31200245

July 10, 2007

Operation and
Maintenance
Manual
TH580B Telehandler
S/N TBJ00100 & 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.
 EFFECTIVITY PAGE

July 14, 2006 - A - Original Issue Of Manual

February 2, 2007 - B - Added Tier III information. Revised pages 9, 18, 19, 36, 76, 94, 109, 124, 125, 126,
127, 129 and 130.
July 10, 2007 - C - Added LSI Cutout information on pages 46 & 47. Revised Tire Information on page 91 and revised
Boom Chain Adjustment Procedure on pages 99 thru 101.

31200245 i
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31200245 1
Table of Contents
Table of
Table of Contents Travel..............................................................29
Lifting Capacities ............................................29
Foreword Work Tools......................................................30
Literature Information ............................................ 5
Engine Stopping...................................................30
Safety .................................................................... 5
Work Tools...........................................................30
Operation .............................................................. 5
Parking.................................................................31
Maintenance.......................................................... 5
Equipment Lowering with Loss of Hydraulic
Maintenance Intervals ...................................... 5
Power...................................................................31
Certified Engine Maintenance ............................... 5
Sound Information and Vibration Information ......31
Machine Capacity.................................................. 5
Sound Level....................................................31
Contact Information ............................................... 6
Vibration Level ................................................31
Safety Section Operator Station .............................................32
Safety Messages................................................... 7 Guards (Operator Protection) ..............................32
Do Not Operate (1)........................................... 9 Rollover Protective Structure (ROPS), Falling
Do Not Stand Under the Load (2) .................. 10 Object Protective Structure (FOPS)................32
No Hands (3).................................................. 10 Other Guards (If Equipped) ............................32
Do Not Operate (4)......................................... 11 Product Information Section
Forks (5)......................................................... 11
General Information .............................................33
ROPS/FOPS Structure (6) ............................. 12
Lifting Capacities ............................................33
No Hands (7).................................................. 12
Examples of Estimating the Lift Operation from
Crushing Hazard (8)....................................... 13
the Load Chart ................................................34
Seat Belt (9) ................................................... 13
Specifications.......................................................35
Crushing Hazard (10)..................................... 14
Intended Use ..................................................35
Crushing Hazard (11)..................................... 14
Application/Configuration Restrictions ............36
Engine Coolant (12) ....................................... 15
Identification Information......................................36
Avoid Power Lines (13) .................................. 15
Plate Locations and Film Locations ................36
Low Bridge (14).............................................. 16
Serial Number.................................................36
Jump Start Cables (15) .................................. 16
Certification.....................................................37
Ether (16) ....................................................... 17
Sound .............................................................37
Crushing Hazard (17)..................................... 17
ROPS/FOPS Film ...........................................37
Crushing Hazard (18)..................................... 17
Machine Security System ...............................38
Crushing Hazard (19)..................................... 18
Italian Roading Homologation.........................38
Ether (20) ....................................................... 18
Emissions Certification Film.................................39
Universal Warning (21) .................................. 19
Hand (High Pressure) (22) ............................. 19 Operation Section
Additional Messages ...................................... 19 Before Operation..................................................41
General Hazard Information ................................ 23 Mounting and Dismounting .............................41
Pressurized Air and Water ............................. 24 Alternate Exit ..................................................41
Trapped Pressure .......................................... 24 Daily Inspection ..............................................41
Fluid Penetration ............................................ 24 Machine Operation...............................................42
Containing Fluid Spillage ............................... 24 Alternate Exit ..................................................42
Dispose of Waste Properly............................. 25 Seat ................................................................42
Crushing Prevention and Cutting Prevention ...... 25 Air Suspension (If Equipped) ..........................43
Burn Prevention .................................................. 25 Seat Belt .........................................................43
Coolant........................................................... 25 Operator Controls (Side Console) ..................46
Oils ................................................................. 25 Operator Controls ...........................................48
Batteries ......................................................... 25 Battery Disconnect Switch (If Equipped) ........58
Fire Prevention and Explosion Prevention .......... 26 Boom Cylinder Lock (If Equipped) ..................59
Fire Extinguisher ............................................ 27 Operation Information .....................................60
Lines, Tubes and Hoses ................................ 27 Work Tools......................................................67
Fire Extinguisher Location.............................. 27 Monitoring System ..........................................72
Tire Information .............................................. 27 Backup Alarm .................................................75
Electrical Storm Injury Prevention .................. 28 Cab Door ........................................................75
Before Starting Engine ................................... 28 Engine Starting ....................................................76
Engine Starting.................................................... 28 Engine Starting ...............................................76
Before Operation ................................................. 29 Starting Below 0 °C (32°F)..............................76
Operation ............................................................ 29 Engine and Machine Warm-Up.......................77
Machine Operating Temperature Range........ 29 Parking.................................................................77
Machine Operation......................................... 29 Stopping the Machine .....................................77
31200245 2
Table of Contents

