Cat Caterpillar TH255 Telehandler Service Repair Manual + Operation and Maintenance Manual + Parts Manual on CD

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your CAT. Read and print pages directly from the CD, or copy the entire manual to your hard drive.

1250 Pages

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SERAIL NUMBERS:

S/N TBS00100 & After  

ENGINE:

C4.4  (Mech) Industrial Engine   4461-up

MANUAL COVERS:

SERVICE REPAIR MANUAL:

Table of Contents
 

Section 1 Safety Practices
1.1 Introduction
1.2 Disclaimer
1.3 Operation & Maintenance Manual
1.4 Do Not Operate Tags
1.5 Safety Information
1.5.1 Safety Alert System and Signal Words
1.6 Safety Instructions
1.6.1 Personal Hazards
1.6.2 Equipment Hazards
1.6.3 General Hazards
1.6.4 Operational Hazards
1.7 Safety Decals
 

Section 2 General Information and Specifications
2.1 Replacement Parts and Warranty Information
2.2 Specifications
2.2.1 Travel Speed
2.2.2 Hydraulic Cylinder Performance Specifications
2.2.3 Electrical System
2.2.4 Engine Performance Specifications
2.2.5 Tires
2.3 Fluids, Lubricants and Capacities
2.4 Maintenance Schedules
2.4.1 10,1st 50 & 50 Hour Maintenance Schedule
2.4.2 1st 250, 250 & 500 Hour Maintenance Schedule
2.4.3 1000 Hour Maintenance Schedule
2.5 Lubrication Schedule
2.5.1 250 Hour Lubrication Schedule
2.6 Torque Charts
2.6.1 SAE Fastener Torque Chart
2.6.2 Metric Fastener Torque Chart
2.7 Hydraulic Connection Assembly and Torque Specification
2.7.1 Definitions
2.7.2 Assembly Instructions for American Standard Pipe Thread Tapered Connections
2.7.3 Assembly Instructions for British Standard Pipe Thread Tapered Connections
2.7.4 Assembly Instructions for 37° (JIC) Flare Fittings
2.7.5 Assembly Instructions for 45° SAE Flare Fittings
2.7.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
2.7.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
2.7.8 Assembly Instructions for Bulkhead (BH) Fittings
2.7.9 Assembly Instructions for O-Ring Boss (ORB) Fittings
2.7.10 Assembly Instructions for Adjustable Port End Metric Fittings
2.7.11 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends
2.7.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings
2.7.13 Assembly Instructions for Flange Connections (FL61 and FL62)
2.7.14 Double Wrench Method
2.7.15 FFWR and TFFT Methods
2.7.16 Adjustable Stud End Assembly
2.7.17 O-ring Installation (Replacement)
 

Section 3 Boom
3.1 Boom System Component Terminology
3.2 Safety Information
3.3 Boom System - Two Section Boom
3.3.1 Boom System Description
3.4 Boom Assembly Maintenance
3.4.1 Second Boom Section Removal
3.4.2 First Boom Section Removal
3.4.3 First Boom Section Installation
3.4.4 Second Boom Section Installation
3.4.5 Complete Boom Removal
3.4.6 Second Boom Section Removal
3.4.7 Second Boom Section Installation
3.4.8 Boom Installation
3.4.9 Tilt and Auxiliary Hose Removal
3.4.10 Tilt and Auxiliary Hose Installation
3.4.11 Extend/Retract Cylinder Removal
3.4.12 Extend/Retract Cylinder Installation
3.5 Boom Wear Pads
3.5.1 Wear Pad Inspection
3.5.2 Wear Pad Installation and Lubrication
3.5.3 Boom Wear Pad Lubrication
3.6 Quick Coupler Assembly
3.6.1 Quick Coupler Removal
3.6.2 Quick Coupler Installation
3.7 Forks
3.8 Boom Prop (If Equipped)
3.8.1 Installation and Removal Procedures
3.9 Emergency Boom Lowering Procedure
3.9.1 Equipment and Supplies Required
3.9.2 Lowering Procedure
3.10 Troubleshooting
 

