Caterpillar TH360B Telehandler: Maintenance (Every 500 Service Hours or 6 Months)

Check Condition

• Park the machine on level ground. Fully retract the boom and lower the boom.

• Remove the cover from the rear of the chassis.

• A limited inspection of the chains can be made through the rear of the boom. The boom extension chain can be inspected by fully extending the boom and looking on top of the intermediate section. If the chains are corroded, the chains must be removed from the boom for cleaning and a full inspection. If the chains require lubricant, the chains must be removed from the boom for cleaning and a full inspection. Refer to the Hydraulic System Systems Operation, Testing and Adjusting, "Boom Chain - Clean/Inspect/Lubricate" or consult your Caterpillar dealer.

• Install the cover on the rear of the boom.

Check and Adjust the Chain Tension

• Slacken the extension chain and the retraction chain slightly. Raise the boom to the maximum angle and retract the boom. This ensures that all sections of the boom are fully retracted. If the retraction chain requires adjustment and the boom is retracted in a lowered position, all the sections will not fully retract.

• Lower the boom to the horizontal position and install a suitable stand under the first section in order to prevent the boom from falling unexpectedly. To properly support the boom, use the following tools:

• Lower the boom to a position just above the stand and stop the engine.

• Set the minimum distance to 224 mm (8.8 inch) between boom section 2 and boom section 3. The maximum allowable distance is 234 mm (9.2 inch). Tighten extension chain (1) in order to move section 3 outward. Tighten retraction chain (2) in order to move section 3 inward. If the distance is significantly more than 224 mm (8.8 inch), slacken both chains and refer to Step 1.

• After setting the distance to the required tolerance, tighten the extension chain to 20 N-m (15 lb ft).

• Tighten the retraction chain to 18 N-m (13 lb ft).

• Tighten the extension chain to 105 ± 5 Nm (77 ± 4 lb ft).

• Tighten the retraction chain to 70 ± 5 Nm (52 ± 4 lb ft).

• Extend the boom and retract the boom several times. Check the torque for the extension chain. Check the torque for the retraction chain.

• Install the locknut for the extension chain. Torque the locknut for the extension chain to 105 ± 5 Nm (77 ± 4 lb ft).

• Install the locknut for the retraction chain. Torque the locknut for the retraction chain to 70 ± 5 Nm (52 ± 4 lb ft).

• Check the shackles on both chains. If necessary, adjust the shackles in order to set the shackles horizontally.

• Remove the stand and lower the boom.

Measure the Chain for Wear

• Fully retract the boom. Position the boom horizontally.

• Extend the boom by 2 m (6 ft 7 inch) or extend the boom to the section of chain that most frequently passes over the boom extension chain pulley.

• Do not retract the boom sections before you begin to measure the chains.

• Use a caliper in order to measure the height of inner plate (A) and the height of outer plate (A) over 15 pitches of the selected worn section of chain. If any inner plate or any outer plate shows a reduction in height of more than 5% wear, all chains must be replaced. Also, if the measurement is less than 22.89 mm (0.901 inch), all chains must be replaced.

• Use a 6V- 0028 Wear Gauge As (CHAIN) in order to measure the chain between the 16 pin centers of the selected worn section (B). The nominal length of 16 pin centers is 381 mm (15 inch).If the measurement shows an elongation of more that 2%, all chains must be replaced. Also, if the measurement is greater than 388.6 mm (15.30 inch), all chains must be replaced.

Primary Cab Air Filter

• The primary cab air filter is located behind protection cover (3) on the left side of the cab. In order to open the protection cover, unlock lock (2) and turn lock (4) counterclockwise. Then, pull latch (1) outward.

• Open filter cover (6) by removing retaining screw (5).

• Remove the filter from behind filter cover (6).

• If the air filter is not damaged, clean the air filter with pressurized air. The maximum air pressure for cleaning is 205 kPa (30 psi).

The secondary cab air filter is located inside the cab. The filter is on the rear wall of the cab behind the seat.

• Open filter cover (7) by removing retaining screws (8).

• Remove the filter from the filter housing.

• If the air filter is not damaged, clean the air filter with pressurized air. The maximum air pressure for cleaning is 205 kPa (30 psi).

The following drive shafts must be lubricated:

• The front drive shaft

• The rear drive shaft

Illustration 235

• Ensure that the bolts for the front drive shaft universal joints and the rear drive shaft universal joints are tightened to the correct standard torque. Refer to the appropriate Service Manual for the correct torque.

Engine Air Filter Primary Element - Clean/Replace

• Open the engine enclosure.

• Slide out retaining clip (1).

• Release cover (2) from air filter housing (3) by rotating counterclockwise. Remove the cover from the housing.

