Operation and Maintenance Manual: TH360B Telehandler

31200243
July 14, 2006
Operation and
Maintenance
Manual
TH360B Telehandler
S/N TBH00100 & After
Keep this manual with machine at all times.

Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar® dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type, strength
and material.
Failure to heed this warning can lead to

premature failures, product damage, personal
injury or death.
31200243 1
Table of Contents
Table of
Table of Contents Before Operation..................................................30
Operation .............................................................30
Foreword Machine Operating Temperature Range ........30
Literature Information ............................................ 5
Machine Operation .........................................30
Safety .................................................................... 5
Travel..............................................................30
Operation .............................................................. 5
Lifting Capacities ............................................30
Maintenance.......................................................... 5
Work Tools......................................................31
Maintenance Intervals ...................................... 5
Engine Stopping...................................................31
Certified Engine Maintenance ............................... 5
Work Tools...........................................................31
Machine Capacity.................................................. 5
Parking.................................................................31
Contact Information ............................................... 6
Equipment Lowering with Loss of Hydraulic
Safety Section Power...................................................................32
Safety Messages................................................... 7 Sound Information and Vibration Information ......32
Do Not Operate (1)......................................... 10 Sound Level....................................................32
Do Not Stand Under the Load (2) .................. 10 Vibration Level ................................................32
No Hands (3).................................................. 11 Operator Station...................................................32
Do Not Operate (4)......................................... 11 Guards (Operator Protection) ..............................32
Forks (5)......................................................... 12 Rollover Protective Structure (ROPS), Falling
Do Not Weld On The ROPS/FOPS Object Protective Structure (FOPS)................33
Structure (6) ................................................... 12 Other Guards (If Equipped) ............................33
Crushing Hazard (7)....................................... 13 Product Information Section
No Hands (8).................................................. 13
General Information .............................................35
Seat Belt (9) ................................................... 14
Lifting Capacities ............................................35
Crushing Hazard (10)..................................... 14
Examples of Estimating the Lift Operation from
Crushing Hazard (11)..................................... 15
the Load Chart ................................................36
Engine Coolant (12) ....................................... 15
Specifications.......................................................37
Avoid Power Lines (13) .................................. 16
Intended Use ..................................................38
Low Bridge (14).............................................. 16
Application/Configuration Restrictions ............38
Jump Start Cables (15) .................................. 17
Identification Information......................................38
Ether (16) ....................................................... 17
Plate Locations and Film Locations ................38
Crushing Hazard (17)..................................... 18
Serial Number.................................................39
Crushing Hazard (18)..................................... 18
Certification.....................................................39
Operation (19) ................................................ 18
Sound .............................................................39
Impaling Hazard (20)...................................... 18
ROPS/FOPS Film ...........................................40
Crushing Hazard (21)..................................... 19
Machine Security System ...............................40
Entanglement and Flying Objects (22)........... 19
Italian Roading Homologation.........................40
Trap Point (23) ............................................... 19
Emissions Certification Film.................................42
Crushing Hazard (24)..................................... 19
Ether (25) ....................................................... 20 Operation Section
Additional Messages ...................................... 20 Before Operation..................................................43
General Hazard Information ................................ 24 Mounting and Dismounting .............................43
Pressurized Air and Water ............................. 25 Alternate Exit ..................................................43
Trapped Pressure .......................................... 25 Daily Inspection ..............................................43
Fluid Penetration ............................................ 25 Machine Operation...............................................45
Containing Fluid Spillage ............................... 25 Alternate Exit ..................................................45
Dispose of Waste Properly............................. 25 Seat ................................................................45
Crushing Prevention and Cutting Prevention ...... 25 Air Suspension (If Equipped) ..........................46
Burn Prevention ............................................. 26 Seat Belt .........................................................46
Coolant........................................................... 26 Operator Controls (Side Console) ..................49
Oils ................................................................. 26 Operator Controls ...........................................51
Batteries ......................................................... 26 Operation Information .....................................67
Fire Prevention and Explosion Prevention .......... 26 Work Tools......................................................75
Fire Extinguisher ............................................ 27 Monitoring System ..........................................80
Lines, Tubes and Hoses ................................ 27 Backup Alarm .................................................83
Fire Extinguisher Location.............................. 28 Cab Door ........................................................84
Tire Information .............................................. 28 Engine Starting ....................................................84
Electrical Storm Injury Prevention .................. 28 Engine Starting ...............................................84
Before Starting Engine ................................... 29 Starting Below 0 °C (32°F)..............................85
Engine Starting.................................................... 29 Engine and Machine Warm-Up.......................85
31200243 2
Table of Contents
Parking ................................................................ 86 Primary Cab Air Filter ...................................115

Stopping the Machine .................................... 86 Secondary Cab Air Filter...............................116
Stopping the Engine....................................... 86 Circuit Breakers - Test .......................................116
Stopping the Engine if an Electrical Malfunction Cooling System Coolant - Change.....................117
Occurs............................................................ 86 Cooling System Coolant Level - Check .............118
Leaving the Machine ...................................... 86 Cooling System Coolant Sample (Level 1) -
Transportation Information .................................. 87 Obtain ................................................................119
Shipping the Machine..................................... 87 Cooling System Coolant Sample (Level 2) -
Roading the Machine ..................................... 87 Obtain ................................................................119
Lifting and Tying Down the Machine .............. 88 Cooling System Pressure Cap - Clean/Replace 120
Towing Information.............................................. 88 Cooling System Water Temperature Regulator
Towing the Machine ....................................... 88 Replace..............................................................120
Types of Towing Hitches................................ 90 Differential Oil - Change.....................................121
Engine Starting (Alternate Methods) ................... 91 Rear Axle Differential....................................121
Engine Starting with Jump Start Cables......... 91 Front Axle Differential ...................................122
Equipment Lowering with Loss of Hydraulic Differential Oil Level - Check .............................122
Power ............................................................. 93 Rear Axle Differential....................................122
Front Axle Differential ...................................123
Maintenance Section
Differential Oil Sample - Obtain .........................123
Maintenance Access ........................................... 97
Drive Shaft Spline - Lubricate ............................124
Access Doors and Covers.............................. 97
Drive Shaft Universal Joint Bolts - Check ..........124
Tire Inflation Information ..................................... 97
Engine Air Filter Primary Element -
Tire Inflation with Air....................................... 97
Clean/Replace ...................................................125
Tire Pressure.................................................. 98
Cleaning Primary Air Filter Elements............125
Tire Inflation Pressure Adjustment ................. 99
Inspecting the Primary Air Filter Elements....126
Tire Damage .................................................. 99
Engine Air Filter Secondary Element - Replace.127
Tire Replacement........................................... 99
Engine Air Filter Primary Element - Replace .....127
Wheel and Tire Installation............................. 99
Engine Mounts - Inspect ....................................127
Lubricant Viscosities and Refill Capacities........ 100
Engine Oil Level - Check ...................................127
Lubricant Viscosities .................................... 100
Engine Oil Sample - Obtain ...............................128
Capacities (Refill) ......................................... 102
Engine Oil and Filter - Change...........................128
SOS Information........................................... 103
Engine Valve Lash - Check................................129
Maintenance Support ........................................ 103
Final Drive Oil - Change.....................................130
Welding on Machines and Engines with
Final Drive Oil Level - Check .............................130
Electronic Controls ....................................... 103
Final Drive Oil Sample - Obtain .........................131
Maintenance Interval Schedule ......................... 104
Fork Leveling Cylinder Pin -Lubricate ................132
Axle Breathers - Clean/Replace ........................ 106
Frame Leveling Cylinder Pin -Lubricate.............132
Backup Alarm - Test.......................................... 106
Fuel System - Prime ..........................................132
Battery - Recycle ............................................... 106
Fuel System Secondary Filter Replace..............133
Battery or Battery Cable -Inspect/Replace ........ 106
Fuel System Water Separator - Drain................133
Belt - Inspect/Replace ....................................... 107
Fuel System Water Separator Element -
Inspect ......................................................... 107
Replace..............................................................134
Replace ........................................................ 107
Fuel Tank Cap - Clean.......................................135
Boom Chain - Inspect/ Lubricate ....................... 108
Fuel Tank Water and Sediment - Drain .............135
Boom Chain Tension -Check/Adjust ................. 108
Fuses and Relays - Replace..............................136
Check Condition........................................... 108
Fuses ............................................................136
Check and Adjust the Chain Tension........... 108
Relays...........................................................138
Measure the Chain for Wear ........................ 109
Indicators and Gauges - Test.............................138
Boom Cylinder Pin - Lubricate .......................... 110
Longitudinal Stability Indicator - Calibrate..........139
Boom Head Section - Lubricate ........................ 110
Longitudinal Stability Indicator -Test ..................139
Boom Pivot Shaft - Lubricate ............................ 110
Initial Test .....................................................139
Boom Telescoping Cylinder Air- Purge ............. 110
Second Test..................................................139
Boom Wear Pad Clearance -Inspect/Adjust...... 111
Oil Filter - Inspect...............................................139
Adjustment ................................................... 112
Inspect a Used Filter for Debris ....................139
Boom and Frame - Inspect................................ 113
Parking Brake - Adjust .......................................140
Braking System - Test ....................................... 114
Pulley for Boom Extension Chain - Lubricate ....140
Service Brake............................................... 114
Pulley for Boom Retraction Chain - Lubricate....140
Parking Brake............................................... 115
Radiator Core - Clean ........................................141
Cab Air Filter - Clean/Replace........................... 115
Refrigerant Dryer - Replace ...............................141
3 31200243
Table of Contents
Rollover Protective Structure (ROPS) and Falling

