Cat Caterpillar TH220B Telehandler Service Repair Manual on CD

SKU: Cat Caterpillar TH220B Telehandler Service Repair Manual on CD
Price: $39.00

Cat Caterpillar TH220B Telehandler Service Repair Manual on CD

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your CAT. Read and print pages directly from the CD, or copy the entire manual to your hard drive.

11245 Pages

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SERAIL NUMBERS:

S/N   TBF00100 & After

S/N   TBG00100 & After

 

MANUAL COVERS:

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

ENGINE:
Engine Disassembly-Assembly
Table of Contents
Disassembly and Assembly Section:
Battery - Remove and Install
Removal Procedure
Installation Procedure
Alternator - Remove and Install
Removal Procedure
Installation Procedure
Electric Starting Motor -Remove and Install
Removal Procedure
Installation Procedure
Air Cleaner - Remove and Install
Removal Procedure
Installation Procedure
Muffler - Remove and Install
Removal Procedure
Installation Procedure
Expansion Tank - Remove and Install
Removal Procedure
Radiator - Remove
Removal Procedure
Radiator - Install
Installation Procedure
Fan Guard - Remove and Install
Removal Procedure
Installation Procedure
Fan - Remove and Install
Removal Procedure
Installation Procedure
Engine Mount - Remove and Install
Removal Procedure
Installation Procedure
Refrigerant Compressor - Remove and Install
Removal Procedure
Installation Procedure
Refrigerant Condenser - Remove and Install
Removal Procedure
Installation Procedure
Engine Enclosure - Remove and Install
Removal Procedure
Installation Procedure
Engine - Remove
Removal Procedure
Engine - Install
Installation Procedure

