Caterpillar Telehander Th360b (Tbh) Operation Manual

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31200243
July 14, 2006

Operation and
Maintenance
Manual
TH360B Telehandler
S/N TBH00100 & After

Keep this manual with machine at all times.

This is the cut pages sample. Download all 164 page(s) at: ManualPlace.com
 Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar® dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type, strength
and material.

Failure to heed this warning can lead to

premature failures, product damage, personal
injury or death.
31200243 1
Table of Contents
Table of
Table of Contents Before Operation..................................................30
Operation .............................................................30
Foreword Machine Operating Temperature Range ........30
Literature Information ............................................ 5
Machine Operation .........................................30
Safety .................................................................... 5
Travel..............................................................30
Operation .............................................................. 5
Lifting Capacities ............................................30
Maintenance.......................................................... 5
Work Tools......................................................31
Maintenance Intervals ...................................... 5
Engine Stopping...................................................31
Certified Engine Maintenance ............................... 5
Work Tools...........................................................31
Machine Capacity.................................................. 5
Parking.................................................................31
Contact Information ............................................... 6
Equipment Lowering with Loss of Hydraulic
Safety Section Power...................................................................32
Safety Messages................................................... 7 Sound Information and Vibration Information ......32
Do Not Operate (1)......................................... 10 Sound Level....................................................32
Do Not Stand Under the Load (2) .................. 10 Vibration Level ................................................32
No Hands (3).................................................. 11 Operator Station...................................................32
Do Not Operate (4)......................................... 11 Guards (Operator Protection) ..............................32
Forks (5)......................................................... 12 Rollover Protective Structure (ROPS), Falling
Do Not Weld On The ROPS/FOPS Object Protective Structure (FOPS)................33
Structure (6) ................................................... 12 Other Guards (If Equipped) ............................33
Crushing Hazard (7)....................................... 13 Product Information Section
No Hands (8).................................................. 13
General Information .............................................35
Seat Belt (9) ................................................... 14
Lifting Capacities ............................................35
Crushing Hazard (10)..................................... 14
Examples of Estimating the Lift Operation from
Crushing Hazard (11)..................................... 15
the Load Chart ................................................36
Engine Coolant (12) ....................................... 15
Specifications.......................................................37
Avoid Power Lines (13) .................................. 16
Intended Use ..................................................38
Low Bridge (14).............................................. 16
Application/Configuration Restrictions ............38
Jump Start Cables (15) .................................. 17
Identification Information......................................38
Ether (16) ....................................................... 17
Plate Locations and Film Locations ................38
Crushing Hazard (17)..................................... 18
Serial Number.................................................39
Crushing Hazard (18)..................................... 18
Certification.....................................................39
Operation (19) ................................................ 18
Sound .............................................................39
Impaling Hazard (20)...................................... 18
ROPS/FOPS Film ...........................................40
Crushing Hazard (21)..................................... 19
Machine Security System ...............................40
Entanglement and Flying Objects (22)........... 19
Italian Roading Homologation.........................40
Trap Point (23) ............................................... 19
Emissions Certification Film.................................42
Crushing Hazard (24)..................................... 19
Ether (25) ....................................................... 20 Operation Section
Additional Messages ...................................... 20 Before Operation..................................................43
General Hazard Information ................................ 24 Mounting and Dismounting .............................43
Pressurized Air and Water ............................. 25 Alternate Exit ..................................................43
Trapped Pressure .......................................... 25 Daily Inspection ..............................................43
Fluid Penetration ............................................ 25 Machine Operation...............................................45
Containing Fluid Spillage ............................... 25 Alternate Exit ..................................................45
Dispose of Waste Properly............................. 25 Seat ................................................................45
Crushing Prevention and Cutting Prevention ...... 25 Air Suspension (If Equipped) ..........................46
Burn Prevention ............................................. 26 Seat Belt .........................................................46
Coolant........................................................... 26 Operator Controls (Side Console) ..................49
Oils ................................................................. 26 Operator Controls ...........................................51
Batteries ......................................................... 26 Operation Information .....................................67
Fire Prevention and Explosion Prevention .......... 26 Work Tools......................................................75
Fire Extinguisher ............................................ 27 Monitoring System ..........................................80
Lines, Tubes and Hoses ................................ 27 Backup Alarm .................................................83
Fire Extinguisher Location.............................. 28 Cab Door ........................................................84
Tire Information .............................................. 28 Engine Starting ....................................................84
Electrical Storm Injury Prevention .................. 28 Engine Starting ...............................................84
Before Starting Engine ................................... 29 Starting Below 0 °C (32°F)..............................85
Engine Starting.................................................... 29 Engine and Machine Warm-Up.......................85
31200243 2
Table of Contents

