Caterpillar Cat Th360b Th560b Telehandler Service Repair Manual
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Caterpillar Cat Th360b Th560b Telehandler Service Repair Manual
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- Caterpillar Cat Th360b Th560b Telehandler Service Repair Manual
- The logic for the longitudinal stability indicator processed by the machine ECM. The machine ECM receives data from the sensor. The sensor data and other data from the machine ECM is used by the machine ECM to formulate a value that is sent to the gauge on the instrument cluster.
- While the longitudinal stability indicator is in the green zone (2) no further outputs are needed because the green zone (2) is the normal operating range. When the longitudinal stability indicator enters the amber zone (3) an alarm will buzz continuously.
- This indicates that the limit for the longitudinal stability of the machine has been reached. Extra caution is necessary. Do not increase the outreach of the load. As the longitudinal stability indicator moves into the red zone (4), the audible alarm output starts to buzz constantly and the visual alarm will begin to light (1).
- This indicates that the limit for the longitudinal stability of the machine has been exceeded. When this condition occurs do not proceed with the lift operation. Retract the boom if the boom is extended. Lower the boom if the boom is elevated.
TABLE OF CONTENTS:
Caterpillar Cat Th360b Th560b Telehandler Service Repair Manual
31200264 TH360B_TH560B Service Manual..................................................................................... 1 31200265_Contents of 31200264......................................................................................... 1 TORQUE SPECIFICATIONS................................................................................................. 23 31200268_Torque Specifications.................................................................................... 2 Table of Contents............................................................................................. 4 Specifications Section........................................................................................ 6 General Information....................................................................................... 6 Introduction to Torque................................................................................ 6 Torque-Turn........................................................................................... 6 Torque Sequence....................................................................................... 6 Metric (ISO) Fasteners.................................................................................... 7 Metric (ISO) Nuts and Bolts........................................................................... 7 Metric (ISO) Taperlock Studs.......................................................................... 7 Metric (ISO) Machine Screws........................................................................... 7 Hex Button Head Screw and Set Screw................................................................... 7 English (SAE) Fasteners................................................................................... 8 English (SAE) Nuts and Bolts.......................................................................... 8 English (SAE) Taperlock Studs......................................................................... 8 English (SAE) Machine Screws.......................................................................... 8 Hex Button Head Screw and Set Screws.................................................................. 9 Ground Engaging Tool (G.E.T.) Fasteners................................................................... 9 Installation of Fittings.................................................................................. 10 Installation of Split Flange Couplings................................................................ 10 Installation of Adjustable STOR Fittings.............................................................. 11 Straight Thread O-Ring Fittings........................................................................... 11 Plugs..................................................................................................... 13 Straight Thread O-Ring Plugs (Hex Drive).............................................................. 13 Straight Thread O-Ring Plugs (Socket Drive)........................................................... 14 Drain Plugs with Straight Thread...................................................................... 14 Straight Thread O-Ring Plugs (Mechanical Joint Tube Assemblies)....................................... 14 O-Ring Face Seal Fittings................................................................................. 15 Bulkhead Nuts............................................................................................. 15 Flare Fittings............................................................................................ 16 37 Degree Flare Fitting............................................................................... 16 45 Degree Flare and 45 Degree Inverted Flare Fittings................................................. 16 Air Conditioning Fittings................................................................................. 17 Air Brake Fittings........................................................................................ 17 Tapered Pipe Thread Fittings.............................................................................. 17 Miscellaneous Fittings.................................................................................... 18 Hi Duty Tube Fittings (Shear Sleeve).................................................................. 18 SAE Flareless Fittings................................................................................ 18 Flex Fittings......................................................................................... 18 Hose Clamps............................................................................................... 18 Worm Drive Band Type Clamps........................................................................... 18 Constant Torque Hose Clamps........................................................................... 19 ENGINE................................................................................................................ 0 31200299_Engine Disassembly-Assembly.............................................................................. 24 Table of Contents............................................................................................. 4 Disassembly and Assembly Section.............................................................................. 28 Battery - Remove and Install.............................................................................. 28 Removal Procedure..................................................................................... 28 Installation Procedure................................................................................ 29 Alternator - Remove and Install........................................................................... 29 Removal Procedure..................................................................................... 29 Installation Procedure................................................................................ 30 Electric Starting Motor -Remove and Install............................................................... 30 Removal Procedure..................................................................................... 30 Installation Procedure................................................................................ 30 Air Cleaner - Remove...................................................................................... 31 Removal Procedure..................................................................................... 31 Air Cleaner - Install..................................................................................... 32 Installation Procedure................................................................................ 32 Muffler - Remove and Install.............................................................................. 33 Removal Procedure..................................................................................... 33 Installation Procedure................................................................................ 33 Expansion Tank - Remove and Install....................................................................... 34 Removal Procedure..................................................................................... 34 Installation Procedure................................................................................ 35 Radiator - Remove......................................................................................... 35 Removal Procedure..................................................................................... 35 Radiator - Disassemble.................................................................................... 37 Disassembly Procedure................................................................................. 37 Radiator - Assemble....................................................................................... 38 Assembly Procedure.................................................................................... 38 Radiator - Install........................................................................................ 38 Installation Procedure................................................................................ 38 Fan Guard - Remove and Install............................................................................ 40 Removal Procedure..................................................................................... 40 Transmission Oil Cooler - Remove.......................................................................... 40 Removal Procedure..................................................................................... 40 Transmission Oil Cooler -Install.......................................................................... 41 Installation Procedure................................................................................ 41 Refrigerant Condenser - Remove and Install................................................................ 42 Removal Procedure..................................................................................... 42 Installation Procedure................................................................................ 43 Refrigerant Compressor - Remove and Install............................................................... 44 Removal Procedure..................................................................................... 44 Installation Procedure................................................................................ 44 Engine Mount (Front) - Remove............................................................................. 45 Removal Procedure..................................................................................... 45 Engine Mount (Front) - Install............................................................................ 46 Installation Procedure................................................................................ 46 Engine Mount (Rear) - Remove.............................................................................. 47 Removal Procedure..................................................................................... 47 Engine Mount (Rear) - Install............................................................................. 48 Installation Procedure................................................................................ 48 Engine Enclosure - Remove and Install..................................................................... 48 Removal Procedure..................................................................................... 48 Installation Procedure................................................................................ 49 Engine - Remove........................................................................................... 50 Removal Procedure..................................................................................... 50 Engine - Install.......................................................................................... 53 Installation Procedure................................................................................ 53 POWER TRAIN........................................................................................................... 0 31200270_Power Train Test-Adjust.................................................................................. 60 Table of Contents............................................................................................. 4 Systems Operation Section..................................................................................... 64 Graphic Color Codes....................................................................................... 64 Introduction.............................................................................................. 65 General Information....................................................................................... 66 Location of Electrical Components......................................................................... 67 Transmission Neutralizer Switch....................................................................... 68 Parking Brake Switch.................................................................................. 68 Service Brake Pressure Switch......................................................................... 68 Transmission Direction Control Lever (Power Shuttle Transmission)..................................... 69 Transmission Speed Selector (Powersynchro Transmission)............................................... 69 Differential Lock Switch (if Equipped................................................................. 69 Transmission Oil Temperature Sensor................................................................... 69 Torque Converter Output Sensor for the Temperature of the Oil......................................... 69 Engine Speed Sensor................................................................................... 69 Torque Converter Output Speed Sensor.................................................................. 69 Transmission Intermediate Speed Sensors............................................................... 70 Transmission Output Speed Sensor...................................................................... 70 Shift Rail Sensors.................................................................................... 70 Electronic Control Module............................................................................. 70 Modulating Valve for the Synchronizers................................................................ 70 Solenoid Valves....................................................................................... 71 Transmission Neutralizer Override Switch.............................................................. 71 Location of Hydraulic Components.......................................................................... 71 Transmission Charge Pump.............................................................................. 72 Torque Converter...................................................................................... 72 Hydraulic Oil Cooler.................................................................................. 72 Electrical Input Components............................................................................... 73 Sensors............................................................................................... 73 Switches.............................................................................................. 75 Transmission Control.................................................................................. 76 Electronic Control Module................................................................................. 77 Inputs................................................................................................ 77 Outputs............................................................................................... 77 Input/Output.......................................................................................... 77 Electrical Output Components.............................................................................. 81 Synchronizer Solenoids................................................................................ 82 Directional Solenoids................................................................................. 82 Instrument Cluster.................................................................................... 82 Data Link................................................................................................. 83 CAT Data Link......................................................................................... 83 CAN Data Link......................................................................................... 83 Electrical Schematic...................................................................................... 