TH210 and TH215 Telehandlers Machine Systems Caterpillar

Removal Procedure

Start By:

1. Remove the grill and the hood. Refer to Operation and Maintenance Manual, "Engine Enclosure - Remove and Install".

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Cylinders equipped with lock valves can remain pressurized for very long periods of time, even with the hoses removed. Failure to relieve pressure before removing a lock valve or disassembling a cylinder can result in personal injury or death. Ensure all pressure is relieved before removing a lock valve or disassembling a cylinder.

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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.

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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. Make sure all of the attachments have been lowered to the ground, and the 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.

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Illustration 1	g00946216

1. Start the engine and install Tooling (A) under the boom head in order to support the boom assembly. Refer to Illustration 1. Make sure that Tooling (A) is fully extended. Shut off the engine.

2. Unlock the latch that secures the door to the engine enclosure. Open the door in order to allow complete access to the engine enclosure.

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Illustration 2	g00946217

3. Loosen clamp (1) in order to disconnect elbow (2) for muffler (3) from the engine.

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Illustration 3	g00946218

4. Attach a suitable nylon lifting sling around muffler (3) and to a suitable hoist in order to support the weight of the muffler and panel (4). The weight of the muffler and panel is approximately 34 kg (75 lb).

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Illustration 4	g00946219

5. Remove bolts (5), the washers, bolts (6), the nuts and the washers that secure panel (4) and the attached muffler to the machine.

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Illustration 5	g00946220

6. Use the attached lifting equipment in order to remove muffler (3) and panel (4) from the machine. Place the muffler and the panel on suitable cribbing before removing the lifting equipment.

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Illustration 6	g00946222

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Illustration 7	g00946223

7. Use the following procedure to remove compressor (9) for the air conditioning system (if equipped).

   Note: Do not disconnect any of the hoses that are connected to the compressor.

   1. Disconnect electrical wire (11) for compressor (9) .

   2. Loosen bolt (8), bolt (10) and bolt (12) in order to slacken the tension on belt (7). Remove the belt from compressor (9) and the engine.

   3. Remove bolt (8) and bolt (12) with the nuts and the washers in order to disconnect compressor (9) from the top of the engine.
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   Illustration 8	g00946224

   4. Carefully move compressor (9) to the front of the machine. Place the compressor in a position so that the attached hoses are not pulled and the compressor will not move.

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Illustration 9	g00946227

8. Attach a suitable nylon lifting sling around the boom cylinder and the boom. Attach the nylon lifting sling to a suitable hoist. Use the attached lifting equipment to support the weight of the boom cylinder. The weight of the boom cylinder is approximately 80 kg (176 lb).

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Illustration 10	g00946228

9. Remove bolt (15) and the washer. Remove bolt (13), the washer and spacer (14) (not shown) that secures pin (16) in place.

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Illustration 11	g00946229

10. Install Tooling (B) to pin (16) before using the Tooling to remove the pin.

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Illustration 12	g00946230

11. Use the attached lifting equipment in order to carefully lower the boom cylinder onto some suitable cribbing.

12. Remove the lifting equipment from the boom cylinder.

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Illustration 13	g00946506

13. Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release".

14. Release the pressure in the boom cylinder. Refer to Testing and Adjusting, RENR5159, "Hydraulic System Pressure - Release".

15. Disconnect hoses (17) from the boom cylinder at the elbow fittings.

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Illustration 14	g00946507

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Illustration 15	g00946508

16. Attach two suitable nylon lifting slings around the boom cylinder and a suitable hoist. The weight of the boom cylinder is approximately 80 kg (176 lb). Take up the tension on the lifting slings but do not lift the boom cylinder.

    Note: Install a suitable shackle between the eye of the nylon lifting sling which is attached to the head end of the cylinder and the hoist. This will lift the boom cylinder at an angle which will assist in the removal of the boom cylinder.

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Illustration 16	g00946509

17. Remove bolt (19), the washer and spacer (20) (not shown) that secures pin (18) in place.

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Illustration 17	g00946510

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Illustration 18	g00946511

18. Position a suitable driver through the two holes on the left of the frame and to the back of pin (18). Use a suitable mallet and the drive in order to remove the pin.

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Illustration 19	g00946512

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Illustration 20	g00946513

19. Use the attached lifting equipment to carefully raise the head end of the boom cylinder out of the mounting on the frame.

20. Remove the cribbing that was installed in Step 11.

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Illustration 21	g00946514

21. Use the attached lifting equipment to carefully maneuver the boom cylinder out of the front of the machine.

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Illustration 22	g00946515

22. Place the boom cylinder on suitable cribbing before removing the lifting equipment.

Installation Procedure

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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 23	g00946515

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Illustration 24	g00946847

2. Attach two suitable nylon lifting slings around the boom cylinder and a suitable hoist. The weight of the boom cylinder is approximately 80 kg (176 lb). Take up the tension on the lifting slings but do not lift the boom cylinder.

