TH210 and TH215 Telehandlers Power Train Caterpillar

Removal Procedure

1. Put identification marks on all wires and all connectors for installation purposes.
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   Illustration 1	g00931527

2. Remove cover (1).
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   Illustration 2	g00931528

3. Remove cotter pin (2). Remove pin (5) and the washer and loosen adjusting nuts (3) in order to disconnect parking brake control cable (4) from the parking brake control.
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   Illustration 3	g00931529

4. Disconnect electrical wires (6) from the parking brake control. Place identification marks on the electrical wires in order to clearly identify the correct electrical wires that must be connected to the correct terminals for the purpose of installation. Move the electrical wires aside.
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   Illustration 4	g00931530

5. Loosen bolts (7) and the washers that secure the parking brake control to the frame of the cab. Wind the bolts halfway down the mounting studs in order to allow some movement of the parking brake control.
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   Illustration 5	g00931531

6. In order to remove the parking brake control, it will be necessary to remove floormat (8). Perform the following steps in order to remove the floormat.

   1. Remove the steering column. Refer to Disassembly and Assembly Manual, "Steering Column - Remove and Install".

   2. Remove the seat. Refer to Disassembly and Assembly Manual, "Seat - Remove and Install".
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      Illustration 6	g00933021

   3. Remove harness (9) for the joystick from bulkhead fitting (10).
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      Illustration 7	g00933018

   4. Remove the screws and the washers that secure panel (11) to the cab. It will be necessary to remove the caps from the heads of the screws first. Place the caps in a safe place. Reuse the caps during the installation procedure. Make a note of the location of all the screws and washers for the purpose of installation.

   5. Dislodge panel (11) from the panel's location in the cab.
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      Illustration 8	g00933017

   6. Remove bulkhead fitting (10) from panel (11).
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      Illustration 9	g00932895

   7. Remove panel (11) from the cab. Move bulkhead fitting (10) aside.
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      Illustration 10	g00932894

   8. Remove stud (12), the guard and the washers from the frame of the cab.
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      Illustration 11	g00932893

   9. Remove handle (13) from the frame of the cab.
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      Illustration 12	g00932892

   10. Remove fuse panel (14) from panel (15).
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       Illustration 13	g00932889

   11. Remove panel (16) from panel (15).
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       Illustration 14	g00932888

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       Illustration 15	g00932834

   12. Pull switch panel (17) out of panel (15). Disconnect electrical connectors (19) and electrical wires (18) from the switch panel before removing the switch panel from the cab. Place identification marks on all the electrical connectors and electrical wires in order to identify the correct positions of all the electrical connectors and the electrical wires for the purpose of installation.
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       Illustration 16	g00932832

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       Illustration 17	g00932833

   13. Remove retaining nut (21) that secures engine start switch (20) to panel (15). Move the engine start switch aside. Note the orientation of the engine start switch with respect to the markings that identify the different positions of the engine start switch key for the purpose of installation. Refer to the white arrow in Illustration 17.
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       Illustration 18	g00932831

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       Illustration 19	g00932830

   14. Pull switch panel (22) out of panel (15). Disconnect electrical connectors (23) from the switch panel before removing the switch panel from the cab. Place identification marks on the electrical connectors in order to identify the correct positions of all the electrical connectors for the purpose of installation.
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       Illustration 20	g00932829

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       Illustration 21	g00932513

   15. Pull display (24) out of panel (15). Disconnect electrical connectors (25) from the display before removing the display from the machine. Place identification marks on the electrical connectors in order to identify the correct positions of all the electrical connectors for the purpose of installation.
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       Illustration 22	g00932511

   16. Loosen the clamps that secure hoses (26) in place. Disconnect the hoses from panel (15).
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       Illustration 23	g00932503

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       Illustration 24	g00932506

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       Illustration 25	g00932510

   17. Remove the screws that secure panel (15) in position. For the locations of the screws, refer to the white arrows in Illustration 24 and Illustration 25. Make a note of the location of the screws for the purpose of installation.
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       Illustration 26	g00932499

   18. Lift the left hand side of panel (15) first before removing the panel from the cab.
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       Illustration 27	g00932498

   19. Remove the screws and the washers that secure panel (27) to panel (28). It will be necessary to remove the caps from the heads of the screws first. Place the caps in a safe place. Reuse the caps during the installation procedure. Make a note of the location of all the screws and washers for the purpose of installation.

