Caterpillar Cat TH255C Telehandler Service Repair Manual SN JK300150 to Present

Service Manual Model TH255C SN JK200150 to Present SN JK300150 to Present

31200927 UENR6264-03 Revised August 11, 2016

SECTION CONTENTS Section

Subject

Section 1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 1.2 1.3 1.4 1.5 1.6 1.7

Page

1-1

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation & Maintenance Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2 1-2 1-2 1-2 1-2 1-3 1-4

Section 2 General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

Section 3 Boom 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10

Section 4 Cab 4.1 4.2 4.3 4.4 4.5 4.6

TH255C

Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3 2-4 2-6 2-11 2-14 2-15 2-16 2-26

.......................................................................

3-1

Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two Section Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Prop (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2 3-3 3-3 3-3 3-10 3-11 3-12 3-13 3-14 3-16

.......................................................................

4-1

Operator Cab Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2 4-3 4-3 4-3 4-12 4-13

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iii

Section

Subject

Section 5 Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9

Page

5-1

Axle, Drive Shaft and Wheel Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2 5-3 5-3 5-3 5-9 5-10 5-11 5-11 5-11

Section 6 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

6.1 6.2 6.3 6.4 6.5

Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2 6-3 6-3 6-3 6-3

.......................................................................

7-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2 7-4 7-4 7-4 7-8 7-8 7-10 7-11 7-13

Section 8 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1

Section 7 Engine 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9

8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12

iv

Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hoses, Tube Lines, Fittings, Etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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8-3 8-4 8-4 8-4 8-4 8-5 8-8 8-16 8-18 8-19 8-20 8-33

TH255C

Section

Subject

Section 9 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14 9.15 9.16 9.17

TH255C

Electrical Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical System Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Window Wiper/Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Heater/AC and Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switches, Solenoids and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Stability Indicator System (LSI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analyzer (CE & AUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analyzer Software Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Trouble Codes (DTC) on Ground Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Diagnostic Trouble Code E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Page

9-1 9-3 9-5 9-5 9-8 9-26 9-29 9-31 9-32 9-34 9-35 9-37 9-38 9-42 9-51 9-53 9-57 9-61

v

Section 1 Safety Practices

Contents PARAGRAPH 1.1 1.2 1.3 1.4 1.5 1.6

1.7

TH255C

TITLE

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.1 Safety Alert System and Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.1 Personal Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.2 Equipment Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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PAGE 1-2 1-2 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-3 1-4 1-4

1-1

Safety Practices

1.1

INTRODUCTION

1.4

DO NOT OPERATE TAGS

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.

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.

Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes, regulations and laws.

1.5

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 on SIS Web.

1.2

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.

1.5.1

Safety Alert System and Signal Words

DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

DISCLAIMER

WARNING

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

SAFETY INFORMATION

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

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.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

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 Service Dealer before proceeding.

1-2

31200927

TH255C

Safety Practices

1.6

SAFETY INSTRUCTIONS

1.6.3

Following are general safety statements to consider BEFORE performing maintenance procedures on the telehandler.

Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the potential of a hazard occurs.

For all safety messages, carefully read, understand and follow the instructions BEFORE proceeding.

1.6.1

Personal Hazards

PERSONAL SAFETY GEAR: Wear all the protective clothing and personal safety gear necessary to perform the job safely.

This might include heavy gloves, safety glasses or goggles, filter mask or respirator, safety shoes or a hard hat.

LIFTING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist.

1.6.2

Equipment Hazards

LIFTING OF EQUIPMENT: Before using any lifting equipment (chains, slings, brackets, hooks, etc.), verify that it is of the proper capacity, in good working order, and is properly attached.

NEVER stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip.

DO NOT use a hoist, jack or jack stands only to support equipment. Always support equipment with the proper capacity blocks or stands properly rated for the load.

General Hazards

SOLVENTS: Only use approved solvents that are known to be safe for use.

HOUSEKEEPING: Keep the work area and operator’s cab clean, and remove all hazards (debris, oil, tools, etc.).

FIRST AID: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor the injury may seem. Know the location of a First Aid Kit, and know how to use it.

CLEANLINESS: Wear eye protection and clean all components with a high-pressure or steam cleaner before attempting service.

When removing hydraulic components, plug hose ends and connections to prevent excess leakage and contamination.

