Caterpillar Cat Th360b Th560b Telehandler Service Repair Workshop Manual Download

TH360B & TH560B Telehandler Service Manual 31200264 S/N TBH00100 & After S/N TBP00100 & After

Section

Title

Service Manual Contents Torque Specifications

Manual No. 31200265 31200268

Engine Disassembly & Assembly

Engine Supplement

31200299

Power Train Systems Operation, Testing & Adjusting Disassembly & Assembly

Power Train Power Train

31200270 31200300

Vehicle Systems Schematic Systems Operation, Testing & Adjusting Systems Operation, Testing & Adjusting Systems Operation, Testing & Adjusting Machine Components Specs Disassembly & Assembly

Hydraulic System Hydraulic System Steering System Brake System Machine Systems Machine Systems

31200304 31200302 31200273 31200274 31200306 31200308

Electrical System Electrical System Hydrostatic Transmission Electronic Control System LSI System Monitoring System

31200310 31200311 31200279

Electrical Systems Schematic - TH360B Schematic - TH560B Machine Troubleshooting Systems Operation, Testing & Adjusting Systems Operation, Testing & Adjusting

31200265 A

31200280 31200281

31200268 December 15, 2006

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

Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. CaterpillarÂŽ dealers have the most current information available.

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

Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

31200268

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

1 Table of Contents

2 Table of Contents

31200268

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31200268

Specifications Section General Information

Mismatched or incorrect fasteners can result in damage or malfunction, or personal injury.

Take care to avoid mixing metric dimensioned fasteners and inch dimensioned fasteners.

Introduction to Torque "Torque" is measured in terms of force and distance.

Force is the amount of pushing or pulling applied at the end of the lever. Distance is the length of the lever that is being used. Torque values are given in the following units: NEWTON meters (Nm), pound inches (lb in), and pound feet (lb ft) This manual is intended to provide the operator with a reference. This manual will provide the standard torque settings for the following: bolts, nuts, plugs, fittings, and clamps.

Exceptions to these torques are given in the Service Manual, if necessary.

Be sure to use a torque wrench that has the proper range. Torque wrenches must be used properly in order to ensure that the correct torque is applied.

Always use a smooth pull for torque wrenches. Do not jerk a torque wrench. Do not use adapters that change the length of the torque wrench. For the correct use of your torque wrench, refer to the instructions that were packaged with your torque wrench.

Prior to installation of any hardware, ensure that components are in near new condition. Bolts and threads must not be worn or damaged. Threads must not have burrs or nicks. Hardware must be free of rust and corrosion. Clean reused fasteners with a noncorrosive cleaner. Lightly lubricate the threads of reused fasteners. Lightly lubricate the mating surface of the head of reused fasteners. Other applications for lubricating fasteners may also be specified in the Service Manual. The Service Manual may also specify the use of sealants and compounds.

Note: Do not use sealants that are not specified in the Service Manual. Do not use compounds that are not specified in the Service Manual. Clean old compound from the bolt and from the hole before installation.

3 Specifications Section

Torque-Turn The torque-turn method is used when precise control over clamping force is required. There is an initial torque and an additional turn. The initial torque is required to bring all parts of the joint into contact. The additional turn provides the desired clamping force.

Ensure that all fasteners have been torqued before you perform the additional turns. Turn the fastener according to the specified amount. The specified amount will normally be equal to or greater than 90°.

The specified amount will normally be in 30° increments. Turns of 120° or 180° are preferred. Turns of 120° or 180° are easily measured by the points of the hex head of the fastener. Lubrication may be specified in order to reduce the effort that is required for the final turn. The use of the torque-turn method will allow the following: • Increase the life of the fastener.

• Maximize the potential clamping force of a fastener.

Typical applications are the following: • Track bolts • Sprocket bolts • Connecting rod bolts • Engine Cylinder Heads • Drive Shaft bolts Note: Too much tension on the bolt will cause the bolt to be stretched beyond the point of yield. The bolt will be permanently stretched. The bolt will loosen the grip on the parts that are being fastened. If the bolt is tightened again, the bolt will break. Do not reuse bolts that have been permanently stretched.

Torque Sequence Unless the bolt tightening sequence is specified by the Service Manual, the fasteners should be tightened in a cross pattern. Use Step 1 through Step 5 unless the tightening sequence is specified: 1. Hand tighten all fasteners. Larger fasteners may require the use of a small hand wrench.

2. Torque all fasteners to 40% of full torque.

3. Torque all fasteners to 70% of full torque.

4. Torque all fasteners to full torque by using a cross pattern. Large flanges may require additional passes.

5. Apply at least one final full torque to all fasteners in a clockwise direction until all torque is uniform.

Large flanges may require additional passes.

Note: Final torque may be a turn.

4 Specifications Section

31200268

Metric (ISO) Fasteners Metric (ISO) Nuts and Bolts

Illustration 2

g00908932

Table 3

Illustration 1

g00909614

Thread Size mm

Torque

M1.6

0.10 ±0.01 Nm (0.9 ±0.1 lb in)

M2

0.15 ±0.01 Nm (1.3 ±0.1 lb in)

M2.5

0.35 ± 0.05 Nm (3.1 ±0. 4 lb in)

M3

0.50 ± 0.05 Nm (4.4 ±0. 4 lb in)

M4

1.70 ± 0.25 Nm (15.0 ± 2.2 lb in)

M5

2.25 ± 0.25 Nm (19.9 ± 2.2 lb in)

Note: The following table has the recommended standard torque values for Metric nuts and bolts for use on Perkins engines.

Table 1

Thread Size mm

Torque

M6

5 Nm (44 lb in)

M8

22 Nm (16 lb ft)

M10

44 Nm (32 lb ft)

M12

78 Nm (60 lb ft)

M14

124 Nm (90 lb ft)

M16

177 Nm (130 lb ft)

M18

200 Nm (150 lb ft)

M20

400 Nm (300 lb ft)

M24

790 Nm (580 lb ft)

Note: The difference between Caterpillar standard torque values and Perkins standard torque values are due to different classes of fasteners. Caterpillar uses class 10.9 fasteners. Perkins uses class 8.8 fasteners.

The different class of fasteners have different tensile strengths.

Metric (ISO) Taperlock Studs Note: The following table has the recommended standard torque values for metric nuts and bolts for use on Perkins engines.

Table 2

Thread Size mm

Torque

M6

5 Nm (44 lb in)

M8

11 Nm (97 lb in)

M10

18 Nm (13 lb ft)

M12

25 Nm (18 lb ft)

Metric (ISO) Machine Screws

Hex Button Head Screw and Set Screw

Illustration 3

g01186742

Table 4

Thread Size mm

Torque

M3

.6± .1 Nm (5 ± 0.9 lb in)

M4

2± .3 N m ( 1 8 ± 3 l b i n )

M5

4± .5 Nm (35 ± 4 lb in)

M6

6± 1 N m ( 5 5 ± 9 l b in)

M8

15 ±3 Nm (11 ± 2 lb ft)

M10

30 ± 7 Nm (22 ± 5 lb ft)

M12

50 ± 10 Nm (37 ± 7 lb ft)

M14

80 ± 15 Nm (60 ± 11 lb ft)

M16

125 ± 20 Nm (90 ± 15 lb ft)

M20

250 ± 40 Nm(185 ± 30 lb ft)

M24

425 ± 50 Nm (310 ± 37 lb ft)

M30

850 ± 100 Nm (620 ± 75 lb ft)

M36

1500 ± 200 Nm (1100 ± 150 lb ft)

31200268

5 Specifications Section

English (SAE) Fasteners

English (SAE) Taperlock Studs Table 6

English (SAE) Nuts and Bolts

Illustration 4

Thread Size Inch

Standard Torque

1/4

8 ± 3 Nm (6 ± 2 lb ft)

5/16

17 ± 5 Nm (13 ± 4 lb ft)

