Cat Telehandler Th360b Service Manual

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TH360B & TH560B

Telehandler Service Manual
31200264
S/N TBH00100 & After
S/N TBP00100 & After

Section Title Manual No.

Service Manual Contents 31200265

Torque Specifications 31200268

Engine
Disassembly & Assembly Engine Supplement 31200299

Power Train
Systems Operation, Testing & Adjusting Power Train 31200270
Disassembly & Assembly Power Train 31200300

Vehicle Systems
Schematic Hydraulic System 31200304
Systems Operation, Testing & Adjusting Hydraulic System 31200302
Systems Operation, Testing & Adjusting Steering System 31200273
Systems Operation, Testing & Adjusting Brake System 31200274
Machine Components Specs Machine Systems 31200306
Disassembly & Assembly Machine Systems 31200308

Electrical Systems
Schematic - TH360B Electrical System 31200310
Schematic - TH560B Electrical System 31200311
Machine Troubleshooting Hydrostatic Transmission 31200279
Electronic Control System
Systems Operation, Testing & Adjusting LSI System 31200280
Systems Operation, Testing & Adjusting Monitoring System 31200281

31200265 A

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 31200268
December 15, 2006

Specifications
Torque Specifications - TH220B, TH330B,
TH360B, TH560B & TH580B Telehandlers
S/N TBF00100 & After
S/N TBG00100 & After
S/N TBH00100 & After
S/N TBP00100 & After
S/N TBJ00100 & After
 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.
31200268 1
Table of Contents
Table of
Table of Contents
Specifications Section
General Information .............................................. 3
Introduction to Torque ...................................... 3
Torque-Turn ..................................................... 3
Torque Sequence ............................................ 3
Metric (ISO) Fasteners .......................................... 4
Metric (ISO) Nuts and Bolts ............................. 4
Metric (ISO) Taperlock Studs........................... 4
Metric (ISO) Machine Screws .......................... 4
Hex Button Head Screw and Set
Screw ............................................................... 4
English (SAE) Fasteners ....................................... 5
English (SAE) Nuts and Bolts .......................... 5
English (SAE) Taperlock Studs........................ 5
English (SAE) Machine Screws ....................... 5
Hex Button Head Screw and Set Screws......... 6
Ground Engaging Tool (G.E.T.) Fasteners ........... 6
Installation of Fittings ............................................ 7
Installation of Split Flange Couplings ............... 7
Installation of Adjustable STOR Fittings........... 8
Straight Thread O-Ring Fittings ............................ 8
Plugs ................................................................... 10
Straight Thread O-Ring Plugs (Hex Drive)..... 10
Straight Thread O-Ring Plugs (Socket Drive) 11
Drain Plugs with Straight Thread .................. 11
Straight Thread O-Ring Plugs (Mechanical Joint
Tube Assemblies) .......................................... 11
O-Ring Face Seal Fittings ................................... 12
Bulkhead Nuts ..................................................... 12
Flare Fittings ....................................................... 13
37 Degree Flare Fitting .................................. 13
45 Degree Flare and 45 Degree Inverted Flare
Fittings ........................................................... 13
Air Conditioning Fittings ...................................... 14
Air Brake Fittings ................................................. 14
Tapered Pipe Thread Fittings.............................. 14
Miscellaneous Fittings ......................................... 15
Hi Duty Tube Fittings (Shear Sleeve)............. 15
SAE Flareless Fittings.................................... 15
Flex Fittings.................................................... 15
Hose Clamps....................................................... 15
Worm Drive Band Type Clamps..................... 15
Constant Torque Hose Clamps...................... 16
2 31200268
Table of Contents
31200268 3
Specifications Section

Specifications Section Torque-Turn

The torque-turn method is used when precise control
General Information over clamping force is required. There is an initial
torque and an additional turn. The initial torque is
required to bring all parts of the joint into contact. The
additional turn provides the desired clamping force.
Ensure that all fasteners have been torqued before you
Mismatched or incorrect fasteners can result in perform the additional turns. Turn the fastener
damage or malfunction, or personal injury. according to the specified amount. The specified
Take care to avoid mixing metric dimensioned fasteners amount will normally be equal to or greater than 90°.
and inch dimensioned fasteners. The specified amount will normally be in 30°
increments. Turns of 120° or 180° are preferred. Turns
Introduction to Torque of 120° or 180° are easily measured by the points of
the hex head of the fastener. Lubrication may be
"Torque" is measured in terms of force and distance. specified in order to reduce the effort that is required for
Force is the amount of pushing or pulling applied at the the final turn. The use of the torque-turn method will
end of the lever. Distance is the length of the lever that allow the following:
is being used. Torque values are given in the following
• Increase the life of the fastener.
units: NEWTON meters (Nm), pound inches (lb in), and
pound feet (lb ft) • Maximize the potential clamping force of a fastener.
This manual is intended to provide the operator with a
reference. This manual will provide the standard torque Typical applications are the following:
settings for the following: bolts, nuts, plugs, fittings, and • Track bolts
clamps.
• Sprocket bolts
Exceptions to these torques are given in the Service
Manual, if necessary. • Connecting rod bolts
Be sure to use a torque wrench that has the proper • Engine Cylinder Heads
range. Torque wrenches must be used properly in • Drive Shaft bolts
order to ensure that the correct torque is applied.
Always use a smooth pull for torque wrenches. Do not Note: Too much tension on the bolt will cause the bolt to
jerk a torque wrench. Do not use adapters that change be stretched beyond the point of yield. The bolt will be
the length of the torque wrench. For the correct use of permanently stretched. The bolt will loosen the grip on
your torque wrench, refer to the instructions that were the parts that are being fastened. If the bolt is
packaged with your torque wrench. tightened again, the bolt will break. Do not reuse bolts
that have been permanently stretched.
Prior to installation of any hardware, ensure that
components are in near new condition. Bolts and
threads must not be worn or damaged. Threads must Torque Sequence
not have burrs or nicks. Hardware must be free of rust Unless the bolt tightening sequence is specified by the
and corrosion. Clean reused fasteners with a Service Manual, the fasteners should be tightened in a
noncorrosive cleaner. Lightly lubricate the threads of cross pattern. Use Step 1 through Step 5 unless the
reused fasteners. Lightly lubricate the mating surface of tightening sequence is specified:
the head of reused fasteners. Other applications for
lubricating fasteners may also be specified in the 1. Hand tighten all fasteners. Larger fasteners may
Service Manual. The Service Manual may also specify require the use of a small hand wrench.
the use of sealants and compounds. 2. Torque all fasteners to 40% of full torque.
Note: Do not use sealants that are not specified in 3. Torque all fasteners to 70% of full torque.
the Service Manual. Do not use compounds that 4. Torque all fasteners to full torque by using a cross
are not specified in the Service Manual. Clean old pattern. Large flanges may require additional
compound from the bolt and from the hole before passes.
installation.
5. Apply at least one final full torque to all fasteners
in a clockwise direction until all torque is uniform.
Large flanges may require additional passes.
Note: Final torque may be a turn.
4 31200268
Specifications Section

