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Operation and Maintenance Manual

1. Table 10 Lubricant Viscosities for Ambient Temperatures Compartment or System Type and Classification OilViscosities T Min Max Min Max SAE 0W 20 40 10 40 50 SAE 0W 30 40 30 40 86 Cat DEO SAE OW 40 40 40 40 104 vat Engine Crankease Cat Arctic DEO SYN SAENWSO 90 090 1 02 90 Cat ECF 109 SAE 5W 40 30 50 22 122 CG 4 Multigrade 9 SAE 10W 30 18 40 0 104 SAE 10W 40 18 50 0 122 SAE 15W 40 9 5 50 15 122 SAE 0W 20 40 40 40 104 SAE 0W 30 40 40 40 104 SAE 5W 30 30 40 22 104 Hydraulic System Service Brake Cat TDTO SAE 5W 40 30 40 22 104 System Transmission PR ua die SR SAE 10W 0 40 4 104 Differentials and Final Drives commercial TO 4 5 30 10 50 50 122 SAE 10W 30 20 40 4 104 SAE 15W 40 15 50 5 122 CatTDTO TMS 20 50 4 122 0 Supplemental heat is recommended for cold soaked starts below the minimum ambient temperature Supplemental heat may be required for cold soaked starts that are above the minimum temperature that is stated depending on the parasitic load and other factors Cold soaked starts occur when the engine has not been operated for a period of time allowing the oil to become more viscous due to cooler ambient temperatures CF oils are not recommended for Caterpillar 3500 Series and smaller Direct Injection DI diesel engines
2. E Safety Section Safety Section Safety Messages 7 4 8 Matos TER stration 3 8 Safety Section 31200242 Mustraton 4 lustration 5 25 Zo 4 901106462 901106485 31200242 9 Safety Section Tert There are several specific safety messages on these machines The exact location of the messages and the description of the messages are reviewed in this section Please understand all safety messages Make sure that all of the safety messages are legible Clean the safety messages or replace the safety messages if you cannot read the words Replace the illustrations if the illustrations are not legible When you clean the safety messages use a cloth water and Soap Do not use solvent gasoline or other harsh chemicals to clean the safety messages Solvents gasoline or harsh chemicals could loosen the adhesive that secures the safety message Loose adhesive will allow the safety message to fall Replace any safety message that is damaged or missing If a safety message is attached to a part that is replaced install a safety message on the replacement part Any Caterpillar dealer can provide new safety messages Do Not O
3. continued 92 31200242 Operation Section Table 7 contd Type of Hitch TH220B 2200 TH330B TH330 Maximum weight of towed attachment 12000 kg 12000 kg 12000 kg 12000 kg and freight 26400 Ib 26400 Ib 26400 Ib 26400 Ib Maximum vertical weight component Mechanical Hitch on the auto hitch interface in lowest 000 on i id ts position Maximum vertical weight component 1250 kg 1000 kg 1850 kg 1200 kg onthe hitch interface in any other 25040 22000 97015 position Maximum weight of towed attachment 12000 kg 12000 kg 12000 kg 12000 kg and freight 264001b 264001b 2640010 264001b Maximum vertical weight component k 2500 2500 k 2500 k 2500 Clevis Hitch onthe hitch interface inthe lowest 24040 25046 250049 50019 position Maximum vertical weight component lt 1350 kg 1200 kg 1450 kg 1300 kg onthe hitch interface in any other 90 2840 819010 206016 position continued 31200242 93 Operation Section Table 7 contd Type of Hitch TH220B TH220 TH3300 Maximum weight of towed attachment 12000kg 12000 kg 12000 kg 12000 kg and freight 26400 Ib 26400 Ib 26400 Ib 26400 Ib Maximum vertical weight component 2 ET A 2500 kg 2450 kg 2500 kg 2450 kg Manual Swivel Hitch on the hitch interface in the lowest
4. Mustration 11 00831915 If the primary exit is blocked exit the machine through the rear window Use the ring on the rear window latch in order to pull out the retaining pin This action will unlock the rear window Transmission and Hydraulic Oil 4 If equipped this message is located next to the sight gauge for the transmission and hydraulic istration 12 01059267 Check the transmission and hydraulic oil when the oil is warm Do not add oil when the system is cold If the system is cold and you add oil you can overfill the system This could cause machine damage Refer to Operation and Maintenance Manual Transmission and Hydraulic System Oil Level Check for the correct procedure 22 Safety Section 31200242 Xx R134a kg PAG 4C 2959 Mustration 13 500934175 Do not work on the air conditioning system until you have read the service manual and you understand the service manual Tire Pressures 6 This message is located behind the protection cover on the left side of the cab Mustration 14 00031919 Personal injury can result from improper tire inflation Refer to Operation and Maintenance Manual Tire Inflation Information for more information Machine Security System 7 If equipped this message is located on the left side of the steering column ahead of the engine start switch Hustration 15 900951606 This machine is equipped
5. 31200242 105 Maintenance Section Tables NACD Standards Weight of Model Tire Size Ply Rating Tire Pressure ov Foam per oem Wheel 310 kPa 1 TH220B 17 5LR24xM27 12 45 psi No TH2208 15 5 25 SGL 2A 12 es Yes oe 3 500 70 R24 MX37 350 kPa a TH330B 19 5 LR24 51 psi a 320 kPa 262 kg TH330B 15 5 25SGL 2A 12 46 psi Yes 678 b 370 kPa 288kg TH330B 13 00 24 SGG 2ATL 12 54 psi Yes 51416 400 kPa a TH330B 15 5825 12 amt No 450 kPa 262 kg 13 00 24 CATERPILLAR 12 pelos Yes can 15 5 25 400 kPa 233 kg Ta CATERPILLAR 58 psi 514 1 The R in the tire size signifies radial construction Table 9 EAME Standards Weight of Model Tire Size Ply Rating Ti Operating Compatible Foam per Pressure with Foam Wheel 810 TH220B 1 17 5LR24XM27 12 No 45 psi 250 262 Kk TH2208 15 5 25SGL 2A 12 x Yes d 36 psi 578 Ib 410 kPa TH220B 15 5 80 24 16PR 16 No 59 psi 500 70 R24 MX37 350 kPa 1 Radial pen No 440 70 R24 XM37 350 kPa TH330B 1 ferien 12 No 320 262 15 5 25SGL 2A 12 2 Yes 46 psi 578 Ib 400 TH330B 1 15 5R25XHA 12 No 58 psi 155 25 400 kPa 283 kg TH330B 12 Ye CATERPILLAR 68 psi idi 514b 1 The R in the tire size signifies radial construction Refer to the topics in the following list for m
6. 539019 6500 E 6390 b position Maximum vertical weight component 4 g 1000 kg 1350 kg 1200 kg on the hitch interface in any other position 2750 1b 2200 Ib 2970 6 2640 Ib Maximum weight of towed attachment 3000 kg 3000 kg 3000 kg 3000 kg and freight 66001 660010 6600 1b 6600 Ib Retrieval Hich 4 Maximum vertical weight component 500 kg 500 kg 500 kg 500 kg on the hitch interface 1100 Ib 1100 1b 1100 b 1100 0 1 A work tool is attached to the front of the machine No work tool attached to the front of the machine The hitch is equipped with an additional Mechanical Auto Hitch Only for off highway use Refer to Types of Towing Hitches and Hydraulic Piton Hitch Services for illustrations of the different types of hitches that are available Note When you operate the machine with a towed attachment check the engine temperature and the transmission temperature more frequently Check the temperatures more frequently when you operate the machine on a grade If either temperature rises above the normal operating range for the machine operate the machine in a lower gear Types of Towing Hitches and Hydraulic Services Mustration 163 100098 Your machine may be equipped with a number of different types of towing hitch Refer to the appropriate section that is listed below for a description of the operation of the hitch that is on your machine In order to connect the attachment of towing remove
7. Fire Extinguisher Location Stopping the Engine if an Electrical Malfunction Tire Information Occurs 86 31200242 Leaving the Machine Transportation Information Shipping the Machine Roading the Machine Lifting and Tying Down the Machine Towing Information Towing the Machine Types of Towing Hitches and Hydraulic Services Hydraulic Hitch and Hydraulic Service Engine Starting Alternate Methods Engine Starting with Jump Start Cable Equipment Lowering with Loss of Hydraulic 95 96 96 Maintenance Section Maintenance Access Access Doors and Covers Tire Inflation Information Tire Inflation with Air Tire Pressure Tire Inflation Pressure Adjustment Tire Damage Tire Replacement Wheel and Tire Installation Lubricant Viscosities and Refill Capa Lubricant Viscosities Capacities Refill SOS Information Maintenance Support Welding on Machines and Engines with Electronic Controls Maintenance Interval Schedule Axle Breathers Clean Replace Backup Alarm Test Battery Recycle Battery or Battery Cable Inspect Replace Belt Inspect Replace Inspect Replace Boom Cylinder Pin Lubricate Boom Head Section Lubricat Boom Pivot Shaft Lubricate Boom Telescoping Cylinder Air Purge Boom Wear Pad Clearance Inspect Adjust Adjustment Boom and Frame Inspec Braking System Test Service Brake Parking Brake Cab Air Filt
8. Your machine may be equipped with a hydraulic quick coupler Illustrations in the following procedure show a carriage which is equipped with forks The procedure is applicable to all work tools with the same types of mounting points 900975278 4 Extend the boom slowly until the quick coupler tubes contact the carriage Raise the boom until the quick coupler tubes are engaged with the hooks Installation Procedure Musraton 85 91060075 o 1 Move the red portion of the switch for the quick Senne oin coupler downward and press the top of the switch Hold the top of the switch until the quick coupler pins are fully disengaged Release the switch 2 Lower and extend the boom approximately 2 m 6 6 ft so that the quick coupler can be seen from the cab Position the quick coupler in line with the carriage 5 Tilt back the quick coupler until the lower part of the carriage is in contact with the quick coupler 6 Press and hold the bottom of the switch for the quick coupler in order to engage the quick coupler pins Release the switch after the pins are fully engaged An improperly installed work tool could become dislodged from the machine during operation This could cause injury or death Do not operate the machine until you have positive indication that the quick coupler pins are fully engaged Mustration 86 900975380 3 Tilt the quick coupler forward until the quick coupl
9. A WARNING n Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury 31200242 19 Safety Section Hand High Pressure 28 Tier Ill This message is located on the top of the fuel manifold A WARNING l M CANTO WARNING Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fuel spray may cause a fire hazard Failure to follow inspection maintenance and service instructions may cause personal injury or death Universal Warning 29 Tier Ill This message is located on both sides of the valve mechanism cover base WARI H WARNING Do not operate or work on this equipment unless you have read and understand the instructon and warnings in the Operation and Maintenance Manuals Failure to follow the instructions or heed the warnings could result in serious injury or death NING Additional Messages There are several specific messages on these machines The exact location of the messages and the description of the messages are reviewed in this section Please understand all messages Make sure that all of the messages are legible Clean the messages or replace the messages if the words or images are unreadable When you clean the messages use a cloth water and soap Do not use solvent gasoline or other harsh chemicals to clean the messages So
10. Push joystick control 14 Quick Coupler Tilt Backward Push joystick control 14 to the left in order to tilt the quick coupler backward When joystick control 14 is released the joystick control will return to the HOLD position Boom Extend Push thumb wheel 14B 105 forward order to extend the boom When the thumb wheel is released the thumb wheel will return to the HOLD position Note The boom will not extend when the transmission control is in the REVERSE position The function for extending the boom will resume if the transmission is neutralized by the service brake the parking brake or the transmission neutralizer button Boom Retract Pull thumb wheel 14B backward in order to retract the boom When the thumb wheel is released the thumb wheel will return to the HOLD position Auxiliary Controls Press switch 14E in order to toggle between the hydraulic circuits for the auxiliary 1 and auxiliary 2 Press switch 14C in order to operate an actuator for a work tool in the positive direction Press switch 14D in order to operate an actuator for a work tool in the negative direction Switches 14 14 and 14D are not operated proportionally x d Cx Oy D E lostration 63 901147848 When auxiliary 2 is selected indicator light 14G will be illuminated The speed of the following functions is governed by the amount of movement of the joystick con
11. Turbocharger Inspect 153 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace 22148 Every 3000 Service Hours or 3 Years Cooling System Water Temperature Regulator Replace Engine Mounts Inspect 31200242 113 Maintenance Section Axle Breathers Clean Replace 1 Park the machine on level ground Fully retract the boom and fully lower the boom Move the transmission control to the NEUTRAL position and ensure that the parking brake is engaged Shut off the engine IHustration 169 Front axle breather b lt 00850516 Mustration 171 Rear axle breather 2 Clean the area around the breathers Remove the breathers from the front and rear axles 3 Wash the breathers in clean nonflammable solvent Wipe the breathers dry and check the breathers for damage 4 Replace the breathers if the breathers are damaged Install the clean breathers back into the axles Backup Alarm Test The backup alarm is mounted at the rear of the machine Turn the engine start switch to the ON position in order to perform the test Apply the service brake Move the transmission control lever to the REVERSE position The backup alarm should start to sound immediately The backup alarm will continue to sound until the transmission control lever is moved to the NEUTRAL position or to the FORWARD position The backup alarm has one
12. 25 Steering Mode Control 5 Transmission Control 22 Transmission Neutralizer Control 4 Operator Controls Side Console Boom Floodlights 9 Cab Floodlights 8 Fan Control 1 Front Window Washer 5 Front Window Wiper 4 Heating and Air Conditioning Control 3 Hydraulic Lockout Control 11 Rear Window Wiper and Washer 7 Roof Wiper Washer 6 Temperature Control 2 Towing Hitch Control 10 Operator Station Parking Brake Adjust Parking Plate and Decal Locations Plate Locations and Film Locations Certification Serial Number Product Information Section 31200242 Radiator Core Clean Reference Information Section Refrigerant Dryer Replace Roading the Machine Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect 5 Safety Messages Safety Section Seat Seat Adjustment Storage Compartment Seat Belt Extension of the Seat Belt Seat Belt Adjustment for Non Retractable Seat Belts Seat Belt Adjustment for Retractable Seat Belts Seat Belt Inspect Seat Belt Replace Sound Information and Vibration Informatior Sound Level Vibration Level Specifications Intended Use Stopping the Engine if an Electrical Malfunction Occurs Stopping the Engine Stopping the Machine Table of Contents
13. Before installation apply thread lock compound to bolts that secure wear pads Mustration 189 1 800999755 Remove bolts 5 that secure the rear top wear pads Install sufficient shims in order to reduce the clearance to 0 75 mm 0 030 inch Tighten the bolts to a torque of 75 5 N m 55 4 Ib ft Remove bolts 6 that secure the rear side wear pads Install sufficient shims in order to reduce the clearance to 0 75 mm 0 030 inch at each side Install sufficient shims in order to produce an equal clearance between the boom sections at each side It may be necessary to install more shims at one side than the other side Tighten the bolts to a torque of 75 5 Nm 55 4 Ib ft Mustration 190 3 Mustration 191 4 Mustration 192 900857793 Raise the sufficiently above the stand Fully extend the boom and lower the boom to the horizontal position Support the boom under the second section 00999286 Remove bolts 7 that secure the bottom wear pads Install sufficient shims in order to reduce the clearance to 0 75 mm 0 030 inch Tighten the bolts to a torque of 75 5 Nm 55 4 Ib ft 00865472 118 Maintenance Section 31200242 5 Remove bolts 8 that secure the side wear pads Install sufficient shims in order to reduce the clearance to 0 75 mm 0 030 inch at each side Install sufficient shims in order to produce an equal clearance between the wear pads an
14. Check for both vertical clearance and for horizontal clearance Check for the presence of overhead obstructions Check for electrical power lines Keep the machine and the attachments away from electrical power lines at least 8 m 25 ft Check for steam lines Check for compressed air lines Check for changes in the stability of the surface of the job site Check trenches that have been backfilled Check deteriorated roofs of basements and of tunnels Check sewers and service ducts When a load is picked up or when the boom is extended ensure that the surface on the job site offers even resistance for the tires Also when a load is picked up or when the boom is extended ensure that the surface on the job site offers even penetration for the stabilizers Make sure that the load charts and the instruction plates are in place and that the load charts and the instructions can be read Do not operate the machine until you understand the correct method of using the load charts On machines that are equipped with a cab secure the door in the shut position Secure the windows either 28 Safety Section 31200242 the open position or in the shut position Ensure that all windows are clean for the best visibility Inspect the condition of the seat belt and of the mounting hardware Replace any parts that are worn or damaged Regardless of appearance replace the seat belt after three years of use Do not use a seat
15. Check with the proper officials in order to obtain the required licenses and other similar items Inflate the tires to the correct air pressure Use a self attaching inflation chuck and stand behind the tire tread during the inflation Refer to Operation and Maintenance Manual Tire Inflation Check Only operate the machine in two wheel steer mode when you are roading a machine Refer to Operation and Maintenance Manual Operator Controls for more information Travel with the boom fully retracted and the boom lowered as far as possible while you are maintaining an adequate ground clearance for the coupler or for the work tool Locking out the boom and auxiliary functions before roading the machine is a legal requirement in some countries For information on locking out all boom and auxiliary hydraulic functions refer to Operation and Maintenance Manual Operator Controls Travel at a moderate speed Observe all speed limitations when you road the machine 88 Operation Section 31200242 When you travel for long distances schedule stops in order to allow the tires and components to cool Stop for 30 minutes after 40 km 25 miles or stop for 30 minutes after every hour Lifting and Tying Down the Machine WARNING A machine may shift if improper procedures or equipment are used for lifting and tying down for transport Ensure that proper equipment and procedures are used for lifting and tying machi down for tr
16. Cleaning Primary Air Filter Elements When you clean the inside of the pleats direct the air along the pleats Inspect the primary element after you clean the primary element Clean the inside of the filter housing and clean the cover Pay particular attention to the sealing surface of the outlet tube which fits inside the primary element Install a clean primary element 9 Install the cover Wustration 233 Reset the engine air filter service indicator by pressing button 5 31200242 181 Maintenance Section 11 Start the engine If the engine air filter service indicator 6 illuminates on the dash panel install a new primary element Refer to the Alert Indicators section of Operation and Maintenance Manual Monitoring System for further information Also if the exhaust smoke is black install a new primary element Replace the engine air filter secondary element when you replace the primary filter element Refer to the Operation and Maintenance Manual Engine Air Filter Secondary Element Replace 12 Close the engine enclosure Cleaning Primary Air Filter Elements NOTICE Caterpillar recommends certified air filter cleaning services available at participating Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do no
17. On machines that are equipped with cabs the windshield should also be closed Safety glasses are recommended when flying hazards exist for machines with cabs and machines with open canopies If the work material extends above the cab top guards and front guards should be used Typical examples of this type of application are listed below Demolition applications Rock quarries Forestry products Additional guards may be required for specific applications or work tools The Operation and Maintenance Manual for your machine or your work tool will provide specific requirements for the guards Consult your Caterpillar dealer for additional information 32 31200242 Safety Section 31200242 33 Product Information Section Product Information Section General Information Lifting Capacities The instability of the machine could result in injury or death In order to ensure the stability during operation the following conditions must be observed The tires must be inflated correctly or the tires must have the correct amount of ballast if equipped The machine must be level The correct load chart must be referenced for the work tool that is installed on the machine The specified weights and load centers must never be exceeded The machine must never be moved when the boom is raised above the travelling position The boom angle reference scale and boom extension reference scale are standard equipment
18. Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates stration 245 1 check the oil level on the final drive position the machine on level ground Position the plug for the final drive on the horizontal center line of the wheel 2 Fully retract the boom and fully lower the boom Move the transmission control to the NEUTRAL position and engage the parking brake Shut off the engine 3 Clean the area around the plug Remove the plug 4 Check that the oil is level with the plug hole If necessary add oil through the plug hole 5 Clean the plug and reinstall the plug 6 Repeat Step 1 through Step 5 for each of the three remaining final drives al Drive Oil Sample Obt Hot oil and components could cause personal injury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar product
19. Remove the water temperature regulator and the gasket f mo ow ge c NOTICE If the water temperature regulator is installed incorrectly it will cause the engine to overheat 7 Install a new water temperature regulator and a new gasket 8 Install water temperature regulator housing 6 9 Install washers and bolts 5 Tighten the bolts 10 Install hose 4 Tighten hose clamp 3 11 Install hose 2 Tighten hose clamp 1 12 Refill the cooling system Refer to Operation and Maintenance Manual Capacities Refill and the appropriate Service Manual 31200242 127 Maintenance Section Differential Oil Change NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Park the machine on level ground Fully retract the boom and fully lower the boom Move the transmission control to the NEUTRAL position and ensure that the parking brake is engaged Shut off the engine Rear Axle Differential T Mustration 222 00952909 1 Clean
20. Tire Inflation Information Tire Inflation with Air Use a self attaching inflation chuck and stand behind the tread when inflating a tire Proper inflation equipment and training in using the equipment are necessary to avoid over inflation A tire blowout or rim failure could result from improper or misused equipment Before inflating tire install on the machine or put tire in restraining device NOTICE Set the tire inflation equipment regulator at no more than 140 kPa 20 psi over the recommended tire pressure Refer to Operation and Maintenance Manual Tire Shipping Pressure for operating pressures Tire Pressure Personal injury could result from improper tire inflation A tire blowout or rim failure could result from improper or misused equipment Use a self inflating chuck and stand behind the tread when inflating a tire Proper inflating equipment and training in using the equipment are necessary to avoid over inflating Before inflating tire put the tire in a restraining device The tire inflation pressures that are shown in the following table are cold inflation pressures Stand behind the tire tread and use an inflation chuck on the air line with a Caterpillar 49 6524 Pressure Gauge or 1P 0545 Pressure Gauge If these pressure gauges are not available use an equivalent tool to check the tire pressure Tire pressures for tires operated in the NACD and EAME areas are shown in the following tables
21. exits For additional information see Operation and Maintenance Manual Alternate Exit Daily Inspection Hot oil and hot components could cause personal injury Do not allow hot oil or hot components to contact skin At operating temperature the engine coolant is hot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand Remove the cooling system pressure cap slowly to relieve pressure Cooling system conditioner contains alkali Avoid contact with the skin and eyes to prevent personal injury NOTICE Accumulated grease and oil on a machine is a fire hazard Remove this debris with steam cleaning or high pressure water at least every 1000 hours or each time any significant quantity of oil is spilled on a machine NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note For maximum service life of the mac
22. raised or when the stabilizers are lowered Check that the frame is level after you lower the stabilizers If necessary adjust the level of the frame Use the stabilizers in order to make the adjustment Do not adjust the position of the stabilizers when the boom is raised If the frame is not level do not raise the boom Before you transport a load or before you elevate a load the load must be adequately secured on the forks or on the work tool Any loads such as pipe scaffolding lumber and beams must be adequately secured Use lifting slings that are approved and use lifting slings that are load tested Also all wire ropes or chains must be properly maintained The wire ropes and chains must meet local regulations You must know the load carrying capacity of these devices and you must know the correct use of these devices Work Tools Use of non approved work tools on Telehandler machines could result in injury or death Before installing a work tool on this machine ensure that it is approved by Caterpillar and that a Caterpillar load chart covering its use is installed in the machin cab NOTICE When certain work tools are fitted the work tools can contact the front tires or the front fenders This situation can occur when the boom is retracted and the work tool is rotated fully forward Always check for interference when first operating a new work tool Before you use a work tool ensure that the work tool is ap
23. stration 26 900955167 The load charts are located on the dash panel at the right side of the instrument cluster Ensure that the correct load chart is used The chart is intended for the type of attachment that is represented by symbol at the top of the chart The load charts may be in metric units meters and kilograms or conventional units feet and pounds When the machine is operated on tires the weight of the intended load determines the maximum height above ground The weight of the intended load also determines the maximum distance that is between the load center of gravity and the front wheels The machine boom has two scales which must be used for reference with the load chart in order to assess the lift operation The boom extension reference scale gives an indication of the boom length The letters B and C correspond to the same letters on the load chart The letter A on the load chart corresponds to the fully retracted position of the boom The letter D on the load chart corresponds to the fully extended position of the boom Mustraton 27 900955168 Boom angle reference scale 1 gives an indication of the angle of the boom Follow the instructions below in order to assess the intended load 1 Carefully position the machine The machine should be as close as possible to the intended load For more information on operating the machine refer to the appropriate topic in the Operation Sect
24. without rotating locknut 21 on the screw Measure the distance from the head of adjustment screw 20 to the top of locknut 21 Record this measurement This measurement will be required later when adjustment screw 20 is reset Spin locknut 21 to the head of adjustment screw 20 Tum adjustment screw 20 by hand into load control valve 19 in order to contact the ball Attach a wrench to adjustment screw 20 and turn the screw clockwise until the screw becomes tight Note Do not use excessive force when a wrench is used to tum adjustment screw 20 3 Locate control valve 14 Refer to Illustration 148 4 Measure the distance from the head of adjustment screw 16 to the top of locknut 15 Completely remove locknut 15 Tum the screw clockwise by hand until the screw is tight Use an allen wrench to tum the adjustment screw clockwise in order to lower the boom Allow the boom to fully lower Note If necessary turn adjustment screw 16 counterclockwise in order to stop the boom from lowering 5 When the boom has fully lowered turn adjustment screw 16 in a counterclockwise direction until the adjustment screw is returned to the original position 6 Tighten locknut 15 Note Do not start the engine until you have reset adjustment screw 16 and adjustment screw 20 7 Start the engine Raise and lower the boom Extend and retract the boom approximately 300 mm 12 inch 8 Position the boom to th
25. 1 Tilt back the quick coupler Lower and extend the boom approximately 2 m 6 6 ft so that the quick coupler can be seen from the cab p 2 If equipped disconnect the hydraulic lines for the Mostation 92 attachment from the changeover valve 2 Remove the retaining clip from pin 3 Remove the pin 3 Tilt the quick coupler forward until the quick coupler tubes 1 are below the level of hooks 2 Mustration 90 901060075 3 Move the red portion of the switch for the quick coupler downward and press the top of the switch Hold the top of the switch until the quick coupler pins are fully disengaged Release the switch 4 Lower the boom and tilt the quick coupler forward until the carriage is on the ground If necessary 31200242 69 Operation Section 4 Extend the boom slowly until the quick coupler tubes contact the carriage Raise the boom until the quick coupler tubes are engaged with the hooks ixl Mustration 94 00975322 5 Tilt back the quick coupler until the lower part of the carriage is in contact with the quick coupler 6 Install pin 3 and the retaining clip 7 Install auxiliary hydraulic hoses or control cables to the machine if equipped Removal Procedure 1 Extend the boom approximately 2 m 6 6 ft so that the carriage is just clear of the ground and visible from the cab Tilt back the quick coupler Disconnect the hydr
26. 6 When switch 6 is released the cooling fan will return to the normal rotation NOTICE Before operating the reversible fan control ensure that the machine is in an area clear of personnel and other objects that may be effected by the airborne debris blown from the radiator grill Engage the parking brake and move the transmission control 22 to the NEUTRAL position Depress switch 6 only when the engine speed is less than 1000 rpm The engine speed can be increased while the fan is operating in the reverse direction The engine speed must be reduced to less than 1000 rpm before switch 6 is released Note Do not hold the switch for more than thirty seconds at a time Frame Leveling Control 7 If equipped frame leveling control switch 7 is a three position switch The frame leveling control is used to level the machine when the machine is on an uneven surface The frame leveling control can cause the frame to tilt to the left or to the right The maximum amount of tilt is 10 degrees in either of these directions Lower the boom before you use the frame leveling control The boom must be close to the ground Press the right side of switch 7 in order to lower the right side of the frame The frame rotates clockwise Press the left side of switch 7 in order to lower the left side of the frame The frame rotates counterclockwise When switch 7 is released the frame leveling control returns to the HOLD positio
27. 900955706 Pull out exterior door latch 1 in order to open the door from the outside 4 Mustration 140 00955718 Push interior door latch 2 toward the front of the cab in order to open the door from the inside The door should be closed while you operate the machine Engine Starting Engine Starting WARNING Diesel engine exhaust contains products of combustion which could cause personal injury Always start and operate the engine in a well ventilated area and if an enclosed area vent the exhaust to the outside 1 Adjust the operator seat Refer to Operation and Maintenance Manual Seat for more information 2 Adjust the steering column Refer to Operation and Maintenance Manual Operator Controls for more information 3 Fasten the seat belt y lt M stration 150 901117943 4 Move the transmission control 1 to the NEUTRAL position N The engine will not start unless the transmission control is in the NEUTRAL position 5 Move the parking brake control 2 to the ENGAGED position Mustration 151 901117946 6 the engine start switch key 3 to the RUN position in order to initialize the machine The 31200242 85 Operation Section machine will run a self test that must be completed before you start the engine 7 Before you crank the engine depress the accelerator control pedal slightly 8 Tum the engine start switch key to the START posit
28. Do not level the frame when the boom is raised Mustration 103 900832857 11 Use the joystick control to move the load away from the stack Mustration 104 00832858 12 Retract the boom and lower the load to the travel position before the machine is moved or before the stabilizers are raised If necessary level the frame Make sure that the area behind the machine is clear of personnel and obstacles before backing up Mustration 106 00892860 14 If you are operating with stabilizers lower the stabilizers until the front tires are just clear of the ground Mustration 107 00832861 15 Raise the boom and extend the boom until the load is directly over the set down position Do not exceed the maximum angle of the boom and do not exceed the maximum length of the boom Use the load chart to determine the maximum angle of the boom and the maximum length of the boom 72 Operation Section 31200242 Proceed with caution when you approach the maximum angle and or extension indicated by the load chart If you are not sure that the machine is stable retract the boom Lower the load to the travel position Move the machine closer to the load placement location If the machine cannot be moved closer to the load placement location the load placement location is outside the capacity of the machine The load cannot be placed at the intended load placement location lustration 108 90
29. F Special configurations for different ambient temperatures may be available Consult your Caterpillar dealer for additional information on special configurations of your machine Machine Operation Check for proper operation of the steering controls and of the braking controls for the machine while the machine is moving slowly in an open area Check the steering controls and the braking controls while the boom is retracted fully and the work tool is just clear of the ground With the machine in a stationary position check for the proper operation of the other controls for the machine Unless the machine frame is level do not 31200242 29 Safety Section raise the boom The boom should only be extended if the machine frame is level Extend the boom and retract the boom several times in order to warm the hydraulic oil Travel Only operate the machine while you are in a seat The seat belt must be fastened while you operate the machine Only operate the controls while the engine is running When you travel on the roadways operate the machine in two wheel steer mode only Before you maneuver the machine make sure that no personnel are between the machine and the work tools Use caution when you change direction of travel Use caution when you operate the boom Use caution when you are picking up loads or when you are setting down loads Travel in the direction of the best visibility Travel with the boom fully retracted A
30. Inspect Replace Boom Telescoping Cylinder Air Purge Boom and Frame Inspect Cab Air Filter Clean Replace Circuit Breakers Test Cooling System Pressure Cap Clean Replace Engine Air Filter Primary Element lean Replace Engine Air Filter Secondary Element Replace Fuel System Prime Fuel Tank Cap Clean Fuses and Relays Replace Oil Filter Inspect Parking Brake Adjust Radiator Core Clean Window Washer Reservoir Fill Window Wiper Inspect Replace 118 118 2113 Every 10 Service Hours or Daily Backup Alarm Test Braking System Test Cooling System Coolant Level Check Engine Oil Level Check 118 Fuel System Water Separator Drain 138 Fuel Tank Water and Sediment Drain 2141 Indicators and Gauges Test 144 Seat Belt Inspect 148 112 Maintenance Section 31200242 Tire Inflation Check Transmission and Hydraulic System Oil Level Check Wheel Nut Torque Check 153 Windows Clean 154 Work Tool Inspect Replace 154 Every 100 Service Hours or Monthly Longitudinal Stability Indicator Test 144 Every 250 Service Hours Cooling System Coolant Sample Level 1 Obtain Engine Oil Sample Obtain 124 133 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 Obtain Every 500 Service Hours Differential Oil S
31. Install the oil filler cap 5 Close the engine enclosure Engine Oil Sample Obtain Park the machine on level ground Fully retract and fully lower the boom Move the transmission control to the NEUTRAL position and ensure that the parking brake is engaged AES e 500951796 Mustration 238 1 Open the engine enclosure The oil level dipstick is located on the front of the engine 2 Maintain the oil level between the ADD mark and the FULL mark on the dipstick Note When you operate the machine on severe slopes the oil level in the engine crankcase must be at the FULL mark on the dipstick Mustration 240 Obtain an engine sample while the engine is running The sampling valve for the engine is located in the engine compartment on the filter head for the engine oil filter Refer to the appropriate Service Manual for information that pertains to obtaining a sample of the engine oil 184 Maintenance Section 31200242 Engine Oil and Filter Change Hot oil and hot components could cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to coll
