Cat Caterpillar TH255C 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.

922 Pages

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SERAIL NUMBERS:

SN TBS00100 to Present

SN JK200150 to Present

SN JK300150 to Present 

ENGINE:

441-9208  

441-9209 

MANUAL COVERS:

SERVICE RAPAIR 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 Steering Angle Specification
2.2.5 Engine Performance Specifications
2.2.6 Tires
2.3 Fluids, Lubricants and Capacities
2.3.1 Fluids
a. Prior to SN JK201000
b. SN JK300150 to Present
2.3.2 Capacities
2.4 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
2.5 Lubrication Schedule
2.5.1 250 Hour Lubrication Schedule
2.6 Thread Locking Compound
2.7 Torque Charts
2.7.1 SAE Fastener Torque Chart
2.7.2 Metric Fastener Torque Chart
2.8 Hydraulic Connection Assembly and Torque Specification
2.8.1 Definitions
a. Tapered Thread Types
b. Straight Thread Types, Tube and Hose Connections
c. Straight Thread Types, Port Connections
d. Flange Connection Types
e. Tightening Methods
f. Assembly and Torque Specifications
g. General Tube Type FITTING ASSEMBLY INSTRUCTIONS
2.8.2 Assembly Instructions for American Standard Pipe Thread Tapered Connections
a. NPTF Pipe Thread
2.8.3 Assembly Instructions for British Standard Pipe Thread Tapered Connections
a. BSPT Pipe Thread
2.8.4 Assembly Instructions for 37° (JIC) Flare Fittings
a. 37° Flare (JIC) Thread - Steel
b. 37° Flare (JIC) Thread - Aluminum Brass
2.8.5 Assembly Instructions for 45° SAE Flare Fittings
a. 45° Flare (SAE)
2.8.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
a. O-ring Face Seal (ORFS)
2.8.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
a. DIN 24° CONE (MBTL & MBTS)
2.8.8 Assembly Instructions for Bulkhead (BH) Fittings
a. Bulkhead Fittings (BH) - INCH
b. Bulkhead Fittings (BH) - METRIC
2.8.9 Assembly Instructions for O-Ring Boss (ORB) Fittings
a. O-ring Boss (ORB) - Table 1 of 6
b. O-ring Boss (ORB) - Table 2 of 6
c. O-ring Boss (ORB) - Table 3 of 6
d. O-ring Boss (ORB) - Table 4 of 6
e. O-ring Boss (ORB) - Table 5 of 6
f. O-ring Boss (ORB) - Table 6 of 6
2.8.10 Assembly Instructions for Adjustable Port End Metric Fittings
a. Metric Flat Face Port (MFF) L Series - Table 1 of 3
b. Metric Flat Face Port (MFF) L Series - Table 2 of 3
c. Metric Flat Face Port (MFF) L Series - Table 3 of 3
d. Metric Flat Face Port (MFF) S Series - Table 1 of 3
e. Metric Flat Face Port (MFF) S Series - Table 2 of 3
f. Metric Flat Face Port (MFF) S Series - Table 3 of 3
2.8.11 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends
a. Metric Pipe Parallel O-Ring Boss (MPP)
2.8.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings
a. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
b. British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3
c. British Standard Parallel Pipe Port (BSPP) L Series - Table 3 of 3
d. British Standard Parallel Pipe Port (BSPP) S Series - Table 1 of 3
e. British Standard Parallel Pipe Port (BSPP) S Series - Table 2 of 3
f. British Standard Parallel Pipe Port (BSPP) L Series - Table 3 of 3
2.8.13 Assembly Instructions for Flange Connections (FL61 and FL62)
a. Flange Code (FL61 & FL62) - Inch Fasteners
b. Flange Code (FL61 & FL62) - Metric Fasteners
2.8.14 Double Wrench Method
2.8.15 FFWR and TFFT Methods
2.8.16 Adjustable Stud End Assembly
2.8.17 O-ring Installation (Replacement)
Section 3 Boom
3.1 Boom System Component Terminology
3.2 Safety Information
3.3 Two Section Boom System
3.3.1 Boom System Description
3.4 Boom Assembly Maintenance
3.4.1 Complete Boom Removal
3.4.2 Complete Boom Installation
3.4.3 Second Boom Section Removal
3.4.4 Second Boom Section Installation
3.4.5 Extend/Retract Cylinder Removal
3.4.6 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 Assembly Removal
3.6.2 Quick Coupler Assembly Installation
3.7 Forks
3.8 Boom Prop (If Equipped)
3.8.1 Prop Installation
3.8.2 Prop Removal
3.9 Emergency Boom Lowering Procedure
3.9.1 Equipment and Supplies Required
3.9.2 Lowering Procedure
a. Retract the boom as follows:
b. Lower the boom as follows:
3.10 Troubleshooting
Section 4 Cab
4.1 Operator Cab 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
a. Steering Wheel Removal
b. Steering Wheel Installation
4.4.2 Steering Column/Valve Replacement
a. Steering Column and Valve Removal
b. Steering Column and Valve Installation
c. Power Steering Test
4.4.3 Brake Pedal and Valve
a. Brake Valve Removal
b. Brake Valve Installation
c. Service Brake Pedal Removal
d. Service Brake Pedal Installation