Stopping the Engine ............................................ 77 Service Brake ...............................................106

Stopping the Engine if an Electrical Malfunction Parking Brake ...............................................107
Occurs............................................................ 78 Cab Air Filter - Clean/Replace ...........................107
Leaving the Machine ...................................... 78 Primary Cab Air Filter ...................................107
Transportation Information .................................. 78 Secondary Cab Air Filter...............................108
Shipping the Machine..................................... 78 Circuit Breakers - Test .......................................108
Roading the Machine ..................................... 79 Cooling System Coolant -Change......................109
Lifting and Tying Down the Machine .............. 79 Cooling System Coolant Level - Check .............110
Towing Information.............................................. 80 Cooling System Coolant Sample (Level 1) -
Towing the Machine ....................................... 80 Obtain ................................................................111
Engine Starting (Alternate Methods) ................... 82 Cooling System Coolant Sample (Level 2) -
Engine Starting with Jump Start Cables......... 82 Obtain ................................................................111
Equipment Lowering with Loss of Hydraulic Cooling System Pressure Cap - Clean/Replace 112
Power ............................................................. 83 Cooling System Water Temperature Regulator
Procedure for Retracting the Boom without Hand Replace..............................................................112
Pump.............................................................. 84 Differential Oil - Change.....................................113
Procedure for Lowering the Boom with Hand Rear Axle Differential....................................113
Pump.............................................................. 85 Front Axle Differential ...................................113
Procedure for Lowering the Boom without Hand Differential Oil Level - Check .............................114
Pump.............................................................. 85 Rear Axle Differential....................................114
Resetting the Load Control System ............... 86 Front Axle Differential ...................................114
Differential Oil Sample - Obtain .........................115
Maintenance Section
Drive Shaft Spline - Lubricate ............................115
Maintenance Access ........................................... 89
Drive Shaft Universal Joint Bolts - Check ..........116
Access Doors and Covers.............................. 89
Engine Air Filter Primary Element - Clean/Replace .
Tire Inflation Information ..................................... 89
116
Tire Inflation with Air....................................... 89
Cleaning Primary Air Filter Elements............117
Tire Pressure.................................................. 90
Inspecting the Primary Air Filter Elements....117
Tire Inflation Pressure Adjustment ................. 91
Engine Air Filter Primary Element - Replace .....118
Tire Damage .................................................. 91
Engine Air Filter Secondary Element - Replace.118
Tire Replacement........................................... 91
Engine Mounts - Inspect ....................................118
Wheel and Tire Installation............................. 92
Engine Oil Level - Check ...................................119
Lubricant Viscosities and Refill Capacities.......... 92
Engine Oil Sample - Obtain ...............................119
Lubricant Viscosities ...................................... 92
Engine Oil and Filter - Change...........................119
Capacities (Refill) ........................................... 94
Engine Valve Lash - Check................................121
SOS Information............................................. 94
Final Drive Oil - Change.....................................121
Maintenance Support .......................................... 95
Final Drive Oil Level - Check .............................122
Welding on Machines and Engines with
Final Drive Oil Sample - Obtain .........................122
Electronic Controls ......................................... 95
Fork Leveling Cylinder Pin -Lubricate ................123
Maintenance Interval Schedule ........................... 95
Frame Leveling Cylinder Pin - Lubricate............123
Axle Breathers - Clean/Replace .......................... 97
Fuel System - Prime ..........................................123
Backup Alarm - Test............................................ 97
Fuel System Water Separator - Drain................124
Battery - Recycle ................................................. 97
Fuel System Water Separator Element - Replace
Battery or Battery Cable -Inspect/Replace .......... 97
(Tier II) ...............................................................124
Belt - Inspect/Replace ......................................... 97
Fuel System Water Separator Element - Replace
Inspect ........................................................... 97
(Tier III) ..............................................................125
Replace .......................................................... 98
Fuel Tank Cap - Clean.......................................126
Boom Chain - Inspect/ Lubricate ......................... 98
Fuel Tank Water and Sediment - Drain .............127
Boom Chain Tension -Check/Adjust ................... 99
Fuses and Relays - Replace..............................127
Check Condition............................................. 99
Fuses ............................................................127
Check and Adjust the Chain Tension............. 99
Relays...........................................................129
Measure the Chain for Wear ........................ 101
Indicators and Gauges - Test.............................130
Boom Head Section - Lubricate ........................ 102
Longitudinal Stability Indicator - Calibrate..........130
Boom Pivot Shaft - Lubricate ............................ 102
Longitudinal Stability Indicator -Test ..................130
Boom Telescoping Cylinder Air - Purge ............ 102
Initial Test .....................................................130
Boom Wear Pad Clearance -Inspect/Adjust...... 103
Second Test..................................................131
Adjustment ................................................... 104
Oil Filter - Inspect...............................................131
Boom and Frame - Inspect................................ 105
Inspect a Used Filter for Debris ....................131
Braking System - Test ....................................... 106
Parking Brake - Adjust .......................................131
3 31200245
Table of Contents