32. Roof Wiper Washer Push the top of switch in order to operate the window wiper for the roof Push the switch and hold the top of switch in order to activate the pump for the washer and the window wiper for the roof Release the top of the switch The switch will return to the OFF position Rear Window Wiper and Washer 7 Rear Window Wiper and Washer Push the top of the switch in order to operate the rear window wiper Push the switch and hold the top of switch in order to activate the pump for the washer and the rear window wiper Release the top of the switch The switch will return to the OFF position Cab Floodlights 8 Cab Floodlights Push the top of switch in order to turn on the cab floodlights Push the bottom of the switch in order to turn off the cab floodlights 31200242 63 Operation Section Boom Floodlights 9 Boom Floodlights Push the top of switch in order to turn on the boom floodlights Push the bottom of the switch in order to tur off the boom floodlights Towing Hitch Control 10 The switch for the towing hitch is a three position switch In order for the hitch to be functional the hitch must be connected to the trailer service valve Hydraulic Hitch Control Push in the top of the switch in order to raise the hitch Push in the bottom of the switch in order to lower the hitch The switch will return to the MIDDLE position when you release the switch Mustration
33. Section 31200242 11 Install the key for the battery disconnect switch Turn the battery disconnect switch to the ON position Belt Inspect Replace Inspect Note If a new belt is installed check the decal on the belt tensioner 2 after 30 minutes of operation A belt is considered to be used after 30 minutes of operation 1 Park the machine on level ground Fully retract the boom and fully lower the boom Move the transmission control to the NEUTRAL position and engage the parking brake Shut off the engine 2 Open the engine enclosure 173 Equipped with a reversible fan 3 Inspect the condition of belt 1 4 Replace the belt if any of the following conditions exist excessive cracking excessive wear excessive damage Inspect the free arm stop of the belt tensioner 2 The free arm stop must be aligned with the black line which is on the decal of the belt tensioner 2 If the free arm stop is in the red area replace the belt Close the engine enclosure Replace Park the machine on level ground Fully retract the boom and fully lower the boom Move the transmission control to the NEUTRAL position and engage the parking brake Shut off the engine Open the engine enclosure the battery disconnect switch to the OFF position Remove the retaining bolts for the fan guard Slide the guard out of the engine enclosure Rel
34. Section 31200242 Drive Shaft Universal Joint Bolts Check MHustraion 230 Locations of the Universal Joints 231 Locations of the Universal Joints Ensure that the bolts for the front drive shaft universal joints and the rear drive shaft universal joints are tightened to the correct standard torque Refer to the appropriate Service Manual for the correct torque Engine Air Filter Primary Element Clean Replace Note The primary air filter element can be used up to three times if the element is properly cleaned and inspected Replace the primary air filter element if the element has been in service for 500 hours or six months This replacement should be performed regardless of the number of cleanings 5 592 900950658 Wustration 232 Open the engine enclosure Slide out retaining clip 1 Release cover 2 from air filter housing 3 by rotating counterclockwise Remove the cover from the housing Remove primary element 4 from filter housing 3 To avoid dislodging any dust take care to avoid touching the element against the sides of the housing Inspect the primary element If the pleats or the seals are damaged discard the primary element Replace a damaged primary element with a clean primary element If the primary element is not damaged you may clean the primary element Refer to Operation and Maintenance Manual
35. Tire Inflation Check Tire Inflation Information Tire Inflation Pressure Adjustment Tire Inflation with Air Tire Information Tire Pressure Towing Informatior Towing the Machine Towing a Disabled Machin Towing with the Machine Transmission and Hydraulic System Oil Change Transmission and Hydraulic System Oil Filter Replace Transmission and Hydraulic System Oil Level Checi Transmission and Hydraulic System Oil Sample Obtai Transmission and Hydraulic System Tank Breather Clean s Transportation Information Turbocharger Inspect w Welding on Machines and Engines with Electronic Controls Wheel Nut Torque Check Window Washer Reservoir Fill Window Wiper Inspect Replace Windows Clean Work Tool Inspect Replace Buckets Auxiliary Hydraulic Connections Bale Handler Boom Extension Broom Buckets Carriages and Forks Connecting a Work Tool Disconnecting a Work Tool General Operating Guidelines Hopper Lifting Hook Material Handling Arm Utility Fork with Grapple and Ejector Identification Information Machine Operation 162 31200242 Index MG JLG Industries Inc TRANSFER OF OWNERSHIP To Product Owner If you now own but ARE NOT the original purchaser of the product covered by this manual we would like to know who you are For the purpose of receiving safety related bulletins it is very important to
36. are tight Ensure that the battery caps are correctly placed Ensure that batteries in the stalled machine are not frozen Make sure that the batteries have enough electrolyte Use a face shield and protective clothing in order to perform this task 8 The positive ends of the jump start cable are red Connect one positive end of the jump start cable to the positive cable terminal of the discharged battery Some machines have battery sets Note Batteries that are in series may be in separate compartments Use the terminal that is connected to the starter solenoid This battery or battery set is starting motor 31200242 97 Operation Section Do not allow the positive cable clamps to contact any metal except for the battery terminals 9 Connectthe other positive end of the jump start cable to the positive cable terminal of the electrical source 10 Connect one negative end of the jump start cable to the negative cable terminal of the electrical source 11 Finally connect the other negative end of the jump start cable to the frame of the stalled machine Do not connect the jump start cable to the battery post Do not allow the jump start cables to contact the following components the fuel lines the hydraulic lines and any moving parts 12 Start the engine of the machine that is being used as an electrical source or energize the charging system on the auxiliary power source 13 Wait at least two minutes before
37. attempted If the load chart indicates that the lift operation is within the capacity of the machine attempt to make the operation but proceed with care Remember that the load may weigh more than the estimate for the load The load chart is for estimating the lift operation only Mustration 28 000913591 Typical Load Chart 31200242 35 Product Information Section Specifications stration 29 gooossaot Side view stration 30 900855455 Rear view Specifications are shown for basic machines without a work tool on the quick coupler Table 1 TH220B Machine 2250 mm 7 ft 4 6 inch 4740 mm 15 ft 6 6 inch Overall Height A Overall Length B Overall Width C 2350 mm 7 ft 8 5 inch Wheel Base 2950 mm 9 ft 8 1 inch Ground Clearance 425 mm 1 ft 4 7 inch Approximate Weight 6420 kg 14154 Ib 1 This is the unloaded weight with no work tools The weight that is listed is for machines that are equipped with res that are filed with air Table 2 TH330B Machine 2270 mm 7 ft 5 3 inch 4960 mm 16 ft 3 3 inch 2350 mm 7 ft 8 5 inch 3050 mm 10 ft 0 1 inch 425 mm 1 ft 4 7 inch 6910 kg 15234 Ib Overall Height A Overall Length B Overall Width C Wheel Base Ground Clearance Approximate Weight 1 This is the unloaded weight with no work tools The we
38. blades are worn or damaged or if streaking occurs 154 Maintenance Section 31200242 Windows Clean Mustration 291 900856748 Use commercially available window cleaning solutions to clean the windows Stand on the ground in order to clean the outside windows unless handholds are available Work Tool Inspect Replace In order to help minimize unexpected costly repairs and downtime inspections need to be carried out on a regular basis The interval between the inspections depends on the age of the work tool and the severity of the operating conditions More frequent inspections will be required of older work tools and work tools that are used in particularly severe operating conditions To perform a proper inspection the work tool must thoroughly cleaned It is impossible to inspect the work tool properly if the work tool is dirty Early detection and repair of faults will ensure continued operation of the work tool Also early detection and repair will improve the availability of the work tool Repair of faults will also reduce the risk of accidents The work tool should only be repaired by a qualified Caterpillar dealer in accordance with the manufacturers recommendations However if you decide to carry out your own repairs consult your Caterpillar dealer for the recommended repair techniques Inspect the work tool before the work tool is attached to the machine Forks Forks can wear out The
39. by both dealers and customers Note Level 1 results may indicate a need for Level 2 Analysis Mustraton 218 0101068 Refer to the Operation and Maintenance Manual Access Doors and Covers for the location of the service points Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of SOS analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant Keep the unused sampling bottles stored in plastic bags Keep the lids on empty sampling bottles until you are ready to collect the sample Complete the information on the label for the sampling bottle before you begin to take the samples Use a designated pump to collect the sample in order to avoid contamination Obtain coolant samples directly from the coolant tank You should not obtain the samples from any other location Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see the appropriate Service Manual or consult your Caterpillar dealer 3120024
40. cab the rear window can be used as an alternate exit secondary exit If the primary exit is blocked exit the machine through the rear window Mustraton 45 900951976 Use ring 1 on rear window latch 2 in order to pull out retaining pin 3 This action will unlock the rear window Tractor Cab 2 Mastration 46 If your machine is equipped with a tractor cab a hammer is located on the deck plate for the seat If the primary exit and the secondary exit are blocked use the hammer to break the right hand window in order to exit the machine Note Do not use the right hand window as an altemate exit except in an emergency situation For repair of the windows or replacement of the windows consult your Caterpillar dealer Seat The seat must be adjusted in order to suit the operator When you are sitting against the back of the seat the seat must also be adjusted so that you are allowed full travel of the foot controls Lock the seat into position before you operate the machine in order to prevent movement of the seat Always use the seat belt when you operate the machine Seat Adjustment Mustration 47 00850445 Fore aft Lever 1 Lift the fore aft lever and slide the seat to the required position Release the fore aft lever in order to lock the seat in place Seat Recline Lever 2 This allows the backrest to be set at one of three different angles Push the seat recline lever rearwar
41. caused by friction and by normal wear Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings to the crankshaft and to other parts This can result in larger particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage 146 Maintenance Section 31200242 Parking Brake Adjust If the machine moves during the Parking Brake test in Operation and Maintenance Manual Braking System Test perform the following procedure in order to adjust the parking brake 1 Apply the service brakes Wustraion 262 900851281 2 Disengage the parking brake 3 As you view the parking brake handle from the front of the machine and look toward the rear of the machine turn the handle clockwise for one half of a turn 4 Repeat the Parking Brake test procedure in Operation and Maintenance Manual Braking System Test If the machine moves during the parking brake test then perform the adjustment procedure again If you run out of adjustment on the parking brake handle refer to the appropriate Service Manual Radiator Core Clean If your machine is not equipped with an air conditioning system use compressed air in order to remove dust and other debris from the radiator core If
42. cumulative effects of age abrasion corrosion overloading and misuse can severely weaken forks More frequent inspections will be required of older work tools and work tools that are used in particularly severe operating conditions or in a rental fleet perform a proper inspection the forks must be thoroughly cleaned It is impossible to inspect the forks properly if the work tool is dirty Inspect the forks before the forks are attached to the machine Perform the yearly inspection for the forks prior to the start of each contract for all machines that are operating in a rental fleet Inspect the forks for deformation Check that the upright of the fork is at 90 degrees to the blade of the fork Check the fork for cracks in the metal Closely inspect the area around the heel of the fork This is the area of the fork that is subject to the greatest stresses If a crack is visible take the fork out of service immediately until the fork can be thoroughly examined Keep a record of each fork in order to establish a routine of regular inspection Include the following initial information in the record Manufacturer of the fork Type of fork Original size of fork section Original length of the fork Record the date of each inspection and the results of each inspection Ensure that the following information is included Amount of wear on the blade Any damage failure or deformation which might impair the use of
43. damaging or dislodging the load Do not move the machine while the boom is raised or while the boom is extended If it is necessary to reposition the machine lower and retract the boom first The transmission neutralizer switch operates in conjunction with the service brake The switch must be in the OFF position when you travel on the roadways Do not use the machine for lifting loads in tandem with other machines The combined load weight and force of the other machine can exceed machine capacity This could cause the machine to turn over 66 Operation Section 31200242 Ensure that the correct machine load capacity chart is used for the work tool that is installed Ensure that you use the correct machine load capacity chart for operation on tires Make sure that you understand the machine load capacity chart before you attempt to lift a load Be alert at all times for changing conditions which may affect the stability of the machine Extending the boom or lowering the boom increases the outreach of the load This decreases the capacity and the stability of the machine Retract the boom before you lower the boom Be careful when you position a load or when you engage a load Be careful when you are using clamps or when you are using cylinders Also be careful when you are using a device that pierces the load Ensure that the operation can be completed without pushing the load off the stack Note Refer to Operation and
44. direction Move thumb wheel 14C backward in order to operate an actuator for a work tool in the negative direction Switch 14 is not operated proportionally ustration 72 901147848 When auxiliary 2 is selected indicator light 14G will illuminated The speed of the following functions is governed by the amount of movement of the joystick control and engine speed Boom raise Boom lower Boom extend Boom retract For smooth operation first increase the engine speed from low idle Then move joystick control 14 slowly until the attachment is moving at the required speed The speed of the quick coupler tilt forward and quick coupler tilt backward is governed by the amount of movement of thumb wheel 14B Move joystick control 14 diagonally in order to simultaneously extend the boom or retract the boom while the boom is being raised or lowered Move joystick control 14 diagonally At the same time operate thumb wheel 14B in order to simultaneously tilt the quick coupler while the boom is being operated in two directions Adjustable Armrest 15 Wustration 73 31200242 57 Operation Section Armrest 15 is adjustable In order to access the adjustment knobs for armrest 15 rotate armrest 15 upward In order to adjust the angle of armrest 15 rotate knob 15A To increase the angle of the armrest turn the knob clockwise To decrease the angle of the armrest
45. extend cylinder after the hydraulic oil has been changed It may also be necessary to purge air from the boom extend cylinder after any disassembly of hydraulic system components Normally the hydraulic system will purge air from the boom extend cylinder but air can be trapped Air in boom extend cylinder can cause erratic boom motion 1 If necessary warm the hydraulic oil by raising the boom and lowering the boom 116 Maintenance Section 31200242 Wostration 184 900837537 2 Retract and lower the boom Position the machine a down slope Engage the parking brake 3 Fully extend the boom and retract the boom six times This will purge air from the cylinders 4 Move the machine back to level ground and check the operation of the boom motion Boom Wear Pad Clearance Inspect Adjust The clearance between the wear pads and the boom section should be checked at more frequent intervals when the machine is operated in severe conditions Note Sand or grit particles can cause accelerated wear to the wear pads 1 Park the machine in a clear area on level ground and chock the wheels WARNING The boom could fall if a control is moved or if a hydraulic component fails This could cause personal injury or death Support the boom with stands Do not rely on the cylinder to hold the boom up lustration 185 900857782 2 Raise the boom to the horizontal position and fully extend the boom Install a suitable
46. forks from service when the length of the blade is no longer adequate for the intended loads 296 901001990 6 Check markings for readability Renew the markings if the markings are not legible Buckets Mounting Bracket Inspect the mounting brackets on the bucket and ensure that the mounting plates are not bent or otherwise damaged Inspect the angled plate and ensure that the plate is not bent or otherwise damaged If any wear or damage is suspected consult your Caterpillar dealer before you use the bucket Bucket Cutting Edges Personal injury or death could result from bucket falling Block the bucket before changing bucket cutting edges 1 Raise the bucket Place a block under the bucket 2 Lower the bucket to the block Do not block up the bucket too high Block up the bucket so that the bucket is high enough to remove the cutting edges and the end bits 3 Remove the bolts Remove the cutting edge and the end bits 4 Clean the contact surfaces 5 Use the opposite side of the cutting edge if this side is not worn 6 Install a new cutting edge if both edges are wom 7 Install the bolts Tighten the bolts to the specified torque Refer to the appropriate Service Manual for more information 8 Raise the bucket Remove the block 9 Lower the bucket to the ground 10 After a few hours of operation check the bolts for proper torque Bucket Wear Plates Personal i
47. 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 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 Maintenance Manual and Service Manual It is prohibited for any
48. has drifted consult your Caterpillar dealer Do not operate the machine until any necessary repairs are completed or until any necessary adjustments are completed Turn adjustment screw 16 and adjustment screw 18 in a clockwise direction Tighten the screws Tighten locknut 15 and locknut 17 102 31200242 Operation Section 31200242 108 Maintenance Section Maintenance Section Maintenance Access Access Doors and Covers Mustration 166 900954656 Access door 1 is located on the right side of the machine Open the access door in order to access the following components Batteries Belt Circuit breakers Coolant tank and pressure cap Water temperature regulator Engine air filters Engine mounts Engine oil dipstick Engine oil filler cap Engine oil filter Engine crankcase drain line Fuel injectors Fuel system priming pump Primary fuel filter water separator element Radiator Turbocharger 3 Mustration 167 901206261 In order to open protection cover 4 on the left side of the machine unlock lock 3 and turn lock 5 counterclockwise Then pull latch 2 outward Open the protection cover in order to access the following components Primary cab air filter Fuses and relays Fuel tank and filler Hydraulic oil tank and filler cap Sight gauge for the hydraulic oil 104 Maintenance Section 31200242
49. hydraulic component is removed Sudden movement of the boom could cause personal injury or death Remove any load from the work tool retract the boom and install the boom cylinder lock or a suitable supporting stand before working under a raised boom When you are working under the boom it is necessary to install a boom cylinder lock on the boom cylinder Installation and Removal Procedures Installation 1 Park the machine on level ground Retract and lower the boom Move the transmission control to NEUTRAL Engage the parking brake 2 Raise the boom to an angle of approximately 20 degrees Stop the engine Remove the engine start switch key If equipped remove the battery disconnect switch key Note Make sure that the front axle and the top of the main frame are clear of debris before you attempt to install the boom cylinder lock Clean the area if necessary 3 Check that the cylinder lock is the correct type for your machine Inspect the boom cylinder lock for damage Inspect pad 4 Do not use the cylinder lock if the cylinder lock is damaged or if pad 4 is loose or missing 4 Place the cylinder lock onto the top of the main frame above the front axle Allow sufficient access to stand on the flat area of the frame Make sure that both of your hands are free Approach the machine from the front Use the fender bracket if equipped and the edge of the main frame for support Step onto the axle Then step o
50. if necessary Note Your machine may not utilize all of the fuses that are listed here You should only replace these fuses with fuses of the same type and current rating Use the fuse puller in order to remove the fuses The fuse puller is located to the left of the fuse panel 13 14 15 16 78 21 22 2324 25 26 27 28 29 30 3132 1 je 2y Mastraton 257 Illustration 257 shows the location of fuses The fuses are numbered from the top to the bottom Blu amp RI amp e v o 8 15 dew che Pa lc 80 els peo pe u Bom Bape meme Decal on fuse access cover A decal with the positions of the fuses is located on the inside of the access cover The location of the fuse matches the location of the pictograph on the decal Frame Level 1 10 AMP Differential Lock 2 10 Front Window Wiper 3 10 AMP Rear Window Wiper 4 15 High Speed Air Conditioner Blower 5 88 25 Low Speed Air Conditioner Blower 6 96 15 31200242 148 Maintenance Section Hydraulic Auxiliary Circuit 7 10 Steering Alignment 8 10 AMP Joystick Control 9 10 AMP Spare Position 10 Access Platform 11 10 AMP PHS Circuit 12 15 Turn Signals 13 10 Work Light
51. in welded structures Pay particular attention to the mounting points for the following parts Boom Cab Axles 31200242 119 Maintenance Section Engine Transmission Towing attachment if equipped Mountings on the frame Stabilizers if equipped Tie down lugs stration 204 Stabilzer and rollover protection structure 900836172 Lower stabilizers 2 until the stabilizer pads are touching the ground Inspect each stabilizer fully Inspect the beams stabilizer pads mounting hardware cylinders and the pivot pins If equipped inspect Rollover Protection Structure ROPS 3 or inspect Falling Objects Protection Structure FOPS 3 Inspect the ROPS or the FOPS carefully Do not attempt to straighten the structure Do not attempt to repair the structure by welding Consult your Caterpillar dealer if damage is found to the ROPS or to the FOPS O Mustration 205 Boom and quick coupler 900836174 Inspect all sections of boom 4 Inspect the boom after the boom is extended fully and the work tool is on the ground Completely inspect quick coupler 5 Also inspect the work tool Mustration 206 Pivot pins and anchor points 900836176 Inspect all pivot pins and inspect all anchor points for wear Braking System Test Service Brake Check the area around the machine Make sure that the area is clear of personnel and obstacles Check th
52. keep JLG Industries Inc updated with the current ownership of all JLG products JLG maintains owner information for each JLG product and uses this information in cases where owner notification is necessary Please use this form to provide JLG with updated information with regard to the current ownership of JLG products Please return completed form to the JLG Product Safety amp Reliability Department via facsimile or mail to address as specified below Thank You Product Safety amp Reliability Department JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Telephone 717 485 5161 Fax 717 485 6573 NOTE Leased or rented units should not be included on this form Mfg Model Serial Number Previous Owner Address Country Telephone Date of Transfer Current Owner Address Country Telephone Who in your organization should we notify Name Title 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 Inform
53. of intersection for the values of the boom angle reference and the boom extension reference This point of intersection is the load zone for 80 units intended load of 45 units is less than the value in the load zone so the load chart indicates that the load is within the capacity of the machine Example 2 The weight of the intended load is 125 units The boom angle reference is 40 degrees The boom extension reference scale is at B With reference to the load chart Y is the point of intersection for the values of the boom angle reference and the boom extension reference This point of intersection is in the load zone for 125 units The intended load of 125 units is the same value as the value in the load zone so the load chart indicates that the load is at the maximum capacity of the machine Example 3 The weight of the intended load is 27 units The boom angle reference is 22 degrees The boom extension reference scale is approximately 66 percent between D and full extension Full extension is E on the load chart With reference to the load chart Z is the point of intersection for the values of the boom angle reference and the boom extension reference This point of intersection is in the load zone for 20 units The intended load of 27 units is greater than the value the load zone so the load chart indicates that the load is beyond the capacity of the machine The lift operation must not be
54. or death In order to ensure the stability during operation the following conditions must be observed The tires must be inflated correctly and the tires must have the correct amount of ballast if equipped The machine must be level The frame level switch must never be operated when the boom is raised The frame level switch must never be operated when the stabilizers are lowered The switches for the stabilizers must never be operated when the boom is raised The correct load chart must be referenced for the work tool that is installed on the machine The specified weights and load centers must never be exceeded The machine must never be moved when the boom is raised above the carry position If equipped use the frame leveling control in order to level the machine on uneven ground Use the level indicator in order to verify that the frame is level Level the frame before you lift a load Never operate the frame leveling control when you have raised the boom Always use the boom in order to engage the load with the work tool Do not move the machine in order to engage the load with the work tool Always use the boom in order to position the load with the work tool Do not move the machine in order to place the load with the work tool Always use the boom in order to disengage the load from the work tool Do not move the machine in order to disengage the load from the work tool Operate the boom smoothly in order to avoid
55. order to open protection cover 3 unlock lock 2 and tum lock 4 counterclockwise Then pull latch 1 outward Mustration 253 901204058 2 Locate fuel filler cap 6 and remove the padlock if equipped 3 Lift latch 5 and turn the fuel filler cap counterclockwise This will release the fuel filler cap 4 Remove fuel filler cap 6 and inspect the fuel filler cap Replace the fuel filler cap if the fuel filler is damaged 5 Install the fuel filler cap 6 Install the padlock if equipped 7 Close the protection cover Fuel Tank Water and Sediment Drain Personal injury or death could result from failure to adhere to the following procedures Fuel leaked or spilled onto hot surfaces or electrical components could cause a fire Clean up leaked or spilled fuel Do not smoke while working on the fuel system Tum the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regu
56. raise the boom and lower the boom For starting below 18 C 0 F the use of additional cold weather starting aids is recommended Any of the following may be required A coolant heater A fuel heater heater An extra capacity battery Before you operate the machine in temperatures below 23 C 10 F consult your Caterpillar dealer Engine and Machine Warm Up NOTICE Keep engine speed low until the engine oil pressure alert indicator goes out If the alert indicator does not go out within ten seconds stop the engine and investigate the cause before starting again Failure to do so can cause engine damage 1 Do not increase the engine speed from low idle Do not apply load to the engine during the first ten seconds of operation 2 Check all other gauges and indicators All gauges and indicators should show normal operation 3 Operate the engine at low idle for at least five minutes in order to warm the oil More than five minutes warm up time may be required when the machine is operated in low temperature conditions Use this warm up time to help warm the hydraulic oil by operating the joystick control in order to raise and lower the boom 86 Operation Section 31200242 Par 9 Stopping the Machine NOTICE Park on a level surface If it is necessary to park on a grade block the wheels securely Engage the parking brake Do not engage the secondary brake while the machine is movi
57. sound level The sound level is not adjustable Battery Recycle Always recycle a battery Never discard a battery Always return used batteries to one of the following locations A battery supplier An authorized battery collection facility Recycling facility Battery or Battery Cable Inspect Replace 1 Tum the engine start switch key to the OFF position Turn all switches to the OFF position 2 The battery disconnect switch if equipped is located in the engine compartment above the battery Turn the key for the battery disconnect Switch to the OFF position Remove the key Refer to Operation and Maintenance Manual Battery Disconnect Switch for further information 3 Disconnect the negative battery cable at the battery disconnect switch Note Some machines are equipped with two batteries Do not allow the disconnected battery cable to contact the battery disconnect switch or the machine 4 Disconnect the negative battery cable from the battery 5 Disconnect the positive cable at the battery end 6 Inspect the battery terminals for corrosion Inspect the battery cables for wear or damage 7 If necessary make repairs If necessary replace the battery cables the battery or the battery disconnect switch 8 Connect the positive cable at the battery end 9 Connect the negative battery cable at the battery 10 Connect the negative battery cable at the battery disconnect switch 114 Maintenance
58. stand under the first section in order to prevent the boom from falling unexpectedly Do not support the second section To properly support the boom use the following tools Table 14 Required Tools PartNumber Description Quantity 85 7641 Tube 1 4C 6486 Stand 85 7615 1 85 7625 Collar 1 85 8048 Saddle 1 3 Stop the engine Mustraton 186 4 Measure clearances 1 between the wear pads and the side of the boom sections at each side 5 Measure clearances 2 between the wear pads and the top of the boom sections Instron 187 900057765 6 Raise the boom and remove the stand Fully retract the boom and support the boom in the horizontal position In order to support the boom install the stand under the second section or install cribbing under the quick coupler 31200242 117 Maintenance Section ustration 188 7 00099284 Remove the cover from the rear of the chassis and measure clearances 3 between the rear wear pads and the side of the boom sections at each side Measure clearances 4 between the rear wear pads and the top of the boom sections The clearance at each location must not exceed 1 5 mm 0 06 inch If the clearances are excessive adjustments must be made Adjustment Note The bolts that secure different wear pads are not identical lengths Do not mix the bolts Clean all used bolts
59. steer mode circle steer mode is selected 2 Turn the steering wheel until the left rear wheel is in line with the side of the machine Instron 60 3 Change to two wheel steer and tum the steering wheel until the left front wheel is in line with the side of the machine 4 Change to either crab steer mode or circle steer mode as required Steering Arrangement with Self Aligning Rear Steering Your machine may be equipped with self aligning rear steering The self aligning feature ensures that the rear wheels are aligned before the steering mode is changed When switch 5 is pressed by the operator the machine will not change to the desired steering mode unless the rear wheels are in the straight ahead position If switch 5 is pressed by the operator and the rear wheels of the machine are not aligned the current steering mode will remain selected The indicator for the current steering mode on the display panel will remain and the desired mode indicator will flash When the rear wheels are moved to the straight ahead position by the operator the steering mode will then change to the desired mode Reversible Fan Control 6 Reversible Fan Control If equipped switch 6 is a momentary toggle switch The reversible fan control reverses the rotation of the cooling fan in order to remove debris from the radiator grill The fan is reversed by depressing switch
60. tested and certified for that machine Any alteration or any modification to the ROPS FOPS Structure could weaken the structure This places the operator into an unprotected environment Modifications or attachments that cause the machine to exceed the weight that is stamped on the certification plate also place the operator into an unprotected environment Excessive weight may inhibit the brake performance the steering performance and the ROPS The protection that is offered by the ROPS FOPS Structure will be impaired if the ROPS FOPS Structure has structural damage Damage to the structure can be caused by an overturn a falling object a collision etc Do not mount items fire extinguishers first aid kits work lights etc by welding brackets to the ROPS FOPS Structure or by drilling holes in the ROPS FOPS Structure Welding brackets or drilling holes in the ROPS FOPS Structures can weaken the structures Consult your Caterpillar dealer for mounting guidelines Other Guards If Equipped Protection from flying objects and or falling objects is required for special applications Logging applications and demolition applications are two examples that require special protection A front guard needs to be installed when a work tool that creates flying objects is used Mesh front guards that are approved by Caterpillar or polycarbonate front guards that are approved by Caterpillar are available for machines with a cab or an open canopy
61. the seat height with the weight adjustment switch The seat height must be set while the operator is seated Adjust the seat height until the indicator is in the green zone Note The indicator can be anywhere within the green zone This allows a range of seat heights for a particular operator When you have adjusted the seat ensure that all the controls for the seat are locked in order to prevent unexpected movement stration 49 900100709 1 Unfasten the seat belt Storage Compartment A storage compartment is located on the back of the operator seat This may be used for storing documents or other small objects 101822242 Mustraton 50 900922817 2 To remove the slack in outer loop 1 rotate buckle 2 This will free the lock bar This permits the seat belt to move through the buckle 3 Remove the slack from the outer belt loop by pulling on the buckle 4 Loosen the other half of the seat belt in the same manner If the seat belt does not fit snugly with the buckle in the center readjust the seat belt Shortening the Seat Belt 31200242 45 Operation Section stration 51 900100713 1 Fasten the seat belt Pull out on the outer belt loop in order to tighten the seat belt 2 Adjust the other half of the seat belt in the same manner 3 If the seat belt does not fit snugly with the buckle the center readjust the seat belt Fastening The Seat Belt Musraton S2 90003
62. the ROPS FOPS structure consult your Caterpillar dealer for repairs Seat Belt Inspect Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine Wustration 271 Typical example 00932801 Check the seat belt mounting hardware 1 for wear or for damage Replace any mounting hardware that is or damaged Make sure that the mounting bolts are tight Check buckle 2 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect the seat belt 3 for webbing that is worn or frayed Replace the seat belt if the seat belt is wom or frayed Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware Note Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat beltis attached to the seat belt the seat belt buckle and the seat belt retractor If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension Seat Belt Replace Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occ
63. the entire engine can result Turbocharger bearing failures can cause large quantities of oil to enter the intake system and the exhaust system Loss of engine oil can result in serious engine damage Do not continue to operate the engine when a turbocharger bearing failure is accompanied by a significant loss of engine performance Engine smoke and speeding up of the engine with no load are characteristics of a loss of engine performance Reference For more information about inspecting the turbocharger refer to the appropriate Service Manual for your machine s engine Wheel Nut Torque Check Check the wheel nut torque on new wheels and on repaired wheels after every ten service hours until the specified torque is maintained Tighten the wheel nuts to a torque of 460 60 Nm 340 45 Ib ft When you install new wheels or repaired wheels apply one drop of lubricating oil to the threads before you install the wheel nuts and the washers Window Washer Reservoir Fill NOTICE Use Caterpillar nonfreezing window washer solvent a commercially available windshield washer fluid order to prevent freezing of the windshield washer system ed Histraion 290 1 Remove the filler cap 2 Fill the tank with the appropriate window washer solvent Install the filler cap e Window Wiper Inspect Replace Inspect the condition of the wiper blades Replace the wiper blades if the wiper
