31200243.book (EN)

31200243_A_TH360B_CAT_O&MM

31200243 July 14, 2006 Operation and Maintenance Manual TH360B Telehandler S/N TBH00100 & After Keep this manual with machine at all times.

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31200243_A_TH360B_CAT_O&MM

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.

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Table of Contents

31200243 1 Table of Contents Table of Table of Contents Before Operation..................................................30 Operation .............................................................30 Machine Operating Temperature Range ........30 Machine Operation .........................................30 Travel..............................................................30 Lifting Capacities ............................................30 Work Tools......................................................31 Engine Stopping...................................................31 Work Tools...........................................................31 Parking.................................................................31 Equipment Lowering with Loss of Hydraulic Power...................................................................32 Sound Information and Vibration Information ......32 Sound Level....................................................32 Vibration Level................................................32 Operator Station...................................................32 Guards (Operator Protection) ..............................32 Rollover Protective Structure (ROPS), Falling Object Protective Structure (FOPS)................33 Other Guards (If Equipped) ............................33 Foreword Literature Information ............................................

5 Safety .................................................................... 5 Operation .............................................................. 5 Maintenance.......................................................... 5 Maintenance Intervals...................................... 5 Certified Engine Maintenance ............................... 5 Machine Capacity.................................................. 5 Contact Information............................................... 6 Safety Section Safety Messages................................................... 7 Do Not Operate (1)......................................... 10 Do Not Stand Under the Load (2) ..................

10 No Hands (3).................................................. 11 Do Not Operate (4)......................................... 11 Forks (5)......................................................... 12 Do Not Weld On The ROPS/FOPS Structure (6) ................................................... 12 Crushing Hazard (7)....................................... 13 No Hands (8).................................................. 13 Seat Belt (9) ................................................... 14 Crushing Hazard (10)..................................... 14 Crushing Hazard (11)..................................... 15 Engine Coolant (12) .......................................

15 Avoid Power Lines (13).................................. 16 Low Bridge (14).............................................. 16 Jump Start Cables (15) .................................. 17 Ether (16) ....................................................... 17 Crushing Hazard (17)..................................... 18 Crushing Hazard (18)..................................... 18 Operation (19)................................................ 18 Impaling Hazard (20)...................................... 18 Crushing Hazard (21)..................................... 19 Entanglement and Flying Objects (22)........... 19 Trap Point (23) ...............................................

19 Crushing Hazard (24)..................................... 19 Ether (25) ....................................................... 20 Additional Messages...................................... 20 General Hazard Information................................ 24 Pressurized Air and Water ............................. 25 Trapped Pressure .......................................... 25 Fluid Penetration............................................ 25 Containing Fluid Spillage ............................... 25 Dispose of Waste Properly............................. 25 Crushing Prevention and Cutting Prevention ...... 25 Burn Prevention .............................................

26 Coolant........................................................... 26 Oils................................................................. 26 Batteries......................................................... 26 Fire Prevention and Explosion Prevention .......... 26 Fire Extinguisher ............................................ 27 Lines, Tubes and Hoses ................................ 27 Fire Extinguisher Location.............................. 28 Tire Information.............................................. 28 Electrical Storm Injury Prevention.................. 28 Before Starting Engine...................................

29 Engine Starting....................................................

29 Product Information Section General Information .............................................35 Lifting Capacities ............................................35 Examples of Estimating the Lift Operation from the Load Chart................................................36 Specifications.......................................................37 Intended Use ..................................................38 Application/Configuration Restrictions ............38 Identification Information......................................38 Plate Locations and Film Locations ................38 Serial Number.................................................39 Certification.....................................................39 Sound .............................................................39 ROPS/FOPS Film ...........................................40 Machine Security System ...............................40 Italian Roading Homologation.........................40 Emissions Certification Film.................................42 Operation Section Before Operation..................................................43 Mounting and Dismounting.............................43 Alternate Exit ..................................................43 Daily Inspection ..............................................43 Machine Operation...............................................45 Alternate Exit ..................................................45 Seat ................................................................45 Air Suspension (If Equipped)..........................46 Seat Belt .........................................................46 Operator Controls (Side Console) ..................49 Operator Controls ...........................................51 Operation Information .....................................67 Work Tools......................................................75 Monitoring System ..........................................80 Backup Alarm .................................................83 Cab Door ........................................................84 Engine Starting ....................................................84 Engine Starting ...............................................84 Starting Below 0 °C (32°F)..............................85 Engine and Machine Warm-Up.......................85

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Table of Contents

31200243 2 Table of Contents Parking ................................................................ 86 Stopping the Machine .................................... 86 Stopping the Engine....................................... 86 Stopping the Engine if an Electrical Malfunction Occurs............................................................ 86 Leaving the Machine...................................... 86 Transportation Information .................................. 87 Shipping the Machine..................................... 87 Roading the Machine ..................................... 87 Lifting and Tying Down the Machine..............

