemby
• Special Tools
• AXLE AND DIFFERENTIAL (REAR)
• General Information
• Planetary Carrier And Wheel Hub Parts Identification
• Planetary Carrier Disassembly
• Steering Knuckle Parts Identification
• Steering Knuckle Disassembly
• Differential Parts Identification
• Differential Disassembly
• Bevel Pinion Parts Identification
• Bevel Pinion Disassembly
• Bevel Pinion Assembly
• Differential Assembly
• Steering Knuckle Assembly
• Planetary Carrier Assembly
• Special Tools
• FRONT AXLE
• Removal
• Installation
• AXLE TOE-IN
• Adjustment
• PARKING BRAKE
• Releasing The Brake For Towing
• Re-Activating The Brake
• STEERING ANGLE ADJUSTMENT
• Adjustment
• DRIVESHAFT
• Removal And Installation
• SERVICE BRAKE
• Description
• Bleeding The Brake Circuit
• REAR AXLE
• Removal
• Installation
• MAIN FRAME
• OPERATOR CAB (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)
• Removal And Installation
• OPERATOR CAB (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)
• Removal And Installation
• OPERATOR SEAT
• Removal And Installation
• BOOM ASSEMBLY
• Removal And Installation
• INNER BOOM
• Removal
• Installation
• WEAR PADS (FRONT)
• Removal And Installation
• WEAR PADS (REAR)
• Removal
• Installation
• ENGINE COVER
• Gas Cylinder Removal And Installation
• Removal And Installation
• AIR INTAKE COWLING
• Removal And Installation
• FUEL TANK
• Removal And Installation
• QUICK TACH
• Removal And Installation
• REAR WEIGHTS
• Removal And Installation
• FENDER
• Removal And Installation
• JOYSTICK PANEL (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)
• Removal And Installation
• JOYSTICK PANEL (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)
• Removal And Installation
• DASH COVER / STEERING COLUMN COVER (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)
• Removal And Installation
• DASH COVER / STEERING COLUMN COVER (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)
• Removal And Installation
• ELECTRICAL SYSTEM AND ANALYSIS
• ELECTRICAL SYSTEM INFORMATION (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)
• Troubleshooting Chart
• Description
• Fuses, Diodes And Relays
• ELECTRICAL SCHEMATICS (S/N 13000 & ABOVE)
• ELECTRICAL SCHEMATICS (S/N 12001 – 12999)
• ELECTRICAL SYSTEM INFORMATION (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)
• Troubleshooting Chart
• Description
• Fuses, Diodes And Relays
• BATTERY
• Removal And Installation
• Servicing
• Using A Booster Battery (Jump Starting)
• ALTERNATOR
• Removal And Installation
• Adjusting The Alternator Belt
• STARTER
• Removal And Installation
• Parts Identification
• Disassembly
• Inspection And Repair
• Assembly
• LIGHTS
• Rear Light Removal And Installation
• Front Light Removal And Installation
• TRAVEL / SIGNAL LEVER (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)
• Removal And Installation
• TRAVEL / SIGNAL LEVER (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)
• Removal And Installation
• INSTRUMENT PANEL
• Removal And Installation
• SWITCH PANEL (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)
• Removal And Installation
• Parts description
• SWITCH PANEL (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)
• Removal And Installation
• Parts description
• BRAKE LIGHT SWITCH
• Removal And Installation
• Adjustment
• FRONT WIPER MOTOR
• Removal And Installation
• TOP WIPER MOTOR
• Removal And Installation
• REAR WIPER MOTOR
• Removal And Installation
• PEDAL ASSEMBLY
• Removal And Installation
• Disassembly And Assembly
• INCHING SWITCH
• Removal And Installation
• Adjustment
• SERVICE SOFTWARE
• Connecting The Laptop Computer
• Entering The Service Software
• Monitor Screen
• Warnings Screen
• Calibrate Inch Pedal
• Calibrate Creep Potentiometer
• Program / Update Susmic Controller
• ENGINE SERVICE
• TROUBLESHOOTING
• Chart
• ENGINE SPEED CONTROL
• Removal And Installation
• MUFFLER
• Removal And Installation
• AIR CLEANER
• Housing Removal And Installation
• OIL COOLER / RADIATOR
• Removal And Installation
• Disassembly And Assembly
• ENGINE AND ENGINE MOUNTS
• Removal And Installation
• ENGINE COMPONENTS AND TESTING
• Fuel Injection Pump Removal
• Fuel Injection Pump Installation
• Fuel Injectors Removal And Installation
• Checking The Fuel Lift Pump
• Fuel Lift Pump Removal And Installation
• Compression Checking
• Glow Plugs Checking
• Glow Plugs Removal And Installation
• ENGINE TIMING
• Procedure
• ENGINE / HYDROSTAT ASSEMBLY
• Removal And Installation
• FLYWHEEL AND HOUSING
• Removal And Installation
• Ring Gear Removal
• Ring Gear Installation
• RECONDITIONING THE ENGINE
• Turbo Charger Troubleshooting
• Turbo Charger Description
• Turbo Charger Removal And Installation
• Exhaust Manifold Removal And Installation
• Fuel Injector Cover Removal And Installation
• Rocker Cover Removal And Installation
• Cylinder Head Removal
• Cylinder Head Inspection
• Cylinder Head Installation
• Rocker Shaft Disassembly And Assembly
• Valve Removal