3/8

35 ± 5 Nm (26 ± 4 lb ft)

7/16

45 ± 10 N m ( 3 3 ± 7 lb ft)

1/2

65 ± 10 N m ( 4 8 ± 7 lb ft)

5/8

110 ±20 N m ( 8 0 ± 15 lb ft)

3/4

170 ± 30 N m ( 1 2 5 ±2 2 lb ft)

7/8

260 ±40 N m ( 1 9 0 ± 30 lb ft)

1

400 ± 60 Nm (300 ± 44 lb ft)

1 1/8

525 ± 60 Nm (390 ± 44 lb ft)

1 1/4

750 ± 80 Nm (550 ± 60 lb ft)

1 3/8

950 ± 125 Nm(700±90 lb ft)

1 1/2

1200 ± 150Nm(880± 110 lb ft)

g00908911

Table 5

Thread Size Inch

Torque

1/4

12 ± 3 N m ( 9 ± 2 lb ft)

5/16

25 ± 6 Nm (18 ± 4 lb ft)

3/8

47 ± 9 Nm (35 ± 7 lb ft)

7/16

70 ± 15 N m ( 5 0 ± 11 lb ft)

1/2

105 ±20 N m ( 7 5 ± 15 lb ft)

9/16

160 ± 30 N m ( 1 2 0 ±2 2 lb ft)

5/8

215 ±40 N m ( 1 6 0 ± 30 lb ft)

3/4

370 ± 50 Nm (275 ± 37 lb ft)

7/8

620 ± 80 Nm (460 ± 60 lb ft)

1

900 ± 100 Nm(660±75 lb ft)

1 1/8

1300 ± 150Nm(960± 110 lb ft)

1 1/4

1800 ± 200 Nm (1320 ± 150 lb ft)

1 3/8

2400 ± 300 Nm (1780 ± 220 lb ft)

1 1/2

3100 ± 350 Nm (2280 ± 260 lb ft)

English (SAE) Machine Screws

Illustration 5

g00908932

Table 7

Thread Size No.

Torque

0-80

0.10 ±0.01 Nm (0.9 ±0.1 lb in)

1-64

0.15 ±0.01 Nm (1.3 ±0.1 lb in)

2-56

0.25 ± 0.02 Nm (2.2 ± 0.2 lb in)

3-48

0.35 ± 0.05 Nm (3.1 ± 0.4 lb in)

4-40

0.50 ± 0.05 Nm (4.4 ± 0.4 lb in)

5-40

0.70 ± 0.10 Nm (6.2 ± 0.9 lb in)

6-32

0.90 ± 0.10 Nm (8.0 ± 0.9 lb in)

8-32

1.70 ± 0.25 Nm (15.0 ± 2.2 lb in)

10-24

2.25 ± 0.25 Nm (19.9 ± 2.2 lb in)

12-24

3.40 ± 0.60 Nm (30.1 ± 5.3 lb in)

6 Specifications Section

31200268

Hex Button Head Screw and Set Screws

Ground Engaging Tool (G.E.T.) Fasteners Ground Engaging Tools (G.E.T.) are secured by many types of bolts. Refer to Table 9 for the correct torque for the following combinations of fasteners for G.E.T.: • plow bolts and nuts • hex head bolts and nuts

Illustration 6

g01186972

Table 9

Thread Size

Table 8

Torque(1)

Inch

Nm

lb ft

5/8 inch

270 ± 40

200 ± 30

3/4 inch

475 ± 60

350 ± 45

7/8 inch

750 ± 90

550 ± 65

4± . 5 N m ( 3 5 ± 4 lb in)

1 inch

1150 ± 150

850 ± 110

1/4

6± 1 N m ( 5 5 ± 9 lb in)

1 1/4 inch

2300 ± 300

1700 ± 220

5/16

13±3Nm(115±27 lbin)

3/8

25±6Nm(18±4 lb ft)

7/16

40±8Nm(20±6 lb ft)

1/2

60 ± 1 2 N m ( 4 4 ±9 l b f t )

9/16

85 ± 1 5 N m ( 6 5 ± 11 lb ft)

5/8

11 5 ±2 0 N m ( 8 5 ± 15 lb ft)

3/4

200 ± 40 Nm (150 ± 30 lb ft)

7/8

325 ± 40 Nm (240 ± 30 lb ft)

1

500 ± 65 Nm (370 ± 48 lb ft)

1 1/8

700 ± 90 Nm (520 ± 65 lb ft)

1 1/4

1000 ± 125 Nm (740 ± 90 lb ft)

1 3/8

1300 ± 150 Nm (960 ± 110 lb ft)

1 1/2

1700 ± 200 Nm (1260 ± 150 lb ft)

Thread Size inch

Torque

#4 &#5

.6± .1 N m ( 5 ± 0 . 9 lb in)

#6 & #8

2± . 3 N m ( 1 8 ± 3 lb in)

#10 &#12

(1) These values are only for Caterpillar bolts for cutting edges.

31200268

7 Specifications Section • Tapered Pipe Thread (NPT and NPTF) • 37 Degree Flare Fitting

Personal injury can result when installing plow bolts.

The appropriate safety equipment must be worn when striking the plow bolts. To avoid injury to your eyes and ears, wear protective glasses and hearing protection during this procedure.

• 45 Degree Flare Fitting • 45 Degree Inverted Flare Fitting • Split Flange Coupling

Installation of Split Flange Couplings 1. For a metal tube to hose installation, install the tube and tighten all bolts finger tight at the rigid end.

2. Install the hose and tighten all bolts finger tight.

Illustration 7

g00909058

Plow bolts must be installed properly. Refer to the following procedure for the correct installation of plow bolts.

3. Put the hose in a position so that the hose does not make contact with the machine or with another hose.

1. Clean all surfaces that contact the bolt. Remove all occurrences of the following conditions:rust, paint, nicks, and burrs 2. Tighten the nut to the correct torque. Refer to Table 9 for the correct torque.

3. Use a hammer to strike the head of the bolt. The bolt must be struck with significant force.

Note: The head of the bolt may be recessed below the mounting surface. Use a suitable punch in order to transfer the hammer blow to the bolt head.

4. Tighten the nut to the correct torque. Refer to Table 9 for the correct torque.

Installation of Fittings Note: The tightening sequence of the fasteners that attach a tube assembly or hose assembly to the machine is very critical to the proper function of the machine. The sealing surfaces of the tube assembly or hose assembly should be secured squarely. The sealing surfaces of the tube assembly or hose assembly should be tightened to the serviced component (control valve, cylinder, hydraulic motor, etc). Perform this procedure prior to the final tightening of any clamps or clips that are used in order to fasten the tube assembly or the hose assembly to the machine.

Fittings have different connections. Fittings may have two completely different ends. Be sure to use the proper torque for the end of the fitting that is used. The following list contains some common types of fittings.

• Straight Thread O-Ring (STOR) • Adjustable Straight Thread O-Ring (STOR) • O-Ring Face Seal (ORFS)

Illustration 8

g00906528

4. Tighten the bolts on both connections to the proper torque. Follow the prescribed torque sequence for split flange connections. Refer to Illustration 8. Add the measurement of gap (A) to the measurement of gap (B). The total must not exceed 4.0 mm (0.16 inch).

5. Start the engine.

6. Move the implement control levers to all of the positions.

7. Look at the hose during movement of the implement. Ensure that the hose is not in contact with the machine or with other hoses.

Note: For hoses that cross an articulation hitch, check for contact during articulation. For hoses that connect to the steering system, check for contact during steering.

8. Shut off the engine.

9. If the hose contacts other hoses or the machine during the test, loosen the bolts and reposition the hose. Repeat steps 3 through 8 until there is no contact.

8 Specifications Section

31200268

Installation of Adjustable STOR Fittings

• Excessive tightening can expand a loose ferrule into the nut. This will cause the ferrule to lock up in the nut and the nut will not function properly.

