TH210 and TH215 Telehandlers Machine Systems Caterpillar

Removal Procedure

Start By:

1. Raise the boom and install the boom cylinder lock. Refer to Operation and Maintenance Manual, "Boom Cylinder Lock - Removal and Installation Procedures".
2. Apply the foot brake valve several times in order to relieve the pressure in the brake system. Refer to Systems Operation, Testing and Adjusting, RENR5156, "Machine Preparation for Troubleshooting".
3. Remove the hood, the door and the grill from the engine enclosure. Refer to Disassembly and Assembly Manual, RENR5153, "Engine Enclosure - Remove and Install".
4. Remove the battery. Refer to Disassembly and Assembly Manual, RENR5153, "Battery - Remove and Install".
5. Remove the upper hydraulic tank. Refer to Disassembly and Assembly Manual, "Hydaulic Tank - Remove".
6. Remove the bottom guard. Refer to Disassembly and Assembly Manual, "Sump Guard - Remove and Install".

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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 work tools 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.

1. Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, all hoses and all tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.

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Illustration 1	g00984285

2. Disconnect electrical wires (2) from window washer reservoir (1) .

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Illustration 2	g00984287

3. Disconnect lines (4) for the window washers at the connections to valves (3). Cut the cable straps that secure the lines to the underside of the machine and move the lines aside. Make a note of the number and the location of all the cable straps for the purpose of installation.

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Illustration 3	g00984288

4. Cut the cable straps that secure fuses (5) to battery tray (6). Make a note of the number and location of all the cable straps for the purpose of installation.

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Illustration 4	g00984289

5. Cut the cable straps that secure electrical component (7) to battery tray (6). Make a note of the number and location of the cable straps for the purpose of installation.

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Illustration 5	g00984290

6. Remove bolts (9), the nuts and the washers that secure the accumulator charging valve (8) to the battery tray (6) .

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Illustration 6	g00984291

7. Remove bolts (11), the nuts and the washers that secure battery tray (6) to post (10) .

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Illustration 7	g00984292
Position of nylon lifting sling

8. Attach a suitable nylon lifting sling and a suitable hoist to battery tray (6). Refer to the white arrow in Illustration 7. Use the attached lifting equipment to support the weight of the battery tray. The weight of the battery tray is approximately 24 kg (53 lb).

9. Remove bolts (12), the nuts, the washers, bolts (13), and the washers that secure battery tray (6) onto the machine.

10. Use the attached lifting equipment to remove battery tray (6) from the machine. Place the battery tray on suitable cribbing. Remove the nylon lifting sling and the hoist from the battery tray.

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Illustration 8	g00984275
The accumulator charging valve has been removed for photographic clarity.

11. Disconnect hoses (14) from the trailer brake valve.

12. Remove bolts (15) (not shown) and the washers in order to remove the trailer brake valve from the machine.

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 9	g00984275
The accumulator charging valve has been removed for photographic clarity.

2. Position the trailer brake valve to the frame of the machine. Install bolts (15) (not shown) and the washers in order to secure the trailer brake valve to the frame of the machine.

3. Connect hoses (14) to the trailer brake valve.

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Illustration 10	g00984295
Position of nylon lifting sling

4. Attach a suitable nylon lifting sling and a suitable hoist to battery tray (6). The weight of the battery tray is approximately 24 kg (53 lb).

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Illustration 11	g00984292

5. Use the attached lifting equipment to carefully position battery tray (6) to the machine. Secure the battery tray in position with bolts (12), the nuts, the washers, bolts (13) and the washers.

6. Remove the nylon lifting sling and the hoist from battery tray (6) .

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Illustration 12	g00984291

7. Install bolts (11), the nuts and the washers that secure battery tray (6) to post (10) .

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Illustration 13	g00984290

8. Position accumulator charging valve (8) to battery tray (6). Secure the accumulator charging valve in position with bolts (9), the nuts and washers.

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Illustration 14	g00984289

9. Position electrical component (7) to battery tray (6) before securing the electrical component in place with new cable straps. For the location and the number of the cable straps, refer to the note that was made during the removal procedure.

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Illustration 15	g00984288

10. Position fuses (5) onto battery tray (6) before securing the fuses in place with new cable straps. For the location and the number of the cable straps, refer to the note that was made during the removal procedure.

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Illustration 16	g00984287

11. Connect lines (4) for the window washers at the connections to valves (3). Install new cable straps in order to secure the lines to the underside of the machine. For the location and the number of the cable straps, refer to the note that was made during the removal procedure.

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Illustration 17	g00984285

12. Connect electrical wires (2) to window washer reservoir (1) .

End By:

1. Install the battery. Refer to Disassembly and Assembly ManualRENR5153, "Battery - Remove and Install".
2. Install the upper hydraulic tank. Refer to Disassembly and Assembly Manual, "Hydaulic Tank - Install".
3. Install the hood, the door and the grill from the engine enclosure. Refer to Disassembly and Assembly ManualRENR5153, "Engine Enclosure - Remove and Install".
4. Install the bottom guard. Refer to Disassembly and Assembly Manual, "Sump Guard - Remove and Install".
5. Remove the boom cylinder lock and lower the boom. Refer to Operation and Maintenance Manual, "Boom Cylinder Lock - Removal and Installation Procedures".
6. Check the hydraulic tank oil level. Refer to Operation and Maintenance Manual, "Hydraulic Tank - Check Oil Level".
7. Purge the service brake system of air. Refer to System Operations, Testing and AdjustingRENR5156, "Service Brake Air - Purge".