Cat TH560B Telehandler Operation & Maintenance Manual – PDF DOWNLOAD

Description

Cat TH560B Telehandler Operation & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

Cat TH560B Telehandler Operation & Maintenance Manual – PDF DOWNLOAD

Foreword

Literature Information

• This manual should be stored in the operator’s compartment in the literature holder or seat back literature storage area. This manual contains safety information, operation instructions, transportation information, lubrication information and maintenance information.
• Some photographs or illustrations in this publication show details or attachments that can be different from your machine. Guards and covers might have been removed for illustrative purposes.
• Continuing improvement and advancement of product design might have caused changes to your machine which are not included in this publication. Read, study and keep this manual with the machine.
• Whenever a question arises regarding your machine, or this publication, please consult your Caterpillar dealer for the latest available information.

Safety

• The safety section lists basic safety precautions. In addition, this section identifies the text and locations of warning signs and labels used on the machine.
• Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this machine.

Operation

• The operation section is a reference for the new operator and a refresher for the experienced operator. This section includes a discussion of gauges, switches, machine controls, attachment controls, transportation and towing information.
• Photographs and illustrations guide the operator through correct procedures of checking, starting, operating and stopping the machine.
• Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the machine and its capabilities

Maintenance

The maintenance section is a guide to equipment care. The Maintenance Interval Schedule (MIS) lists the items to be maintained at a specific service interval. Items without specific intervals are listed under the “When Required” service interval. The Maintenance Interval Schedule lists the page number for the step-by-step instructions required to accomplish the scheduled maintenance. Use the Maintenance Interval Schedule as an index or “one safe source” for all maintenance procedures.

Maintenance Intervals

• Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first.
• Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in the maintenance intervals chart might be necessary.

Certified Engine Maintenance

• Proper maintenance and repair is essential to keep the engine and machine systems operating correctly. As the heavy duty off-road diesel engine owner, you are responsible for the performance of the required maintenance listed in the Owner Manual, Operation and Maintenance Manual, and Service Manual.
• It is prohibited for any person engaged in the business of repairing, servicing, selling, leasing, or trading engines or machines to remove, alter, or render inoperative any emission related device or element of design installed on or in an engine or machine that is in compliance with the regulations (40 CFR Part 89). Certain elements of the machine and engine such as the exhaust system, fuel system, electrical system, intake air system and cooling system may be emission related and should not be altered unless approved by Caterpillar.

Machine Capacity

Additional attachments or modifications may exceed machine design capacity which can adversely affect performance characteristics. Included would be stability and system certifications such as brakes, steering, and rollover protective structures (ROPS). Contact your Caterpillar dealer for further information

TABLE OF CONTENTS:

Cat TH560B Telehandler Operation & Maintenance Manual – PDF DOWNLOAD

31200244_B_TH560B_CAT_O&MM...............................................................................  1
	Effectivity..........................................................................................  3
	Table of Contents....................................................................................  5
	Foreword.............................................................................................  9
		Literature Information...........................................................................  9
		Safety...........................................................................................  9
		Operation........................................................................................  9
		Maintenance......................................................................................  9
			Maintenance Intervals........................................................................  9
		Certified Engine Maintenance.....................................................................  9
		Machine Capacity.................................................................................  9
		Contact Information.............................................................................. 10
	Safety Section....................................................................................... 11
		Safety Messages.................................................................................. 11
			Do Not Operate (1)........................................................................... 14
			Do Not Stand Under the Load (2).............................................................. 14
			No Hands (3)................................................................................. 15
			Do Not Operate (4)........................................................................... 15
			Forks (5).................................................................................... 16
			Do Not Weld On The ROPS/FOPS Structure (6)................................................... 16
			Crushing Hazard (7).......................................................................... 17
			No Hands (8)................................................................................. 17
			Seat Belt (9)................................................................................ 18
			Crushing Hazard (10)......................................................................... 18
			Crushing Hazard (11)......................................................................... 19
			Engine Coolant (12).......................................................................... 19
			Avoid Power Lines (13)....................................................................... 20
			Low Bridge (14).............................................................................. 20
			Jump Start Cables (15)....................................................................... 21
			Ether (16)................................................................................... 21
			Crushing Hazard (17)......................................................................... 21
			Crushing Hazard (18)......................................................................... 21
			Operation (19)............................................................................... 22
			Impaling Hazard (20)......................................................................... 22
			Crushing Hazard (21)......................................................................... 22
			Entanglement and Flying Objects (22)......................................................... 22
			Trap Point (23).............................................................................. 23
			Crushing Hazard (24)......................................................................... 23
			Ether (25)................................................................................... 23
			Hand (High Pressure) (26).................................................................... 24
			Universal Warning (27)....................................................................... 24
			Additional Messages.......................................................................... 24
		General Hazard Information....................................................................... 28
			Pressurized Air and Water.................................................................... 28
			Trapped Pressure............................................................................. 28
			Fluid Penetration............................................................................ 29
			Containing Fluid Spillage.................................................................... 29
			Dispose of Waste Properly.................................................................... 29
		Crushing Prevention and Cutting Prevention....................................................... 29
		Burn Prevention.................................................................................. 30
			Coolant...................................................................................... 30
			Oils......................................................................................... 30
			Batteries.................................................................................... 30
		Fire Prevention and Explosion Prevention......................................................... 30
			Fire Extinguisher............................................................................ 31
			Lines, Tubes and Hoses....................................................................... 31
			Fire Extinguisher Location................................................................... 31
			Tire Information............................................................................. 32
			Electrical Storm Injury Prevention........................................................... 32
			Before Starting Engine....................................................................... 32
		Engine Starting.................................................................................. 33
		Before Operation................................................................................. 33
		Operation........................................................................................ 33
			Machine Operating Temperature Range.......................................................... 33
			Machine Operation............................................................................ 33
			Travel....................................................................................... 34
			Lifting Capacities........................................................................... 34
			Work Tools................................................................................... 34
		Engine Stopping.................................................................................. 34
		Work Tools....................................................................................... 35
		Parking.......................................................................................... 35
		Equipment Lowering with Loss of Hydraulic Power.................................................. 35
		Sound Information and Vibration Information...................................................... 35
			Sound Level.................................................................................. 35
			Vibration Level.............................................................................. 35
		Operator Station................................................................................. 36
		Guards (Operator Protection)..................................................................... 36
			Rollover Protective Structure (ROPS), Falling Object Protective Structure (FOPS)............. 36
			Other Guards (If Equipped)................................................................... 36
	Product Information Section.......................................................................... 37
		General Information.............................................................................. 37
			Lifting Capacities........................................................................... 37
			Examples of Estimating the Lift Operation from the Load Chart................................ 38
		Specifications................................................................................... 39
			Intended Use................................................................................. 39
			Application/Configuration Restrictions....................................................... 39
		Identification Information....................................................................... 40
			Plate Locations and Film Locations........................................................... 40
			Serial Number................................................................................ 40
			Certification................................................................................ 41
			Sound........................................................................................ 41
			ROPS/FOPS Film............................................................................... 41
			Machine Security System...................................................................... 41
			Italian Roading Homologation................................................................. 42
		Emissions Certification Film..................................................................... 43
	Operation Section.................................................................................... 45
		Before Operation................................................................................. 45
			Mounting and Dismounting..................................................................... 45
			Alternate Exit............................................................................... 45
			Daily Inspection............................................................................. 45
		Machine Operation................................................................................ 47
			Alternate Exit............................................................................... 47
			Seat......................................................................................... 47
			Air Suspension (If Equipped)................................................................. 47
			Seat Belt.................................................................................... 48
			Operator Controls (Side Console)............................................................. 50
			Operator Controls............................................................................ 52
			Battery Disconnect Switch (If Equipped)...................................................... 65
			Boom Cylinder Lock (If Equipped)............................................................. 65
			Operation Information........................................................................ 68
			Work Tools................................................................................... 75
			Monitoring System............................................................................ 82
			Backup Alarm................................................................................. 85
			Cab Door..................................................................................... 85
		Engine Starting.................................................................................. 86
			Engine Starting.............................................................................. 86
			Starting Below 0 C (32F)................................................................... 86
			Engine and Machine Warm-Up................................................................... 87
		Parking.......................................................................................... 87
			Stopping the Machine......................................................................... 87
			Stopping the Engine.......................................................................... 87
			Stopping the Engine if an Electrical Malfunction Occurs...................................... 88
			Leaving the Machine.......................................................................... 88
		Transportation Information....................................................................... 88
			Shipping the Machine......................................................................... 88