• Remove primary element (4) from filter housing (3). To avoid dislodging any dust, take care to avoid touching the element against the sides of the housing. Inspect the primary element. If the pleats or the seals are damaged, discard the primary element. Replace a damaged primary element with a clean primary element.

• If the primary element is not damaged, you may clean the primary element. Refer to Operation and Maintenance Manual, "Cleaning Primary Air Filter Elements".

• When you clean the inside of the pleats, direct the air along the pleats. Inspect the primary element after you clean the primary element.

• Clean the inside of the filter housing and clean the cover. Pay particular attention to the sealing surface of the outlet tube, which fits inside the primary element.

• Install a clean primary element.

• Install the cover.

• Reset the engine air filter service indicator by pressing button (5).

• Start the engine. If the engine air filter service indicator (6) illuminates on the dash panel, install a new primary element. Refer to the "Alert Indicators" section of Operation and Maintenance Manual, "Monitoring System" for further information. Also, if the exhaust smoke is black, install a new primary element. Replace the engine air filter secondary element when you replace the primary filter element. Refer to the Operation and Maintenance Manual, "Engine Air Filter Secondary Element - Replace".

• Close the engine enclosure.

The secondary filter element should be replaced at the time the primary element is serviced for the third time.

• Open the engine enclosure.

• Slide out retaining clip (1).

• Release cover (2) from air filter housing (3) by rotating counterclockwise. Remove the cover from the housing.

• Remove primary element (4) from filter housing (3). To avoid dislodging any dust, take care to avoid touching the element against the sides of the housing.

• Remove secondary filter element (5).

• Cover the air inlet opening. Clean the inside of the air cleaner housing.

• Uncover the air inlet opening. Install a new secondary element.

• Install the primary element and the air filter cover.

• Close the engine enclosure.

Note: Change the engine oil and the filter after every 500 hours. This is the normal interval provided that the following conditions are met:

• Only genuine Caterpillar filters must be used.

• Only Caterpillar Multigrade Diesel Engine Oil (DEO) to specification CG-4 or an equivalent must be used. Refer to Operation and Maintenance Manual, "Lubricant Viscosities" and the appropriate Service Manual for more detailed lubricant information.

• Working conditions must be clean and applications must be light. Obtain an SOS oil sample at the first 250 hours in order to determine if the oil change interval can be decreased.

• The sulfur content of the fuel must be between 0.05% to 0.5%. If a higher percentage of sulfur is present in the fuel, the engine oil and the filter will need to be changed more often. 0.5% to 1.0% of sulfur content will require the engine oil and the filter to be changed after every 250 hours. 1.0% to 1.5% of sulfur content will require the engine oil and the filter to be changed after every 125 hours.

Draining the engine:

• Before you drain the engine oil, park the machine on a level surface and engage the parking brake. The engine oil should be warm before you drain the oil. Stop the engine.

• Open the engine access door.

• Position the end of hose (3) into a suitable container. Turn shutoff valve (2) counterclockwise in order to drain the engine oil from the crankcase. Turn the shutoff valve clockwise in order to close the shutoff valve. Allow the oil to drain from the hose.

• Remove old engine oil filter (1) with a filterwrench.

• Clean the filter housing base. Ensure that all of the old seal is removed.

• Apply a thin film of clean engine oil to the seal of the new engine oil filter.

• Install new engine oil filter (1) hand tight until the seal of engine oil filter (1) contacts the base. Note the position of the index marks on the filter in relation to a fixed point on the filter base.

• Note: There are rotation index marks on engine oil filter (1) that are spaced 90 degrees or 1/4 of a turn away from each other. When you tighten engine oil filter (1), use the rotation index marks as a guide.

• Tighten the filter according to the instructions that are printed on the filter. Use the index marks as a guide. For non-Caterpillar filters, refer to the installation instructions that are provided by the supplier of the filter.

• Note: You may need to use a Caterpillar strap wrench, or another suitable tool, in order to turn the filter to the amount that is required for final installation. Make sure that the installation tool does not damage the filter.

• Remove filler cap (4) and fill the crankcase with new oil.

• Refer to Operation and Maintenance Manual, "Lubricant Viscosities" for more information on the type of oil that is required. Refer to Operation and Maintenance Manual, "Capacities (Refill)" for more information on the quantity of oil that is required.

• Check that the parking brake is engaged and that the transmission is in NEUTRAL and then start the engine. Operate the engine for five minutes at low idle. Inspect the engine for leaks and make any repairs that are necessary.

• Stop the engine. Wait for two minutes after you stop the engine. Stopping the engine allows oil to drain back to the crankcase. Check the oil level. If necessary, add oil. Maintain the oil level between the "ADD" mark and the "FULL" mark on the dipstick. Install the filler cap.

• Close the engine access door.