Object Protective Structure (FOPS) -Inspect .... 142
Seat Belt - Inspect ............................................. 142
Seat Belt - Replace ........................................... 143
Stabilizer and Cylinder Bearings - Lubricate ..... 143
Tire Inflation - Check ......................................... 143
Transmission and Hydraulic System Oil -
Change.............................................................. 144
Transmission and Hydraulic System Oil Filter -
Replace ............................................................. 145
Transmission and Hydraulic System Oil Level -
Check ................................................................ 146
Transmission and Hydraulic System Oil Sample -
Obtain................................................................ 147
Transmission and Hydraulic System Tank
Breather - Clean ................................................ 147
Turbocharger - Inspect ...................................... 147
Wheel Nut Torque - Check................................ 147
Window Washer Reservoir -Fill ......................... 148
Window Wiper -Inspect/Replace ....................... 148
Windows - Clean ............................................... 148
Work Tool - Inspect/Replace ............................. 148
Forks ............................................................ 148
Buckets ........................................................ 150
Reference Information Section
Approved Work Tools.................................. 153
31200243 4
Table of Contents
31200243 5
Foreword
Foreword Maintenance
The maintenance section is a guide to equipment care.
Literature Information The Maintenance Interval Schedule (MIS) lists the
items to be maintained at a specific service interval.
This manual should be stored in the operator's Items without specific intervals are listed under the
compartment in the literature holder or seat back "When Required" service interval. The Maintenance
literature storage area. Interval Schedule lists the page number for the step-
This manual contains safety information, operation by-step instructions required to accomplish the
instructions, transportation information, lubrication scheduled maintenance. Use the Maintenance Interval
information and maintenance information. Schedule as an index or "one safe source" for all
maintenance procedures.
Some photographs or illustrations in this publication
show details or attachments that can be different from
your machine. Guards and covers might have been Maintenance Intervals
removed for illustrative purposes.
Use the service hour meter to determine servicing
Continuing improvement and advancement of product intervals. Calendar intervals shown (daily, weekly,
design might have caused changes to your machine monthly, etc.) can be used instead of service hour
which are not included in this publication. Read, study meter intervals if they provide more convenient
and keep this manual with the machine. servicing schedules and approximate the indicated
Whenever a question arises regarding your machine, or service hour meter reading. Recommended service
this publication, please consult your Caterpillar dealer should always be performed at the interval that occurs
for the latest available information. first.
Under extremely severe, dusty or wet operating
Safety conditions, more frequent lubrication than is specified
in the maintenance intervals chart might be necessary.
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.
Certified Engine Maintenance
Read and understand the basic precautions listed in Proper maintenance and repair is essential to keep the
the safety section before operating or performing engine and machine systems operating correctly. As the
lubrication, maintenance and repair on this machine. heavy duty off-road diesel engine owner, you are
responsible for the performance of the required
maintenance listed in the Owner Manual, Operation
Operation and Maintenance Manual, and Service Manual.
The operation section is a reference for the new It is prohibited for any person engaged in the business
operator and a refresher for the experienced operator. of repairing, servicing, selling, leasing, or trading
This section includes a discussion of gauges, engines or machines to remove, alter, or render
switches, machine controls, attachment controls, inoperative any emission related device or element of
transportation and towing information. design installed on or in an engine or machine that is in
Photographs and illustrations guide the operator compliance with the regulations (40 CFR Part 89).
through correct procedures of checking, starting, Certain elements of the machine and engine such as
operating and stopping the machine. the exhaust system, fuel system, electrical system,
intake air system and cooling system may be emission
Operating techniques outlined in this publication are related and should not be altered unless approved by
basic. Skill and techniques develop as the operator Caterpillar.
gains knowledge of the machine and its capabilities.
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.
6 31200243
Foreword
Contact Information
For:
• Accident Reporting and Product Safety Publications
• Current Owner Updates
• Questions Regarding Product Applications and
Safety
• Standards and Regulations Compliance Information
• Questions Regarding Product Modifications
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233
USA
or Your Local JLG Office
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: 717-485-5161 or 717-485-6591
E-mail: ProductSafety@JLG.com
31200243 7
Safety Section
Safety Section
Safety Messages
Illustration 2 g01106084
8 31200243
Safety Section
31200243 9
Safety Section
Illustration g01213316
Make sure that all of the safety messages are legible.

Clean the safety messages or replace the safety
messages if you cannot read the words. Replace the
illustrations if the illustrations are not legible. When
you clean the safety messages, use a cloth, water and
soap. Do not use solvent, gasoline, or other harsh
chemicals to clean the safety messages. Solvents,
gasoline, or harsh chemicals could loosen the adhesive
that secures the safety message. Loose adhesive will
allow the safety message to fall.
Replace any safety message that is damaged, or
missing. If a safety message is attached to a part that
is replaced, install a safety message on the
replacement part. Any Caterpillar dealer can provide
new safety messages.
There are several specific safety messages on these
machines. The exact location of the messages and the
description of the messages are reviewed in this
section. Please become familiarized with all safety
messages.
10 31200243
Safety Section
Do Not Operate (1) Do Not Stand Under the Load (2)

This safety message is positioned on the panel at the This message is positioned on the side of the boom
right side of the operator station. head on both sides of the machine
g00931194
Do not operate or work on this equipment unless you

have read and understand the instructions and
warnings in the Operation and Maintenance Manual. g00930659
Failure to follow the instructions or heed the warnings
could result in injury or death. Contact any Caterpillar
dealer for replacement manuals. Proper care is your
responsibility.
A crushing hazard exists when the boom is lowered or
from a falling load. Stay clear of the boom when the
machine is in operation. Failure to stay clear of the
boom can cause injury or death.
31200243 11
Safety Section
No Hands (3) Do Not Operate (4)