83 Transmission Charge Pump.................................................................................. 85 Modulating Valve (Transmission)........................................................................... 85 Solenoid Valves (Transmission)............................................................................ 85 Directional Solenoids................................................................................. 85 Speed or Synchronized Solenoids....................................................................... 86 Torque Converter.......................................................................................... 87 Transmission.............................................................................................. 89 Clutch Operation...................................................................................... 92 Operation of the Synchronizers........................................................................ 93 Synchronizer for the Third Speed and Fourth Speed..................................................... 96 Limits................................................................................................ 98 Cooler (Hydraulic Oil).................................................................................... 99 Transmission Control (Shift Lever)........................................................................ 99 Powersynchro Transmission............................................................................. 100 Power Shuttle Transmission............................................................................ 100 Transmission Power Flow................................................................................... 101 Examples of Power Flow Through the Transmission....................................................... 103 Differential Lock Control (If Equipped)................................................................... 105 Front Axle and Rear Axle.................................................................................. 107 Final Drives.......................................................................................... 107 Hydraulic Schematic (Power Train System).................................................................. 109 Neutral (Power Shuttle Transmission).................................................................. 109 Neutral (Powersynchro Transmission)................................................................... 110 Neutral into First Gear (Start of shift).............................................................. 111 Neutral Into First Gear (End of Shift) (FORWARD)...................................................... 112 Configuration Parameters.................................................................................. 114 Testing and Adjusting Section................................................................................. 116 Transmission Shift Rail - Calibrate....................................................................... 116 Machine Preparation................................................................................... 116 Transmission Fill - Calibrate............................................................................. 123 Machine Preparation................................................................................... 123 Torque Converter Stall - Test............................................................................. 130 Introduction.......................................................................................... 130 Required Tools........................................................................................ 130 Test Procedure........................................................................................ 130 Measurement of the Stall Speed........................................................................ 131 Transmission Pressures - Test and Adjust.................................................................. 131 Pressure Test Points for the Powersynchro Transmission................................................ 132 Pressure Test Points for the Power Shuttle Transmission............................................... 133 Oil Level Check....................................................................................... 133 Torque Converter Inlet Pressure....................................................................... 133 Regulated Pump Pressure............................................................................... 134 Operating Pressures of Clutches and Synchronizers..................................................... 135 Differential Pinion Bearing - Adjust...................................................................... 136 Introduction.......................................................................................... 136 Required Tools........................................................................................ 136 Procedure............................................................................................. 137 Differential Backlash and Bearings - Adjust............................................................... 142 Front Axle Differential............................................................................... 142 Rear Axle Differential................................................................................ 145 Tooth Contact Pattern................................................................................. 146 Axle Housing and Bearing Preload - Adjust................................................................. 148 Introduction.......................................................................................... 148 Adjustment Procedure.................................................................................. 149 31200300_Powertrain Disassembly-Assembly.......................................................................... 154 Table of Contents............................................................................................. 4 Disassembly and Assembly Section.............................................................................. 158 Transmission Control (Select Lever) - Remove.............................................................. 158 Removal Procedure..................................................................................... 158 Transmission Control (Select Lever) - Install............................................................. 160 Installation Procedure................................................................................ 160 Transmission - Remove..................................................................................... 161 Removal Procedure..................................................................................... 161 Transmission - Disassemble................................................................................ 165 Disassembly Procedure................................................................................. 165 Transmission - Assemble................................................................................... 193 Assembly Procedure.................................................................................... 193 Transmission - Install.................................................................................... 221 Installation Procedure................................................................................ 221 Drive Shaft (Front) - Remove and Install.................................................................. 223 Removal Procedure..................................................................................... 223 Installation Procedure................................................................................ 224 Drive Shaft (Rear) - Remove and Install................................................................... 224 Removal Procedure..................................................................................... 224 Installation Procedure................................................................................ 225 Drive and Steering Axle (Front) - Remove.................................................................. 225 Removal Procedure..................................................................................... 225 Drive and Steering Axle (Front) - Install................................................................. 230 Installation Procedure................................................................................ 230 Drive and Steering Axle (Rear) - Remove................................................................... 234 Removal Procedure..................................................................................... 234 Drive and Steering Axle (Rear) - Install.................................................................. 237 Tie Rod (Steering) - Remove and Install................................................................... 241 Removal Procedure..................................................................................... 241 Installation procedure................................................................................ 241 Steering Cylinder - Remove and Install.................................................................... 242 Removal Procedure..................................................................................... 242 Installation Procedure................................................................................ 243 Final Drive Planetary - Remove............................................................................ 244 Removal Procedure..................................................................................... 244 Final Drive Planetary Disassemble......................................................................... 245 Disassembly Procedure................................................................................. 245 Final Drive Planetary Assemble............................................................................ 245 Assembly Procedure.................................................................................... 245 Final Drive Planetary - Install........................................................................... 246 Installation Procedure................................................................................ 246 Axle Housing and Flange Remove............................................................................ 246 Removal Procedure..................................................................................... 246 Axle Housing and Flange - Disassemble..................................................................... 249 Disassembly Procedure................................................................................. 249 Axle Housing and Flange - Assemble........................................................................ 251 Assembly Procedure.................................................................................... 251 Axle Housing and Flange Install........................................................................... 253 Installation Procedure................................................................................ 253 Axle Shaft - Remove and Install........................................................................... 256 Removal Procedure..................................................................................... 256 Installation Procedure................................................................................ 257 Axle Housing (Service Brakes, Differential and Bevel Gear) (Front) - Remove............................... 258 Removal Procedure..................................................................................... 258 Axle Housing (Service Brakes, Differential and Bevel Gear) (Front) - Disassemble.......................... 259 Disassembly Procedure................................................................................. 259 Axle Housing (Service Brakes, Differential and Bevel Gear) (Front) - Assemble............................. 264 Assembly Procedure.................................................................................... 264 Axle Housing (Service Brakes, Differential and Bevel Gear) (Front) - Install.............................. 274 Installation Procedure................................................................................ 274 Axle Housing (Differential and Bevel Gear) (Rear) - Remove................................................ 275 Removal Procedure..................................................................................... 275 Axle Housing (Differential and Bevel Gear) (Rear) - Disassemble........................................... 276 Disassembly Procedure................................................................................. 276 Axle Housing (Differential and Bevel Gear) (Rear) - Assemble.............................................. 279 Assembly Procedure.................................................................................... 279 Axle Housing (Differential and Bevel Gear) (Rear) - Install............................................... 285 Installation Procedure................................................................................ 285 Parking Brake Control -Remove and Install................................................................. 285 Removal Procedure..................................................................................... 285 Installation Procedure................................................................................ 286 Parking Brake - Remove.................................................................................... 287 Removal Procedure..................................................................................... 287 Parking Brake - Disassemble............................................................................... 288 Disassembly Procedure................................................................................. 288 Parking Brake - Assemble.................................................................................. 289 Assembly Procedure.................................................................................... 289 Parking Brake - Install................................................................................... 291 Installation Procedure................................................................................ 291 Brake Cylinder (Master) Remove and Install................................................................ 292 Removal Procedure..................................................................................... 292 Installation Procedure................................................................................ 294 Tire and Rim - Remove and Install......................................................................... 295 Removal Procedure..................................................................................... 295 Installation Procedure................................................................................ 296 VEHICLE SYSTEMS....................................................................................................... 302 31200304_Hydraulic System Schematic............................................................................... 302 31200302_Hydraulic System Test-Adjust............................................................................. 304 Table of Contents............................................................................................. 4 Systems Operation Section..................................................................................... 310 Graphic Color Codes....................................................................................... 310 Introduction.............................................................................................. 311 General Information....................................................................................... 312 Main Control Valve Group (Implement).................................................................. 312 Electronic Pilot Valve Group (Implement).............................................................. 313 Stabilizer Control Valve Gp (If Equipped)............................................................. 314 Machine ECM........................................................................................... 315 Electronic Joystick................................................................................... 317 Operator Switches..................................................................................... 318 Piston Pump (Implement and Steering).................................................................. 318 Hydraulic Oil Tank.................................................................................... 318 Hydraulic Oil Filter.................................................................................. 318 System Operation...................................................................................... 318 Load Independent Flow Division (LIFD)................................................................. 320 Location of Electrical Components......................................................................... 