Caterpillar TH360B & TH560B Telehandler OEM Service & Repair Manual

Section Title Manual No. Service Manual Contents 31200265 Torque Specifications 31200268 Engine Disassembly & Assembly Engine Supplement 31200299 Power Train Systems Operation, Testing & Adjusting Power Train 31200270 Disassembly & Assembly Power Train 31200300 Vehicle Systems Schematic Hydraulic System 31200304 Systems Operation, Testing & Adjusting Hydraulic System 31200302 Systems Operation, Testing & Adjusting Steering System 31200273 Systems Operation, Testing & Adjusting Brake System 31200274 Machine Components Specs Machine Systems 31200306 Disassembly & Assembly Machine Systems 31200308 Electrical Systems Schematic - TH360B Electrical System 31200310 Schematic - TH560B Electrical System 31200311 Machine Troubleshooting Hydrostatic Transmission Electronic Control System 31200279 Systems Operation, Testing & Adjusting LSI System 31200280 Systems Operation, Testing & Adjusting Monitoring System 31200281 TH360B & TH560B Telehandler Service Manual S/N TBH00100 & After S/N TBP00100 & After 31200264 31200265 A

Specifications 31200268 December 15, 2006 Torque Specifications - TH220B, TH330B, TH360B, TH560B & TH580B Telehandlers S/N TBF00100 & After S/N TBG00100 & After S/N TBH00100 & After S/N TBP00100 & After S/N TBJ00100 & After

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.

31200268 1 Table of Contents Table of Contents Specifications Section General Information .............................................. 3 Introduction to Torque ...................................... 3 Torque-Turn ..................................................... 3 Torque Sequence ............................................ 3 Metric (ISO) Fasteners .......................................... 4 Metric (ISO) Nuts and Bolts ............................. 4 Metric (ISO) Taperlock Studs ........................... 4 Metric (ISO) Machine Screws .......................... 4 Hex Button Head Screw and Set Screw ............................................................... 4 English (SAE) Fasteners ....................................... 5 English (SAE) Nuts and Bolts .......................... 5 English (SAE) Taperlock Studs ........................ 5 English (SAE) Machine Screws ....................... 5 Hex Button Head Screw and Set Screws......... 6 Ground Engaging Tool (G.E.T.) Fasteners ........... 6 Installation of Fittings ............................................ 7 Installation of Split Flange Couplings ............... 7 Installation of Adjustable STOR Fittings........... 8 Straight Thread O-Ring Fittings ............................ 8 Plugs ................................................................... 10 Straight Thread O-Ring Plugs (Hex Drive) ..... 10 Straight Thread O-Ring Plugs (Socket Drive) 11 Drain Plugs with Straight Thread .................. 11 Straight Thread O-Ring Plugs (Mechanical Joint Tube Assemblies) .......................................... 11 O-Ring Face Seal Fittings ................................... 12 Bulkhead Nuts ..................................................... 12 Flare Fittings ....................................................... 13 37 Degree Flare Fitting .................................. 13 45 Degree Flare and 45 Degree Inverted Flare Fittings ........................................................... 13 Air Conditioning Fittings ...................................... 14 Air Brake Fittings ................................................. 14 Tapered Pipe Thread Fittings .............................. 14 Miscellaneous Fittings ......................................... 15 Hi Duty Tube Fittings (Shear Sleeve)............. 15 SAE Flareless Fittings .................................... 15 Flex Fittings .................................................... 15 Hose Clamps ....................................................... 15 Worm Drive Band Type Clamps..................... 15 Constant Torque Hose Clamps ...................... 16 Table of