The message is positioned on the side of the number This safety message is located on the front dash in the
one boom section on both sides of the machine operator compartment.
g00936539
Improper operation or maintenance of the machine

could result in injury or death. Do not operate or
g00930870 work on this machine unless you have been properly
trained and authorized and have read and understood
the warnings and instructions in the Operation and
Maintenance Manual.
A crushing hazard exists when the boom sections are
being retracted or extended. Stay clear of the boom Refer to Operation and Maintenance Manual, "Load
when the machine is in operation. Failure to stay clear of Charts" for more information.
the boom when the machine is operation can cause
injury or death.
12 31200243
Safety Section
Forks (5) Do Not Weld On The ROPS/FOPS

This safety message is positioned on the panel at the Structure (6)
right side of the operator station.
This safety message is positioned behind the seat near
the window.
g01059274
g01211890
Side loading of the forks may cause premature failure

of the forks and thus a crush hazard which may cause
Structural damage, an overturn, modification,
personal injury or death. Never push loads with the
forks and inspect the forks daily for any twisting or alteration, or improper repair can impair this
structure's protection capability thereby voiding this
bending observed in the forks. Should twisting or
certification. Do not weld on or drill holes in the
bending be observed, change the fork(s) prior to any
lifting operation. Read the Operation and Maintenance structure. This will void the certification. Consult a
Caterpillar dealer to determine this structure's
Manual for more information about the correct use of
limitations without voiding its certification.
the forks.
This machine has been certified to the standards that

are listed on the certification film. The maximum mass
of the machine, which includes the operator and the
attachments without a payload, should not exceed the
mass on the certification film.
A typical example of the warning film and certification
film are shown above.
Refer to Operation and Maintenance Manual, "Guards
(Operator Protection)" for more information.
31200243 13
Safety Section
Crushing Hazard (7) No Hands (8)

The message is positioned on the underside of the The message is positioned on the top of stabilizer
stabilizer beam on both sides of the machine. cylinders on both sides of the machine.
g00930659 g00930870
A crushing hazard exists when raising or lowering the A crushing hazard exists when raising or lowering the
stabilizers. Ensure that personnel stand clear when the stabilizers. Ensure that personnel stand clear when the
stabilizers are being raised or lowered. Operating the stabilizers are being raised or lowered. Operating the
stabilizers when personnel are nearby could result in stabilizers when personnel are nearby could result in
personal injury or death. personal injury or death.
14 31200243
Safety Section
Seat Belt (9) Crushing Hazard (10)

This safety message is positioned on the panel at the This message is positioned on the chassis on the right
right side of the operator station. side of the machine.
g00931188
A seat belt should be worn at all times during machine

operation to prevent serious injury or death in the event g01212730
of an accident or machine overturn. Failure to wear a
seat belt during machine operation may result in
serious injury or death.
A crushing hazard exists when the boom is lowered or

Refer to Operation and Maintenance Manual, "Seat
Belt" for more information. machine is in operation. Failure to stay clear of the
boom can cause injury or death.
Refer to the "Procedure for Retracting and Lowering the

Boom with the Emergency Lower System (If
Equipped)" topic in Operation and Maintenance
Manual, "Equipment Lowering with Loss of Hydraulic
Power" for more information.
31200243 15
Safety Section
Crushing Hazard (11) Engine Coolant (12)

This message is positioned on the chassis on the right This safety message is positioned on the coolant tank in the
side of the machine. engine enclosure.
g00931247
Pressurized system! Hot coolant can cause serious

g00930659
burns, injury or death. To open the cooling system
filler cap, stop the engine and wait until the cooling
system components are cool. Loosen the cooling
system pressure cap slowly in order to relieve the
pressure. Read and understand the Operation and
Maintenance Manual before performing any cooling
A crushing hazard exists when the boom is lowered or system maintenance.
machine is in operation. Failure to stay clear of the
boom can cause injury or death. Refer to Operation and Maintenance Manual, "Cooling
System Coolant - Change" for the correct procedure to
remove the pressure cap.
16 31200243
Safety Section
Avoid Power Lines (13) Low Bridge (14)

This safety message is positioned in the operator This safety message is positioned in the operator
station on the right side of the window. station on the right side of the window. This message is
only located on machines that will be used in the United
Kingdom.
g00936329
g00931533
Electrocution Hazard! Keep the machine and

attachments a safe distance from electrical power. Stay
clear 3 m (10 ft) plus twice the line insulator length. The coupler/work tool shall not be raised above this
Read and understand the instructions and warnings in height during roading. Personal injury, property
the Operation and Maintenance Manual. Failure to follow damage, or death may occur.
the instructions and warnings will cause serious injury
or death
Always check for power lines before raising the boom.

Failure to check for power lines before raising the boom
could result in injury or death by electrocution. Refer to
Operation and Maintenance Manual, "Before Starting
Engine" for more information.
31200243 17
Safety Section
Jump Start Cables (15) Ether (16)

This safety message is positioned on a bracket next to This safety message is positioned on the intake for the
the batteries. air cleaner.
g00931020 g00931562
Explosion Hazard! Improper jumper cable connections Explosion hazard! Do not use ether! This machine is
can cause an explosion resulting in serious injury or equipped with an air inlet heater. Using ether can
death. Batteries may be located in separate create explosions or fires that can cause personal
compartments. Refer to the Operation and injury or death. Read and follow the starting procedure
Maintenance Manual for the correct jump starting in the Operation and Maintenance Manual.
procedure.
Refer to Operation and Maintenance Manual, "Fire

Refer to Operation and Maintenance Manual, "Engine Prevention and Explosion Prevention" for more
Starting with Jump Start Cables" for more information. information.
18 31200243
Safety Section
Crushing Hazard (17) Operation (19)

This message is located on both sides of the This message is located on the left hand cover at the
multipurpose bucket on the top of the bucket. rear of the broom.
g00943172 g00984073
No clearance for person in this area during operation. Do not operate or work on this equipment unless you
Severe injury or death from crushing could occur. Stay have read and understand the instructions and
away from the work tool while it is in operation. warnings in the Operation and Maintenance Manual.
Failure to follow the instructions or heed the warnings
could result in injury or death. Contact any Caterpillar
dealer for replacement manuals. Proper care is your
Crushing Hazard (18) responsibility.
This message is located on both sides of the hopper.
Impaling Hazard (20)

This message is located on both sides of the grapple
bucket.
g00951560
No clearance for person in this area during operation. g00951569

Severe injury or death from crushing could occur. Stay
away from the work tool while it is in operation.
No clearance for person in this area during operation.

Severe injury or death from impalement could occur.
Stay away from the work tool while it is in operation.
31200243 19
Safety Section
Crushing Hazard (21) Trap Point (23)

This message is located on both sides of the grapple This message is located on both sides of the hitch on
bucket. the broom.
g00943172 g00984061
No clearance for person in this area during operation. No clearance for person in this area during operation.
Severe injury or death from crushing could occur. Stay Severe injury or death from crushing could occur. Stay
away from the work tool while it is in operation. away from the work tool while it is in operation.
Entanglement and Flying Objects Crushing Hazard (24)

(22) This message is located on each side of the top cover
This message is located on each side of the top cover for the broom.
for the broom.
g00943172
g00984064
No clearance for person in this area during operation.