64. the forks Any repairs or maintenance to the forks An ongoing record of this information will help in identifying appropriate inspection intervals for each operation and in identifying and solving problem areas and in anticipating time for replacement of the forks Daily Inspection 1 Visually inspect the forks for cracks Look particularly for cracks in the heel of the forks and for cracks around areas of weld Look for tips of forks that are broken or bent Look for twisted blades and shanks Forks which are twisted should be removed from service Also forks which are cracked should be removed from service 2 Make sure that the bolt for locking the fork is in place and that the bolt is working Lock the forks in position before you use the forks 3 Remove all worn forks or damaged forks from service Yearly Inspection 31200242 155 Maintenance Section J Mustration 292 901001950 Iustration 204 901001968 1 Inspect forks carefully for cracks special ip of one attention to heel A and mounting brackets B i 9 et wold Igne di fork against the height of the tip of the other fork when the forks are mounted on the carriage A T ces QU HG mounted difference in the height of the tip of the fork can result in uneven support of the load This could cause problems when the forks are entering the pockets of the load For
65. tire blowout or a rim failure can result from improper equipment or from misused equipment When you inflate a tire stand behind the tread and use self attaching chuck Servicing tires and rims can be dangerous Only trained personnel that use proper tools and proper procedures should perform this maintenance If correct procedures are not used for servicing tires and rims the assemblies could burst with explosive force This explosive force could cause serious personal injury or death Carefully obey the specific instructions from your tire dealer Prevention When lightning is striking in the vicinity of the machine the operator should never attempt the following procedures Mount the machine Dismount the machine If you are in the operator s station during an electrical storm stay in the operator s station If you are on the ground during an electrical storm stay away from the vicinity of the machine Before Starting Engine Operators must have had the proper training and operators must be capable in all aspects of machine operation To comply with some local requirements an operator must attain an operators license or a certificate You must be familiar with your machine in order to understand the machine s capabilities Also before you operate your machine you must become familiar with the job site If necessary walk around the area and take note of the following items Check the area for clearance
66. to the Operation and Maintenance Manual Maintenance Interval Schedule for a specific sampling location and a service hour maintenance interval Consult your Caterpillar dealer for complete information and assistance in establishing an SOS program for your equipment 31200242 111 Maintenance Section Maintenance Support Welding on Machines and Engines with Electronic Controls Proper welding procedures are necessary in order to avoid damage to the electronic controls and to the bearings When possible remove the component that must be welded from the machine or the engine and then weld the component If you must weld near an electronic control on the machine or the engine temporarily remove the electronic control in order to prevent heat related damage The following steps should be followed in order to weld on a machine or an engine with electronic controls 1 Turn off the engine Place the engine start switch in the OFF position 2 If equipped tum the battery disconnect switch to the OFF position If there is no battery disconnect Switch remove the negative battery cable at the battery NOTICE Do NOT use electrical components ECM or ECM sensors or electronic component grounding points for grounding the welder 3 Clamp the ground cable from the welder to the component that will be welded Place the clamp as close as possible to the weld Make sure that the electrical path from the ground cable to the com
67. too low you may not be able to retract the boom If the boom cannot be retracted it might be possible to lower the load to ground level without retracting the boom first Assess the weight of the load and consult the appropriate load chart in order to determine that the load can be lowered in this way without causing the machine to tip forward Do not attempt to lower the boom unless you are satisfied with the stability of the machine You must be sure that the boom can be lowered without hitting an obstacle Due to the size of the hydraulic tank it is possible to return 12 L 3 17 US gal of oil to the tank more than the tank capacity This volume of oil must be removed by the following procedure before lowering the boom or retracting the boom from full stroke 98 Operation Section 31200242 Procedure for Draining Hydraulic Tank WARNING Hot oil and hot components could cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose
68. tools may have been approved since the publication of this manual You must consult your Caterpillar dealer before using any work tool that is not in these tables All work tools must be used conjunction with the appropriate load chart Use the following tables to ensure that you are using the correct load chart You must know the load carrying capacity of these work tools Make sure that you are using the correct load chart 158 Reference Information Section 31200242 Table 18 Approved Work Tools Part Number Work Tool 229 9714 Material Handling Arm 174 7730 Carriage Wide 174 7731 Carriage Wide 174 7728 Rotating Carriage Standard 231 3229 Rotating Carriage Standard 174 7726 Rotating Carriage Wide 227 5748 Rotating Carriage Wide 222 6210 Fork Carriage Ar Sideshift 215 4350 Fork Carriage Gp Standard 145 5346 Fork Gp Pallet 1220 mm 145 5347 Fork Gp Block 1220 mm 145 5342 Fork Gp Pallet 1024 mm 145 5343 Fork Gp Pallet 1220 mm 252 1455 Fork Gp Pallet 1220 mm 252 1459 Fork Gp Pallet 1220 mm 145 5345 Fork Gp Block 1220 252 1460 Fork Gp Block 1220 mm 215 7964 Fork Gp Pallet 1070 mm 252 1454 Fork Gp Pallet 1070 215 7963 Fork Gp Pallet 1525 mm 252 1456 Fork Gp Pallet 1525 mm 186 5843 Fork Gp Manure 186 5851 Grapple and Push Off Fork Gp 186 5847 Gra
69. two wheel steer mode indicator is constantly illuminated Adjust the steering wheel as required 3 Select your desired steer mode and use as normal Machines without Steer Sensors 1 Ina static position select circle steer mode By using your eyes align the rear wheels to a straight position 2 Select two wheel steer mode By using your eyes align the front wheels to a straight position 3 Select your desired steer mode and use as normal Note It is important not to try to turn the steering wheel once the ignition is turned to the OFF position This can lead to steer misalignment which will result in reduced accuracy of the steering system Steering Arrangement Without Self Aligning Rear Steering When you change the steering mode it is possible for the steering to go out of synchronization This will happen under the following conditions The rear wheels are not positioned straight when you change from circle steer mode to two wheel steer mode The rear wheels are not positioned straight when you change from crab steer mode to two wheel steer mode All four wheels are not positioned straight when you change from circle steer mode to crab steer mode All four wheels are not positioned straight when you change from crab steer mode to circle steer mode 50 Operation Section 31200242 Use the following procedure in order to synchronize the steering 1 1 Stop the machine while either crab
70. your machine is equipped with an air conditioning system the condenser must be tilted away from the radiator in order to properly clean the radiator core and the condenser core 1 Open the engine access door lustration 266 900950948 2 Open the latch that is located on top of the condenser tmustaton 267 3 Tilt the condenser away from the radiator 4 Use compressed air to remove dust and other debris from the radiator core and the condenser core 5 Tilt back the condenser and fasten the latch 900951345 31200242 147 Maintenance Section Refrigerant Dryer Replace Personal refrigerant Contact with refrigerant could cause frost bite Keep face and hands away to help prevent injury Protective goggles must always be worn when refrigerant lines are opened even if the gauges indicate the system is empty of refrigerant injury could result from contact with Always use precaution when a fitting is removed Slowly loosen the fitting If the system is still under pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling refrigerant through a lit cigarette Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas could cause bodily harm or death Do not smoke when servicing air conditioners or wherever refrigerant gas may be present Use a
71. 00951212 Illustration 260 shows the location of the relays on fuse panel A pictograph is located on the access cover The location of the relay matches the location of the pictograph on the decal Fuel Pump 33 Ground for Quick Coupler 34 Power for Quick Coupler 35 m Crab Steering 36 Reverse Backup Lights 37 Circle Steer 38 Frame Level 39 Ground for Auxiliary Diverter Valve 40 Power for Auxiliary Diverter Valve 41 Differential Lock 42 Fuel Pump 43 Engine Solenoid 44 Indicators and Gauges Test Check for broken indicator lights broken switches or broken lenses on the instrument panel gauges Start the engine Run the engine until the instrument panel gauges have stabilized Check that the instrument panel gauges are operating correctly Stop the engine and perform any necessary repairs before the machine is operated Longitudinal Stability Indicator Calibrate The use of a defective longitudinal stability indicator LSI could lead to the instability of the machine Do not operate the machine if the LSI is not fully serviceable The instability of the machine could cause personal injury or death Refer to the appropriate Service Manual for information on this procedure Longitudinal Stability Indicator Test The following procedure must be followed when you test the operation of the longitudinal stability indicator system Initial Test 1 Perform th
72. 0832862 16 Tilt the quick coupler forward until the load is level Lower and set down the load in place UP istration 109 0083286 17 Ensure that the load is correctly placed and stable Use the joystick control to raise the boom and retract the boom in a way that withdraws the forks cleanly from the load Do not withdraw the forks by backing up the machine Mostation 110 990822864 18 Retract the boom and lower the boom to the travel position before you move the machine or before you raise the stabilizers Work Tools General Operating Guidelines WARNING Use of non approved work tools on Telehandler machines could result in injury or death Before installing a work tool on this machine ensure that it is approved by Caterpillar and that a Caterpillar load chart covering its use is installed in the machine s cab NOTICE When certain work tools are fitted the work tools can contact the front tires or the front fenders This situation can occur when the boom is retracted and the work tool is rotated fully forward Always check for interference when first operating a new work tool NOTICE When certain work tools are installed the work tools can contact the stabilizers This interference can occur when the boom is retracted and the work tool is rotated fully forward Always check for interference when first operating a new work tool Travel with the work tool lowered as far as possible with adequate ground cl
73. 14 10 Work Light 15 10 Rear Work Lights 16 10 AMP Engine Start 17 10 AMP Hazard Flashers 18 10 AMP Left Side Parking Light Left Side Rear Light and License Plate Light 19 15 AMP Right Side Parking Light Right Side Rear Light and Fog Light 20 15 Rotating Beacon 21 10 Alternator Indicator Light and Oil Pressure Indicator Light 22 15 AMP Seat Height Adjustment 23 15 Radio which is Independent of Engine Start Switch 24 10 AMP LH Tail Lights 25 10 960 9 6 0 6 60 50 6 9 6a RH Tail Lights 26 10 AMP Engine Run 27 10 Fuel Pump 28 This fuse is not used on this machine Radio which is dependent of Engine Start Switch 29 10 AMP Horn 30 10 AMP Electrical Monitoring System 31 15 AMP Electrical Monitoring System 32 20 AMP Mustration 259 01056978 The fuse for the fuel pump is located in the engine compartment next to the circuit breakers Remove the protective cover in order to access the fuse Relays Note Your machine may not utilize all of the relays that are listed here You should only replace these relays with relays of the same type 144 Maintenance Section 31200242 Nnm m E d an i zd 3 istration 260 9
74. 2 125 Maintenance Section Cooling System Coolant Sample Level 2 Obtain NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incorrect interpretation that could lead to by both dealers and custorners oe Er aS stration 219 901081068 Refer to the Operation and Maintenance Manual Access Doors and Covers for the location of the service points Obtain the sample of the coolant as close as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For additional information about coolant analysis see the appropriate Service Manual or consult your Caterpillar dealer Cooling System Pressure Cap Clean Replace Personal injury could result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact could cause severe burns Remove filler cap slowly to relieve pressure only when engine is stopped and
75. 2818 Fasten seat belt catch 3 into buckle 2 Make sure that the seat belt is placed low across the lap of the operator Releasing The Seat Belt Mustration 53 900100717 Pull up on the release lever This will release the seat belt Seat Belt Adjustment for Retractable Seat Belts Fastening The Seat Belt Mustration s4 00100713 Pull seat belt 4 out of the retractor in a continuous motion Fasten seat belt catch 3 into buckle 2 Make sure that the seat belt is placed low across the lap of the operator The retractor will adjust the belt length and the retractor will lock in place The comfort ride sleeve will allow the operator to have limited movement 46 Operation Section 31200242 Releasing The Seat Belt Mostration 55 90009113 Push the release button on the buckle in order to release the seat belt The seat belt will automatically retract into the retractor Extension of the Seat Belt A WARNING When using retractable seat belts do not use seat belt extensions or personal injury or death could result The retractor system may or may not lock up depending on the length of the extension and the size of the person If the retractor does not lock up the seat belt will not retain the person Longer non retractable seat belts and extensions for the non retractable seat belts are available Caterpillar requires only non retractable seat belts to be used with a seat belt extension Con
76. 80 901212988 To connect the trailer raise the hitch off the safety hooks and pull safety hook release cable 10A Once the cable has been pulled lower the hitch until the hook is at the required height in order to lift the tow eye Reverse the machine with assistance or by using the hitch mirror until the hook is under the center of the tow eye Raise the hitch until the safety hooks are engaged If necessary connect the trailer brakes The machine is ready for towing Hydraulic Lockout Control 11 When the top of the switch is pressed all the machine functions are operational When the bottom of the switch is pressed the switch locks in this position In this position only the following machine functions are operational Transmission control Steering control When the bottom of the switch is pressed the following machine functions are locked out Boom raise Boom lower Boom extend Boom retract Quick coupler Auxiliary actuators When the machine is driven on public roads the bottom of the switch must be pressed This will prevent accidental moverent of hydraulically controlled components To allow operation of hydraulic components again move the red lock on the switch to the left and press the top of the switch Battery Disconnect Switch If Equipped Open the engine enclosure on the right side of the machine The battery disconnect switch is located on the right side of the engine compartme
77. 84 Transmission Washer Fluid Bottle 5 13 1 Quantities exclude 0 34 L 0 09 US gal of 197 0017 Friction Modifier Axio and Brake Grease Points Identification Mustration 168 Typical example On machines that are equipped with the Open Roll Over Protective Structure OROPS the identification decal is located in the engine compartment to the back plate of the enclosure group On machines that are equipped with the Enclosed Roll Over Protective Structure EROPS the identification decal is located on the inside of the lower door The identification decal shows the lubrication points on the machine that need to be serviced and the maintenance intervals between each of the checks Note Refer to Operation and Maintenance Manual Maintenance Interval Schedule for the recommended intervals 01211917 110 Maintenance Section 31200242 SOS Information SOS Services is a highly recommended process for Caterpillar customers to use in order to minimize owning and operating cost Customers provide oil samples coolant samples and other machine information The dealer uses the data in order to provide the customer with recommendations for management of the equipment In addition SOS Services can help determine the cause of an existing product problem Refer to the appropriate Service Manual for detailed information concerning SOS Services Refer
78. 878 1 Open filter cover 7 by removing retaining screws 8 2 Remove the filter from the filter housing 3 If the air filter is not damaged clean the air filter with pressurized air The maximum air pressure for cleaning is 205 kPa 30 psi Key Start Breaker 3 Tier Il only The key start breaker is 60 amp Reset the circuit breaker if the breaker trips Push in the Direct pressurized air along the pleats from no button in order to reset the circuit If the button does closer than 160 mm 6 inch from the air filter not remain depressed or the circuit breaker trips soon after being reset check the appropriate electrical If the air filter is damaged replace the air filter circuit Repair the electrical circuit if necessary 122 Maintenance Section 31200242 Compensating Cylinder Bearing Lubricate 211 There is a compensating cylinder under the boom Lubricate the compensating cylinder pin through the fitting at the head end of the cylinder Cooling System Coolant Change WARNING Personal injury could result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand Do
79. 9908516569 A WARNING A WARNING No clearance for person in this area during operation No clearance for person in this area during operation Severe injury or death from impalement could occur Severe injury or death from impalement could occur Stay away from the work tool while it is in operation Stay away from the work tool while it is in operation Impaling Hazard 21 This message is located on each side of the grapple Crushing Hazard 19 This message is located on each side of the grapple fork bucket A WARNING WARNING 200051555 900851569 A WARNING A WARNING No clearance for person in this area during operation No clearance for person in this area during operation Severe injury or death from crushing could occur Stay Severe injury or death from impalement could occur Stay away from the work tool while it is in operation away from the work tool while it is in operation 17 31200242 Safety Section Crushing Hazard 22 Entanglement and Flying Objects This message is located on each side of the grapple 24 bucket This message is located on each side of the top cover for the broom WARNING WARNING 900951565 WARNING No clearance for person in this area during operation WARNING pen SOY ciar of ims werk Tool during operation Flying objects from this work tool could result in personal injury or death Operation 23 This message
80. API CF 4 oils are not recommended for Caterpillar machine diesel engines Cat Arctic DEO SYN is an SAE 0W 30 viscosity grade oil 4 4 PLUS and API CH 4 oils are acceptable if the requirements of Caterpillar s ECF 1 Engine Crankcase Fluid specification 1 are met API Cl 4 API Cl 4 PLUS and CH 4 oils that have not met the requirements of Caterpillar s ECF 1 specification may cause reduced engine life API CG 4 oils are acceptable for use in all Caterpillar machine diesel engines When API CG 4 oils are used the change interval should exceed 250 hours API CG 4 oils that also meet API Cl 4 API 4 PLUS or API CH 4 must also meet the requirements of the Caterpillar ECF 1 specification Refer to Operation and Maintenance Manual Capacities Refill for the amount of 197 0017 Friction Modifier Axle and Brake that needs to be added to the center section of the front axle on your machine CT Cat TDTO TMS Transmission Multi Season synthetic blend that exceeds the TO 4M multigrade specification requirements Recommended Grease Note If the application calls for an MPG and a Cat MPG is not available consult the grease data Cat MPG Multipurpose Grease sheets Use a substitute that meets or exceeds the Cat MPG is a National Lubricating Grease Institute performance characteristics of Cat MPG NLGI grade 2 grease This grease is made with petroleum base oil and a lithium complex thickener
81. Cat MPG is formulated for use in applications that have a low severity to a medium severity in moderate temperatures Cat MPG meets the NLGI certification of GC LB This certification relates to extended service intervals in automotive chassis points and in wheel bearings with disc brakes in automobiles vans and light trucks 31200242 109 Maintenance Section Capacities Refill Table 11 APPROXIMATE REFILL CAPACITIES FOR THE TH220B AND TH330B Compartment System Liter US gal Imp gal Cooling System Total Capacity without Heater 22 5 59 50 12 kW gold cooler Cooling System Total Capacity with Heater 12 235 62 52 kW gold cooler Cooling System Total Capacity without Heater 23 5 62 52 20 kW black cooler Cooling System Total Capacity with Heater 20 24 5 65 54 KW black cooler Fuel Tank Tank Capacity 115 30 4 25 3 Optional Auxiliary Fuel Tank Tank Capacity 50 13 2 11 0 Total Engine Oil 74 5 FW 99 Min iovel Minievel Minievel eng 7 19 16 Total Engine Oil Max level Maxlevel Max level Capacity 92 kW 123hp 85 22 19 0r93 1 KW 125 hp Min evel Minlevel Min evel engine 68 18 15 Front Axle Differential 9 5 25 24 Rear Axle Differential 10 0 26 22 Final Dive Hubs Each oss Hub Hydraulic System Including the Hydraulic Oil Tank and the 8 183 1
82. D position Boom Lower Push joystick control 14 the right in order to extend the boom When joystick control 14 is released the joystick control will return to the HOLD position Boom Extend Push joystick control 14 to 31200242 55 Operation Section Note The boom will not extend when the transmission control is in the REVERSE position The function for extending the boom will resume if the transmission is neutralized by the service brake the parking brake or the transmission neutralizer button Boom Retract Pull joystick control 14 to the left in order to retract the boom When joystick control 14 is released the joystick control will return to the HOLD position Quick Coupler Tilt Forward Push thumb wheel 148 forward in order to tilt the quick coupler forward When the thumb wheel is released the thumb wheel will return to the HOLD position Quick Coupler Tilt Backward Pull thumb wheel 148 rearward in order to tilt the quick coupler backward When the thumb wheel is released the thumb wheel will return to the HOLD position Auxiliary Controls Press switch 14E in order to toggle between the hydraulic circuits for the auxiliary 1 and auxiliary 2 Press switch 14C in order to operate an actuator for a work tool in the positive direction Press switch 14D in order to operate an actuator for a work tool in the negative direction Switches 14E 14C and 14D are
83. Fully raise the boom and fully lower the boom Repeat this procedure three times in order to purge the air from the hydraulic system Fully extend the boom and fully retract the boom The boom operation should be smooth If necessary repeat this procedure in order to purge the air from the hydraulic system Verifying the Correct Setting of the Load Control Valves 1 Install a work tool onto the quick coupler Raise the boom until the work tool is clear of the ground Extend the boom by approximately 300 mm 12 inch Lookatthe boom extension reference scale and the boom angle reference scale and note the readings Refer to the load chart and use these two values in order to determine the maximum weight that can be lifted with the boom in this position Pick up the maximum load that was determined in Step 2 Refer to the procedure for load handling and stacking in Operation and Maintenance Manual Operation Information Extend the boom approximately 300 mm 12 inch and fully raise the boom Stop the engine On control valve 14 tum locknut 15 and locknut for one turn in a counterclockwise direction Turn adjustment screw 16 and adjustment screwin a counterclockwise direction for four full turns Refer to Illustration 148 Check the position of the boom after 10 minutes The cylinder for the boom retract and the cylinder for the boom raise should not have drifted If either cylinder
84. Maintenance Manual Operator Controls for the location and operation of the machine controls 1 Make sure that no one is on the machine or near the machine before you move the machine Keep the machine under control at all times 2 Start the machine 3 Raise all lowered work tools in order to pass over any obstacles Fully raise the stabilizers 4 Push down on the service brake control in order to prevent the machine from moving 5 Disengage the parking brake The parking brake has an interlock switch which prevents the machine from being driven through the brake The machine will not move in forward or in reverse when the parking brake is engaged 6 Move the transmission control to FORWARD position F or to REVERSE position R 7 Rotate the transmission control until he required transmission speed is selected 8 In order to move the machine release the service brake pedal Push the accelerator control Changing Speed and Direction stration 84 Transmission contro 901042565 Start moving the machine with the machine in first gear or in second gear To upshift rotate the transmission control to the next highest gear It is not necessary to release the accelerator control To downshift rotate the transmission control to the next lowest gear Do not skip gears when you downshift Continue to shift through the gears in this way as the conditions are required To prevent engine overspeed do not downshift i
85. N e 31200242 CATERPILLAR NE Operation and Maintenance Manual TH220B and TH330B Telehandlers S N 00100 amp After S N TBGO00100 amp 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 explai
86. a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Tum the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Park the machine on level ground Fully retract and fully lower the boom Move the transmission control to the NEUTRAL position and ensure that the parking brake is engaged Shut off the engine 2 Open the engine enclosure Mustration 251 3 Loosen valve 3 and drain the contents of housing 2 into a suitable container Tighten the valve Support housing 2 and rotate the housing Remove the housing Rotate the element for 90 degrees counterclockwise and lift the element out of housing 2 6 Clean the gasket sealing surface on mounting base 1 Replace the O ring seal that is located on housing 2 Insert a new fi
87. a slope The work tool is not resting on the ground The machine is left with downward load applied to the rear hitch If the machine fails the system test for the LSI follow the procedure for retesting Refer to Operation and Maintenance Manual Longitudinal Stability Indicator Test for more information Note Consult your Caterpillar dealer for recalibration of the system if the system fails the second test If any changes are made to the standard machine configuration of the Telehandler the system may need to be recalibrated Consult your Caterpillar dealer for recalibration of the LSI The following situations are conditions that require recalibration The type of wheels on the rear axle are changed The type of tires on the rear axle are changed The tire foam fill is added to the tires The rear axle is changed The sensor for the LSI is changed Note The full test which is stated in the Operation and Maintenance Manual Maintenance Interval Schedule must be followed 84 Operation Section 31200242 Backup Alarm The backup alarm is located on the rear of the machine The alarm sounds when the transmission direction and speed control lever is in the REVERSE position The backup alarm is used to alert people behind the machine Cab Door Unlock the cab door Note The key for the cab door is the same key as the engine start key lMustraion 139
88. able criteria Tire Replacement It is recommended that a replacement tire be the same size ply and brand as originally installed Refer to the appropriate parts manual for ordering information If not using an approved replacement tire the replacement tires must have the following characteristics Equal or greater ply load rating and size of original Tire tread contact width equal or greater than original Wheel diameter width and offset dimensions equal to the original Approved for the application by the tire manufacturer including inflation pressure and maximum tire load Wheel Replacement The rims installed have been designed for stability requirements which consist of track width tire pressure and load capacity Size changes such as rim width center piece location larger or smaller diameter etc without written factory recommendations may result in unsafe condition regarding stability Wheel and Tire Installation Torque lug nuts before first use and after each wheel removal Note If machine is equipped with directional tire assemblies the wheel and tire assemblies must be installed with the directional tread pattern arrows facing in the direction of forward travel 1 Start all nuts by hand to prevent cross threading DO NOT use a lubricant on threads or nuts 2 Tighten lug nuts in an alternating pattern Torque to 400 520 Nm 295 384 16 0 WARNING TIP OVER HAZARD Lug nut
89. ailable Be familiar with the operation of the fire extinguisher Inspect the fire extinguisher and service the fire extinguisher regularly Obey the recommendations on the instruction plate Lines Tubes and Hoses Do not bend high pressure lines Do not strike high pressure lines Do not install any lines that are bent or damaged Repair any lines that are loose or damaged Leaks can cause fires Consult your Caterpillar dealer for repair or for replacement parts Check lines tubes and hoses carefully Do not use your bare hand to check for leaks Use a board or cardboard to check for leaks Tighten all connections to the recommended torque Replace the parts if any of the following conditions are present End fittings are damaged or leaking Outer coverings are chafed or cut Wires are exposed Outer coverings are ballooning Flexible part of the hoses are kinked Outer covers have embedded armoring End fittings are displaced Make sure that all clamps guards and heat shields are installed correctly During machine operation this will help to prevent vibration rubbing against other parts and excessive heat Fire Extinguisher Location Make sure that a fire extinguisher is on the machine Make sure that you are familiar with the operation of the fire extinguisher Inspect the fire extinguisher and service the fire extinguisher on a regular basis Obey the recommendations on the instruction plate Th
90. ample Obtain Final Drive Oil Sample Obtain Transmission and Hydraulic System Oil Sample Obtain 128 152 Every 500 Service Hours or 6 Months Boom Oylinder Pin Lubricate Boom Head Section Lubricate Boom Pivot Shaft Lubricate Compensating Cylinder Bearing Lubricate Differential Oil Level Check 127 Drive Shaft Spline Lubricate 129 Drive Shaft Universal Joint Bolts Check 130 Engine Air Filter Primary Element Clean Replace Engine Air Filter Primary Element Replace Engine Air Filter Secondary Element Replace 132 Engine Oil and Filter Change 184 Final Drive Oil Level Check 186 Fork Leveling Cylinder Pin Lubricate 137 Fuel System Water Separator Element Replace 139 Longitudinal Stability Indicator Calibrate 144 Every 1000 Service Hours or 1 Year Belt Inspect Replace Boom Wear Pad Clearance Inspect Adjust Cooling System Coolant Change Differential Oil Change Final Drive Oil Change Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect 1 Transmission and Hydraulic System Oil Change Transmission and Hydraulic System Oil Filter Replace Work Tool Inspect Replace Every 2000 Service Hours or 2 Years Engine Valve Lash Check Refrigerant Dryer Replace Transmission and Hydraulic System Tank Breather Clean 152
91. an cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Tum the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Park the machine on level ground Fully retract and fully lower the boom Move the transmission control to the NEUTRAL position and ensure that the parking brake is engaged Shut off the engine 2 Open the engine enclosure llustration 250 31200242 139 Maintenance Section Loosen the valve and drain the water and sediment into a suitable container 4 Tighten the valve Fuel System Water Separator Element Replace Tier Il Personal injury or death could result from failure to adhere to the following procedures Fuel leaked or spilled onto hot surfaces or electrical components can cause
92. an lead to premature failures product damage personal injury or death EFFECTIVITY PAGE July 13 2006 A Original Issue Of Manual February 2 2007 B Added Tier Ill information Revised pages 9 18 19 35 36 109 121 137 138 139 140 142 and 143 31200242 EFFECTIVITY PAGE 31200242 31200242 1 Table of Contents Table of Contents Electrical Storm Injury Prevention Before Starting Engine orewort Engine Starting Literature Information a Before Operatio Safety 5 Operation Operation 5 ine Machine Operating Temperature Range Maintenance Intervals 5 e Sponge E Certified Engine Maintenance 5 SRM i gt Work Tools Machine Capacity 5 Parking Contact Information 6 Equipment Lowering wit Safety Section Power Sound Information and Vibration Information Sound Level 10 Vibration Level 10 Operator Station E Guards Safety Messages Do Not Operate 1 Do Not Stand Under the Load 2 No Hands 3 Forks 5 Do Not Weld On Operator Protection Structure 6 Rollover Protective Structure ROPS Falling No Access Platform 7 12 Object Protective Structure FOPS Seat Belt 8 18 Other Guards If Equipped Engine Coolant 9 Low Bridge 10 Avoid Power Lines 11 Jump Start Cables 12 Ether 13 Impaling Hazard 14 Crushing Hazard 15 Crushing Hazard 16 Product Inf
93. and hold switch 2 on the joystick control in order to close the prongs Refer to the topic Joystick Control in Operation and Maintenance Manual Operator Controls for full information When the work tool is not active position the bale handler so that personnel cannot contact the prongs 80 Operation Section 31200242 Double Thumb Wheel Mostration 132 01053065 Move thumb wheel 3 forward in order to open the prongs Move thumb wheel 3 backward in order to close the prongs Refer to the topic Joystick Control in Operation and Maintenance Manual Operator Controls for full information When the work tool is not active position the bale handler so that personnel cannot contact the prongs Broom Wustraon 133 901015381 Refer to Operation and Maintenance Manual SEBUT740 BP24 Pickup Broom for information on the installation of the broom and the operation of the broom Monitoring System Alert Indicators Mostation 194 901002552 Engine Oil Pressure 1 This indicator illuminates when the engine oil pressure is low Action Lamp 2 This indicator will illuminate when a failure that is a warning 5 7 category 2 or a higher warning occurs If the lamp is illuminated the machine needs to be serviced soon The color of this indicator can be amber or red An audible alarm may also sound when this indicator is illuminated When a warning category 2 occurs the action lamp
94. ank Cap Clean Fuel Tank Water and Sediment Drain Fuses and Relays Replace Fuses Longitudinal Stability Indicator Calibrat Longitudinal Stability Indicator Test Initial Test Second Test Oil Filter Inspect Inspect a Used Filter for Debris Parking Brake Adjust Radiator Core Clean Refrigerant Dryer Replace Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect 147 Seat Belt Inspect 48 Seat Belt Replac 48 Tire Inflation Check 48 Transmission and Hydraulic System Change Transmission and Hydraulic System Oil Filter Replace 3 31200242 Table of Contents Transmission and Hydraulic System Oil Level 151 Transmission and Hydraulic System Oil Sample Obtaii 152 Transmission and Hydraulic System Tank Breather Clean 152 Turbocharger Inspect 158 Wheel Nut Torque Che Window Washer Reservoir Fill Window Wiper Inspect Replace Windows Clean 158 158 158 154 Work Tool Inspect Replace 154 Forks 154 Buckets 156 Reference Information Se Approved Work Tools 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 oper
95. ansport If a machine shifts it could cause personal injury or death istration 155 g00063232 Note Your machine may be equipped with front retrieval hitches In order to gain access to the lifting points before lifting the machine remove the two retrieval hitches and the lights that are attached to the front of the machine 1 Use equipment which is rated for the weight of the machine that is being lifted 2 Spreader bar widths should be sufficient in order to prevent damage to the machine 3 Attach the equipment to the four lifting points that are provided Wostration 156 900863696 4 Install tie downs which are rated for the weight of the machine Install the tie downs at the four locations that are provided 5 Chock the front road wheels and the rear road wheels of the machine 6 Engage the parking brake and move the transmission control to the NEUTRAL position 7 Ensure that the boom is fully retracted Ensure that the boom is lowered 8 Stop the engine and remove the engine start switch key 9 Cover the outlet of the exhaust pipe in order to prevent possible damage to the engine turbocharger If you are in doubt consult your Caterpillar dealer for more information 31200242 89 Operation Section Towing Information Towing the Machine Towing a Disabled Machine WARNING Personal injury or death could result when towing a disabled machine incorrectly Bl