Place a suitable catch basin beneath the machine to capture fluid run-off.

It is good practice to avoid pressure-washing electrical/ electronic components. In the event pressure-washing the machine is needed, ensure machine is shut down before pressure-washing. Should pressure-washing be utilized to wash areas containing electrical/electronic components, it is recommended a maximum pressure of 750 psi (52 bar) at a minimum distance of 12 in (30,5 cm) away from these components. If electrical/electronic components are sprayed, spraying must not be direct and for brief time periods to avoid heavy saturation, Check and obey all Federal, State and/or Local regulations regarding waste storage, disposal and recycling.

HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tools only as recommended.

TH255C

31200927

1-3

Safety Practices 1.6.4

Operational Hazards

NEVER drain or store fluids in an open container. Engine fuel and hydraulic fluid are flammable and can cause a fire and/or explosion.

ENGINE: Stop the engine before performing any service unless specifically instructed otherwise.

DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause an explosion.

VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation.

SOFT SURFACES AND SLOPES: NEVER work on a machine that is parked on a soft surface or slope. The machine must be on a hard level surface, with the wheels blocked before performing any service.

FLUID TEMPERATURE: NEVER work on a machine when engine, cooling or hydraulic systems are hot. Hot components and fluids can cause severe burns. Allow systems to cool before proceeding.

PRESSURE TESTING: When conducting any test, only use test equipment that is correctly calibrated and in good condition.

Use the correct equipment in the proper manner, and make changes or repairs as indicated by the test procedure to achieve the desired result.

LEAVING MACHINE: Lower the forks or attachment to the ground before leaving the machine.

FLUID PRESSURE: Before loosening any hydraulic or diesel fuel component, hose or tube, turn the engine OFF. Wear heavy, protective gloves and eye protection. NEVER check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. Diesel fluid leaking under pressure can explode. Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin, cause infection, gangrene and other serious personal injury.

Engine fuel lines are pressurized. DO NOT attempt repairs unless specific training has been completed. Refer to the engine manufacturers’ manual for specific details concerning the fuel system.

TIRES: Always keep tires inflated to the proper pressure to help prevent tipover. DO NOT over-inflate tires.

NEVER use mismatched tire types, sizes or ply ratings.

Always use matched sets according to machine specifications.

MAJOR COMPONENTS: Never alter, remove, or substitute any items such as counterweights, tires, batteries or other items that may reduce or affect the overall weight or stability of the machine.

BATTERY: DO NOT charge a frozen battery. Charging a frozen battery may cause it to explode. Allow the battery to thaw before jump-starting or connecting a battery charger.

1.7

Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component.

Before starting the engine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly and are tightened to the proper torque. Capture fluid in an appropriate container and dispose of in accordance with prevailing environmental regulations.

SAFETY DECALS

Check that all safety decals are present and readable on the machine. Refer to the Operation & Safety Manual supplied with machine for information.

COOLANT SYSTEM CAP: The cooling system is under pressure, and escaping coolant can cause severe burns and eye injury. To prevent personal injury, NEVER remove the coolant system cap while the cooling system is hot. Wear safety glasses. Turn the coolant system cap to allow pressure to escape before removing the cap completely. Failure to follow the safety practices could result in death or serious injury.

FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic systems near an open flame, sparks or smoking materials.

Properly disconnect battery prior to servicing the fuel or hydraulic systems.

1-4

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TH255C

Section 2 General Information and Specifications

Contents PARAGRAPH 2.1 2.2

2.3

2.4

2.5 2.6 2.7

TH255C

TITLE

Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.1 Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.2 Hydraulic Cylinder Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.4 Steering Angle Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.5 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.1 Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1 10,1st 50 & 50 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.2 1st 250, 250 & 500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.3 1000 & 1500 Hour Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.1 250 Hour Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31200927

PAGE 2-3 2-4 2-4 2-4 2-4 2-4 2-5 2-5 2-6 2-6 2-10 2-11 2-11 2-12 2-13 2-14 2-14 2-15 2-16 2-16 2-22

2-1

General Information and Specifications 2.8

2-2

Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . 2-26 2.8.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-26 2.8.2 Assembly Instructions for American Standard Pipe Thread Tapered Connections 2-28 2.8.3 Assembly Instructions for British Standard Pipe Thread Tapered Connections.