320 Switch (Lockout Control).............................................................................. 320 Joystick Control...................................................................................... 321 Sensor (Boom Raise/Lower)............................................................................. 322 Sensor for Boom Extend and Boom Retract or Boom Tilt Forward and Tilt Rackback........................ 322 Switch for Boom Extend and Boom Retract or Boom Tilt Forward and Tilt Rackback........................ 322 Switch (Auxiliary Actuator in the + Direction) for Joystick (Type 1).................................. 322 Switch (Auxiliary Actuator in the - Direction) for Joystick (Type 1).................................. 322 Switch (Auxiliary Actuator) for Joystick (Type 2)..................................................... 322 Switch (Auxiliary 1 or 2)............................................................................. 322 Switch (Continuous Auxiliary Flow).................................................................... 322 Switch (Quick Coupler)................................................................................ 323 Switch (Right Stabilizer)............................................................................. 323 Switch (Left Stabilizer).............................................................................. 323 Switch (Frame Level).................................................................................. 323 Pressure Switches (Stabilizer)........................................................................ 324 Switch (Fully Lowered Boom)........................................................................... 324 Switch (Critical Angle)............................................................................... 324 Switch (Fully Retracted Boom)......................................................................... 324 Machine (ECM)......................................................................................... 325 Main Control Valve (Implement)........................................................................ 325 Stabilizer Control Valve Gp (If Equipped)............................................................. 325 Solenoids (Frame Level)............................................................................... 326 Solenoid (Diverter Valve)............................................................................. 326 Relay (Frame Level)................................................................................... 326 Relays (Diverter Valve)............................................................................... 327 Relays (Quick Coupler)................................................................................ 327 Location of Hydraulic Components.......................................................................... 327 Hydraulic Tank........................................................................................ 327 Piston Pump (Implement and Steering).................................................................. 328 Compensator Valve..................................................................................... 328 Main Control Valve (Implement)........................................................................ 328 Inlet Manifold........................................................................................ 329 Outlet Manifold....................................................................................... 330 Boom Cylinder......................................................................................... 330 Load Control Valve (Boom Cylinder) (Lock)............................................................. 330 Telescoping Cylinder.................................................................................. 330 Load Control Valve (Telescoping Cylinder) (Lock)...................................................... 331 Tilt Cylinder......................................................................................... 331 Load Control Valve (Tilt Cylinder) (Lock)............................................................. 331 Compensating Cylinders................................................................................ 331 Diverter Valve........................................................................................ 332 Quick Coupler Cylinder................................................................................ 332 Frame Leveling Cylinder............................................................................... 6 Lock Valve (Frame Leveling Cylinder).................................................................. 333 Control Valve Gp (Stabilizer)......................................................................... 333 Stabilizer Cylinders.................................................................................. 333 Load Control Valve (Stabilizer Cylinders) (Lock)...................................................... 334 Lowering Control Pump (Manual)........................................................................ 334 Switches.............................................................................................. 335 Joystick Control...................................................................................... 336 Auxiliary Switches.................................................................................... 336 Thumb Slider.......................................................................................... 336 Stabilizer Switches................................................................................... 336 Boom Critical Angle Switch............................................................................ 336 Boom Retracted Switch................................................................................. 336 Stabilizer Pressure Switches.......................................................................... 337 Quick Coupler Switch.................................................................................. 337 Continuous Flow SwitchImplement....................................................................... 337 Lockout Switch........................................................................................ 337 Boom Lowered Switch................................................................................... 337 Electronic Control Module................................................................................. 338 Inputs................................................................................................ 338 Outputs............................................................................................... 338 Data Links............................................................................................ 338 Input/Output.......................................................................................... 338 Electrical Output Components.............................................................................. 342 Relays................................................................................................ 343 Solenoids............................................................................................. 343 Electrical Function Requirements.......................................................................... 344 Transmission Neutralizer.............................................................................. 344 Solenoid Outputs...................................................................................... 344 System Voltage........................................................................................ 344 Shuttle Shift for the Power Shuttle Transmission...................................................... 344 Shift Lever (Cat Data Link) for Powersynchro Transmission............................................. 344 Rear Axle Lock (if equipped).......................................................................... 344 Machine Security System............................................................................... 345 Parking Brake......................................................................................... 345 Service Brake Pressure Switch for the Transmission Neutralizer........................................ 345 More Electrical Function Requirements................................................................. 345 Steering.............................................................................................. 345 The Neutral Start Is Disabled......................................................................... 345 Stabilizer Raise/Lower (if equipped) is Disabled...................................................... 346 Boom Raise/Lower Is Disabled.......................................................................... 346 The Boom Extend/Retract Is Disabled................................................................... 346 Disable The Rackback And Dump......................................................................... 346 The Frame Level (if equipped) is Disabled............................................................. 347 Disable the Quick Coupler............................................................................. 347 Miscellaneous......................................................................................... 347 Electrical Schematic.................................................................................. 348 Piston Pump (Implement and Steering)...................................................................... 350 Piston Pump........................................................................................... 350 Compensator Valve..................................................................................... 351 Low Pressure Standby.................................................................................. 352 Upstroke.............................................................................................. 353 Constant Flow......................................................................................... 354 Destroke.............................................................................................. 355 High Pressure Stall................................................................................... 357 Main Control Valve (Implement)............................................................................ 358 Check and Relief Valves................................................................................... 361 Manifold Valve (Outlet)................................................................................... 363 Pilot Hydraulic System.................................................................................... 364 Lowering Control Pump (Electric).......................................................................... 365 Electric Lowering Control Pump (If Equipped).......................................................... 365 Lowering Control Pump (Manual)........................................................................ 368 Boom Hydraulic System..................................................................................... 370 Control valve (implement)............................................................................. 370 Valve for the Cylinder in the HOLD Position........................................................... 371 Valve for the Cylinder in the EXTEND Position......................................................... 372 Valve for the Cylinder in the RETRACT Position........................................................ 373 Load Control Valves................................................................................... 374 Lowering Control Valve (If Equipped).................................................................. 375 Boom RAISE............................................................................................ 376 Boom LOWER............................................................................................ 377 Telescoping System........................................................................................ 378 Valve for the Telescoping Cylinder in the HOLD Position............................................... 378 Valve for the Telescoping Cylinder in the EXTEND Position............................................. 380 Valve for the Telescoping Cylinder in the RETRACT Position............................................ 382 Auxiliary Hydraulic System................................................................................ 384 Introduction.......................................................................................... 384 Auxiliary Control (Combined Circuit).................................................................. 385 Auxiliary Circuit 1................................................................................... 387 Auxiliary Circuit 2................................................................................... 388 Continuous Flow (Auxiliary Hydraulics)................................................................ 389 Quick Coupler......................................................................................... 389 Quick Coupler Circuit DISENGAGED...................................................................... 390 Quick Coupler Pins ENGAGED............................................................................ 391 Relief Valves and Makeup Valves....................................................................... 392 Compensating System....................................................................................... 392 Boom Lower............................................................................................ 393 Boom Raise............................................................................................ 394 Pressure Relief and Makeup Valves..................................................................... 395 Frame Leveling System..................................................................................... 396 Locked Axle (HOLD).................................................................................... 397 Frame that is Angled to the Left...................................................................... 398 Stabilizer System......................................................................................... 399 Stabilizer Cylinders (HOLD)........................................................................... 401 Stabilizer Cylinders (RAISE).......................................................................... 402 Stabilizer Cylinders (LOWER).......................................................................... 403 Hydraulic System Schematic................................................................................ 404 All Implements In HOLD................................................................................ 404 Configuration Parameters.............................................................................. 407 Testing and Adjusting Section................................................................................. 408 Testing and Adjusting..................................................................................... 408 Joystick Control - Calibrate.......................................................................... 408 Main Control Valve (Implement) - Calibrate................................................................ 428 Programmable Hydraulic System (PHS) Valve Calibrations................................................ 428 Manual Adjustment After Calibrating The Valves........................................................ 437 Hydraulic System Pressure - Release....................................................................... 437 Relieving Pressure in the Hydraulic System............................................................ 438 Lock Valve Locations.................................................................................. 438 Location of the Shutoff Valve for the Axle Lock....................................................... 439 Relieving Pressure from the Lock Valves............................................................... 439 Verifying the Correct Setting of the Load Control Valves.............................................. 443 Relieving Pressure from the Shutoff Valve on the Axle Lock............................................ 443 Hydraulic System Pressures - Test and Adjust.............................................................. 443 Test and Adjustment Procedures........................................................................ 443 Pilot Pressure (Pressure Reducing Valve) - Test and Adjust................................................ 444 Pilot Pressure Test................................................................................... 444 Warming the Transmission Oil.......................................................................... 444 Test Procedure........................................................................................ 444 Pressure Reducing Valve Adjustment.................................................................... 445 Relief Valve (Implement) - Test and Adjust................................................................ 