96. ant Viscosities Recommended Grease Lubricant Viscosities and Refill Capacities Lubricant Viscosities Maintenance Access Maintenance Interval Schedule Maintenance Sectio Maintenance Support Monitoring System Alert Indicators Gauges Indicators Longitudinal Stability Indicator Monitoring System Mounting and Dismounting Alternate Exit Oil Filter Inspect Inspect a Used Filter for Debris Operation Machine Operating Temperature Range Machine Operation 31200242 Operation Information Changing Speed and Direction Hydraulic Quick Coupler Load Handling and Stacking Manual Quick Coupler Use of Work Tools Operation Section Operation Operator Controls Accelerator Control 19 Adjustable Armrest 15 Auto Manual Switch 2 Continuous Auxiliary Flow Control 8 Double Thumb Wheel Continuous Auxiliary Flow Control 8 Single Thumb Wheel Differential Lock Control 21 Directional Tum Signal Control 23 Engine Start Switch 24 Fog Lights 9 Frame Leveling Control 7 Hazard Flashers 10 Headlight Dimmer Switch 11 Headlight Parking Lights 12 Horn 1 Interior Light 17 Joystick Control 14 Machine Security System If Equipped Parking and Secondary Brake Control 18 Quick Coupler Control 3 Reversible Fan Control 6 Rotating Beacon Light 19 Service Brake Control 20 Side Console 16 Steering Column Control
97. ation Name Branch Address Dealer Contact Phone Number Hours Sales Parts Service CATERPILLAR Manufactured by JLG under license from Caterpillar
98. ation 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 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
99. ation Serial Number Caterpillar products such as engines transmissions and Plate and Decal Locations major attachments that are not designed for an operator to ride are identified by serial numbers For quick reference record the serial numbers in the spaces that are provided below the illustration Wustraton 31 800937576 lustration 33 901042884 AON GEO information plate is installed on these machines On machines that are delivered into the European Union the CE mark and the PIN are stamped onto the plate On machines that are delivered to countries outside the European Union the PIN is stamped onto the plate This plate is positioned on the left side of the main 1 Engine serial number frame The PIN is used to identify a powered machine that is designed for an operator to ride The PIN plate is located at the left side of the main frame The PIN plate shows the PIN and the number for the arrangement of the machine Several pieces of information are stamped onto the PIN plate For quick reference record this information in the spaces that are provided below Model PIN Ter 2 Transmission serial number Engine serial number Transmission serial number 3 Engine Pod serial number 31200242 37 Product Information Section Certification European Union stration 34 900853367 If the machine is equipp
100. aulic lines or cables for the carriage from the boom head if equipped 5 bye i 4 Mustration 95 901060117 2 Remove the retaining pin and remove pin 3 3 Lower the boom and tit the quick coupler forward until the carriage is on the ground If necessary block the carriage in order to prevent the carriage from moving when the carriage is disengaged from the quick coupler Lower the boom until tubes 1 are disengaged from hooks 2 4 Retract the boom until the quick coupler is clear of the carriage 5 Install the pin into the coupler Use of Work Tools NOTICE When certain work tools are fitted the work tools can contact the front tires or the front fenders This situation can occur when the boom is retracted and the work tool is rotated fully forward Always check for interference when first operating a new work tool When you use a blade to level or when you use a blade to scrape the boom must be fully retracted Operate with the bottom of the blade parallel to the ground number of Caterpillar approved buckets are included as work tools for telehandlers Reference the correct load chart for the work tool that is installed and never exceed the weights and load centers that are specified in the load charts When you load a bucket the boom must be fully retracted Extending the boom increases the outreach of the load which will reduce the forward stability of the machine Note If a
101. belt extension on a retractable seat belt Make sure that all protective guards and covers are secured on the machine Adjust the seat so that full pedal travel can be achieved with the operator s back against the back of the seat Make sure that the machine is equipped with a lighting system that is adequate for the job conditions Make sure that all of the machine lights are working properly Make sure that the machine horn the backup alarm and all other warning devices are working properly Clear all obstacles from the path of the machine Before you attempt to start the engine and before you move the machine ensure that no one is underneath the machine around the machine or on the machine Make sure that the area is free of personnel Fasten the seat belt Engine Starting istration 25 900100646 Before you service the machine or before you repair the machine attach a DO NOT OPERATE warning tag ora similar warning tag to the engine start switch or to the controls This warning tag is available from your Caterpillar dealer If a warning tag is attached to the engine start switch or to the machine controls do not start the engine Also do not move any machine controls Ensure that the transmission control is in the NEUTRAL position N The engine will not start unless the transmission control is in the NEUTRAL position Ensure that the parking brake is engaged Diesel engine exhaust contains products of combus
102. ce dirt particles toward the dirty side outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary air filter element Dirt could be forced further into the pleats Vacuum Cleaning Vacuum cleaning is another method for cleaning primary air filter elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Inspecting the Primary Air Filter Elements Mustration 235 900281693 182 Maintenance Section 31200242 Inspect the clean dry primary air filter element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the primary air filter element Rotate the primary air filter element Inspect the primary air filter element for tears and or holes Inspect the primary air filter element for light that may show through the filter material If it is necessary in order to confirm the result compare the primary air filter element to a new primary air filter element that has the same part number Do not use a primary air filter element that has any tears and or holes in the filter material Do not use a primary air filter element with damaged pleats gaskets or seals Discard damaged primary air filter elements St
103. certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system Mustraion 268 900980936 The refrigerant accumulator is located at the rear of the engine compartment Note When you operate the machine in a climate with high humidity replace the refrigerant accumulator after every 1000 service hours or 6 months Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect Iustration 270 The front bolts 1 are located underneath the left side of the cab 900951451 The rear bolts 3 located underneath the windshield washer reservoir behind the cab 1 Remove the bolts 2 in order to remove the windshield washer reservoir 2 Ifthe bolts are damaged or missing replace the bolts with original equipment parts only Torque the bolts to 450 Nm 332 Ib ft 148 Maintenance Section 31200242 Note Apply to the bolts before you install the bolts Failure to apply oil can result in improper bolt torque 3 Install the windshield washer reservoir and install the two bolts 4 Run the machine on a rough surface Replace the ROPS FOPS mounting supports if the ROPS FOPS structure makes a noise or if the ROPS FOPS structure rattles Do not attempt to straighten or repair the ROPS FOPS structure If there are any cracks in the welds in the castings or in any metal section of
104. charger if equipped damage can result if the engine rpm is not kept low until the engine oil light gauge verifies the oil pressure is sufficient 2 Start the engine Allow the engine to operate at low idle until the engine runs smoothly Note If additional priming is necessary refer to the appropriate Service Manual for additional information 188 Maintenance Section 31200242 Tier III WARNING Personal injury or death may result from failure to adhere to the following procedures Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fuel spray may cause a fire hazard NOTICE Do not crank the engine for more than 30 seconds Allow the starting motor to cool for two minutes before cranking again 1 Operate fuel priming pump 1 2 Stop after 100 depressions of the fuel priming pump 3 The engine fuel system should now be primed 4 Operate engine starter and crank engine After engine has started operate at low idle for a minimum of five minutes immediately after air has been removed from fuel system NOTICE Operating engine for this period of time helps ensure the fuel system is free of air Do not loosen high pressure fuel line to purge air from fuel system Fuel System Water Separator Drain Personal injury or death could result from failure to adhere to the following procedures Fuel leaked or spilled onto hot surfaces or electrical components c
105. d and move the backrest to the required angle Release the seat recline lever in order to lock the backrest in place When you have adjusted the seat ensure that all the controls for the seat are locked in order to prevent unexpected movement Suspension If Equipped Adjustment Lever 3 for the Seat Suspension Adjust the suspension with the adjustment lever The suspension must be set while the operator is seated The indicator for the seat suspension must be in the green zone If the indicator for the seat suspension is in the red zone pull out the handle of adjustment lever 3 and turn the handle counterclockwise until the indicator is in the green zone Note The indicator can be anywhere within the green zone This allows a range of seat heights for a particular operator 44 31200242 Operation Section When you have adjusted the seat ensure that all the Seat Belt controls for the seat are locked in order to prevent unexpected movement Note This machine was equipped with a seat belt when the machine was shipped from the manufacturer Air Suspension If Equipped Always check the condition of the seat belt and the condition of the mounting hardware before you operate the machine Seat Belt Adjustment for Non Retractable Seat Belts Adjust both ends of the seat belt The seat belt should be snug but comfortable Lengthening the Seat Belt Mostration 48 900950464 Weight Adjustment Switch 4 Adjust
106. d may not start under certain conditions Read the following information and know your machine s settings Your Caterpillar dealer can identify your machine settings Machine Security System MSS Machines 8 that are equipped with a Caterpillar Machine Security System MSS can be identified by a decal in the operator station MSS is designed to prevent theft of the machine or unauthorized operation Basic Operation MSS may be programmed to read a standard Caterpillar key or an electronic key The electronic key contains an electronic chip within the plastic housing for the key Each key emits a unique signal to the MSS The keys can be identified by a gray housing or a yellow housing MSS can have programmed settings to require an electronic key or a standard Caterpillar key for starting during certain periods of time When the key start switch of the machine is turned to the ON position the ECM will read the unique ID that is stored in the electronic key The ECM will then compare this ID to the list of authorized keys The 31200242 61 Operation Section following table tells the operator the status for starting the machine The status light is located near the key start switch TableG Green light The machine will start Red light The key is not authorized Note MSS will not shut down the machine after the machine has started Security Management The MSS has the capability to allow yo
107. d the boom sections at each side It may be necessary to install more shims at one side than the other side Tighten the bolts to a torque of 75 5 Nm 55 x 4 Ib ft 6 Fully extend and retract the boom at angles of 0 degrees 45 degrees and 70 degrees The boom operation must be smooth If the boom operation is not smooth operate the boom with a load of 500 kg 1100 Ib on the attachment Fully extend the boom and retract the boom at an angle of 45 degrees Repeat ten times Mostration 198 900909756 7 Extend the boom and lower the work tool to the ground Check the temperature of the top surfaces number 1 boom section and number 2 boom section Check the temperature of the wear pads at opposite locations at positions A Both sides of each section should feel the same temperature If necessary increase the thickness of the shims under the rear wear pad which is in contact with the cool side of the boom section Alternatively decrease the thickness of the shims under the front wear pad which is in contact with the hot side of the boom section 8 Install the cover on the rear of the boom Boom and Frame Inspect In order to help minimize unexpected costly repairs and downtime inspections need to be carried out on a regular basis The interval between the inspections depends on factors These factors are the age of the machine the severity of the application loading routine servic
108. dard machine The measurements are obtained by using the procedures that are in the following standards ISO 2631 1 1997 ISO 5349 1 2001 SAEJ1166 Operator Station Any modifications to the inside of the operator station should not project into the operator space The addition of a radio fire extinguisher and other equipment must be installed so that the defined operator space is maintained Any item that is brought into the cab should not project into the defined operator space A lunch box or other loose items must be secured Objects must not pose an impact hazard in rough terrain or in the event of a rollover Guards Operator Protection There are different types of guards that are used to protect the operator The machine and the machine application determines the type of guard that should be used A daily inspection of the guards is required in order to check for structures that are bent cracked or loose Never operate a machine with a damaged structure The operator becomes exposed to a hazardous situation if the machine is used improperly or if poor operating techniques are used This situation can occur even though a machine is equipped with an appropriate protective guard Follow the established operating procedures that are recommended for your machine Rollover Protective Structure ROPS Falling Object Protective Structure FOPS The ROPS FOPS Structure on your machine is specifically designed
109. ded period of one month or longer perform the following operations Disconnect the battery and remove the battery Relieve hydraulic pressure from the hydraulic system Seal air intake and exhaust openings Grease bright parts Protect rubber components from direct sunlight Fill the fuel tank Ensure that the tires are correctly inflated Transportation Information Shipping the Machine Ensure that the combined weight of the machine and of the transport vehicle complies with local laws and regulations along the entire route Ensure that the intended route has adequate vertical clearances and horizontal clearances for the transport vehicle when the machine is loaded Remove ice snow or other slippery material from the transport vehicle from the car or from the loading dock before you load the machine Always chock the transport vehicle or the rail car wheels before you load the machine The boom must be fully retracted The boom must also be lowered until the quick coupler or the work tool is resting on the transport vehicle NOTICE Obey all state and local laws governing the weight width and length of a load Make sure the cooling system has proper antifreeze if moving machine to a colder climate Observe all regulations governing wide loads Refer to Operation and Maintenance Manual Specifications for the basic dimensions and the weights for shipping a standard machine Roading the Machine
110. djustment screw is returned to the original position 7 Tighten locknut 17 If the boom needs to be lowered proceed to Procedure for Lowering the Boom Note Do not start the engine until you have reset adjustment screws 12 and 18 100 Operation Section 31200242 8 Start the engine Raise and lower the boom Extend and retract the boom approximately 300 mm 12 inch 9 Position the boom to the fully retracted position Position the boom to the fully lowered position 10 Remove the hydraulic tank filler cap Add the 12 L 8 17 US gal of oil that was removed from the hydraulic tank in Step 3 of Procedure for Draining Hydraulic Tank Check the oil level in the hydraulic tank If necessary top up the hydraulic oil to the required level Install the hydraulic tank filler cap Clean up any oil that may have been spilled Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Capacities Refill for further information 12 Install the access cover on the chassis Install the rear cover for the boom Procedure for Lowering the Boom Wustration 149 901205730 1 Locate load control valve 19 for lowering the boom The load control valve is mounted to the underside of the cylinder and toward the rear of the cylinder The valve can be accessed from the underside of the machine 2 Slightly loosen locknut 21 Remove adjustment screw 20
111. e and engage the parking brake The engine oil should be warm before you drain the oil Stop the engine Open the engine access door Musraton 241 900975960 3 Position the end of hose 3 into a suitable container Turn shutoff valve 2 counterclockwise in order to drain the engine oil from the crankcase Tum the shutoff valve clockwise in order to close the shutoff valve Allow the oil to drain from the hose 4 Remove old engine oil filter 1 with a filterwrench 5 Clean the filter housing base Ensure that all of the old seal is removed 6 Apply a thin film of clean engine oil to the seal of the new engine filter 7 Install new engine filter 1 hand tight until the seal of engine oil filter 1 contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on engine oil filter 1 that are spaced 90 degrees or 1 4 of a tum away from each other When you tighten engine oil filter 1 use the rotation index marks as a guide 8 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final instal
112. e brakes on a dry level surface Fasten the seat belt before you check the brakes The following procedure is used in order to determine if the service brake is functional This procedure is not intended to measure the maximum brake performance The brake holding torque that is required to sustain an engine torque at a specific engine rpm varies depending on the machine configuration The variations are the differences in the engine setting in the power train efficiency and in the brake holding ability etc Test Procedure 1 Remove the work tool and park the machine in the travel position 2 Start the engine and disengage the parking brake Place the transmission in FIRST GEAR FORWARD 3 Apply the service brake and fully depress the accelerator pedal in order to increase the engine speed 4 The machine should remain stationary during this test 5 Switch off the engine and engage the parking brake 120 Maintenance Section 31200242 WARNING If the machine moved while testing the service brakes contact your Caterpillar dealer Have the dealer inspect and if necessary repair the service brakes before returning the machine to operation Failure to have the service brakes inspected and repaired could cause injury or death Parking Brake Check the area around the machine Make sure that the area is clear of personnel and obstacles Check the brakes on a dry level surface Fasten the seat belt before you c
113. e differential into the other side of the axle Ensure that the correct quantity of oil is added to the axle in order to fill the differential and the axle housing Damage to the differential will result if this procedure is not observed Refer to Operator and Maintenance Manual Lubricant Viscosities for the correct grade of oil Refer to Operation and Maintenance Manual Capacities Refill and the appropriate Service Manual for more detailed lubricant information 5 Clean combined level plug and filler plug 4 Reinstall combined level plug and filler plug 4 ial Oil Level Check NOTICE 128 Maintenance Section 31200242 Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Park the machine on level ground Fully retract the boom and fully lower the boom Move the transmission control to the NEUTRAL position and ensure that the parking brake is engaged Shut off the engine Rear Axle Differential lustration 224 900953223 1 Cl
114. e following procedures to the machine Remove any work tool from the machine Remove any load that is applied to the rear hitch b Position the machine on level ground If necessary level the frame of the machine c Ensure that all the wheels are facing straight ahead Drive the machine forward and drive the machine in reverse for 3 m 10 ft d For both the TH220B and the TH330B tilt the coupler fully backward On the TH340B tilt the coupler fully forward e Fully lower and retract the boom Engage the parking brake and move the transmission control to the NEUTRAL position 2 Turn the ignition to the OFF position Wait for 30 seconds 31200242 145 Maintenance Section 3 Turn the ignition to the ON position but do not crank the engine Note The machine will perform the self test Refer to the Engine Start Switch topic in Operation and Maintenance Manual Operator Controls for more information 4 After the self tests are completed the machine will test the longitudinal stability indicator system a If the test is successful the gauge will function in the manner that was described in the Operation and Maintenance Manual Monitoring System This indicates that the system is operating correctly The needle of the longitudinal stability indicator will move into the red zone of the gauge if the test is failed An intermittent audible alarm will sound The waming light will be activated Turn th
115. e fully retracted position Position the boom to the fully lowered position 9 Remove the hydraulic tank filler cap Add the 12 L 8 17 US gal of oil that was removed from the hydraulic tank in Step 3 of Procedure for Draining Hydraulic Tank 10 Check the oil level in the hydraulic tank If necessary top up the hydraulic oil to the required level Install the hydraulic tank filler cap Clean up any oil that may have been spilled Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Capacities Refill for further information 11 Install the access cover on the chassis Resetting the Load Control System Resetting the Load Control Valves 1 Reset adjustment screw 12 to the measurement that was recorded in Step 2 of Procedure for Retracting the Boom Refer to Illustration 146 2 Reset adjustment screw 20 to the measurement that was recorded in Step 2 of Procedure for Lowering the Boom Refer to Illustration 149 3 Secure adjustment screw 12 and adjustment screw 20 with locknut 13 and locknut 21 4 Repair the machine before you return the machine to service 31200242 101 Operation Section Purging Air from the System Air may have entered the hydraulic system Ensure that the air is purged from the hydraulic system before the machine is returned to service Note Purging air from the system should be performed on an unloaded boom 1 2
116. e ignition to the OFF position in order to stop the alarm Note This test is performed automatically The test will be conducted when the ignition is switched from the OFF position to the ON position m Second Test Perform the following test if the machine fails the initial test of the longitudinal stability indicator 1 Ensure that all of the steps have been performed in Step 1 of Initial Test 2 Repeat the test of longitudinal stability indicator system Note If the machine continues to fail system tests of the longitudinal stability indicator the machine must not be operated Call your Caterpillar dealer for recalibration of the longitudinal stability indicator system Oil Inspect a Used Filter for Debris er Inspect Mustration 261 The elementis shown with debris 900100013 Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure If metals are found in the filter element a magnet can used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts of debris may be found in the filter element This could be
117. e recommended location for mounting the fire extinguisher is on the plate for the seat to the right side of the operator If the fire extinguisher is mounted on the ROPS strap the mounting plate to a leg of the ROPS If the weight of the fire extinguisher is more than 4 5 kg 10 Ib mount the fire extinguisher as low as possible on one leg Do not mount the fire extinguisher on the upper one third area of the leg 31200242 27 Safety Section Note Do not weld the ROPS in order to install the fire extinguisher Also do not drill holes in the ROPS in order to mount the fire extinguisher on the ROPS Tire Information Explosions of air inflated tires have resulted from heat induced gas combustion inside the tires Explosions can be caused by heat that is generated by welding by heating rim components by external fire or by excessive use of brakes A tire explosion is much more violent than a blowout The explosion can propel the tire the rim components and the axle components as far as 500 m 1500 ft or more from the machine Both the force of the explosion and the flying debris could cause property damage personal injury or death Mustration 24 A Atleast 15 m 50 f At least 500 m 1500 f Do not approach a warm tire Maintain a minimum distance as shown Stay outside the shaded area in Mustration 24 900847810 To avoid overinflation proper training in the usage of the equipment are necessary A
118. e with a towed attachment ensure that the hitch is at the lowest setting Note Before connecting a towing attachment refer to Table 7 WARNING If the combined weight of the machine the towed attachment and the attachment freight exceed the brake capacity available from both the machine and the towed attachment a loss of control could occur The operator must verify that the combined weight does not exceed the combined braking capacity Loss of control could cause injury or death Your machine may be equipped with a number of different types of towing hitch Please refer to Types of Towing Hitches and Hydraulic Services for more information If the towed attachment is not equipped with brakes the following weights must not be exceeded The maximum permissible weight of attachment and freight is 5000 kg 11000 Ib The maximum vertical weight component on the hitch interface is 1500 kg 3300 Ib Note These weights are for the machine on level ground Note The maximum permissible weight of the attachment and freight may need to be reduced if the attachment will be towed on ground which is not level The speed of the machine may also need to be reduced if the attachment will be towed on ground which is not level WARNING Towed attachments which exceed the weights which are shown above must be equipped with a suitable type of brake system The brake system must be of sufficient capacity in order to supplement t
119. ean the area around combined level and filler plug 1 for the rear differential Remove combined level and filler plug 1 and check that the oil is level with the hole for combined level and filler plug 1 2 If necessary add oil through the same hole 3 Clean combined level and filler plug 1 and install combined level and filler plug 1 Front Axle Differential stration 225 1 Clean the area around combined level and filler plug 2 for the front differential Remove combined level and filler plug 2 and check that the oil is level with the hole 2 If necessary add oil through the same hole 3 Clean combined level and filler plug 2 and install combined level and filler plug 2 Differential Oil Sample Obtain Hot oil and components could cause personal injury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 31200242 129 Maintenance Section
120. earance Travel with the boom fully retracted so that you have good visibility and so that the machine has good stability Maintain traction by avoiding excessive downward pressure on the work tool When the machine is operating on a slope position the heaviest end of the machine uphill 31200242 73 Operation Section Make sure that the work tool that is being used is appropriate for the work that is being performed Exceeding the machine limits will reduce the service life of the machine Refer to Operation and Maintenance Manual Caterpillar Approved Work Tools for additional information Auxiliary Hydraulic Connections There are many types of work tools from various manufacturers which may be installed on the machine Caterpillar cannot anticipate every possible Work tool and use which may be encountered When you install a work tool or when you operate a work tool follow the manufacturer s guidelines and instructions If you are in doubt consult your Caterpillar dealer Your Caterpillar dealer can provide you with further information on the proper installation and use of specific work tools dM E 91 f zt a Mustraton 111 900975155 On standard machines a single diverter valve with two quick disconnects is installed The diverter valve allows the operator to direct hydraulic oil to the hydraulic quick coupler function or to the work tool Note The electrical diverter
121. ease the tension on the belt 1 Insert a 12 7 mm 0 50 inch ratchet into the square hole in the belt tensioner 2 and pry the belt tensioner in a clockwise direction Remove the belt from the pulleys Feed the belt over the fan Install the new belt around the pulleys Pry the belt tensioner in a clockwise direction Install the belt around the belt tensioner Release the belt tensioner in order to put tension on the belt The routing of the belt is shown in Illustration 172 and Illustration 173 Install the fan guard and tighten the retaining bolts to a torque of 15 3 Nm 11 1 2 2 Ib ft Turn the battery disconnect switch to the ON position Close the engine enclosure 31200242 115 Maintenance Section Boom Cylinder Pin Lubricate stration 179 There is a boom raise cylinder under the boom Lubricate the boom cylinder pin through the fitting at the rod end of the cylinder Boom Head Section Lubricate 00090020 Lubricate the boom head through lubrication fittings 1 2 and 3 Tilt the work tool forward in order to access lubrication fitting 4 Lubricate fitting 4 Boom Pivot Shaft Lubricate 900856576 Mustration 183 Lubricate the pivot shaft for the boom through the lubrication fitting The lubrication fitting is located on top of the pivot shaft for the boom Boom Telescoping Cylinder Air Purge It may be necessary to purge air from the boom
122. eat Belt for more information Engine Coolant 9 This safety message is positioned on the coolant tank in the engine enclosure A WARNING 725 4256 1 900981247 Pressurized system Hot coolant could cause serious burns injury or death To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pressure Read and understand the Operation and Maintenance Manual before performing any cooling system maintenance Refer to Operation and Maintenance Manual Cooling System Coolant Change for the correct procedure to remove the pressure cap Low Bridge 10 This safety message is positioned in the operator station on the right side of the front window This message is only located on machines that will be used in the United Kingdom THE COUPLER WORK TOOL SHALL NOT BE RAISED ABOVE THIS HEIGHT DURING ROADING PERSONAL INJURY PROPERTY DAMAGE OR DEATH MAY OCCUR 900931533 The coupler work tool shall not be raised above this height during roading Personal injury property damage or death could occur 14 Safety Section 31200242 Avoid Power Lines 11 This safety message is positioned in the operator station on the right side of the front window A DANGER 900936329 Electrocution Hazard Keep the machine and attachments a safe distance from electr
123. ect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note Change the engine oil and the filter after every 500 hours This is the normal interval provided that the following conditions are met Only genuine Caterpillar filters must be used Only Caterpillar Multigrade Diesel Engine Oil DEO to specification CG 4 or an equivalent must be used Refer to Operation and Maintenance Manual Lubricant Viscosities and the appropriate Service Manual for more detailed lubricant information Working conditions must be clean and applications must be light Obtain an SOS oil sample at the first 250 hours in order to determine if the oil change interval can be decreased The sulfur content of the fuel must be between 0 05 to 0 5 If a higher percentage of sulfur is present in the fuel the engine oil and the filter will need to be changed more often 0 5 to 1 0 of sulfur content will require the engine oil and the filter to be changed after every 250 hours 1 0 to 1 5 of sulfur content will require the engine oil and the filter to be changed after every 125 hours Before you drain the engine oil park the machine on a level surfac
124. ed and the sealant is not damaged Mustration 215 00990528 5 Loosen hose clamp 5 that is located on the hydraulic oil cooler Remove hose 4 Allow the coolant to drain into a suitable container stration 216 6 If the machine is equipped with a cab heater turn the heater control that is located inside the cab to the HOT position Loosen hose clamp 6 Remove hose 7 Allow the coolant to drain into a suitable container 7 Flush the cooling system with clean water until the draining water is transparent 8 Close drain valve 2 9 Reinstall coolant drain plug 3 in the engine block above the starter Tighten the plug 10 Reinstall hoses 4 and 7 Tighten clamps 5 and NOTICE Add the coolant solution at a maximum rate of five liters per minute This will reduce the chance of trapping air inside the engine block A large amount of trapped air can cause localized heating to occur upon start up Localized heating may result in engine damage which may lead to failure of the engine Add the coolant into the coolant tank Refer to Operation and Maintenance Manual Capacities Refil 12 Start the engine Operate the engine without the pressure cap for the coolant tank until the coolant temperature regulator opens and the coolant level stabilizes 13 Maintain the coolant level up to the FULL mark on the coolant tank 14 Inspect the gasket of the pressure cap If the gasket is damaged
125. ed as an option with some of the other hitches For the functionality of the switch for the towing hitch refer to Operation and Maintenance Manual Operator Controls Side Console for more information on the towing hitch control Hydraulic Hitch To connect the hydraulic hitch to the machine connect fitting 15 to hose end 17 Then connect fitting 16 to hose end 18 Trailer Brakes Connect the hydraulic coupling for the trailer brake to fitting 14 This connection must conform to ISO 5676 Trailer brakes are integrated with the service brakes for the machine The trailer brakes work immediately when the brakes have been connected properly Using the Hydraulic Services to Tip a Trailer If the machine is equipped with the hydraulic hitch ensure that the hitch is in the UP position The hitch must be held with the safety hooks Disconnect hose fittings 17 and 18 from the valve For a single acting trailer connect the trailer hose to fitting 15 For a double acting trailer connect the tip trailer hose to fitting 15 and connect the lower trailer hose fitting to fitting 16 The tip function is operated with the switch for the towing hitch 96 Operation Section 31200242 Engine Starting Alternate Methods Engine Starting with Jump Start Cables WARNING Never hotwire or short across the starter terminals Hot wiring or shorting across the starter terminals could bypass the engine neutral s
126. ed with the plate for the European Union this plate will be attached to the PIN plate Several pieces of information are stamped onto the CE plate For quick reference record this information in the spaces that are provided below Engine Power kW Machine Weight kg __ Year of Manufacture Sound stration 35 900937584 This message is located on the left side of the main frame stration 36 900993634 Atypical example of his decal is shown Your machine may have a different value If equipped the certification decal is used to verify the environmental sound certification of the machine The value that is listed on the decal indicates the guaranteed sound power level The guaranteed sound power level is measured at the time of manufacture The guaranteed sound power level is measured according to the conditions that are specified in 2000 14 ROPS FOPS Decal This safety sign is positioned behind the seat near the rear window Mustration 37 901211890 Structural damage an overturn modification alteration or improper repair could impair this structure s protection capability thereby voiding this certification Do not weld on or drill holes in the structure This will void the certification Consult a Caterpillar dealer to determine this structure s limitations without voiding its certification This machine has been certified to the standards that are listed on
127. edure for Lowering the Boom Procedure for Retracting the Boom Resetting the Load Control System F Final Drive Oil Change Final Drive Oil Level Check Final Drive Oil Sample Obtain Fire Extinguisher Location Fire Prevention and Explosion Prevention Fire Extinguishe Lines Tubes and Hoses Foreword Certified Engine Maintenance Literature Informatior Machine Capacity Maintenance Operation Safety Fork Leveling Cylinder Pin Lubricate Fuel System Prim Fuel System Water Separator Drain Fuel System Water Separator Element Replace 160 Index Fuel Tank Cap Clean Fuel Tank Water and Sediment Fuses and Relays Replace 140 2141 22142 General Hazard Information Containing Fluid Spillage Dispose of Waste Properly Fluid Penetration Pressurized Air and Water Trapped Pressure General Information Guards Operator Protection Other Guards If Equipped Rollover Protective Structure ROPS Falling Object Protective Structure Guards Operator Protection Important Safety Information Indicators and Gauges Test Leaving the Machine Lifting and Tying Down the Machine Lifting Capacities Examples of Estimating the Lift Operation from the Load Chart Longitudinal Stability Indicator Calibrat Initial Test Second Test Longitudinal Stability Indicator Test Lubric
128. er Clean Replace Primary Cab Air Filter Secondary Cab Air Filter 121 Circuit Breakers Test Compensating Cylinder Bearing Lubricate Cooling System Coolant Change Cooling System Coolant Level Check Cooling System Coolant Sample Level 1 Obtain 2 Table of Contents Cooling System Coolant Sample Level 2 Obtain 125 Cooling System Pressure Cap Clean Replace 125 Cooling System Water Temperature Regulator Replace Differential Oil Change Rear Axle Differential Front Axle Differential Differential Oil Level Check Rear Axle Differential Front Axle Differential Differential Oil Sample Obtain Drive Shaft Spline Lubricate Drive Shaft Universal Joint Bolts Engine Air Filter Primary Element Clean Replace Cleaning Primary Air Filter Elements Inspecting the Primary Air Filter Elements 131 Engine Air Filter Primary Element Replace 132 Engine Air Filter Secondary Element Replace 132 Engine Mounts Inspect Engine Oil Level Check Engine Oil Sample Obtain Engine Oil and Chang Engine Valve Lash Check Final Drive Oil Change Final Drive Oil Level Check Final Drive Oil Sample Obtain Fork Leveling Cylinder Pin Lubricate Fuel System Prime Fuel System Water Separator Drain 38 Fuel System Water Separator Element Replace Tier Il 139 Fuel System Water Separator Element Replace Tier Ill Fuel T
