Cat TH255 Telehandler Service Manual – PDF DOWNLOAD

Description

Cat TH 255 Telehandler Service Manual – PDF DOWNLOAD

DESCRIPTION:

Cat TH 255 Telehandler Service Manual – PDF DOWNLOAD

INTRODUCTION

• This service manual provides general directions for accomplishing service and repair procedures. Following the procedures in this manual will help assure safety and equipment reliability.
• Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes, regulations and laws. These instructions cannot cover all details or variations in the equipment, procedures, or processes described, nor provide directions for meeting every possible contingency during operation, maintenance, or testing.
• When additional information is desired consult the local Caterpillar dealer. Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others.
• For optimal safety, encourage everyone to think, and to act, safely. Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the machine.
• All references to the right side, left side, front and rear are given from the operator’s seat looking in a forward direction. Supplementary information is available from the manufacturer in the form of Service Bulletins, Service Campaigns, Service Training Schools, the service website, other literature, and through updates to the manual itself.

DISCLAIMER

All information in this manual is based on the latest product information available at the time of publication. The manufacturer reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation.

OPERATION & MAINTENANCE MANUAL

• The mechanic must not operate the machine until the Operation & Maintenance Manual has been read & understood, training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator.
• An Operation & Maintenance Manual is supplied with each machine and must be kept in the manual holder located in the cab. In the event that the Operation & Maintenance Manual is missing, consult your local service distributor before proceeding.

DO NOT OPERATE TAGS

Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.

SAFETY INFORMATION

• To avoid possible death or injury, carefully read, understand and comply with all safety messages.
• In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby.
• If working alone, check with another person routinely to help assure personal safety

TABLE OF CONTENTS:

Cat TH 255 Telehandler Service Manual – PDF DOWNLOAD

Safety Practices 1-1
1 1 Introduction 1-2
1 2 Disclaimer 1-2
1 3 Operation & Maintenance Manual 1-2
1 4 Do Not Operate Tags 1-2
1 5 Safety Information 1-2
1 6 Safety Instructions 1-3
1 7 Safety Decals 1-4
Section 2
General Information and Specifications 2-1
2 1 Replacement Parts and Warranty Information 2-2
2 2 Specifications 2-3
2 3 Fluids, Lubricants and Capacities 2-5
2 4 Maintenance Schedules 2-7
2 5 Lubrication Schedule 2-10
2 6 Torque Charts 2-11
2 7 Hydraulic Connection Assembly and Torque Specification 2-21
Section 3
Boom 3-1
3 1 Boom System Component Terminology 3-2
3 2 Safety Information 3-3
3 3 Boom System – Two Section Boom 3-3
3 4 Boom Assembly Maintenance 3-3
3 5 Boom Wear Pads 3-11
3 6 Quick Coupler Assembly 3-12
3 7 Forks 3-13
3 8 Boom Prop (If Equipped) 3-14
3 9 Emergency Boom Lowering Procedure 3-14
3 10 Troubleshooting 3-17
Section 4
Cab and Covers 4-1
4 1 Operator Cab and Covers Component Terminology 4-2
4 2 Safety Information 4-3
4 3 Operator Cab 4-3
4 4 Cab Components 4-3
4 5 Cab Removal 4-8
4 6 Cab Installation 4-9
Section Subject Page
ii TH255
Section 5
Axles, Drive Shafts, Wheels and Tires 5-1
5 1 Axle, Drive Shaft and Wheel Component Terminology 5-2
5 2 Safety Information 5-3
5 3 General Information 5-3
5 4 Axle Assemblies 5-3
5 5 Axle Assembly And Drive Shaft Troubleshooting 5-7
5 6 Drive Shafts 5-10
5 7 Wheels and Tires 5-11
5 8 Steering Angle Adjustment 5-12
5 9 Brakes 5-12
5 10 Towing a Disabled Machine 5-13
Section 6
Transmission 6-1
6 1 Transmission Assembly Component Terminology 6-2
6 2 Safety Information 6-3
6 3 Transmission Description 6-3
6 4 Transmission Specifications 6-3
6 5 Transmission Replacement 6-3
6 6 Transmission Filter Replacement 6-5
Section 7
Engine 7-1
7 1 Introduction 7-2
7 2 Safety Information 7-4
7 3 Engine Serial Number 7-4
7 4 Specifications and Maintenance Information 7-4
7 5 Engine Cooling System 7-4
7 6 Engine Electrical System 7-5
7 7 Fuel System 7-5
7 8 Engine Exhaust System 7-7
7 9 Air Cleaner Assembly 7-8
7 10 Engine Replacement 7-8
7 11 Engine Coupler 7-11
7 12 Troubleshooting 7-11
Section Subject Page
TH255 iii
Section 8
Hydraulic System 8-1
8 1 Hydraulic Component Terminology 8-3
8 2 Safety Information 8-4
8 3 General Information 8-4
8 4 Specifications 8-4
8 5 Hoses, Tube Lines, Fittings, Etc 8-4
8 6 Hydraulic Pressure Diagnosis 8-5
8 7 Hydraulic Schematic 8-7
8 8 Hydraulic Reservoir 8-13
8 9 Hydraulic System Pump 8-13
8 10 Front Drive Motor 8-14
8 11 Control Valves 8-15
8 12 Hydraulic Cylinders 8-29
Section 9
Electrical System 9-1
9 1 Electrical Component Terminology 9-3
9 2 Safety Information 9-4
9 3 Fuses and Relays 9-4
9 4 Electrical System Schematics 9-7
9 5 Circuit Breakdowns 9-18
9 6 Engine Start Circuit 9-22
9 7 Charging Circuit 9-23
9 8 Electrical System Components 9-24
9 9 Window Wiper/Washer 9-26
9 10 Cab Heater and Fan 9-28
9 11 Switches, Solenoids and Senders 9-29
9 12 Load Stability System (CE & AUS) Before S/N TBS00627 9-33
9 13 Load Stability System (CE & AUS) S/N TBS00627 & After 9-35
9 14 Hand Held Analyzer (CE & AUS) S/N TBS00627 & After 9-41
Section Subject Page
1 1 Introduction 1-2
1 2 Disclaimer 1-2
1 3 Operation & Maintenance Manual 1-2
1 4 Do Not Operate Tags 1-2
1 5 Safety Information 1-2
1 5 1 Safety Alert System and Signal Words 1-2
1 6 Safety Instructions 1-3
1 6 1 Personal Hazards 1-3
1 6 2 Equipment Hazards 1-3
1 6 3 General Hazards 1-3
1 6 4 Operational Hazards 1-4
1 7 Safety Decals 1-4

CAT TH255 TELEHANDLER SERVICE MANUAL – PDF DOWNLOAD:

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PLEASE NOTE:

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