Metric (ISO) Fasteners

Metric (ISO) Nuts and Bolts

Illustration 2 g00908932

Table 3

Thread Size
Torque
mm
Illustration 1 g00909614
M1.6 0.10 ±0.01 Nm (0.9 ±0.1 lb in)

Note: The following table has the recommended M2 0.15 ±0.01 Nm (1.3 ±0.1 lb in)
standard torque values for Metric nuts and bolts for use M2.5 0.35 ± 0.05 Nm (3.1 ±0. 4 lb in)
on Perkins engines.
M3 0.50 ± 0.05 Nm (4.4 ±0. 4 lb in)
Table 1
M4 1.70 ± 0.25 Nm (15.0 ± 2.2 lb in)
Thread Size
Torque M5 2.25 ± 0.25 Nm (19.9 ± 2.2 lb in)
mm
M6 5 Nm (44 lb in)
M8 22 Nm (16 lb ft) Hex Button Head Screw and Set
M10 44 Nm (32 lb ft) Screw
M12 78 Nm (60 lb ft)
M14 124 Nm (90 lb ft)
M16 177 Nm (130 lb ft)
M18 200 Nm (150 lb ft)
M20 400 Nm (300 lb ft)
M24 790 Nm (580 lb ft) Illustration 3 g01186742

Note: The difference between Caterpillar standard Table 4

torque values and Perkins standard torque values are Thread Size
due to different classes of fasteners. Caterpillar uses Torque
mm
class 10.9 fasteners. Perkins uses class 8.8 fasteners.
M3 .6± .1 Nm (5 ± 0.9 lb in)
The different class of fasteners have different tensile
strengths. M4 2± .3 N m ( 1 8 ± 3 l b i n )
M5 4± .5 Nm (35 ± 4 lb in)
Metric (ISO) Taperlock Studs M6 6± 1 N m ( 5 5 ± 9 l b in)
Note: The following table has the recommended M8 15 ±3 Nm (11 ± 2 lb ft)
standard torque values for metric nuts and bolts for use
M10 30 ± 7 Nm (22 ± 5 lb ft)
on Perkins engines.
Table 2
M12 50 ± 10 Nm (37 ± 7 lb ft)
M14 80 ± 15 Nm (60 ± 11 lb ft)
Thread Size
Torque
mm M16 125 ± 20 Nm (90 ± 15 lb ft)
M6 5 Nm (44 lb in)
M20 250 ± 40 Nm(185 ± 30 lb ft)
M8 11 Nm (97 lb in)
425 ± 50 Nm
M10 18 Nm (13 lb ft) M24
(310 ± 37 lb ft)
M12 25 Nm (18 lb ft) 850 ± 100 Nm
M30 (620 ± 75 lb ft)

Metric (ISO) Machine Screws M36

1500 ± 200 Nm
(1100 ± 150 lb ft)
31200268 5
Specifications Section

English (SAE) Fasteners English (SAE) Taperlock Studs

Table 6
English (SAE) Nuts and Bolts
Thread Size
Standard Torque
Inch
1/4 8 ± 3 Nm (6 ± 2 lb ft)
5/16 17 ± 5 Nm (13 ± 4 lb ft)
3/8 35 ± 5 Nm (26 ± 4 lb ft)
7/16 45 ± 10 N m ( 3 3 ± 7 lb ft)
Illustration 4 g00908911
1/2 65 ± 10 N m ( 4 8 ± 7 lb ft)
Table 5
5/8 110 ±20 N m ( 8 0 ± 15 lb ft)
Thread Size 3/4 170 ± 30 N m ( 1 2 5 ±2 2 lb ft)
Torque
Inch
7/8 260 ±40 N m ( 1 9 0 ± 30 lb ft)
1/4 12 ± 3 N m ( 9 ± 2 lb ft)
1 400 ± 60 Nm (300 ± 44 lb ft)
5/16 25 ± 6 Nm (18 ± 4 lb ft)
1 1/8 525 ± 60 Nm (390 ± 44 lb ft)
3/8 47 ± 9 Nm (35 ± 7 lb ft)
1 1/4 750 ± 80 Nm (550 ± 60 lb ft)
7/16 70 ± 15 N m ( 5 0 ± 11 lb ft)
1 3/8 950 ± 125 Nm(700±90 lb ft)
1/2 105 ±20 N m ( 7 5 ± 15 lb ft)
1 1/2 1200 ± 150Nm(880± 110 lb ft)
9/16 160 ± 30 N m ( 1 2 0 ±2 2 lb ft)
5/8 215 ±40 N m ( 1 6 0 ± 30 lb ft)
3/4 370 ± 50 Nm (275 ± 37 lb ft)
7/8 620 ± 80 Nm (460 ± 60 lb ft) English (SAE) Machine Screws
1 900 ± 100 Nm(660±75 lb ft)
1 1/8 1300 ± 150Nm(960± 110 lb ft)
1 1/4 1800 ± 200 Nm (1320 ± 150 lb ft)
1 3/8 2400 ± 300 Nm (1780 ± 220 lb ft)
1 1/2 3100 ± 350 Nm (2280 ± 260 lb ft)