This type of fitting is used in many applications. One end of the fitting will be an adjustable STOR fitting. The other end will be different. Always use the same installation procedure for the STOR end. Adjustable STOR fittings can be positioned before tightening.

• Excessive tightening can split the nut on the end of the tube or can split the ferrule.

• Excessive tightening can gall or excessive tightening can strip the threads of the nut.

Note: If the above conditions occur due to excessive tightening, the damaged fluid connector must be scrapped and the fluid connectors must be replaced.

Straight Thread O-Ring Fittings

Illustration 9

g00906575

Elbow Body Assembly (1) End that connects to the tube or hose. (2) Fitting body. (3) Locknut. (4) Backup washer. (5) O-ring seal. (6) End that is assembled to the mating part.

1. Put locknut (3), backup washer (4) and O-ring seal (5) as far away from the threads as possible. Hold these components in this position. Turn the fitting into the mating part. Turn the fitting until backup washer (4) contacts the surface of the mating part.

Note: Excessive use of the wrench will distort the washer. Distortion of the washer will prevent proper sealing.

2. Put the fitting assembly in the correct position, loosen fitting (2) until the correct assembly position is achieved. Do not loosen the fitting more than 360 degrees. Install the tube or hose hand tight in order to verify the orientation of the fitting. Tighten the fitting (2) to the torque that is shown in the correct chart for the fitting that is used. Tighten locknut (3) to the torque that is shown in the correct chart for the fitting that is used. Use a backup wrench, when the locknut is tightened.

Note: Torque the fitting prior to the locknut.

Note: If the fitting is not adjustable, the hex on the body replaces the locknut. To install this type of fitting, tighten the hex against the face of the mating part.

Excessive tightening of the connectors can cause failure. Connectors that are under tightened can also cause failures. The following failures occur:

Illustration 10

g00911924

Note: For torques for plugs, refer to Specifications, "Plugs".

Note: Straight Thread O-Ring fittings for medium pressure usage will have shorter threaded ends than high pressure fittings. The torque value for medium pressure Straight Thread O-Ring fittings will be lower than the torque values that are required for Straight Thread O-Ring fittings for high pressure fittings.

31200268

9 Specifications Section

Table 10

Table 11

Ferrous Straight Thread O-Ring Fitting Torques for Mating with Ferrous Materials Medium Pressure use with 37° Flare Fittings Nominal Outer Diameter of the Tube

Thread Size Inch

3.18 mm (.125 inch)

5 / 16 - 2 4

4.76 mm (.188 inch)

3/8 - 24

6.35 mm (.250 inch)

7/16 - 2 0

7.94 mm (.312 inch)

1/2 - 20

9.52 mm (.375 inch)

9/16 - 18

12.70 mm (.500 inch)

3/4 - 16

Standard Torque Tolerance (+10% - 0%) 8 + 1 Nm (6 + 1 lb ft) 13 + 1.5 Nm (10 + 1.1 lb ft) 17 + 2 Nm (13+ 1.5 lb ft) 28 + 3 Nm (21 + 2 lb ft) 34 + 3 Nm (25 + 2 lb ft) 55 + 6 Nm (41 + 4 lb ft)

Ferrous Straight Thread O-Ring Fitting Torques for Mating with Ferrous Materials Medium Pressure use with 37° Flare Fittings Nominal Outer Diameter of the Tube

Thread Size Inch

Standard Torque Tolerance (+10% - 0%)

15.88 mm (.625 inch)

7/8 - 14

80 + 8 Nm (60 + 6 lb ft)

19.05 mm (.750 inch)

1 1/16- 12

100 + 10 Nm (75 + 7 lb ft)

22.22 mm (.875 inch)

1 3/16 - 12

25.40 mm (1.000 inch)

1 5/16 - 12

31.75 mm (1.250 inch)

1 5/8 - 12

290 + 25 Nm (215+ 18 lb ft)

38.10 mm (1.500 inch)

1 7/8 - 12

325 + 30 Nm (240 + 22 lb ft)

50.80 mm (2.000 inch)

2 1/2 - 12

420 + 40 Nm (310 + 30 lb ft)

135 + 13 Nm (100+ 10 lb ft) 150 + 15 Nm (110+ 11 lbft)

Note: Use 50 percent of the torque values from Table 10 when the fitting or the port material is nonferrous.

Note: Straight Thread O-Ring fittings for high pressure usage will have longer threaded ends than medium pressure fittings. The torque value for high pressure Straight Thread O-Ring fittings will be higher than the torque values that are required for Straight Thread ORing fittings for medium pressure fittings.

Ferrous Straight Thread O-Ring Fittings Torques for Mating with Ferrous Materials High Pressure use with O-Ring Face Seal Fittings Nominal Outer Diameter of the Tube

Thread Size Inch

Standard Torque Tolerance (+10% - 0%)

4.76 mm (0.188 inch)

3/8 - 24

12 + 2 Nm (9 + 1 lb ft)

6.35 mm (0.250 inch)

7/16 - 20

22 + 2 Nm (16+ 1 lb ft)

7.94 mm (0.312 inch)

1/2 - 20

30 + 3 Nm (22 + 2 lb ft)

9.52 mm (0.375 inch)

9/16 - 18

48 + 5 Nm (35 + 4 lb ft)

12.7 mm (0.500 inch)

3/4 - 16

82 + 8 Nm (60 + 6 lb ft)

15.88 mm (0.625 inch)

7/8 - 14

140 + 14 Nm (105+ 10 lb ft)

19.05 mm (0.750 inch)

1 1/16- 12

190 + 15 Nm (140+ 11 lb ft)

22.22 mm (0.875 inch)

1 3/16 - 12

250 + 20 Nm (185+ 15 lb ft)

Ferrous Straight Thread O-Ring Fittings Torques for Mating with Ferrous Materials High Pressure use with O-Ring Face Seal Fittings Nominal Outer Diameter of the Tube

Thread Size Inch

Standard Torque Tolerance (+10% - 0%)

25.40 mm (1.000 inch)

1 5/16 - 12

300 + 30 Nm (220 + 22 lb ft)

31.75 mm (1.250 inch)

1 5/8 -12

350 + 35 Nm (260 + 26 lb ft)

38.10 mm (1.500 inch)

1 7/8 - 12

415 + 40 Nm (305 + 30 lb ft)

Note: Use 50 percent of the torque values from Table 11 when the fitting or the port material is nonferrous.

10 Specifications Section

31200268

Plugs

Table 142

Metric Ferrous Straight Thread O-Ring Fittings Torques for Mating with Ferrous Materials Ref Nominal Outer Diameter of the Tube

Thread Size

Standard Torque Tolerance (+10% -0%)

4 mm

M8X 1

10.5 + 1 Nm (95 + 9 lb in)

5 mm

M10X 1

2 1 + 2 Nm (15+ 1.5 lb ft)

6 mm

M12X 1.5

37 + 3 Nm (27 + 2 lb ft)

8 mm

M14X 1.5

47 + 4 Nm (35 + 3 lb ft)

M16X 1.5

58 + 6 Nm (43 + 4 lb ft)

12 mm

M18X 1.5

75 + 7 Nm (55 + 5 lb ft)

16 mm

M22X 1.5

105 + 10 Nm (75 + 7 lb ft)

20 mm

M27X2

22 mm 25 mm

Straight Thread O-Ring Plugs (Hex Drive)

Illustration 11

g00911999

Table 13

Thread Size Inch

Torque Tolerance (+10% - 0%)

5/16

9+ 1 Nm (80 + 9 lb in)

3/8

17+ 1.5 N m ( 13 + 1 lb ft)

7/16

23 + 2 N m ( 1 7 + 1.5 lb ft)

1/2

28 + 3 Nm(21 + 2 lb ft)

180 + 15 Nm (135+ 11 lb ft)

9/16

34 + 3 Nm (25 + 2 lb ft)

225 + 20 Nm (165+ 15 lb ft)

3/4

60 + 6 Nm (44 + 4 lb ft)

M30X2

7/8

115 + 10 N m ( 8 5 + 7lbft)

M33X2

325 + 30 Nm (240 + 22 lb ft)

1 1/16

140+ 14N m (10 5 + 10 lb ft)

1 3/16

190+ 19N m (14 0 + 14 lb ft)

30 mm

M42X2

350 + 35 Nm (260 + 26 lb ft)

1 5/16

210 + 20Nm(155 + 15 lb ft) 290 + 25Nm(215 + 18 lb ft)

M48X2

440 + 40 Nm (320 + 30 lb ft)

1 5/8

38 mm

1 7/8

325 + 30 Nm (240 + 22 lb ft)

50 mm

M60X2

525 + 50 Nm (390 + 37 lb ft)

2 1/2

420 + 40 Nm (310 + 30 lb ft)

10 mm

Note: Use 50 percent of the torque values from 12 when the fitting or the port material is nonferrous.

