Caterpillar TH360B Telehandler: Maintenance (Every 1000 Service Hours or 1 Year)

Inspect

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

• Open the engine enclosure.

• Inspect the condition of belt (1).

• Replace the belt if any of the following conditions exist: • excessive cracking • excessive wear • excessive damage

• Inspect the free arm stop of the belt tensioner (2). The free arm stop must be aligned with the black line which is on the decal of belt tensioner (2). If the free arm stop is in the red area, replace the belt.

• Close the engine enclosure.

Replace

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

• Open the engine enclosure.

• Turn the battery disconnect switch to the OFF position.

• Remove the retaining bolts for the fan guard. Slide the guard out of the engine enclosure

• Release the tension on the belt (1). Insert a 12.7 mm (0.50 inch) ratchet into the square hole in the belt tensioner (2) and pry the belt tensioner in a clockwise direction.

• Remove the belt from the pulleys. Feed the belt over the fan.

• Install the new belt around the pulleys. Pry the belt tensioner in a clockwise direction. Install the belt around the belt tensioner. Release the belt tensioner in order to put tension on the belt. The routing of the belt is shown in Illustration 177.

• Install the fan guard and tighten the retaining bolts to a torque of 15 ± 3 Nm (11.1 ± 2.2 lb ft).

• Turn the battery disconnect switch to the ON position.

• Close the engine enclosure.

Inspect:

• Park the machine in a clear area on level ground and chock the wheels.

• ! WARNING The boom can fall if a control is moved or if a hydraulic component fails. This can cause personal injury or death. Support the boom with stands. Do not rely on the cylinder to hold the boom up.

• Raise the boom to the horizontal position and fully extend the boom. Install a suitable stand under the first section in order to prevent the boom from falling unexpectedly. Do not support the second and third sections. To properly support the boom, use the following tools:

• Measure clearances (1) between the wear pads and the side of the boom sections at each side.

• Measure clearances (2) between the wear pads and the top of the boom sections.

• Raise the boom and remove the stand. Fully retract the boom and support the boom in the horizontal position. In order to support the boom, install the stand under the third section or install cribbing under the quick coupler.

• Remove the cover from the rear of the chassis and measure clearances (3) between the rear wear pads and the side of the boom sections at each side.

• Measure clearances (4) between the rear wear pads and the top of the boom sections.

• The clearance at each location must not exceed 1.5 mm (0.06 inch). If the clearances are excessive, adjustments must be made.

TABLE 20

• STOP THE ENGINE.

Adjustment

• Loosen bolts (5) that secure the rear top wear pads. Install sufficient shims in order to reduce the clearance to 0.75 mm (0.030 inch). Apply 9S-3263 Thread Lock Compound to the bolts. Tighten the bolts to a torque of 75 ± 5 Nm (55 ± 4 lb ft).

• Remove bolts (6) that secure the rear side wear pads. Install sufficient shims in order to reduce the clearance to 0.75 mm (0.030 inch) at each side. Install sufficient shims in order to produce an equal clearance between the boom sections at each side. It may be necessary to install more shims.

• Raise the boom sufficiently above the stand. Fully extend the boom and lower the boom to the horizontal position. Support the boom under the third section.

• Remove bolts (7) that secure the bottom wear pads. Install sufficient shims in order to reduce the clearance to 0.75 mm (0.030 inch). Apply 9S-3263 Thread Lock Compound to the bolts. Tighten the bolts to a torque of 75 ± 5 Nm (55 ± 4 lb ft).

• Remove bolts (8) that secure the side wear pads. Install sufficient shims in order to reduce the clearance to 0.75 mm (0.030 inch) at each side. Install sufficient shims in order to produce an equal clearance between the wear pads and the boom sections at each side. It may be necessary to install more shims at one side than the other side. Apply 9S-3263 Thread Lock Compound to the bolts. Tighten the bolts to a torque of 75 ± 5 Nm (55 ± 4 lb ft).

• Fully extend and retract the boom at angles of 0 degrees, 45 degrees and 70 degrees. The boom operation must be smooth. If the boom operation is not smooth, operate the boom with a load of 500 kg (1100 lb) on the attachment. Fully extend the boom and retract the boom at an angle of 45 degrees. Repeat ten times.

• Extend the boom and lower the work tool to the ground. Lower the boom to the ground and fully extend the boom. Check the temperature of the top surfaces of number 1 boom section and number 2 boom section. Check the temperature of the wear pads at opposite locations at positions (A) and at positions (B). Both sides of each section should feel the same temperature. If necessary, increase the thickness of the shims under the rear wear pad which is in contact with the cool side of the boom section. Alternatively, decrease the thickness of the shims under the front wear pad which is in contact with the hot side of the boom section.

If the coolant in the machine is changed to another type of coolant, consult your Caterpillar dealer.

• Allow the engine to cool.

• Loosen pressure cap (1) from the coolant tank slowly in order to release pressure. Remove the pressure cap.