   20. Dislodge panel (27) from the panel's position on top of panel (28). Do not remove panel (27).
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       Illustration 28	g00932497

   21. Remove the screws and the washers that secure panel (28) to the cab. It will be necessary to remove the caps from the heads of the screws first. Place the caps in a safe place. Reuse the caps during the installation procedure. Make a note of the location of all the screws and washers for the purpose of installation.
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       Illustration 29	g00940115

   22. Dislodge the bottom of panel (28) from the side of cab. Move the panel to one side. Do not remove the panel.
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       Illustration 30	g00940116

   23. Remove floormat (8) carefully from the cab. Take care to pull the floormat around the parking brake control.
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   Illustration 31	g00932366

7. Remove bolts (7) and the washers in order to remove the parking brake control from the underside of the machine.

Installation Procedure

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 32	g00932366

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   Illustration 33	g00932367

2. Position the parking brake control to the underside of the machine.

3. Install bolts (7) and the washers that secure the parking brake control to the frame of the cab. Install the bolts halfway up the mounting studs for the parking brake control. Do not tighten the bolts at this step in order to give the parking brake control some free movement.
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   Illustration 34	g00931531

4. In order to remove the parking brake control, it was necessary to remove floormat (8). Perform the following steps in order to install the floormat.
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   Illustration 35	g00940116

   1. Install floormat (8) into the cab. Ensure that the pedal for the parking brake control projects through the floormat correctly.
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      Illustration 36	g00932497

   2. Position panel (28) 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 37	g00932498

   3. Position panel (27) to panel (28) 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 38	g00932499

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      Illustration 39	g00932500

   4. Lift panel (15) into the cab. Lower the left 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 39.
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      Illustration 40	g00932503

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      Illustration 41	g00932506

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      Illustration 42	g00932510

   5. Completely position panel (15) 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 41 and Illustration 42.
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      Illustration 43	g00932511

   6. Connect hoses (26) to panel (15) and secure the hoses in place with the clamps.
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      Illustration 44	g00932513

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      Illustration 45	g00932829

   7. Connect electrical connectors (25) to display (24) before fitting the display into panel (15). 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 46	g00932830

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      Illustration 47	g00932831

   8. Connect electrical connectors (23) to switch panel (22) before fitting the switch panel into panel (15). 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 48	g00932832

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      Illustration 49	g00932833

   9. Position engine start switch (20) to the rear of panel (15) and secure the engine start switch in place with retaining nut (21). 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 49.
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      Illustration 50	g00932834

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      Illustration 51	g00932888

   10. Connect electrical connectors (19) and electrical wires (18) to switch panel (17) before fitting the switch panel into panel (15). 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 52	g00932889

   11. Install panel (16) into panel (15).
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       Illustration 53	g00932892

   12. Install fuse panel (14) into panel (15).
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       Illustration 54	g00932893

   13. Install handle (13) into the frame of the cab.
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       Illustration 55	g00932894

   14. Install stud (12), the guard and the washers into the frame of the cab.
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       Illustration 56	g00932895

   15. Position panel (11) 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 (10).
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       Illustration 57	g00933017

   16. Install bulkhead fitting (10) into panel (11).
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       Illustration 58	g00933018

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       Illustration 59	g00933019

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       Illustration 60	g00933020

   17. Install panel (11) 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 59. Also note that the left hand edge of the panel slips behind the post for the door. Refer to the white arrow in Illustration 60.

   18. Secure panel (11) 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 61	g00933021

   19. Install harness (9) for the joystick to bulkhead fitting (10).

   20. Install the seat. Refer to Disassembly and Assembly Manual, "Seat - Remove and Install".

   21. Install the steering column. Refer to Disassembly and Assembly Manual, "Steering Column - Remove and Install".
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   Illustration 62	g00931530

5. Tighten bolts (7) in order to secure the parking brake control in place.
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   Illustration 63	g00931529

6. Connect electrical wires (6) to the parking brake control. Use the identification marks that were placed on the wires during the removal procedure to clearly identify the correct wires to connect to the correct terminals.
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   Illustration 64	g00931528

7. Position parking brake control cable (4) to the parking brake control. Install adjusting nuts (3) in order to temporarily secure the parking brake control cable to the parking brake control. Install pin (5) in order to secure the end of the parking brake control cable to the parking brake control. Install cotter pin (2) in order to secure the pin in place.

8. Adjust the positions of adjusting nuts (3) in order to position parking brake control cable (4) correctly. Refer to Systems Operation, Testing and Adjusting, RENR5156, "Braking System", "Parking Brake Control Cable - Adjust".
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   Illustration 65	g00931527

9. Install cover (1).