POWER TRAIN:
Power Train Test-Adjust
Table of Contents
Systems Operation Section:
Graphic Color Codes
Introduction
General Information
Location of Electrical Components
Transmission Neutralizer Switch
Parking Brake Switch
Service Brake Pressure Switch
Transmission Direction Control Lever (Power Shuttle Transmission)
Transmission Speed Selector (Powersynchro Transmission)
Differential Lock Switch (if Equipped
Transmission Oil Temperature Sensor
Torque Converter Output Sensor for the Temperature of the Oil
Engine Speed Sensor
Torque Converter Output Speed Sensor
Transmission Intermediate Speed Sensors
Transmission Output Speed Sensor
Shift Rail Sensors
Electronic Control Module
Modulating Valve for the Synchronizers
Solenoid Valves
Transmission Neutralizer Override Switch
Location of Hydraulic Components
Transmission Charge Pump
Torque Converter
Hydraulic Oil Cooler
Electrical Input Components
Sensors
Switches
Transmission Control
Electronic Control Module
Inputs
Outputs
Input/Output
Electrical Output Components
Synchronizer Solenoids
Directional Solenoids
Instrument Cluster
Data Link
CAT Data Link
CAN Data Link
Electrical Schematic
Transmission Charge Pump
Modulating Valve (Transmission)
Solenoid Valves (Transmission)
Directional Solenoids
Speed or Synchronized Solenoids
Torque Converter
Transmission
Clutch Operation
Operation of the Synchronizers
Synchronizer for the Third Speed and Fourth Speed
Limits
Cooler (Hydraulic Oil)
Transmission Control (Shift Lever)
Powersynchro Transmission
Power Shuttle Transmission
Transmission Power Flow
Examples of Power Flow Through the Transmission
Differential Lock Control (If Equipped)
Front Axle and Rear Axle
Final Drives
Hydraulic Schematic (Power Train System)
Neutral (Power Shuttle Transmission)
Neutral (Powersynchro Transmission)
Neutral into First Gear (Start of shift)
Neutral Into First Gear (End of Shift) (FORWARD)
Configuration Parameters
Testing and Adjusting Section:
Transmission Shift Rail - Calibrate
Machine Preparation
Transmission Fill - Calibrate
Machine Preparation
Torque Converter Stall - Test
Introduction
Required Tools
Test Procedure
Measurement of the Stall Speed
Transmission Pressures - Test and Adjust
Pressure Test Points for the Powersynchro Transmission
Pressure Test Points for the Power Shuttle Transmission
Oil Level Check
Torque Converter Inlet Pressure
Regulated Pump Pressure
Operating Pressures of Clutches and Synchronizers
Differential Pinion Bearing - Adjust
Introduction
Required Tools
Procedure
Differential Backlash and Bearings - Adjust
Front Axle Differential
Rear Axle Differential
Tooth Contact Pattern
Axle Housing and Bearing Preload - Adjust
Introduction
Adjustment Procedure
Power Train Disassembly-Assembly
Table of Contents
Disassembly and Assembly Section:
Transmission Control (Select Lever) - Remove and Install
Removal Procedure
Installation Procedure
Drive Shaft (Front) - Remove and Install
Removal Procedure
Installation Procedure
Drive Shaft (Rear) - Remove and Install
Removal Procedure
Installation Procedure
Transmission and Torque Converter - Remove
Removal Procedure
Transmission - Disassemble
Disassembly Procedure
Transmission - Assemble
Assembly Procedure
Transmission and Torque Converter - Install
Installation Procedure
Drive and Steering Axle (Front) - Remove
Removal procedure
Drive and Steering Axle (Front) - Install
Installation Procedure
Drive and Steering Axle (Rear) - Remove
Removal procedure
Drive and Steering Axle (Rear) - Install
Installation Procedure
Tie Rod (Steering) - Remove and Install
Removal Procedure
Installation procedure
Steering Cylinder - Remove and Install
Removal Procedure
Installation Procedure
Final Drive Planetary - Remove
Removal Procedure
Final Drive Planetary Disassemble
Disassembly Procedure
Final Drive Planetary - Assemble
Assembly Procedure
Final Drive Planetary - Install
Installation Procedure
Axle Housing and Flange Remove
Removal Procedure
Axle Housing and Flange - Disassemble
Disassembly Procedure
Axle Housing and Flange - Assemble
Assembly Procedure
Axle Housing and Flange Install
Installation Procedure
Axle Shaft - Remove and Install
Removal Procedure
Installation Procedure
Axle Housing (Service Brakes, Differential and Bevel Gear) (Front) - Remove
Removal Procedure
Axle Housing (Service Brakes, Differential and Bevel Gear) (Front) - Disassemble
Disassembly Procedure
Axle Housing (Service Brakes, Differential and Bevel Gear) (Front) - Assemble
Assembly Procedure
Axle Housing (Service Brakes, Differential and Bevel Gear) (Front) - Install
Installation Procedure
Axle Housing (Differential and Bevel Gear) (Rear) - Remove
Removal Procedure
Axle Housing (Differential and Bevel Gear) (Rear) - Assemble
Assembly Procedure
Axle Housing (Differential and Bevel Gear) (Rear) - Disassemble
Disassembly Procedure
Axle Housing (Differential and Bevel Gear) (Rear) - Install
Installation Procedure
Brake Cylinder (Master) Remove and Install
Removal Procedure
Installation Procedure
Parking Brake Control -Remove and Install
Removal Procedure
Installation Procedure
Parking Brake - Remove
Removal Procedure
Parking Brake - Disassemble
Disassembly Procedure
Parking Brake - Assemble
Assembly Procedure
Parking Brake - Install
Installation Procedure
Tire and Rim - Remove and Install
Removal Procedure
Installation Procedure

