TH210 and TH215 Telehandlers Machine Systems Caterpillar

Installation Procedure

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Personal injury or death can result from a fire. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel filters.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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

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Illustration 1	g00939821

2. Place the fuel tank on a suitable floor jack. The weight of the fuel tank is approximately 44 kg (97 lb). Maneuver the fuel tank under the machine. Pass the filler tube for the fuel tank between the wheel and the frame of the cab. Refer to Illustration 1.

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Illustration 2	g00939808

3. Carefully turn the fuel tank by approximately 90 degrees. Refer to Illustration 2.

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Illustration 3	g00939809

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Illustration 4	g00939810

4. Carefully raise the fuel tank up to the machine.

5. When the fuel tank is close to the machine, position electrical connector (23) inside the cab through the access hole for the fuel level sender.

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Illustration 5	g00939811

6. Carefully raise the fuel tank into the fuel tank's position on the machine.

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Illustration 6	g00939813
Inside of the cab

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Illustration 7	g00939814
Outside of the cab

7. Install bolts (25) and the washers in order to secure the fuel tank to the machine.

8. Remove the floor jack and any cribbing that was used from the machine.

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Illustration 8	g00939816

9. Connect fuel lines (24) to the fuel tank.

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Illustration 9	g00939817

10. Connect electrical connector (23) for the fuel level sender.

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Illustration 10	g00939218

11. Install floormat (22) into the cab. Ensure that the pedal for parking brake control (21) projects through the floormat correctly.

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Illustration 11	g00939219

12. Position panel (20) to the cab and secure the panel in place with the screws. Install the caps on the heads of the screws. For the locations of the screws, refer to the note that was made during the removal procedure.

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Illustration 12	g00939220

13. Position panel (19) to panel (20) and secure the panel in place with the screws. Install the caps on the heads of the screws. For the locations of the screws, refer to the note that was made during the removal procedure.

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Illustration 13	g00939221

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Illustration 14	g00939222

14. Lift panel (7) into the cab. Lower the right hand side of the panel into position. Ensure that the screw hole in the panel fits behind the bracket on the side of the cab. Refer to the white arrow in Illustration 14.

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Illustration 15	g00939223

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Illustration 16	g00939224

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Illustration 17	g00939244

15. Completely position panel (7) into the panel's correct position. Secure the panel in place with the screws. For the locations of the screws, refer to the note that was made during the installation procedure and to the white arrows in Illustration 16 and Illustration 17.

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Illustration 18	g00939225

16. Connect hoses (18) to panel (7) and secure the hoses in place with the clamps.

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Illustration 19	g00939227

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Illustration 20	g00939226

17. Connect electrical connectors (17) to display (16) before fitting the display into panel (7). Refer to the identification marks that were placed on the electrical connectors during the removal procedure in order to identify the correct positions of all the electrical connectors.

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Illustration 21	g00939228

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Illustration 22	g00939229

18. Connect electrical connectors (15) to switch panel (14) before fitting the switch panel into panel (7). Refer to the identification marks that were placed on the electrical connectors during the removal procedure in order to identify the correct positions of all the electrical connectors.

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Illustration 23	g00939230

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Illustration 24	g00939231

19. Position engine start switch (12) to the rear of panel (7) and secure the engine start switch in place with retaining nut (13). Note the orientation of the engine start switch with respect to the markings that identify the different positions of the engine start switch key. Refer to the white arrow in Illustration 24.

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Illustration 25	g00939232

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Illustration 26	g00939233

20. Connect electrical connectors (11) and electrical wires (10) to switch panel (9) before fitting the switch panel into panel (7). Refer to the identification marks that were placed on the electrical connectors and the electrical wires during the removal procedure in order to identify the correct positions of all the electrical connectors and the electrical wires.

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Illustration 27	g00939265

21. Install panel (8) into panel (7) .

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Illustration 28	g00939235

22. Install fuse panel (6) into panel (7) .

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Illustration 29	g00939236

23. Install handle (5) into the frame of the cab.

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Illustration 30	g00939237

24. Install stud (4), the guard and the washers into the frame of the cab.

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Illustration 31	g00939238

25. Position panel (3) into the rear of the cab. Do not install the panel into the panel's final position. Leave plenty of room for access in order to install bulkhead fitting (2) .

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Illustration 32	g00939239

26. Install bulkhead fitting (2) into panel (3) .

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Illustration 33	g00939240

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Illustration 34	g00939241

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Illustration 35	g00939242

27. install panel (3) into position in the cab. Note that the rear edge of the panel slips in front of the rear window. Refer to the white arrow in Illustration 34. Also note that the left hand edge of the panel slips behind the post for the door. Refer to the white arrow in Illustration 35.

28. Secure panel (3) in place with the screws. Install the caps on the heads of the screws. Note that some of the screws are installed with washers. For the locations of the screws and the location of the screws that are installed with washers, refer to the note that was made during the removal procedure.

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Illustration 36	g00939243

29. Install harness (1) for the joystick to bulkhead fitting (2) .

End By:

1. Install the drive shaft. Refer to Disassembly and Assembly ManualRENR5155, "Drive Shaft - Remove and Install".
2. Install the steering column. Refer to Disassembly and Assembly Manual, "Steering Column - Remove and Install".
3. Install the seat. Refer to Disassembly and Assembly Manual, "Seat - Remove and Install".
4. Fill the fuel tank. Refer to Operation and Maintenance Manual, "Fuel Tank Water and Sediment - Drain".