Severe injury or death from crushing could occur. Stay
away from the work tool while it is in operation.
Stay clear of this work tool during operation.
Entanglement could result in personal injury or death.
Flying objects from this work tool could result in
personal injury or death.
20 31200243
Safety Section
Ether (25)
This message is located on the side of the valve cover.
g00924889
If equipped with an air inlet heater (AIH) for cold

weather starting, do not use aerosol types of starting
aids such as ether. Such use could result in an
explosion and personal injury.
Additional Messages
There are several specific messages on these
machines. The exact location of the messages and the
description of the messages are reviewed in this
section. Please become familiarized with all messages.
Make sure that all of the messages are legible. Clean
the messages or replace the messages if the words or
images are unreadable. When you clean the
messages, use a cloth, water and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean the
messages. Solvents, gasoline, or harsh chemicals
could loosen the adhesive that secures the messages.
Loose adhesive will allow the messages to fall.
Replace any message that is damaged, or missing. If a
message is attached to a part that is replaced, install a
message on the replacement part. Any Caterpillar
dealer can provide new messages.
31200243 21
Safety Section
22 31200243
Safety Section
Coolant (1) Auxiliary Hydraulics (3)

This message is located on the coolant tank. This message is located on the left side of the boom
head.
50% Ethylene
Glycol
OAM1010
Refill with only 50/50 mixture of ethylene glycol and Illustration 11 g00934458
water. Refer to Operation and Maintenance Manual,
"Cooling System Coolant Level - Check" and Use only work tools that are approved by Caterpillar.
Operation and Maintenance Manual, "Cooling System Refer to the topic "Auxiliary Hydraulic Connections" in
Coolant - Change" for more information. Operation and Maintenance Manual, "Work Tools" for
more information.
Air Cleaner (2)

Starting Aid (4)
This message is located on the cover for the air
cleaner. The message is located on the panel at the right side of
the operator station.
Illustration10 g00931688
Clean the filter element or replace the filter element
when the restriction indicator shows red. Refer to Use the cold weather starting aid to start the engine
Operation and Maintenance Manual, "Engine Air Filter below 0 °C (32 °F). Refer to Operation and
Primary Element - Clean/Replace" and Operation and Maintenance Manual, "Engine Starting" for more
Maintenance Manual, "Engine Air Filter Secondary information.
Element - Replace" for more information.
31200243 23
Safety Section
Alternate Exit (5) Air Conditioner (7)

This message is located on the rear window of the cab. On machines that are equipped with an air
conditioner, this label is located behind the protection
cover at the rear of the door.
If the primary exit is blocked, exit the machine through Illustration 16 g00934175
the rear window. Use the ring on the rear window latch
in order to pull out the retaining pin. This action will Do not work on the air conditioning system until you
unlock the rear window. have read the service manual and you understand the
service manual.
Transmission and Hydraulic Oil (6)

Tire Pressures (8)
If equipped, this message is located next to the sight
gauge for the transmission and hydraulic oil. This message is located behind the protection cover on
the left side of the cab.
Check the transmission and hydraulic oil when the oil is
warm. Do not add oil when the system is cold. If the Personal injury can result from improper tire inflation.
system is cold and you add oil, you can overfill the Refer to Operation and Maintenance Manual, "Tire
system. This could cause machine damage. Refer to Inflation Information" for more information.
Operation and Maintenance Manual, "Transmission
and Hydraulic System Oil Level - Check" for the
correct procedure.
24 31200243
Safety Section
Machine Security System (9)

If equipped, this message is located on the left side of
the steering column ahead of the engine start switch.
Wear a hard hat, protective glasses, and other

protective equipment, as required.
Do not wear loose clothing or jewelry that can snag on
This machine is equipped with a security system. Read controls or on other parts of the equipment.
the Operation and Maintenance Manual before you Make sure that all protective guards and all covers are
operate the machine. secured in place on the equipment.
Keep the equipment free from foreign material.
Remove debris, oil, tools, and other items from the
General Hazard Information deck, from walkways, and from steps.
Secure all loose items such as lunch boxes, tools, and
other items that are not a part of the equipment.
Know the appropriate work site hand signals and the
personnel that are authorized to give the hand signals.
Accept hand signals from one person only.
Do not smoke when you service an air conditioner.
Also, do not smoke if refrigerant gas may be present.
Inhaling the fumes that are released from a flame that
contacts air conditioner refrigerant can cause bodily
harm or death. Inhaling gas from air conditioner
refrigerant through a lighted cigarette can cause bodily
harm or death.
Never put maintenance fluids into glass containers.
Drain all liquids into a suitable container.
Attach a "Do Not Operate" warning tag or a similar Obey all local regulations for the disposal of liquids.
warning tag to the start switch or to the controls before Use all cleaning solutions with care. Report all
you service the equipment or before you repair the necessary repairs.
equipment. These warning tags are available from your
Do not allow unauthorized personnel on the
Caterpillar dealer.
equipment.
Know the width of your equipment in order to maintain
Unless you are instructed otherwise, perform
proper clearance when you operate the equipment
maintenance with the equipment in the servicing
near fences or near boundary obstacles.
position. Refer to Operation and Maintenance Manual
Be aware of high voltage power lines and power for the procedure for placing the equipment in the
cables that are buried. If the machine comes in contact servicing position.
with these hazards, serious injury or death will occur
from electrocution.
31200243 25
Safety Section
Pressurized Air and Water treatment immediately. Seek treatment from a doctor
that is familiar with this type of injury.
Pressurized air and/or water can cause debris and/or
hot water to be blown out. This could result in personal Containing Fluid Spillage
injury.
When pressurized air and/or pressurized water is used Care must be taken in order to ensure that fluids are
for cleaning, wear protective clothing, protective shoes, contained during performance of inspection,
and eye protection. Eye protection includes goggles or maintenance, testing, adjusting and repair of the
a protective face shield. equipment. Prepare to collect the fluid with suitable
containers before opening any compartment or
The maximum air pressure for cleaning purposes must disassembling any component that contains fluids.
be below 205 kPa (30 psi). The maximum water
pressure for cleaning purposes must be below 275 kPa Refer to Special Publication, NENG2500, "Caterpillar
(40 psi). Dealer Service Tool Catalog" for the following items:
• Tools that are suitable for collecting fluids and
Trapped Pressure equipment that is suitable for collecting fluids
• Tools that are suitable for containing fluids and
Pressure can be trapped in a hydraulic system.
equipment that is suitable for containing fluids
Releasing trapped pressure can cause sudden
machine movement or attachment movement. Use Obey all local regulations for the disposal of liquids.
caution if you disconnect hydraulic lines or fittings. High
pressure oil that is released can cause a hose to whip. Dispose of Waste Properly
High pressure oil that is released can cause oil to spray.
Fluid penetration can cause serious injury and possible
death.
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.
Do not remove any hydraulic components or parts until
pressure has been relieved or personal injury may
occur. Do not disassemble any hydraulic components
or parts until pressure has been relieved or personal Illustration 23 g00706404
injury may occur. Refer to the Service Manual for any
procedures that are required to relieve the hydraulic Improperly disposing of waste can threaten the
pressure. environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain fluids.
Do not pour waste onto the ground, down a drain, or
into any source of water.
Crushing Prevention and