Section 4 Cab and Covers
4.1 Operator Cab and Covers Component Terminology
4.2 Safety Information
4.3 Operator Cab
4.3.1 Operator Cab Description
4.3.2 Serial Number Decal
4.4 Cab Components
4.4.1 Steering Wheel
4.4.2 Steering Column/Valve Replacement
4.4.3 Brake Pedal and Valve
4.4.4 Throttle Pedal Replacement
4.4.5 Throttle Cable Adjustment
4.4.6 High Idle Adjustment
4.4.7 Joystick Replacement
4.4.8 Windshield Wiper Assembly (If Equipped)
4.4.9 Windshield Washer Assembly (If Equipped)
4.4.10 Heater/Defroster System (If Equipped)
4.5 Cab Removal
4.6 Cab Installation
 

Section 5 Axles, Drive Shafts, Wheels and Tires
5.1 Axle, Drive Shaft and Wheel Component Terminology
5.2 Safety Information
5.3 General Information
5.4 Axle Assemblies
5.4.1 Axle Serial Number Plate
5.4.2 Axle Specifications
5.4.3 Axle Internal Service
5.4.4 Axle Maintenance
5.4.5 Axle Removal
5.4.6 Axle Installation
5.4.7 Steering System Purge Procedure
5.5 Axle Assembly And Drive Shaft Troubleshooting
5.6 Drive Shafts
5.6.1 Drive Shaft Inspection
5.6.2 Drive Shaft Maintenance
5.6.3 Drive Shaft Removal
5.6.4 Drive Shaft Cleaning and Drying
5.6.5 Drive Shaft Installation
5.7 Wheels and Tires
5.7.1 Removing Wheel and Tire Assembly from Machine
5.7.2 Installing Wheel and Tire Assembly onto Machine
5.8 Steering Angle Adjustment
5.9 Brakes
5.9.1 Brake Disc Inspection
5.10 Towing a Disabled Machine
5.10.1 Equipment and Supplies Required
5.10.2 Towing Procedure
 

Section 6 Transmission
6.1 Transmission Assembly Component Terminology
6.2 Safety Information
6.3 Transmission Description
6.4 Transmission Specifications
6.4.1 Transmission Maintenance
6.5 Transmission Replacement
6.5.1 Transmission Removal
6.5.2 Transmission Disassembly
6.5.3 Transmission Installation
6.5.4 After Transmission Replacement
6.6 Transmission Filter Replacement
6.6.1 Filter Removal
6.6.2 Filter Installation
 

Section 7 Engine
7.1 Introduction
7.1.1 Disclaimer and Scope
7.1.2 Component Terminology
7.2 Safety Information
7.3 Engine Serial Number
7.4 Specifications and Maintenance Information
7.5 Engine Cooling System
7.5.1 Radiator Pressure Cap
7.5.2 Radiator/Oil Cooler and Coolant Heater Replacement
7.6 Engine Electrical System
7.7 Fuel System
7.7.1 Diesel Fuel
7.7.2 Fuel/Hydraulic Oil Tank
7.7.3 After Fuel System Service
7.8 Engine Exhaust System
7.8.1 Exhaust System Removal
7.8.2 Exhaust System Installation
7.9 Air Cleaner Assembly
7.9.1 Air Cleaner Assembly Removal
7.9.2 Air Cleaner Assembly Installation
7.10 Engine Replacement
7.10.1 Engine Removal
7.10.2 Engine Disassembly, Inspection and Service
7.10.3 Engine Installation
7.11 Engine Coupler
7.11.1 Engine Coupler Removal
7.11.2 Engine Coupler Installation
7.12 Troubleshooting
 