Illustration 5 g00908932

Table 7

Thread Size
Torque
No.
0-80 0.10 ±0.01 Nm (0.9 ±0.1 lb in)
1-64 0.15 ±0.01 Nm (1.3 ±0.1 lb in)
2-56 0.25 ± 0.02 Nm (2.2 ± 0.2 lb in)
3-48 0.35 ± 0.05 Nm (3.1 ± 0.4 lb in)
4-40 0.50 ± 0.05 Nm (4.4 ± 0.4 lb in)
5-40 0.70 ± 0.10 Nm (6.2 ± 0.9 lb in)
6-32 0.90 ± 0.10 Nm (8.0 ± 0.9 lb in)
8-32 1.70 ± 0.25 Nm (15.0 ± 2.2 lb in)
10-24 2.25 ± 0.25 Nm (19.9 ± 2.2 lb in)
12-24 3.40 ± 0.60 Nm (30.1 ± 5.3 lb in)
6 31200268
Specifications Section

Hex Button Head Screw and Set Ground Engaging Tool (G.E.T.)
Screws Fasteners
Ground Engaging Tools (G.E.T.) are secured by many
types of bolts. Refer to Table 9 for the correct torque for
the following combinations of fasteners for G.E.T.:
• plow bolts and nuts
• hex head bolts and nuts
Illustration 6 g01186972
Table 9

Table 8 Thread Size Torque(1)

Thread Size Inch Nm lb ft

Torque
inch 5/8 inch 270 ± 40 200 ± 30
#4 &#5 .6± .1 N m ( 5 ± 0 . 9 lb in) 3/4 inch 475 ± 60 350 ± 45
#6 & #8 2± . 3 N m ( 1 8 ± 3 lb in) 7/8 inch 750 ± 90 550 ± 65
#10 &#12 4± . 5 N m ( 3 5 ± 4 lb in) 1 inch 1150 ± 150 850 ± 110
1/4 6± 1 N m ( 5 5 ± 9 lb in) 1 1/4 inch 2300 ± 300 1700 ± 220
5/16 13±3Nm(115±27 lbin)
(1) These values are only for Caterpillar bolts for cutting edges.
3/8 25±6Nm(18±4 lb ft)
7/16 40±8Nm(20±6 lb ft)
1/2 60 ± 1 2 N m ( 4 4 ±9 l b f t )
9/16 85 ± 1 5 N m ( 6 5 ± 11 lb ft)
5/8 11 5 ±2 0 N m ( 8 5 ± 15 lb ft)
200 ± 40 Nm
3/4
(150 ± 30 lb ft)
325 ± 40 Nm
7/8
(240 ± 30 lb ft)
500 ± 65 Nm
1
(370 ± 48 lb ft)
700 ± 90 Nm
1 1/8
(520 ± 65 lb ft)
1000 ± 125 Nm
1 1/4
(740 ± 90 lb ft)
1300 ± 150 Nm
1 3/8
(960 ± 110 lb ft)
1700 ± 200 Nm
1 1/2
(1260 ± 150 lb ft)
31200268 7
Specifications Section

• Tapered Pipe Thread (NPT and NPTF)

• 37 Degree Flare Fitting
Personal injury can result when installing plow bolts. • 45 Degree Flare Fitting
The appropriate safety equipment must be worn when • 45 Degree Inverted Flare Fitting
striking the plow bolts. To avoid injury to your eyes and
ears, wear protective glasses and hearing protection • Split Flange Coupling
during this procedure.
Installation of Split Flange
Couplings
1. For a metal tube to hose installation, install the
tube and tighten all bolts finger tight at the rigid
end.
2. Install the hose and tighten all bolts finger tight.
Illustration 7 g00909058 3. Put the hose in a position so that the hose does
Plow bolts must be installed properly. Refer to the not make contact with the machine or with another
following procedure for the correct installation of plow hose.
bolts.

1. Clean all surfaces that contact the bolt. Remove

all occurrences of the following conditions:rust,
paint, nicks, and burrs
2. Tighten the nut to the correct torque. Refer to
Table 9 for the correct torque.
3. Use a hammer to strike the head of the bolt. The
bolt must be struck with significant force.
Note: The head of the bolt may be recessed below the
mounting surface. Use a suitable punch in order to
transfer the hammer blow to the bolt head. Illustration 8 g00906528
4. Tighten the nut to the correct torque. Refer to 4. Tighten the bolts on both connections to the
Table 9 for the correct torque. proper torque. Follow the prescribed torque
sequence for split flange connections. Refer to
Illustration 8. Add the measurement of gap (A) to
the measurement of gap (B). The total must not
Installation of Fittings exceed 4.0 mm (0.16 inch).
Note: The tightening sequence of the fasteners that 5. Start the engine.
attach a tube assembly or hose assembly to the 6. Move the implement control levers to all of the
machine is very critical to the proper function of the positions.
machine. The sealing surfaces of the tube assembly or
hose assembly should be secured squarely. The 7. Look at the hose during movement of the
sealing surfaces of the tube assembly or hose assembly implement. Ensure that the hose is not in contact
should be tightened to the serviced component (control with the machine or with other hoses.
valve, cylinder, hydraulic motor, etc). Perform this Note: For hoses that cross an articulation hitch, check
procedure prior to the final tightening of any clamps or for contact during articulation. For hoses that connect to
clips that are used in order to fasten the tube the steering system, check for contact during steering.
assembly or the hose assembly to the machine. 8. Shut off the engine.
Fittings have different connections. Fittings may have 9. If the hose contacts other hoses or the machine
two completely different ends. Be sure to use the during the test, loosen the bolts and reposition
proper torque for the end of the fitting that is used. The the hose. Repeat steps 3 through 8 until there is
following list contains some common types of fittings. no contact.
• Straight Thread O-Ring (STOR)
• Adjustable Straight Thread O-Ring (STOR)
• O-Ring Face Seal (ORFS)
8 31200268
Specifications Section

Installation of Adjustable STOR • Excessive tightening can expand a loose ferrule

into the nut. This will cause the ferrule to lock up in
Fittings the nut and the nut will not function properly.
This type of fitting is used in many applications. One • Excessive tightening can split the nut on the end of
end of the fitting will be an adjustable STOR fitting. The the tube or can split the ferrule.
other end will be different. Always use the same
• Excessive tightening can gall or excessive
installation procedure for the STOR end. Adjustable
tightening can strip the threads of the nut.
STOR fittings can be positioned before tightening.
Note: If the above conditions occur due to excessive
tightening, the damaged fluid connector must be
scrapped and the fluid connectors must be replaced.

