Caterpillar Cat TH580B Telehandler Parts Manual

31200254 July 11, 2008 Parts Manual TH580B TELEHANDLER S/N TBJ00100 thru TBJ00408

Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual. Delivery Date: Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number: Dealer Information Name: Branch: Address: D e a l e r C o n t a c t P h o n e N u m b e r H o u r s Sales: Parts: Service:

EFFECTIVITY PAGE 31200254 TH580B i July 14, 2006 - A - Original issue of manual. February 2, 2007 - B - Revised page559 and added Tier III engine information (Section C). July 11, 2008 - C - Revised Manual

EFFECTIVITY PAGE TH580B 31200254 ii

31200254    iii S/N TBJ00165 & AFTER TIER III ENGINE INFORMATION LOCATED IN SECTION C

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TABLE OF CONTENTS Name Page Name Page MAINTENANCE PARTS ........... ........... A10 INDEX ................... ................... A13 MACHINE ARRANGEMENT ......... ......... 1 BOOM & CHASSIS AR .......... .......... 1 CHASSIS AR ............... ............... 1 COMMON AR .............. .............. 2 ENGINE ARRANGEMENT .......... .......... 4 ENGINE & TRANSMISSION AR ...... ...... 4 ENGINE AR-PRIMARY .......... .......... 7 INSTALLATION AR-ENGINE . . ......  ........  1 2 BASIC ENGINE ............... ............... 13 BELT GP-SERPENTINE .......... .......... 13 BELT TENSIONER GP .......... .......... 14 CAMSHAFT GP . . . . . . . . . . . . .  . . . . . . . . . . . . .  16 COVER GP-FRONT HOUSING ...... ...... 17 COVER GP-VALVE MECHANISM . . . . . . . . . . 23 CRANKSHAFT GP ............  ...........  27 CYLINDER BLOCK GP ..........  ..........  30 CYLINDER HEAD GP . . . . . . . . . . .  . . . . . . . . . . .  34 DRAIN GP-ENGINE OIL .......... .......... 36 DRIVE GP-FAN .............. .............. 38 FASTENER GP-PULLEY .........  .........  41 FLYWHEEL GP .............. .............. 42 HOUSING GP-FLYWHEEL . . . . . . . .  . . . . . . . .  45 HOUSING GP-FRONT ..........  .........  50 LIFTING GP-ENGINE ...........  ...........  53 MOUNTING GP-ENGINE . . ...... .  .... .....  55 MOUNTING GP-ENGINE & TMSN ..... ..... 56 PAN GP-OIL ...... ...... ............. .....  64 PISTON  & ROD  GP . . . . . . . . . . . .  . . . . . . . . . . . .  68 PLUG GP-ENGINE ............ ............ 69 VALVE MECHANISM GP .........  .........  75 LUBRICATION SYSTEM .......... .......... 76 FILTER GP-ENGINE OIL ......... ......... 76 PUMP GP-ENGINE OIL ..........  ..........  80 COOLING SYSTEM .......................... 