Caterpillar (CAT) TH220B/TH330B Telescopic Handlers (Telehandlers) Owners Manual (+ Maintenance Instruction Manual)

Operation and Maintenance Manual 31200242 February 2, 2007 TH220B and TH330B Telehandlers S/N TBF00100 & After S/N TBG00100 & After Keep this manual with machine at all times.

Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar ® dealers have the most current information available. When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

EFFECTIVITY PAGE 31200242 i July 13, 2006 - A - Original Issue Of Manual February 2, 2007 - B - Added Tier III information. Revised pages 9, 18, 19, 35, 36, 109, 121, 137, 138, 139, 140, 142 and 143.

EFFECTIVITY PAGE 31200242 -ii

31200242 1 Table of Contents Table of Contents Foreword Literature Information ............................................ 5 Safety .................................................................... 5 Operation .............................................................. 5 Maintenance.......................................................... 5 Maintenance Intervals ...................................... 5 Certified Engine Maintenance ............................... 5 Machine Capacity .................................................. 5 Contact Information ............................................... 6 Safety Section Safety Messages ................................................... 7 Do Not Operate (1)........................................... 9 Do Not Stand Under the Load (2) .................. 10 No Hands (3) .................................................. 10 Forks (5) ......................................................... 11 Do Not Weld On The ROPS/FOPS Structure (6) ................................................... 12 No Access Platform (7) .................................. 12 Seat Belt (8) ................................................... 13 Engine Coolant (9) ......................................... 13 Low Bridge (10) .............................................. 13 Avoid Power Lines (11) .................................. 14 Jump Start Cables (12) .................................. 14 Ether (13) ....................................................... 14 Impaling Hazard (14)...................................... 15 Crushing Hazard (15) ..................................... 15 Crushing Hazard (16) ..................................... 15 Crushing Hazard (17) ..................................... 15 Impaling Hazard (18)...................................... 16 Crushing Hazard (19) ..................................... 16 Impaling Hazard (20)...................................... 16 Impaling Hazard (21)...................................... 16 Crushing Hazard (22) ..................................... 17 Operation (23) ................................................ 17 Entanglement and Flying Objects (24) ........... 17 Trap Point (25) ............................................... 17 Crushing Hazard (26) ..................................... 18 Ether (27) ....................................................... 18 Hand (High Pressure) (28) ............................. 19 Universal Warning (29) .................................. 19 Additional Messages ...................................... 19 General Hazard Information ................................ 23 Pressurized Air and Water ............................. 23 Trapped Pressure .......................................... 23 Fluid Penetration ............................................ 24 Containing Fluid Spillage ............................... 24 Dispose of Waste Properly............................. 24 Crushing Prevention and Cutting Prevention ...... 24 Burn Prevention .................................................. 25 Coolant ........................................................... 25 Oils ................................................................. 25 Batteries ......................................................... 25 Fire Prevention and Explosion Prevention ..... 25 Fire Extinguisher ............................................ 26 Lines, Tubes and Hoses ................................ 26 Fire Extinguisher Location................................... 26 Tire Information ................................................... 27 Electrical Storm Injury Prevention ........................ 27 Before Starting Engine ......................................... 27 Engine Starting .................................................... 28 Before Operation.................................................. 28 Operation ............................................................. 28 Machine Operating Temperature Range ........ 28 Machine Operation ......................................... 28 Engine Stopping................................................... 29 Work Tools ........................................................... 30 Parking ................................................................. 30 Equipment Lowering with Loss of Hydraulic Power ................................................................... 30 Sound Information and Vibration Information ...... 30 Sound Level .................................................... 30 Vibration Level ................................................ 31 Operator Station................................................... 31 Guards (Operator Protection) ........................................... 31 Rollover Protective Structure (ROPS), Falling Object Protective Structure (FOPS) ................ 31 Other Guards (If Equipped) ............................ 31 Product Information Section General Information ............................................. 33 Lifting Capacities ............................................ 33 Examples of Estimating the Lift Operation from the Load Chart ................................................ 34 Specifications ....................................................... 35 Intended Use .................................................. 35 Application/Configuration Restrictions ............ 35 Identification Information ...................................... 36 Plate and Decal Locations .............................. 36 Emissions Certification Decal .............................. 39 Operation Section Before Operation.................................................. 41 Mounting and Dismounting ............................. 41 Daily Inspection .............................................. 41 Machine Operation............................................... 43 Alternate Exit .................................................. 43 Seat ................................................................ 43 Seat Belt ......................................................... 44 Operator Controls ........................................... 47 Operator Controls (Side Console) .................. 62 Battery Disconnect Switch (If Equipped) ........ 63 Boom Cylinder Lock (If Equipped) .................. 64 Operation Information ..................................... 65 Work Tools...................................................... 72 Monitoring System .......................................... 80 Backup Alarm ................................................. 84 Cab Door ........................................................ 84 Engine Starting .................................................... 84 Engine Starting ............................................... 84 Starting Below 0 °C (32°F).............................. 85 Engine and Machine Warm-Up....................... 85 Parking ................................................................. 86 Stopping the Machine ..................................... 86 Stopping the Engine ....................................... 86 Stopping the Engine if an Electrical Malfunction Occurs ............................................................ 86 Table of