Straight Thread O-Ring Fittings

Illustration 9 g00906575
Elbow Body Assembly Illustration 10 g00911924
(1) End that connects to the tube or hose. (2) Fitting body. (3) Locknut. (4)
Backup washer. (5) O-ring seal. (6) End that is assembled to the mating part.
Note: For torques for plugs, refer to Specifications,
"Plugs".
1. Put locknut (3), backup washer (4) and O-ring seal
(5) as far away from the threads as possible. Hold
these components in this position. Turn the fitting Note: Straight Thread O-Ring fittings for medium
into the mating part. Turn the fitting until backup pressure usage will have shorter threaded ends than
washer (4) contacts the surface of the mating part. high pressure fittings. The torque value for medium
Note: Excessive use of the wrench will distort the pressure Straight Thread O-Ring fittings will be lower
washer. Distortion of the washer will prevent proper than the torque values that are required for Straight
sealing. Thread O-Ring fittings for high pressure fittings.

2. Put the fitting assembly in the correct position,

loosen fitting (2) until the correct assembly position
is achieved. Do not loosen the fitting more than
360 degrees. Install the tube or hose hand tight in
order to verify the orientation of the fitting. Tighten
the fitting (2) to the torque that is shown in the
correct chart for the fitting that is used. Tighten
locknut (3) to the torque that is shown in the correct
chart for the fitting that is used. Use a backup
wrench, when the locknut is tightened.
Note: Torque the fitting prior to the locknut.

Note: If the fitting is not adjustable, the hex on the body

replaces the locknut. To install this type of fitting, tighten
the hex against the face of the mating part.

Excessive tightening of the connectors can cause

failure. Connectors that are under tightened can also
cause failures. The following failures occur:
31200268 9
Specifications Section

Table 10 Table 11

Ferrous Straight Thread O-Ring Fittings Torques for

Mating with Ferrous Materials High Pressure use with
Ferrous Straight Thread O-Ring Fitting Torques for
O-Ring Face Seal Fittings
Mating with Ferrous Materials Medium Pressure use
with 37° Flare Fittings Nominal Outer Standard
Thread Size
Diameter of the Torque Tolerance
Nominal Outer Standard Inch
Thread Size Tube (+10% - 0%)
Diameter of the Torque Tolerance
Inch
Tube (+10% - 0%) 4.76 mm (0.188 12 + 2 Nm
3/8 - 24
inch) (9 + 1 lb ft)
3.18 mm (.125 8 + 1 Nm
5 / 16 - 2 4
inch) (6 + 1 lb ft) 6.35 mm (0.250 22 + 2 Nm
7/16 - 20
inch) (16+ 1 lb ft)
4.76 mm (.188 13 + 1.5 Nm
3/8 - 24
inch) (10 + 1.1 lb ft) 7.94 mm (0.312 30 + 3 Nm
1/2 - 20
inch) (22 + 2 lb ft)
6.35 mm (.250 17 + 2 Nm
7/16 - 2 0
inch) (13+ 1.5 lb ft) 9.52 mm (0.375 48 + 5 Nm
9/16 - 18
inch) (35 + 4 lb ft)
7.94 mm (.312 28 + 3 Nm
1/2 - 20
inch) (21 + 2 lb ft) 12.7 mm (0.500 82 + 8 Nm
3/4 - 16
inch) (60 + 6 lb ft)
9.52 mm (.375 34 + 3 Nm
9/16 - 18
inch) (25 + 2 lb ft) 15.88 mm (0.625 140 + 14 Nm
7/8 - 14
inch) (105+ 10 lb ft)
12.70 mm (.500 55 + 6 Nm
3/4 - 16
inch) (41 + 4 lb ft) 19.05 mm (0.750 190 + 15 Nm
1 1/16- 12
inch) (140+ 11 lb ft)
Ferrous Straight Thread O-Ring Fitting Torques for
Mating with Ferrous Materials Medium Pressure use 22.22 mm (0.875 250 + 20 Nm
1 3/16 - 12
with 37° Flare Fittings inch) (185+ 15 lb ft)
Ferrous Straight Thread O-Ring Fittings Torques for
Nominal Outer Standard
Thread Size Mating with Ferrous Materials High Pressure use with
Diameter of the Torque Tolerance
Inch O-Ring Face Seal Fittings
Tube (+10% - 0%)
Nominal Outer Standard
15.88 mm (.625 80 + 8 Nm Thread Size
7/8 - 14 Diameter of the Torque Tolerance
inch) (60 + 6 lb ft) Inch
Tube (+10% - 0%)
19.05 mm (.750 100 + 10 Nm
1 1/16- 12
inch) (75 + 7 lb ft) 25.40 mm (1.000 300 + 30 Nm
1 5/16 - 12
inch) (220 + 22 lb ft)
22.22 mm (.875 135 + 13 Nm
1 3/16 - 12
inch) (100+ 10 lb ft) 31.75 mm (1.250 350 + 35 Nm
1 5/8 -12
inch) (260 + 26 lb ft)
25.40 mm (1.000 150 + 15 Nm
1 5/16 - 12
inch) (110+ 11 lbft) 38.10 mm (1.500 415 + 40 Nm
1 7/8 - 12
inch) (305 + 30 lb ft)
31.75 mm (1.250 290 + 25 Nm
1 5/8 - 12
inch) (215+ 18 lb ft)
Note: Use 50 percent of the torque values from Table 11
38.10 mm (1.500 325 + 30 Nm when the fitting or the port material is nonferrous.
1 7/8 - 12
inch) (240 + 22 lb ft)
50.80 mm (2.000 420 + 40 Nm
2 1/2 - 12
inch) (310 + 30 lb ft)