Cutting Prevention
Support the equipment properly before you perform any
work or maintenance beneath that equipment. Do not
depend on the hydraulic cylinders to hold up the
equipment. Equipment can fall if a control is moved, or if
Illustration 21 g00687600 a hydraulic line breaks.
Always use a board or cardboard when you check for a
Do not work beneath the cab of the machine unless the
leak. Leaking fluid that is under pressure can penetrate
cab is properly supported.
body tissue. Fluid penetration can cause serious injury
and possible death. A pin hole leak can cause severe Unless you are instructed otherwise, never attempt
injury. If fluid is injected into your skin, you must get adjustments while the machine is moving or while the
engine is running.
26 31200243
Safety Section
Never jump across the starter solenoid terminals in Oils

order to start the engine. Unexpected machine
movement could result. Hot oil and hot components can cause personal injury.
Do not allow hot oil to contact the skin. Also, do not
Whenever there are equipment control linkages the
allow hot components to contact the skin.
clearance in the linkage area will change with the
movement of the equipment or the machine. Stay clear Remove the hydraulic tank filler cap only after the
of areas that may have a sudden change in clearance engine has been stopped. The filler cap must be cool
with machine movement or equipment movement. enough to touch with a bare hand. Follow the standard
If it is necessary to remove guards in order to perform procedure in this manual in order to remove the
maintenance, always install the guards after the hydraulic tank filler cap.
maintenance is performed.
Keep objects away from moving fan blades. The fan
Batteries
blade will throw objects or cut objects. Electrolyte is an acid. Electrolyte can cause personal
Do not use a kinked wire cable or a frayed wire cable. injury. Do not allow electrolyte to contact the skin or the
Wear gloves when you handle wire cable. eyes. Always wear protective glasses for servicing
batteries. Wash hands after touching the batteries and
When you strike a retainer pin with force, the retainer
connectors. Use of gloves is recommended.
pin can fly out. The loose retainer pin can injure
personnel. Make sure that the area is clear of people
when you strike a retainer pin. To avoid injury to your Fire Prevention and Explosion
eyes, wear protective glasses when you strike a Prevention
retainer pin.
Chips or other debris can fly off an object when you
strike the object. Make sure that no one can be injured
by flying debris before striking any object.
Burn Prevention
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the air
system, in the oil system, in the lubrication system, in the
fuel system, or in the cooling system before any lines,
fittings or related items are disconnected.
Coolant
All fuels, most lubricants, and some coolant mixtures are
When the engine is at operating temperature, the
flammable.
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or to Flammable fluids that are leaking or spilled onto hot
the engine contain hot coolant. surfaces or onto electrical components can cause a
fire. Fire may cause personal injury and property
Any contact with hot coolant or with steam can cause
damage.
severe burns. Allow cooling system components to cool
before the cooling system is drained. Remove all flammable materials such as fuel, oil, and
debris from the machine. Do not allow any flammable
Check the coolant level only after the engine has been
materials to accumulate on the machine.
stopped.
Store fuels and lubricants in properly marked
Ensure that the filler cap is cool before removing the
containers away from unauthorized persons. Store oily
filler cap. The filler cap must be cool enough to touch
rags and any flammable materials in protective
with a bare hand. Remove the filler cap slowly in order
containers. Do not smoke in areas that are used for
to relieve pressure.
storing flammable materials.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact the
skin, the eyes, or the mouth.
Stay clear of all rotating and moving parts.
31200243 27
Safety Section
Do not operate the machine near any flame.

Exhaust shields (if equipped) protect hot exhaust
components from oil spray or fuel spray in case of a
break in a line, in a hose, or in a seal. Exhaust shields
must be installed correctly.
Do not weld on lines or on tanks that contain
flammable fluids. Do not flame cut lines or tanks that
contain flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Check all electrical wires daily. Repair any wires that
are loose or frayed before you operate the machine.
Clean all electrical connections and tighten all electrical
connections.
Dust that is generated from repairing nonmetallic
hoods or nonmetallic fenders can be flammable and/or
explosive. Repair such components in a well ventilated
area away from open flames or sparks. Illustration 26 g00704135
Inspect all lines and hoses for wear or for
deterioration. The hoses must be properly routed. The Gases from a battery can explode. Keep any open
lines and the hoses must have adequate support and flames or sparks away from the top of a battery. Do not
secure clamps. Tighten all connections to the smoke in battery charging areas.
recommended torque. Leaks can cause fires. Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or a
hydrometer.
Improper jumper cable connections can cause an
explosion that can result in injury. Refer to the
Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. This may cause an
explosion.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations on
the instruction plate.
Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike high
Use caution when you are refueling a machine. pressure lines. Do not install any lines that are bent or
Remove debris from the top of the tank before damaged.
refueling. Do not smoke while you are refueling a Repair any lines that are loose or damaged. Leaks can
machine. Do not refuel a machine near open flames or cause fires. Consult your Caterpillar dealer for repair or
sparks. Always stop the engine before refueling. Fill the for replacement parts.
fuel tank outdoors. Check lines, tubes and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections to
the recommended torque.
Replace the parts if any of the following conditions are
present:
• End fittings are damaged or leaking.
28 31200243
Safety Section
• Outer coverings are chafed or cut.

• Wires are exposed.
• Outer coverings are ballooning.
• Flexible part of the hoses are kinked.
• Outer covers have embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields are
installed correctly. During machine operation, this will
help to prevent vibration, rubbing against other parts,
and excessive heat.
(A) At least 15 m (50 ft)
Fire Extinguisher Location (B) At least 500 m (1500 ft)
Make sure that a fire extinguisher is on the machine.