Section 8 Hydraulic System
8.1 Hydraulic Component Terminology
8.2 Safety Information
8.3 General Information
8.4 Specifications
8.5 Hoses, Tube Lines, Fittings, Etc.
8.5.1 Replacement Considerations
8.5.2 Hose, Tube, Line and Fitting Replacement
8.6 Hydraulic Pressure Diagnosis
8.6.1 Pressure Checks and Adjustments
8.6.2 Main Control Valve Pressure Checking
8.6.3 Charge Pressure Checking
8.6.4 Boom Function Pressure Checking
8.6.5 Steering Pressure Checking
8.7 Hydraulic Schematic
8.7.1 Before S/N TBS00627
8.7.2 S/N TBS00627 & After
8.7.3 Options
8.8 Hydraulic Reservoir
8.8.1 Pressurized Hydraulic Oil Fill Cap
8.8.2 Hydraulic Oil Reservoir Draining
8.8.3 Hydraulic Oil Reservoir Filling
8.9 Hydraulic System Pump
8.9.1 Implement Pump Replacement
8.10 Front Drive Motor
8.11 Control Valves
8.11.1 Main Control Valve
8.11.2 Service Brake Valve
8.11.3 Parking Brake Valve (ANSI)
8.11.4 Hand Brake Valve (CE & AUS)
8.11.5 Steering Orbitrol Valve
8.11.6 Pilot Select Valve
8.11.7 Inching Valve
8.11.8 Priority Valve
8.11.9 Steer Select Valve
8.11.10 Joystick Enable Valve
8.11.11 Decompression Valve
8.11.12 Quick Attach Valve
8.11.13 Load Stability Indicator Valve (CE & AUS)
8.12 Hydraulic Cylinders
8.12.1 General Cylinder Removal Instructions
8.12.2 General Cylinder Disassembly
8.12.3 Cylinder Cleaning Instructions
8.12.4 Cylinder Inspection
8.12.5 General Cylinder Assembly
8.12.6 General Cylinder Installation
8.12.7 Steering Cylinders
8.12.8 Hydraulic Cylinder Torque Specifications
 

Section 9 Electrical System
9.1 Electrical Component Terminology
9.2 Safety Information
9.3 Fuses and Relays
9.3.1 Engine Compartment Relays and Fuses
9.3.2 Cab Compartment Fuses and Relays
9.3.3 Power Distribution Module
9.3.4 Cab Fuses / Relays
9.4 Electrical System Schematics
9.4.1 Before S/N TBS00627
9.4.2 S/N TBS00627 & After
9.5 Circuit Breakdowns
9.5.1 Charge Circuit Breakdown
9.5.2 Start Circuit Breakdown
9.5.3 Constant Power Circuit Breakdown
9.5.4 Drive Circuit Breakdown
9.6 Engine Start Circuit
9.6.1 Starter
9.7 Charging Circuit
9.7.1 Alternator
9.8 Electrical System Components
9.8.1 Back-up Alarm
9.8.2 Instrument Cluster
9.8.3 Speedometer
9.9 Window Wiper/Washer
9.9.1 Windshield Wiper Motor
9.9.2 Rear Window or Roof Wiper Motor (if equipped)
9.9.3 Windshield Washer Reservoir and Pump
9.10 Cab Heater and Fan
9.10.1 Cab Heater Controls
9.11 Switches, Solenoids and Senders
9.11.1 Ignition Key Switch
9.11.2 Dash Switches
9.11.3 Fuel Level Indicator and Fuel Level Sender
9.11.4 Hour meter
9.11.5 Coolant Temperature Sender
9.11.6 Fuel Shut-off Solenoid
9.11.7 Oil Pressure Sender
9.12 Load Stability System (CE & AUS) Before S/N TBS00627
9.12.1 Load Stability Indicator
9.12.2 Load Stability Indicator
9.12.3 Load Stability Sensor
9.13 Load Stability System (CE & AUS) S/N TBS00627 & After
9.13.1 LSI Axle Sensor
9.13.2 LSI Boom Sensors
9.13.3 LSI Modules
9.13.4 LSI System Calibration
9.13.5 LSI-CAN Check PT
9.13.6 500 Hour - LSI UGM Calibration Check
9.14 Hand Held Analyzer (CE & AUS) S/N TBS00627 & After
9.14.1 Analyzer Usage
9.14.2 Analyzer Software - Version 1.2
9.14.3 Diagnostic Trouble Codes (DTC) on Ground Module 

DISASSEMBLY and ASSEMBLY MANUAL HYDROSTATIC TRANSMISSION PUMP  (26 Pages)

AXLE SERVICE MANUAL (368 Pages)

PARTS MANUAL (344 Pages)

OPERATION and MAINTENANCE MANUAL (144 Pages)

ENGINE OPERATION MANUAL (86 Pages)

ELECTRICAL SYSTEM

HYDRAULIC SYSTEM

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

Language: English 
Format: PDF - Indexed and Searchable

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 10, WINDOWS 8, WINDOWS 7, VISTA 32 and 64, XP, ME, 98, NT, 2000 ETC.) 

Windows/Mac/Tablet/Phone Friendly

32 / 64 bit