446 Auxiliary Pressure Test (Port A and Portable.......................................................... 446 Warming the Transmission Oil.......................................................................... 446 Test Procedure........................................................................................ 447 Auxiliary Relief Valve Adjustments.................................................................... 447 Pressure Adjustment for Disengaging the Quick Coupler................................................. 447 Pressure Adjustment for Engaging the Quick Coupler.................................................... 448 Hydraulic Oil Contamination - Test........................................................................ 448 Hydraulic Oil Contamination........................................................................... 448 Flushing the Sampling Valve........................................................................... 448 In order to obtain a representative oil sample, it is first necessary to flush the sampling valve..... 448 Obtaining the Sample.................................................................................. 449 Maximum Contamination Levels.......................................................................... 449 Boom Chain - Clean/Inspect/ Lubricate..................................................................... 449 Boom Chains........................................................................................... 449 Check Condition....................................................................................... 449 Cleaning and Inspection............................................................................... 449 General Information Table................................................................................. 450 31200273_Steering System Test-Adjust.............................................................................. 458 Table of Contents............................................................................................. 4 Systems Operation Section..................................................................................... 462 Graphic Color Codes....................................................................................... 462 General Information....................................................................................... 463 Steering Arrangement.................................................................................. 463 Introduction.............................................................................................. 465 Location of Electrical Components......................................................................... 466 Selector Switch for the Steering Mode................................................................. 466 Position Sensors...................................................................................... 466 Electronic Control Module............................................................................. 467 Solenoid for Crab Steer............................................................................... 467 Solenoid for Circle Steer............................................................................. 467 Relay (Crab Steer).................................................................................... 467 Relay (Circle Steer).................................................................................. 468 Location of Hydraulic Components.......................................................................... 468 Steering Wheel........................................................................................ 468 Metering Pump......................................................................................... 469 Piston Pump........................................................................................... 469 Line for the Signal Limiter Valve for the Steering.................................................... 469 Priority Valve........................................................................................ 34 Control Valve (Steering).............................................................................. 470 Steering Cylinders.................................................................................... 470 Hydraulic Tank........................................................................................ 470 Hydraulic Tank Breather............................................................................... 470 Hydraulic Oil Level Indicator......................................................................... 471 Hydraulic Oil Drain Plugs............................................................................. 471 Electrical Input Components............................................................................... 471 Steering Mode Switch.................................................................................. 471 Position Sensor....................................................................................... 472 Electronic Control Module................................................................................. 472 Electrical Output Components.............................................................................. 473 Relays................................................................................................ 473 Instrument Cluster.................................................................................... 473 Data Link................................................................................................. 473 CAT Data Link......................................................................................... 473 CAN Data Link......................................................................................... 474 Electrical Schematic...................................................................................... 474 Inlet Manifold............................................................................................ 474 Steering Priority Valve............................................................................... 475 Screens (75 and 100 Micron)........................................................................... 475 Flow Control Valve (Dump valve for the load sensing oil).............................................. 475 Relief Valve (Load sensing oil)....................................................................... 475 Check Valve........................................................................................... 475 Steering Not Activated................................................................................ 476 Steering Activated.................................................................................... 477 Steering System........................................................................................... 478 Steering Control System............................................................................... 478 Steering in Neutral................................................................................... 479 Right Turn in Two-Wheel Steer Mode.................................................................... 481 Left Turn in Circle Steer Mode........................................................................ 483 Left Turn in Crab Steer Mode.......................................................................... 485 Hydraulic Schematic (Steering System)..................................................................... 487 Piston Pump (Implement and Steering)...................................................................... 488 Piston Pump........................................................................................... 488 Compensator Valve..................................................................................... 489 Low Pressure Standby.................................................................................. 490 Upstroke.............................................................................................. 491 Constant Flow......................................................................................... 492 Destroke.............................................................................................. 493 High Pressure Stall................................................................................... 495 Solenoid Valve (Steering Mode Selector)................................................................... 496 Solenoid Valve........................................................................................ 53 Metering Pump (Steering).................................................................................. 496 Hold.................................................................................................. 498 Right Turn............................................................................................ 499 Position Sensor (Steering)................................................................................ 501 Configuration Parameters.................................................................................. 502 Testing and Adjusting Section................................................................................. 504 Hydraulic Oil Contamination - Test........................................................................ 504 Hydraulic Oil Contamination........................................................................... 504 Flushing the Sampling Valve........................................................................... 504 Obtaining the Sample.................................................................................. 504 Pump Flow - Test.......................................................................................... 505 Pump Flow............................................................................................. 505 Test On The Machine................................................................................... 505 Test On The Bench..................................................................................... 506 Steering System Pressures - Test and Adjust............................................................... 506 Steering System Pressure Tests and Adjustments........................................................ 506 Steering Pressure Test................................................................................ 507 Steering Pressure Adjustment.......................................................................... 507 Margin Pressure Test.................................................................................. 508 Margin Pressure Adjustment............................................................................ 509 Test for the Relief Valve (Load Sensing Oil).......................................................... 509 Adjustment of the Relief Valve (Load Sensing Oil)..................................................... 510 Test for Pressure Compensator......................................................................... 510 Pressure Compensator Adjustment....................................................................... 511 Low Pressure Standby Test............................................................................. 511 Low Pressure Standby Adjustment....................................................................... 512 Steering System - Purge................................................................................... 513 Purging the Steering System........................................................................... 513 Solenoid Valve (Steering Mode Selector) - Test............................................................ 513 The Solenoid's for the Steering Modes................................................................. 513 Position Sensor (Steering) - Adjust....................................................................... 514 Position Sensor....................................................................................... 514 Wheel Alignment - Check and Adjust........................................................................ 516 Checking the Wheel Alignment With Wheels In Place..................................................... 517 Adjusting the Wheel Alignment......................................................................... 517 Adjusting the Steering Angle.......................................................................... 518 General Information Table................................................................................. 519 31200274_Braking System Test-Adjust............................................................................... 524 Table of Contents............................................................................................. 4 Systems Operation Section..................................................................................... 528 Graphic Color Codes....................................................................................... 528 Introduction.............................................................................................. 529 General Information....................................................................................... 530 Brake Packs........................................................................................... 530 Brake Pedal........................................................................................... 530 Brake Cylinder........................................................................................ 530 Service Brake Pressure Switch......................................................................... 531 Parking Brake Lever................................................................................... 531 Location of Electrical Components......................................................................... 531 Parking Brake Switch.................................................................................. 531 Service Brake Pressure Switch......................................................................... 531 Stoplight Switch...................................................................................... 531 Location of Components (Braking).......................................................................... 532 Parking Brake Lever................................................................................... 532 Parking Brake Actuator................................................................................ 532 Service Brake Pedal................................................................................... 532 Brake Cylinder........................................................................................ 533 Service Brake Discs................................................................................... 533 Service Brake............................................................................................. 533 Service Brake......................................................................................... 533 The Service Brake System with the Brakes Disengaged................................................... 535 The Service Brake System with the Brakes Engaged...................................................... 536 Parking Brake............................................................................................. 537 Engaging the Parking Brake............................................................................ 537 Disengaging the Parking Brake......................................................................... 538 Brake Cylinder (Master)................................................................................... 539 Brake Cylinder with the Brakes Disengaged............................................................. 540 Brake Cylinder with the Brakes Engaged................................................................ 542 Hydraulic Schematic (Braking System)...................................................................... 544 Configuration Parameters.................................................................................. 545 Electrical Function Requirements.......................................................................... 546 Transmission Neutralizer.............................................................................. 546 System Voltage........................................................................................ 546 Shuttle Shift for the Power Shuttle Transmission...................................................... 546 Shift Lever (Cat Data Link) for Powersynchro Transmission............................................. 546 Rear Axle Lock (if equipped).......................................................................... 462 Machine Security System............................................................................... 462 Parking Brake......................................................................................... 546 Service Brake Pressure Switch for the Transmission Neutralizer........................................ 547 More Electrical Function Requirements..................................................................... 547 Steering.............................................................................................. 547 The Neutral Start Is Disabled......................................................................... 