Make sure that you are familiar with the operation of the Do not approach a warm tire. Maintain a minimum
fire extinguisher. Inspect the fire extinguisher and distance, as shown. Stay outside the shaded area in
service the fire extinguisher on a regular basis. Obey Illustration 27.
the recommendations on the instruction plate. To avoid overinflation, proper training in the usage of
The recommended location for mounting the fire the equipment are necessary. A tire blowout or a rim
extinguisher is on the plate for the seat to the right side failure can result from improper equipment or from
of the operator. misused equipment.
If the fire extinguisher is mounted on the ROPS, strap When you inflate a tire, stand behind the tread and use
the mounting plate to a leg of the ROPS. If the weight of a self-attaching chuck.
the fire extinguisher is more than 4.5 kg (10 lb), mount Servicing tires and rims can be dangerous. Only
the fire extinguisher as low as possible on one leg. Do trained personnel that use proper tools and proper
not mount the fire extinguisher on the upper one-third procedures should perform this maintenance. If correct
area of the leg. procedures are not used for servicing tires and rims,
Note: Do not weld the ROPS in order to install the fire the assemblies could burst with explosive force. This
extinguisher. Also, do not drill holes in the ROPS in explosive force can cause serious personal injury or
order to mount the fire extinguisher on the ROPS. death. Carefully obey the specific instructions from your
tire dealer.
Tire Information
Electrical Storm Injury Prevention
Explosions of air inflated tires have resulted from heat-
induced gas combustion inside the tires. Explosions When lightning is striking in the vicinity of the
can be caused by heat that is generated by welding, by machine, the operator should never attempt the
heating rim components, by external fire, or by following procedures:
excessive use of brakes. • Mount the machine.
A tire explosion is much more violent than a blowout. • Dismount the machine.
The explosion can propel the tire, the rim components,
If you are in the operator's station during an electrical
and the axle components as far as 500 m (1500 ft) or
storm, stay in the operator's station. If you are on the
more from the machine. Both the force of the explosion
ground during an electrical storm, stay away from the
and the flying debris can cause property damage,
vicinity of the machine.
personal injury, or death.
31200243 29
Safety Section
Before Starting Engine Make sure that the machine horn, the backup alarm and
all other warning devices are working properly.
Operators must have had the proper training and
Clear all obstacles from the path of the machine.
operators must be capable in all aspects of machine
operation. To comply with some local requirements, an Before you attempt to start the engine and before you
operator must attain an operators license or a move the machine, ensure that no one is underneath the
certificate. machine, around the machine, or on the machine. Make
sure that the area is free of personnel. Fasten the seat
You must be familiar with your machine in order to belt.
understand the machine's capabilities. Also, before you
operate your machine you must become familiar with
the job site. If necessary, walk around the area and Engine Starting
take note of the following items.
• Check the area for clearance. Check for both
vertical clearance and for horizontal clearance.
• Check for the presence of overhead obstructions.
• Check for electrical power lines. Keep the machine
and the attachments away from electrical power
lines at least 8 m (25 ft).
• Check for steam lines. Check for compressed air
lines.
• Check for changes in the stability of the surface
of the job site. Check trenches that have been
backfilled. Check deteriorated roofs of basements Illustration 28 g00100846
and of tunnels. Before you service the machine or before you repair
• Check sewers and service ducts. the machine, attach a "DO NOT OPERATE" warning tag
or a similar warning tag to the engine start switch or to
When a load is picked up or when the boom is the controls. This warning tag is available from your
extended, ensure that the surface on the job site offers Caterpillar dealer.
even resistance for the tires. Also, when a load is
picked up or when the boom is extended, ensure that If a warning tag is attached to the engine start switch or
the surface on the job site offers even penetration for to the machine controls, do not start the engine. Also,
the stabilizers. do not move any machine controls.
Ensure that the transmission control is in the
Make sure that the load charts and the instruction
NEUTRAL position (N). The engine will not start unless
plates are in place and that the load charts and the
the transmission control is in the NEUTRAL position.
instructions can be read. Do not operate the machine
until you understand the correct method of using the Ensure that the parking brake is engaged.
load charts. Diesel engine exhaust contains products of
On machines that are equipped with a cab, secure the combustion which can be harmful to your health.
door in the shut position. Secure the windows in either Always run the engine in a well ventilated area. If you
the open position or in the shut position. Ensure that all are in an enclosed area, vent the exhaust to the outside.
windows are clean for the best visibility. Start the engine only when you are properly seated in
Inspect the condition of the seat belt and of the the operator's compartment. Do not short across the
mounting hardware. Replace any parts that are worn or battery terminals and do not short across the batteries.
damaged. Regardless of appearance, replace the seat A short could cause a bypass of the engine neutral
belt after three years of use. Do not use a seat belt start system and this could cause the machine to move
extension on a retractable seat belt. if the machine was left in gear.
Make sure that all protective guards and covers are
secured on the machine.
Adjust the seat so that full pedal travel can be
achieved with the operator's back against the back of
the seat.
Make sure that the machine is equipped with a lighting
system that is adequate for the job conditions. Make sure
that all of the machine lights are working properly.
30 31200243
Safety Section
Before Operation Before you maneuver the machine, make sure that no
personnel are between the machine and the work tools.
Clear all personnel from the machine and from the area. Use caution when you change direction of travel. Use
Clear all obstacles from the path of the machine. caution when you operate the boom. Use caution when
Beware of hazards such as wires, ditches, etc. you are picking up loads or when you are setting down
loads. Travel in the direction of the best visibility. Travel
Make sure that all windows are clean. Secure the doors with the boom fully retracted. Also, travel with the boom
in the open position or in the shut position. Secure the lowered as far as possible. Maintain adequate ground
windows in the open position or in the shut position. clearance for conditions. Never travel if a load is raised
Make sure that all mirrors (if equipped) are clean. For beyond the travel position. Be careful to avoid any
the best vision of the area which is close to the ground condition which could cause the machine to tip.
machine, adjust the mirrors. All mirrors should be Avoid any conditions that can lead to tipping of the
adjusted for optimal visibility while the operator is machine. The machine can tip when you work on the
seated in the cab. following obstacles: banks, hills, and slopes. If the
machine is equipped with stabilizers the stabilizers must
Make sure that the machine horn, the backup alarm (if
be fully raised before you move the machine.
equipped), and all other warning devices are working
properly.
Fasten the seat belt securely.
Lifting Capacities
Make sure that the load charts and the instruction Maintain control of the machine. Do not overload the
plates are in place and that the load charts and the machine beyond the machine capacity. Ensure that the
instructions can be read. correct load chart is referenced. Loads must be within
the weight limit of the machine and loads must be within
the load center limit for the machine. Lifting capacity
Operation decreases as the load is moved further from the
machine.
Machine Operating Temperature Note: If an 180-6137 Coupler Adapter Gp for a work
Range tool is installed on the quick coupler, reduce the load
carrying capacity of the machine by 200 kg (440 lb) for
The standard machine configuration is intended for all work tools and with the boom in any position. Refer
use within an ambient temperature range of -40 °C (- to Operation and Maintenance Manual, "Lifting
40 °F) to 50 °C (122 °F). Special configurations for Capacities" for additional information.
different ambient temperatures may be available.
Ensure that the tires are serviceable and that the tires
Consult your Caterpillar dealer for additional
are inflated to the correct pressure.
information on special configurations of your machine.
On machines that are equipped with a frame leveling
Machine Operation switch, always level the frame before you raise the
boom or before you lower the stabilizers. Never
Check for proper operation of the steering controls and operate the frame leveling switch when the boom is
of the braking controls for the machine while the raised or when the stabilizers are lowered. Check that
machine is moving slowly in an open area. Check the the frame is level after you lower the stabilizers. If
steering controls and the braking controls while the necessary, adjust the level of the frame. Use the
boom is retracted fully and the work tool is just clear of stabilizers in order to make the adjustment. Do not
the ground. With the machine in a stationary position, adjust the position of the stabilizers when the boom is
check for the proper operation of the other controls for raised. If the frame is not level, do not raise the boom.
the machine. Unless the machine frame is level, do not Before you transport a load or before you elevate a
raise the boom. The boom should only be extended if load, the load must be adequately secured on the forks
the machine frame is level. Extend the boom and retract or on the work tool. Any loads such as pipe,
the boom several times in order to warm the hydraulic scaffolding, lumber and beams must be adequately
oil. secured.
Use lifting slings that are approved and use lifting
Travel slings that are load tested. Also, all wire ropes or
Only operate the machine while you are in a seat. The chains must be properly maintained. The wire ropes
seat belt must be fastened while you operate the and chains must meet local regulations. You must know
machine. Only operate the controls while the engine is the load carrying capacity of these devices and you
running. must know the correct use of these devices.
When you travel on the roadways, operate the
machine in two-wheel steer mode only.
31200243 31
Safety Section
Work Tools Work Tools
Use of non approved work tools on Telehandler Use of non approved work tools on Telehandler
machines could result in injury or death. machines could result in injury or death.
Before installing a work tool on this machine, ensure Before installing a work tool on this machine, ensure
that it is approved by Caterpillar and that a Caterpillar that it is approved by Caterpillar and that a Caterpillar
load chart covering its use is installed in the machine's load chart covering its use is installed in the machine's
cab. cab.
NOTICE
When certain work tools are fitted, the work tools can If you are in doubt about the compatibility of a
contact the front tires or the front fenders. This situation particular work tool with your machine, consult your
can occur when the boom is retracted and the work tool Caterpillar dealer.
is rotated fully forward. Always check for interference
Make sure that all necessary guarding is in place on the
when first operating a new work tool.
host machine and on the work tool.
Before you use a work tool, ensure that the work tool is Keep all windows and doors closed on the host
approved by Caterpillar. Also, ensure that the machine machine. Always wear protective glasses. Always wear
has a Caterpillar load chart. Consult your Caterpillar the protective equipment that is recommended in the
dealer for information on the proper application and the work tool's operation manual. Wear any other
proper use of a specific work tool. protective equipment that is required for the operating
environment.
Engine Stopping To prevent personnel from being struck by flying
Do not stop the engine immediately after the machine objects, ensure that all personnel are out of the work
has been operated under load. This can cause area.
overheating and accelerated wear of engine While you are performing any maintenance, any
components. testing, or any adjustments to the work tool stay clear
After the machine is parked and the parking brake is of the following areas: cutting edges, pinching surfaces,
engaged, allow the engine to run for five minutes and crushing surfaces.
before shutdown. This allows hot areas of the engine to
cool gradually. Parking
For more information, refer to the following topics in the Park the machine on a level surface. If you must park on
Operation Section of the Operation and Maintenance a grade, chock the machine's wheels. The boom must
Manual: be fully retracted. Fully retract the boom and lower the
• "Stopping the Engine" boom until the work tool is on the ground.
• "Stopping the Engine if an Electrical Malfunction Apply the service brakes in order to stop the machine.
Occurs" Move the transmission control to the NEUTRAL
position. Move the accelerator control to the LOW
IDLE position. Engage the parking brake.
Lower all equipment to the ground. Activate any control
locks.
Stop the engine.
Turn the engine start switch to the OFF position and
remove the engine start switch key.
Turn the battery disconnect switch (if equipped) to the
OFF position. Remove the disconnect switch key if you
do not operate the machine for an extended period of
time. This will prevent drainage of the battery. A
battery short circuit, any current draw from certain
components, and vandalism can cause drainage of the
battery.
32 31200243
Safety Section
Equipment Lowering with Loss Operator Station