Pulley for Boom Extension Chain - Lubricate.... 132

Pulley for Boom Retraction Chain - Lubricate ... 132
Radiator Core - Clean ....................................... 132
Refrigerant Dryer - Replace .............................. 133
Rollover Protective Structure (ROPS) and Falling
Object Protective Structure (FOPS) - Inspect .. 133
Seat Belt - Inspect ............................................. 134
Seat Belt - Replace ........................................... 134
Stabilizer and Cylinder Bearings - Lubricate ..... 134
Tire Inflation - Check ......................................... 135
Transmission and Hydraulic System Oil -
Change.............................................................. 135
Transmission and Hydraulic System Oil Filter -
Replace ............................................................. 136
Transmission and Hydraulic System Oil Level -
Check ................................................................ 137
Transmission and Hydraulic System Oil Sample -
Obtain................................................................ 138
Transmission and Hydraulic System Tank Breather -
Clean ................................................................. 138
Turbocharger - Inspect ...................................... 139
Wheel Nut Torque - Check................................ 139
Window Washer Reservoir -Fill ......................... 139
Window Wiper -Inspect/Replace ....................... 140
Windows - Clean ............................................... 140
Work Tool - Inspect/Replace ............................. 140
Forks ............................................................ 140
Buckets ........................................................ 142
Reference Information Section
Approved Work Tools........................................ 143
31200245 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 31200245
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: [email protected]
31200245 7
Safety Section

Safety Section
Safety Messages

Illustration 2 g01106545
8 31200245
Safety Section

Illustration 3 g01212742

Illustration 4 g01212850
31200245 9
Safety Section

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.
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
Illustration 5 g01212851 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.

Do Not Operate (1)

This safety message is positioned on the panel at the
right side of the operator station.

Illustration 6 g01212853
Tier II

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.
Tier III
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.