VEHICLE SYSTEMS:
Hydraulic System Schematic
Hydraulic System Test Adjust
Table of Contents
Systems Operation Section
Graphic Color Codes
Introduction
General Information
Main Control Valve Group (Implement)
Electronic Pilot Valve Group (Implement)
Machine ECM
Electronic Joystick
Operator Switches
Piston Pump (Implement and Steering)
Hydraulic Oil Tank
Hydraulic Oil Filter
System Operation
Load Independent Flow Division (LIFD)
Location of Electrical Components
Switch (Lockout Control)
Joystick Control
Sensor (Boom Raise/Lower)
Sensor For Boom Extend And Boom Retract Or Boom Tilt Forward And Rackback
Switch (Continuous Auxiliary Flow)
Switch For Boom Extend and Boom Retract Or Boom Tilt Forward And Rackback
Switch (Auxiliary Actuator in the + Direction)
Switch (Auxiliary Actuator in the - Direction)
Switch (Auxiliary Services 1 or 2)
Switch (Quick Coupler)
Switch (Frame Level)
Switch (Fully Lowered Boom)
Switch (Critical Angle)
Switch (Fully Retracted Boom)
Switch (Reversing Fan (If Equipped))
Machine (ECM)
Main Control Valve (Implement)
Solenoids (Frame Level)
Solenoid (Diverter Valve)
Relay (Frame Level)
Relays (Diverter Valve)
Relays (Quick Coupler)
Location of Hydraulic Components
Hydraulic Tank
Piston Pump (Implement and Steering)
Compensator Valve
Main Control Valve Group (Implement)
Inlet Manifold
Outlet Manifold
Trailer and Towing Hitch Hydraulic System (Option)
Boom Cylinder
Load Control Valve (Boom Cylinder Lock)
Telescoping Cylinder
Load Control Valve (Telescoping Cylinder Lock)
Tilt Cylinder
Lock for Load Control Valve (Tilt Cylinder)
Compensating Cylinder
Load Control Valve (Compensating Cylinder Lock)
Frame Leveling Cylinder
Lock Valve (Frame Leveling Cylinder)
Diverter Valve
Quick Coupler Cylinder
Electrical Input Components
Switches
Joystick Control
Auxiliary Switches
Thumb Slider
Boom Critical Angle Switch
Frame Leveling Switch
Boom Retracted Switch
Quick Coupler Switch
Continuous Flow Switch
Implement Lockout Switch
Boom Lowered Switch
Electronic Control Module
Inputs
Outputs
Data Links
Input/Output
Electrical Output Components
Relays
Solenoids
Electrical Function Requirements
Transmission Neutralizer
Solenoid Outputs
System Voltage
Shuttle Shift for the Power Shuttle Transmission
Shift Lever (Cat Data Link) for Powersynchro Transmission
Rear Axle Lock (if equipped)
Machine Security System
Parking Brake
Service Brake Pressure Switch for the Transmission Neutralizer
More Electrical Function Requirements
Steering
The Neutral Start Is Disabled
Stabilizer Raise/Lower (if equipped) is Disabled
Boom Raise/Lower Is Disabled
The Boom Extend/Retract Is Disabled
Disable The Rackback And Dump
The Frame Level (if equipped) is Disabled
Disable the Quick Coupler
Miscellaneous
Electrical Schematic
Programmable Hydraulic System (PHS)
Piston Pump (Implement and Steering)
Piston Pump
Compensator Valve
Low Pressure Standby
Upstroke
Constant Flow
Destroke
High Pressure Stall
Main Control Valve (Implement)
Manifold Valve (Inlet)
Check and Relief Valves
Manifold Valve (Outlet)
Pilot Hydraulic System
Telescoping System
Valve for the Telescoping Cylinder in the HOLD Position
Valve for the Telescoping Cylinder in the EXTEND Position
Valve for the Telescoping Cylinder in the RETRACT Position
Hydraulic Fan System
Reversing Fan (If Equipped)
Auxiliary Hydraulic System
Auxiliary Control (Combined Circuit)
Auxiliary Circuit 1
Auxiliary Circuit 2
Continuous Flow (Auxiliary Hydraulics)
Quick Coupler
Quick Coupler Circuit DISENGAGED
Quick Coupler Pins ENGAGED
Relief Valves and Makeup Valves
Compensating System
Trailer and Towing Hitch Hydraulic System
Introduction
Towing Hitch Cylinder LOWER
Towing Hitch Cylinder RAISE
Trailer DUMP
Trailer LOWER
Service Brakes ENGAGED
Hydraulic System Schematic
Configuration Parameters