of Hydraulic Power Any modifications to the inside of the operator station
should not project into the operator space. The addition
Before you lower any equipment with loss of hydraulic
of a radio, fire extinguisher, and other equipment must
power, clear the area around the equipment of all
be installed so that the defined operator space is
personnel. The procedure to lower the equipment will
maintained. Any item that is brought into the cab should
vary with the type of equipment that is being lowered.
not project into the defined operator space. A lunch
Most systems use high pressure air or fluid to control
box or other loose items must be secured. Objects
the equipment. The procedure may release the
must not pose an impact hazard in rough terrain or in
pressure in a high pressure system in order to lower
the event of a rollover.
the equipment. Wear appropriate protective equipment.
Follow the established procedure for lowering
equipment without hydraulic power in the Operation Guards (Operator Protection)
Section of the Operation and Maintenance Manual.
There are different types of guards that are used to
protect the operator. The machine and the machine
Sound Information and application determines the type of guard that should be
Vibration Information used.
A daily inspection of the guards is required in order to
check for structures that are bent, cracked or loose.
Sound Level Never operate a machine with a damaged structure.
The operator sound pressure level that is measured The operator becomes exposed to a hazardous
according to the test procedure that is specified in "EN situation if the machine is used improperly or if poor
12053:2001" is 80 dB(A) for an enclosed cab. The cab operating techniques are used. This situation can occur
was properly installed and maintained. The test was even though a machine is equipped with an appropriate
conducted with the doors and the windows closed. protective guard. Follow the established operating
Hearing protection may be needed when the machine procedures that are recommended for your machine.
is operated with an open operator station for extended
periods or in a noisy environment. Hearing protection
may be needed when the machine is operated with a
cab that is not properly maintained or when the doors
and windows are open for extended periods or in a
noisy environment.
Vibration Level
The hands and arms are exposed to a weighted root
mean square acceleration that is less than 2.5 m/sec2
(8.20 ft/sec2).
The whole body is exposed to a weighted root mean
square acceleration that is less than 0.5000 m/s2 (1.70
ft/sec2).
The measurements are obtained on a standard
machine. The measurements are obtained by using the
procedures that are in the following standards:
• "ISO 2631-1:1997"
• "ISO 5349-1:2001"
• "SAEJ1166"
31200243 33
Safety Section
Rollover Protective Structure Other Guards (If Equipped)

(ROPS), Falling Object Protective Protection from flying objects and/or falling objects is
Structure (FOPS) required for special applications. Logging applications
and demolition applications are two examples that
The ROPS/FOPS Structure (if equipped) on your require special protection.
machine is specifically designed, tested and certified for
A front guard needs to be installed when a work tool
that machine. Excavators are not equipped with ROPS
that creates flying objects is used. Mesh front guards
structures. Any alteration or any modification to the
that are approved by Caterpillar or polycarbonate front
ROPS/FOPS Structure could weaken the structure.
guards that are approved by Caterpillar are available
This places the operator into an unprotected
for machines with a cab or an open canopy. On
environment. Modifications or attachments that cause
machines that are equipped with cabs, the windshield
the machine to exceed the weight that is stamped on
should also be closed. Safety glasses are
the certification plate also place the operator into an
recommended when flying hazards exist for machines
unprotected environment. Excessive weight may inhibit
with cabs and machines with open canopies.
the brake performance, the steering performance and
the ROPS. The protection that is offered by the ROPS/ If the work material extends above the cab, top guards
FOPS Structure will be impaired if the ROPS/FOPS and front guards should be used. Typical examples of
Structure has structural damage. Damage to the this type of application are listed below:
structure can be caused by an overturn, a falling • Demolition applications
object, a collision, etc.
• Rock quarries
Do not mount items (fire extinguishers, first aid kits,
work lights, etc) by welding brackets to the ROPS/ • Forestry products
FOPS Structure or by drilling holes in the ROPS/FOPS Additional guards may be required for specific
Structure. Welding brackets or drilling holes in the applications or work tools. The Operation and
ROPS/FOPS Structures can weaken the structures. Maintenance Manual for your machine or your work
Consult your Caterpillar dealer for mounting guidelines. tool will provide specific requirements for the guards.
Consult your Caterpillar dealer for additional
information.
34 31200243
Safety Section
31200243 35
Product Information Section
Product Information When the machine is operated on tires, the weight of

the intended load determines the maximum height
Section above ground. The weight of the intended load also
determines the maximum distance that is between the
load center of gravity and the front wheels.
General Information When the machine is operated with lowered
stabilizers, the weight of the intended load determines
Lifting Capacities the maximum height above ground. The weight of the
intended load also determines the maximum distance
When a machine is operated on tires, the machine that is between the load center of gravity and the
capacities are different from a machine that is operated stabilizer pads.
on stabilizers. Also, the machine capacities for each
The machine boom has two scales which must be
type of attachment are different.
used for reference with the load chart in order to
assess the lift operation. The boom extension
reference scale gives an indication of the boom length.
The letters "B", "C" and "D" correspond to the same
Machine instability can result in injury or death. To letters on the load chart.
ensure stability during operation the following
conditions must be observed:
Tires must be correctly inflated and have the correct
amount of ballast (if equipped).
The machine frame must be level.
The frame level switch must never be operated when
the boom is raised.
The frame level switch must never be operated when
stabilizers are lowered.
Stabilizer switches must never be operated when the
boom is raised.
The correct load chart for the machine as equipped
must be referenced and the weights and load centers Illustration 30 g00955168
specified must never be exceeded.
The machine must never be moved when the boom is Boom angle reference scale (1) gives an indication of
raised. the angle of the boom.
Follow the instructions below in order to assess the
intended load:
1. Carefully position the machine. The machine
should be as close as possible to the intended
load. For more information on operating the
machine, refer to the appropriate topic in the
Operation Section of the Operation and
Maintenance Manual.
2. In order to move the attachment into position for
the operation, raise the boom and extend the
boom, as required. Do not make the liftoperation.
3. Look at the boom extension reference scale and the
boom angle reference scale and note the readings.
The load charts are located on the dash panel at the Refer to the load chart and use these two values in
right side of the instrument cluster. Ensure that the order to locate the equivalent load zone.
correct load chart is used. The chart is intended for the 4. If the intended load is equal to the value in the
type of attachment that is represented by a symbol at equivalent load zone the lift operation can be
the top of the chart. Symbols are also shown for attempted with caution. Also, if the intended load
operation on tires or on stabilizers. The load charts is less than the value in the equivalent load zone
may be in metric units (meters and kilograms) or the lift operation can be attempted with caution.
conventional units (feet and pounds).
36 31200243
5. If the intended load is heavier than the value in the Example 3