81 CONNECTION GP-WATER . . . . . . . .  . . . . . . . .  83 COOLER GP-ENGINE OIL ........ ........ 84 COOLER GP-FLTR BASE & ENG OIL . . . . . . 89 COOLING AR-HIGH AMBIENT TEMP ... ... 90 FAN GP-SUCTION ............ ............ 91 LINES GP-COOLANT ...........  ...........  94 PUMP GP-WATER............  ............  98 . RADIATOR GP ............................ 103 RECOVERY GP-COOLANT ........ ........ 105 AIR INLET AND EXHAUST SYSTEM ..... ..... 107 AIR CLEANER GP ............ ............ 107 ELBOW GP-AIR INLET .......... .......... 109 INDICATOR GP-AIR FILTER CHANGE ... ... 111 LINES GP-AIR .............. .............. 112 MUFFLER GP .............. .............. 115 SHIELD GP-EXHAUST .......... .......... 116 TURBOCHARGER GP . . . . . . . . . .  . . . . . . . . . .  119 FUEL SYSTEM ............... ............... 123 LINES GP-FUEL ............. ............. 123 PUMP GP-FUEL INJECTION ....... ....... 125 PUMP GP-FUEL TRANSFER & FILTER . . . . . . 1 TANK & MTG GP-FUEL .......... .......... 142 TANK GP-FUEL ............. ............. 145 ELECTRICAL AND STARTING SYSTEM ... ... 146 ALTERNATOR GP-CHARGING ...... ...... 146 BATTERY & WIRING GP ......... ......... 149 CONTROL & MTG GP-MACHINE ..... ..... 153 CONTROL GP-UNPROGRAMMED .... .... 154 ELECTRONICS GP-MACHINE ....... ....... 155 ELECTRONICS GP-WORK TOOL ..... ..... 156 GLOW PLUG GP .......................... 157 HEATER GP-JACKET WATER ....... ....... 158 INDICATOR GP-LOAD .......... .......... 162 INSTALLATION AR-SECURITY ...... ...... 163 INSTALLATION GP-SECURITY ...... ...... 164 LAMP GP-FLOOD ............ ............ 167 LAMP GP-HEAD & SIGNAL ........ ........ 168 LAMP GP-REGISTRATION PLATE ..... ..... 172 LAMP GP-STOP & TAIL .......... .......... 174 LAMP GP-WARNING BEACON ...... ...... 176 LIGHTING AR-FLOOD .......... .......... 177 LIGHTING GP-FLOOD .......... .......... 178 LIGHTING GP-FRONT .......... .......... 181 LIGHTING GP-REAR ........... ........... 183 LIGHTING GP-ROADING ......... ......... 185 LIGHTING GP-WARNING ......... ......... 185 PANEL GP-FUSE ............. ............. 187 PLUG GP-CONNECTOR ......... ......... 189 SENSOR & MTG GP-POSITION ...... ...... 190 SENSOR GP-POSITION ......... ......... 191 SENSOR GP-PRESSURE ......... ......... 192 SENSOR GP-SPEED ........... ........... 193 STARTING MOTOR GP-ELECTRIC .... .... 194 SWITCH GP-DIFFERENTIAL LOCK .... .... 195 SWITCH GP-DISCONNECT ........ ........ 196 31200254 TABLE OF CONTENTS A1

