CAT TH255C Telehandler Service manual + Engine + Axle Service Manual & Schematic Manual – PDF DOWNLOAD

Description

CAT TH255C Telehandler Service manual + Engine + Axle Service Manual & Schematic Manual – PDF DOWNLOAD

DESCRIPTION:

CAT TH255C Telehandler Service manual + Engine + Axle Service Manual & Schematic Manual – PDF DOWNLOAD

1.1 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 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.

1.2 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.

1.3 OPERATION & MAINTENANCE MANUAL

The mechanic must not operate the machine until the Operation & Maintenance Manual has been read and 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 the local Caterpillar dealer before proceeding.

1.4 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.

1.5 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 TH255C Telehandler Service manual + Engine + Axle Service Manual & Schematic 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 2-3
2 2 Specifications 2-4
2 3 Fluids, Lubricants and Capacities 2-6
2 4 Maintenance Schedule 2-11
2 5 Lubrication Schedule 2-14
2 6 Thread Locking Compound 2-15
2 7 Torque Charts 2-16
2 8 Hydraulic Connection Assembly and Torque Specification 2-26
Section 3
Boom 3-1
3 1 Boom System Component Terminology 3-2
3 2 Safety Information 3-3
3 3 Two Section Boom System 3-3
3 4 Boom Assembly Maintenance 3-3
3 5 Boom Wear Pads 3-10
3 6 Quick Coupler Assembly 3-11
3 7 Forks 3-12
3 8 Boom Prop (If Equipped) 3-13
3 9 Emergency Boom Lowering Procedure 3-14
3 10 Troubleshooting 3-16
Section 4
Cab 4-1
4 1 Operator Cab 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 4-12
4 6 Cab Installation 4-13
Section Subject Page
iv 31200927 TH255C
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 Drive Shafts 5-9
5 6 Wheels and Tires 5-10
5 7 Steering Angle Adjustment 5-11
5 8 Brakes 5-11
5 9 Towing a Disabled Machine 5-11
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
Section 7
Engine 7-1
7 1 Introduction 7-2
7 2 Engine Serial Number 7-4
7 3 Specifications and Maintenance Information 7-4
7 4 Engine Cooling System 7-4
7 5 Engine Electrical System 7-8
7 6 Fuel System 7-8
7 7 Engine Exhaust System 7-10
7 8 Air Cleaner Assembly 7-11
7 9 Engine Replacement 7-13
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 8-8
8 8 Hydraulic Reservoir 8-16
8 9 Hydraulic System Pump 8-18
8 10 Front Drive Motor 8-19
8 11 Control Valves 8-20
8 12 Hydraulic Cylinders 8-33
Section Subject Page
TH255C 31200927 v
Section 9
Electrical System 9-1
9 1 Electrical Component Terminology 9-3
9 2 Safety Information 9-5
9 3 Fuses and Relays 9-5
9 4 Electrical System Schematics 9-8
9 5 Dielectric Grease Application 9-26
9 6 Engine Start Circuit 9-29
9 7 Charging Circuit 9-31
9 8 Battery 9-32
9 9 Electrical System Components 9-34
9 10 Window Wiper/Washer 9-35
9 11 Cab Heater/AC and Fan 9-37
9 12 Switches, Solenoids and Senders 9-38
9 13 Load Stability Indicator System (LSI) 9-42
9 14 Analyzer (CE & AUS) 9-51
9 15 Analyzer Software Accessibility 9-53
9 16 Diagnostic Trouble Codes (DTC) on Ground Module 9-57
9 17 Engine Diagnostic Trouble Code E 9-61
Section Subject Page
vi 31200927 TH255C
TH255C 31200927 1-1
Section 1
Safety Practices
Contents
PARAGRAPH TITLE 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 TH255C TELEHANDLER SERVICE MANUAL + ENGINE + AXLE SERVICE MANUAL & SCHEMATIC MANUAL – PDF DOWNLOAD:

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected]should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.M