Final Drive Oil Level - Check

• To check the oil level on the final drive, position the machine on level ground. Position the plug for the final drive on the horizontal center line of the wheel.

• Fully retract the boom and fully lower the boom. Move the transmission control to the NEUTRAL position and engage the parking brake. Shut off the engine.

• Clean the area around the plug. Remove the plug.

• Check that the oil is level with the plug hole. If necessary, add oil through the plug hole.

• Clean the plug and reinstall the plug.

• Repeat Step 1 through Step 5 for each of the three remaining final drives.

The frame leveling cylinder is located at the front right of the machine.

• Lubricate the frame leveling cylinder pin through the fitting on the top mounting point.

The secondary fuel filter is located on the front of the engine.

• Park the machine on level ground. Fully retract and fully lower the boom. Move the transmission control to the NEUTRAL position and engage the parking brake. Shut off the engine.

• Open the engine enclosure.

• Clean the outside of the secondary fuel filter.

• Remove cap (1) from the secondary fuel filter.

• Remove the white plunger that is located below cap (1) in order to prevent fuel from spilling down the side of the filter when you remove the filter.

• Internally, remove the fuel filter plug from the secondary fuel filter. Remove any sediment from the sediment chamber. Reinstall the plug. Reinstall both the cap and the nut onto the secondary fuel filter.

• Valve (2) is located at the bottom of the fuel filter element. Open valve (2) in order to drain fuel or sediment from the fuel filter element.

• Unscrew retaining ring (3). Remove filter element (4) from filter base (5).

• Clean the gasket sealing surface on filter base (5).

• Lubricate the seals on the replacement filter element with clean diesel fuel.

• Install the new filter element and hand tighten the retaining ring. Do not overtighten the retaining ring.

• Note: The primary fuel filter should be changed whenever the secondary fuel filter is changed. Refer to Operation and Maintenance Manual, "Fuel System Water Separator Element - Replace" for further instructions.

• Prime the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for further instructions.

• Start the engine and check for leaks.

Fuel System Water Separator Element - Replace

• Park the machine on level ground. Fully retract and fully lower the boom. Move the transmission control to the NEUTRAL position and ensure that the parking brake is engaged. Shut off the engine.

• Open the engine enclosure.

• Loosen valve (3) and drain the contents of housing (2) into a suitable container. Tighten the valve.

• Support housing (2) and rotate the housing. Remove the housing.

• Rotate the element for 90 degrees counterclockwise and lift the element out of housing (2).

• Clean the gasket sealing surface on mounting base (1). Replace the O-ring seal that is located on housing (2). Insert a new filter element into the housing and rotate the element for 90 degrees clockwise in order to lock the element into position.

• Lubricate the O-ring seal on the new element with clean diesel fuel.

• Install the housing onto the mounting base. Tighten the housing by hand. Do not overtighten the housing.

• Prime the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for further instructions.

• Start the engine and check for leaks.

Initial Test

• Perform the following procedures to the machine: a. Remove any work tool from the machine. Remove any load that is applied to the rear hitch. b. Position the machine on level ground. If necessary, level the frame of the machine. c. If the machine is equipped with stabilizers, ensure that the stabilizers are raised fully. d. Ensure that all the wheels are facing straight ahead. Drive the machine forward and drive the machine in reverse for 3 m (10 ft). e. Tilt the coupler fully forward. f. Fully lower and retract the boom. g. Engage the parking brake and move the transmission control to the NEUTRAL position.

• Turn the ignition to the OFF position. Wait for 30 seconds.

• Turn the ignition to the ON position, but do not crank the engine.

• Note: The machine will perform the self test. Refer to "Engine Start Switch" topic in Operation and Maintenance Manual, "Operator Controls" for more information.

• After the self tests are completed, the machine will test the longitudinal stability indicator system. a. If the test is successful, the gauge will function in the manner that was described in Operation and Maintenance Manual, "Monitoring System". This indicates that the system is operating correctly. b. The needle of the longitudinal stability indicator will move into the red zone of the gauge if the test is failed. An intermittent audible alarm will sound. The warning light will be activated. Turn the ignition to the OFF position in order to stop the alarm.

Perform the following test if the machine fails the system test of the longitudinal stability indicator.

• Completely perform Step 1 of "Initial Test".

• Repeat the test of the longitudinal stability indicator system.

Pulley for Boom Extension Chain - Lubricate

• Lubricate the pulley for the boom extension chain through one fitting.

Pulley for Boom Retraction Chain - Lubricate

• Fully raise the boom and lubricate the boom retraction chain roller through one fitting. Access is through a hole on the left side of the boom.

Stabilizer and Cylinder Bearings - Lubricate

• If your machine is equipped with stabilizers, lubricate the stabilizer cylinder bearings and the legs of the stabilizer through eight fittings.