463 Stabilizer Raise/Lower (if equipped) is Disabled...................................................... 548 Boom Raise/Lower Is Disabled.......................................................................... 548 The Boom Extend/Retract Is Disabled................................................................... 548 Disable The Rackback And Dump......................................................................... 548 The Frame Level (if equipped) is Disabled............................................................. 549 Disable the Quick Coupler............................................................................. 549 Miscellaneous......................................................................................... 549 Testing and Adjusting Section................................................................................. 550 Testing and Adjusting Service Brake - Test................................................................ 550 Holding Ability Test for the Service Brakes........................................................... 550 Stopping Performance Test for the Service Brakes...................................................... 550 Service Brake Control - Check and Adjust.................................................................. 550 Adjusting the Brake Pedal Linkage..................................................................... 550 Service Brake Discs - Check............................................................................... 552 Checking the Wear on the Service Brake Discs.......................................................... 552 Procedure for Checking the Wear....................................................................... 552 Service Brake Air - Purge................................................................................. 553 Purging Air from the Braking System................................................................... 553 Parking Brake - Test...................................................................................... 554 Holding Ability Test for the Parking Brake............................................................ 554 Parking Brake Control - Check and Adjust.................................................................. 555 Adjusting the Parking Brake Control Cable............................................................. 555 31200306_Machine Components Specifications........................................................................ 562 Table of Contents............................................................................................. 4 Specifications Section........................................................................................ 566 Hydraulic Tank............................................................................................ 566 Hydraulic Tank............................................................................................ 568 Hydraulic Tank............................................................................................ 569 Piston Pump (Implement and Steering)...................................................................... 464 Solenoid Valve (Pilot Selector)........................................................................... 571 Main Control Valve (Implement)............................................................................ 572 Frame..................................................................................................... 574 Boom...................................................................................................... 575 Boom...................................................................................................... 576 Boom Cylinder............................................................................................. 577 Boom Cylinder............................................................................................. 578 Boom Cylinder............................................................................................. 579 Load Control Valve (Boom Cylinder) (Lock)................................................................. 580 Compensating Cylinder..................................................................................... 581 Compensating Cylinder..................................................................................... 582 Telescoping Cylinder...................................................................................... 583 Load Control Valve (Telescoping Cylinder) (Lock).......................................................... 584 Tilt Cylinder............................................................................................. 585 Tilt Cylinder............................................................................................. 586 Load Control Valve (Tilt Cylinder) (Lock)................................................................. 587 Diverter Valve............................................................................................ 587 Diverter Valve............................................................................................ 588 Towing Hitch.............................................................................................. 589 Towing Hitch.............................................................................................. 589 Towing Hitch.............................................................................................. 590 Towing Hitch.............................................................................................. 590 Towing Hitch.............................................................................................. 591 Towing Hitch.............................................................................................. 591 Frame Leveling Cylinder................................................................................... 592 Frame Leveling Cylinder................................................................................... 593 Load Control Valve (Frame Leveling Cylinder) (Lock)....................................................... 594 Control Valve (Stabilizer)................................................................................ 595 Stabilizer Cylinder....................................................................................... 596 Stabilizer Cylinder....................................................................................... 597 Stabilizer Cylinder....................................................................................... 598 Load Control Valve (Stabilizer Cylinder) (Lock)........................................................... 599 Axle Lock Cylinder........................................................................................ 600 Metering Pump (Steering).................................................................................. 601 Solenoid Valve (Steering Mode Selector)................................................................... 601 Position Sensor (Steering)................................................................................ 602 Position Sensor (Steering)................................................................................ 602 Flexible Coupling Drive................................................................................... 603 Transmission.............................................................................................. 604 Transmission.............................................................................................. 606 Position Sensor (Transmission)............................................................................ 608 Oil Filter................................................................................................ 609 Hydraulic Oil Cooler...................................................................................... 611 Drive Shaft............................................................................................... 612 Drive and Steering Axle (Front)........................................................................... 613 271 -6425 Drive and Steering Axle Gp.................................................................. 613 271 -6426 Drive and Steering Axle Gp.................................................................. 615 Drive and Steering Axle (Front)........................................................................... 617 271 -6427 Drive and Steering Axle Gp, with Steering Sensor............................................ 617 Drive and Steering Axle (Rear)............................................................................ 619 189-5717 Drive and Steering Axle Gp, with Steering Sensor............................................. 619 168-7443 Drive and Steering Axle Gp, with Steering Sensor............................................. 620 Drive and Steering Axle (Rear)............................................................................ 621 231 -0710 Drive and Steering Axle Gp, without Steering Sensor......................................... 621 231 -0709 Drive and Steering Axle Gp, with Steering Sensor............................................ 622 Differential and Bevel Gear Group......................................................................... 623 Differential and Bevel Gear Group......................................................................... 624 Axle Housing and Flange Group............................................................................. 625 Axle Housing and Flange Group............................................................................. 625 Final Drive Planetary Group............................................................................... 626 Final Drive Planetary Group............................................................................... 627 Axle Housing Group (Differential and Brake Cylinder)...................................................... 628 174-4642 Axle Housing Gp with a Locking Differential.................................................. 628 219-8780 Axle Housing Gp.............................................................................. 630 219-8831 Axle Housing Gp with a Locking Differential.................................................. 632 219-8842 Axle Housing Gp without a Locking Differential............................................... 634 Axle Housing Group (Differential and Brake Cylinder)...................................................... 636 253-4990 Axle Housing Gp with a Locking Differential.................................................. 636 253-4985 Axle Housing Gp without a Locking Differential............................................... 638 Brake Cylinder (Master)................................................................................... 639 Parking Brake Control..................................................................................... 640 Parking Brake............................................................................................. 641 Fender.................................................................................................... 642 Wheel (Tire and Rim)...................................................................................... 643 Fuel Tank................................................................................................. 644 Fuel Tank................................................................................................. 645 Engine Enclosure.......................................................................................... 646 Engine and Transmission Mounting.......................................................................... 648 Air Cleaner............................................................................................... 649 Engine Oil Drain.......................................................................................... 651 Muffler................................................................................................... 652 Suction Fan............................................................................................... 653 Battery................................................................................................... 654 Alternator................................................................................................ 655 Coolant Lines Group....................................................................................... 656 Coolant Recovery Group.................................................................................... 657 Cab....................................................................................................... 659 Latch Adjustment...................................................................................... 659 Cab Mounting.............................................................................................. 660 Cab Door.................................................................................................. 661 Access Door............................................................................................... 663 Joystick Control.......................................................................................... 664 Steering Wheel and Column................................................................................. 665 Window Wiper and Wiper Motor.............................................................................. 666 Window Washer Tank........................................................................................ 667 Rear View Mirror.......................................................................................... 668 Carriage Cylinder (Rotate)................................................................................ 668 Carriage Cylinder (Sideshift)............................................................................. 669 Hydraulic Cylinder (Multipurpose Bucket).................................................................. 670 Grapple Cylinder.......................................................................................... 671 31200308_Machine Systems Disassembly-Assembly..................................................................... 676 Table of Contents............................................................................................. 4 Disassembly and Assembly Section.............................................................................. 682 Hydraulic System Pressure - Release....................................................................... 682 Release Procedure..................................................................................... 682 Steering Wheel - Remove and Install....................................................................... 682 Removal Procedure..................................................................................... 682 Installation Procedure................................................................................ 683 Metering Pump (Steering) - Remove......................................................................... 683 Removal Procedure..................................................................................... 683 Metering Pump (Steering) - Install........................................................................ 686 Installation Procedure................................................................................ 686 Steering Column - Remove.................................................................................. 688 Removal Procedure..................................................................................... 688 Steering Column - Install................................................................................. 691 Installation Procedure................................................................................ 691 Main Control Valve (Implement) - Remove................................................................... 694 Removal Procedure..................................................................................... 694 Electronic Pilot Valve - Remove and Install............................................................... 696 Removal Procedure..................................................................................... 696 Installation Procedure................................................................................ 698 Bank Valve (Implement) - Disassemble...................................................................... 699 Disassembly Procedure................................................................................. 699 Bank Valve (Implement) - Assemble......................................................................... 705 Assembly Procedure.................................................................................... 705 Main Control Valve (Implement) - Install.................................................................. 712 Installation Procedure................................................................................ 712 Solenoid Valve (Steering Mode Selector) - Remove and Install.............................................. 714 Removal Procedure..................................................................................... 714 Installation Procedure................................................................................ 