			Roading the Machine.......................................................................... 88
			Lifting and Tying Down the Machine........................................................... 89
		Towing Information............................................................................... 90
			Towing the Machine........................................................................... 90
		Engine Starting (Alternate Methods).............................................................. 92
			Engine Starting with Jump Start Cables....................................................... 92
			Equipment Lowering with Loss of Hydraulic Power.............................................. 93
	Maintenance Section.................................................................................. 97
		Maintenance Access............................................................................... 97
			Access Doors and Covers...................................................................... 97
		Tire Inflation Information....................................................................... 97
			Tire Inflation with Air...................................................................... 97
			Tire Pressure................................................................................ 98
			Tire Inflation Pressure Adjustment........................................................... 98
			Tire Damage.................................................................................. 99
			Tire Replacement............................................................................. 99
			Wheel and Tire Installation.................................................................. 99
		Lubricant Viscosities and Refill Capacities......................................................100
			Lubricant Viscosities........................................................................100
			Capacities (Refill)..........................................................................102
			SOS Information..............................................................................102
		Maintenance Support..............................................................................103
			Welding on Machines and Engines with Electronic Controls.....................................103
		Maintenance Interval Schedule....................................................................103
		Axle Breathers - Clean/Replace...................................................................105
		Backup Alarm - Test..............................................................................105
		Battery - Recycle................................................................................105
		Battery or Battery Cable - Inspect/Replace.......................................................105
		Belt - Inspect/Replace...........................................................................105
			Inspect......................................................................................105
			Replace......................................................................................106
		Boom Chain - Inspect/ Lubricate..................................................................107
		Boom Chain Tension -Check/ Adjust................................................................107
			Check Condition..............................................................................107
			Check and Adjust the Chain Tension...........................................................107
			Measure the Chain for Wear...................................................................108
		Boom Cylinder Pin - Lubricate....................................................................109
		Boom Head Section - Lubricate....................................................................109
		Boom Pivot Shaft - Lubricate.....................................................................109
		Boom Telescoping Cylinder Air- Purge.............................................................109
		Boom Wear Pad Clearance - Inspect/Adjust.........................................................110
			Adjustment...................................................................................111
		Boom and Frame - Inspect.........................................................................112
		Braking System - Test............................................................................113
			Service Brake................................................................................113
			Parking Brake................................................................................113
		Cab Air Filter - Clean/Replace...................................................................114
			Primary Cab Air Filter.......................................................................114
			Secondary Cab Air Filter.....................................................................115
		Circuit Breakers - Test..........................................................................115
		Compensating Cylinder Bearing - Lubricate........................................................115
		Cooling System Coolant - Change..................................................................116
		Cooling System Coolant Level - Check.............................................................117
		Cooling System Coolant Sample (Level 1) - Obtain.................................................117
		Cooling System Coolant Sample (Level 2) - Obtain.................................................118
		Cooling System Pressure Cap - Clean/Replace......................................................119
		Cooling System Water Temperature Regulator Replace...............................................119
		Differential Oil - Change........................................................................120
			Rear Axle Differential.......................................................................120
			Front Axle Differential......................................................................120
		Differential Oil Level - Check...................................................................121
			Rear Axle Differential.......................................................................121
			Front Axle Differential......................................................................121
		Differential Oil Sample - Obtain.................................................................122
		Drive Shaft Spline - Lubricate...................................................................122
		Drive Shaft Universal Joint Bolts - Check........................................................123
		Engine Air Filter Primary Element - Clean/Replace................................................123
			Cleaning Primary Air Filter Elements.........................................................124
			Inspecting the Primary Air Filter Elements...................................................124
		Engine Air Filter Primary Element - Replace......................................................125
		Engine Air Filter Secondary Element - Replace....................................................125
		Engine Mounts - Inspect..........................................................................125
		Engine Oil Level - Check.........................................................................126
		Engine Oil Sample - Obtain.......................................................................126
		Engine Oil and Filter - Change...................................................................126
		Engine Valve Lash - Check........................................................................128
		Final Drive Oil - Change.........................................................................128
		Final Drive Oil Level - Check....................................................................129
		Final Drive Oil Sample - Obtain..................................................................129
		Fork Leveling Cylinder Pin - Lubricate...........................................................130
		Frame Leveling Cylinder Pin - Lubricate..........................................................130
		Fuel System - Prime..............................................................................130
		Fuel System Water Separator - Drain..............................................................131
		Fuel System Water Separator Element - Replace (Tier II)..........................................131
		Fuel System Water Separator Element - Replace (Tier III).........................................132
		Fuel Tank Cap - Clean............................................................................133
		Fuel Tank Water and Sediment - Drain.............................................................133
		Fuses and Relays - Replace.......................................................................134
			Fuses........................................................................................134
			Relays.......................................................................................136
		Indicators and Gauges - Test.....................................................................137
		Longitudinal Stability Indicator - Calibrate.....................................................137
		Longitudinal Stability Indicator - Test..........................................................137
			Initial Test.................................................................................137
			Second Test..................................................................................137
		Oil Filter - Inspect.............................................................................138
			Inspect a Used Filter for Debris.............................................................138
		Parking Brake - Adjust...........................................................................138
		Pulley for Boom Extension Chain - Lubricate......................................................139
		Pulley for Boom Retraction Chain - Lubricate.....................................................139
		Radiator Core - Clean............................................................................139
		Refrigerant Dryer - Replace......................................................................140
		Rollover Protective Structure (ROPS) and Falling Object Protective Structure (FOPS) - Inspect....140
		Seat Belt - Inspect..............................................................................141
		Seat Belt - Replace..............................................................................141
		Stabilizer and Cylinder Bearings - Lubricate.....................................................141
		Tire Inflation - Check...........................................................................142
		Transmission and Hydraulic System Oil - Change...................................................142
		Transmission and Hydraulic System Oil Filter - Replace...........................................143
		Transmission and Hydraulic System Oil Level - Check..............................................145
		Transmission and Hydraulic System Oil Sample - Obtain............................................145
		Transmission and Hydraulic System Tank Breather - Clean..........................................146
		Turbocharger - Inspect...........................................................................146
		Wheel Nut Torque - Check.........................................................................146
		Window Washer Reservoir -Fill....................................................................146
		Window Wiper -Inspect/ Replace...................................................................147
		Windows - Clean..................................................................................147
		Work Tool - Inspect/Replace......................................................................147
			Forks........................................................................................147
			Buckets......................................................................................149
	Reference Information Section........................................................................151
		Approved Work Tools..............................................................................151
	Index................................................................................................153

CAT TH560B TELEHANDLER OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.M