129. er tubes 1 are below the level of hooks 2 68 31200242 Operation Section block the carriage in order to prevent the carriage from moving when the carriage is disengaged from the quick coupler Lower the boom until tubes 1 are disengaged from hooks 2 Retract the boom until the quick coupler is clear of the carriage Manual Quick Coupler Your machine may be equipped with a manual quick coupler Illustrations in the following procedure show a carriage which is equipped with forks The procedure is applicable to all work tools with the same types of Mastaton 89 900975388 able to Left quick coupler pin mounting points 7 Check the positions of the pins on both sides of the quick coupler Both quick coupler pins must be Installation Procedure fully engaged Lower the boom until the carriage 1 1 Lower and extend the boom approximately 2 m is pressed against the ground Slowly back up the 6 6 ft so that the quick coupler can be seen from machine As the machine starts to move check the cab Position the quick coupler in line with the for movement between the carriage and the quick carriage coupler Movement indicates that the pins for the quick coupler are not properly installed Do not operate the machine unless the pins for the quick coupler are fully engaged through the quick coupler and the carriage 8 If equipped install the hydraulic lines for the carriage to the diverter valve Removal Procedure
130. ere injury I fluid is injected into your skin you must get treatment immediately Seek treatment from a doctor that is familiar with this type of injury Containing Fluid Spillage Care must be taken in order to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the equipment Prepare to collect the fluid with suitable containers before opening any compartment or disassembling any component that contains fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for the following items Tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids Tools that are suitable for containing fluids and equipment that is suitable for containing fluids Obey all local regulations for the disposal of liquids Dispose of Waste Properly Mustration 20 00706404 Improperly disposing of waste can threaten the environment Potentially harmful fluids should be disposed of according to local regulations Always use leakproof containers when you drain fluids Do not pour waste onto the ground down a drain or into any source of water Crushing Prevention and Cutting Prevention Support the equipment properly before you perform any work or maintenance beneath that equipment Do not depend on the hydraulic cylinders to hold up the equipment Equipment could fall if a control is moved or if a hydraulic line break
131. eries must be charged to proper voltage with a battery charger Many batteries thought to be unusable are still rechargeable This machine has a 12 volt starting system Use only the same voltage for jump starting Use of a welder or higher voltage damages the electrical system Refer to Special Instruction Battery Test Procedure 87633 available from your Caterpillar dealer for complete testing and charging information If your battery is dead you may need to charge the battery at a low rate of charge When auxiliary start receptacles are not available use the following procedure 1 Engage the parking brake on the stalled machine Place the transmission into neutral Lower the equipment to the ground Move all of the controls to the HOLD position 2 Tum the engine start switch on the stalled machine to the OFF position Tum off all of the accessories 3 Tum the battery disconnect switch on the stalled machine to the ON position if equipped 4 Move the machine that is being used as an electrical source near the stalled machine so that the jump start cables reach the stalled machine Do not allow the machines to contact each other 5 Engage the parking brake of the machine that is being used as an electrical source 6 Stop the engine of the machine that is being used as an electrical source If you are using an auxiliary power source tum off the charging system 7 Ensure that battery caps on both machines
132. f the engine speed is high Refer to the topic Transmission Control in Operation and Maintenance Manual Operator Controls for additional information Control the speed of the machine in order to suit conditions Make an allowance for surface conditions weather conditions and load NOTICE Damage to the transmission could occur if the machine is allowed to coast in neutral Damage to the transmission could also occur if a change of direction is selected while the machine is moving Do not allow the machine to coast Only select a transmission direction change if the machine is completely stopped Note These machines are not equipped with speedometers Before you change the direction of the machine from forward to reverse or from reverse to forward stop the machine completely Select the correct gear before you travel downhill Select the necessary travel speed before you start downhill Do not change gears while you are going downhill When you go downhill use the same speed that would be used to go uphill Do not allow the engine to overspeed when you go downhill Use the service brake to prevent engine overspeed when you go downhill Select a lower gear before you go down the same hill again 31200242 67 Operation Section When you are travelling uphill select a lower gear when the engine speed starts to fall Drive the machine in the gear that will allow the required speed to be maintained Hydraulic Quick Coupler
133. flashes red and there is no audible alarm In order to prevent severe damage to components the operator is required to change the machine operation or the operator is required to perform maintenance to the machine When a warning category 2S occurs the action lamp flashes red and there is a constant audible alarm In order to prevent severe damage to components the operator is required to change the machine operation When a warning category 3 occurs the action lamp flashes red and there is an intermittent audible alarm In order to prevent personal injury or severe damage to components the operator is required to perform a safe engine shutdown When the machine has been configured with no model designation indicator 2 flashes amber and no audible alarm will sound This condition will not log an error code When the data link is not communicating with the display unit indicator 2 flashes amber and no audible alarm will sound This condition will log an error code Battery Condition 3 This indicator illuminates when the battery is not receiving charge from the alternator 31200242 81 Operation Section Combined Transmission and Hydraulic Oil Filter 4 This indicator illuminates when the transmission oil filter needs to be replaced Engine Air Filter 5 This indicator illuminates when the engine air filter needs to be replaced Indicators ustration 135 901002580 Left Turn S
134. ft side of the switch in order to select automatic shifting between the gears of the transmission The operator will select the highest speed range and the machine ECM will automatically shift the transmission between the lowest gears to the highest gear that has been selected based on ground speed of the machine A lamp inside the switch will be illuminated Push the right side of the switch in order to manually select a specific speed gear Quick Coupler Control 3 Quick Coupler Control This is a three position switch if equipped When switch 3 is released the switch will return to the HOLD position Disengage Move the red slider on switch 3 3 downward and push the top of switch 3 Hold the top of switch 3 until the quick coupler pins 2 are fully disengaged Hold When switch 3 is released the switch will return to the HOLD position grs Engage Press the bottom of switch 9 Hold the bottom of switch 3 until the quick coupler 57 pins are fully engaged 9 Transmission Neutralizer Control 4 WARNING If the transmission neutralizer control switch is in the ON position and the service brake control pedal is pressed the transmission will shift into NEUTRAL When the service brake control pedal is released it will take a short period of time for the transmission to reengage the original gear If the machine is on a hill during this time the machine can roll forward or the machine can r
135. he brake capacity of the machine Ensure that the braking specification for the towed attachment meets the local regulations for your intended application Ensure that this has been confirmed by the supplier for the towed attachment For towed attachments that are equipped with a brake system of sufficient capacity refer to Table 7 31200242 91 Operation Section Table 7 Type of Hitch TH220B TH220 THssoB 0 Maximum weight of towed attachment 12000 kg 12000 kg 12000 kg 12000 kg and freight 26400 Ib 26400 Ib 26400 Ib 26400 Ib Hydraulic Hitch Maximum vertical weight component 2500 kg 2500 kg 2500 kg 2500 kg on the hitch interface 5500 Ib 5500 Ib 5500 Ib 5500 Ib Maximum weight of towed attachment 12000 kg 12000 kg 12000 kg 12000 kg and freight 26400 Ib 26400 Ib 26400 Ib 26400 Ib Piton Hitch Maximum vertical weight component 2500 kg 2500 kg 2500 kg 2500 kg on the hitch interface 5500 Ib 5500 Ib 5500 Ib 5500 Ib Maximum weight of towed attachment 12000 kg 12000 kg 12000 kg 12000 kg and freight 26400 Ib 26400 Ib 26400 Ib 26400 Ib Maximum vertical weight component h 1900 kg 1700 kg 1900 kg 1750 kg on the as hitch interface in the 4180 Ib 8740 Ib 4180 Ib 8850 Ib Piton Hitch lowest position If Equippedy 3 Maximum vertical weight component bog 1250 kg 1000 kg 1350 kg 1200 kg on the auto am Iud inany other 2200 Ib 2970 Ib 2640 Ib
136. heck the brakes The following procedure is used in order to determine if the parking brake is functional This procedure is not intended to measure the maximum brake performance The brake holding torque that is required to sustain an engine torque at a specific engine rpm varies depending on the machine configuration The variations are the differences in the engine setting in the power train efficiency and in the brake holding ability etc Test Procedure 1 Start the engine 2 Engage the parking brake 3 If the machine is equipped with a standard transmission move the transmission control lever in the following pattern SECOND NEUTRAL SECOND This is done in order to override the transmission neutralizer for this test Note The indicator light for the parking brake should come on 4 If the machine is equipped with a power shift transmission move the transmission control lever in the following pattern SECOND GEAR FORWARD NEUTRAL SECOND GEAR FORWARD This is done in order to override the transmission neutralizer for this test Note The indicator light for the parking brake should come on 5 Gradually increase the engine speed to high idle The machine should not move If the machine begins to move reduce the engine speed immediately and apply the service brake pedal 6 Reduce the engine speed Move the transmission control lever to NEUTRAL If the machine moved during the test perfor
137. hine make a thorough daily inspection before you operate the machine Inspect the machine for leaks Remove any debris from the engine compartment and the undercarriage Ensure that all guards covers and caps are secured Inspect all hoses and belts for damage Inspect all lights and mirrors for damage If visibility is impaired adjust or replace the lights and the mirrors Inspect the brackets for the lights and the mirrors Replace the brackets if damage or corrosion exists Check the condition of the fan drive belt Check the fuel gauge If necessary fill the fuel system Make the needed repairs before you operate the machine Perform the following procedures on a daily basis Backup Alarm Test Braking System Test 42 Operation Section 31200242 Cooling System Coolant Level Check Engine Oil Level Check Fuel System Water Separator Drain Fuel Tank Water and Sediment Drain Indicators and Gauges Test Seat Belt Inspect Tire Inflation Check Transmission and Hydraulic System Oil Level Check Wheel Nut Torque Check Windows Clean Work Tool Inspect Replace Refer to the Maintenance Section for the detailed procedures Refer to the Maintenance Interval Schedule for a complete list of scheduled maintenance 31200242 48 Operation Section Machine Operation Alternate Exit The door on the left side of the machine is the primary exit On machines which are equipped with an enclosed
138. ical power Stay clear 3 m 10 ft plus twice the line insulator length Read and understand the instructions and warnings in the Operation and Maintenance Manual Failure to follow the instructions and warnings will cause serious injury or death Always check for power lines before raising the boom Failure to check for power lines before raising the boom could result in injury or death by electrocution Refer to Operation and Maintenance Manual Before Starting Engine for more information Jump Start Cables 12 This safety message is positioned on a bracket next to the batteries WARNING 900931020 WARNING Explosion Hazard Improper jumper cable connections could cause an explosion resulting in serious injury or death Batteries be located in separate compartments Refer to the Operation and Maintenance Manual for the correct jump starting procedure Refer to Operation and Maintenance Manual Engine Starting with Jump Start Cables for more information Ether 13 This safety message is positioned on the intake for the air cleaner A WARNING 900931562 WARNING Explosion hazard Do not use ether This machine is equipped with an air inlet heater Using ether can create explosions or fires that could cause personal injury or death Read and follow the starting procedure in the Operation and Maintenance Manual Refer to Operation and Maintenance Manual Fire Prevention and Explosion Preven
139. ight that is listed is for machines that are equipped with tires that are filed with air Intended Use This vehicle is classified either as A self propelled variable reach truck Telehandler as defined in ISO 3691 2 and 1459 1998 An agricultural tractor when meeting the requirements of European Union Directive 74 150 This vehicle is all wheel drive and has all wheel steer ability This vehicle has a rigid chassis with a variable reach boom mounted centrally on to which a range of Caterpillar approved attachments may be attached As a machine the vehicle has a primary use as a material handler to pickup and place materials As an agricultural tractor the vehicle has a primary use for towing Application Configuration Restrictions Maximum approved operating weight TH220B 8925 kg 19635 Ib TH330B 9300 kg 20460 Ib Maximum draw bar towing force Refer to Operation and Maintenance Manual Towing the Machine for more information Maximum draw bar vertical load Refer to Operation and Maintenance Manual Towing the Machine for more information Maximum fore and aft slope on this machine in a static condition to maintain proper lubrication For machines equipped with a 92 kW engine 57 7 percent grade or 30 degrees For machines equipped with a 74 5 kW or 93 1 kW engine 44 5 percent grade or 24 degrees 36 31200242 Product Information Section Identification Inform
140. ignal 6 This indicator flashes when the left turn signal is operating Circle Steer 7 This indicator is illuminated when circle steer mode is selected Crab Steer 8 This indicator is illuminated when crab steer mode is selected Two Wheel Steer 9 This indicator is 8 illuminated when two wheel steer mode is selected Engine Starting Aid 10 This indicator is illuminated when the engine starting aid is Switched on 9 Parking Brake Indicator 11 This indicator illuminates when the parking brake is engaged Right Turn Signal 12 This indicator flashes 9 when the right turn signal is operating Trailer Turn Signals 13 This indicator flashes when a trailer turn signal is operating High Beam 14 This illuminates when the high beam headlights are switched on Hydraulic Auxiliary 2 15 This indicates VE when the solenoids on the diverter valve have been energized in order to divert oil flow to the second auxiliary circuit Gauges These gauges are used to help the operator to monitor trends in machine operation or changes in machine operation Mustration 137 Display panel with longitudinal stabilty indicator 901002588 Engine Coolant Temperature 16 This gauge indicates the temperature of the engine coolant The green zone indicates that the engine coolant temperature is normal The red zone indicates that the engine coolant is
141. iliary 2 is selected indicator light 14G will be illuminated The speed of the following functions is governed by the amount of movement of the joystick control and engine speed Boom raise Boom lower Quick coupler tilt forward Quick coupler tilt backward For smooth operation first increase the engine speed from low idle Then move joystick control 14 slowly until the attachment is moving at the required speed The speed of the boom extend and boom retract is governed by the amount of movement of thumb wheel 148 Move joystick control 14 diagonally in order to simultaneously tilt the quick coupler forward or backward while the boom is being raised or lowered Move joystick control 14 diagonally At the same time operate thumb wheel 14B in order to simultaneously tilt the quick coupler while the boom is being operated in two directions B Control Arrangement Single Thumb Wheel 14F Mostration 67 901147854 Machines that have the Type B control arrangement are equipped with decal 14F that is shown above Joystick control 14 operates in the following way station 68 901217641 backward in order to raise the boom When joystick control 14 is released the joystick control will return to the HOLD position Boom Raise Pull joystick control 14 forward in order to lower the boom When joystick control 14 is released the joystick control will return to the HOL
142. ing clip 1 3 Release cover 2 from air filter housing 3 by rotating counterclockwise Remove the cover from the housing 4 Remove primary element 4 from filter housing 3 To avoid dislodging any dust take care to avoid touching the element against the sides of the housing 5 Remove secondary filter element 5 6 Cover the air inlet opening Clean the inside of the air cleaner housing 31200242 188 Maintenance Section 7 Uncover the air inlet opening Install a new secondary element 8 Install the primary element and the air filter cover 9 Close the engine enclosure Engine Mounts Inspect Check the engine mounts for deterioration Check the bolts on the engine mounts for the proper torque correct torque on the bolts will prevent excessive engine vibration that is caused from improper mounting Engine Oil Level Check Hot oil and hot components could cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Do not under fill or overfill engine crankcase with oil Either condition can cause engine damage Park the machine on level ground Check the crankcase level with the machine level If the machine has just been stopped wait for a minimum of one minute The minute will allow oil to drain back into the crankcase Mustration 239 901081071 3 Clean the oil filler cap Remove the oil filler cap If necessary add oil 4
143. ing which has been carried out on the machine and the operating conditions More frequent inspections will be required of older machines and machines that are used in particularly severe applications If the machine has been involved in any kind of accident the machine must be taken out of service immediately The machine must be inspected again perform a proper inspection the machine must be thoroughly cleaned It is impossible to inspect the machine properly if the machine is dirty Early detection and repair of faults will ensure continued operation of the machine Also early detection and repair will improve the availability of the machine Repair of faults will also reduce the risk of accidents The machine should only be repaired by a qualified Caterpillar dealer However if you decide to carry out your own repairs consult your Caterpillar dealer for the recommended repair techniques lustration 203 Main frame and support cradle 900861901 Retract the boom and raise the boom away from the main frame and support cradle 1 Support the boom with a suitable stand To properly support the boom use the following tools Table 16 Required Tools PartNumber Description Quantity 85 7641 Tube 1 4C 6486 Stand 1 8S 7615 Pin 1 85 7625 Collar 1 85 8048 Saddle 1 Inspect the complete main frame and the support cradle Inspect the main frame and the support cradle particularly
144. ion 100 900832853 7 Raise the boom and extend the boom The forks must be in line with the pockets of the load 8 Use the load chart to assess the intended load The load chart must indicate that the intended load is within the capacity of the machine Refer to Operation and Maintenance Manual Lifting Capacities lustration 98 900832851 5 Tilt the quick coupler until the forks are level The machine is equipped with an automatic system for keeping the quick coupler at the selected angle when the boom is raised or lowered Mustration 101 900832854 9 Extend and lower the boom The forks must enter the pockets of the load cleanly The forks must be fully engaged with the pockets of the load Take care not to dislodge the load 31200242 71 Operation Section 900832856 Mustration 102 10 Raise the load carefully When you are sure that the machine is stable tilt the quick coupler backward in order to raise the load If you are not sure that the machine is stable tilt the quick coupler forward in order to lower the load Do not proceed Reposition the machine in order to shorten the reach before you attempt to lift the load again Mustration 105 00832859 13 Approach the destination slowly Position the machine square Get as close to the load placement location as possible Engage the parking brake and move the transmission control to NEUTRAL position If necessary level the frame
145. ion in order to start the engine Release the engine start switch key when the engine starts Allow the engine to operate at low idle Note Before you attempt to start the engine again move the engine start switch key to the OFF position for 10 seconds This will allow the diagnostic system to reset Refer to the appropriate Service Manual for more detailed information about the self test NOTICE Do not crank the engine for more than 30 seconds Allow the starting motor to cool for two minutes before cranking again Turbocharger if equipped damage can result if the engine rpm is not kept low until the engine oil light gauge verifies the oil pressure is sufficient Starting Below 0 C 32 F A WARNING If equipped with an air inlet heater AIH for cold weather starting do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury 1 Follow Step 1 to Step 7 of the Engine Starting procedure Mustraton 152 2 If the temperature is below the preset limit indicator 4 wil illuminate on the instrument panel 3 When indicator 4 goes out turn the engine start switch key to the START position in order to start the engine 4 Allow the engine to warm up for several minutes The actual time depends on the outside temperature Use the latter part of this time to help warm up the hydraulic oil by operating the joystick control in order to
146. ion of the Operation and Maintenance Manual 2 In order to move the attachment into position for the operation raise the boom and extend the boom as required Do not make the lift operation 3 Look at the boom extension reference scale and the boom angle reference scale and note the readings Refer to the load chart and use these two values in order to locate the equivalent load zone 4 If the intended load is equal to or lower than the value in the equivalent load zone the lift operation can be attempted with caution Also if the intended load is less than the value in the equivalent load zone the lift operation can be attempted with caution 5 If the intended load is heavier than the value in the equivalent load zone the lift operation must not be made 34 Product Information Section 31200242 Examples of Estimating the Lift Operation from the Load Chart Note In the examples that follow the numbers are from the load chart that is shown at the end of this section This load chart is only for illustrative purposes This load chart does not relate to any particular machine The numbers that are quoted have no units The units on the load charts which are installed in a particular machine may be kilograms or pounds Example 1 The weight of the intended load is 45 units The boom angle reference is 56 degrees The boom extension reference scale is at D With reference to the load chart X is the point
147. ipes are in good condition 5 Connect the quick disconnects on the work tool to the quick disconnects on the machine Ensure that the quick disconnects are correctly engaged The lock rings must be fully engaged and secure Disconnecting a Work Tool 1 The work tool must be resting on the ground If necessary support the work tool on blocks 2 Engage the parking brake Move the transmission control to the NEUTRAL position and stop the engine Move all the hydraulic controls to the HOLD position 3 Clean the quick disconnects Pull back on the lock rings in order to disengage the quick disconnects Install protective caps on the quick disconnects on the machine and on the quick disconnects on the work tool 74 Operation Section 31200242 Carriages and Forks lustration 112 Typical carriage and forks 900974120 All Caterpillar approved carriages that are used on these machines can be installed directly to the quick coupler All carriages are designed with backrests to support the load Wide versions should be used for additional support when large loads are handled Forks A WARNING A crushing hazard exists when the boom is lowered or from a falling load Stay clear of the boom when the machine is in operation Failure to stay clear of the boom could cause injury or death A WARNING Failure to comply to the rated load could cause possible personal injury or attachment damage Review the rated load
148. ired travel speeds All four speeds can be selected in both forward and reverse travel Speed changes are possible when you are moving and when the machine is at full engine speed Mustration 77 900846950 Move the transmission speed lever according to the shift pattern in Illustration 77 60 Operation Section 31200242 Directional Turn Signal Control 23 Directional Turn Signal Push up on switch 23 in order to activate the left turn signal Pull down on switch 23 in order to activate the right turn signal The mid position is the OFF position Note The turn signal only operates when the ignition is in the ON position Engine Start Switch 24 Engine start switch 24 is located on the right side of the dash panel The engine start switch has three positions Electrical power is supplied to the systems in the cab when the engine start switch key has returned from the START position to the ON position key and when you remove the engine start Switch key the engine start switch key must be in the OFF position To disconnect the power to the electrical circuits in the cab turn the engine start switch key to the OFF position Also tum the engine start Switch key to the OFF position in order to stop the engine OFF When you insert the engine start switch When the key is in the OFF position the following circuits remain activated Hazard warning Interior light Parking lights cl
149. is located on the left hand cover at the rear of i the broom Trap Point 25 This message is located on both sides of the hitch on WARNING the broom le WARNING 4 e 900951585 WARNING Soma Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual WARNING Failure to follow the instructions or heed the warnings No clearance for person in this area during operation could result in injury or death Contact any Caterpillar Severe injury or death from crushing could occur Stay dealer for replacement manuals Proper care is your away from the work tool while it is in operation responsibility 18 Safety Section 31200242 Crushing Hazard 26 This message is located on each side of the top cover for the broom WARNING 900951565 WARNING No clearance for person in this area during operation Severe injury or death from crushing could occur Stay away from the work tool while it is in operation Ether 27 Tier This message is located on the side of the valve cover WARNING 59 900924889 WARNING If equipped with an air inlet heater AIH for cold Weather starting do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury Tier This message is located on the inlet manifold cover
150. jury or damage to surrounding structures and materials could result Extremely cold temperatures could cause a load to be frozen to the ground Free the load before you attempt to raise the load Failure to comply could affect the stability of the machine when a lift is attempted Use tag lines to assist in the control of loads that require accurate placement When a load is lifted and the boom is extended and raised the boom will deflect under the load This has the effect of moving the load away from the machine as the load is raised Make an allowance for this deflection Maneuver the load into position by operating the boom functions Do not use the quick coupler to position the load when the boom extension is installed The operator must remain at the controls of the machine when a load is suspended from the boom extension Lifting Hook MWostation 119 900974785 Before you raise the load position the lifting point on the lifting hook directly above the lifting point on the load Failure to follow this procedure could cause the load to swing when the load is lifted Personal injury or damage to surrounding structures and materials could result Material Handling Arm Mustraton 120 901097376 Reference the correct load chart and do not exceed the machine capacities Use only approved lifting equipment with a current certificate of serviceability when you attach a load to a material handling arm Short slings wi
151. k tool s operation manual Wear any other protective equipment that is required for the operating environment To prevent personnel from being struck by flying objects ensure that all personnel are out of the work area While you are performing any maintenance any testing or any adjustments to the work tool stay clear of the following areas cutting edges pinching surfaces and crushing surfaces Parking Park the machine on a level surface If you must park on a grade chock the machine s wheels The boom must be fully retracted Fully retract the boom and lower the boom until the work tool is on the ground Apply the service brakes in order to stop the machine Move the transmission control to the NEUTRAL position Move the accelerator control to the LOW IDLE position Engage the parking brake Lower all equipment to the ground Activate any control locks Stop the engine Turn the engine start switch to the OFF position and remove the engine start switch key Tum the battery disconnect switch if equipped to the OFF position Remove the disconnect switch key if you do not operate the machine for an extended period of time This will prevent drainage of the battery A battery short circuit any current draw from certain components and vandalism can cause drainage of the battery Equipment Lowering with Loss of Hydraulic Power Before you lower any equipment with loss of hydraulic power clear the area around the eq
152. ks with cracks should be removed from service a E The maximum recommended difference in the height of the tip of the forks F is 6 5 mm 0 25 inch for pallet forks The maximum recommended difference in the height of the tip of the forks F is 3 D mm 0 125 inch for fully tapered forks The maximum allowable difference in the height of the tips between two or more forks is 3 percent of the length L of the blade Replace one or both forks when the difference in eases RUE the height of the tip of the fork exceeds the maximum allowable difference 2 Check the angle between the upper face of blade D and the front face of shank E Remove the fork from service if angle C exceeds 93 degrees 3 Check the straightness of the upper face of blade D and the front face of shank E with a straight edge Remove the fork from service if the deviation from straightness exceeds 0 5 percent of the length of the blade Remove the fork from service if the deviation from height exceeds 0 5 percent of the height of the shank A Iustration 295 901001977 156 Maintenance Section 31200242 5 Check the thickness J of the blade and the thickness H of the shank for wear Pay special attention to heel A Remove the fork from service if the thickness is reduced to 90 percent or less of the original thickness The length of the fork may also be reduced by wear especially on tapered forks Remove the
153. l Homologation number Allowed total weight Allowed front axle weight Allowed rear axle weight Permissible towable mass Un braked towable mass Independently braked towable mass Inertia braked towable mass Towable mass fitted with an assisted braking system hydraulic or pneumatic 31200242 39 Product Information Section Emissions Certification Decal Note This information is pertinent in the United States and in Canada If equipped the EPA EU Emission Certification decal is located on the side of the engine block A typical example is shown IMPORTANT ENGINE INFORMATION dt Habs 89 Engine Engine Familyreesesi2 sass Displacement 44 e Factory Reset if EPA Family DEPEN Refer to ar Setting Applicable EPA Advertised kW 957 O RPM 9944 0 Family Fuel Rate at adv kW 5e4mmo stk 2 Max Velues Init Timing eseelleewes NLIT cat e sssessslSesesss O 100 005 O Settings ore fo be made c normal operating temperature with transmission in neutral This engine comforms to 4 U S EPA segase 0 non rood and California off road Regulations for large C l engines ond is certified to operate on commercially available diesel fuel amp amp Emissions Control System Valve Lash Cold Cinchl seses
154. l alarm and the audible alarm When the ignition of the machine is turned from the OFF position to the ON position the machine will perform the system test for the LSI If the system passes the test for the LSI the machine may be operated as normal If the LSI system should detect a problem the machine will fail the system test This will cause indicator 23 to hold in the red zone 26 An intermittent audible alarm will sound and the warning lamp will be illuminated Refer to Operation and Maintenance Manual Longitudinal Stability Indicator Test for more information if the test fails For optimum performance of the LSI system the procedure for parking the machine must be followed Refer to Operation and Maintenance Manual Parking for more information During normal operation if the indicator for the LSI moves to the amber zone with light loads on the work tool perform the following actions Follow the procedure for parking the machine Turn the ignition to the OFF position Wait for 30 seconds Start the machine and resume operation Leaving the machine in any of the following states may result in reduced performance of the 1 51 system Reduced performance is indicated when the indicator moves to the amber zone with light loads on the work tool Reduced performance of the LSI system could cause the test for the LSI to fail The boom is left in the raised position The parked machine is facing upward on
155. l gauge reaches the red area the fuel tank should be filled Note TH220B and TH330B are available with an auxiliary fuel tank which increases the capacity of the fuel system from 115 L 30 4 US gal to 165 L 43 6 US gal If the machine is equipped with an auxiliary fuel tank then the rate of movement of the needle on the fuel gauge of the indicator for the fuel level will slow down as the tank approaches the empty level For a constant rate of fuel consumption the needle movement will slow down as the tank is emptied Longitudinal Stability Indicator 23 This gauge indicates the longitudinal stability of the machine if equipped Refer to Illustration 137 Refer to Longitudinal Stability Indicator for more information Longitudinal Stability Indicator A WARNING Operating the machine beyond its stability limit could result in a tip over or failure of the work tool Check the proposed lift with the load chart Do not attempt the lift if the longitudinal stability limit of the machine will be exceeded Tip over or failure of the work tool could cause personnel injury or death Your machine may be equipped with a longitudinal stability indicator The longitudinal stability indicator provides audible signals and visual signals in order to indicate the limit of the forward stability of the machine if equipped The audible signal is shared with other system failures Refer to Operation and Maintenance Manual for usages of the a
156. l information 9 Tighten hydraulic tank filler cap 6 10 Close the protection cover Transmission and Hydraulic System Oil Level Check Before you check the level of the hydraulic oil perform the following procedures Park the machine on a level surface Retract the boom Lower the work tool to the ground mustraton 282 901202853 An oil level gauge is located behind protection cover 3 on the left side of the machine In order to open the protection cover unlock lock 2 and turn lock 4 counterclockwise Then pull latch 1 outward 152 Maintenance Section 31200242 1 MHustraion 283 Hydraulic tank filer cap 901205926 Note Run the machine for at least five minutes in order to pressurize the hydraulic system You should look at oil level gauge 5 in order to check the level of oil in the hydraulic system The oil level of the hydraulic system is correct when the oil level has reached the line that is marked MAX or if the oil level is halfway between the red line and the blue line on the oil level gauge If necessary add Caterpillar to the correct oil level by the following method 1 Lift latch 6 and loosen hydraulic tank filler cap 7 slowly in order to relieve the pressure in the hydraulic system Remove the hydraulic tank filler cap 2 Top up the hydraulic oil to the required level and install the hydraulic tank filler cap Clean up any oil that has s
157. lation Make sure that the installation tool does not damage the filter 31200242 135 Maintenance Section 901081070 242 9 Remove filler cap 4 and fill the crankcase with new oil Refer to Operation and Maintenance Manual Lubricant Viscosities for more information on the type of oil that is required Refer to Operation and Maintenance Manual Capacities Refill for more information on the quantity of oil that is required Check that the parking brake is engaged and that the transmission is in NEUTRAL and then start the engine Operate the engine for five minutes at low idle Inspect the engine for leaks and make any repairs that are necessary 11 Stop the engine Wait for two minutes after you stop the engine Stopping the engine allows oil to drain back to the crankcase Check the oil level If necessary add oil Maintain the oil level between the ADD mark and the FULL mark on the dipstick Install the filler cap 12 Close the engine access door Engine Valve Lash Check Maintenance is recommended by Caterpillar for engine valve lash adjustments The maintenance for the engine valve lash is part of the lubrication and preventive maintenance schedule in order to provide maximum engine life Note The engine valve lash should be checked at every 2000 hours or 2 years NOTICE Only qualified service personnel should perform this maintenance Refer to the Service Manual
