TH62, TH63, TH82, TH83 and TH103 Telehandlers Machine Systems Caterpillar

Assembly Procedure

Note: Inspect all parts and clean all parts. If any parts are worn or damaged, use new Caterlillar parts for replacement.

Note: The bolts that are used to secure the wear pads to the boom sections will vary in length. Install a longer bolt if you install a large number of shims.

Outer Boom Section

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Illustration 1	g00750960

1. Install the two lower front wear pads (1). Apply a small amount of 9S-3263 Thread Lock Compound onto four bolts (2). Install the four bolts (2) and the washers. Tighten the four bolts to a torque of 70 ± 5 N·m (52 ± 4 lb ft).

2. Install the two upper side front wear pads (3) with one 1.5mm shim under each wear pad. Apply a small amount of 9S-3263 Thread Lock Compound onto four bolts (4). Install the four bolts (4) and the washers. Tighten the four bolts to a torque of 70 ± 5 N·m (52 ± 4 lb ft).

3. Install the two lower side front wear pads (5). Install the four bolts (6) and the washers but do not tighten the bolts.

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Illustration 2	g00750959

4. Use tool (A) or a suitable driver with a copper hammer in order to install two bushings (7).

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Illustration 3	g00750958

5. Install one coupling (8) and one O-ring on one end of each hose for hydraulic oil lines (9) .

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Illustration 4	g00750957

6. Lay hydraulic oil lines (9) along either side of outer boom section (10). Position each hydraulic oil line so that coupling (8) protrudes from the hole in the underside of outer boom section (10) .

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Illustration 5	g00750956
Apply the grease onto the outer boom section along the paths for the wear pads.

7. Use a roller with a long handle to apply a layer of 5P-0960 Molybdenum Grease along the full length of outer boom section (10) .

Boom Head

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Illustration 6	g00751328

1. Install the lower rear wear pad (11). Apply a small amount of 9S-3263 Thread Lock Compound onto two bolts (12). Install two bolts (12) and the washers. Tighten the two bolts to a torque of 70 ± 5 N·m (52 ± 4 lb ft).

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Illustration 7	g00751329

2. Use tool (B) to install two bearing sleeves (13) .

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Illustration 8	g00751330

3. Use tool (A) and tool (C) to install four lip seals (14) .

4. Install the tilt cylinder into the boom head. Refer to Disassembly and Assembly, "Tilt Cylinder - Install".

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Illustration 9	g00751331

5. Install two mounting brackets (15). Apply a small amount of 9S-3263 Thread Lock Compound onto four screws (16) and secure mounting brackets (15) into position.

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Illustration 10	g00751332
Apply the grease onto the boom head along the path for the lower wear pad of the telescoping cylinder.

6. Use a roller with a long handle to apply a layer of 5P-0960 Molybdenum Grease along the full length of boom head (17) .

7. Install the telescoping cylinder into the boom head. Install the pin and the snap rings in order to secure the rod end of the telescoping cylinder in position. Refer to Disassembly and Assembly, "Telescoping Cylinder - Install".

Boom Assembly

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Illustration 11	g00751483

1. Attach two suitable slings and a hoist to boom head (17). Carefully install the boom head into outer boom section (10). Allow the boom head to protrude from the outer boom section by 650mm. The weight of the boom head is 865 kg (1910 lb).

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Illustration 12	g00751696

2. Install the right front top wear pad.

   1. Slide wear pad (18) between outer boom section (10) and boom head (17). Measure the distance between the top of wear pad (18) and the outer boom section by inserting as many shims as possible.

   2. Remove one 0.75mm thick shim.

   3. Use 8T-9021 Adhesive in order to attach the remaining shims to the underside of wear pad (18) .

   4. Use tool (D) to install wear pad (18) and the shims into position. Apply a small amount of 9S-3263 Thread Lock Compound onto two bolts (19). Install the two bolts (19) and the washers. Tighten the two bolts to a torque of 70 ± 5 N·m (52 ± 4 lb ft).

   5. The distance between the top of wear pad (18) and outer boom section (10) should be no less than 0.75mm and no greater than 3.0mm.

3. Repeat steps 2.a through 2.e for the left front top wear pad.

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Illustration 13	g00751713

4. Install the lower front wear pads.

   1. Use tool (E) to push boom head (17) to the left until the boom head is contact with left side lower wear pad.
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   Illustration 14	g00751778

   2. Use tool (D) to remove right side lower wear pad (20) .
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   Illustration 15	g00751800

   3. Slide wear pad (20) between outer boom section (10) and boom head (17). Measure the distance between the top of wear pad (20) and the outer boom section by inserting as many shims as possible.