2-30 2.8.4 Assembly Instructions for 37° (JIC) Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-31 2.8.5 Assembly Instructions for 45° SAE Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-34 2.8.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings. . . . . . . . . . . . . . . . . . .

2-36 2.8.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) . .

2-38 2.8.8 Assembly Instructions for Bulkhead (BH) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-40 2.8.9 Assembly Instructions for O-Ring Boss (ORB) Fittings . . . . . . . . . . . . . . . . . . . . . . . .

2-44 2.8.10 Assembly Instructions for Adjustable Port End Metric Fittings . . . . . . . . . . . . . . . .

2-52 2.8.11 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends . . . . . . . . .

2-60 2.8.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings . . . . . . . . . . . . . . . .

2-62 2.8.13 Assembly Instructions for Flange Connections (FL61 and FL62) . . . . . . . . . . . . . .

2-70 2.8.14 Double Wrench Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-73 2.8.15 FFWR and TFFT Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-74 2.8.16 Adjustable Stud End Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-74 2.8.17 O-ring Installation (Replacement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-74

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TH255C

General Information and Specifications

2.1

REPLACEMENT PARTS AND WARRANTY INFORMATION

1

MY8351

Before ordering parts or initiating service inquiries, make note of the machine serial number. The machine serial number plate (1) is located as indicated in the figure.

Note: The replacement of any part on this machine with any other than factory authorized replacement parts can adversely affect the performance, durability, or safety of the machine, and will void the warranty. Caterpillar disclaims liability for any claims or damages, whether regarding property damage, personal injury or death arising out of the use of unauthorized replacement parts.

A warranty registration form must be filled out by the Caterpillar Dealer.

Registration activates the warranty period and helps to assure that warranty claims are promptly processed to guarantee full warranty service.

TH255C

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2-3

General Information and Specifications

2.2

SPECIFICATIONS

2.2.1

Travel Speed Tires

Approximate Speed

12–16.50 (305/70D16.5)

15 mph (24 km/h)

14–17.50 (355/70D17.5)

17 mph (27 km/h)

10.5–18

17 mph (27 km/h)

2.2.2

Hydraulic Cylinder Performance Specifications

Note: Machine with no load, engine at full throttle, hydraulic oil above 15.6° C (60° F) minimum, engine at operating temperature.

Approximate Times (sec.)

Function

ANSI

CE & AUS

Boom Extend (Boom Level)

6.7

6.7

Boom Retract

3.8

3.5

Boom Lift

6.8

6.6

Boom Lower

4.6

8.2

Quick Attach—UP

2.0

1.8

Quick Attach—DOWN

2.5

2.3

2.2.3

Electrical System

Note: Refer to Section 9.3, “Fuses and Relays”, for more information.

Battery Type, Rating

12 BCI, Negative (-) Ground, Maintenance Free

Cold Cranking Amps @ 0° F (-18° C)

950

Cranking Amps @ 32° F (-18° C)

1190

Reserve Capacity Minutes @ 25 Amps

185

Group/Series

Group 31

Alternator

2.2.4

2-4

14V, 95 Amps

Steering Angle Specification Model

Angle (in Degrees)

TH255C

37

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TH255C

General Information and Specifications 2.2.5

Engine Performance Specifications Description

Engine Make/Model

CAT TD L4

Displacement

177 in³ (2.9 L)

Low Idle

975 - 1075 rpm

High Idle

2300 - 2400 rpm

Horsepower

74 HP (55 kW) @ 2300 rpm

Peak Torque

192 lb-ft (260 Nm) @ 1800 rpm

Fuel Delivery

Fuel Injection

Air Cleaner

2.2.6

Dry Type, Replaceable Primary and Safety Elements

Tires

Note: Standard wheel lug nut torque is 220 lb-ft (300 Nm).