Testing and Adjusting Section
Testing and Adjusting
Joystick Control - Calibrate
Main Control Valve (Implement) - Calibrate
Programmable Hydraulic System (PHS) Valve Calibrations
Manual Adjustment After Calibrating The Valves
Hydraulic System Pressure - Release
Relieving Pressure in the Hydraulic System
Location of the Load Control Valve (Lock)
Relieving Pressure from the Load Control Valves (Lock)
Hydraulic System Pressures - Test and Adjust
Test and Adjustment Procedures
Pilot Pressure (Pressure Reducing Valve) - Test and Adjust
Pilot Pressure Test
Pressure Reducing Valve Adjustment
Relief Valve (Implement) - Test and Adjust
Auxiliary Pressure Test (Port A and Port B)
Auxiliary Relief Valve Adjustments
Hydraulic Oil Contamination - Test
Hydraulic Oil Contamination
Flushing the Sampling Valve
Obtaining the Sample
General Information Table
Steering System Test-Adjust
Table of Contents
Systems Operation Section
Graphic Color Codes
General Information
Steering Arrangement
Introduction
Location of Electrical Components
Selector Switch for the Steering Mode
Position Sensors
Electronic Control Module
Solenoid for Crab Steer
Solenoid for Circle Steer
Relay (Crab Steer)
Relay (Circle Steer)
Location of Hydraulic Components
Steering Wheel
Metering Pump
Piston Pump
Line for the Signal Limiter Valve for the Steering
Priority Valve
Control Valve (Steering)
Steering Cylinders
Hydraulic Tank
Hydraulic Tank Breather
Hydraulic Oil Level Indicator
Hydraulic Oil Drain Plugs
Electrical Input Components
Steering Mode Switch
Position Sensor
Electronic Control Module
Electrical Output Components
Relays
Instrument Cluster
Data Link
CAT Data Link
CAN Data Link
Electrical Schematic
Inlet Manifold
Steering Priority Valve
Screens (75 and 100 Micron)
Flow Control Valve (Dump valve for the load sensing oil)
Relief Valve (Load sensing oil)
Check Valve
Steering Not Activated
Steering Activated
Steering System
Steering Control System
Steering in Neutral
Right Turn in Two-Wheel Steer Mode
Left Turn in Circle Steer Mode
Left Turn in Crab Steer Mode
Hydraulic Schematic (Steering System)
Piston Pump (Implement and Steering)
Piston Pump
Compensator Valve
Low Pressure Standby
Upstroke
Constant Flow
Destroke
High Pressure Stall
Solenoid Valve (Steering Mode Selector)
Solenoid Valve
Metering Pump (Steering)
Hold
Right Turn
Position Sensor (Steering)
Configuration Parameters
Testing and Adjusting Section
Hydraulic Oil Contamination - Test
Hydraulic Oil Contamination
Flushing the Sampling Valve
Obtaining the Sample
Pump Flow - Test
Pump Flow
Test On The Machine
Test On The Bench
Steering System Pressures - Test and Adjust
Steering System Pressure Tests and Adjustments
Steering Pressure Test
Steering Pressure Adjustment
Margin Pressure Test
Margin Pressure Adjustment
Test for the Relief Valve (Load Sensing Oil)
Adjustment of the Relief Valve (Load Sensing Oil)
Test for Pressure Compensator
Pressure Compensator Adjustment
Low Pressure Standby Test
Low Pressure Standby Adjustment
Steering System - Purge
Purging the Steering System
Solenoid Valve (Steering Mode Selector) - Test
The Solenoid's for the Steering Modes
Position Sensor (Steering) - Adjust
Position Sensor
Wheel Alignment - Check and Adjust
Checking the Wheel Alignment With Wheels In Place
Adjusting the Wheel Alignment
Adjusting the Steering Angle
General Information Table
Braking System Test-Adjust
Table of Contents
Systems Operation Section
Graphic Color Codes
Introduction
General Information
Brake Packs
Brake Pedal
Brake Cylinder
Service Brake Pressure Switch
Parking Brake Lever
Location of Electrical Components
Parking Brake Switch
Service Brake Pressure Switch
Stoplight Switch
Location of Components (Braking)
Parking Brake Lever
Parking Brake Actuator