equivalent load zone the lift operation cannot be
• The weight of the intended load is 600 units.
made.
• The boom angle reference is 22 degrees.
Examples of Estimating the Lift • The boom extension reference scale is
Operation from the Load Chart approximately 66 percent between "D" and full
extension.
Note: The examples that follow are only for illustrative
With reference to the load chart, "Z" is the point of
purposes. This chart does not relate to any particular
intersection for the values of the boom angle reference
machine. For lift operation, you should consult the load
and the boom extension reference. This point of
charts that are mounted in the operator station. The
intersection is located in the load zone that is marked
units on the load charts can be either kilograms or
"K". With reference to the derate table, the load zone
pounds.
capacity of the work tool is 400 units. The intended load
Each load chart has two parts: of 600 units is greater than the value in the load zone
• The chart shows regions which indicate if certain so the load chart indicates that the load is beyond the
capacities can be lifted. capacity of the machine. The lift operation must not
be attempted.
• The derate table shows the loads that can be lifted
in the regions that are identified in the chart. Multiple If the load chart indicates that the lift operation is within
work tools are included and the operator must select the capacity of the machine, attempt to make the
the work tool which is being used. The examples use operation but proceed with care. Remember that the
the standard fork carriage. load may weigh more than the estimate for the load.
The load chart is for estimating the lift operation only.
Example 1
• The boom extension reference scale is at "D".
With reference to the load chart, "X" is the point of
"G". With reference to the derate table, the load zone
capacity of the work tool is 2000 units. The intended
load of 1000 units is less than the value in the load
zone so the load chart indicates that the load is within
the capacity of the machine.
Example 2
• The boom extension reference scale is at "B".
With reference to the load chart, "Y" is the point of
"E". With reference to the derate table, the load zone
capacity of the work tool is 3000 units. The intended
load of 3000 units is the same value as the value in the
load zone so the load chart indicates that the load is at
the maximum capacity of the machine.
31200243 37
Specifications
Rear View
Specifications are shown for basic machines without a
work tool on the quick coupler.
Table 7
TH360B Machine
Overall Height (A) 2590 mm (8 ft 6 inch)
Overall Length (B) 6385 mm (20 ft 11 inch)
Overall Width (C) 2440 mm (8 ft 0 inch)
Wheel Base 3200 mm (10 ft 6 inch)
Ground Clearance 500 mm (1 ft 7.7 inch)
Typical Load Chart Approximate Weight 9720 kg (21400 lb)
38 31200243
Intended Use Identification Information

This vehicle is classified either as:
• A self-propelled variable reach truck (Telehandler) as
Plate Locations and Film Locations
defined in "ISO 3691-2" and "EN 1459:1998"
• An agricultural tractor when meeting the
requirements of European Union Directive 74/150/
EEC
This vehicle is all wheel drive and has all wheel steer
ability. This vehicle has a rigid chassis with a variable
reach boom mounted centrally on to which a range of
Caterpillar approved attachments may be attached.
As a machine, the vehicle has a primary use as a
material handler to pickup and place materials. As an
agricultural tractor, the vehicle has a primary use for
towing. Illustration 36 g00937576
Application/Configuration
Restrictions Manufactured by
JLG Manufacturing Europe BVBA
Industrieterrein Oude Bunders 1034, Breitwaterstraat 12
3630 Maasmechelen - Belgium
R
Maximum approved operating weight - Model:

Date of Manufacture:
Model Year:
TH360B 12100 kg (26620 lb) VIN:
Lifting load, max.: kg
Maximum drawbar towing force - Refer to Operation Type of engine:

Output of engine, kW:
and Maintenance Manual, "Towing the Machine" for Gross vehicle weight: kg
more information. Front axle load: kg
Rear axle load: kg
Maximum drawbar vertical load - Refer to Operation Maximum capacity: kg
Maximum capacity at max. Height: kg

and Maintenance Manual, "Towing the Machine" for Manufactured by JLG under license from Caterpillar
100100YYY A 1001002466 A
more information. AOM0980
Maximum fore and aft slope on this machine in a static

condition to maintain proper lubrication - An information plate is installed on these machines. On
• For machines equipped with a 92 kW engine, 57.7 machines that are delivered into the European Union,
percent grade or 30 degrees the CE mark and the PIN are stamped onto the plate.
On machines that are delivered to countries outside the
• For machines equipped with a 74.5 kW engine, 44.5 European Union, the PIN is stamped onto the plate.
percent grade or 24 degrees This plate is positioned on the left side of the main
frame.
The PIN is used to identify a powered machine that is
designed for an operator to ride. The PIN plate is located
at the left side of the main frame.
The PIN plate shows the PIN and the number for the
arrangement of the machine.
Several pieces of information are stamped onto the PIN
plate. For quick reference, record this information in the
spaces that are provided below.
• Model____________________________________
• PIN______________________________________
• Engine serial number________________________
• Transmission serial number___________________

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31200243

July 14, 2006

Keep this manual with machine at all times.

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to

Parking ................................................................ 86 Primary Cab Air Filter ...................................115

Rollover Protective Structure (ROPS) and Falling

Make sure that all of the safety messages are legible.

Do Not Operate (1) Do Not Stand Under the Load (2)

Do not operate or work on this equipment unless you

No Hands (3) Do Not Operate (4)

Improper operation or maintenance of the machine

Forks (5) Do Not Weld On The ROPS/FOPS

Side loading of the forks may cause premature failure

This machine has been certified to the standards that

Crushing Hazard (7) No Hands (8)

Seat Belt (9) Crushing Hazard (10)

A seat belt should be worn at all times during machine

A crushing hazard exists when the boom is lowered or

Refer to the "Procedure for Retracting and Lowering the

Crushing Hazard (11) Engine Coolant (12)

Pressurized system! Hot coolant can cause serious

Avoid Power Lines (13) Low Bridge (14)

Electrocution Hazard! Keep the machine and

Always check for power lines before raising the boom.

Jump Start Cables (15) Ether (16)

Refer to Operation and Maintenance Manual, "Fire

Crushing Hazard (17) Operation (19)

Impaling Hazard (20)

No clearance for person in this area during operation. g00951569

No clearance for person in this area during operation.

Crushing Hazard (21) Trap Point (23)

Entanglement and Flying Objects Crushing Hazard (24)

No clearance for person in this area during operation.

If equipped with an air inlet heater (AIH) for cold

Coolant (1) Auxiliary Hydraulics (3)

Air Cleaner (2)

Alternate Exit (5) Air Conditioner (7)

Transmission and Hydraulic Oil (6)

Machine Security System (9)

Wear a hard hat, protective glasses, and other

Crushing Prevention and

Never jump across the starter solenoid terminals in Oils

Do not operate the machine near any flame.

Lines, Tubes and Hoses

• Outer coverings are chafed or cut.

Make sure that a fire extinguisher is on the machine.

Work Tools Work Tools

Equipment Lowering with Loss Operator Station

Rollover Protective Structure Other Guards (If Equipped)

Product Information When the machine is operated on tires, the weight of

5. If the intended load is heavier than the value in the Example 3

Intended Use Identification Information

Maximum approved operating weight - Model:

Maximum drawbar towing force - Refer to Operation Type of engine:

more information. Front axle load: kg

Rear axle load: kg

Maximum drawbar vertical load - Refer to Operation Maximum capacity: kg