Note: Pressures for Foam filled tires are for initial fill ONLY. Tire Type

Minimum Ply/ Star Rating

12–16.50 (305/70D16.5)

Duraforce DT

Bias 12 Ply

14–17.50 (355/70D17.5)

Outrigger

Bias 14 Ply

10.5–18

MPT-01 TL

Bias 16 Ply

Size

33x12–20

TH255C

Fill Type

Pressure

Pneumatic

80 psi (5,5 bar)

Foam - Approximately 220 lb (100 kg) Pneumatic

70 psi (4,8 bar)

Foam - Approximately 220 lb (100 kg) Pneumatic

87 psi (6,0 bar)

Non–Marking (White)

31200927

2-5

General Information and Specifications

2.3 2.3.1

FLUIDS, LUBRICANTS AND CAPACITIES Fluids

a. Prior to SN JK201000 Ambient Temperature Range Compartment or System

Engine Crankcase

Axle Differential and Wheel End

Type and Classification

Boom Wear Pad Grease

2-6

°F

°C

Min

Max

Min

Max

SAE 0W-20

-40

50

-40

10

SAE 0W-30

-40

86

-40

30

SAE 0W-40

-40

104

-40

40

CAT DEO-ULS

SAE 5W-30

-22

86

-30

30

API CJ-4 Plus

SAE 5W-40

-22

122

-30

50

SAE 10W-30

0

104

-18

40

SAE 10W-40

0

122

-18

50

SAE 15W-40

15

122

-9.5

50

CAT Synthetic Gear Oil (GO)*

SAE 75W-140

-22

113

-30

45

CAT Gear Oil (GO)*

SAE 80W-90

-10

120

-23

49

CAT Gear Oil (GO)*

SAE 85W-140

10

120

-12

59

CAT TDTO-TMS*

Cat TDTO-TMS

-4

122

-20

50

SAE90 SAE90LS

32

115

0

46

80W-90

-4

115

-20

46

75W-90

-40

115

-40

46

75W

-40

50

-40

10

SAE 0W-20

-40

104

-40

40

SAE 0W-30

-40

104

-40

40

SAE 5W-30

-22

104

-30

40

SAE 5W-40

-22

104

-30

40

SAE 10W

-4

104

-20

40

SAE 30

50

122

10

50

SAE 10W-30

-4

104

-20

40

SAE 15W-40

5

122

-15

50

Cat TDTO-TMS

-4

122

-20

50

NLGI Grade 2

-4

104

-20

40

API GL4 with LS Additives or API GL5 with LS Additives

Hydraulic and Brake Systems

Viscosities

CAT TDTO CAT TDTO-TMS CAT Arctic TDTO SYN commercial TO-4

CAT Advanced 3Moly

31200927

TH255C

General Information and Specifications

Ambient Temperature Range Compartment or System

Type and Classification

Viscosities

NLGI Grade 2 EP or NLGI Grade 3 EP with Moly Additive

°F

°C

Min

Max

Min

Max

5

122

-15

50

Grease Fittings

Extreme Pressure Grease

Engine Coolant

CAT Extended Life Coolant (ELC)

50/50 Mix

Fuel

EN 590 ASTM D 975 Grade 1-D ASTM D 975 Grade 2-D (Maximum B5 Biodiesel)

Ultra Low Sulfur (S ≤ 15 mg/kg)

Air Conditioning

Refrigerant R-134-a

Tetrafluoroethane

Note: Friction Modifier (197-0017) required for axle differentials, refer to Section 2.3.2, “Capacities”.

TH255C

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2-7

General Information and Specifications b. SN JK300150 to Present Ambient Temperature Range Compartment or System

Type and Classification

Viscosities

°F

°C

Min

Max

Min

Max

SAE 0W-20

-40

50

-40

10

SAE 0W-30

-40

86

-40

30

SAE 0W-40

-40

104

-40

40

CAT DEO

SAE 5W-30

-22

86

-30

30

API CI-4 Plus

SAE 5W-40

-22

122

-30

50

SAE 10W-30

0

104

-18

40

SAE 10W-40

0

122

-18

50

SAE 15W-40

15

122

-9.5

50

CAT Synthetic Gear Oil (GO)*

SAE 75W-140

-22

113

-30

45

CAT Gear Oil (GO)*

SAE 80W-90

-10

120

-23

49

CAT Gear Oil (GO)*

SAE 85W-140

10

120

-12

59

CAT TDTO-TMS*

Cat TDTO-TMS

-4

122

-20

50

SAE90 SAE90LS

32

115

0

46

80W-90

-4

115

-20

46

75W-90

-40

115

-40

46

75W

-40

50

-40

10

SAE 0W-20

-40

104

-40

40

SAE 0W-30

-40

104

-40

40

SAE 5W-30

-22

104

-30

40

SAE 5W-40

-22

104

-30

40

SAE 10W

-4

104

-20

40

SAE 30

50

122

10

50

SAE 10W-30

-4

104

-20

40

SAE 15W-40

5

122

-15

50

Cat TDTO-TMS

-4

122

-20

50

CAT Advanced 3Moly

NLGI Grade 2

-4

104

-20

40

Grease Fittings

Extreme Pressure Grease

NLGI Grade 2 EP or NLGI Grade 3 EP with Moly Additive

5

122

-15

50

Engine Coolant

CAT Extended Life Coolant (ELC)