Parking ................................................................ 86 Primary Cab Air Filter ...................................115

Stopping the Machine .................................... 86 Secondary Cab Air Filter...............................116
Stopping the Engine....................................... 86 Circuit Breakers - Test .......................................116
Stopping the Engine if an Electrical Malfunction Cooling System Coolant - Change.....................117
Occurs............................................................ 86 Cooling System Coolant Level - Check .............118
Leaving the Machine ...................................... 86 Cooling System Coolant Sample (Level 1) -
Transportation Information .................................. 87 Obtain ................................................................119
Shipping the Machine..................................... 87 Cooling System Coolant Sample (Level 2) -
Roading the Machine ..................................... 87 Obtain ................................................................119
Lifting and Tying Down the Machine .............. 88 Cooling System Pressure Cap - Clean/Replace 120
Towing Information.............................................. 88 Cooling System Water Temperature Regulator
Towing the Machine ....................................... 88 Replace..............................................................120
Types of Towing Hitches................................ 90 Differential Oil - Change.....................................121
Engine Starting (Alternate Methods) ................... 91 Rear Axle Differential....................................121
Engine Starting with Jump Start Cables......... 91 Front Axle Differential ...................................122
Equipment Lowering with Loss of Hydraulic Differential Oil Level - Check .............................122
Power ............................................................. 93 Rear Axle Differential....................................122
Front Axle Differential ...................................123
Maintenance Section
Differential Oil Sample - Obtain .........................123
Maintenance Access ........................................... 97
Drive Shaft Spline - Lubricate ............................124
Access Doors and Covers.............................. 97
Drive Shaft Universal Joint Bolts - Check ..........124
Tire Inflation Information ..................................... 97
Engine Air Filter Primary Element -
Tire Inflation with Air....................................... 97
Clean/Replace ...................................................125
Tire Pressure.................................................. 98
Cleaning Primary Air Filter Elements............125
Tire Inflation Pressure Adjustment ................. 99
Inspecting the Primary Air Filter Elements....126
Tire Damage .................................................. 99
Engine Air Filter Secondary Element - Replace.127
Tire Replacement........................................... 99
Engine Air Filter Primary Element - Replace .....127
Wheel and Tire Installation............................. 99
Engine Mounts - Inspect ....................................127
Lubricant Viscosities and Refill Capacities........ 100
Engine Oil Level - Check ...................................127
Lubricant Viscosities .................................... 100
Engine Oil Sample - Obtain ...............................128
Capacities (Refill) ......................................... 102
Engine Oil and Filter - Change...........................128
SOS Information........................................... 103
Engine Valve Lash - Check................................129
Maintenance Support ........................................ 103
Final Drive Oil - Change.....................................130
Welding on Machines and Engines with
Final Drive Oil Level - Check .............................130
Electronic Controls ....................................... 103
Final Drive Oil Sample - Obtain .........................131
Maintenance Interval Schedule ......................... 104
Fork Leveling Cylinder Pin -Lubricate ................132
Axle Breathers - Clean/Replace ........................ 106
Frame Leveling Cylinder Pin -Lubricate.............132
Backup Alarm - Test.......................................... 106
Fuel System - Prime ..........................................132
Battery - Recycle ............................................... 106
Fuel System Secondary Filter Replace..............133
Battery or Battery Cable -Inspect/Replace ........ 106
Fuel System Water Separator - Drain................133
Belt - Inspect/Replace ....................................... 107
Fuel System Water Separator Element -
Inspect ......................................................... 107
Replace..............................................................134
Replace ........................................................ 107
Fuel Tank Cap - Clean.......................................135
Boom Chain - Inspect/ Lubricate ....................... 108
Fuel Tank Water and Sediment - Drain .............135
Boom Chain Tension -Check/Adjust ................. 108
Fuses and Relays - Replace..............................136
Check Condition........................................... 108
Fuses ............................................................136
Check and Adjust the Chain Tension........... 108
Relays...........................................................138
Measure the Chain for Wear ........................ 109
Indicators and Gauges - Test.............................138
Boom Cylinder Pin - Lubricate .......................... 110
Longitudinal Stability Indicator - Calibrate..........139
Boom Head Section - Lubricate ........................ 110
Longitudinal Stability Indicator -Test ..................139
Boom Pivot Shaft - Lubricate ............................ 110
Initial Test .....................................................139
Boom Telescoping Cylinder Air- Purge ............. 110
Second Test..................................................139
Boom Wear Pad Clearance -Inspect/Adjust...... 111
Oil Filter - Inspect...............................................139
Adjustment ................................................... 112
Inspect a Used Filter for Debris ....................139
Boom and Frame - Inspect................................ 113
Parking Brake - Adjust .......................................140
Braking System - Test ....................................... 114
Pulley for Boom Extension Chain - Lubricate ....140
Service Brake............................................... 114
Pulley for Boom Retraction Chain - Lubricate....140
Parking Brake............................................... 115
Radiator Core - Clean ........................................141
Cab Air Filter - Clean/Replace........................... 115
Refrigerant Dryer - Replace ...............................141
3 31200243
Table of Contents