Note: Use 50 percent of the torque values from Table 13 when the fitting or the port material is nonferrous.

31200268

11 Specifications Section

Straight Thread O-Ring Plugs (Socket Drive)

Table 15

Type of Plug

A

Illustration 12

g00912006

B Note: The socket may be hexagonal or a square recessed drive.

Table 14

Thread Size Inch

Torque Tolerance (+10% - 0%)

1/2 - 13

20 + 5 N m ( 1 5 + 4 lb ft)

5/8 - 11

35 + 5 Nm (26 + 4 lb ft)

3/4 - 12 3/4 - 16

50 + 5 Nm (37 + 4 lb ft)

7/8 - 14 1 1/8- 12

70+ 1 5 N m ( 5 2 + 11 lb ft)

1 5/16 - 12 1 1/2 12

90+ 15Nm(66 + 11 lb ft)

2 - 12

125+ 15 Nm (92+ 11 lb ft)

1 1/8- 12

70+ 1 5 N m ( 5 2 + 11 lb ft)

1 5/16 - 12

90+ 15Nm(66 + 11 lb ft)

1/2 - 20

11 + 4 N m ( 9 7 + 35lbin)

7/8 -14

55 + 7 N m ( 4 1 + 5 lb ft)

C

Thread Size Inch

Torque Tolerance (+10% - 0%)

5/16

5 + 1 Nm (44 + 9 lb in)

3/8

11 + 1 Nm(97 + 9 lb in)

1 3/8 -13

90 + 15 N m ( 6 6 + 11 lb ft)

7/16

16+ 1 . 5 N m ( 1 2 + 1 lb ft)

1 1/2 - 12

110+ 15Nm(81 + 11 lb ft)

1/2

20 + 2 N m ( 1 5 + 1.5 lb ft)

9/16

35 + 3.5 Nm (26+ 3 lb ft)

3/4

70 + 7 Nm (50 + 5 lb ft)

7/8

100+ 10 Nm (75 + 7 lb ft)

1 1/16

170+ 1 5N m (1 2 5 + 11 lb ft)

1 3/16

215 + 20Nm(160 + 15 lb ft)

1 5/16

270 + 25 Nm (200 + 18 lb ft)

1 5/8

285 + 25Nm(210 + 18 lb ft)

1 7/8

370 + 35 Nm (275 + 26 lb ft)

2 1/2

415 + 40 Nm (305 + 30 lb ft)

D

Note: Use 50% of the values in Table 15 when either the plug or the port material is nonferrous.

Straight Thread O-Ring Plugs (Mechanical Joint Tube Assemblies)

Drain Plugs with Straight Thread

Illustration 14

Illustration 13

g00912008

Note: Plug (A), plug (B) and plug (C) are used with a gasket. Conical seal plug (D) does not use a gasket.

g00912010

Note: When you tighten the plug, the torque must not be transmitted to the joint between the tube and the elbow.

12 Specifications Section

31200268

Bulkhead Nuts

Table 16

Thread Size Inch

Torque

7/8

125 ± 15 N m ( 92 ± 11 lb ft)

1 1/16

175 ± 15Nm(130± 11 lb ft)

1 3/16

250±20Nm(185± 15 lb ft)

1 1/4

250±20Nm(185± 15 lb ft)

1 5/16

370±20Nm(275± 15 lb ft)

1 5/8

420 ± 25 Nm (310 ±20 lb ft)

1 7/8

525 ± 35 Nm (390 ±25 lb ft)

2 1/2

900 ± 50 Nm (665 ±40 lb ft) Illustration 16

g00909138

Bulkhead connector (ORFS) (1) and bulkhead nut (1A).

Note: The bulkhead connector may have different connections. The type of fluid connection does not affect the torque for nut (1A).

O-Ring Face Seal Fittings

Note: When you assemble the fluid connection, do not use the bulkhead nut (1A) as leverage for a backup wrench. Use the hex on the body (1) of the connector for leverage.

Table 2018

Illustration 15

g00906427

O-ring face seal fitting (ORFS fitting) (1) O-ring face seal connector (1A) O-ring groove (2) O-ring seal (3) Nut for the O-ring face seal

Table 17

Ferrous ORFS Fitting

Thread Size Inch

Torque

5/16

6± 1 Nm (53 ± 9 lb in)

3/8

8± 1 Nm (71 ± 9 lb in)

7/16

14 ± 1.5 N m ( 1 0 ± 1 lb ft)

1/2

17 ±2 N m ( 1 3 ± 1.4 lb ft)

9/16

22 ±2 N m ( 1 6 ± 1.4 lb ft)

11/16

31 ± 3 Nm (23 ± 2 lb ft)

3/4

37 ± 4 Nm (27 ± 3 lb ft)

13/16

40 ± 4 Nm (30 ± 3 lb ft)

7/8

44 ± 4 Nm (32 ± 3 lb ft)

Thread Size Inch

Standard Torque for Nut (3)

Thread Size Inch

Torque

9/16 - 18

25 + 3 Nm (18 + 2 lb ft)

1

61 ± 6 Nm (45 ± 4 lb ft)

11/16 - 16

40 + 4 Nm (30 + 3 lb ft)

1 1/16

70 ± 7 Nm (52 ± 5 lb ft)

13/16 - 16

55 + 5 Nm (41 + 4 lb ft)

1 3/16

91 ± 10 N m ( 6 7 ± 7 lb ft)

1 - 14

86 +8 Nm (65 + 6 lb ft)

1 5/16

113 ± 10 N m ( 8 3 ± 7 lb ft)

1 13/16 - 12

125 + 15 Nm (90 + 11 lb ft)

1 7/16

125 ± 12 N m ( 9 2 ± 9 lb ft)

1 7/16 - 12

165 + 15 Nm (120 + 11 lb ft)

1 5/8

150 ± 15 N m ( 11 0 ± 11 lb ft)

1 11/16 - 12

200 + 20 Nm (150 + 15 lb ft)

1 11/16

150 ± 15 N m ( 11 0 ± 11 lb ft)

2 - 12

245 + 20 Nm (180 + 15 lb ft)

1 7/8

155 ± 15 N m ( 11 5 ± 11 lb ft)

2

170 ± 17 N m ( 1 2 5 ± 13 lb ft)

2 1/2

220 ±20 N m ( 1 6 0 ± 15 lb ft)

Note: Bulkhead nuts are designed to secure fluid connectors firmly in position.

31200268

13 Specifications Section

Flare Fittings

Note: Use 50 percent of the torque values from Table 21 when the fitting or the port material is nonferrous.

The torques in Table 21 are for 37 degree flare fittings.

The torques in Table 22 are for 45 degree flare fittings and 45 degree inverted flare fittings.

37 Degree Flare Fitting

45 Degree Flare and 45 Degree Inverted Flare Fittings I

llustration 18

Illustration 17

g01185483

(1) 37 degree flare fitting. (2) Swivel nuts.

g01185492

(1) 45 Degree Inverted Flare Fittings. (2) 45 Degree Flare Fittings.