TABLE OF CONTENTS Name Page Name Page SWITCH GP-ROCKER . . . . . . . . . .  . . . . . . . . . .  199 WIRING GP-AIR CONDITIONER ......  ......  202 WIRING GP-AUXILIARY .........  .........  205 WIRING GP-BOOM . . . . . . . . . . . .  . . . . . . . . . . . .  206 WIRING GP-CAB .............  .............  209 WIRING GP-CHASSIS ..........  ..........  227 WIRING GP-COUPLER ....... . . .  ..........  231 WIRING GP-ELECTRONIC CONTROL . . . . . . 235 WIRING GP-ENGINE ....... ....  .... .......  237 WIRING GP-LEVELING .......... .......... 240 WIRING GP-TRANSMISSION CONTROL ................................ 246 POWER TRAIN .............................. 247 AXLE & MOUNTING GP ......... ......... 247 AXLE AR ................. ................. 249 AXLE GP-DRIVE & STEERING ...... ...... 250 CLUTCH GP ............... ............... 259 COUNTERSHAFT GP-TRANSMISSION ........... ........... 261 DIFFERENTIAL & BEVEL GEAR GP .... .... 262 DIFFERENTIAL GP ........................ 264 DRIVE GP-FLEXIBLE COUPLING ..... ..... 266 FILTER & MTG GP-POWER TRAIN .... .... 267 FILTER GP-OIL .............. .............. 268 HOUSING & FLANGE GP-AXLE ...... ...... 269 HOUSING GP-AXLE ........... ........... 271 LINES GP-DIFFERENTIAL LOCK ..... ..... 277 LINES GP-TRANSMISSION OIL ...... ...... 278 PLANETARY GP-FINAL DRIVE ...... ...... 280 POWER TRAIN AR ............ ............ 281 SHAFT GP-AXLE ............. ............. 282 SHAFT GP-DRIVE ............ ............ 284 SHAFT GP-INPUT ............ ............ 287 SHAFT GP-OUTPUT ........... ........... 288 SHAFT GP-PUMP DRIVE ......... ......... 289 TIRE & RIM GP .............. .............. 290 TRANSMISSION AR ........... ........... 294 TRANSMISSION GP ........... ........... 295 VALVE GP-TIRE ............. ............. 302 WHEEL AR ............... ............... 303 FRAME AND BODY ............. ............. 305 BRACE GP-CYLINDER .......... .......... 305 CONVERSION AR-ROADING ....... ....... 307 CONVERSION GP-ROADING .......  .......  308 COUNTERWEIGHT GP .......... .......... 311 COVER GP-ACCESS ........... ........... 312 DOOR GP-ACCESS ........... ........... 313 ENCLOSURE GP-ENGINE . .... . . .  . .... . . .  316 FENDER & MOUNTING GP ........  ........  319 FRAME GP ............... ............... 320 FRAME GP-MAIN .............  .............  325 GUARD GP-BOTTOM ........... ........... 326 HANDHOLD GP ............. ............. 327 HITCH GP ................ ................ 328 HOOD GP ................  ................  332 LEVELING AR-FRAME .......... .......... 333 PANEL GP-SOUND SUPPRESSION .... .... 334 REFLECTOR GP ............. ............. 338 STEP GP ................ ................ 339 BRAKING SYSTEM .......................... 342 CONTROL GP-PARKING BRAKE . . . . . . . . . . 344 LEVER AS ................................ 346 CONTROL GP-SERVICE BRAKE ..... ..... 347 CYLINDER GP-BRAKE .......... .......... 348 LEVER GP-HAND CONTROL ....... ....... 350 LEVER AS ................................ 352 LINES GP-BRAKE ............ ............ 353 MOUNTING GP-CABLE .......... .......... 355 STEERING SYSTEM ............ ............ 356 KNOB GP-STEERING .......... .......... 356 LINES GP-STEERING .......... .......... 357 STEERING COLUMN GP .........  .........  361 STEERING GP-HYDRAULIC ....... ....... 365 HYDRAULIC SYSTEM ........... ........... 366 ACCUMULATOR GP-HYDRAULIC ..... ..... 366 COOLER & MTG GP-HYDRAULIC OIL ... ... 372 COOLER GP-HYDRAULIC OIL ...... ...... 374 CYLINDER & MTG GP-BOOM ....... ....... 375 CYLINDER & MTG GP-CARRIAGE .... .... 377 CYLINDER & MTG GP-COMPENSATING ...................... 379 CYLINDER & MTG GP-COUPLER ..... ..... 380 CYLINDER & MTG GP-FRAME LEVEL ... ... 381 CYLINDER & MTG GP-STABILIZER .... .... 382 CYLINDER & MTG GP-TELESCOPING ... ... 383 CYLINDER & MTG GP-TILT ........ ........ 384 CYLINDER & VALVE GP-BOOM ...... ...... 385 CYLINDER & VALVE GP-COUPLER .... .... 386 CYLINDER & VALVE GP-FRAME LVL ... ... 387 CYLINDER & VALVE GP-STABILIZER ... ... 388 CYLINDER & VALVE GP-TELESCOPE ... ... 389 CYLINDER & VALVE GP-TILT ....... ....... 390 CYLINDER GP-BOOM .......... .......... 391 CYLINDER GP-CARRIAGE ........ ........ 392 CYLINDER GP-COMPENSATING ..... ..... 393 CYLINDER GP-FRAME LEVELING .... .... 394 CYLINDER GP-STABILIZER ........ ........ 395 CYLINDER GP-TELESCOPING ...... ...... 396 CYLINDER GP-TILT ........... ........... 397 FITTING GP-HYDRAULIC ......... ......... 399 HANDLE GP-HAND PUMP ........ ........ 400 HYDRAULIC AR ............. ............. 401 A2 TABLE OF CONTENTS 31200254

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Caterpillar Cat TH580B Telehandler Parts Manual

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