Rollover Protective Structure (ROPS) and Falling

Object Protective Structure (FOPS) -Inspect .... 142
Seat Belt - Inspect ............................................. 142
Seat Belt - Replace ........................................... 143
Stabilizer and Cylinder Bearings - Lubricate ..... 143
Tire Inflation - Check ......................................... 143
Transmission and Hydraulic System Oil -
Change.............................................................. 144
Transmission and Hydraulic System Oil Filter -
Replace ............................................................. 145
Transmission and Hydraulic System Oil Level -
Check ................................................................ 146
Transmission and Hydraulic System Oil Sample -
Obtain................................................................ 147
Transmission and Hydraulic System Tank
Breather - Clean ................................................ 147
Turbocharger - Inspect ...................................... 147
Wheel Nut Torque - Check................................ 147
Window Washer Reservoir -Fill ......................... 148
Window Wiper -Inspect/Replace ....................... 148
Windows - Clean ............................................... 148
Work Tool - Inspect/Replace ............................. 148
Forks ............................................................ 148
Buckets ........................................................ 150
Reference Information Section
Approved Work Tools.................................. 153
31200243 4
Table of Contents
31200243 5
Foreword

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

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 31200243
Foreword

Contact Information
For:
• Accident Reporting and Product Safety Publications
• Current Owner Updates
• Questions Regarding Product Applications and
Safety
• Standards and Regulations Compliance Information
• Questions Regarding Product Modifications

Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233
USA
or Your Local JLG Office

In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)

Outside USA:
Phone: 717-485-5161 or 717-485-6591

E-mail: ProductSafety@JLG.com
31200243 7
Safety Section

Safety Section
Safety Messages

Illustration 2 g01106084
Caterpillar Telehander Th360b (Tbh) Operation Manual
Full download:
8 http://manualplace.com/download/caterpillar-telehander-th360b-tbh-operation-manual/ 31200243
Safety Section

Illustration 3 g01213315

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