158. lations and mandates stration 255 900079514 The fuel tank drain plug is located on the bottom of the fuel tank 1 Loosen the fuel tank drain plug Do not remove the fuel tank drain plug Allow the water and the sediment to drain into a suitable container and then tighten the fuel tank drain plug 2 Add fuel to the fuel tank Fill the fuel tank at the end of each day of operation Filling the fuel tank after every day of operation will drive out moist air Also filing the fuel tank helps to minimize condensation Do not fill the fuel tank to the top Warm fuel expands and the fuel may overflow if the fuel tank is overfilled Note Never allow the fuel tank to run dry 142 Maintenance Section 31200242 Fuses and Relays Replace 156 78 Mustration 256 Fuse panel 900951206 The fuse panel is located behind an access cover in the left side of the cab arrangement Remove the cover in order to expose the fuses and relays Fuses NOTICE Replace fuses with the same type and size only Otherwise electrical damage can result If it is necessary to replace fuses frequently an electrical problem may exist Contact your Caterpillardealer The fuses protect the electrical system from damage that is caused by overloaded circuits If the element inside the fuse separates replace the fuse Check the circuit if the element is separated in the new fuse Repair the circuit
159. lds must be provided on both machines This will protect the operator if the tow line breaks or the tow bar breaks Do not allow any person on the disabled machine except the operator Only allow the operator on the disabled machine if the operator can control the steering and or braking Use an observer in a safe position in order to watch the procedure The observer can stop the procedure if the rope starts to break or the rope starts to unravel Stop the procedure if the towing machine moves without moving the towed machine Do not disengage the parking brake or remove chocks from the wheels before the tow line or tow bar has taken the weight of the disabled machine Quick machine movement could overload the tow line or tow bar This could cause the tow line or tow bar to break Gradual smooth machine movement will be more effective Keep the tow line angle to a minimum Do not exceed a 30 degree angle from the straight ahead position All situation requirements cannot be listed Minimal towing machine capacity is required on smooth level surfaces while maximum towing machine capacity is required on grades with poor ground conditions If you are doubt consult your Caterpillar dealer for advice before you attempt to tow a disabled machine Towing with the Machine Note TH220B TH330B and TH340B machines are designed for use as towing machines when an approved towing hitch is installed Note When you operate the machin
160. le to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Primary Filter 1 Park the machine on level ground Fully retract and fully lower the boom Move the transmission control to the NEUTRAL position and ensure that the parking brake is engaged Shut off the engine 2 Open the engine enclosure 3 Loosen valve 1 and drain contents of glass bow 2 into suitable container Tighten valve 4 Support glass bow 2 and remove screw 3 Remove glass bowl and clean 5 Remove canister 4 and old seals 6 Install new canister and tighten by hand 7 Install new seals on screw and glass bowl 8 Align glass bowl to canister and install screw Torque to 5 Nm 44 Ib in 9 Replace secondary fuel filter Secondary Filter 1 Place suitable container under fuel filter 2 Clean outside of filter and remove canister 5 3 Install new canister and tighten by hand 4 Prime the fuel system Refer to Operation and Maintenance Manual Fuel System Prime for further instructions 5 Start the engine and check for leaks Fuel Tank Cap Clean Wustration 252 The fuel filler cap is located behind protection cover 3 on the left side of the cab Note Before the machine is refueled or before the fuel filler cap is cleaned remove foreign material from the top of the fuel tank 31200242 141 Maintenance Section 1 In
161. lear of location tongue 5 Stop the engine If equipped remove the battery disconnect switch key Remove the engine start switch key 2 Remove retaining clip 3 and pin 2 Remove boom cylinder lock 1 from boom cylinder and place the lock on the flat area of the main frame Descend from the machine Hustration 83 Typical example of storage bracket 901071445 3 Stow boom cylinder lock onto the storage bracket that is mounted on the machine The bracket can be mounted on the left side of the machine or on the right side of the machine 4 Install the engine start key If equipped install the battery disconnect switch key Start the engine and fully lower the boom Operation Information A WARNING Do not operate or work on this machine unless training has been accomplished and you have read and understand the instructions and warnings in the Operation and Maintenance Manuals Failure to follow the instructions or heed the warnings could result in injury or death Contact your Caterpillar dealer for replacement manuals Proper care is your responsibility A DANGER If the machine is positioned too close to electric power lines electric current will pass through the machine This will cause injury or death by electrocution Keep the machine at least 8 m 25 ft away from electric power lines Always check for power lines before raising the boom A WARNING The instability of the machine could result in injury
162. lisses Use service tool tattare Exhaust 5 5 LABEL to verify current Honger No s3 Position ses Lobel No 3I8IAO8 engine settings The EPA EU Emissions Certification Film Gf applicable is located either on the side the top or the front of the engine stration 43 901148857 40 31200242 Product Information Section 31200242 Operation Section Operation Section Before Operation Mounting and Dismounting Mustration 44 Typical example 900037860 Mount the machine and dismount the machine only at locations that have steps and or handholds Before you mount the machine clean the steps and the handholds Inspect the steps and handholds Make all necessary repairs Face the machine whenever you get on the machine and whenever you get off the machine Maintain a three point contact with the steps and with the handholds Note Three point contact can be two feet and hand Three point contact can also be one foot and two hands Do not mount a moving machine Do not dismount a moving machine Never jump off the machine Do not carry tools or supplies when you try to mount the machine or when you try to dismount the machine Use a hand line to pull equipment onto the platform Do not use any controls as handholds when you enter the operator compartment or when you exit the operator compartment Alternate Exit Machines that are equipped with cabs have alternate
163. ll prevent excessive load swing WARNING Before you raise the load position the lifting point on the material handling arm directly above the lifting point on the load Failure to follow this procedure could cause the load to swing when the load is lifted Personal injury or damage to surrounding structures and materials could result Extremely cold temperatures could cause a load to be frozen to the ground Free the load before you attempt to raise the load Failure to comply could affect the stability of the machine when a lift is attempted 31200242 77 Operation Section Use tag lines to assist in the control of loads that require accurate placement When a load is lifted and the boom is extended and raised the boom will deflect under the load This has the effect of moving the load away from the machine as the load is raised Make an allowance for this deflection Maneuver the load into position by operating the boom functions Do not use the quick coupler to position the load when the material handling arm is installed Hopper Mustraton 121 900974787 Picking up the Hopper Position the machine square to the hopper Extend and lower the boom The forks must enter the pockets of the hopper cleanly The forks must be fully engaged with the pockets of the hopper Wusraton 122 0087405 When the forks fully engage a bar that is spring loaded will lock each fork in position Establish that the forks are securel
164. lso travel with the boom lowered as far as possible Maintain adequate ground clearance for conditions Never travel if a load is raised beyond the travel position Be careful to avoid any ground condition which could cause the machine to tip Avoid any conditions that could lead to tipping of the machine The machine could tip when you work on the following obstacles banks hills and slopes If the machine is equipped with stabilizers the stabilizers must be fully raised before you move the machine Lifting Capacities Maintain control of the machine Do not overload the machine beyond the machine capacity Ensure that the correct load chart is referenced Loads must be within the weight limit of the machine and loads must be within the load center limit for the machine Lifting capacity decreases as the load is moved further from the machine Note If an 180 6137 Coupler Adapter Gp for a work tool is installed on the quick coupler reduce the load carrying capacity of the machine by 200 kg 440 Ib for all work tools and with the boom in any position Refer to Operation and Maintenance Manual Lifting Capacities for additional information Ensure that the tires are serviceable and that the tires are inflated to the correct pressure On machines that are equipped with a frame leveling Switch always level the frame before you raise the boom or before you lower the stabilizers Never operate the frame leveling switch when the boom is
165. lter element into the housing and rotate the element for 90 degrees clockwise in order to lock the element into position Lubricate the O ring seal on the new element with clean diesel fuel Install the housing onto the mounting base Tighten the housing by hand Do not overtighten the housing Note Ensure that the O ring seal is not damaged during the installation of the housing Replace the O ring if the O ring is damaged 9 Prime the fuel system Refer to Operation and Maintenance Manual Fuel System Prime for further instructions Start the engine and check for leaks 140 Maintenance Section 31200242 Fuel System Water Separator Element Replace Tier Personal injury or death may result from failure to adhere to the following procedures Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitab
166. lvents gasoline or harsh chemicals could loosen the adhesive that secures the messages Loose adhesive will allow the messages to fall Replace any message that is damaged or missing If a message is attached to a part that is replaced install a message on the replacement part Any Caterpillar dealer can provide new messages 20 31200242 Safety Section MHustration 901106884 31200242 21 Safety Section Air Cleaner 1 This message is located on the cover for the air cleaner tustraton 9 00891688 Clean the filter element or replace the filter element when the restriction indicator shows red Refer to Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace and Operation and Maintenance Manual Engine Air Filter Secondary Element Replace for more information Auxiliary Hydraulics 2 If equipped this message is located on the left side of the boom head Mustration 10 00894458 Use only work tools that are approved by Caterpillar Refer to Operation and Maintenance Manual Operator Controls and Operation and Maintenance manual Work Tools for more information On machines that are equipped with an air conditioner this label is located behind the protection cover at the rear of the door Alternate Exit 3 This message is located on the rear window of the cab
167. m the maintenance procedure Operation and Maintenance Manual Parking Brake Adjust Cab Air Filter Clean Replace There are two cab air filters Primary Cab Air Filter Mustraton 207 1 The primary cab air filter is located behind protection cover 3 on the left side of the cab In order to open the protection cover unlock lock 2 and tum lock 4 counterclockwise Then pull latch 1 outward 31200242 121 Maintenance Section Circuit Breakers Test TE The circuit breakers are located under the engine hood on the front right side of the engine compartment Mustraton 208 901205873 2 Open filter cover 6 by removing retaining screw Remove the filter from behind filter cover 6 If the air filter is not damaged clean the air filter with pressurized air The maximum air pressure for cleaning is 205 kPa 30 psi Direct pressurized air along the pleats from closer than 160 mm 6 inch from the air filter If the air filter is damaged replace the air filter Secondary Cab Air Filter The secondary cab air filter is located inside the cab The filter is on the rear wall of the cab behind the seat Main Circuit Breaker 1 The main circuit breaker is 120 amp Alternator Circuit Breaker 2 Tier Il only The circuit breaker is 105 or 135 amp Mastration 209 901205
168. move debris oil tools and other items from the deck from walkways and from steps Secure all loose items such as lunch boxes tools and other items that are not a part of the equipment Know the appropriate work site hand signals and the personnel that are authorized to give the hand signals Accept hand signals from one person only Do not smoke when you service an air conditioner Also do not smoke if refrigerant gas may be present Inhaling the fumes that are released from a flame that contacts air conditioner refrigerant can cause bodily harm or death Inhaling gas from air conditioner refrigerant through a lighted cigarette can cause bodily harm or death Never put maintenance fluids into glass containers Drain alll liquids into a suitable container Obey all local regulations for the disposal of liquids Use all cleaning solutions with care Report necessary repairs Do not allow unauthorized personnel on the equipment Unless you are instructed otherwise perform maintenance with the equipment in the servicing position Refer to Operation and Maintenance Manual for the procedure for placing the equipment in the servicing position Pressurized Air and Water Pressurized air and or water can cause debris and or hot water to be blown out This could result in personal injury When pressurized air and or pressurized water is used for cleaning wear protective clothing protective shoes and eye protection E
169. n Use the level indicator to determine when the frame is level The frame is level when the bubble is in the middle of the sight glass Frame Level Interlock If Equipped 31200242 51 Operation Section When the boom is extended outward the frame level will be isolated The operator will not be able to use the frame level function until the boom has been fully retracted The operation of the Frame Level Interlock will not affect any other functions of the machine hydraulics Continuous Auxiliary Flow Control 8 Single Thumb Wheel If equipped switch 8 is a momentary toggle switch Depress switch 8 when the auxiliary hydraulics are being operated This will provide continuous flow to the auxiliary hydraulics The button on joystick 14 that is pressed will determine the direction of flow In order to resume normal operation depress switch B again Alternately press one of the buttons on the joystick Normal operation will resume Continuous Auxiliary Flow Control 8 Double Thumb Wheel Depress switch 8 when the auxiliary hydraulics are being operated This will provide continuous flow to the auxiliary hydraulics The direction of movement of the right thumb wheel on joystick 14 will determine the direction of flow The flow rate is fixed when continuous flow is requested In order to resume normal operation depress the switch again Alternately move the right thumb wheel upward or move the right thumb
170. n adapter for a work tool is installed on the quick coupler reduce the load carrying capacity of the machine by 200 kg 440 Ib for all work tools and with the boom in any position NOTICE To avoid damage to the boom during digging and or backgrading operations keep the boom fully retracted material from the stockpiles in a way which avoids undercutting the pile or creating an overhang Load Handling and Stacking The illustrations that follow show a machine that is equipped with work tool carriage The work tool carriage is an example of a work tool that can be mounted on the quick coupler MWostration 96 900832840 70 31200242 Operation Section 1 The machine must be positioned square to the intended load Approach the load slowly with the boom in the travel position and get as close to the load as possible Engage the parking brake and move the transmission control to the NEUTRAL position e If necessary level the frame before you raise the boom or before you engage the load Do not level the frame when the boom is raised Mustration 99 900832852 6 Ensure that the forks are spread apart as far as possible This gives increased stability to the load Wustration 97 900832850 4 If you are operating with stabilizers lower the stabilizers until the front tires are just clear of the ground and the frame is level Mustrat
171. n the fully open position Drive the forks into the load to the desired position Press and hold switch 2 on the joystick control in order to close the grapple over the load Release the switch when the grapple is fully closed Refer to the topic Joystick Control in Operation and Maintenance Manual Operator Controls for additional information tustration 125 900974772 Double Thumb Wheel Mustration 126 01059965 Move thumb wheel 3 forward in order to open the grapple Release the thumb wheel when the grapple is fully open Refer to the topic Joystick Control in Operation and Maintenance Manual Operator Controls for full information Approach the load with the grapple in the fully open position Drive the forks into the load to the desired position Move thumb wheel 3 backward in order to close the grapple over the load Release the thumb wheel when the grapple is fully closed Refer to the topic Joystick Control in Operation and Maintenance Manual Operator Controls for additional information Ejecting a Load Position the load over the intended dump area ustration 127 900974863 Single Thumb Wheel lustration 128 900974772 Press and hold switch 1 in order to open the grapple Continue to hold switch 1 after the grapple has fully opened in order to operate the ejector Note The ejector will only operate when the grapple is fully open When the load has been ejected press and hold switch 2 on
172. nd turn the latch counterclockwise in order to relieve the pressure in the hydraulic system Remove hydraulic tank filler cap 6 3 Open the engine enclosure Mustration 281 901205008 4 Remove oil filter 7 After you remove the oil filter discard the oil filter The oil filter will contain oil 5 Clean the housing base for the oil filter Make sure that all of the old filter seal has been removed 6 Apply a thin film of oil to the seal of the new oil filter 7 Install the new oil filter hand tight until the seal of the filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the oil filler use the rotation index marks as a guide 8 Tighten the oil filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter Reference Refer to Operation and Maintenance Manual Transmission and Hydraulic System Oil Level Check for additiona
173. ng unless the primary service brakes fail 1 Apply service brake 2 in order to stop the machine Hold down pedal 2 after the machine has stopped 2 Move transmission control 1 to the NEUTRAL position 3 Engage parking brake 3 4 Release brake pedal 2 Ensure that the parking brake is holding the machine 5 Fully retract the boom and fully lower the boom If equipped ensure that the work tool is resting on the ground Stopping the Engine NOTICE Stopping the engine immediately after it has been working under load can result in overheating and accelerated wear of the engine components Refer to the following stopping procedure to allow the engine to cool and to prevent excessive temperatures in the turbocharger center housing if equipped which could cause oil coking problems 1 Operate the engine for five minutes at low idle with no load This procedure allows the temperature of the components to equalize Mastraton 154 00852425 2 Tum the engine start switch key to the OFF position in order to stop the engine 3 Remove the engine start switch key Stopping the Engine if an Electrical Malfunction Occurs Tum the engine start switch to the OFF position If the engine does not stop perform the following procedure 1 Locate the fuse for the fuel pump This fuse is located in the engine compartment next to the circuit breakers Remove the protective cover in order to access the fuse Refer
174. njury or death could result from falling bucket When working under or around the bucket or linkage with the bucket raised proper support must be provided for the bucket and or the linkage Replace the wear plates before damage to the bottom of the bucket occurs 1 Raise the bucket and block up the bucket 2 Loosen bolts and remove wear plates 3 Install new wear plates Tighten the bolts to the specified torque Refer to the appropriate Service Manual for more information 31200242 157 Reference Information Section Reference Information Section Approved Work Tools Use of non approved work tools on Telehandler machines could result in injury or death Before installing a work tool on this machine ensure that it is approved by Caterpillar and that a Caterpillar load chart covering its use is installed in the machine s cab NOTICE When certain work tools are fitted the work tools can contact the front tires or the front fenders This situation can occur when the boom is retracted and the work tool is rotated fully forward Always check for interference when first operating a new work tool The work tools that are listed in these tables are approved by Caterpillar for use on the machines that are covered by this manual The part number of the work tool is marked on the identification plate for the work tool Use the following tables to determine that the work tool has been approved by Caterpillar Additional work
175. nlock lock 2 and turn lock 4 counterclockwise Then pull latch 1 outward lustration 274 Hydraulic tank filler cap 901205579 2 Lift latch 5 Turn the latch counterclockwise in order to relieve the pressure in the hydraulic system Remove hydraulic tank filler cap 6 150 Maintenance Section 31200242 44 7 p m o1 Mustration 276 01205969 3 Remove drain plug 7 from the bottom of the hydraulic tank and drain the oil into a suitable container Clean the drain plug Install the drain plug back into the hydraulic tank Mustraton 277 901205970 4 Remove drain plug 8 from the bottom of the transmission and drain the oil into a suitable container Clean the drain plug Install the drain plug back into the transmission 5 Fill the hydraulic tank with new Caterpillar TDTO oil and install the hydraulic tank filler cap Clean up any oil that has spilled Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Capacities Refill for additional information Note Do not start the engine until the hydraulic tank is filled with new oil Starting the engine before refilling with oil may damage the scavenge pump or the transmission 6 Start the engine Check for clearance for the boom The boom will need clearance for full extension You need enough clearance to fully raise the boom and you need enough clearance t
176. not operated proportionally stration 69 901147848 When auxiliary 2 is selected indicator light 14G will be illuminated The speed of the following functions is governed by the amount of movement of the joystick control and engine speed Boom raise Boom lower Boom extend Boom retract For smooth operation first increase the engine speed from low idle Then move joystick control 14 slowly until the attachment is moving at the required speed The speed of the quick coupler tilt forward and quick coupler tilt backward is governed by the amount of movement of thumb wheel 14B Move joystick control 14 diagonally in order to simultaneously extend the boom or retract the boom while the boom is being raised or lowered Move joystick control 14 diagonally At the same time operate thumb wheel 14B in order to simultaneously tilt the quick coupler while the boom is being operated in two directions Type B Control Arrangement Double Thumb Wheel ustration 70 Decal for joystick with double thumb wheel 01147867 Machines that have the Type B control arrangement are equipped with decal 14F that is shown above The joystick control operates in the following way Wostration 71 001213551 56 Operation Section 31200242 Boom Raise Pull joystick control 14 0 backward in order to raise the boom When the joystick control is released the joystick con
177. not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates If the coolant in the machine is changed to another type of coolant consult your Caterpillar dealer 1 Allow the engine to cool MX iastration 212 901081067 2 Loosen pressure cap 1 from the coolant tank slowly in order to release pressure Remove the pressure cap iustration 219 900984483 3 Loosen drain valve 2 that is located at the bottom right comer of the radiator Drain the coolant into a suitable container F Mostration 214 90809488 4 Remove coolant drain plug 3 that is located in the engine block above the starter Drain the coolant into a suitable container 31200242 128 Maintenance Section Note Check the threads of the drain plug for damage Check the sealant on the drain plug for damage The drain plug can be reused if threads are not damag
178. ns 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 c
179. nt 31200242 59 Operation Section Speed Selection Powersynchro Transmission 901147874 Four transmission speeds can be selected The speeds are indicated on collar 22A Rotate transmission control 22 until the required transmission speed is opposite the line All four speeds can be selected for forward travel Some machines are equipped with an automatic fifth speed Machines that are equipped with this feature will automatically shift into fifth speed when the appropriate engine speed is reached Fifth speed cannot be manually selected by the operator The first three speeds can be selected for reverse travel Select the proper speed for the application Start moving the machine in first gear or in second gear To upshift move the transmission control to the next highest gear It is not necessary to release the accelerator control To downshift move the transmission control to the next lowest gear Do not skip gears when you down shift Continue to shift through the gears in this way as the conditions are required To prevent engine overspeed do not downshift if the engine speed is high Control the speed of the machine in order to suit conditions Make an allowance for surface conditions weather conditions and load Note The machine should be in first speed or second speed when you change the direction of the machine from forward to reverse or from reverse to forward Select the correct gear before you travel do
180. nt above the battery Mustration 81 Battery disconnect switch 900951966 and turn the battery disconnect switch key clockwise in order to activate the electrical system The switch must be ON before you start the engine D ON Insert the battery disconnect switch key OFF Turn the battery disconnect switch key counterclockwise in order to shut off the entire electrical system The battery disconnect switch and the engine start Switch serve different functions When the battery disconnect switch is turned off the entire electrical system is disabled When only the engine start switch is turned off the battery remains connected to the electrical system 64 Operation Section 31200242 Turn the battery disconnect switch key to the OFF position and remove the battery disconnect switch key when you service the electrical system or you service any other components of the machine Tum the battery disconnect switch key to the OFF position and remove the battery disconnect switch key when the machine is left for a period of one month or longer Adopt this procedure in order to prevent the following circumstances A short circuit from draining the battery Active components from draining the battery Draining of the battery through vandalism Note The battery disconnect switch should never be disconnected while the machine is running Boom Cylinder Lock If Equipped WARNING A raised boom can fall if a
181. nto the top of the main frame Use the nonslip treads that are provided Musraton 901071483 5 Install boom cylinder lock 1 onto the boom cylinder Insert pin 2 and retaining clip 3 Align boom cylinder lock 1 Location tongue 5 must pass between boom plates 6 when the boom is lowered Note When you descend from the machine use the supports and use the nonslip treads in the same manner that is indicated in the previous steps 6 Replace the battery disconnect switch key if equipped and the engine start key 7 Start the engine Lower the boom slowly Make sure that location tongue 5 passes between boom plates 6 Lower the boom until there is a clearance of 6 mm 0 25 inch between the boom plates 6 and the yellow nylon pad 4 NOTICE Do not operate the boom with the boom cylinder lock installed Operating the boom with the boom cylinder lock installed will damage the boom cylinder lock and the boom oylinder 8 Stop the engine Remove the engine start switch key If equipped remove the battery disconnect Switch key Attach a Do Not Operate or a similar warning tag to the joystick control 31200242 65 Operation Section Removal Note Follow the same mounting and dismounting guidelines that are detailed in the installation section 1 Install the engine start key If equipped install the battery disconnect switch key Start the engine Slowly raise the boom until boom plates 6 are c
182. o lower the boom Raise and lower the boom several times Extend and retract the boom several times 7 With the boom in the travel position drive the machine slowly forward Steer the machine from the left to the right 8 Park the machine and check the oil level If necessary add oil 9 Close the protection cover Reference Refer to Operation and Maintenance Manual Transmission and Hydraulic System Oil Level Check for additional information Transmission and Hydraulic System Oil Filter Replace Hot oil and hot components could cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Wustraon 278 901202853 1 In order to open protection cover 3 unlock lock 2 and tum lock 4 counterclockwise Then pull latch 1 outward 31200242 151 Maintenance Section stration 279 Hydraulic tank filler cap 901205579 2 Lift latch 5 a
183. o collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Failure to replace the engine s water temperature regulator on a regularly scheduled basis could cause severe engine damage NOTICE Since Caterpillar engines incorporate a shunt design cooling system it is mandatory to always operate the engine with a water temperature regulator Depending on load failure to operate with a water temperature regulator could result in either an overheating or an over cooling condition Replace the water temperature regulator on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system The water temperature regulator should also be replaced after the cooling system has been cleaned Replace the water temperature regulator while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the water temperature regulator housing Loosen hose clamp 1 Remove hose 2 from the housing Loosen hose clamp 3 Remove hose 4 from the fitting Remove bolts and washers 5 Remove water temperature regulator housing 6
184. ock the machine to prevent movement before releasing the brakes The machine can roll free if it is not blocked Follow the recommendations below to properly perform the towing procedure The towing instructions which follow are for moving the machine for a short distance at low speed Move the machine at a speed of 8 km h 5 mph or less to a convenient location for repair These instructions are only for emergencies Always load the machine onto a suitable transport vehicle if long distance moving is required The parking brake must be engaged on the disabled machine and the wheels must be chocked The boom must be fully retracted lowered and the load must be removed before you tow the machine If hydraulic power is not available refer to Operation and Maintenance Manual Equipment Lowering with Loss of Hydraulic Power in the Operation Section in order to retract the boom and lower the boom In order to prevent damage to the disabled machine the front drive shaft and the rear drive shaft must be removed before you tow the machine Refer to the appropriate Service Manual for your machine Do not use chains to tow a machine Chain links can break with no warning Use wire rope with ends that have loops or rings or use a rigid tow bar Before the machine is towed make sure that the tow line or tow bar is in good condition Make sure that the tow line or tow bar has enough strength for the conditions that are involved The
185. ockwise to the ON position in order to activate all electrical circuits except the staring motor circuit Before the engine will start transmission control 22 must be in the NEUTRAL position To start the engine turn the engine start switch key clockwise from the ON position to the START position Release engine start switch 24 after the engine starts The engine start switch key will retum to the ON position Note If the engine fails to start return the engine start switch key to the OFF position This must be done before you attempt to start the engine again Note As the machine powers up the machine goes through a number of self test and system checks The machine is not available for operation for four seconds until the self test is completed Your machine may be equipped with a security system When a security system is installed only the D ON Turn the engine start switch key correct electronically programmed key will start the engine Steering Column Tilt Control 25 1 901147877 Mustration If equipped move lever 25 upward in order to unlock the steering column Pivot the steering column to the desired position Move lever 25 downward in order to lock the steering column in place Always lock the steering column before you move the machine or before you operate the machine Machine Security System If Equipped NOTICE This machine is equipped with a Caterpillar Machine Security System MSS an
186. of a particular attachment before performing any operation Make adjustments to the rated load as necessary A WARNING Personal injury or death could result from sudden machine movement Sudden movement of the machine could cause injury to persons on or near the machine To prevent injury or death make sure that the area around the machine is clear of personnel and obstructions before operating the machine Refer to the topic Load Handling and Stacking in Operation and Maintenance Manual Operation Information Correct Use of Forks Always position the forks into the lifting pockets before you lift a load Always position the load over all of the forks so that the weight distribution is even Only lift the load if the load is within the loading capacity that is shown on the load chart The load chart is attached to the dash panel of the machine Incorrect Use of Forks Do not use the forks for any of the following operations Pushing the load or dragging the load Excavating ground embedded objects Attaching chains or slings Lifting a load with only one fork Forks that have been used for any of the applications that are listed above must be removed from the machine The forks must be destroyed Note Slings and chains must be used with a lifting hook Buckets NOTICE When a bucket is used for dozing a site or for clearing a site keep the bottom face parallel to the ground This will av
187. of all fluids according to local regulations and mandates Mostration 141 Protection cover 901202853 1 Inorder to open protection cover 3 unlock lock 2 and tum lock 4 counterclockwise Then pull latch 1 outward stration 142 Hydraulic tank filer cap 901208679 2 Lift latch 5 and turn the latch counterclockwise in order to relieve the pressure in the hydraulic system Remove hydraulic tank filler cap 6 7 Mostration 144 901205675 3 Remove drain plug 7 from the bottom of the hydraulic tank and drain 12 L 3 17 US gal of oil into a suitable container Clean the drain plug Install the drain plug back into the hydraulic tank Install the hydraulic tank filler cap If the boom does not need to be retracted proceed to Procedure for Lowering the Boom 31200242 99 Operation Section Procedure for Retracting the Boom Note If the angle of the boom is below approximately 55 degrees the boom may not retract If the boom is below 55 degrees and there is only a light load on the work tool it may not be necessary to perform Procedure for Retracting the Boom Note Do not use excessive force when a wrench is used in order to turn adjustment screw 12 Mustration 147 ol 00864682 3 Locate the rear access cover on the right side of the chassis Remove the two washers and two bolts that secure the access cover to the chassi
188. oid damage to the leading edge of the bucket Maintain traction for the machine by avoiding excessive down force on the bucket Keep the boom extension to a minimum in order to prevent twisting of the boom Use a bucket that is suitable for the job stration 113 Typical bucket 900974741 Light material buckets have a large capacity Light material buckets are intended for use with materials that have a low density such as grain 31200242 75 Operation Section Note The maximum density of material that should be used in a light material bucket is 750 kg m 3 46 8 lb ft Buckets that are used in heavy applications are equipped with a cutting edge General purpose buckets are used for digging and material handling Typical materials would be earth sand cement and aggregates Grapple Buckets Wustration 114 Typical grapple bucket 900074763 Grapple buckets are equipped with a cutting edge Grapple buckets are equipped with hydraulic cylinders that must be connected to the machine hydraulic system The jaws of the bucket grip the load For the best operator visibility travel with the bucket close to the ground Install the bucket that is appropriate for the intended task Install the correct wear plate and the correct cutting edge Single Thumb Wheel Musraton 115 00874772 Press and hold switch 1 in order to open the grapple Press and hold switch 2 in order to close the grapple Refer to the
189. oll backward The unexpected movement of the machine could cause personal injury or death Refer to Operation and Maintenance Manual Transmission Control for additional information Transmission Neutralizer Control This is a two position switch if equipped Push the top of switch 4 in order for the transmission neutralizer to be operational A lamp inside switch 4 wil be illuminated The transmission will be neutralized whenever the service brake is applied Push the bottom of switch 4 in order for the transmission to remain engaged whenever the service brake is applied Steering Mode Control 5 Personal injury or death could result if the machine is roaded in any mode other than two wheel steer Always road the machine with the rear wheels centered and the machine in the two wheel steer mode NOTICE To avoid possible damage to the steering system always center the rear wheels before operating the machine in the two wheel steer mode It is important to check the alignment of the wheels at least once per day Failure to do this may result in reduced accuracy in the steering system 31200242 49 Operation Section position switch controls the steering mode Push the top of switch 5 in order to select crab steer Set switch 5 to the middle position in order to select circle steer Push the bottom of switch 5 in order to select two wheel steer Note Always move the front wheels and the rear wheels