Note: Use 50 percent of the torque values from Table 10

when the fitting or the port material is nonferrous.
Note: Straight Thread O-Ring fittings for high pressure
usage will have longer threaded ends than medium
pressure fittings. The torque value for high pressure
Straight Thread O-Ring fittings will be higher than the
torque values that are required for Straight Thread O-
Ring fittings for medium pressure fittings.
10 31200268
Specifications Section

Table 142
Plugs
Metric Ferrous Straight Thread O-Ring Fittings Torques
for Mating with Ferrous Materials
Straight Thread O-Ring Plugs (Hex
Ref Nominal Standard Drive)
Outer Diameter of Thread Size Torque Tolerance
the Tube (+10% -0%)

10.5 + 1 Nm
4 mm M8X 1
(95 + 9 lb in)
2 1 + 2 Nm
5 mm M10X 1
(15+ 1.5 lb ft)
37 + 3 Nm Illustration 11 g00911999
6 mm M12X 1.5
(27 + 2 lb ft)
47 + 4 Nm Table 13
8 mm M14X 1.5
(35 + 3 lb ft) Thread Size Torque
58 + 6 Nm Inch Tolerance (+10% - 0%)
10 mm M16X 1.5
(43 + 4 lb ft) 5/16 9+ 1 Nm (80 + 9 lb in)
75 + 7 Nm
12 mm M18X 1.5 3/8 17+ 1.5 N m ( 13 + 1 lb ft)
(55 + 5 lb ft)
7/16 23 + 2 N m ( 1 7 + 1.5 lb ft)
105 + 10 Nm
16 mm M22X 1.5
(75 + 7 lb ft) 1/2 28 + 3 Nm(21 + 2 lb ft)
180 + 15 Nm 9/16 34 + 3 Nm (25 + 2 lb ft)
20 mm M27X2
(135+ 11 lb ft)
3/4 60 + 6 Nm (44 + 4 lb ft)
225 + 20 Nm
22 mm M30X2 7/8 115 + 10 N m ( 8 5 + 7lbft)
(165+ 15 lb ft)
325 + 30 Nm 1 1/16 140+ 14N m (10 5 + 10 lb ft)
25 mm M33X2
(240 + 22 lb ft)
1 3/16 190+ 19N m (14 0 + 14 lb ft)
350 + 35 Nm
30 mm M42X2 1 5/16 210 + 20Nm(155 + 15 lb ft)
(260 + 26 lb ft)
1 5/8 290 + 25Nm(215 + 18 lb ft)
440 + 40 Nm
38 mm M48X2
(320 + 30 lb ft) 1 7/8 325 + 30 Nm (240 + 22 lb ft)
525 + 50 Nm 2 1/2 420 + 40 Nm (310 + 30 lb ft)
50 mm M60X2
(390 + 37 lb ft)
Note: Use 50 percent of the torque values from Table 13
Note: Use 50 percent of the torque values from 12 when the fitting or the port material is nonferrous.
when the fitting or the port material is nonferrous.
31200268 11
Specifications Section

Straight Thread O-Ring Plugs Table 15

Type of Thread Size Torque Tolerance
(Socket Drive) Plug Inch (+10% - 0%)
1/2 - 13 20 + 5 N m ( 1 5 + 4 lb ft)
5/8 - 11 35 + 5 Nm (26 + 4 lb ft)

A 3/4 - 12 3/4 - 16 50 + 5 Nm (37 + 4 lb ft)

7/8 - 14 1 1/8- 12 70+ 1 5 N m ( 5 2 + 11 lb ft)

Illustration 12 g00912006 1 5/16 - 12 1 1/2 -

90+ 15Nm(66 + 11 lb ft)
B 12
Note: The socket may be hexagonal or a square recessed 2 - 12 125+ 15 Nm (92+ 11 lb ft)
drive.
1 1/8- 12 70+ 1 5 N m ( 5 2 + 11 lb ft)
Table 14 C
1 5/16 - 12 90+ 15Nm(66 + 11 lb ft)
Thread Size Torque
Inch Tolerance (+10% - 0%) 1/2 - 20 11 + 4 N m ( 9 7 + 35lbin)

5/16 5 + 1 Nm (44 + 9 lb in) 7/8 -14 55 + 7 N m ( 4 1 + 5 lb ft)

D
3/8 11 + 1 Nm(97 + 9 lb in) 1 3/8 -13 90 + 15 N m ( 6 6 + 11 lb ft)

7/16 16+ 1 . 5 N m ( 1 2 + 1 lb ft) 1 1/2 - 12 110+ 15Nm(81 + 11 lb ft)

1/2 20 + 2 N m ( 1 5 + 1.5 lb ft) Note: Use 50% of the values in Table 15 when either the
9/16 35 + 3.5 Nm (26+ 3 lb ft) plug or the port material is nonferrous.