Service Brake Pedal
Brake Cylinder
Service Brake Discs
Service Brake
Service Brake
The Service Brake System with the Brakes Disengaged
The Service Brake System with the Brakes Engaged
Parking Brake
Engaging the Parking Brake
Disengaging the Parking Brake
Brake Cylinder (Master)
Brake Cylinder with the Brakes Disengaged
Brake Cylinder with the Brakes Engaged
Hydraulic Schematic (Braking System)
Configuration Parameters
Electrical Function Requirements
Transmission Neutralizer
System Voltage
Shuttle Shift for the Power Shuttle Transmission
Shift Lever (Cat Data Link) for Powersynchro Transmission
Rear Axle Lock (if equipped)
Machine Security System
Parking Brake
Service Brake Pressure Switch for the Transmission Neutralizer
More Electrical Function Requirements
Steering
The Neutral Start Is Disabled
Stabilizer Raise/Lower (if equipped) is Disabled
Boom Raise/Lower Is Disabled
The Boom Extend/Retract Is Disabled
Disable The Rackback And Dump
The Frame Level (if equipped) is Disabled
Disable the Quick Coupler
Miscellaneous
Testing and Adjusting Section
Testing and Adjusting Service Brake - Test
Holding Ability Test for the Service Brakes
Stopping Performance Test for the Service Brakes
Service Brake Control - Check and Adjust
Adjusting the Brake Pedal Linkage
Service Brake Discs - Check
Checking the Wear on the Service Brake Discs
Procedure for Checking the Wear
Service Brake Air - Purge
Purging Air from the Braking System
Parking Brake - Test
Holding Ability Test for the Parking Brake
Parking Brake Control - Check and Adjust
Adjusting the Parking Brake Control Cable
Machine Components Specifications
Table of Contents
Specifications Section
Hydraulic Tank
Piston Pump (Implement and Steering)
Solenoid Valve (Pilot Selector)
Frame
Boom
Boom Cylinder
Boom Cylinder
Boom Cylinder
Load Control Valve (Boom Cylinder) (Lock)
Compensating Cylinder
Compensating Cylinder
Telescoping Cylinder
Telescoping Cylinder
Load Control Valve (Telescoping Cylinder) (Lock)
Tilt Cylinder
Tilt Cylinder
Load Control Valve (Tilt Cylinder) (Lock)
Diverter Valve
Diverter Valve
Towing Hitch
Towing Hitch
Towing Hitch
Towing Hitch
Towing Hitch
Towing Hitch
Piston Pump (Hydraulic Fan)
Piston Pump Gp
Relief Valve
Elbow
Solenoid Valve Gp
Fan Drive Mounting Group
Metering Pump (Steering)
Solenoid Valve (Steering Mode Selector)
Position Sensor (Steering)
Flexible Coupling Drive
Transmission
Transmission
Position Sensor (Transmission)
Oil Filter
Hydraulic Oil Cooler
Drive Shaft
Drive Shaft
Drive and Steering Axle (Front)
Drive and Steering Axle Gp
Drive and Steering Axle Gp
Drive and Steering Axle (Rear)
Drive and Steering Axle Gp
Differential and Bevel Gear Group
Axle Housing and Flange Group
Axle Housing and Flange Group
Final Drive Planetary Group
Axle Housing Group (Differential and Brake Cylinder)
Axle Housing Gp with a Locking Differential
Axle Housing Gp without a Locking Differential
Brake Cylinder (Master)
Parking Brake Control
Parking Brake
Fender
Wheel (Tire and Rim)
Fuel Tank (Auxiliary)
Fuel Tank
Engine Enclosure
Engine and Transmission Mounting
Air Cleaner
Engine Oil Drain
Muffler
Suction Fan
Battery
Coolant Lines Group
Coolant Recovery Group
Cab
Latch Adjustment
Cab Mounting
Cab Door
Access Door
Joystick Control
Steering Wheel and Column
Window Wiper and Wiper Motor
Window Washer Tank
Rear View Mirror
Work Tool Linkage
Carriage Cylinder (Rotate)
Carriage Cylinder (Sideshift)
Hydraulic Cylinder (Multipurpose Bucket)
Grapple Cylinder
Machine Systems Disassembly-Assembly
Table of Contents
Disassembly and Assembly Section
Hydraulic System Pressure - Release
Release Procedure
Bottom Guard - Remove and Install
Removal Procedure
Installation Procedure
Hydraulic Tank - Remove
Removal Procedure
Hydraulic Tank - Install
Installation Procedure