190. on level ground Position the drain plug in the position that is shown in Illustration 243 136 Maintenance Section 31200242 2 Fully retract the boom and fully lower the boom Move the transmission control to the NEUTRAL position and engage the parking brake Shut off the engine 3 Clean the area around the drain plug Remove the drain plug and drain the oil into a suitable container Position of the plug for draining the oil 900952220 4 Move the machine until the plug hole is at the horizontal center line of the wheel The correct position is shown in Illustration 244 5 Add oil to the final drive through the plug hole Oil should be dripping out of the plug hole when the final drive is full of oil Refer to Operation and Maintenance Manual Capacities Refill and Operation and Maintenance Manual Lubricant Viscosities for more information Refer to the appropriate Service Manual for more detailed lubricant information 6 Clean the drain plug and reinstall the drain plug 7 Repeatthe steps that are explained above for each of the three remaining final drives Final Drive Oil Level Check NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids
191. operated spring return switch Press control 21 and hold control 21 in order to engage the differential lock In order to disengage the differential lock release pressure from accelerator pedal 19 and release differential lock control 21 NOTICE Use the differential lock only in conditions where wheel spin has or will be encountered If wheel spin has already developed release pressure from the accelerator pedal and allow the engine speed to fall sufficiently to stop wheel spin before engaging the differential lock Failure to follow this procedure can result in machine damage Keep steering maneuvers to a minimum when the differential lock is engaged Steering maneuvers with the differential lock engaged can result in machine damage The differential lock should only be engaged with all of the wheels in the straight ahead position The differential lock should only be engaged when the machine is stopped Transmission Control 22 Direction Selection Transmission control lever 22 is located on the steering console Forward F Push lever 22 fully upward in order to select forward movement position in order to select NEUTRAL Move lever 22 to the NEUTRAL position when you park the machine Lever 22 must be in the NEUTRAL position before the engine can be started Neutral Move lever 22 to the mid Reverse R Pull lever 22 fully downward in order to select reverse moveme
192. or your Caterpillar Dealer for the complete engine valve lash adjustment procedure Be sure the engine cannot be started while this maintenance is being performed To prevent possible injury do not use the starting motor to turn the flywheel Hot engine components could cause burns Allow additional time for the engine to cool before measuring adjusting engine valve lash clearance NOTICE Operation of Caterpillar Engines with improper engine valve lash adjustments will reduce the engine efficiency This reduced efficiency could result in excessive fuel usage and or shortened engine component life Measure the engine valve lash with the engine stopped To obtain an accurate measurement allow at least 20 minutes for the valves to cool to engine cylinder head and block temperature Final Drive Oil Change NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 243 Position of the plug for draining the oil 900952214 1 Park the machine
193. ore information on tire inflation Operation and Maintenance Manual Tire Inflation with Air Operation and Maintenance Manual Tire Inflation Pressure Adjustment 106 Maintenance Section 31200242 Tire Inflation Pressure Adjustment The tire pressure in a warm shop area 18 to 21 C 65 to 70 F will significantly change when you move the machine into freezing temperatures If you inflate the tire to the correct pressure in a warm shop the tire will be under inflated in freezing temperatures Low pressure shortens the life of a tire Tire Damage For pneumatic tires when any cut rip or tear is discovered that exposes sidewall or tread area cords in the tire measures be taken to remove the product from service immediately Arrangements must be made for replacement of the tire or tire assembly For polyurethane foam filled tires when any of the following are discovered measures must be taken to remove the product from service immediately Arrangements must be made for replacement of the tire or tire assembly A smooth even cut through the cord piles which exceeds 7 5 cm 3 in in total length Any tears or rips ragged edges in the cord piles which exceeds 2 5 cm 1 in in any direction Any punctures which exceed 2 5 cm 1 in in diameter If a tire is damaged but within the above noted criteria the tire must be inspected daily to ensure the damage has not propagated beyond the allow
194. oring Primary Air Filter Elements If a primary air filter element that passes inspection will not be used the primary air filter element can be stored for future use lMustraton 296 Do not use paint waterproof cover or plastic as protective covering for storage An airflow restriction may result To protect against dirt and damage wrap the primary air filter elements in Volatile Corrosion Inhibited VCI paper Place the primary air filter element into a box for storage For identification mark the outside of the box and mark the primary air filter element Include the following information Date of cleaning Number of cleanings Store the box in a dry location Engine Air Filter Primary Element Replace NOTICE The filter should be kept in service no longer than six months or 500 service hours Refer to Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace for the replacement procedure Write the date on the element when the element is replaced Engine Air Filter Secondary Element Replace NOTICE Always replace the secondary filter element Never attempt to reuse the element by cleaning The secondary filter element should be replaced at the time the primary element is serviced for the third time 1 Open the engine enclosure 1 VES 1 5 4 2 E 4 istration 237 2 Slide out retain
195. ormation Section General Information Lifting Capacities Examples of Estimating the Lift Operation from the Load Chart Specifications Intended Use Application Configuration Restriction Crushing Hazard 17 715 Identification Information eae unl Me Plate and Decal Location impaling Hazard 20 p Emissions Geitiication Decal Impaling Hazard 21 16 Operation Section Crushing Hazard 22 17 Before Operatioi Operation 23 a7 Mounting and Dismountin Entanglement and Flying Objects 24 aT Daily Inspection Trap Point 25 7 Machine Operation Crushing Hazard 26 Alternate Exit Ether 27 Hand High Pressure 28 Universal Warning 29 Additional Messages General Hazard Information Pressurized Air and Water Trapped Pressure Fluid Penetration Containing Fluid Spillage Dispose of Waste Properly Crushing Prevention and Cutting Prevention Burn Prevention Coolant Operator Controls Operator Controls Side Console Battery Disconnect Switch If Equipped 123 Boom Cylinder Lock If Equipped 23 Operation Information 24 Work Tools 24 Monitoring System 124 Backup Alarm 24 Cab Door 25 Engine Starting 25 Engine Starting Oils 25 Starting Below 0 C 32 F Batterie Engine and Machine Warm Up Fire Prevention and Explosion Prevention 25 Parking Fire Extinguisher Stopping the Machine Lines Tubes and Hoses Stopping the Engine
196. overheating If the gauge indicates overheating stop the engine Investigate the cause Check the coolant level Check that the fan drive belt is not broken or loose Check that the radiator fins are clean 82 Operation Section 31200242 Tachometer 17 This gauge indicates the speed of the engine in revolutions per minute if equipped Refer to Illustration 137 Torque Converter Oil Temperature 18 This gauge indicates the temperature of the transmission and hydraulic system oil after the oil has passed through the torque converter The green zone indicates that the temperature of the transmission and hydraulic system oil is normal The red zone indicates that the torque converter temperature is overheating Hydraulic Oil Temperature 19 This gauge indicates the temperature of the transmission and hydraulic system oil in the sump The green zone indicates that the temperature of the transmission and hydraulic system oil is normal The red zone indicates that the transmission and hydraulic system oil is overheating Speedometer 20 This digital display indicates the current speed of the machine Service Hour Meter 21 This digital display indicates the total operating hours of the engine The service hour meter should be used to determine the service hour maintenance intervals Fuel Level 22 This gauge indicates the amount of fuel that is left in the fuel tank When the needle on the fue
197. ped When the parking brake is in the ENGAGED position the transmission is neutralized Parking Brake Disengaged Pull back lever 18 and pull lever 18A in order to release the latch Lower lever 18 to the DISENGAGED position Note The parking brake has an interlock switch in order to prevent the machine from being driven through the brake The machine will not move in either FORWARD or REVERSE when the parking brake is engaged The machine will not move if the parking brake lever is slightly engaged Secondary Brake The parking brake also functions as a secondary brake The parking brake must be used to bring the machine to a stop only if the service brakes fail to stop the machine If the parking brake has been used as secondary brake do not move or operate the machine until the service brake system has been checked and any necessary repairs have been completed Note The parking brake operates on the front axle only Accelerator Control 19 Accelerator control pedal 19 is located on the floor of the cab Depress pedal 19 in order to increase the engine speed Release pedal 19 in order to decrease the engine speed 58 Operation Section 31200242 Service Brake Control 20 Brakes are installed on the front axle The brakes on the front axle are applied when service brake control pedal 20 is pressed Service Brake Control 20 Service brake control pedal 20 is located to the left of
198. perate 1 This safety message is positioned on the panel at the right side of the operator station WARNING 000931194 WARNING Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual Failure to follow the instructions or heed the warnings could result in injury or death Contact any Caterpillar dealer for replacement manuals Proper care is your responsibility 10 Safety Section 31200242 Do Not Stand Under the Load 2 This message is positioned on the side of the boom head on both sides of the machine A WARNING 900930650 A crushing hazard exists when the boom is lowered or from a falling load Stay clear of the when the machine is in operation Failure to stay clear of the boom could cause injury or death No Hands 3 The message is positioned on the side of the number one boom section on both sides of the machine WARNING 900930870 A crushing hazard exists when the boom sections are being retracted or extended Stay clear of the boom when the machine is in operation Failure to stay clear of the boom when the machine is operation could cause injury or death 31200242 11 Safety Section Do Not Operate 4 This safety message is located on the front dash in the operator compartment 0098539 Improper operation or main
199. 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 Foreword 31200242 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 31200242
200. pilled Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Capacities Refill for additional information 3 Close the protection cover Transmission and Hydraulic System Oil Sample Obtain The sampling valve for the transmission and hydraulic system oil is located in the engine compartment on the filter base for the transmission and hydraulic system oil filter Refer to the appropriate Service Manual for information that pertains to obtaining a sample of the hydraulic oil Transmission and Hydraulic System Tank Breather Clean The breather for the transmission and hydraulic system tank is located directly undemeath the windshield washer reservoir 206 00851527 1 Remove two bolts 1 from the top of windshield washer reservoir Lift the windshield washer reservoir in order to access breather 2 31200242 158 Maintenance Section 2 Loosen hose clamps 3 and remove the hoses from the breather 3 Loosen bolt 4 and remove the breather 4 Wash the breather in clean nonflammable solvent 5 Install the clean breather and reattach the two hoses Tighten the two hose clamps 6 Install the windshield washer reservoir and install the two bolts Turbocharger Inspect If the turbocharger fails during engine operation severe damage to the turbocharger compressor wheel and to
201. pin 1 and lift locking latch 2 Insert pin 1 in order to hold locking latch 2 in the UP position Align the machine and the tow eye Reverse the machine with assistance in order to ensure an easy connection 94 Operation Section 31200242 Remove pin 1 and lower locking latch 2 Secure locking latch 2 with pin 1 and the attached pin Mechanical Auto Hitch p In order to adjust the height of the hitch of different attachments press pin 3 and rotate lever 4 in order to disengage the locking mechanism Lift the hitch to the required height and rotate lever 4 back to the original position When the locking mechanism is engaged pin 3 will return to the original position In order to connect the attachment for towing rotate lever 5 until pin 6 moves vertically and pin 6 latches into the FULLY UP position Align the jaws of the hitch and the tow eye of the attachment Reverse the machine toward the attachment As the tow eye on the attachment contacts the jaws of the hitch and trigger 7 the latch mechanism will release the spring loaded pin 6 and the lever 5 Clevis Hitch Mostraon 162 01002103 In order to adjust the height of the hitch for different attachments remove pin 8 and rotate lever 9 in order to disengage the locking mechanism Lift the hitch to the required height and rotate lever 9 back to the original position When the locking mechanism is engaged ret
202. ponent does not go through any bearing Use this procedure in order to reduce the possibility of damage to the following components Bearings of the drive train Hydraulic components Electrical components Other components of the machine gt Protect any wiring harnesses from the debris which is created from welding Protect any wiring harnesses from the splatter which is created from welding Use standard welding procedures in order to weld the materials together Maintenance Interval Schedule Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each consecutive interval is performed alll maintenance from the previous interval must be performed When Required Axle Breathers Clean Replace Battery Recycle Battery or Battery Cable
203. pple Fork Ar 186 6054 Grapple Fork Gp 163 4263 Bale Handler Ar 169 3945 Truss Boom Gp 169 6460 Lifting Hook Gp 163 4261 General Purpose Bucket Ar 1 0 m 1 31 yd3 163 4265 Multipurpose Bucket Ar 1 0 m 1 31 yd 186 5838 Material Handling Bucket Gp 1 5 m 1 96 yd 219 5515 Grapple Bucket Ar 220 4759 Light Material Bucket Gp 2 0 m 2 62 yd 220 4760 Light Material Bucket Gp 2 5 m 3 27 yd 220 4761 Light Material Bucket Gp 3 0 m 3 92 yd 190 0913 Hopper 221 1960 Pickup Broom Arrangement 31200242 Access Doors and Covers Additional Messages Alternate Exit Tractor Cab Approved Work Tools Axle Breathers Clean Replace B Backup Alarm Test Backup Alarm Battery Recycle Battery Disconnect Switch If Equippe Battery or Battery Cable Inspect Replace Before Operation Before Starting Engine Belt Inspect Replace Inspect Replace Boom and Frame Inspect Boom Cylinder Lock If Equipped Installation and Removal Procedures Boom Cylinder Lock If Equipped Boom Cylinder Pin Lubricate Boom Head Section Lubricate Boom Pivot Shaft Lubricate Boom Telescoping Cylinder Air Purge Boom Wear Pad Clearance Inspect Adjust Adjustment Braking System Test Parking Brake Service Brake Bum Prevention Cab Air Filter Clear Replace Primary Cab Air Filter Secondary Cab Air Filter Cab Door Capacities Refill G
204. proved by Caterpillar Also ensure that the machine has a Caterpillar load chart Consult your Caterpillar dealer for information on the proper application and the proper use of a specific work tool Engine Stopping Do not stop the engine immediately after the machine has been operated under load This can cause overheating and accelerated wear of engine components After the machine is parked and the parking brake is engaged allow the engine to run for five minutes before shutdown This allows hot areas of the engine to cool gradually For more information refer to the following topics in the Operation Section of the Operation and Maintenance Manual Stopping the Engine 30 Safety Section 31200242 Stopping the Engine if an Electrical Malfunction Occurs Work Tools WARNING Use of non approved work tools on Telehandler machines could result in injury or death Before installing a work tool on this machine ensure that it is approved by Caterpillar and that a Caterpillar load chart covering its use is installed in the machine s cab If you are in doubt about the compatibility of a particular work tool with your machine consult your Caterpillar dealer Make sure that all necessary guarding is in place on the host machine and on the work tool Keep all windows and doors closed on the host machine Always wear protective glasses Always wear the protective equipment that is recommended in the wor
205. radiator cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Mustration 220 d 901081068 The cooling system pressure cap is located on the coolant tank inside the engine compartment 1 Remove the cap slowly in order to relieve the pressure 2 Inspect the cap and the gasket for damage for foreign material and for deposits 3 Clean the cap with a clean cloth or replace the cap if itis necessary Note Always check the pressure rating of the old cap before you replace the cap Replace the old cap with a new cap of the same pressure rating 4 Reinstall the cap 126 Maintenance Section 31200242 Cooling System Water Temperature Regulator Replace Personal injury could result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact could cause severe burns Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared t
206. rease Points Identification Capacities Refill Circuit Breakers Test Compensating Cylinder Bearing Lubricate Contact Information Cooling System Coolant Change Cooling System Coolant Level Check Cooling System Coolant Sample Level 1 btair Cooling System Coolant Sample Level 2 Obtai Cooling System Pressure Cap Clean Replace Cooling System Water Temperature Regulator Replace Crushing Prevention and Cutting Preventio 159 Index Daily Inspectio Differential Oil Change Front Axle Differential Rear Axle Differential Differential Oil Level Check Front Axle Differential Rear Axle Differential Differential Oil Sample Obtain Drive Shaft Spline Lubricate Drive Shaft Universal Joint Bolts Check E Electrical Storm Injury Prevention Emissions Certification Film Engine Air Filter Primary Element Clean Replace Inspecting the Primary Air Filter Elements Engine Air Filter Primary Element Replace Engine Air Filter Secondary Element Replace Engine and Machine Warm Up Engine Mounts Inspect Engine Oil and Filter Change Engine Oil Level Checi Engine Oil Sample Obtai Engine Starting Starting Below 0 C 32 F Engine Starting Alternate Methods Engine Starting with Jump Start Cables Engine Starting Engine Stopping Engine Valve Lash Check Equipment Lowering with Loss of Hydraulic Power Procedure for Draining Hydraulic Tank Proc
207. replace the cap 15 Install the pressure cap on the coolant tank 16 Stop the engine Cooling System Coolant Level Check Personal injury could result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact could cause severe burns Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Park the machine on level ground Fully retract the boom and fully lower the boom Move the transmission control to the NEUTRAL position and ensure that the parking brake is engaged Shut off the engine 901057534 124 Maintenance Section 31200242 The coolant tank for the cooling system is located in the engine compartment Check the coolant level while the engine is cold The coolant level should be maintained to the FULL line the coolant tank Cooling System Coolant Sample Level 1 Obtain NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns
208. rol to the right in order to tilt the quick coupler forward When the joystick control is released the joystick control will return to the HOLD position Quick Coupler Tilt Backward Push the joystick control to the left in order to tilt the quick coupler backward When the joystick control is released the joystick control will return to the HOLD position Boom Extend Move thumb wheel 148 forward in order to extend the boom When the thumb wheel is released the thumb wheel will retum to the HOLD position Note The boom will not extend when the transmission control is in the REVERSE position The function for extending the boom will resume if the transmission is neutralized by the service brake the parking brake or the transmission neutralizer button Boom Retract Move thumb wheel 14B backward in order to retract the boom When the thumb wheel is released the thumb wheel will return to the HOLD position Auxiliary Controls If equipped press Switch 14E in order to toggle between the hydraulic circuits for the auxiliary 1 and auxiliary 2 Move thumb wheel 14C forward in order to operate an actuator for work tool in the positive direction Move thumb wheel 14C backward in order to operate an actuator for a work tool in the negative direction Switch 14E is not operated proportionally Boom Lower Push the joystick control 54 Operation Section 31200242 lMustration 66 901147848 When aux
209. rotating beacon Joystick Control 14 Improper use of the boom and work tools could result in injury or death The operator must be fully aware of all the functions for the joystick control and proper operating techniques The following information describes two types of operating arrangement for the joystick control A decal that shows the configuration is located forward of joystick control 14 The decal indicates the movements that will be produced when you operate the joystick control You must understand all of the functions of the joystick control before you operate the machine 52 Operation Section 31200242 Type A Control Arrangement Single Thumb Wheel 14 Iustation 61 Machines that have the Type A control arrangement are equipped with decal 14A that is shown above Joystick control 14 operates in the following way 9012138580 Boom Raise Pull joystick control 14 backward in order to raise the When joystick control 14 is released the joystick control will return to the HOLD position W stration 62 forward in order to lower the boom When joystick control 14 is released the joystick control will return to the HOLD position Quick Coupler Tilt Forward Push joystick control 14 to the right in order to tit the quick coupler forward When joystick control 14 is released the joystick control will return to the HOLD position Boom Lower
210. rt of an operating engine Allow the engine to cool before any maintenance is performed on the engine Relieve all pressure in the air system in the oil system in the lubrication system in the fuel system or in the cooling system before any lines fittings or related items are disconnected Coolant When the engine is at operating temperature the engine coolant is hot The coolant is also under pressure The radiator and all lines to the heaters or to the engine contain hot coolant Any contact with hot coolant or with steam can cause severe burns Allow cooling system components to cool before the cooling system is drained Check the coolant level only after the engine has been stopped Ensure that the filler cap is cool before removing the filler cap The filler cap must be cool enough to touch with a bare hand Remove the filler cap slowly in order to relieve pressure Cooling system conditioner contains alkali Alkali can cause personal injury Do not allow alkali to contact the skin the eyes or the mouth Oils Hot oil and hot components can cause personal injury Do not allow hot oil to contact the skin Also do not allow hot components to contact the skin Remove the hydraulic tank filler cap only after the engine has been stopped The filler cap must be cool enough to touch with a bare hand Follow the standard procedure in this manual in order to remove the hydraulic tank filler cap Batteries Electrolyte i
211. s Dispose of all fluids according to local regulations and mandates 31200242 137 Maintenance Section Mustraton 246 900952220 Fully retract the boom and fully lower the boom Move the transmission control to the NEUTRAL position and engage the parking brake Shut off the engine Obtain a sample of oil from each final drive Keep the oil samples separate from each other Select a final drive in order to obtain a sample of oil Park the machine on level ground and position the plug for the final drive on the horizontal center line of the wheel Clean the area around the plug and remove the plug Use a sampling gun in the plug hole in order to obtain an oil sample from the final drive Inspect the plug for damage Install the plug Repeat this procedure for the remaining final drives Analysis of oil from the corresponding final drive will provide an accurate representation of oil condition within each system Use SOS Oil Analysis in order to monitor the condition of your oil For additional information refer to the appropriate Service Manual Mustration 247 900977344 Lubricate the pin for the fork leveling cylinder through the fitting Fuel System Prime Tier II 1 Turn the engine start switch to the ON position Leave the switch in the ON position for 3 minutes NOTICE Do not crank the engine for more than 30 seconds Allow the starting motor to cool for two minutes before cranking again Turbo
212. s Do not work beneath the cab of the machine unless the cab is properly supported Unless you are instructed otherwise never attempt adjustments while the machine is moving or while the engine is running Never jump across the starter solenoid terminals in order to start the engine Unexpected machine movement could result Whenever there are equipment control linkages the clearance in the linkage area will change with the movement of the equipment or the machine Stay clear of areas that may have a sudden change in clearance with machine movement or equipment movement Stay clear of all rotating and moving parts If itis necessary to remove guards in order to perform maintenance always install the guards after the maintenance is performed Keep objects away from moving fan blades The fan blade will throw objects or cut objects Do not use a kinked wire cable or a frayed wire cable Wear gloves when you handle wire cable 31200242 25 Safety Section When you strike a retainer pin with force the retainer pin can fly out The loose retainer pin can injure personnel Make sure that the area is clear of people when you strike a retainer pin To avoid injury to your eyes wear protective glasses when you strike a retainer pin Chips or other debris can fly off an object when you strike the object Make sure that no one can be injured by flying debris before striking any object Burn Prevention Do not touch any pa
213. s Remove the access cover in order to gain access to the control valve Wosraion 145 20195716 1 Locate the rear cover on the back of the Remove three bolts 8 and three hard washers 9 that hold rear cover 10 in place Remove the rear cover istration 46 901205723 2 Locate load control valve 11 Slightly loosen locknut 13 Remove adjustment screw 12 without rotating locknut 13 on the screw Measure the distance from the head of adjustment screw 12 to the top of locknut 13 Record this measurement This measurement will be required later when adjustment screw 12 is reset Spin locknut 13 to the head of adjustment screw 12 Tum adjustment screw 12 by hand into load control valve 11 in order to contact the ball Attach a wrench to adjustment screw 12 and turn the screw clockwise until the screw becomes tight 16 Mustration 148 901205727 4 Locate control valve 14 5 Measure the distance from the head of adjustment screw 18 to the top of locknut 17 Completely remove locknut 17 Turn the screw clockwise by hand until the screw is tight Use an allen wrench to turn the adjustment screw clockwise in order to retract the boom Allow the boom to fully retract Note If necessary turn adjustment screw 18 counterclockwise in order to stop the boom from retracting 6 When the boom has fully retracted turn adjustment screw 18 in a counterclockwise direction until the a
214. s an acid Electrolyte can cause personal injury Do not allow electrolyte to contact the skin or the eyes Always wear protective glasses for servicing batteries Wash hands after touching the batteries and connectors Use of gloves is recommended Fire Prevention and Explosion Prevention Mustration 21 900704000 All fuels most lubricants and some coolant mixtures are flammable Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire Fire may cause personal injury and property damage Remove all flammable materials such as fuel oil and debris from the machine Do not allow any flammable materials to accumulate on the machine Store fuels and lubricants in properly marked containers away from unauthorized persons Store oily rags and any flammable materials in protective containers Do not smoke in areas that are used for storing flammable materials Do not operate the machine near any flame Exhaust shields if equipped protect hot exhaust components from oil spray or fuel spray in case of a break in a line in a hose or in a seal Exhaust shields must be installed correctly Do not weld on lines or on tanks that contain flammable fluids Do not flame cut lines or tanks that contain flammable fluid Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting Check all electrical wires daily Repair any wires that are loo
215. s machine has been certified to the standards that are listed on the certification decal The maximum mass of the machine which includes the operator and the attachments without a payload should not exceed the mass on the certification decal A typical example of the warning decal and certification decal are shown above Refer to Operation and Maintenance Manual Guards Operator Protection for more information No Access Platform 7 This safety message is positioned on the panel at the right side of the operator station WARNING 900931208 This machine was not manufactured for and has not been modified for use with an access platform attachment Use of an access platform attachment on a machine not manufactured or properly modified for use with such an attachment could result in injury or death Do not use this machine with an access platform attachment See your Caterpillar dealer for more information about this machine and access platforms 31200242 13 Safety Section Seat Belt 8 This safety message is positioned on the panel at the right side of the operator station WARNING 900981188 seat belt should be worn at all times during machine operation to prevent serious injury or death in the event of an accident or machine overturn Failure to wear a seat belt during machine operation could result in serious injury or death Refer to Operation and Maintenance Manual S
216. s must be installed and maintained at the proper torque to prevent loose wheels broken studs and possible separation of wheel from axle Failure to comply could result in death or serious injury 31200242 107 Maintenance Section Lubricant Viscosi Capacities Lubricant Viscosities The proper oil viscosity grade is determined by the minimum outside ambient temperature This is the temperature when the machine is started and while the machine is operated In order to determine the proper oil viscosity grade refer to the Min column in the table This information reflects the coldest ambient temperature condition for starting a cold machine and for operating a cold machine Refer to the Max column in the table in order to select the oil viscosity grade for operating the machine at the highest temperature that is anticipated Unless specified otherwise in the Lubricant Viscosities for Ambient Temperatures tables use the highest oil viscosity that is allowed for the ambient temperature when you start the machine Machines that are operated continuously should use oils that have the higher oil viscosity in the final drives and in the differentials The oils that have the higher oil viscosity will maintain the highest possible oil film thickness Consult your dealer if additional information is needed Refer to the appropriate Service Manual for further information Tire tread 108 31200242 Maintenance Section
217. se or frayed before you operate the machine Clean all electrical connections and tighten all electrical connections 26 Safety Section 31200242 Dust that is generated from repairing nonmetallic hoods or nonmetallic fenders can be flammable and or explosive Repair such components in a well ventilated area away from open flames or sparks Inspect all lines and hoses for wear or for deterioration The hoses must be properly routed The lines and the hoses must have adequate support and secure clamps Tighten all connections to the recommended torque Leaks can cause fires istration 22 00704059 Use caution when you are refueling a machine Remove debris from the top of the tank before refueling Do not smoke while you are refueling a machine Do not refuel a machine near open flames or sparks Always stop the engine before refueling Fill the fuel tank outdoors istration 23 00704195 Gases from a battery can explode Keep any open flames or sparks away from the top of a battery Do not smoke in battery charging areas Never check the battery charge by placing a metal object across the terminal posts Use a voltmeter or a hydrometer Improper jumper cable connections can cause an explosion that could result in injury Refer to the Operation Section of this manual for specific instructions Do not charge a frozen battery This may cause an explosion Fire Extinguisher Make sure that a fire extinguisher is av
218. stration 226 Rear axe differential 900953223 Mustration 226 Rear axe differential 901054761 Fully retract the boom and fully lower the boom Move the transmission control to the NEUTRAL position and ensure that the parking brake is engaged Shut off the engine Obtain an oil sample from each axle Keep the oil samples separate from each other Clean the area around combined level and filler plug 1 for the differential Remove combined level and filer plug 1 Use a sampling gun in the filler hole in order to obtain an oil sample Inspect combined level and filer plug 1 for damage Install combined level and filler plug 1 Analysis of oil from each axle will provide an accurate representation of oil condition within each system Use SOS Oil Analysis in order to monitor the condition of your oil For additional information refer to the appropriate Service Manual Drive Shaft Spline Lubricate NOTICE Apply lubricant to the fittings with a hand operated grease gun only Use of pressure operated lubricating equipment damages the seals iustration 228 Location of the Drive Shafts 900837541 The following drive shafts must be lubricated The front drive shaft The rear drive shaft ustration 229 Typical Lubrication Point 90064761 There is a grease nipple on the slider of each drive shaft Lubricate the drive shaft splines through the grease nipples 130 Maintenance
219. sult your Caterpillar dealer for longer seat belts and for information on extending the seat belts 31200242 47 Operation Section Operator Controls Mustration 56 1 Hom 2 Auto Manual switch if equipped Quick coupler control Transmission neutralizer control Steering mode control Reversible fan control Frame leveling control Continuous auxiliary flow control Fog lights 10 Hazard flashers 11 Headlight dimmer switch 12 18 14 15 16 17 18 19 20 21 22 901213443 Headlight Parking lights Rotating beacon light Joystick control Adjustable armrest Side console Interior light Parking and secondary brake control Accelerator control Service brake control Differential lock control Transmission control 48 Operation Section 31200242 SD 23 Q 25 a gx 23 Directional turn signal control 24 Engine start switch 25 Steering column tilt control Note Your machine may not be equipped with all of the controls that are described in this topic Horn 1 Horn Horn 1 is located in the center of the steering wheel Push horn 1 in order to sound the hom Use the horn in order to alert personnel Also use the hom in order to signal personnel Auto Manual Switch 2 Auto Manual Switch This is a two position 2 switch It your machine is equipped with the VUA Powersynchro transmission this switch is an option on your machine Push the le
220. t tap or strike the filter element in order to remove dust Do not wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components NOTICE Do not clean the air filter elements by bumping or tapping This could damage the seals Do not use elements with damaged pleats gaskets or seals Damaged elements will allow dirt to pass through Engine damage could result Visually inspect the primary air filter element before cleaning Inspect the air filter element for damage to the seal the gaskets and the outer cover Discard any damaged air filter elements There are two common methods that are used to clean primary air filter elements Pressurized air Vacuum cleaning Pressurized Air Pressurized air can be used to clean primary air filter elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Mustration 234 00081682 Note When the primary air filter elements are cleaned always begin with the clean side inside in order to for
221. tart system damage the electrical system and result in unexpected machine motion or behavior This could cause personal injury or death Failure to properly service the batteries could cause personal injury Prevent sparks near the batteries They could cause vapors to explode Do not allow the jump start cable ends to contact each other or the machine Do not smoke when checking battery electrolyte levels Electrolyte is an acid and can cause personal injury if it contacts the skin or eyes Always wear eye protection when starting a machine with jump start cables Improper jump start procedures can cause an explosion resulting in personal injury When using jumper cables always connect the Positive jumper cable 10 the positive battery terminal first Next connect the negative jumper cable to the frame away from the batteries Follow the procedure in the Operation and Maintenance Manual Jump start only with an energy source of the same voltage as the stalled machine Turn off all lights and accessories on the stalled machine Otherwise they will operate when the energy source is connected normally on the same side of the machine as the NOTICE When starting from another machine make sure that the machines do not touch This could prevent damage to engine bearings and electrical circuits Severely discharged maintenance free batteries do not fully recharge from the alternator after jump starting The batt