2 31200268 Table of Contents

31200268 3 Specifications Section Specifications Section General Information Mismatched or incorrect fasteners can result in damage or malfunction, or personal injury. Take care to avoid mixing metric dimensioned fasteners and inch dimensioned fasteners. Introduction to Torque "Torque" is measured in terms of force and distance. Force is the amount of pushing or pulling applied at the end of the lever. Distance is the length of the lever that is being used. Torque values are given in the following units: NEWTON meters (Nm), pound inches (lb in), and pound feet (lb ft) This manual is intended to provide the operator with a reference. This manual will provide the standard torque settings for the following: bolts, nuts, plugs, fittings, and clamps. Exceptions to these torques are given in the Service Manual, if necessary. Be sure to use a torque wrench that has the proper range. Torque wrenches must be used properly in order to ensure that the correct torque is applied. Always use a smooth pull for torque wrenches. Do not jerk a torque wrench. Do not use adapters that change the length of the torque wrench. For the correct use of your torque wrench, refer to the instructions that were packaged with your torque wrench. Prior to installation of any hardware, ensure that components are in near new condition. Bolts and threads must not be worn or damaged. Threads must not have burrs or nicks. Hardware must be free of rust and corrosion. Clean reused fasteners with a noncorrosive cleaner. Lightly lubricate the threads of reused fasteners. Lightly lubricate the mating surface of the head of reused fasteners. Other applications for lubricating fasteners may also be specified in the Service Manual. The Service Manual may also specify the use of sealants and compounds. Note: Do not use sealants that are not specified in the Service Manual. Do not use compounds that are not specified in the Service Manual. Clean old compound from the bolt and from the hole before installation. Torque-Turn The torque-turn method is used when precise control over clamping force is required. There is an initial torque and an additional turn. The initial torque is required to bring all parts of the joint into contact. The additional turn provides the desired clamping force. Ensure that all fasteners have been torqued before you perform the additional turns. Turn the fastener according to the specified amount. The specified amount will normally be equal to or greater than 90°. The specified amount will normally be in 30° increments. Turns of 120° or 180° are preferred. Turns of 120° or 180° are easily measured by the points of the hex head of the fastener. Lubrication may be specified in order to reduce the effort that is required for the final turn. The use of the torque-turn method will allow the following: • Increase the life of the fastener. • Maximize the potential clamping force of a fastener. Typical applications are the following: • Track bolts • Sprocket bolts • Connecting rod bolts • Engine Cylinder Heads • Drive Shaft bolts Note: Too much tension on the bolt will cause the bolt to be stretched beyond the point of yield. The bolt will be permanently stretched. The bolt will loosen the grip on the parts that are being fastened. If the bolt is tightened again, the bolt will break. Do not reuse bolts that have been permanently stretched. Torque Sequence Unless the bolt tightening sequence is specified by the Service Manual, the fasteners should be tightened in a cross pattern. Use Step 1 through Step 5 unless the tightening sequence is specified: 1. Hand tighten all fasteners. Larger fasteners may require the use of a small hand wrench. 2. Torque all fasteners to 40% of full torque. 3. Torque all fasteners to 70% of full torque. 4. Torque all fasteners to full torque by using a cross pattern. Large flanges may require additional passes. 5. Apply at least one final full torque to all fasteners in a clockwise direction until all torque is uniform. Large flanges may require additional passes. Note: Final torque may be a turn.

4 31200268 Specifications Section Metric (ISO) Fasteners Metric (ISO) Nuts and Bolts Illustration 1 g00909614 Note: The following table has the recommended standard torque values for Metric nuts and bolts for use on Perkins engines. Table 1 Note: The difference between Caterpillar standard torque values and Perkins standard torque values are due to different classes of fasteners. Caterpillar uses class 10.9 fasteners. Perkins uses class 8.8 fasteners. The different class of fasteners have different tensile strengths. Metric (ISO) Taperlock Studs Note: The following table has the recommended standard torque values for metric nuts and bolts for use on Perkins engines. Table 2 Metric (ISO) Machine Screws Illustration 2 g00908932 Table 3 Hex Button Head Screw and Set Screw Illustration 3 g01186742 Table 4 Thread Size mm Torque M6 5 Nm (44 lb in) M8 22 Nm (16 lb ft) M10 44 Nm (32 lb ft) M12 78 Nm (60 lb ft) M14 124 Nm (90 lb ft) M16 177 Nm (130 lb ft) M18 200 Nm (150 lb ft) M20 400 Nm (300 lb ft) M24 790 Nm (580 lb ft) Thread Size mm Torque M6 5 Nm (44 lb in) M8 11 Nm (97 lb in) M10 18 Nm (13 lb ft) M12 25 Nm (18 lb ft) Thread Size mm Torque M1.6 0.10 ±0.01 Nm (0.9 ±0.1 lb in) M2 0.15 ±0.01 Nm (1.3 ±0.1 lb in) M2.5 0.35 ± 0.05 Nm (3.1 ±0 . 4 lb in) M3 0.50 ± 0.05 Nm (4.4 ±0 . 4 lb in) M4 1.70 ± 0.25 Nm (15.0 ± 2.2 lb in) M5 2.25 ± 0.25 Nm (19.9 ± 2.2 lb in) Thread Size mm Torque M3 .6± .1 Nm (5 ± 0.9 lb in) M4 2± .3 N m ( 1 8 ± 3 l b i n ) M5 4± .5 Nm (35 ± 4 lb in) M6 6± 1 N m ( 5 5 ± 9 l b in) M8 15 ±3 Nm (11 ± 2 lb ft) M10 30 ± 7 Nm (22 ± 5 lb ft) M12 50 ± 10 Nm (37 ± 7 lb ft) M14 80 ± 15 Nm (60 ± 11 lb ft) M16 125 ± 20 Nm (90 ± 15 lb ft) M20 250 ± 40 Nm(185 ± 30 lb ft) M24 425 ± 50 Nm (310 ± 37 lb ft) M30 850 ± 100 Nm (620 ± 75 lb ft) M36 1500 ± 200 Nm (1100 ± 150 lb ft)