Piston Pump (Implement and Steering) - Remove
Removal Procedure
Piston Pump (Implement and Steering) - Disassemble
Disassembly Procedure
Piston Pump (Implement and Steering) - Assemble
Assembly Procedure
Piston Pump (Implement and Steering) - Install
Installation Procedure
Main Control Valve (Implement) - Remove
Removal Procedure
Electronic Pilot Valve - Remove and Install
Removal Procedure
Installation Procedure
Bank Valve (Implement) - Disassemble
Disassembly Procedure
Bank Valve (Implement) - Assemble
Assembly Procedure
Main Control Valve (Implement) - Install
Installation Procedure
Tilt Cylinder - Remove and Install
Removal Procedure
Installation Procedure
Control Valve (Compensating Cylinder) - Remove and Install
Removal Procedure
Installation Procedure
Compensating Cylinder Remove and Install
Removal Procedure
Installation Procedure
Load Control Valve (Telescoping Cylinder) Remove and Install
Removal Procedure
Installation Procedure
Telescoping Cylinder - Remove and Install
Removal Procedure
Installation Procedure
Diverter Valve (Boom Head) - Remove and Install
Removal Procedure
Installation Procedure
Load Control Valve (Boom Cylinder) - Remove and Install
Removal Procedure
Installation Procedure
Boom Cylinder - Remove and Install
Removal Procedure
Installation Procedure
Coupler Cylinder - Remove and Install
Removal Procedure
Installation Procedure
Quick Coupler (Hydraulic) - Remove and Install
Removal Procedure
Installation Procedure
Work Tool Linkage - Remove and Install
Removal Procedure
Installation Procedure
Boom - Remove
Removal Procedure
Boom - Disassemble
Disassembly Procedure
Boom -Assemble
Assembly Procedure
Boom - Install
Installation Procedure
Hydraulic Oil Cooler (Transmission and Hydraulic System) - Remove and Install
Removal Procedure
Installation Procedure
Transmission Oil Cooler
Hitch Cylinder - Remove and Install
Removal Procedure
Installation Procedure
Towing Hitch (Hydraulic) - Remove and Install
Removal Procedure
Installation Procedure
Control Valve (Trailer and Towing Hitch) - Remove
Removal Procedure
Control Valve (Trailer and Towing Hitch) - Disassemble
Disassembly Procedure
Control Valve (Trailer and Towing Hitch) - Assemble
Assembly Procedure
Control Valve (Trailer and Towing Hitch) - Install
Installation Procedure
Fuel Tank - Remove
Removal Procedure
Fuel Tank - Install
Installation Procedure
Steering Wheel - Remove and Install
Removal Procedure
Installation Procedure
Steering Column - Remove
Removal Procedure
Steering Column - Install
Installation Procedure
Solenoid Valve (Steering Mode Selector) - Remove and Install
Removal Procedure
Installation Procedure
Metering Pump (Steering) - Remove
Removal Procedure
Metering Pump (Steering) - Install
Installation Procedure
Window Wiper and Wiper Motor (Front) - Remove and Install
Removal Procedure
Installation Procedure
Window Wiper and Wiper Motor (Rear) - Remove and Install
Removal Procedure
Installation Procedure
Window Wiper and Wiper Motor (Roof) - Remove and Install
Removal Procedure
Installation procedure
Joystick Control - Remove and Install
Removal Procedure
Installation Procedure
Seat - Remove and Install
Removal Procedure
Installation Procedure
Cab Heater - Remove
Removal Procedure
Cab Heater - Install
Installation Procedure
Heater Core - Remove and Install
Removal Procedure
Installation Procedure
Air Conditioner - Remove
Removal Procedure
Air Conditioner - Install
Installation Procedure
Evaporator Coil - Remove and Install
Removal Procedure
Installation procedure
Blower Motor (Air Conditioner and Heater) - Remove and Install
Removal Procedure
Installation procedure
Cab - Remove
Removal Procedure
Cab - Install
Installation Procedure
Fender - Remove and Install
Removal Procedure
Installation Procedure