222. tem 3 Remove the dust cover for the valve stem 4 Stand behind the tire tread and use a Caterpillar 48 6524 Pressure Gauge or 1P 0545 Pressure Gauge to check the tire pressure If these pressure gauges are not available use an equivalent tool to check the tire pressure Add air if the pressure 5 islow 6 Install the dust cover on the valve stem Refer to the following additional information about tire inflation Operation and Maintenance Manual Tire Pressure Operation and Maintenance Manual Tire Inflation Pressure Adjustment Consult your Caterpillar Dealer for further information on the correct operating pressures and the correct load ratings Transmission and Hydraulic System Oil Change Hot oil and hot components could cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Wastraion 273 pr 1 In order to open protection cover 3 u
223. tenance of the machine could result in injury or death Do not operate or work on this machine unless you have been properly trained and authorized and have read and understood the warnings and instructions in the Operation and Maintenance Manual Refer to Operation and Maintenance Manual Lifting Capacities for more information Forks 5 This safety message is positioned on the panel at the right side of the operator station WARNING 901050274 Side loading of the forks may cause premature failure of the forks and thus a crush hazard which could cause personal injury or death Never push loads with the forks and inspect the forks daily for any twisting or bending observed in the forks Should twisting or bending be observed change the fork s prior to any lifting operation Read the Operation and Maintenance Manual for more information about the correct use and inspection of the forks 12 Safety Section 31200242 Do Not Weld On The ROPS FOPS Structure 6 This safety message is positioned behind the seat near the rear window 900932470 Structural age overturn modification alteration or improper repair can impair this structure s protection capability thereby voiding this certification Do not weld on or drill holes in the structure This will void the certification Consult a Caterpillar dealer to determine this structure s limitations without voiding its certification Thi
224. the accelerator control Pedal 20 controls the service brakes Depress pedal 20 in order to engage the service brakes Release pedal 20 in order to disengage the service brakes Depress the pedal in order to decelerate or stop the machine Deceleration is controlled by the downward force that is applied to the pedal Pedal 20 can be used in conjunction with transmission neutralizer control switch 4 When the top of switch 4 is pushed in the transmission is automatically neutralized when a firm pressure is applied to the brake pedal This allows a higher engine speed for improved hydraulic response time when you operate the machine implements This mode of operation should only be used when the boom is retracted and below horizontal When the bottom of switch 4 is pushed in the transmission remains engaged when pedal 20 is depressed Refer to Transmission Neutralizer Control 4 for more information Differential Lock Control 21 The differential lock can be selected in order to override the normal operation of the front axle differential The differential lock will help maintain traction when the ground conditions are soft or slippery When the differential lock is selected torque is transmitted to both wheels even though one wheel may not have traction Differential Lock Control 21 Differential lock control 21 is located to the left of service brake pedal 20 Differential lock control 21 is a foot
225. the area around the plugs Remove the following plugs for the rear differential Drain plug 1 Combined level plug and filler plug 2 Allow the oil to drain into a suitable container 2 Clean drain plug 1 and reinstall drain plug 1 3 Add new oil to the differential housing through filler hole 2 until the is level with the threads for plug 2 Refer to Operator and Maintenance Manual Lubricant Viscosities for the correct grade of oil Refer to Operation and Maintenance Manual Capacities Refill and the appropriate Service Manual for more detailed lubricant information Differen 4 Clean combined level plug and filler plug 2 Reinstall combined level plug and filler plug 2 Front Axle Differential Mustration 223 900953178 1 Clean the area around the plugs Remove the following plugs for the front differential Drain plug 3 Combined level plug and filler plug 4 Allow the oil to drain into a suitable container 2 Clean drain plug 3 and reinstall drain plug 3 3 Add new197 0017 Axle and Brake Oil Additive to the differential housing through hole 4 Refer to Operation and Maintenance Manual Capacities Refill for more detailed information 4 Add new oil to the differential housing through filler hole 4 until the oil is level with the threads for plug 4 When you are filing the front axle with oil you should allow time for the oil to drain through th
226. the certification decal The maximum mass of the machine which includes the operator and the attachments without a payload should not exceed the mass on the certification decal Refer to Operation and Maintenance Manual Guards Operator Protection for more information Machine Security System If equipped this message is used to verify the certification of the Machine Security System MSS as a RF transmitter The following specifications are provided to aid in ensuring compliance with all local regulations Table 5 Field strength 1 16 12 dB micro amp meter Operating frequency range 134 2 kHz 0 055 seconds 1 18 Operating time second f Field strength at 10 meters 2 The operating time is measured after the key switch is first activated 38 Product Information Section 31200242 Hustration 38 01018647 This plate is located on the control group for the MSS The control group is located in the engine compartment FCC ID PQMMSS1 CANADA 4071104478A C O 0888 en 021747 MHustration 39 00995398 Consult your Caterpillar dealer with any questions that concern the operation of the MSS in a specific country Italian Roading Homologation MHustration 40 900937590 This plate is located on the right side of the machine behind the front tire stration 41 900937218 The following information is stamped on the plate Mode
227. the joystick control in order to retract the ejector Continue to hold switch 2 after the ejector has fully retracted in order to close the grapple Note The grapple will only close when the ejector is fully retracted Refer to the topic Joystick Control in Operation and Maintenance Manual Operator Controls for full information 31200242 79 Operation Section When the work tool is not active position the fork that personnel cannot contact the fork tines Double Thumb Wheel Mustration 126 901053965 Move thumb wheel 3 forward in order to open the grapple Continue to hold thumb wheel 3 after the grapple has fully opened in order to operate the ejector Note The ejector will only operate when the grapple is fully open When the load has been ejected move thumb wheel 3 backward in order to retract the ejector Continue to hold thumb wheel 3 after the ejector has fully retracted in order to close the grapple Note The grapple will only close when the ejector is fully retracted Refer to the topic Joystick Control in Operation and Maintenance Manual Operator Controls for full information When the work tool is not active position the fork so that personnel cannot contact the fork tines Bale Handler Single Thumb Wheel 1 rc Y m Press and hold switch 1 on the joystick control in order to open the prongs Press
228. tion for more information 31200242 15 Safety Section Impaling Hazard 14 This message is located on each side of the bale handler WARNING 900951589 WARNING No clearance for person in this area during operation Severe injury or death from impalement could occur Stay away from the work tool while it is in operation Crushing Hazard 15 This message is located on each side of the bale handler AA WARNING mm 900951585 A WARNING No clearance for person in this area during operation Severe injury or death from crushing could occur Stay away from the work tool while it is in operation Crushing Hazard 16 This message is located on both sides of the hopper 900951580 A WARNING No clearance for person in this area during operation Severe injury or death from impalement could occur Stay away from the work tool while it is in operation Crushing Hazard 17 This message is located on each side of the bucket on the top of the bucket WARNING lev 00951565 No clearance for person in this area during operation Severe injury or death from crushing could occur Stay away from the work tool while it is in operation 31200242 16 Safety Section Impaling Hazard 20 This message is located on each side of the grapple Impaling Hazard 18 This message is located on each side of the manure fork fork WARNING WARNING 00851569
229. tion which can be harmful to your health Always run the engine in a well ventilated area If you are in an enclosed area vent the exhaust to the outside Start the engine only when you are properly seated in the operator s compartment Do not short across the battery terminals and do not short across the batteries A short could cause a bypass of the engine neutral start system and this could cause the machine to move if the machine was left in gear Before Operation Clear all personnel from the machine and from the area Clear all obstacles from the path of the machine Beware of hazards such as wires ditches etc Make sure that all windows are clean Secure the doors in the open position or in the shut position Secure the windows in the open position or in the shut position Make sure that all mirrors are clean For the best vision of the area which is close to the machine adjust the mirrors All mirrors should be adjusted for optimal visibility while the operator is seated in the cab Make sure that the machine horn the backup alarm and all other warning devices are working properly Fasten the seat belt securely Make sure that the load charts and the instruction plates are in place and that the load charts and the instructions can be read Operation Machine Operating Temperature Range The standard machine configuration is intended for use within an ambient temperature range of 40 C 40 F to 50 C 122
230. to Operation and Maintenance Manual Fuses and Relays Replace 2 Remove the fuse The engine will stop Note Do not attempt to operate the machine again until the malfunction has been corrected Leaving the Machine 1 Tum the engine start switch key to the ON position Operate each hydraulic function several times in order to relieve pressure from the hydraulic system Turn the engine start switch key to the OFF position and remove the key 2 Close the windows and ensure that the windows are properly locked before you exit the cab 3 Use steps and handholds whenever you dismount the machine Face the machine and maintain a three point contact with the steps and with the handholds Three point contact can be two feet and one hand Three point contact can also be one foot and two hands 4 Lock the cab door 31200242 87 Operation Section 5 Chock the wheels if the machine is parked slope 6 Inspect the engine compartment for debris Clean out any debris and any paper in order to avoida fire 7 Turn the key for the battery disconnect switch to the OFF position When the machine is left for an extended period of one month you should remove the key for the battery disconnect switch Alternatively the battery should be removed 8 Close the engine enclosure and lock the engine enclosure 9 Install all vandalism caps and covers before you leave the machine When the machine is left for an exten
231. to the straight ahead position before you change the steering modes amp Steering Mode Select Switch This three Mustraton 58 901053883 Circle Steer Mode When circle steer mode is selected indicator 5A is illuminated Crab Steer Mode When crab steer mode is selected indicator 5B is illuminated Two Wheel Steer Mode When two wheel steer mode is selected indicator 5C is illuminated Use of Steering Modes The machine can be operated in the following steering modes Two Wheel Steer Circle Steer Crab Steer Only the front wheels are steered in two wheel steer mode This mode must be used when you road the machine When the machine is in circle steer mode the front wheels and the rear wheels turn in opposite directions This allows the machine to make tighter turns When the machine is in crab steer mode the front wheels and the rear wheels tum in the same direction When you select the crab steer mode the machine will move forward and the machine will move to one side Alternatively the machine will move backward and the machine will move to one side This allows the machine to operate in confined locations Checking or Synchronizing the Wheels Machines with Steer Sensors 1 Ina static position select circle steer mode and ensure that the circle steer mode indicator is constantly illuminated Adjust the steering wheel as required 2 Select two wheel steer mode and ensure that the
232. topic Joystick Control in Operation and Maintenance Manual Operator Controls for full information Double Thumb Wheel Mustraton 116 01052965 Move thumb wheel 3 forward in order to open the grapple Move thumb wheel 3 backward in order to close the grapple Refer to the topic Joystick Control in Operation and Maintenance Manual Operator Controls for full information Multipurpose Buckets Mustration 117 Typical multipurpose bucket 901037342 Multipurpose buckets are equipped with a cutting edge For the best operator visibility travel with the bucket close to the ground Install the bucket that is appropriate for the intended task Install the correct wear plate and the correct cutting edge 76 Operation Section 31200242 Boom Extension Mustration 118 900074780 A boom extension is intended to be used in applications when additional reach or height is required in order to place light loads such as supports for roofs Reference the correct load chart and do not exceed the machine capacities Use only approved lifting equipment with a current certificate of serviceability when you attach a load to boom extension Short slings will prevent excessive load swing Before you raise the load position the lifting point on the boom extension directly above the lifting point on the load Failure to follow this procedure could cause the load to swing when the load is lifted Personal in
233. tow line or tow bar should be able to pull at least 150 percent of the gross weight of the towed machine This pertains to towing a disabled machine from mud and to towing a machine on a grade Mustration 157 Lifing and tie down points ront For towing or retrieving the machine from the front attach towing equipment to the lifting points on the frame at the front of the machine Mustration 158 Typical front retrieval hitches i equipped For retrieving the machine from the front attach towing equipment to the retrieval hitches at the front of the machine Hustraion 159 Typical rear retrieval hitch 900052474 If itis not possible to tow the machine from the front or if itis not possible to retrieve the machine from the front attach the tow line or tow bar to the retrieval hitch at the rear of the machine When the machine has been retrieved attach towing equipment to the lifting points on the frame at the front of the machine for towing 90 Operation Section 31200242 Normally the towing machine should be at least the size of the disabled machine Make sure that the towing machine has enough brake capacity weight and power The towing machine must be able to control both machines for the grade distance and conditions that are involved Alarger towing machine and a solid tow bar will be required in order to provide sufficient control and braking when a disabled machine is moved downhill Shie
234. trol will return to the HOLD position Boom Lower Push joystick control 14 forward in order to lower the boom When joystick control is released the joystick control will return to the HOLD position the right in order to extend the boom When the joystick control is released the joystick control will return to the HOLD position Note The boom will not extend when the transmission control is in the REVERSE position The function for extending the boom will resume if the transmission is neutralized by the service brake the parking brake or the transmission neutralizer button Boom Retract Pull joystick control 14 to the left in order to retract the boom When the joystick control is released the joystick control will return to the HOLD position Boom Extend Push joystick control 14 to Quick Coupler Tilt Forward Move thumb wheel 14B forward in order to tilt the quick coupler forward When the thumb wheel is released the thumb wheel will return to the HOLD position Quick Coupler Tilt Backward Move thumb wheel 14B backward in order to tilt the quick coupler backward When the thumb wheel is released the thumb wheel will return to the HOLD position Auxiliary Controls If equipped press switch 14E in order to toggle between the hydraulic circuits for the auxiliary 1 and auxiliary 2 Move thumb wheel 14C forward in order to operate an actuator for a work tool in the positive
235. trol and engine speed Boom raise Boom lower Quick coupler tilt forward Quick coupler tilt backward 31200242 53 Operation Section For smooth operation first increase the engine speed from low idle Then move joystick control 14 slowly until the attachment is moving at the required speed The speed of the boom extend and boom retract is governed by the amount of movement of thumb wheel 148 Move joystick control 14 diagonally in order to simultaneously tilt the quick coupler forward or backward while the boom is being raised or lowered Move joystick control 14 diagonally At the same time operate thumb wheel 14B in order to simultaneously tilt the quick coupler while the boom is being operated in two directions Type A Control Arrangement Double Thumb Wheel 14A stration 64 Decal for joystick with double thumb wheel 901147850 Machines that have the Type A control arrangement are equipped with decal 14A that is shown above The joystick control operates in the following way stration 65 901213551 backward in order to raise the boom When the joystick control is released the joystick control will return to the HOLD position Boom Raise Pull the joystick control forward in order to lower the boom When joystick control is released the joystick control will return to the HOLD position Quick Coupler Tilt Forward Push the joystick cont
236. tum the knob counterclockwise In order to adjust the height of armrest 15 loosen knob 15B and raise the armrest to the desired height To secure the armrest at the desired height tighten the knob Side Console 16 The side console contains controls for the following features Heating and air conditioning Window wiper and window washer Floodlights for the cab Boom floodlights Hydraulic towing hitch Hydraulic lockout control Refer to Operation and Maintenance Manual Operator Controls Side Console for more detailed information on each of these controls Interior Light 17 Interior Light if equipped Press either side of the lens in order to turn on the interior light Press the opposite side of the lens in order to tum off the interior light Parking and Secondary Brake Control 18 Parking Brake The parking brake is controlled by a hand operated lever 18 which is located at the left side of the seat Note The parking brake operates on the front axle only Engage the parking brake after the machine has stopped and when the transmission control has been moved to the NEUTRAL position 01147873 Parking Brake Engaged Pull lever 18 fully upward in order to engage the parking brake A latch is located at the rear of lever 18 When lever 18 is pulled fully upward the latch will lock in order to hold the parking brake in the ENGAGED position Engage the parking brake after the machine has stop
237. u to program the system to automatically activate at different time periods with different keys The MSS can also be programmed to reject a specific electronic key after a selected date and time When you turn the key to the OFF position and the MSS is active you have a 30 second interval in order to restart the machine with an unauthorized key Also if the machine stalls there is a 30 second interval for restarting the machine This 30 second interval is counted from the time of tuming the key to the OFF position Note Know your machine s settings because the use of an electronic key is no guarantee that the machine can be restarted expiration date can be set for each electronic key that is contained in the list of keys for the machine key will no longer start the machine when the internal clock in the security system passes the expiration date Each entry in the list of keys can have a different expiration date Spare keys are available from your dealer Before a key can operate the machine the MSS must be set to accept that particular key Consult your Caterpillar dealer for information on additional features of the MSS 62 31200242 Operation Section Operator Controls Side Console Note Your machine may not be equipped with all of the controls that are described in this topic Fan Control 1 Fan Control Push the bottom of the switch 96 in order to operate the fan at low speed Set the s
238. udible signal The longitudinal stability indicator is powered by the machine electrical system which is activated when the engine start switch key is turned to the ON position Ensure that a Caterpillar work tool is attached to machine and use the correct load chart in order to verify that the intended lift operation is within the capability of the machine Refer to Operation and Maintenance Manual Lifting Capacities for the location of the load charts The forward stability of the machine will depend on the following factors weight of the attachment weight of the load angle of the boom length of the boom Musraton 139 901002576 The longitudinal stability indicator has a variable gauge 23 that indicates the longitudinal stability of the machine The indicator shows the status of the attempted lift operation in comparison to the limit of the machine stability The variable gauge is located in the center of the display panel As the load on the machine increases the indicator moves through the green zone toward the red zone of the gauge 31200242 83 Operation Section The scale on the gauge has three colored zones Green Zone 24 The machine is operating within the limit of forward longitudinal stability Amber zone 25 The limit for the forward longitudinal stability of the machine has been reached or exceeded Red zone 26 The limit for the forward longitudinal stabilit
239. uipment of all personnel The procedure to lower the equipment will vary with the type of equipment that is being lowered Most systems use high pressure air or fluid to control the equipment The procedure may release the pressure in a high pressure system in order to lower the equipment Wear appropriate protective equipment Follow the established procedure for lowering equipment without hydraulic power in the Operation Section of the Operation and Maintenance Manual Sound Information and Vibration Information Sound Level The operator sound pressure level that is measured according to the test procedure that is specified in EN 12053 2001 is 80 dB A for an enclosed cab The cab was properly installed and maintained The test was conducted with the doors and the windows closed Hearing protection may be needed when the machine is operated with an open operator station for extended periods or in a noisy environment Hearing protection may be needed when the machine is operated with a cab that is not properly maintained or when the doors and windows are open for extended periods or in noisy environment 31200242 31 Safety Section Vibration Level The hands and arms are exposed to a weighted root mean square acceleration that is less than 2 5 m sec 8 20 ft sec The whole body is exposed to a weighted root mean square acceleration that is less than 0 5000 m s 1 70 The measurements are obtained on a stan
240. urn pin 8 to the original position In order to connect the attachment for towing remove pin 10 Align the machine and the tow eye for the attachment Reverse the machine with assistance in order to ensure an easy connection Secure pin 10 with spring pin 11 Manual Swivel Hitch Iastraton 163 In order to adjust the height of the hitch of different attachments press pin 3 and rotate lever 2 in order to disengage the locking mechanism Lift the hitch to the required height and rotate lever 2 back to the original position When the locking mechanism is engaged pin 3 will return to the original position In order to connect the attachment for towing remove locking pin 1 and remove pin 4 Align the machine and the tow eye Reverse the machine with assistance in order to ensure an easy connection Insert pin 4 into the hitch Secure pin 4 with locking pin 1 31200242 95 Operation Section Retrieval Hitch 12 stration 164 z01002135 In order to connect the attachment for towing remove pin 12 Align the machine and the tow eye of the attachment Reverse the machine with assistance in order to ensure an easy connection Secure pin 12 with spring pin 13 Note The retrieval hitch is only suitable for off highway use Hydraulic Hitch and Hydraulic Services Mustraton 165 01000150 Hydraulic services are included with the hydraulic hitch Hydraulic services can be purchas
241. urs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor 7 stration 272 1 Date of installation retractor 2 Date of installation buckle 8 Date of manufacture tag fully extended web 4 Date of manufacture underside buckle 1 2 Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension Tire Inflation Check Personal injury could result from improper tire inflation A tire blowout or rim failure could result from improper or misused equipment Use self inflating chuck and stand behind the tread when inflating a tire Proper inflating equipment and training in using the equipment are necessary to avoid over inflating Before inflating tire put the tire in a restraining device Some machines are equipped with tires that are filled with air Other machines are equipped with tires that are filled with foam Pressures of tires that are filled with air must be checked Pressures of tires that are filled with foam do not require checking 31200242 149 Maintenance Section 1 Park the machine on level ground Apply the parking brake Retract and lower the boom Shut off the engine 2 Clean the area around the valve s
242. valve may not be installed on certain merchandising arrangements Consult your Caterpillar Dealer for installation of the connection points for the auxiliary hydraulic service with manual quick couplers Note A dual diverter valve is installed as an option Refer to the topic Joystick Control in Operation and Maintenance Manual Operator Controls for more detailed information on operating the boom and the work tools Connecting a Work Tool Refer to the procedures that are described in the topic Quick Coupler in Operation and Maintenance Manual Operation Information in order to install the work tools When you attach work tools that require hydraulic connections extend the boom by approximately 1 m 3 ft after installing the work tool onto the quick coupler This extra space is necessary in order to connect the auxiliary hoses 1 Position the machine Rest the quick coupler or the work tool on the ground 2 Engage the parking brake Move the transmission control to the NEUTRAL position and stop the engine 3 The hydraulic controls must be in the HOLD position The hydraulic controls return to the HOLD position when the hydraulic controls are released 4 Carefully inspect the hydraulic hoses or pipes on the work tool for any signs of damage The hydraulic hoses or the pipes must be free of following defects Cuts abrasions bulging kinking and dents Do not use any work tool unless the hydraulic hoses and the p
243. wheel downward Normal operation will resume Fog Lights 9 Fog Lights Push the right side of switch 9 in order to tum on the fog lights Push the left side of switch 9 in order to turn off the fog lights Hazard Flashers 10 Hazard Flashers Push the right side of switch 10 in order to activate the hazard flashers All the turn signal lights will flash simultaneously Push the left side of switch 10 in order to deactivate the hazard flashers Headlight Dimmer Switch 11 Dimmer Control Push the right side of switch 11 in order to activate the high beam headlights Switch 12 for the headlights must be in the HEADLIGHTS position in order to activate the high beam The headlights remain on high beam until the left side of switch 11 is pushed to the LOW BEAM position Headlight Parking Lights 12 Low Beam Headlights Push the right side of switch 12 in order to turn on the parking lights and the rear lights Push the right side of switch 12 again in order to turn on the headlights the parking lights and the rear lights Push the left side of Switch 12 in order to turn off the headlights Push the left side of switch 12 again in order to tum off the parking lights and the rear lights Rotating Beacon Light 13 Rotating Beacon if equipped Push the right side of switch 13 in order to activate the rotating beacon Push the left side of switch 13 in order to deactivate the
244. witch the MIDDLE position to operate the fan at medium speed Push the top of the switch in order to operate the fan at high speed Temperature Control 2 Temperature Control Turning the temperature control clockwise provides warmed air Tuming the temperature control counterclockwise provides cooler air Heating and Air Conditioning Control 3 Heating and Air Conditioning Switch Push 4 the top of the switch in order to operate the heater Set the switch in the MIDDLE position in order to return the switch to the OFF position Push the bottom of the switch in order to operate the air conditioning compressor Note Use the air conditioning in conjunction with the temperature control and the fan control in order to reduce the temperature of the cab The air conditioning compressor may be operated intermittently during heater operation in order to remove excess humidity from the cab Front Window Wiper 4 Front Window Wiper 4 When the bottom of switch is pressed the switch is in the OFF position Press the top of the switch one click in order to operate the wiper motor at slow speed In order to operate the motor at high speed press the top of switch to the next detent Front Window Washer 5 Front Window Washer Push the top of switch and hold the top of switch in order to activate the washer motor Release the switch The switch will retum to the OFF position Roof Wiper Washer 6
245. with a security system Read the Operation and Maintenance Manual before you operate the machine Coolant 8 This message is located on the coolant tank 50 Ethylene Glycol TD Refill with only 50 50 mixture of ethylene glycol and water Refer to Operation and Maintenance Manual Cooling System Coolant Level Check and Operation and Maintenance Manual Cooling System Coolant Change for more information 31200242 23 Safety Section General Hazard Information Mustration 16 200104545 Attach a Do Not Operate warning tag or a similar warning tag to the start switch orto the controls before you service the equipment or before you repair the equipment These waming tags are available from your Caterpillar dealer Know the width of your equipment in order to maintain proper clearance when you operate the equipment near fences or near boundary obstacles Be aware of high voltage power lines and power cables that are buried If the machine comes in contact with these hazards serious injury or death will occur from electrocution 900702020 94 HD Mustration 17 Wear a hard hat protective glasses and other protective equipment as required Do not wear loose clothing or jewelry that can snag on controls or on other parts of the equipment Make sure that all protective guards and all covers are secured in place on the equipment Keep the equipment free from foreign material Re
246. wnhill Select the necessary travel speed before you start downhill Do not change gears while you are going downhill When you go downhill use the same speed that would be used to go uphill Do not allow the engine to overspeed when you go downhill Use the service brake to prevent engine overspeed when you go downhill Select a lower gear before you go down the same hill again When you are travelling uphill select a lower gear when the engine speed starts to fall Drive the machine in the gear that will allow the required speed to be maintained Do not allow the torque converter to slip and do not allow the engine to lug Note When you operate a machine on a slope certain conditions may prevent the machine from changing to a lower gear If the operator selects a lower gear and the current gear that is displayed next to the speedometer begins to flash apply the service brakes When the gear change has been completed the gear display will cease to flash Manual Transmission T 901147875 Some machines are equipped with a manual transmission shift Transmission Neutralizer Button 22B Push the button and hold the button when you are changing speed ranges This will disengage the transmission from the driving wheels Transmission Speed Shift Lever 22C Push transmission neutralizer button 22B and hold button 228 in order to neutralize the transmission Then move lever 22C to one of the four des
247. y locked in place before you raise the hopper Before you raise the hopper ensure that the latch for the trip lever is securely engaged Raise the hopper Tilt the quick coupler slightly backward in order to better secure the hopper Travel with the boom fully retracted so that you have good visibility and so that the machine has good stability Discharging the Hopper Travel the machine to the work area Stop the machine and apply the parking brake Lower the hopper Mustration 123 900074801 Pull down on the release lever The hopper will tilt forward and the load will be discharged To remove the hopper lower the hopper to the ground The bar that secures the forks in place will automatically disengage when the hopper is placed on the ground Withdraw the forks from the pockets by retracting the boom Utility Fork with Grapple and Ejector Mustration 124 pores The forks are used to tear out material from a pile The fork with the grapple has the same function as the fork The grapple is used for increased load retention The ejector dumps the load more efficiently 78 Operation Section 31200242 Picking up a Load When you load a fork the boom must be fully retracted Raise the forks in order to clear the ground Single Thumb Wheel EAEI Press and hold switch 1 in order to open the grapple Release the switch when the grapple is fully open Approach the load with the grapple i
248. y of the machine has been exceeded When the indicator enters the amber zone an audible signal will sound continuously and a visible alarm 2 will begin to light The audible signal will sound and the visible alarm will light in the red zone This audible signal indicates that the limit of longitudinal stability has been reached or exceeded When this condition occurs do not proceed with the lift operation Retract the boom if the boom is extended If the boom is retracted return the load to the original position If the indicator is not in the amber zone or the red zone the alarm may be caused by another system Check the other gauges for the indication of other problem Change the operation of the machine Extending the boom or lowering a raised boom further increases the outreach of the load This can reduce the forward stability of the machine Machine tip over could result If the longitudinal stability indicator shows that the machine stability limit is being approached do not lower or further extend the boom Retract the boom before lowering Machine tip over could cause personal injury or death to the operator or other personnel in the work area The visual alarm and the audible alarm may operate momentarily when the machine is traveling with a load on the work tool This may occur more frequently on uneven ground or rough terrain Turning the steering system onto the full lock may also cause unexpected operation of the visua
249. ye protection includes goggles or a protective face shield The maximum air pressure for cleaning purposes must be below 205 kPa 30 psi The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi Trapped Pressure Pressure can be trapped in a hydraulic system Releasing trapped pressure can cause sudden machine movement or attachment movement Use caution if you disconnect hydraulic lines or fittings High pressure oil that is released can cause a hose to whip High pressure oil that is released can cause oil to spray Fluid penetration could cause serious injury and possible death 24 Safety Section 31200242 Fluid Penetration Pressure can be trapped in the hydraulic circuit long after the engine has been stopped The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury could occur Refer to the Service Manual for any procedures that are required to relieve the hydraulic pressure istration 18 00687600 Always use a board or cardboard when you check for a leak Leaking fluid that is under pressure can penetrate body tissue Fluid penetration could cause serious injury and possible death A pin hole leak can cause sev
250. you attempt to start the stalled machine This will allow the batteries in the stalled machine to partially charge 14 Attempt to start the stalled engine Refer to Operation and Maintenance Manual Engine Starting for the correct starting procedure 15 Immediately after you start the stalled engine disconnect the jump start cables in reverse order Equipment Lowering with Loss of Hydraulic Power A WARNING Lowering the boom with the engine stopped could cause personal injury or death Keep all personnel away from the boom drop area when lowering the boom with the engine stopped A WARNING Personal injury could result from not following the specified procedure To avoid personal injury follow the procedure as specified A WARNING Lowering a raised boom increases the outreach of the load This could reduce the forward stability of the machine resulting in machine tip over This could cause injury or death to the operator or other personnel in the work area Always retract the boom if possible before lowering it The cylinder for retracting the boom and the cylinder for lowering the boom are equipped with load control valves The load control valves lock oil in the cylinders if hydraulic power is lost The locked oil in the cylinders prevents the boom from moving In most situations the boom can be retracted and the boom can be lowered from ground level if hydraulic power is lost If the angle of the boom is

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