Table 20

Table 19

Nuts for 37 Degree Flare Fittings Nominal Outer Diameter of the Tube 3.18 mm (.125 inch) 4.76 mm (.188 inch)

Thread Size Inch

Standard Torque Tolerance (+ 10% - 0%)

5/16

5.0 + 1 Nm (44 + 9 lb in)

3/8

11 + 1 Nm (100 + 9 lb in)

Nuts for 37 Degree Flare Fittings Nominal Outer Diameter of the Tube

Thread Size Inch

Standard Torque Tolerance (+ 10% - 0%)

6.35 mm (.250 inch)

7/16

16 + 1.5 Nm (12+ 1.1 lb ft)

7.94 mm (.312 inch)

1/2

20 + 2 Nm (15+ 1.5 lb ft)

9.52 mm (.375 inch)

9/16

27 + 3 Nm (20 + 2 lb ft)

12.70 mm (.500 inch)

3/4

58 + 6 Nm (43 + 4 lb ft)

15.88 mm (.625 inch)

7/8

74 + 7 Nm (55 + 5 lb ft)

19.05 mm (.750 inch)

1 1/16

108 + 10 Nm (80 + 7 lb ft)

22.22 mm (.875 inch)

1 3/16

135 + 13 Nm (100+ 10 lb ft)

25.40 mm (1.000 inch)

1 5/16

156 + 15 Nm (115+ 11 lb ft)

31.75 mm (1.250 inch)

1 5/8

217 + 20 Nm (160+ 15 lb ft)

38.10 mm (1.500 inch)

1 7/8

251 + 25 Nm (185+ 18 lb ft)

50.80 mm (2.000 inch)

2 1/2

339 + 30 Nm (250 + 22 lb ft)

45 Degree Flare Fittings and 45 Degree Inverted Flare Fittings Nominal Outer Diameter of the Tube

Thread Size Inch

Standard Torque

3.18 mm (.125 inch)

5/16

5.0 ± 1.5 Nm (44 ± 13 lbin)

4.76 mm (.188 inch)

3/8

8.0 ± 1.5 Nm (70 ± 13 lbin)

6.35 mm (.250 inch)

7/16

11 ± 2 Nm (100 ± 18 lbin)

7.94 mm (.312 inch)

1/2

17 ± 3 Nm (13 ± 2 lbft)

9.52 mm (.375 inch)

5/8

30 ± 3 Nm (22 ± 2 lb ft)

11.11 mm (.438 inch)

11/16

30 ± 3 Nm (22 ± 2 lb ft)

12.70 mm (.500 inch)

3/4

38 ± 4 Nm (28 ± 3 lb ft)

15.88 mm (.625 inch)

7/8

50 ± 5 Nm (37 ± 4 lb ft)

19.05 mm (.750 inch)

1 1/16

90 ± 8 Nm (65 ± 6 lb ft)

22.22 mm (.875 inch)

1 1/4

100 ± 10 Nm (75 ± 7 lb ft)

14 Specifications Section

31200268

Air Conditioning Fittings

Table 22

Nominal Outer Diameter of the Tube

Illustration 19

g01185521

(1) O-ring seal. (2) 45 degree flare fitting.

Table 21

Air Conditioning Fittings Thread Size Inch

O-Ring Fitting End

45 Degree Flare Fitting End

Torque

Torque for Steel Tubes

Torque for Aluminum Tubes

5/8- 18

14 ±4 Nm (10 ±3 lbft)

30 ± 3 Nm (22 ± 2 lb ft)

23 ±3 Nm (17 ±2 lbft)

3/4 - 16

27 ±4 Nm (20 ± 3 lb ft)

52 ± 5 Nm (38 ± 4 lb ft)

33 ±4 Nm (24 ± 4 lb ft)

7/8 - 14 1 14

40 ± 4 Nm (30 ± 3 lb ft)

60 ± 7 Nm (44 ± 5 lb ft)

38 ±4 Nm (28 ± 3 lb ft)

1 1/16-14

45 ± 5 Nm (33 ± 4 lb ft)

75 ± 8 Nm (55 ± 6 lb ft)

50 ±5 Nm (37 ± 4 lb ft)

Turn Tightening

Torque

Nonmetallic Tubing

Copper Tubing

6.35 mm (0.250 inch)

11 ± 3 Nm (8 ± 2 lb ft)

3

2

9.53 mm (0.375 inch)

20 ± 3 Nm (15 ± 2 lb ft)

4

2

12.70 mm (0.500 inch)

35 ±6 Nm (26 ± 4 lb ft)

4

2

15.88 mm (0.625 inch)

40 ± 6 Nm (30 ± 4 lb ft)

3 1/2

3

19.05 mm (0.750 inch)

50 ±6 Nm (37 ± 4 lb ft)

3 1/2

3

Note: Clean the connectors and the seals and lubricate the connectors and seals by using Refrigerant Mineral Oil. This is a special oil that is compatible with R-134a.

Tapered Pipe Thread Fittings Torque is based on the diameter of the thread. The torque values are identical for coarse threads and fine threads.

Note: The following table has the recommended standard torque value for tapered pipe thread fitting for use on all Caterpillar equipment and Mitsubishi engines. Use Table 23 as a general recommendation only. Actual values may vary due to variations in the material of the connector. Actual values may vary due to variations in the characteristics of the threads.

Table 23

Air Brake Fittings

Tapered Pipe Thread Fittings Diameter of the Standard Torque Pipe Thread Threads with 5PThreads without (Inch) 3413 Pipe Pipe Sealant Sealant

Illustration 20

g00909062

Put nut (1) and sleeve (2) over the tube. Push the tube into the counterbore of the fitting body as far as possible. There are two methods that may be used to tighten the nut. Tighten the nut with one of two methods.

• Tighten nut (1) to the torque that is specified in Table 22.

• Tighten nut (1) by the number of turns that is specified in Table 22. The number of turns is for the turns after the nut is finger tight.

1/16

10Nm(90 lb in)

1 0Nm ( 90 lb in)

1/8

16 Nm (12 lb ft)

16 Nm (12 lb ft)

1/4

20 Nm (15 lb ft)

25 Nm (18 lb ft)

3/8

35 Nm (26 lb ft)

45 Nm (33 lb ft)

1/2

45 Nm (33 lb ft)

60 Nm (44 lb ft)

3/4

60 Nm (44 lb ft)

75 Nm (55 lb ft)

1

75 Nm (55 lb ft)

90 Nm (65 lb ft)

1 1/4

95 Nm (70 lb ft)

110Nm(80 lb ft)

1 1/2

110 Nm (80 lb ft)

130Nm(95lb ft)

2

130 Nm (95 lb ft)

160 Nm (120 lb ft)

31200268

15 Specifications Section

Note: Use 50 percent of the torque values from Table 25 when the fitting, the plug, or the port material is nonferrous.

Note: Use 50 percent of the torque values from Table 25 when a tapered thread is mated with a straight thread.

be next to the nut. Push the tube into the counterbore of the fitting body as far as possible. Tighten the nut until a sudden increase in torque is felt. Next, tighten the fitting for an additional 1/6 to 1/3 turn in order to seat the sleeve.

Flex Fittings

Miscellaneous Fittings Hi Duty Tube Fittings (Shear Sleeve)

Illustration 23

Illustration 21

g00909648

Put nut (1) over the tube and push the tube into the counterbore of the fitting body as far as possible. Turn the nut with a wrench until a small decrease in torque is felt. The small decrease in torque indicates that the sleeve (1A) has been broken off of the nut. Hold the tube in order to prevent the tube from turning. Tighten the nut for an additional 1 1/2 turns.

g00909645

Put nut (1) and sleeve (2) over the tube and push the tube into the counterbore of the fitting body as far as possible. Tighten the nut until the nut is against the hex part of the fitting body.