ELECTRICAL SYSTEMS:
Electrical System Schematic
Electronic Control System, Hydrostatic Transmission Troubleshooting Test-Adjust
Table of Contents
Introduction
General Information
Service Tools
Connector Locations
Connector Contact Numbers
Diagnostic Capabilities
Monitoring System/Instrument Cluster
The Caterpillar Electronic Technician (ET)
Logged Event Codes
Status Groups For The Electronic Technician
Machine Preparation for Troubleshooting
General Troubleshooting Information
Visual Inspection
Operational Checks
Operational Checks (Braking System)
Operational Checks (Steering System)
Operational Checks (Power Train)
Operational Checks (Hydraulic System)
Event Code List
Warning Levels
Indications and System Response
Troubleshooting
Telehandler Event Code List
Symptom Procedures
Steering System
Troubleshooting The Steering System
Brake System
Troubleshooting The Brake System
Troubleshooting The Parking Brake
Transmission
Troubleshooting The Transmission System
Hydraulic System
Troubleshooting The Hydraulic System
Torque Converter
Troubleshooting The Torque Converter
Differential and Final Drive
The Differential And The Final Drive Troubleshooting
Diagnostic Code Procedures
Diagnostic Code List
Module Identifier (MID)
Component Identifier (CID)
Failure Mode Identifier (FMI)
Using the Operator Monitor to Determine Diagnostic Codes
Using Caterpillar Electronic Technician to Determine Diagnostic Codes
Active Diagnostic Codes
Logged Diagnostic Codes
Testing and Adjusting Section
Testing and Adjusting
General Information
Electrical Connector - Inspect
Wiring Harness (Open Circuit) -Test
Wiring Harness (Short Circuit) -Test
Electronic Control Module (ECM) - Flash Program
Electronic Control Module (ECM) - Configure
Electronic Control Module (ECM) - Replace
Connector Contact Description
Glossary of Electrical Terms
System Schematic
LSI System Operation & Maintenance
Table of Contents
Systems Operation Section
Introduction
General Information
Operational Modes
Location of Electrical Components
Electrical Control Module
Instrument Cluster
Sensor
Electrical Input Components
Sensor
Electronic Control Module
Electrical Output Components
Testing and Adjusting Section
Testing and Adjusting Sensor - Test
Test On The Vehicle
Removal And Installation of the Sensor for the Longitudinal Stability Indicator System
General Instructions
Removal Instructions
Surface Preparation
Application of the Adhesive
Sensor Installation
Coverage of the Mounting Pads
Calibration of the Sensor
Electrical Information
Display Module - Replace
Calibration
Longitudinal Stability Indicator (LSI) Calibration
Monitor System Test-Adjust
Table of Contents
Systems Operation Section
Introduction
Operation
Power Up
Power Down
Diagnostics
Failure Modes
Software
Features
Instrument Cluster
Status Indicators
Gauge Indicators
Location of Electrical Components
Instrument Cluster
Electronic Control Module
Turn Signal
High Beam Switch
Starting Aid Switch
Hydraulic Oil Filter Bypass Pressure Switch
Engine Oil Pressure Switch
Air Filter Restriction Indicator
Fuel Level Sensor
Transmission Oil Temperature Sensor
Engine Speed Sensor
Engine Coolant Temperature Sensor
Component Description
Switches
Sensors
Additional Circuits
Data Link
CAT Data Link
CAN Data Link
Warning Operation
Diagnostic Operation
Troubleshooting Procedures
Module Identifier (MID)
Component Identifier (CID)
Failure Mode Identifier (FMI)
Testing and Adjusting Section
Testing and Adjusting
Self Test
Self Test
Module - Replace
Connector Contact Description
System Schematic 