   Note: Install a suitable shackle between the eye of the nylon lifting sling which is attached to the head end of the cylinder and the hoist. This will lift the boom cylinder at an angle which will assist in the removal of the boom cylinder.

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Illustration 25	g00946514

3. Use the attached lifting equipment to carefully maneuver the boom cylinder to the front of the machine.

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Illustration 26	g00946512

4. Use the attached lifting equipment to carefully position the eye of the head end of the boom cylinder to the mounting on the frame.

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Illustration 27	g00946510

5. Line up the bore on the cylinder with the bores on the frame of the machine. Lubricate pin (18) with 5P-0960 Molybdenum Grease before using a suitable mallet to install the pin.

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Illustration 28	g00946509

6. Install bolt (19), the washer and spacer (20) (not shown) that secures pin (18) in place.

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Illustration 29	g00946513

7. Use the attached lifting equipment to carefully lower the boom cylinder onto suitable cribbing. Remove the lifting equipment from the boom cylinder.

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Illustration 30	g00946506

8. Connect hoses (17) to the boom cylinder at the elbow fittings.

9. Check the hydraulic tank oil level. Refer to Operation and Maintenance Manual, "Hydraulic Tank - Check Oil Level".

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Illustration 31	g00946230

10. Attach one end of a suitable nylon lifting sling to a suitable hoist. Feed the opposite end of the sling down one side of the boom. Then feed the sling around boom cylinder and up the opposite side of the boom to the hoist. The weight of the boom cylinder is approximately 80 kg (176 lb).

11. Take up the tension on the sling in order to support the boom cylinder before removing the cribbing.

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Illustration 32	g00946851

12. Use the hoist in order to lift the boom cylinder into position. With the aid of a second person, start the engine and extend the boom cylinder. Align the bore in the boom cylinder with the bores in the boom. Stop the engine.

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Illustration 33	g00946852

13. Lubricate pin (16) with 5P-0960 Molybdenum Grease before using a suitable mallet and a suitable driver to install the pin.

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Illustration 34	g00946228

14. Install bolt (15) and the washer. Install bolt (13), the washer and spacer (14) (not shown) that secures pin (16) in place.

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Illustration 35	g00946227

15. Remove the lifting equipment from the boom cylinder.

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Illustration 36	g00946224

16. Use the following procedure to install compressor (9) for the air conditioning system (if equipped).

    1. Carefully move compressor (9) from the front of the machine to the back of the engine. Ensure that none of the hoses for the compressor are twisted.
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    Illustration 37	g00946222

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    Illustration 38	g00946223

    2. Install bolt (8), bolt (12), the nuts and the washers in order to secure compressor (9) to the top of the engine. Ensure that bolt (8), bolt (10) and bolt (12) are left loose.

    3. Position belt (7) onto compressor (9) and the engine before adjusting the position of the compressor in order to tension the belt. Check the tension of the belt midway between the compressor and the crankshaft pulley. A belt that is tensioned correctly will deflect approximately 10 mm (0.4 inch). Move the compressor until the tension in the belt is at the correct setting before tightening bolt (8), bolt (10) and bolt (12) in order to secure the compressor in position.

       Note: If a new belt is installed, the tension in the belt should be checked after 30 minutes of operation.

    4. Connect electrical wire (11) for compressor (9) .

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Illustration 39	g00946220

17. Attach a suitable nylon lifting sling around muffler (3) and to a suitable hoist in order to lift the muffler and panel (4). The weight of the muffler and panel is approximately 34 kg (75 lb).

18. Use the attached lifting equipment in order to position muffler (3) and panel (4) onto the machine.

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Illustration 40	g00946217

19. Position elbow (2) for muffler (3) to clamp (1). Do not tighten the clamp at this step.

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Illustration 41	g00946219

20. Install bolts (5), the washers, bolts (6), the nuts and the washers in order to secure panel (4) and the attached muffler to the machine.

21. Tighten clamp (1) that was left loose in step 19.

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Illustration 42	g00946218

22. Remove the lifting equipment from muffler (3) and panel (4) .

23. Close the door to the engine enclosure and lock the door in place with the latch.

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Illustration 43	g00946216

24. Start the engine. Raise the boom head in order to remove Tooling (A). Refer to Illustration 43. After the Tooling is removed, lower the boom fully. Shut off the engine.

End By:

1. Lubricate the pins of the boom cylinder. Refer to Operation and Maintenance Manual, "Boom Cylinder Pin - Lubricate".
2. Install the grill and the hood. Refer to Operation and Maintenance Manual, "Engine Enclosure - Remove and Install".