715 Master Cylinder (Brake) - Remove.......................................................................... 716 Removal Procedure..................................................................................... 716 Master Cylinder (Brake) - Install......................................................................... 331 Installation Procedure................................................................................ 717 Hydraulic Tank - Remove................................................................................... 719 Removal Procedure..................................................................................... 719 Hydraulic Tank - Install.................................................................................. 720 Installation Procedure................................................................................ 720 Piston Pump (Implement and Steering) - Remove............................................................. 721 Removal Procedure..................................................................................... 721 Piston Pump (Implement and Steering) - Disassemble........................................................ 723 Disassembly Procedure................................................................................. 83 Piston Pump (Implement and Steering) - Assemble........................................................... 727 Assembly Procedure.................................................................................... 727 Piston Pump (Implement and Steering) - Install............................................................ 732 Installation Procedure................................................................................ 732 Solenoid Valve (Frame Leveling) - Remove and Install...................................................... 733 Removal Procedure..................................................................................... 733 Installation Procedure................................................................................ 733 Diverter Valve (Boom Head) - Remove and Install........................................................... 734 Removal Procedure..................................................................................... 734 Installation Procedure................................................................................ 734 Control Valve (Stabilizer) - Remove....................................................................... 735 Removal Procedure..................................................................................... 735 Electronic Pilot Valve (Stabilizer) - Remove and Install.................................................. 736 Removal Procedure..................................................................................... 736 Installation Procedure................................................................................ 737 Bank Valve (Stabilizer) - Disassemble..................................................................... 737 Disassembly Procedure................................................................................. 737 Bank Valve (Stabilizer) - Assemble........................................................................ 740 Assembly Procedure.................................................................................... 740 Control Valve (Stabilizer) -Install....................................................................... 742 Installation Procedure................................................................................ 742 Stabilizer Cylinder - Remove and Install.................................................................. 744 Removal Procedure..................................................................................... 744 Disassembly and Assembly Information.................................................................. 746 Installation Procedure................................................................................ 748 Load Control Valve (Stabilizer Cylinder) - Remove and Install............................................. 749 Removal Procedure..................................................................................... 749 Installation Procedure................................................................................ 750 Fuel Tank - Remove........................................................................................ 750 Removal Procedure..................................................................................... 355 Fuel Tank - Install....................................................................................... 752 Installation Procedure................................................................................ 752 Cab - Remove.............................................................................................. 753 Removal Procedure..................................................................................... 753 Cab - Install............................................................................................. 757 Installation Procedure................................................................................ 757 Window Wiper and Wiper Motor (Front) - Remove and Install................................................. 760 Removal Procedure..................................................................................... 760 Installation Procedure................................................................................ 761 Window Wiper and Wiper Motor (Rear) - Remove and Install.................................................. 762 Removal Procedure..................................................................................... 762 Installation Procedure................................................................................ 763 Window Wiper and Wiper Motor (Roof) - Remove and Install.................................................. 764 Removal Procedure..................................................................................... 764 Installation procedure.................................................................................... 765 Cab Heater - Remove....................................................................................... 766 Removal Procedure..................................................................................... 766 Cab Heater - Install...................................................................................... 768 Installation Procedure................................................................................ 768 Heater Coil - Remove and Install.......................................................................... 770 Removal Procedure..................................................................................... 770 Installation Procedure................................................................................ 771 Air Conditioner - Install................................................................................. 771 Installation Procedure................................................................................ 771 Evaporator Coil - Remove and Install...................................................................... 776 Removal Procedure..................................................................................... 776 Installation procedure................................................................................ 777 Joystick Control - Remove and Install..................................................................... 778 Removal Procedure..................................................................................... 778 Installation Procedure................................................................................ 779 Seat - Remove and Install................................................................................. 779 Removal Procedure..................................................................................... 779 Installation Procedure................................................................................ 780 Fender - Remove and Install............................................................................... 780 Removal Procedure..................................................................................... 780 Installation Procedure................................................................................ 780 Sump Guard - Remove and Install........................................................................... 781 Removal Procedure..................................................................................... 781 Installation Procedure................................................................................ 781 Counterweight - Remove and Install........................................................................ 781 Removal Procedure..................................................................................... 781 Installation Procedure................................................................................ 783 Quick Coupler - Remove.................................................................................... 784 Removal Procedure..................................................................................... 784 Quick Coupler - Disassemble............................................................................... 786 Disassembly Procedure................................................................................. 786 Quick Coupler - Assemble.................................................................................. 788 Assembly Procedure.................................................................................... 788 Quick Coupler - Install................................................................................... 789 Installation Procedure................................................................................ 789 Boom - Remove............................................................................................. 791 Removal Procedure..................................................................................... 791 Boom - Disassemble........................................................................................ 793 Disassembly Procedure................................................................................. 793 Boom - Assemble........................................................................................... 799 Assembly Procedure.................................................................................... 799 Boom - Install............................................................................................ 808 Installation Procedure................................................................................ 808 Hydraulic Oil Lines (Boom) - Remove....................................................................... 810 Removal Procedure..................................................................................... 810 Tilt Cylinder Hoses (Boom)............................................................................ 811 Auxiliary Hoses (Boom)................................................................................ 814 Hydraulic Oil Lines (Boom) - Install...................................................................... 817 Installation Procedure................................................................................ 817 Telescoping Cylinder - Remove and Install................................................................. 824 Removal Procedure..................................................................................... 824 Disassembly and Assembly Information.................................................................. 829 Installation Procedure................................................................................ 830 Load Control Valve (Telescoping Cylinder) - Remove and Install............................................ 835 Removal Procedure..................................................................................... 835 Installation Procedure................................................................................ 836 Boom Cylinder - Remove and Install........................................................................ 837 Removal Procedure..................................................................................... 837 Disassembly and Assembly Information.................................................................. 839 Installation Procedure................................................................................ 840 Load Control Valve (Boom Cylinder) - Remove and Install................................................... 842 Removal Procedure..................................................................................... 842 Installation Procedure................................................................................ 843 Tilt Cylinder - Remove and Install........................................................................ 843 Removal Procedure..................................................................................... 843 Disassembly and Assembly Information.................................................................. 845 Installation Procedure................................................................................ 846 Load Control Valve (Tilt Cylinder) - Remove and Install................................................... 848 Removal Procedure..................................................................................... 848 Installation Procedure................................................................................ 848 Frame Leveling Cylinder - Remove and Install.............................................................. 849 Removal Procedure..................................................................................... 849 Disassembly and Assembly Information.................................................................. 851 Installation Procedure................................................................................ 852 Load Control Valve (Frame Leveling Cylinder) - Remove and Install......................................... 854 Removal Procedure..................................................................................... 854 Installation Procedure................................................................................ 855 Compensating Cylinder Remove and Install.................................................................. 855 Removal Procedure..................................................................................... 855 Disassembly and Assembly Information.................................................................. 857 Installation Procedure................................................................................ 858 Axle Lock Cylinder - Remove and Install................................................................... 859 Removal Procedure..................................................................................... 859 Disassembly and Assembly Information.................................................................. 862 Installation Procedure................................................................................ 863 Shutoff Valve (Axle Lock) - Remove and Install............................................................ 865 Removal Procedure..................................................................................... 865 Installation Procedure................................................................................ 865 Stabilizer - Remove....................................................................................... 866 Removal Procedure..................................................................................... 866 Stabilizer - Install...................................................................................... 869 Installation Procedure................................................................................ 869 Stabilizer............................................................................................ 873 ELECTRICAL SYSTEMS.................................................................................................... 881 31200310_TH360B Electrical System Schematic....................................................................... 882 31200311_TH560B Electrical System Schematic....................................................................... 886 31200279_Electronic Control System, Hydrostatic Transmission Troubleshooting Test-Adjust.......................... 890 Table of Contents............................................................................................. 892 Introduction.................................................................................................. 896 General Information....................................................................................... 896 Service Tools............................................................................................. 896 Connector Locations....................................................................................... 897 Connector Contact Numbers............................................................................. 