Tier III
10 31200245
Safety Section

Do Not Stand Under the Load (2) No Hands (3)

This message is positioned on the side of the boom The message is positioned on the side of the number
head on both sides of the machine. one boom section on both sides of the machine.

g00930659 g00930870

A crushing hazard exists when the boom is lowered or A crushing hazard exists when the boom sections are
from a falling load. Stay clear of the boom when the being retracted or extended. Stay clear of the boom
machine is in operation. Failure to stay clear of the when the machine is in operation. Failure to stay clear of
boom can cause injury or death. the boom when the machine is operation can cause
injury or death.
31200245 11
Safety Section

Do Not Operate (4) Forks (5)

This safety message is located on the front dash in This safety message is positioned on the panel at the
the operator compartment. right side of the operator station.

g01059274
g00936539

Improper operation or maintenance of the machine Side loading of the forks may cause premature
could result in injury or death. Do not operate or work failure of the forks and thus a crush hazard which
on this machine unless you have been properly trained may cause personal injury or death. Never push
and authorized and have read and understood the loads with the forks and inspect the forks daily for
warnings and instructions in the Operation and any twisting or bending observed in the forks.
Maintenance Manual. Should twisting or bending be observed, change the
fork(s) prior to any lifting operation. Read the
Operation and Maintenance Manual for more
Refer to Operation and Maintenance Manual, "Load information about the correct use of the forks.
Charts" for more information.
12 31200245
Safety Section

ROPS/FOPS Structure (6) No Hands (7)

This safety message is positioned behind the seat The message is positioned on the top of stabilizer
near the window. cylinders on both sides of the machine.

g01211890

Structural damage, an overturn, modification,

g00930870
alteration, or improper repair can impair this
structure's protection capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. This will void the certification. Consult a
Caterpillar dealer to determine this structure's
limitations without voiding its certification. A crushing hazard exists when raising or lowering
the stabilizers. Ensure that personnel stand clear
when the stabilizers are being raised or lowered.
This machine has been certified to the standards Operating the stabilizers when personnel are nearby
that are listed on the certification film. The maximum could result in personal injury or death.
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.
31200245 13
Safety Section

Crushing Hazard (8) Seat Belt (9)

The message is positioned on the underside of the This safety message is positioned on the panel at the right
stabilizer beam on both sides of the machine. side of the operator station.

g00931188

g00930659
A seat belt should be worn at all times during
machine operation to prevent serious injury or death
in the event of an accident or machine overturn.
Failure to wear a seat belt during machine operation
A crushing hazard exists when raising or lowering
may result in serious injury or death.
the stabilizers. Ensure that personnel stand clear
when the stabilizers are being raised or lowered.
Operating the stabilizers when personnel are nearby Refer to Operation and Maintenance Manual, "Seat
could result in personal injury or death.
Belt" for more information.
14 31200245
Safety Section

Crushing Hazard (10) Crushing Hazard (11)

This message is positioned on the chassis on the This message is positioned on the chassis on the
right side of the machine. right side of the machine.

g00930659

g01212730

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
A crushing hazard exists when the boom is lowered the boom can cause injury or death.
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.

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.
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31200245 15
Safety Section

Engine Coolant (12) Avoid Power Lines (13)

This safety message is positioned on the coolant This safety message is positioned in the operator
tank in the engine enclosure. station on the right side of the window.

g00931247

Pressurized system! Hot coolant can cause serious

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 g00936329
system pressure cap slowly in order to relieve the
pressure. Read and understand the Operation and
Maintenance Manual before performing any cooling
system maintenance.
Electrocution Hazard! Keep the machine and
attachments a safe distance from electrical power.
Refer to Operation and Maintenance Manual, Stay clear 3 m (10 ft) plus twice the line insulator
"Cooling System Coolant - Change" for the correct length. Read and understand the instructions and
procedure to remove the pressure cap. warnings in the Operation and Maintenance Manual.
Failure to follow 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.
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