• Valve Springs Checking
• Valve Depth Checking
• Valve Guides Checking
• Valve Guide Removal
• Valve Guide Installation
• Valves Checking
• Cutting A Valve Seat
• Valve Seat Assembly
• Changing Valve Springs (With Cylinder Head Installed)
• Valve Clearance Adjustment
• Timing Case And Drive Assembly Description
• Timing Cover Removal
• Timing Cover Installation
• Crankshaft Pulley Removal And Installation
• Front Oil Seal Removal And Installation
• Timing Case And Gear Removal
• Timing Case And Gear Installation
• Camshaft And Tappets Removal
• Camshaft And Tappets Installation
• Pistons And Connecting Rods Description
• Pistons And Connecting Rods Removal
• Pistons And Connecting Rods Disassembly
• Piston Ring End Gap
• Piston Ring Installation
• Piston Ring Groove Clearance
• Connecting Rod Inspection
• Connecting Rod Bushing Replacement
• Piston And Connecting Rod Assembly
• Piston And Connecting Rod Installation
• Checking Piston Height
• Crankshaft And Bearings Description
• Crankshaft And Bearings Removal
• Inspection Of Crankshaft And Bearings
• Crankshaft And Bearings Installation
• Rear Oil Seal Removal
• Rear Oil Seal Housing Positioning
• Rear Oil Seal Installation
• Checking Crankshaft End Play
• Cooling System Description
• Thermostat Removal and Installation
• Thermostat Testing
• Lubricating Oil Cooler Removal And Installation
• Water Pump Removal
• Water Pump Installation
• Engine Lubrication System Description
• Oil Filter Adapter Removal And Installation
• Oil Pan Removal And Installation
• Oil Screen And Pick-up Tube
• Oil Pump Removal
• Oil Pump Installation
• Oil Pump Disassembly And Assembly
• Oil Pressure Relief Valve Disassembly And Assembly
• Engine Block Description
• Engine Block Disassembly And Assembly
• Piston Cooling Jet Removal
• Piston Cooling Jet Installation
• Piston Cooling Jet Alignment
• Inspection
• Cylinder Liner Inspection
• Cylinder Liner Removal
• Cylinder Liner Installation
• HEATING, VENTILATION, AIR CONDITIONING
• AIR CONDITIONING SYSTEM FLOW
• Principles
• Chart
• COMPONENTS
• Identification
• SAFETY
• Safety Equipment
• REGULAR MAINTENANCE
• Filter Element Removal And Installation
• Compressor Drive Belt Inspection
• Cleaning The Condenser
• BASIC TROUBLESHOOTING
• Poor A/C Performance
• Compressor Drive Belt Inspection
• Checking The Electrical System
• GENERAL AIR CONDITIONING SERVICE GUIDELINES
• Compressor Oil
• Compressor Oil Check
• Component Replacement And Refrigeration Leaks
• SYSTEM TROUBLESHOOTING CHART
• TEMPERATURE / PRESSURE
• Chart
• AIR CONDITIONING SERVICE
• Chart
• SYSTEM CHARGING AND RECLAMATION
• Reclamation Procedure
• Charging Procedure With A Manifold Gauge Set
• Charging Procedure
• COMPRESSOR
• Removal And Installation
• Compressor Clutch Disassembly And Assembly
• CONDENSER (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)
• Removal And Installation
• CONDENSER (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)
• Removal And Installation
• RECEIVER / DRIER
• Removal And Installation
• PRESSURE SWITCH
• Removal And Installation
• EVAPORATOR / BLOWER UNIT (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)
• Removal And Installation
• EVAPORATOR / BLOWER / HEATER UNIT (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)
• Removal And Installation
• EXPANSION VALVE (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)
• Removal And Installation
• EXPANSION VALVE (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)
• Removal And Installation
• HEATER ASSEMBLY
• Removal And Installation
• Fan Removal And Installation
• Core Removal And Installation
• SPECIFICATIONS
• TELESCOPIC HANDLER SPECIFICATIONS
• Dimensional Specifications
• Performance Specifications
• Engine
• Fan Pump
• Controls
• Drive System
• Tyres
• Capacities
• Hydraulic System
• Electrical System
• Instrument Panel
• ENGINE SPECIFICATIONS
• General
• Cylinder Head
• Valve Guides
• Exhaust Valves
• Intake Valves
• Valve Springs
• Rocker Shaft, Rockers And Bushings
• Pistons And Piston Rings
• Connecting Rods And Bearings
• Crankshaft
• Crankshaft Re-Grind Data
• Main Bearings
• Thrust Washers
• Camshaft And Thrust Washer
• Cylinder Block
• Cylinder Liners
• Fuel Injection Pump
• Fuel Injectors
• Fuel Lift Pump
• Timing Case And Timing Gears
• Oil Pump, Gear And Relief Valve
• Turbocharger
• Flywheel
• Water Pump And Thermostat
• Engine Torque Component
• MACHINE TORQUE SPECIFICATIONS
• Axle
• Boom
• Drive Box
• Drive Motor
• Engine
• Hydraulic Pump
• TORQUE SPECIFICATIONS FOR BOLTS
• Torque for General SAE Bolts
• Torque For General Metric Bolts
• HYDRAULIC CONNECTION SPECIFICATIONS
• O-ring Face Seal Connection
• Straight Thread O-ring Fitting
• Tubelines And Hoses
• Port Seal Fitting
• HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
• Specifications
• CONVERSIONS
• Decimal And Millimeter Equivalents
• U.S. To Metric Conversion
• ALPHABETICAL INDEX
• SERVICE MANUAL REVISION
• Revision No: T2556, T2566 – 1