TH210 and TH215 Telehandlers Machine Systems Caterpillar

Assembly 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 1	g00905005

2. Install wear pad (28) and wear pad (29) with one 2 mm (0.08 inch) shim under each wear pad. Install retainers (27) in order to secure the wear pads to outer boom section (6) .

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Illustration 2	g00904600
Locations of the six paths for the wear pads

3. Use a roller with a long handle to apply a layer of 5P-0960 Molybdenum Grease along the full inside length of the outer boom section. Apply the grease along the six paths for the wear pads.

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Illustration 3	g00905004

4. Install one 1 mm (0.04 inch) shim and one 2 mm (0.08 inch) shim between wear pad (25) and inner boom section (7). Install taperlock studs (23), the washers and locknuts (24) in order to secure the wear pad to the inner boom section.

5. Repeat Step 4 for wear pad (26) .

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Illustration 4	g00905003
Location of the nylon lifting slings

6. Attach two suitable nylon lifting slings and a suitable hoist to inner boom section (7). The weight of the inner boom section is approximately 360 kg (795 lb).

7. Use the attached lifting equipment to slide inner boom section (7) inside the front of outer boom section (6) until the nylon lifting slings come into contact with the outer boom section. Install a suitable stand under the head of the inner boom section and then remove the lifting equipment.

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Illustration 5	g00904980
Location of the nylon lifting sling

8. Attach a suitable nylon lifting sling and a suitable hoist to the head of inner boom section (7). The weight of the inner boom section is approximately 360 kg (795 lb).

9. Use the attached lifting equipment to slide inner boom section (7) fully into outer boom section (6) .

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Illustration 6	g00904604

10. Install wear pad (22), button head screws (19) and the washers onto inner boom section (7) .

    Note: Do not install any shims between the wear pad and the inner boom section.

11. Install wear pad (21), button head screws (20) and the washers onto inner boom section (7) .

    Note: Do not install any shims between the wear pad and the inner boom section.

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Illustration 7	g00904995

12. Use suitable pry bar to push inner boom section (7) to the left until the left wear pad is in contact with outer boom section (6) .

13. Measure the distance between the right wear pad and outer boom section (6) by inserting as many shims as possible.

14. Remove one 1 mm (0.04 inch) shim.

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Illustration 8	g00904606

15. Install half of the remaining shims between right wear pad (21) and inner boom section (7). Save the rest of the shims for Step 17.

16. Use a suitable pry bar to push inner boom section (7) to the right until right wear pad (21) is in contact with outer boom section (6) .

17. Install the other half of the remaining shims between left wear pad (22) and inner boom section (7) .

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Illustration 9	g00904994

18. Install wear pad (16), taperlock studs (18), the washers and locknuts (18) .

    Note: Install the wear pad without any shims.

19. Measure the distance between wear pad (16) and outer boom section (6) by inserting as many shims as possible.

20. Remove one 1 mm (0.04 inch) shim.

21. Install the remaining shims between wear pad (16) and inner boom section (7) .

22. Repeat Step 18 to Step 21 in order to install wear pad (15) .

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Illustration 10	g00905002

23. Use the attached lifting equipment to slide inner boom section (7) approximately 30 cm (12 inch) from outer boom section (6) .

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Illustration 11	g00904609

24. Install wear pad (11) and measure the distance between the wear pad and inner boom section (7) by inserting as many shims as possible.

25. Remove one 1 mm (0.04 inch) shim.

26. Install the remaining shims between wear pad (11) and outer boom section (6) .

27. Install retainer (12) in order to secure wear pad (11) and the shims onto outer boom section (6) .

28. Repeat Step 24 to Step 27 in order to install wear pad (10) .

29. Install wear pad (8) between inner boom section (7) and outer boom section (6) .

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Illustration 12	g00904610

30. Use a suitable pry bar to push inner boom section (7) to the left until the inner boom section is in contact with the wear pad.

31. Install wear pad (14) and measure the distance between the wear pad and inner boom section (7) by inserting as many shims as possible.

32. Remove one 1 mm (0.04 inch) shim.

33. Install half of the remaining shims between wear pad (14) and outer boom section (6). Save the rest of the shims for Step 35.

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Illustration 13	g00904611

34. Install retainer (13) in order to secure wear pad (14) and the shims onto outer boom section (6) .

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Illustration 14	g00904987

35. Install the other half of the remaining shims between wear pad (8) and outer boom section (6) .

36. Install retainer (9) in order to secure wear pad (8) and the shims onto outer boom section (6) .

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Illustration 15	g00905002

37. Use the attached lifting equipment to fully insert inner boom section (7) into outer boom section (6), before removing the lifting equipment from the boom.

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Illustration 16	g00905151

38. Install bolts (3) and the washers in order to install brackets (5) and lights (1) onto outer boom section (6) .

39. Install wiring harness (2) along the bottom of the boom. Secure the wiring harness in place with cable straps. For the route of the wiring harness along the bottom of the boom, refer to the note that was made during the removal procedure. For the number and the position of the cable straps, refer to the note that was made during the removal procedure.

40. Connect wiring harness (2) to the rear of lights (1). Connect the wiring harness to auxiliary connector (4). Refer to the identification marks that were placed on the electrical connectors during the disassembly procedure in order to correctly identify the positions of each of the electrical connectors.

End By:

1. Install the telescoping cylinder. Refer to Disassembly and Assembly, "Telescoping Cylinder - Remove and Install".
2. Install the tilt cylinder. Refer to Disassembly and Assembly, "Tilt Cylinder - Remove and Install".
3. Install the boom onto the machine. Refer to Disassembly and Assembly, "Boom - Install".