Electrical System

Hydraulic System

 

OPERATION AND MAINTENANCE MANUAL:

Table of Contents

Foreword
Literature Information
Safety
Operation
Maintenance
Maintenance Intervals
Certified Engine Maintenance
Machine Capacity
Contact Information
Safety Section
Safety Messages
Do Not Operate
Do Not Stand Under the Load
No Hands
Forks
Do Not Weld On The ROPS/FOPS Structure
No Access Platform

Seat Belt
Engine Coolant
Low Bridge
Avoid Power Lines
Jump Start Cables
Ether
Impaling Hazard
Crushing Hazard
Crushing Hazard
Crushing Hazard
Impaling Hazard
Crushing Hazard
Impaling Hazard
Impaling Hazard
Crushing Hazard
Operation
Entanglement and Flying Objects
Trap Point
Crushing Hazard )
Ether
Hand (High Pressure) )
Universal Warning
Additional Messages
General Hazard Information
Pressurized Air and Water
Trapped Pressure
Fluid Penetration
Containing Fluid Spillage
Dispose of Waste Properly
Crushing Prevention and Cutting Prevention
Burn Prevention
Coolant
Oils
Batteries
Fire Prevention and Explosion Prevention
Fire Extinguisher
Lines, Tubes and Hoses
Fire Extinguisher Location
Tire Information
Electrical Storm Injury Prevention
Before Starting Engine
Engine Starting
Before Operation
Operation
Machine Operating Temperature Range
Machine Operation
Engine Stopping
Work Tools
Parking
Equipment Lowering with Loss of Hydraulic Power
Sound Information and Vibration Information
Sound Level
Vibration Level
Operator Station
Guards (Operator Protection)
Rollover Protective Structure (ROPS), Falling Object Protective Structure (FOPS)
Other Guards (If Equipped)
Product Information Section
General Information
Lifting Capacities
Examples of Estimating the Lift Operation from the Load Chart
Specifications
Intended Use
Application/Configuration Restrictions
Identification Information
Plate and Decal Locations
Emissions Certification Decal
Operation Section
Before Operation
Mounting and Dismounting
Daily Inspection
Machine Operation
Alternate Exit
Seat
Seat Belt
Operator Controls
Operator Controls (Side Console)
Battery Disconnect Switch (If Equipped)
Boom Cylinder Lock (If Equipped)
Operation Information
Work Tools
Monitoring System
Backup Alarm
Cab Door
Engine Starting
Engine Starting
Starting Below 0 °C (32°F)
Engine and Machine Warm-Up
Parking
Stopping the Machine
Stopping the Engine
Stopping the Engine if an Electrical Malfunction Occurs
Leaving the Machine
Transportation Information
Shipping the Machine
Roading the Machine
Lifting and Tying Down the Machine
Towing Information
Towing the Machine
Types of Towing Hitches and Hydraulic Services
Hydraulic Hitch and Hydraulic Services
Engine Starting (Alternate Methods)
Engine Starting with Jump Start Cables
Equipment Lowering with Loss of Hydraulic Power
Maintenance Section
Maintenance Access
Access Doors and Covers
Tire Inflation Information
Tire Inflation with Air
Tire Pressure
Tire Inflation Pressure Adjustment
Tire Damage
Tire Replacement
Wheel and Tire Installation
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities
Capacities (Refill)
SOS Information
Maintenance Support
Welding on Machines and Engines with Electronic Controls
Maintenance Interval Schedule
Axle Breathers - Clean/Replace
Backup Alarm - Test
Battery - Recycle
Battery or Battery Cable - Inspect/Replace
Belt - Inspect/Replace
Inspect
Replace
Boom Cylinder Pin - Lubricate
Boom Head Section - Lubricate
Boom Pivot Shaft - Lubricate
Boom Telescoping Cylinder Air- Purge
Boom Wear Pad Clearance - Inspect/Adjust
Adjustment
Boom and Frame - Inspect
Braking System - Test
Service Brake
Parking Brake
Cab Air Filter - Clean/Replace
Primary Cab Air Filter
Secondary Cab Air Filter
Circuit Breakers - Test
Compensating Cylinder Bearing - Lubricate
Cooling System Coolant - Change
Cooling System Coolant Level - Check
Cooling System Coolant Sample (Level 1) - Obtain
Cooling System Coolant Sample (Level 2) - Obtain
Cooling System Pressure Cap - Clean/Replace
Cooling System Water Temperature Regulator Replace
Differential Oil - Change
Rear Axle Differential
Front Axle Differential
Differential Oil Level - Check
Rear Axle Differential
Front Axle Differential
Differential Oil Sample - Obtain
Drive Shaft Spline - Lubricate
Drive Shaft Universal Joint Bolts - Check
Engine Air Filter Primary Element - Clean/Replace
Cleaning Primary Air Filter Elements
Inspecting the Primary Air Filter Elements
Engine Air Filter Primary Element - Replace
Engine Air Filter Secondary Element - Replace
Engine Mounts - Inspect
Engine Oil Level - Check
Engine Oil Sample - Obtain
Engine Oil and Filter - Change
Engine Valve Lash - Check
Final Drive Oil - Change
Final Drive Oil Level - Check
Final Drive Oil Sample - Obtain
Fork Leveling Cylinder Pin - Lubricate
Fuel System - Prime
Fuel System Water Separator - Drain
Fuel System Water Separator Element - Replace (Tier II)
Fuel System Water Separator Element - Replace (Tier III)
Fuel Tank Cap - Clean
Fuel Tank Water and Sediment - Drain
Fuses and Relays - Replace
Fuses
Relays
Indicators and Gauges - Test
Longitudinal Stability Indicator - Calibrate
Longitudinal Stability Indicator - Test
Initial Test
Second Test
Oil Filter - Inspect
Inspect a Used Filter for Debris
Parking Brake - Adjust
Radiator Core - Clean
Refrigerant Dryer - Replace
Rollover Protective Structure (ROPS) and Falling Object Protective Structure (FOPS) - Inspect
Seat Belt - Inspect
Seat Belt - Replace
Tire Inflation - Check
Transmission and Hydraulic System Oil - Change
Transmission and Hydraulic System Oil Filter - Replace
Transmission and Hydraulic System Oil Level - Check
Transmission and Hydraulic System Oil Sample - Obtain
Transmission and Hydraulic System Tank Breather - Clean
Turbocharger - Inspect
Wheel Nut Torque - Check
Window Washer Reservoir - Fill
Window Wiper - Inspect/ Replace
Windows - Clean
Work Tool - Inspect/Replace
Forks
Buckets
Reference Information Section
Approved Work Tools
Index 

 

PARTS MANUAL (854 pages):

Table of Contents

Maintenance Parts
Index
Machine Arrangement
Engine Arrangement
Basic Engine
Lubrication System
Cooling System
Air Inlet and Exhaust System
Fuel System
Electrical and Starting System
Power Train
Frame and Body
Braking System
Steering System
Hydraulic System
Implements
Work Tools
Operator Station
Service Equipment and Supplies
Part Number Index
TIER III 

 

 

 

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 

Language: English 
Format: PDF - Indexed and Searchable

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 10, WINDOWS 8, WINDOWS 7, VISTA 32 and 64, XP, ME, 98, NT, 2000 ETC.) 

Windows/Mac/Tablet/Phone Friendly

32 / 64 bit

$39.00