Hose Clamps Worm Drive Band Type Clamps

SAE Flareless Fittings

Illustration 24

Illustration 22

g00910017

g00909647

Installing a New Flareless Fitting Put nut (1) and sleeve (2) over the tube. The head end of the sleeve should be next to the nut. The head end has a shoulder. The nut will be seated against this shoulder when the nut is tightened. Push the tube into the counterbore of the fitting body as far as possible.

Turn nut (1) clockwise until the sleeve grips the tube.

The sleeve must prevent all movement of the tube.

Tighten the nut for an additional 1 1/4 turns. The sleeve should be seated and the sleeve should give a locking action.

Installing a Used Flareless Fitting Less turns are required for a used fitting. Put nut (1) and sleeve (2) over the tube. The head of the sleeve should

Table 24 Width (A) of Clamp

Torque for New Hose

7.9 mm (0.31 inch)

0.9 ± 0.2 N m ( 8 ± 2 lb in)

13.5 mm (0.53 inch)

4.5 ± 0.5 N m ( 4 0 ± 4 lb in)

15.9 mm (0.63 inch)

7.5 ± 0.5 N m ( 6 5 ± 4 lb in)

Width (A) of Clamp

Torque for Reused Hose(1)

7.9 mm (0.31 inch)

0.7 ± 0.2 N m ( 6 ± 2 lb in)

13.5 mm (0.53 inch)

3.0 ± 0.5 N m ( 2 7 ± 4 lb in)

15.9 mm (0.63 inch)

4.5 ± 0.5 N m ( 4 0 ± 4 lb in)

(1) Use this value when the hose is reused. The clamp may be new or reused.

16 Specifications Section

31200268

Constant Torque Hose Clamps Use a constant torque hose clamp in place of any worm drive band type clamp. Ensure that the constant torque hose clamp is the same size as the worm drive band type clamp. Due to extreme temperature changes, the hose will heat set. Heat setting can cause worm drive band type clamps to loosen. Loose hose clamps can result in leaks. There have been reports of component failures that have been caused by worm drive band type clamps that have loosened.

The constant torque hose clamp will help prevent these failures.

Illustration 25

g00906389

(1) Constant Torque Hose Clamp (Belleville Washer) (2) Constant Torque Hose Clamp (Tee bolt and Spring)

Use a torque wrench for proper installation of all constant torque hose clamps. There are two types of constant torque hose clamps: Belleville washer (1) and Tee bolt and spring (2) When the constant torque hose clamp (Belleville washer) (1) is assembled correctly, the Belleville washers (1A) are nearly collapsed flat. The proper torque for screw (1B) is based on the diameter (B) of the clamp. Refer to the following table for the correct torque.

Table 25

Diameter (B)

Standard Torque

Up to 50.8 mm (2 inch)

7.5±0.5Nm(65±5 lb in)

Greater than 50.8 mm (2 inch)

11 ± 1 Nm(95± 10 lb in)

The correct torque for the constant torque hose clamp (tee bolt and spring) (2) is 7.5 ± 1 Nm (65 ± 10 lb in).

31200268

17 Index

Index

A

S

Air Brake Fittings................................................................ 14 Air Conditioning Fittings ..................................................... 14

Specifications Section .......................................................... 3 Straight Thread O-Ring Fittings ........................................... 8

B

T

Bulkhead Nuts.................................................................... 12

Table of Contents................................................................. 1 Tapered Pipe Thread Fittings............................................. 14

E English (SAE) Fasteners English (SAE) Machine Screws ...................................... 5 English (SAE) Nuts and Bolts ......................................... 5 English (SAE) Taperlock Studs ...................................... 5 Hex Button Head Screw and Set Screws ....................... 6 English (SAE) Fasteners...................................................... 5

F Flare Fittings ...................................................................... 13 37 Degree Flare Fittings ............................................... 13 45 Degree Flare and 45 Degree Inverted Flare Fittings 13

G General Information ............................................................. 3 Introduction to Torque..................................................... 3 Torque Sequence ........................................................... 3 Torque-Turn.................................................................... 3 Ground Engaging Tool (G.E.T.) Fasteners .......................... 6

H Hose Clamps...................................................................... 15 Constant Torque Hose Clamps .................................... 16 Worm Drive Band Type Clamps ................................... 15

I Important Safety Information.................................................ii Installation of Fittings ........................................................... 7 Installation of Adjustable STOR Fittings ......................... 8 Installation of Split Flange Couplings.............................. 7

M Metric (ISO) Fasteners......................................................... 4 Hex Button Head Screw and Set Screw......................... 4 Metric (ISO) Machine Screws ......................................... 4 Metric (ISO) Nuts and Bolts............................................ 4 Metric (ISO) Taperlock Studs ......................................... 4 Miscellaneous Fittings........................................................ 15 Flex Fittings .................................................................. 15 Hi Duty Tube Fittings (Shear Sleeve) ........................... 15 SAE Flareless Fittings .................................................. 15

O O-Ring Face Seal Fittings .................................................. 12

P Plugs .................................................................................. 10 Drain Plugs with Straight Thread.................................. 11 Straight Thread O-Ring Plugs (Hex Drive) ................... 10 Straight Thread O-Ring Plugs (Mechanical Joint Tube Assemblies) .................................................................. 11 Straight Thread O-Ring Plugs (Socket Drive)............... 11

18 Index

31200268

Manufactured by JLG under license from Caterpillar

31200299 December 15, 2006

Disassembly and Assembly TH360B, TH560B and TH580B Telehandlers Engine Supplement S/N TBH00100 & After S/N TBP00100 & After S/N TBJ00100 & After

Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. CaterpillarÂŽ 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.

31200299

Table of Table of Contents Disassembly and Assembly Section

Battery - Remove and Install ................... 3 Removal Procedure............................. 3 Installation Procedure.......................... 4 Alternator - Remove and Install ............... 4 Removal Procedure............................. 4 Installation Procedure.......................... 5 Electric Starting Motor -Remove and Install ....................................................... 5 Removal Procedure............................. 5 Installation Procedure.......................... 5 Air Cleaner - Remove .............................. 6 Removal Procedure............................. 6 Air Cleaner - Install .................................. 7 Installation Procedure.......................... 7 Muffler - Remove and Install.................... 8 Removal Procedure............................. 8 Installation Procedure.......................... 8 Expansion Tank - Remove and Install..... 9 Removal Procedure............................. 9 Installation Procedure........................ 10 Radiator - Remove ................................ 10 Removal Procedure........................... 10 Radiator - Disassemble ......................... 12 Disassembly Procedure .................... 12 Radiator - Assemble .............................. 13 Assembly Procedure ......................... 13 Radiator - Install .................................... 13 Installation Procedure........................ 13 Fan Guard - Remove and Install ........... 15 Removal Procedure........................... 15 Transmission Oil Cooler -Remove......... 15 Removal Procedure........................... 15 Transmission Oil Cooler -Install............. 16 Installation Procedure........................ 16 Refrigerant Condenser -Remove and Install ..................................................... 17 Removal Procedure........................... 17 Installation Procedure........................ 18 Refrigerant Compressor -Remove and Install ..................................................... 19 Removal Procedure........................... 19 Installation Procedure........................ 19 Engine Mount (Front) - Remove ............ 20 Removal Procedure........................... 20 Engine Mount (Front) - Install ................ 21 Installation Procedure........................ 21 Engine Mount (Rear) - Remove............. 22 Removal Procedure........................... 22

1 Table of Contents

Engine Mount (Rear) - Install ................. 23 Installation Procedure ........................ 23 Engine Enclosure - Remove and Install . 23 Removal Procedure ........................... 23 Installation Procedure ........................ 24 Engine - Remove ................................... 25 Removal Procedure ........................... 25 Engine - Install ....................................... 28 Installation Procedure ........................ 28

2 Table of Contents

31200299

31200299

3 Disassembly and Assembly Section

Disassembly and Assembly Section Battery - Remove and Install Removal Procedure Start By: a. If equipped, turn the battery disconnect switch to the OFF position. Refer to Operation and Maintenance Manual, "Battery Disconnect Switch (if equipped) ".