897 Diagnostic Capabilities................................................................................... 898 Monitoring System/Instrument Cluster.................................................................. 898 The Caterpillar Electronic Technician (ET)............................................................ 899 Logged Event Codes.................................................................................... 900 Status Groups For The Electronic Technician........................................................... 901 Machine Preparation for Troubleshooting................................................................... 901 General Troubleshooting Information....................................................................... 902 Visual Inspection......................................................................................... 902 Operational Checks........................................................................................ 902 Operational Checks (Braking System)................................................................... 902 Operational Checks (Steering System).................................................................. 903 Operational Checks (Power Train)...................................................................... 903 Operational Checks (Hydraulic System)................................................................. 903 Event Code List........................................................................................... 905 Warning Levels........................................................................................ 905 Indications and System Response....................................................................... 905 Troubleshooting....................................................................................... 906 Telehandler Event Code List........................................................................... 906 Symptom Procedures............................................................................................ 908 Steering System........................................................................................... 908 Troubleshooting The Steering System................................................................... 908 Brake System.............................................................................................. 909 Troubleshooting The Brake System...................................................................... 909 Troubleshooting The Parking Brake..................................................................... 910 Transmission.............................................................................................. 910 Troubleshooting The Transmission System............................................................... 910 Hydraulic System.......................................................................................... 912 Troubleshooting The Hydraulic System.................................................................. 912 Torque Converter.......................................................................................... 914 Troubleshooting The Torque Converter.................................................................. 914 Differential and Final Drive.............................................................................. 915 The Differential And The Final Drive Troubleshooting.................................................. 915 Diagnostic Code Procedures.................................................................................... 918 Diagnostic Code List...................................................................................... 918 Module Identifier (MID)............................................................................... 918 Component Identifier (CID)............................................................................ 918 Failure Mode Identifier (FMI)......................................................................... 920 Using the Operator Monitor to Determine Diagnostic Codes.................................................. 922 Using Caterpillar Electronic Technician to Determine Diagnostic Codes..................................... 922 Active Diagnostic Codes............................................................................... 923 Logged Diagnostic Codes............................................................................... 924 MID 039 - CID 0041 - FMI 03............................................................................... 925 MID 039 - CID 0041 - FMI 04............................................................................... 926 MID 039 - CID 0070 - FMI 03............................................................................... 927 MID 039 - CID 0070 - FMI 04............................................................................... 929 MID 039 - CID 0096 - FMI 03............................................................................... 930 MID 039 - CID 0096 - FMI 04............................................................................... 931 MID 039 - CID0 110 - FMI 03............................................................................... 932 MID 039 - CID 0110 - FMI 04............................................................................... 933 MID 039 - CID 0177 - FMI 03............................................................................... 934 MID 039 - CID 0177 - FMI 04............................................................................... 936 MID 039 - CID 0191 - FMI 02............................................................................... 936 MID 039 - CID 0246 - FMI 12............................................................................... 938 MID 039 - CID 0262 - FMI 03............................................................................... 939 MID 039 - CID 0262 - FMI 04............................................................................... 940 MID 039 - CID 0271 - FMI 03............................................................................... 941 MID 039 - CID 0271 - FMI 04............................................................................... 942 MID 039 - CID 0271 - FMI 05............................................................................... 943 MID 039 - CID 0368 - FMI 03............................................................................... 945 MID 039 - CID 0368 - FMI 04............................................................................... 946 MID 039 - CID 0444 - FMI 03............................................................................... 947 MID 039 - CID 0444 - FMI 04............................................................................... 948 MID 039 - CID 0444 - FMI 05............................................................................... 949 MID 039 - CID 0489 - FMI 02............................................................................... 951 MID 039 - CID 0489 - FMI 04............................................................................... 953 MID 039 - CID 0490 - FMI 02............................................................................... 955 MID 039 - CID 0590 - FMI 02............................................................................... 958 MID 039 - CID 0590 - FMI 09............................................................................... 960 MID 039 - CID 0590 - FMI 12............................................................................... 962 MID 039 - CID 0629 - FMI 04............................................................................... 964 MID 039 - CID 0668 - FMI 02............................................................................... 965 MID 039 - CID 0668 - FMI 09............................................................................... 967 MID 039 - CID 0668 - FMI 12............................................................................... 969 MID 039 - CID 0672 - FMI 02............................................................................... 971 MID 039 - CID 0702 - FMI 02............................................................................... 972 MID 039 - CID 0750 - FMI 02............................................................................... 975 MID 039 - CID 0811 - FMI 09............................................................................... 976 MID 039 - CID 0817 - FMI 04............................................................................... 978 MID 039 - CID 0826 - FMI 03............................................................................... 979 MID 039 - CID 0882 - FMI 05............................................................................... 981 MID 039 - CID 0882 - FMI 06............................................................................... 982 MID 039 - CID 1127 - FMI 00............................................................................... 983 MID 039 - CID 1127 - FMI 01............................................................................... 986 MID 039 - CID 1127 - FMI 02............................................................................... 989 MID 039 - CID 1127 - FMI 08............................................................................... 991 MID 039 - CID 1128 - FMI 00............................................................................... 994 MID 039 - CID 1128 - FMI 01............................................................................... 997 MID 039 - CID 1128 - FMI 02...............................................................................1000 MID 039 - CID 1128 - FMI 08...............................................................................1003 MID 039 - CID 1138 - FMI 05...............................................................................1006 MID 039 - CID 1138 - FMI 06...............................................................................1008 MID 039 - CID 1187 - FMI 04...............................................................................1009 MID 039 - CID 1189 - FMI 00...............................................................................1010 MID 039 - CID 1189 - FMI 01...............................................................................1013 MID 039 - CID 1189 - FMI 02...............................................................................1015 MID 039 - CID 1189 - FMI 08...............................................................................1018 MID 039 - CID 1193 - FMI 05...............................................................................1021 MID 039 - CID 1193 - FMI 06...............................................................................1023 MID 039 - CID 1251 - FMI 08...............................................................................1024 MID 039 - CID 1326 - FMI 02...............................................................................1025 MID 039 - CID 1401 - FMI 03...............................................................................1026 MID 039 - CID 1401 - FMI 05...............................................................................1027 MID 039 - CID 1401 - FMI 06...............................................................................1028 MID 039 - CID 1402 - FMI 03...............................................................................1029 MID 039 - CID 1402 - FMI 06...............................................................................1032 MID 039 - CID 1403 - FMI 03...............................................................................1033 MID 039 - CID 1403 - FMI 05...............................................................................1034 MID 039 - CID 1403 - FMI 06...............................................................................1035 MID 039 - CID 1404 - FMI 03...............................................................................1036 MID 039 - CID 1404 - FMI 05...............................................................................1037 MID 039 - CID 1404 - FMI 06...............................................................................1038 MID 039 - CID 1405 - FMI 03...............................................................................1040 MID 039 - CID 1405 - FMI 05...............................................................................1041 MID 039 - CID 1405 - FMI 06...............................................................................1042 MID 039 - CID 1406 - FMI 03...............................................................................1043 MID 039 - CID 1406 - FMI 05...............................................................................1044 MID 039 - CID 1406 - FMI 06...............................................................................1046 MID 039 - CID 1407 - FMI 03...............................................................................1047 MID 039 - CID 1407 - FMI 05...............................................................................1048 MID 039 - CID 1407 - FMI 06...............................................................................1049 MID 039 - CID 1410 - FMI 05...............................................................................1051 MID 039 - CID 1410 - FMI 06...............................................................................1053 MID 039 - CID 1482 - FMI 03...............................................................................1055 MID 039 - CID 1482 - FMI 04...............................................................................1057 MID 039 - CID 1529 - FMI 02...............................................................................1058 MID 039 - CID 1603 - FMI 09...............................................................................1060 MID 039 - CID 1639 - FMI 02...............................................................................1062 MID 039 - CID 1639 - FMI 09...............................................................................1064 MID 039 - CID 1658 - FMI 00...............................................................................1066 MID 039 - CID 1658 - FMI 01...............................................................................1069 MID 039 - CID 1658 - FMI 02...............................................................................1072 MID 039 - CID 1658 - FMI 08...............................................................................1074 MID 039 - CID 1718 - FMI 02...............................................................................1077 MID 039 - CID 1740 - FMI 03...............................................................................1079 MID 039 - CID 1740 - FMI 04...............................................................................1080 MID 039 - CID 1740 - FMI 05...............................................................................1081 MID 039 - CID 1741 - FMI 03...............................................................................1083 MID 039 - CID 1741 - FMI 04...............................................................................1084 MID 039 - CID 1741 - FMI 05...............................................................................1085 MID 039 - CID 1763 - FMI 02...............................................................................1087 MID 039 - CID 1788 - FMI 02...............................................................................1089 MID 039 - CID 1789 - FMI 02...............................................................................1090 MID 039 - CID 1820 - FMI 05...............................................................................1092 MID 039 - CID 1820 - FMI 06...............................................................................1093 MID 039 - CID 1823 - FMI 03...............................................................................1094 MID 039 - CID 1823 - FMI 04...............................................................................1096 MID 039 - CID 1823 - FMI 08...............................................................................1099 MID 039 - CID 1824 - FMI 03...............................................................................1101 MID 039 - CID 1824 - FMI 04...............................................................................1103 MID 039 - CID 1824 - FMI 08...............................................................................1105 MID 039 - CID 1825 - FMI 03...............................................................................1107 MID 039 - CID 1825 - FMI 04...............................................................................1109 MID 039 - CID 1825 - FMI 08...............................................................................1111 MID 039 - CID 1826 - FMI 00...............................................................................1113 MID 039 - CID 1826 - FMI 01...............................................................................1115 MID 039 - CID 1826 - FMI 02...............................................................................1118 MID 039 - CID 1826 - FMI 08...............................................................................1120 MID 039 - CID 1827 - FMI 13...............................................................................1121 MID 039 - CID 1828 - FMI 