3/4 70 + 7 Nm (50 + 5 lb ft)

Straight Thread O-Ring Plugs
7/8 100+ 10 Nm (75 + 7 lb ft)
(Mechanical Joint Tube Assemblies)
1 1/16 170+ 1 5N m (1 2 5 + 11 lb ft)
1 3/16 215 + 20Nm(160 + 15 lb ft)
1 5/16 270 + 25 Nm (200 + 18 lb ft)
1 5/8 285 + 25Nm(210 + 18 lb ft)
1 7/8 370 + 35 Nm (275 + 26 lb ft)
2 1/2 415 + 40 Nm (305 + 30 lb ft)

Drain Plugs with Straight Thread

Illustration 14 g00912010

Note: When you tighten the plug, the torque must not
be transmitted to the joint between the tube and the
Illustration 13 g00912008 elbow.
Note: Plug (A), plug (B) and plug (C) are used with a gasket. Conical seal plug
(D) does not use a gasket.
12 31200268
Specifications Section

Table 16
Bulkhead Nuts
Thread Size
Torque
Inch
7/8 125 ± 15 N m ( 92 ± 11 lb ft)
1 1/16 175 ± 15Nm(130± 11 lb ft)
1 3/16 250±20Nm(185± 15 lb ft)
1 1/4 250±20Nm(185± 15 lb ft)
1 5/16 370±20Nm(275± 15 lb ft)
1 5/8 420 ± 25 Nm (310 ±20 lb ft)
1 7/8 525 ± 35 Nm (390 ±25 lb ft)
2 1/2 900 ± 50 Nm (665 ±40 lb ft)
Illustration 16 g00909138
Bulkhead connector (ORFS) (1) and bulkhead nut (1A).
Note: The bulkhead connector may have different
O-Ring Face Seal Fittings connections. The type of fluid connection does not affect
the torque for nut (1A).
Note: When you assemble the fluid connection, do not
use the bulkhead nut (1A) as leverage for a backup
wrench. Use the hex on the body (1) of the connector for
leverage.
Table 2018

Thread Size
Torque
Inch
5/16 6± 1 Nm (53 ± 9 lb in)
3/8 8± 1 Nm (71 ± 9 lb in)
7/16 14 ± 1.5 N m ( 1 0 ± 1 lb ft)
Illustration 15 g00906427
1/2 17 ±2 N m ( 1 3 ± 1.4 lb ft)
O-ring face seal fitting (ORFS fitting)
(1) O-ring face seal connector 9/16 22 ±2 N m ( 1 6 ± 1.4 lb ft)
(1A) O-ring groove
(2) O-ring seal 11/16 31 ± 3 Nm (23 ± 2 lb ft)
(3) Nut for the O-ring face seal
3/4 37 ± 4 Nm (27 ± 3 lb ft)
Table 17 13/16 40 ± 4 Nm (30 ± 3 lb ft)
Ferrous ORFS Fitting 7/8 44 ± 4 Nm (32 ± 3 lb ft)
Thread Size Thread Size
Standard Torque for Nut (3) Torque
Inch Inch
9/16 - 18 25 + 3 Nm (18 + 2 lb ft) 1 61 ± 6 Nm (45 ± 4 lb ft)
11/16 - 16 40 + 4 Nm (30 + 3 lb ft) 1 1/16 70 ± 7 Nm (52 ± 5 lb ft)
13/16 - 16 55 + 5 Nm (41 + 4 lb ft) 1 3/16 91 ± 10 N m ( 6 7 ± 7 lb ft)
1 - 14 86 +8 Nm (65 + 6 lb ft) 1 5/16 113 ± 10 N m ( 8 3 ± 7 lb ft)
1 13/16 - 12 125 + 15 Nm (90 + 11 lb ft) 1 7/16 125 ± 12 N m ( 9 2 ± 9 lb ft)
1 7/16 - 12 165 + 15 Nm (120 + 11 lb ft) 1 5/8 150 ± 15 N m ( 11 0 ± 11 lb ft)

1 11/16 - 12 200 + 20 Nm (150 + 15 lb ft) 1 11/16 150 ± 15 N m ( 11 0 ± 11 lb ft)

2 - 12 245 + 20 Nm (180 + 15 lb ft) 1 7/8 155 ± 15 N m ( 11 5 ± 11 lb ft)

2 170 ± 17 N m ( 1 2 5 ± 13 lb ft)
2 1/2 220 ±20 N m ( 1 6 0 ± 15 lb ft)

Note: Bulkhead nuts are designed to secure fluid

connectors firmly in position.
31200268 13
Specifications Section

Flare Fittings Note: Use 50 percent of the torque values from Table 21
when the fitting or the port material is nonferrous.
The torques in Table 21 are for 37 degree flare fittings.
The torques in Table 22 are for 45 degree flare fittings
and 45 degree inverted flare fittings. 45 Degree Flare and 45 Degree
Inverted Flare Fittings
37 Degree Flare Fitting I

llustration 18 g01185492
Illustration 17 g01185483 (1) 45 Degree Inverted Flare Fittings. (2) 45 Degree Flare Fittings.
(1) 37 degree flare fitting. (2) Swivel nuts. Table 20
Table 19
45 Degree Flare Fittings and 45 Degree
Nuts for 37 Degree Flare Fittings Inverted Flare Fittings
Nominal Outer
Nominal Outer Standard Torque Thread Size
Thread Size Diameter of the Standard Torque
Diameter of the Tolerance Inch
Inch Tube
Tube (+ 10% - 0%)
3.18 mm 5.0 ± 1.5 Nm
5/16
3.18 mm 5.0 + 1 Nm (.125 inch) (44 ± 13 lbin)
5/16
(.125 inch) (44 + 9 lb in)
4.76 mm 8.0 ± 1.5 Nm
3/8
4.76 mm 11 + 1 Nm (.188 inch) (70 ± 13 lbin)
3/8
(.188 inch) (100 + 9 lb in)
6.35 mm 11 ± 2 Nm
7/16
Nuts for 37 Degree Flare Fittings (.250 inch) (100 ± 18 lbin)
7.94 mm 17 ± 3 Nm
Nominal Outer Standard Torque 1/2
Thread Size (.312 inch) (13 ± 2 lbft)
Diameter of the Tolerance
Inch 9.52 mm 30 ± 3 Nm
Tube (+ 10% - 0%) 5/8
(.375 inch) (22 ± 2 lb ft)
6.35 mm 16 + 1.5 Nm
7/16 11.11 mm 30 ± 3 Nm
(.250 inch) (12+ 1.1 lb ft) 11/16
(.438 inch) (22 ± 2 lb ft)
7.94 mm 20 + 2 Nm
1/2 12.70 mm 38 ± 4 Nm
(.312 inch) (15+ 1.5 lb ft) 3/4
(.500 inch) (28 ± 3 lb ft)
9.52 mm 27 + 3 Nm
9/16 15.88 mm 50 ± 5 Nm
(.375 inch) (20 + 2 lb ft) 7/8
(.625 inch) (37 ± 4 lb ft)
12.70 mm 58 + 6 Nm
3/4 19.05 mm 90 ± 8 Nm
(.500 inch) (43 + 4 lb ft) 1 1/16
(.750 inch) (65 ± 6 lb ft)
15.88 mm 74 + 7 Nm
7/8 22.22 mm 100 ± 10 Nm
(.625 inch) (55 + 5 lb ft) 1 1/4
(.875 inch) (75 ± 7 lb ft)
19.05 mm 108 + 10 Nm
1 1/16
(.750 inch) (80 + 7 lb ft)
22.22 mm 135 + 13 Nm
1 3/16
(.875 inch) (100+ 10 lb ft)
25.40 mm 156 + 15 Nm
1 5/16
(1.000 inch) (115+ 11 lb ft)
31.75 mm 217 + 20 Nm
1 5/8
(1.250 inch) (160+ 15 lb ft)
38.10 mm 251 + 25 Nm
1 7/8
(1.500 inch) (185+ 18 lb ft)
50.80 mm 339 + 30 Nm
2 1/2
(2.000 inch) (250 + 22 lb ft)
14 31200268
Specifications Section