88 Towing Information.............................................. 88 Towing the Machine....................................... 88 Types of Towing Hitches................................ 90 Engine Starting (Alternate Methods) ................... 91 Engine Starting with Jump Start Cables......... 91 Equipment Lowering with Loss of Hydraulic Power.............................................................

93 Primary Cab Air Filter ...................................115 Secondary Cab Air Filter...............................116 Circuit Breakers - Test .......................................116 Cooling System Coolant - Change.....................117 Cooling System Coolant Level - Check .............118 Cooling System Coolant Sample (Level 1) - Obtain ................................................................119 Cooling System Coolant Sample (Level 2) - Obtain ................................................................119 Cooling System Pressure Cap - Clean/Replace 120 Cooling System Water Temperature Regulator Replace..............................................................120 Differential Oil - Change.....................................121 Rear Axle Differential....................................121 Front Axle Differential ...................................122 Differential Oil Level - Check .............................122 Rear Axle Differential....................................122 Front Axle Differential ...................................123 Differential Oil Sample - Obtain .........................123 Drive Shaft Spline - Lubricate ............................124 Drive Shaft Universal Joint Bolts - Check ..........124 Engine Air Filter Primary Element - Clean/Replace ...................................................125 Cleaning Primary Air Filter Elements............125 Inspecting the Primary Air Filter Elements....126 Engine Air Filter Secondary Element - Replace.127 Engine Air Filter Primary Element - Replace .....127 Engine Mounts - Inspect ....................................127 Engine Oil Level - Check ...................................127 Engine Oil Sample - Obtain ...............................128 Engine Oil and Filter - Change...........................128 Engine Valve Lash - Check................................129 Final Drive Oil - Change.....................................130 Final Drive Oil Level - Check .............................130 Final Drive Oil Sample - Obtain .........................131 Fork Leveling Cylinder Pin -Lubricate ................132 Frame Leveling Cylinder Pin -Lubricate.............132 Fuel System - Prime ..........................................132 Fuel System Secondary Filter Replace..............133 Fuel System Water Separator - Drain................133 Fuel System Water Separator Element - Replace..............................................................134 Fuel Tank Cap - Clean.......................................135 Fuel Tank Water and Sediment - Drain .............135 Fuses and Relays - Replace..............................136 Fuses ............................................................136 Relays...........................................................138 Indicators and Gauges - Test.............................138 Longitudinal Stability Indicator - Calibrate..........139 Longitudinal Stability Indicator -Test..................139 Initial Test .....................................................139 Second Test..................................................139 Oil Filter - Inspect...............................................139 Inspect a Used Filter for Debris ....................139 Parking Brake - Adjust .......................................140 Pulley for Boom Extension Chain - Lubricate ....140 Pulley for Boom Retraction Chain - Lubricate....140 Radiator Core - Clean........................................141 Refrigerant Dryer - Replace...............................141 Maintenance Section Maintenance Access ...........................................

97 Access Doors and Covers.............................. 97 Tire Inflation Information ..................................... 97 Tire Inflation with Air....................................... 97 Tire Pressure.................................................. 98 Tire Inflation Pressure Adjustment................. 99 Tire Damage .................................................. 99 Tire Replacement........................................... 99 Wheel and Tire Installation............................. 99 Lubricant Viscosities and Refill Capacities........ 100 Lubricant Viscosities .................................... 100 Capacities (Refill).........................................

102 SOS Information........................................... 103 Maintenance Support ........................................ 103 Welding on Machines and Engines with Electronic Controls....................................... 103 Maintenance Interval Schedule......................... 104 Axle Breathers - Clean/Replace........................ 106 Backup Alarm - Test.......................................... 106 Battery - Recycle............................................... 106 Battery or Battery Cable -Inspect/Replace........ 106 Belt - Inspect/Replace ....................................... 107 Inspect .........................................................

107 Replace........................................................ 107 Boom Chain - Inspect/ Lubricate....................... 108 Boom Chain Tension -Check/Adjust ................. 108 Check Condition........................................... 108 Check and Adjust the Chain Tension........... 108 Measure the Chain for Wear........................ 109 Boom Cylinder Pin - Lubricate .......................... 110 Boom Head Section - Lubricate ........................ 110 Boom Pivot Shaft - Lubricate ............................ 110 Boom Telescoping Cylinder Air- Purge ............. 110 Boom Wear Pad Clearance -Inspect/Adjust......

111 Adjustment ................................................... 112 Boom and Frame - Inspect................................ 113 Braking System - Test....................................... 114 Service Brake............................................... 114 Parking Brake............................................... 115 Cab Air Filter - Clean/Replace........................... 115

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