31200242 2 Table of Contents Leaving the Machine ...................................... 86 Transportation Information .................................. 87 Shipping the Machine..................................... 87 Roading the Machine ..................................... 87 Lifting and Tying Down the Machine .............. 88 Towing Information .............................................. 89 Towing the Machine ....................................... 89 Types of Towing Hitches and Hydraulic Services ......................................................... 93 Hydraulic Hitch and Hydraulic Services ......... 95 Engine Starting (Alternate Methods) ................... 96 Engine Starting with Jump Start Cables......... 96 Equipment Lowering with Loss of Hydraulic Power ............................................................. 97 Maintenance Section Maintenance Access ......................................... 103 Access Doors and Covers............................ 103 Tire Inflation Information ................................... 104 Tire Inflation with Air..................................... 104 Tire Pressure................................................ 104 Tire Inflation Pressure Adjustment ............... 106 Tire Damage ................................................ 106 Tire Replacement ......................................... 106 Wheel and Tire Installation........................... 106 Lubricant Viscosities and Refill Capacities ........ 107 Lubricant Viscosities .................................... 107 Capacities (Refill) ......................................... 109 SOS Information........................................... 110 Maintenance Support ........................................ 111 Welding on Machines and Engines with Electronic Controls ....................................... 111 Maintenance Interval Schedule ......................... 111 Axle Breathers - Clean/Replace ........................ 113 Backup Alarm - Test .......................................... 113 Battery - Recycle ............................................... 113 Battery or Battery Cable -Inspect/Replace ........ 113 Belt - Inspect/Replace ....................................... 114 Inspect ......................................................... 114 Replace ........................................................ 114 Boom Cylinder Pin - Lubricate .......................... 115 Boom Head Section - Lubricate ........................ 115 Boom Pivot Shaft - Lubricate ............................ 115 Boom Telescoping Cylinder Air- Purge ............. 115 Boom Wear Pad Clearance -Inspect/Adjust ...... 116 Adjustment ................................................... 117 Boom and Frame - Inspect ................................ 118 Braking System - Test ....................................... 119 Service Brake ............................................... 119 Parking Brake............................................... 120 Cab Air Filter - Clean/Replace........................... 120 Primary Cab Air Filter ................................... 120 Secondary Cab Air Filter .............................. 121 Circuit Breakers - Test ...................................... 121 Compensating Cylinder Bearing - Lubricate...... 122 Cooling System Coolant - Change .................... 122 Cooling System Coolant Level - Check ............. 123 Cooling System Coolant Sample (Level 1) - Obtain ................................................................ 124 Cooling System Coolant Sample (Level 2) - Obtain ................................................................ 125 Cooling System Pressure Cap - Clean/Replace 125 Cooling System Water Temperature Regulator Replace .............................................................. 126 Differential Oil - Change.....................................127 Rear Axle Differential .................................... 127 Front Axle Differential ................................... 127 Differential Oil Level - Check ............................. 127 Rear Axle Differential .................................... 128 Front Axle Differential ................................... 128 Differential Oil Sample - Obtain ......................... 128 Drive Shaft Spline - Lubricate ....................... 129 Drive Shaft Universal Joint Bolts - Check .......... 130 Engine Air Filter Primary Element - Clean/Replace ................................................... 130 Cleaning Primary Air Filter Elements ............ 131 Inspecting the Primary Air Filter Elements....131 Engine Air Filter Primary Element - Replace ..... 132 Engine Air Filter Secondary Element - Replace.132 Engine Mounts - Inspect .................................... 133 Engine Oil Level - Check ................................... 133 Engine Oil Sample - Obtain ............................... 133 Engine Oil and Filter - Change........................... 134 Engine Valve Lash - Check................................ 135 Final Drive Oil - Change.....................................135 Final Drive Oil Level - Check ............................. 136 Final Drive Oil Sample - Obtain ......................... 136 Fork Leveling Cylinder Pin -Lubricate ................ 137 Fuel System - Prime .......................................... 137 Fuel System Water Separator - Drain ................ 138 Fuel System Water Separator Element - Replace (Tier II) ............................................................... 139 Fuel System Water Separator Element - Replace (Tier III) .............................................................. 140 Fuel Tank Cap - Clean ....................................... 140 Fuel Tank Water and Sediment - Drain ............. 141 Fuses and Relays - Replace ..............................142 Fuses ............................................................ 142 Relays ........................................................... 143 Indicators and Gauges - Test ............................. 144 Longitudinal Stability Indicator - Calibrate.......... 144 Longitudinal Stability Indicator -Test .................. 144 Initial Test ..................................................... 144 Second Test ..................................................145 Oil Filter - Inspect ............................................... 145 Inspect a Used Filter for Debris .................... 145 Parking Brake - Adjust ....................................... 146 Radiator Core - Clean ........................................ 146 Refrigerant Dryer - Replace ............................... 147 Rollover Protective Structure (ROPS) and Falling Object Protective Structure (FOPS) -Inspect ..... 147 Seat Belt - Inspect.............................................. 148 Seat Belt - Replace ............................................ 148 Tire Inflation - Check .......................................... 148 Transmission and Hydraulic System Oil - Change .............................................................. 149 Transmission and Hydraulic System Oil Filter - Replace .............................................................. 150