Air Conditioning Fittings Table 22

Nominal Turn Tightening
Outer Torque
Diameter of Nonmetallic Copper
the Tube Tubing Tubing
6.35 mm 11 ± 3 Nm (8
3 2
(0.250 inch) ± 2 lb ft)
9.53 mm 20 ± 3 Nm
4 2
(0.375 inch) (15 ± 2 lb ft)
12.70 mm 35 ±6 Nm
4 2
(0.500 inch) (26 ± 4 lb ft)
15.88 mm 40 ± 6 Nm
3 1/2 3
(0.625 inch) (30 ± 4 lb ft)

Illustration 19 g01185521
19.05 mm 50 ±6 Nm
3 1/2 3
(0.750 inch) (37 ± 4 lb ft)
(1) O-ring seal. (2) 45 degree flare fitting.

Note: Clean the connectors and the seals and

Table 21 lubricate the connectors and seals by using
Air Conditioning Fittings Refrigerant Mineral Oil. This is a special oil that is
compatible with R-134a.
O-Ring 45 Degree Flare Fitting
Thread Size Fitting End End
Inch Torque for
Torque
Torque for
Steel Tubes
Aluminum Tapered Pipe Thread Fittings
Tubes
Torque is based on the diameter of the thread. The
14 ±4 Nm 30 ± 3 Nm 23 ±3 Nm
5/8- 18 torque values are identical for coarse threads and fine
(10 ±3 lbft) (22 ± 2 lb ft) (17 ±2 lbft)
threads.
27 ±4 Nm 52 ± 5 Nm 33 ±4 Nm
3/4 - 16
(20 ± 3 lb ft) (38 ± 4 lb ft) (24 ± 4 lb ft)
Note: The following table has the recommended
standard torque value for tapered pipe thread fitting for
7/8 - 14 1 - 40 ± 4 Nm 60 ± 7 Nm 38 ±4 Nm use on all Caterpillar equipment and Mitsubishi
14 (30 ± 3 lb ft) (44 ± 5 lb ft) (28 ± 3 lb ft) engines. Use Table 23 as a general recommendation
1 1/16-14
45 ± 5 Nm 75 ± 8 Nm 50 ±5 Nm only. Actual values may vary due to variations in the
(33 ± 4 lb ft) (55 ± 6 lb ft) (37 ± 4 lb ft) material of the connector. Actual values may vary due
to variations in the characteristics of the threads.

Table 23
Air Brake Fittings
Tapered Pipe Thread Fittings
Diameter of the Standard Torque
Pipe Thread
Threads with 5P-
(Inch) Threads without
3413 Pipe
Pipe Sealant
Sealant
1/16 10Nm(90 lb in) 1 0Nm ( 90 lb in)
1/8 16 Nm (12 lb ft) 16 Nm (12 lb ft)
Illustration 20 g00909062

Put nut (1) and sleeve (2) over the tube. Push the tube 1/4 20 Nm (15 lb ft) 25 Nm (18 lb ft)
into the counterbore of the fitting body as far as 3/8 35 Nm (26 lb ft) 45 Nm (33 lb ft)
possible. There are two methods that may be used to 1/2 45 Nm (33 lb ft) 60 Nm (44 lb ft)
tighten the nut. Tighten the nut with one of two
methods. 3/4 60 Nm (44 lb ft) 75 Nm (55 lb ft)

• Tighten nut (1) to the torque that is specified in 1 75 Nm (55 lb ft) 90 Nm (65 lb ft)
Table 22. 1 1/4 95 Nm (70 lb ft) 110Nm(80 lb ft)
• Tighten nut (1) by the number of turns that is 1 1/2 110 Nm (80 lb ft) 130Nm(95lb ft)
specified in Table 22. The number of turns is for
the turns after the nut is finger tight. 2 130 Nm (95 lb ft) 160 Nm (120 lb ft)
31200268 15
Specifications Section

Note: Use 50 percent of the torque values from Table 25 be next to the nut. Push the tube into the counterbore
when the fitting, the plug, or the port material is of the fitting body as far as possible. Tighten the nut
nonferrous. until a sudden increase in torque is felt. Next, tighten
Note: Use 50 percent of the torque values from Table 25 the fitting for an additional 1/6 to 1/3 turn in order to
when a tapered thread is mated with a straight thread. seat the sleeve.