31200268 5 Specifications Section English (SAE) Fasteners English (SAE) Nuts and Bolts Illustration 4 g00908911 Table 5 English (SAE) Taperlock Studs Table 6 English (SAE) Machine Screws Illustration 5 g00908932 Table 7 Thread Size Inch Torque 1/4 12 ± 3 N m ( 9 ± 2 lb ft) 5/16 25 ± 6 Nm (18 ± 4 lb ft) 3/8 47 ± 9 Nm (35 ± 7 lb ft) 7/16 70 ± 15 N m ( 5 0 ± 11 lb ft) 1/2 105 ±20 N m ( 7 5 ± 15 lb ft) 9/16 160 ± 30 N m ( 1 2 0 ± 2 2 lb ft) 5/8 215 ±40 N m ( 1 6 0 ± 30 lb ft) 3/4 370 ± 50 Nm (275 ± 37 lb ft) 7/8 620 ± 80 Nm (460 ± 60 lb ft) 1 900 ± 100 Nm(660±75 lb ft) 1 1/8 1300 ± 150Nm(960± 110 lb ft) 1 1/4 1800 ± 200 Nm (1320 ± 150 lb ft) 1 3/8 2400 ± 300 Nm (1780 ± 220 lb ft) 1 1/2 3100 ± 350 Nm (2280 ± 260 lb ft) Thread Size Inch Standard Torque 1/4 8 ± 3 Nm (6 ± 2 lb ft) 5/16 17 ± 5 Nm (13 ± 4 lb ft) 3/8 35 ± 5 Nm (26 ± 4 lb ft) 7/16 45 ± 10 N m ( 3 3 ± 7 lb ft) 1/2 65 ± 10 N m ( 4 8 ± 7 lb ft) 5/8 110 ±20 N m ( 8 0 ± 15 lb ft) 3/4 170 ± 30 N m ( 1 2 5 ± 2 2 lb ft) 7/8 260 ±40 N m ( 1 9 0 ± 30 lb ft) 1 400 ± 60 Nm (300 ± 44 lb ft) 1 1/8 525 ± 60 Nm (390 ± 44 lb ft) 1 1/4 750 ± 80 Nm (550 ± 60 lb ft) 1 3/8 950 ± 125 Nm(700±90 lb ft) 1 1/2 1200 ± 150Nm(880± 110 lb ft) Thread Size No. Torque 0-80 0.10 ±0.01 Nm (0.9 ±0.1 lb in) 1-64 0.15 ±0.01 Nm (1.3 ±0.1 lb in) 2-56 0.25 ± 0.02 Nm (2.2 ± 0.2 lb in) 3-48 0.35 ± 0.05 Nm (3.1 ± 0.4 lb in) 4-40 0.50 ± 0.05 Nm (4.4 ± 0.4 lb in) 5-40 0.70 ± 0.10 Nm (6.2 ± 0.9 lb in) 6-32 0.90 ± 0.10 Nm (8.0 ± 0.9 lb in) 8-32 1.70 ± 0.25 Nm (15.0 ± 2.2 lb in) 10-24 2.25 ± 0.25 Nm (19.9 ± 2.2 lb in) 12-24 3.40 ± 0.60 Nm (30.1 ± 5.3 lb in)