Engine Crankcase

Axle Differential and Wheel End

API GL4 with LS Additives or API GL5 with LS Additives

Hydraulic and Brake Systems

Boom Wear Pad Grease

2-8

CAT TDTO CAT TDTO-TMS CAT Arctic TDTO SYN commercial TO-4

50/50 Mix 31200927

TH255C

General Information and Specifications

Ambient Temperature Range Compartment or System

Type and Classification

Viscosities

°F Min

°C Max

Fuel

EN 590 ASTM D 975 Grade 1-D ASTM D 975 Grade 2-D (Maximum B5 Biodiesel)

Low Sulfur (S ≤ 500 mg/)kg

Air Conditioning

Refrigerant R-134-a

Tetrafluoroethane

Min

Max

Note: Friction Modifier (197-0017) required for axle differentials, refer to Section 2.3.2, “Capacities”.

TH255C

31200927

2-9

General Information and Specifications 2.3.2

Capacities

Engine Crankcase Oil Capacity w/Filter Change

7.5 qt (7,1 L)

Fuel Tank Capacity Prior to SN JK2010000, Prior to SN JK301000

24 gal (91 L)

SN JK201000 to Present, SN JK301000 to Present

20 gal (76 L)

Cooling System System Capacity

14 qt (13,2 L)

Hydraulic System System Capacity Prior to SN JK2010000, Prior to SN JK301000

24 gal (91 L)

SN JK201000 to Present, SN JK301000 to Present

27 gal (103 L)

Reservoir Capacity to Full Mark Prior to SN JK2010000, Prior to SN JK301000

16 gal (61 L)

SN JK201000 to Present, SN JK301000 to Present

19 gal (73 L)

Auxiliary Hydraulic Circuit Max Flow

18.7 gpm (71 lpm)

Brake System System Capacity

0.7 qt (0,7 L)

Axles Differential Housing Capacity

3.5 qt (3,3 L)

Friction Modifier (197-0017) - Required for front axle differential (Must be premixed with axle fluid)

Not to exceed 5.4 oz (160 ml)

Wheel End Capacity

24 oz (0,7 L)

Front Axle Drop Box

21 oz (0,6 L)

Air Conditioning System (if equipped) System Capacity

2-10

2.5 lb (1134 g)

31200927

TH255C

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General Information and Specifications

2.4 2.4.1

MAINTENANCE SCHEDULE 10,1st 50 & 50 Hour Maintenance Schedule

EVERY

10

Check Fuel Level

Check Engine Oil Level

Check Hydraulic Oil Level

Check Tire Condition & Pressure

Additional Checks Section 8

Check Air Filter

Check Battery

Check Brake Fluid Level

1st

50 LB/F T (N m)

Check Wheel Lug Nut Torque

EVERY

50

Drain Fuel/ Water Separator

Check Engine Coolant Level

Check Washer Fluid Level (if equipped) OAH2341

TH255C

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2-11

General Information and Specifications 2.4.2

1st 250, 250 & 500 Hour Maintenance Schedule

1st

250

Change Axle Differential Oil

Change Wheel End Oil

Change Front Axle Drop Box Oil

EVERY

250

Check Axle Differential Oil Level

Check Wheel End Oil Levels

Check Enclosed Cab Air Filter (if equipped)

Lubrication Schedule

Check Front Axle Drop Box Oil Level

Check Fan Belt

Check Boom Wear Pads

EVERY

500

LB/F T (N m)

Change Engine Oil and Filter

Change Air Filter Elements

Change Fuel Filter (if equipped for LS)

Check LSI Calibration (CE & AUS)

Check Wheel Lug Nut Torque OAH2211

2-12

31200927

TH255C