Flex Fittings
Miscellaneous Fittings
Hi Duty Tube Fittings (Shear Sleeve)

Illustration 23 g00909645

Put nut (1) and sleeve (2) over the tube and push the
tube into the counterbore of the fitting body as far as
possible. Tighten the nut until the nut is against the hex
part of the fitting body.
Illustration 21 g00909648

Put nut (1) over the tube and push the tube into the
counterbore of the fitting body as far as possible. Turn
the nut with a wrench until a small decrease in torque is Hose Clamps
felt. The small decrease in torque indicates that the
sleeve (1A) has been broken off of the nut. Hold the Worm Drive Band Type Clamps
tube in order to prevent the tube from turning. Tighten
the nut for an additional 1 1/2 turns.

SAE Flareless Fittings

Illustration 24 g00910017
Illustration 22 g00909647
Table 24
Installing a New Flareless Fitting
Width (A) of Clamp Torque for New Hose
Put nut (1) and sleeve (2) over the tube. The head end
of the sleeve should be next to the nut. The head end 7.9 mm (0.31 inch) 0.9 ± 0.2 N m ( 8 ± 2 lb in)
has a shoulder. The nut will be seated against this 13.5 mm (0.53 inch) 4.5 ± 0.5 N m ( 4 0 ± 4 lb in)
shoulder when the nut is tightened. Push the tube into
15.9 mm (0.63 inch) 7.5 ± 0.5 N m ( 6 5 ± 4 lb in)
the counterbore of the fitting body as far as possible.
Turn nut (1) clockwise until the sleeve grips the tube. Width (A) of Clamp Torque for Reused Hose(1)
The sleeve must prevent all movement of the tube. 7.9 mm (0.31 inch) 0.7 ± 0.2 N m ( 6 ± 2 lb in)
Tighten the nut for an additional 1 1/4 turns. The sleeve
should be seated and the sleeve should give a locking 13.5 mm (0.53 inch) 3.0 ± 0.5 N m ( 2 7 ± 4 lb in)
action. 15.9 mm (0.63 inch) 4.5 ± 0.5 N m ( 4 0 ± 4 lb in)
Installing a Used Flareless Fitting (1) Use this value when the hose is reused. The clamp may be
new or reused.
Less turns are required for a used fitting. Put nut (1) and
sleeve (2) over the tube. The head of the sleeve should
16 31200268
Specifications Section

Constant Torque Hose Clamps

Use a constant torque hose clamp in place of any
worm drive band type clamp. Ensure that the constant
torque hose clamp is the same size as the worm drive
band type clamp. Due to extreme temperature
changes, the hose will heat set. Heat setting can
cause worm drive band type clamps to loosen. Loose
hose clamps can result in leaks. There have been
reports of component failures that have been caused
by worm drive band type clamps that have loosened.
The constant torque hose clamp will help prevent these
failures.

Illustration 25 g00906389
(1) Constant Torque Hose Clamp (Belleville Washer)
(2) Constant Torque Hose Clamp (Tee bolt and Spring)

Use a torque wrench for proper installation of all

constant torque hose clamps. There are two types of
constant torque hose clamps: Belleville washer (1) and
Tee bolt and spring (2)
When the constant torque hose clamp (Belleville
washer) (1) is assembled correctly, the Belleville
washers (1A) are nearly collapsed flat. The proper
torque for screw (1B) is based on the diameter (B) of
the clamp. Refer to the following table for the correct
torque.
Table 25

Diameter (B) Standard Torque

Up to 50.8 mm (2 inch) 7.5±0.5Nm(65±5 lb in)
Greater than 50.8 mm
11 ± 1 Nm(95± 10 lb in)
(2 inch)

The correct torque for the constant torque hose clamp

(tee bolt and spring) (2) is 7.5 ± 1 Nm (65 ± 10 lb in).
Cat Telehandler Th360b Service Manual
Full download: http://manualplace.com/download/cat-telehandler-th360b-service-manual/
31200268 17
Index Index

A S
Air Brake Fittings................................................................ 14 Specifications Section .......................................................... 3
Air Conditioning Fittings ..................................................... 14 Straight Thread O-Ring Fittings ........................................... 8

B T
Bulkhead Nuts.................................................................... 12 Table of Contents................................................................. 1
Tapered Pipe Thread Fittings............................................. 14
E
English (SAE) Fasteners
English (SAE) Machine Screws ...................................... 5
English (SAE) Nuts and Bolts ......................................... 5
English (SAE) Taperlock Studs ...................................... 5
Hex Button Head Screw and Set Screws ....................... 6
English (SAE) Fasteners...................................................... 5

F
Flare Fittings ...................................................................... 13
37 Degree Flare Fittings ............................................... 13
45 Degree Flare and 45 Degree Inverted Flare Fittings 13

G
General Information ............................................................. 3
Introduction to Torque..................................................... 3
Torque Sequence ........................................................... 3
Torque-Turn.................................................................... 3
Ground Engaging Tool (G.E.T.) Fasteners .......................... 6

H
Hose Clamps...................................................................... 15
Constant Torque Hose Clamps .................................... 16
Worm Drive Band Type Clamps ................................... 15

I
Important Safety Information.................................................ii
Installation of Fittings ........................................................... 7
Installation of Adjustable STOR Fittings ......................... 8
Installation of Split Flange Couplings.............................. 7

M
Metric (ISO) Fasteners......................................................... 4
Hex Button Head Screw and Set Screw......................... 4
Metric (ISO) Machine Screws ......................................... 4
Metric (ISO) Nuts and Bolts............................................ 4
Metric (ISO) Taperlock Studs ......................................... 4
Miscellaneous Fittings........................................................ 15
Flex Fittings .................................................................. 15
Hi Duty Tube Fittings (Shear Sleeve) ........................... 15
SAE Flareless Fittings .................................................. 15

O
O-Ring Face Seal Fittings .................................................. 12

P
Plugs .................................................................................. 10
Drain Plugs with Straight Thread.................................. 11
Straight Thread O-Ring Plugs (Hex Drive) ................... 10
Straight Thread O-Ring Plugs (Mechanical Joint Tube
Assemblies) .................................................................. 11
Straight Thread O-Ring Plugs (Socket Drive)............... 11

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