3 31200242 Table of Contents Transmission and Hydraulic System Oil Level - Check ................................................................ 151 Transmission and Hydraulic System Oil Sample - Obtain ................................................................ 152 Transmission and Hydraulic System Tank Breather - Clean ................................................ 152 Turbocharger - Inspect ...................................... 153 Wheel Nut Torque - Check ................................ 153 Window Washer Reservoir - Fill ........................ 153 Window Wiper - Inspect/Replace ...................... 153 Windows - Clean ............................................... 154 Work Tool - Inspect/Replace ............................. 154 Forks ............................................................ 154 Buckets ........................................................ 156 Reference Information Section Approved Work Tools................................... 157

31200242 4 Table of Contents

31200242 5 Foreword Foreword Literature Information This manual must be stored in the operator's compartment in the literature holder or seat back literature storage area. This manual contains safety information, operation instructions, transportation information, lubrication information and maintenance information. Some photographs or illustrations in this publication show details or attachments that can be different from your machine. Guards and covers might have been removed for illustrative purposes. Continuing improvement and advancement of product design might have caused changes to your machine which are not included in this publication. Read, study and keep this manual with the machine. Whenever a question arises regarding your machine, or this publication, please consult your Caterpillar dealer for the latest available information. Safety The safety section lists basic safety precautions. In addition, this section identifies the text and locations of warning signs and labels used on the machine. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this machine. Operation The operation section is a reference for the new operator and a refresher for the experienced operator. This section includes a discussion of gauges, switches, machine controls, attachment controls, transportation and towing information. Photographs and illustrations guide the operator through correct procedures of checking, starting, operating and stopping the machine. Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the machine and its capabilities. Maintenance The maintenance section is a guide to equipment care. The Maintenance Interval Schedule (MIS) lists the items to be maintained at a specific service interval. Items without specific intervals are listed under the "When Required" service interval. The Maintenance Interval Schedule lists the page number for the step-by-step instructions required to accomplish the scheduled maintenance. Use the Maintenance Interval Schedule as an index or "one safe source" for all maintenance procedures. Maintenance Intervals Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first. Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in the maintenance intervals chart is necessary. Certified Engine Maintenance Proper maintenance and repair is essential to keep the engine and machine systems operating correctly. As the heavy duty off-road diesel engine owner, you are responsible for the performance of the required maintenance listed in the Owner Manual, Operation and Maintenance Manual, and Service Manual. It is prohibited for any person engaged in the business of repairing, servicing, selling, leasing, or trading engines or machines to remove, alter, or render inoperative any emission related device or element of design installed on or in an engine or machine that is in compliance with the regulations (40 CFR Part 89). Certain elements of the machine and engine such as the exhaust system, fuel system, electrical system, intake air system and cooling system may be emission related and should not be altered unless approved by Caterpillar. Machine Capacity Additional attachments or modifications may exceed machine design capacity which can adversely affect performance characteristics. Included would be stability and system certifications such as brakes, steering, and rollover protective structures (ROPS). Contact your Caterpillar dealer for further information.

6 31200242 Foreword Contact Information For: • Accident Reporting and Product Safety Publications • Current Owner Updates • Questions Regarding Product Applications and Safety • Standards and Regulations Compliance Information • Questions Regarding Product Modifications Contact: Product Safety and Reliability Department JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233 USA or Your Local JLG Office In USA: Toll Free: 877-JLG-SAFE (877-554-7233) Outside USA: Phone: 717-485-5161 or 717-485-6591 E-mail: ProductSafety@JLG.com

Caterpillar (CAT) TH220B/TH330B Telescopic Handlers (Telehandlers) Owners Manual (+ Maintenance Instruction Manual)

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