Illustration 2

Batteries give off flammable fumes that can explode resulting in personal injury.

g00909220

2. Pull back the terminal cover (1) in order to disconnect positive cable (2). Pull back the terminal cover (3) in order to disconnect negative cable (4).

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 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.

Always connect the positive (+) to positive (+) and the negative (-) to negative (-).

Illustration 3

g00909235

3. Remove nuts (5), the washers and hold down bracket (6).

Jump start only with an energy source with 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.

Illustration 4

g00909831

4. With the aid of a second person or with the aid of a suitable lifting device, remove battery (7). The weight of the battery is approximately 25 kg (55 lb).

Remove studs (8).

Illustration 1

g00909832

1. The following procedure shows the removal of the front battery which is an attachment. Use the same procedure when you are removing the rear battery.

4 Disassembly and Assembly Section

31200299

Installation Procedure

Illustration 8 Illustration 5

g00909832

1. The following procedure shows the installation of the front battery which is an attachment. Use the same procedure when you are installing the rear battery.

g00909220

4. Connect positive cable (2) and slide terminal cover (1) into position. Connect Negative cable (4) and slide terminal cover (3) into position.

End By: a. If equipped, turn the battery disconnect switch to the ON position. Refer to Operation and Maintenance Manual, "Battery Disconnect Switch (if equipped)".

Alternator - Remove and Install Removal Procedure Start By: a. Turn the battery disconnect switch to the OFF position.

Refer to Operation and Maintenance Manual, "Battery Disconnect Switch (if equipped)". If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and insulate the battery clamps.

Illustration 6

g00909831

2. Install studs (8). With the aid of a second person or with the aid of a suitable lifting device, install battery (7). The weight of the battery is approximately 25 kg (55 lb).

1. Put identification marks on all wires for installation purposes.

Illustration 9

Illustration 7

g00909235

3. Install hold down bracket (6), nuts (5), and the washers.

g00908444

2. Remove belt (1) from alternator (2). Refer to Operation and maintenance Manual, "Belts Inspect/Adjust/Replace".

3. Disconnect wires (3) and positive cable (4).

4. Remove bolt (5), the washer, nut (6), bolt (7) and the washers before removing alternator (2) from the machine.

31200299

5 Disassembly and Assembly Section

Installation Procedure 1. Clean all parts and inspect all parts. If any parts are worn or damaged, use new Caterpillar parts for replacement.

Illustration 11

g00908447

2. Disconnect positive cable (2) from starter motor (1).

Lift the plastic cap (not shown) in order to access screw (3) and disconnect wire (4).

Illustration 10

g00908444

2. Position alternator (2) onto the machine. Install bolt (7), nut (6) and washers. Install bolt (5) and the washer.

3. Connect wires (3) and positive cable (4) to alternator (2).

4. Install belt (1) from alternator (2). Refer to Operation and maintenance Manual, "Belts Inspect/Adjust/Replace".

End By: a. Turn the battery disconnect switch to the ON position.

Refer to Operation and Maintenance Manual, "Battery Disconnect Switch (if equipped)". If the machine is not equipped with a battery disconnect switch and the battery was disconnected, remove the insulation from the battery clamps and install the battery cables onto the battery.

Electric Starting Motor -Remove and Install Removal Procedure

Illustration 12

g00908460

3. Remove bolt (5) in order to disconnect ground cable (6).

4. Remove bolts (7) and remove starter motor (1) from the engine.

Installation Procedure Accidental machine starting can cause injury or death to personnel working on the machine.

To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps.

Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

1. Put identification marks on all wires for installation purposes.

1. Clean all parts and inspect all parts. If any parts are worn or damaged, use new Caterpillar parts for replacement.

6 Disassembly and Assembly Section

31200299

Air Cleaner - Remove Removal Procedure

Illustration 15 Illustration 13

g00908460

2. Position starter motor (1) onto the engine and install bolts (7).

g00909117

1. Disconnect inlet duct (2) from air cleaner assembly (1).

3. Position ground cable (6) and install bolt (5).

Illustration 16

g00909118

2. Remove hose clamp (3) and disconnect inlet hose (4) from air cleaner assembly (1).

Illustration 14

g00908447

4. Install screw (3) in order to connect wire (4). Close the plastic cap (not shown). Connect positive cable (2) to starter motor (1).

End By: a.

Turn the battery disconnect switch to the ON position.

Refer to Operation and Maintenance Manual, "Battery Disconnect Switch (if equipped)". If the machine is not equipped with a battery disconnect switch and the battery was disconnected, remove the insulation from the battery clamps and install the battery cables onto the battery.

Illustration 17

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3. Disconnect hose (5) from air cleaner assembly (1).

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Illustration 18

7 Disassembly and Assembly Section

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Illustration 21

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2. Position air cleaner assembly (1) on the engine and install bolts (7), nuts (6) and the washers.

Illustration 19

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4. Remove nuts (6), bolts (7) and the washers before removing air cleaner assembly (1) from the engine.

Illustration 22

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3. Connect hose (5) to air cleaner assembly (1).

Air Cleaner - Install Installation Procedure 1. Clean all parts and inspect all parts. If any parts are worn or damaged, use new Caterpillar parts for replacement.

Illustration 23

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4. Connect inlet hose (4) to air cleaner assembly (1) and install hose clamp (3).

Illustration 20

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8 Disassembly and Assembly Section

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2. Remove clamp (4) which connects exhaust pipe (5) to muffler (6).

Illustration 24

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5. Connect inlet duct (2) to air cleaner assembly (1).

Muffler - Remove and Install

Illustration 27

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Illustration 28

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Removal Procedure

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

3. Remove bolts (7) and the washers before sliding muffler (6) away from exhaust pipe (5). Remove the muffler from the machine.

Installation Procedure

Illustration 25

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1. Remove bolts (1) and the washers in order to remove cover (2) and exhaust shield (3).

Illustration 29

Illustration 26 The photograph is from the top side of the muffler

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9 Disassembly and Assembly Section

Expansion Tank - Remove and Install Removal Procedure

At operating temperature, the engine coolant is hot and under pressure.

Steam can cause personal injury.

Illustration 30

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1. Position muffler (6) and then slide the muffler onto exhaust pipe (5) before installing bolts (7) and the washers.

Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand.

Remove the fill cap slowly to relieve pressure.

Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

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.

Illustration 31

g00914594

The photograph is from the top side of the muffler.

2. Install clamp (4) which connects exhaust pipe (5) to muffler (6).

Illustration 32

Dispose of all fluids according to local regulations and mandates.

1. Drain the coolant from the radiator into a suitable container so that the level of the coolant in the radiator is below the level of the expansion tank.

The capacity of the cooling system is approximately 27.5 L (7.3 US gal). Refer to the appropriate Operation and Maintenance Manual.

g00914593

3. Position exhaust shield (3) with cover (2) and install bolts (1) with the washers.

Illustration 33

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2. Loosen the hose clamp and disconnect hose (6) from expansion tank (3).

3. Disconnect hose (4) from filler cap (5).

10 Disassembly and Assembly Section

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4. Connect hose (1) and hose (2) to expansion tank (3) and tighten the hose clamps.

5. Fill the cooling system. The capacity of the cooling system is approximately 27.5 L (7.3 US gal).

Refer to the appropriate Operation and Maintenance Manual.

Radiator - Remove Removal Procedure Start By: Illustration 34

g00914264

a. Remove the access plate.

4. Loosen the hose clamps and disconnect hose (1) and hose (2) from expansion tank (3).

5. Remove bolts (7) and the washers in order to remove expansion tank (3).

Installation Procedure

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 fill cap is cool enough to touch with your bare hand.

Remove the fill cap slowly to relieve pressure.

Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

NOTICE

Illustration 35

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1. Position expansion tank (3) and install bolts (7) and the washers.

2. Connect hose (6) to expansion tank (3) and tighten the hose clamp.

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.

Dispose of all fluids according to local regulations and mandates.

1. Put identification marks on all hoses for installation purposes. Plug all hoses. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.

2. Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is approximately 27.5 L (7.3 US gal). Refer to the appropriate Operation and Maintenance Manual.

Illustration 36

3. Disconnect hose (4) from filler cap (5).

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Illustration 37

11 Disassembly and Assembly Section

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3. If equipped, release latch (1) in order to remove condenser (2) from radiator (3). Tilt the condenser and remove the condenser from the mounts at the base of the radiator. Move the condenser aside.

Illustration 40

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6. Loosen the hose clamp and disconnect hose (6) from radiator (3).

Note: Do not disconnect the hose to the condenser.

The radiator can be removed without discharging the refrigerant.

Illustration 41

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7. Remove bolts (7) and the washer from both sides of shroud (8).

Illustration 38

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4. Loosen the hose clamp and disconnect hose (top) (4) from radiator (3).

Illustration 42

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8. Remove bolts (9), the washers, bolt (10), the washer and mount (11) in order to remove bracket (12) from radiator (3) and the chassis.

Illustration 39

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5. Loosen the hose clamp and disconnect hose (bottom) (5) from the radiator.

12 Disassembly and Assembly Section

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Radiator - Disassemble Disassembly Procedure Start By: a. Remove the radiator from the machine. Refer to Disassembly and Assembly, "Radiator - Remove".

Illustration 43

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9. Remove bolt (13), the washers, mount (14), bolt (15) and the washer in order to remove bracket (16) from radiator (3) and the chassis.

Illustration 46

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1. Remove bolts (1) and the washers in order to remove bracket (2) from radiator (3).

Illustration 44

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10. Remove bolts (17), the washers and the nuts that secure radiator (3) to the chassis.

11. With the aid of a second person, remove radiator (3) from the machine.

Illustration 47

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2. Remove bolts (4) and the washers in order to remove bracket (5) from radiator (3).

Illustration 45

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12. Remove mounts (18) from the chassis.

Illustration 48

00913575

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13 Disassembly and Assembly Section

3. Remove bolts (6) and the washers in order to remove mounting bracket (7) from radiator core (3).

4. Remove bolts (8) and the washers in order to remove mounting bracket (9) from radiator core (3).

Radiator - Assemble Assembly Procedure Illustration 51

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4. Position bracket (2) onto the front of radiator (3) and install bolts (1) with the washers.

End By: a. Install the radiator onto the machine. Refer to Disassembly and Assembly, "Radiator - Install".

Radiator - Install Installation Procedure 1. Clean all parts and inspect all parts. If any parts are worn or damaged, use new Caterpillar parts for replacement.

Illustration 49

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1. Position mounting bracket (9) onto radiator (3) and install bolts (8) with the washers.

2. Position mounting bracket (7) onto radiator (3) and install bolts (6) with the washers.

Illustration 52

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2. Install mounts (18) into the chassis.

Illustration 50

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3. Position bracket (5) onto the front of radiator (3) and install bolts (4) with the washers.

Illustration 53

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14 Disassembly and Assembly Section

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3. With aid of a second person, lift radiator (3) into position. Install bolts (17), the washers and the nuts that secure the radiator to the chassis.

Illustration 57

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7. Connect hose (6) to radiator (3) and tighten the hose clamp.

Illustration 54

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4. Install bolt (13), the washer, mount (14), bolt (15) and the washer in order to secure bracket (16) to radiator (3) and the chassis.

Illustration 58

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8. Connect hose (bottom) (5) to radiator (3) and tighten the hose clamp.

Illustration 55

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5. Install bolts (9), the washer, bolt (10), the washer and mount (11) in order to secure bracket (12) to radiator (3) and the chassis.

Illustration 59

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9. Connect hose (top) (4) to radiator (3) and tighten the hose clamp.

Illustration 56

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6. Install bolts (7) and the washers into both sides of shroud (8).

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15 Disassembly and Assembly Section

Installation Procedure

Illustration 60

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10. If equipped, Install condenser (2) into the mounts at the base of radiator (3) before you fasten latch (1).

11. Fill the cooling system. The capacity of the cooling system is approximately 27.5 L (7.3 US gal).

Refer to the appropriate Operation and Maintenance Manual.

Illustration 62

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1. Position fan guard (2) on shroud (3) and install bolts (1) and the washers.

End By: a. Install the access plate.

Fan Guard - Remove and Install

Transmission Oil Cooler Remove

Removal Procedure Removal Procedure Start By: a. Remove the access plate.

Personal injury can result from hydraulic oil pressure and hot oil.

Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

Illustration 61

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1. Remove bolts (1) and the washers in order to remove fan guard (2) from shroud (3).

Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

At operating temperature, the engine coolant is hot and under pressure.

Steam can cause personal injury.

16 Disassembly and Assembly Section

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Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand.

Note: The following procedure will give additional information that is required to install an oil cooler for the high ambient temperature cooling arrangement.

Remove the fill cap slowly to relieve pressure.

Remove Components

Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

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.

Dispose of all fluids according to local regulations and mandates.

1. Put Identification marks on all hoses for installation purposes. Plug all hoses. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.

2. Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is approximately 27.5 L (7.3 US gal). Refer to the appropriate Operation and Maintenance Manual.

Illustration 64

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1. Loosen the hose clamp and remove hose (1) from radiator (2).

2. Remove all hose clips and any cable straps which secure hose (3).

3. Loosen the hose clamp and disconnect hose (3) from water pump (4).

4. Loosen the hose clamp and disconnect hose (3) from expansion tank (5) before removing the hose from the machine.

Install Components

Illustration 63

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3. From the underside of the machine, loosen the hose clamps and disconnect hoses (1) from oil cooler (2).

4. Loosen the hose clamps and disconnect hoses (3) from oil cooler (2).

5. Remove bolts (4) and the washer in order to remove oil cooler (2) from the machine.

Transmission Oil Cooler -Install Installation Procedure Oil Cooler (High Ambient Temperature Cooling Arrangement)

Illustration 65

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1. The following steps show the location of all hoses to be installed with the high ambient temperature cooling arrangement. Refer to Parts Manual, "Lines

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17 Disassembly and Assembly Section

Gp - Coolant" for the part numbers for all components.

2. Connect a new hose (3) to expansion tank (5) and tighten the hose clamp.

3. Connect hose (3) to water pump (4) and tighten the hose clamp.

Refrigerant Condenser Remove and Install Removal Procedure

4. Install all hose clips and any cable straps which secure hose (3).

Note: A new hose clamp (6) is installed as part of the installation procedure for the oil cooler. Refer to Disassembly and Assembly, "Transmission Oil Cooler Install".

5. Connect a new hose (1) to radiator (2).

Note: A new hose clamp (6) is installed as part of the installation procedure for the oil cooler. Refer to Disassembly and Assembly, "Transmission Oil Cooler Install".

Transmission Oil Cooler 1. Clean all parts and inspect all parts. If any parts are worn or damaged, use new Caterpillar parts for replacement.

Personal injury can result from contact with refrigerant.

Contact with refrigerant can 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.

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, can cause bodily harm or death.

Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.

Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.

1. Recover the air conditioner refrigerant from the air conditioner system. The correct charge is 0.8 kg (1.8 lb).

Illustration 66

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2. At the underside of the machine, position oil cooler (2) and install bolts (4) and the washers.

3. Connect hoses (3) and tighten the hose clamps.

4. Connect hoses (1) and tighten the hose clamps.

5. Fill the cooling system. The capacity of the cooling system is approximately 27.5 L (7.3 US gal).

Refer to the appropriate Operation and Maintenance Manual.

Illustration 67

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2. Disconnect two hoses (1) from condenser (2).

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