   4. Remove one 1.5mm thick shim.

   5. Use 8T-9021 Adhesive in order to attach half the remaining thickness of shims to the underside of wear pad (20) .
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   Illustration 16	g00751778

   6. Use tool (D) to install wear pad (20) and the shims into position. Apply a small amount of 9S-3263 Thread Lock Compound onto two bolts (21). Install two bolts (21) and the washers. Tighten the two bolts to a torque of 70 ± 5 N·m (52 ± 4 lb ft).

   7. Use tool (E) to push boom head (17) to the right until the boom head is contact with right side lower wear pad (20) .

   8. Use tool (D) to remove the left side lower wear pad. Repeat steps 4.e through 4.f in order to install the left side lower wear pad.

   9. Repeat step 4.a. The distance between the top of wear pad (20) and outer boom section (10) should be no less than 1.5mm and no greater than 3.0mm.

5. With the aid of a second person, push boom head (17) back into outer boom section (10) .

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Illustration 17	g00752012

6. Repeat steps 2.a through 2.e in order to install upper rear wear pads (21), bolts (22) and the washers.

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Illustration 18	g00752015

7. Install the upper rear side wear pads.

   1. Insert wear pad (23) between the right side of outer boom section (10) and boom head (17). At the same time use tool (E) to push boom head (17) to the right until wear pad (23 ) is wedged in position.
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   Illustration 19	g00752018

   2. Slide wear pad (24) between outer boom section (10) and boom head (17). Measure the distance between the top of wear pad (24) and the outer boom section by inserting as many shims as possible.

   3. Remove one 1.5mm thick shim.

   4. Use 8T-9021 Adhesive in order to attach half the remaining thickness of shims to the underside of wear pad (24) .
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   Illustration 20	g00752028

   5. Use tool (D) to install wear pad (24) and the shims into position. Apply a small amount of 9S-3263 Thread Lock Compound onto two screws (25). Install the two screws (25) and the washers. Tighten the two screws to a torque of 70 ± 5 N·m (52 ± 4 lb ft).

   6. Use tool (E) to push boom head (17) to the left until the boom head is contact with left upper side wear pad (24) .

   7. Repeat steps 7.d through 7.e in order to install upper right side wear pad (23) .

   8. The distance between the top of wear pad (23) and outer boom section (10) should be no less than 1.5mm and no greater than 3.0mm.

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Illustration 21	g00752116

8. Install two half clamps (26), the bolt, the washer, and the nut in position (X) on tubes (27) and tubes (28). Install two half clamps (26), the bolt, the washer, and the nut in position (Y) on tubes (27) and tubes (28).
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   Table 2

   Distance (X)	610 mm (24 inch)
   Distance (Y)	3160 mm (124 inch)

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Illustration 22	g00752297

9. Install one pair of tubes (27) into the left side of boom head (17). Install one pair of tubes (28) into the right side of boom head (17). The longest tube is positioned on the right side of the shorter tube. Install two clamps (29), the plates and the bolts that support the rear of the tubes.

10. With the aid of a second person, connect the hoses for the hydraulic oil lines onto the tubes and clip the end of each cage (30) into each mounting bracket (15). Install the clamps, the plates and the bolts that secure the front of the two pairs of tubes in position. Refer to Disassembly and Assembly, "Hydraulic Oil Lines (Boom) - Install".

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Illustration 23	g00752298

11. Install four tubes (31), four clamps (32) and the bolts but do not tighten the bolts. Connect the four couplings for the hydraulic oil lines onto four tubes (31). Slide tubes (31) rearward until the rear face of the front nut is a distance of 130mm away from the front face of front clamp (32) .

12. Install the bracket, the shims, the hydraulic lines and the cover for the rear of the boom. Refer to Disassembly and Assembly, "Telescoping Cylinder - Install".

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Illustration 24	g00752300

13. Install diverter valve (33), mounting bracket (34) and hydraulic lines (35). Refer to Disassembly and Assembly, "Diverter Valve (Boom Head) - Remove and Install".

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Illustration 25	g00752299

14. Use tool (E) to push the boom head left until the boom head is in contact with the left side wear pads. Install switch (36), shims (37), four bolts and the washers. Install enough shims so that the distance between the back of wheel (38) and the boom head (17) should be no less than 5mm and no greater than 8mm. Connect harness (39) and secure the harness onto outer boom section (10) with cable straps. Install the cover, four bolts and the washers.

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Illustration 26	g00752320

15. Install boom angle indicator (40), two screws (41) and the washers. Install pointer (42), two screws (43) and the washers. Install two lights (44) and harness (45). Secure the harness onto outer boom section (10) with cable straps.

End By: Install the boom onto the machine. Refer to Disassembly and Assembly, "Boom - Install".