• Loosen drain valve (2) that is located at the bottom right corner of the radiator. Drain the coolant into a suitable container.

• Remove coolant drain plug (3) that is located in the engine block above the starter. Drain the coolant into a suitable container.

• Note: Check the threads of the drain plug for damage. Check the sealant on the drain plug for damage. The drain plug can be reused if threads are not damaged and the sealant is not damaged.

• Loosen hose clamp (5) that is located on the hydraulic oil cooler. Remove hose (4). Allow the coolant to drain into a suitable container.

• If the machine is equipped with a cab heater, turn the heater control that is located inside the cab to the HOT position. Loosen hose clamp (6). Remove hose (7). Allow the coolant to drain into a suitable container.

• Flush the cooling system with clean water until the draining water is transparent.

• Close drain valve (2).

• Reinstall coolant drain plug (3) in the engine block above the starter. Tighten the plug.

• 10.Reinstall hoses (4) and (7). Tighten clamps (5) and (6).

• NOTICE: Add the coolant solution at a maximum rate of five liters per minute. This will reduce the chance of trapping air inside the engine block. A large amount of trapped air can cause localized heating to occur upon start-up. Localized heating may result in engine damage, which may lead to failure of the engine.

• Add the coolant into the coolant tank. Refer to Operation and Maintenance Manual, "Capacities (Refill)"

• Start the engine. Operate the engine without the pressure cap for the coolant tank until the coolant temperature regulator opens and the coolant level stabilizes.

• Maintain the coolant level up to the FULL mark on the coolant tank.

• Inspect the gasket of the pressure cap. If the gasket is damaged, replace the cap.

• Install the pressure cap on the coolant tank.

• Stop the engine.

Final Drive Oil - Change

• Park the machine on level ground. Position the drain plug in the position that is shown in Illustration 250.

• 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 drain plug. Remove the drain plug and drain the oil into a suitable container.

• Move the machine until the plug hole is at the horizontal center line of the wheel. The correct position is shown in Illustration 251.

• Add oil to the final drive through the plug hole. Oil should be dripping out of the plug hole when the final drive is full of oil. Refer to Operation and Maintenance Manual, "Capacities (Refill)" and Operation and Maintenance Manual, "Lubricant Viscosities" for more information.

• Refer to the appropriate Service Manual for more detailed lubricant information.

• Clean the drain plug and reinstall the drain plug.

• Repeat the steps that are explained above for each of the three remaining final drives.

Rollover Protective Structure (ROPS) and Falling Object Protective Structure (FOPS) - Inspect

• Remove the bolts (2) in order to remove the windshield washer reservoir.

• If the bolts are damaged or missing replace the bolts with original equipment parts only. Torque the bolts to 450 Nm (332 lb ft).

• Note: Apply oil to the bolts before you install the bolts. Failure to apply oil can result in improper bolt torque.

• Install the windshield washer reservoir, and install the two bolts.

• Run the machine on a rough surface. Replace the ROPS/FOPS mounting supports if the ROPS/ FOPS structure makes a noise or if the ROPS/ FOPS structure rattles.

Dispose of all fluids according to local regulations and mandates.

• In order to open protection cover (3), unlock lock (2) and turn lock (4) counterclockwise. Then, pull latch (1) outward.

• Lift latch (5). Turn the latch counterclockwise in order to relieve the pressure in the hydraulic system. Remove hydraulic tank filler cap (6).

• Remove drain plug (7) from the bottom of the hydraulic tank and drain the oil into a suitable container. Clean the drain plug. Install the drain plug back into the hydraulic tank.

• Remove drain plug (8) from the bottom of the transmission and drain the oil into a suitable container. Clean the drain plug. Install the drain plug back into the transmission.

• Fill the hydraulic tank with new oil and install the hydraulic tank filler cap. Clean up any oil that has spilled. Refer to Operation and Maintenance Manual, "Lubricant Viscosities" and Operation and Maintenance Manual, "Capacities (Refill)" for additional information.

• Note: Do not start the engine until the hydraulic tank is filled with new oil. Starting the engine before refilling with oil may damage the scavenge pump or the transmission.

• Start the engine. Check for clearance for the boom. The boom will need clearance for full extension. You need enough clearance to fully raise the boom and you need enough clearance to lower the boom. Raise and lower the boom several times. Extend and retract the boom several times.

• With the boom in the travel position, drive the machine slowly forward. Steer the machine from the left to the right.

• Park the machine and check the oil level. If necessary, add oil.

• Close the protection cover.

Transmission and Hydraulic System Oil Filter - Replace

• In order to open protection cover (3), unlock lock (2) and turn lock (4) counterclockwise. Then, pull latch (1) outward.

• Open the engine enclosure.

• Remove oil filter (7). After you remove the oil filter, discard the oil filter. The oil filter will contain oil.

• Clean the housing base for the oil filter. Make sure that all of the old filter seal has been removed.

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

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

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

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

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

• Tighten hydraulic tank filler cap (6).

• Close the protection cover.