6 31200268 Specifications Section Hex Button Head Screw and Set Screws Illustration 6 g01186972 Table 8 Ground Engaging Tool (G.E.T.) Fasteners Ground Engaging Tools (G.E.T.) are secured by many types of bolts. Refer to Table 9 for the correct torque for the following combinations of fasteners for G.E.T.: • plow bolts and nuts • hex head bolts and nuts Table 9 (1) These values are only for Caterpillar bolts for cutting edges. Thread Size inch Torque #4 &#5 .6± .1 Nm(5±0.9 lb in) #6 & #8 2± . 3 N m ( 1 8 ± 3 lb in) #10 &#12 4± . 5 N m ( 3 5 ± 4 lb in) 1/4 6± 1 N m ( 5 5 ± 9 lb in) 5/16 13±3Nm(115±27 lbin) 3/8 25±6Nm(18±4 lb ft) 7/16 40±8Nm(20±6 lb ft) 1/2 60 ± 1 2 N m ( 4 4 ± 9 l b f t ) 9/16 85 ± 1 5 N m ( 6 5 ± 11 lb ft) 5/8 115±20Nm(85± 15 lb ft) 3/4 200 ± 40 Nm (150 ± 30 lb ft) 7/8 325 ± 40 Nm (240 ± 30 lb ft) 1 500 ± 65 Nm (370 ± 48 lb ft) 1 1/8 700 ± 90 Nm (520 ± 65 lb ft) 1 1/4 1000 ± 125 Nm (740 ± 90 lb ft) 1 3/8 1300 ± 150 Nm (960 ± 110 lb ft) 1 1/2 1700 ± 200 Nm (1260 ± 150 lb ft) Thread Size Torque(1) Inch Nm lb ft 5/8 inch 270 ± 40 200 ± 30 3/4 inch 475 ± 60 350 ± 45 7/8 inch 750 ± 90 550 ± 65 1 inch 1150 ± 150 850 ± 110 1 1/4 inch 2300 ± 300 1700 ± 220

31200268 7 Specifications Section Personal injury can result when installing plow bolts. The appropriate safety equipment must be worn when striking the plow bolts. To avoid injury to your eyes and ears, wear protective glasses and hearing protection during this procedure. Illustration 7 g00909058 Plow bolts must be installed properly. Refer to the following procedure for the correct installation of plow bolts. 1. Clean all surfaces that contact the bolt. Remove all occurrences of the following conditions:rust, paint, nicks, and burrs 2. Tighten the nut to the correct torque. Refer to Table 9 for the correct torque. 3. Use a hammer to strike the head of the bolt. The bolt must be struck with significant force. Note: The head of the bolt may be recessed below the mounting surface. Use a suitable punch in order to transfer the hammer blow to the bolt head. 4. Tighten the nut to the correct torque. Refer to Table 9 for the correct torque. Installation of Fittings Note: The tightening sequence of the fasteners that attach a tube assembly or hose assembly to the machine is very critical to the proper function of the machine. The sealing surfaces of the tube assembly or hose assembly should be secured squarely. The sealing surfaces of the tube assembly or hose assembly should be tightened to the serviced component (control valve, cylinder, hydraulic motor, etc). Perform this procedure prior to the final tightening of any clamps or clips that are used in order to fasten the tube assembly or the hose assembly to the machine. Fittings have different connections. Fittings may have two completely different ends. Be sure to use the proper torque for the end of the fitting that is used. The following list contains some common types of fittings. • Straight Thread O-Ring (STOR) • Adjustable Straight Thread O-Ring (STOR) • O-Ring Face Seal (ORFS) • Tapered Pipe Thread (NPT and NPTF) • 37 Degree Flare Fitting • 45 Degree Flare Fitting • 45 Degree Inverted Flare Fitting • Split Flange Coupling Installation of Split Flange Couplings 1. For a metal tube to hose installation, install the tube and tighten all bolts finger tight at the rigid end. 2. Install the hose and tighten all bolts finger tight. 3. Put the hose in a position so that the hose does not make contact with the machine or with another hose. Illustration 8 g00906528 4. Tighten the bolts on both connections to the proper torque. Follow the prescribed torque sequence for split flange connections. Refer to Illustration 8. Add the measurement of gap (A) to the measurement of gap (B). The total must not exceed 4.0 mm (0.16 inch). 5. Start the engine. 6. Move the implement control levers to all of the positions. 7. Look at the hose during movement of the implement. Ensure that the hose is not in contact with the machine or with other hoses. Note: For hoses that cross an articulation hitch, check for contact during articulation. For hoses that connect to the steering system, check for contact during steering. 8. Shut off the engine. 9. If the hose contacts other hoses or the machine during the test, loosen the bolts and reposition the hose. Repeat steps 3 through 8 until there is no contact.

Caterpillar TH360B & TH560B Telehandler OEM Service & Repair Manual

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