02...............................................................................1122 MID 039 - CID 1829 - FMI 02...............................................................................1123 MID 039 - CID 1830 - FMI 02...............................................................................1125 MID 039 - CID 1831 - FMI 05...............................................................................1127 MID 039 - CID 1831 - FMI 06...............................................................................1129 MID 039 - CID 1832 - FMI 02...............................................................................1130 MID 039 - CID 1833 - FMI 02...............................................................................1131 MID 039 - CID 1834 - FMI 03...............................................................................1132 MID 039 - CID 1845 - FMI 02...............................................................................1134 MID 039 - CID 1845 - FMI 05...............................................................................1136 MID 039 - CID 1845 - FMI 06...............................................................................1138 MID 039 - CID 1845 - FMI 09...............................................................................1140 MID 039 - CID 1846 - FMI 02...............................................................................1143 MID 039 - CID 1846 - FMI 05...............................................................................1145 MID 039 - CID 1846 - FMI 06...............................................................................1147 MID 039 - CID 1846 - FMI 09...............................................................................1149 MID 039 - CID 1847 - FMI 02...............................................................................1152 MID 039 - CID 1847 - FMI 05...............................................................................1154 MID 039 - CID 1847 - FMI 06...............................................................................1156 MID 039 - CID 1847 - FMI 09...............................................................................1158 MID 039 - CID 1930 - FMI 05...............................................................................1161 MID 039 - CID 1930 - FMI 06...............................................................................1162 MID 039 - CID 1935 - FMI 03...............................................................................1164 MID 039 - CID 1935 - FMI 04...............................................................................1166 MID 039 - CID 1960 - FMI 09...............................................................................1169 MID 039 - CID 2101 - FMI 08...............................................................................1171 MID 039 - CID 2197 - FMI 02...............................................................................1173 MID 039 - CID 2240 - FMI 05...............................................................................1175 MID 039 - CID 2240 - FMI 06...............................................................................1177 MID 039 - CID 2241 - FMI 05...............................................................................1178 MID 039 - CID 2241 - FMI 06...............................................................................1180 MID 039 - CID 2242 - FMI 05...............................................................................1181 MID 039 - CID 2242 - FMI 06...............................................................................1183 MID 039 - CID 2243 - FMI 05...............................................................................1184 MID 039 - CID 2243 - FMI 06...............................................................................1186 MID 039 - CID 2281 - FMI 05...............................................................................1187 MID 039 - CID 2281 - FMI 06...............................................................................1189 MID 039 - CID 2282 - FMI 05...............................................................................1190 MID 039 - CID 2282 - FMI 06...............................................................................1191 MID 039 - CID 2287 - FMI 05...............................................................................1193 MID 039 - CID 2287 - FMI 06...............................................................................1194 MID 039 - CID 2288 - FMI 05...............................................................................1196 MID 039 - CID 2288 - FMI 06...............................................................................1198 MID 039 - CID 2289 - FMI 05...............................................................................1200 MID 039 - CID 2289 - FMI 06...............................................................................1202 MID 039 - CID 2290 - FMI 05...............................................................................1203 MID 039 - CID 2525 - FMI 03...............................................................................1207 MID 039 - CID 2525 - FMI 05...............................................................................1208 MID 039 - CID 2525 - FMI 06...............................................................................1209 MID 039 - CID 2670 - FMI 03...............................................................................1210 MID 039 - CID 2670 - FMI 05...............................................................................1211 MID 039 - CID 2670 - FMI 06...............................................................................1212 MID 039 - CID 2722 - FMI 02...............................................................................1214 MID 082 - CID 0271 - FMI 04...............................................................................1216 MID 082 - CID 0271 - FMI 05...............................................................................1217 MID 082 - CID 0324 - FMI 03...............................................................................1219 MID 082 - CID 0324 - FMI 04...............................................................................1220 MID 082 - CID 0324 - FMI 05...............................................................................1221 MID 082 - CID 1125 - FMI 03...............................................................................1222 MID 082 - CID 1125 - FMI 04...............................................................................1224 MID 082 - CID 1125 - FMI 08...............................................................................1226 MID 082 - CID 1763 - FMI 02...............................................................................1228 MID 082 - CID 1763 - FMI 03...............................................................................1230 MID 082 - CID 1763 - FMI 04...............................................................................1233 MID 082 - CID 1763 - FMI 05...............................................................................1235 MID 082 - CID 1879 - FMI 03...............................................................................1238 MID 082 - CID 1879 - FMI 04...............................................................................1240 MID 082 - CID 1879 - FMI 08...............................................................................1241 MID 117 - CID 0168 - FMI 00...............................................................................1243 MID 117 - CID 0168 - FMI 01...............................................................................1244 MID 117 - CID 0668 - FMI 12...............................................................................1245 Testing and Adjusting Section.................................................................................1248 Testing and Adjusting.....................................................................................1248 General Information...................................................................................1248 Electrical Connector - Inspect........................................................................1248 Wiring Harness (Open Circuit) -Test...................................................................1252 Wiring Harness (Short Circuit) -Test..................................................................1252 Electronic Control Module (ECM) - Flash Program.......................................................1253 Electronic Control Module (ECM) - Configure...........................................................1253 Electronic Control Module (ECM) - Replace.............................................................1259 Connector Contact Description.........................................................................1260 Glossary of Electrical Terms..........................................................................1262 System Schematic......................................................................................1264 31200280_LSI System Operation & Maintenance.......................................................................1278 Table of Contents............................................................................................. 4 Systems Operation Section.....................................................................................1282 Introduction..............................................................................................1282 General Information.......................................................................................1283 Operational Modes.....................................................................................1283 Location of Electrical Components.........................................................................1283 Electrical Control Module............................................................................. 499 Instrument Cluster....................................................................................1283 Sensor................................................................................................1284 Electrical Input Components...............................................................................1284 Sensor................................................................................................1284 Electronic Control Module.................................................................................1284 Electrical Output Components..............................................................................1284 Testing and Adjusting Section.................................................................................1286 Testing and Adjusting Sensor - Test.......................................................................1286 Test On The Vehicle...................................................................................1286 Removal And Installation of the Sensor for the Longitudinal Stability Indicator System................ 553 General Instructions..................................................................................1287 Removal Instructions..................................................................................1287 Surface Preparation...................................................................................1287 Application of the Adhesive...........................................................................1287 Sensor Installation...................................................................................1287 Coverage of the Mounting Pads.........................................................................1288 Calibration of the Sensor.............................................................................1288 Electrical Information................................................................................1288 Display Module - Replace..................................................................................1288 Calibration...............................................................................................1289 Longitudinal Stability Indicator (LSI) Calibration....................................................1289 31200281_Monitor System Test-Adjust...............................................................................1300 Table of Contents............................................................................................. 4 Systems Operation Section.....................................................................................1282 Introduction..............................................................................................1282 Operation............................................................................................. 158 Power Up..............................................................................................1304 Power Down............................................................................................1304 Diagnostics...........................................................................................1304 Failure Modes.........................................................................................1304 Software..............................................................................................1304 Features..................................................................................................1304 Instrument Cluster....................................................................................1304 Status Indicators.....................................................................................1305 Gauge Indicators...................................................................................... 532 Location of Electrical Components.........................................................................1307 Instrument Cluster....................................................................................1307 Electronic Control Module.............................................................................1307 Turn Signal...........................................................................................1307 High Beam Switch......................................................................................1308 Starting Aid Switch...................................................................................1308 Hydraulic Oil Filter Bypass Pressure Switch...........................................................1308 Engine Oil Pressure Switch............................................................................1308 Air Filter Restriction Indicator......................................................................1309 Fuel Level Sensor.....................................................................................1309 Transmission Oil Temperature Sensor...................................................................1309 Engine Speed Sensor...................................................................................1309 Engine Coolant Temperature Sensor.....................................................................1310 Component Description.....................................................................................1311 Switches..............................................................................................1311 Sensors...............................................................................................1312 Additional Circuits...................................................................................1312 Data Link.............................................................................................1312 CAT Data Link.........................................................................................1312 CAN Data Link.........................................................................................1313 Warning Operation.........................................................................................1313 Diagnostic Operation......................................................................................1313 Troubleshooting Procedures............................................................................1313 Module Identifier (MID)...............................................................................1314 Component Identifier (CID)............................................................................1314 Failure Mode Identifier (FMI).........................................................................1314 Testing and Adjusting Section.................................................................................1316 Testing and Adjusting.....................................................................................1316 Self Test.................................................................................................1316 Self Test.............................................................................................1316 Module - Replace.......................................................................................... 504 Connector Contact Description.............................................................................1317 System Schematic..........................................................................................1318
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