4.4.4 Accelerator Pedal Replacement
a. Accelerator Pedal Removal
b. Accelerator Pedal Installation
4.4.5 Joystick Replacement
a. Joystick Removal
b. Joystick Installation
4.4.6 Windshield Wiper Assembly (if equipped)
4.4.7 Windshield Washer Assembly (if equipped)
4.4.8 Heater System (if equipped)
a. Removal
b. Installation
4.4.9 Heater and A/C System (if equipped)
a. Removal
b. Installation
4.4.10 Air Filter 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 Axle Assembly and Drive Shaft Troubleshooting
5.5 Drive Shafts
5.5.1 Drive Shaft Inspection
5.5.2 Drive Shaft Maintenance
5.5.3 Drive Shaft Removal
5.5.4 Drive Shaft Cleaning and Drying
5.5.5 Drive Shaft Installation
5.6 Wheels and Tires
5.6.1 Removing Wheel and Tire Assembly from Machine
5.6.2 Installing Wheel and Tire Assembly onto Machine
5.7 Steering Angle Adjustment
5.8 Brakes
5.8.1 Brake Disc Inspection
5.9 Towing a Disabled Machine
5.9.1 Equipment and Supplies Required
5.9.2 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
Section 7 Engine
7.1 Introduction
7.1.1 Disclaimer and Scope
7.1.2 Component Terminology
7.2 Engine Serial Number
7.3 Specifications and Maintenance Information
7.4 Engine Cooling System
7.4.1 Surge Tank Cap
7.4.2 Radiator/Oil Cooler Replacement
a. Radiator/Oil Cooler Removal
b. Cooler/Fan Motor Removal
c. Cooler/Fan Motor Installation
d. Radiator/Oil Cooler Installation
7.5 Engine Electrical System
7.6 Fuel System
7.6.1 Diesel Fuel
7.6.2 Fuel/Hydraulic Oil Tank - Prior to SN JK201000 & Prior to SN JK301000
a. Cleaning and Drying
b. Inspection
c. Disassembly and Assembly
7.6.3 Fuel Tank - SN JK201000 to Present & SN JK301000 to Present
a. Fuel Tank Removal
b. Cleaning and Drying
c. Inspection
d. Fuel Tank Installation
7.6.4 After Fuel System Service
7.7 Engine Exhaust System
7.7.1 Exhaust System Removal
7.7.2 Exhaust System Installation
7.8 Air Cleaner Assembly
7.8.1 Air Cleaner Assembly Removal
7.8.2 Air Cleaner Assembly Installation
7.9 Engine Replacement
7.9.1 Engine Removal
7.9.2 Engine Disassembly, Inspection and Service
7.9.3 Engine Installation
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
8.6.6 Fan Speed Pressure and Direction Checking
8.7 Hydraulic Schematic
8.7.1 Prior to SN JK201000 & Prior to SN JK301000
a. ANSI
b. CE & AUS
8.7.2 SN JK201000 to Present & SN JK301000 to Present
a. ANSI
b. CE & AUS
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
8.8.4 Hydraulic Oil Reservoir Removal/ Installation
a. Reservoir Removal
b. Cleaning and Drying
c. Inspection
d. Reservoir Installation
8.9 Hydraulic System Pump
8.9.1 Implement Pump Removal
8.9.2 Implement Pump Installation
8.9.3 Pump Test
8.10 Front Drive Motor
8.10.1 Front Drive Motor Removal
8.10.2 Front Drive Motor Installation
8.11 Control Valves
8.11.1 Main Control Valve
a. Main Control Valve Removal
b. Main Control Valve Disassembly
c. Main Control Valve Parts Cleaning
d. Main Control Valve Parts Inspection
e. Main Control Valve Assembly
f. Main Control Valve Installation
g. Main Control Valve Test
8.11.2 Service Brake Valve
a. Service Brake Valve Removal
b. Service Brake Valve Installation
c. Service Brake Bleeding Procedure
d. Brake Performance Test
8.11.3 Park Brake Valve (ANSI)
a. Park Brake Valve Removal
b. Park Brake Valve Disassembly, Cleaning, Inspection and Assembly
c. Park Brake Valve Installation
d. Park Brake Bleeding Procedure
e. Park Brake Valve Test
8.11.4 Hand Brake Valve (CE & AUS)
a. Hand Brake Valve Removal
b. Hand Brake Valve Disassembly, Cleaning, Inspection and Assembly
c. Hand Brake Valve Installation
d. Hand Brake Valve Test
8.11.5 Steering Orbital Valve
8.11.6 Pilot Select Valve
a. Pilot Select Valve Removal
b. Pilot Select Valve Disassembly, Cleaning, Inspection and Assembly
c. Pilot Select Valve Installation
d. Pilot Select Valve Test
8.11.7 Inching Valve
a. Inching Valve Removal
b. Inching Valve Disassembly, Cleaning, Inspection and Assembly
c. Inching Valve Installation
d. Inching Valve Bleeding Procedure
e. Inching Test
8.11.8 Priority Valve
a. Priority Valve Removal
b. Priority Valve Disassembly, Cleaning, Inspection and Assembly
c. Priority Valve Installation
d. Priority Valve Test
8.11.9 Steer Select Valve
a. Steer Select Manifold and Valve Removal
b. Steer Select Valve and Manifold Disassembly, Cleaning, Inspection and Assembly
c. Steer Select Manifold and Valve Installation
d. Steering Test
8.11.10 Quick Attach Valve
a. Quick Attach Valve Removal
b. Quick Attach Valve Disassembly, Cleaning, Inspection and Assembly
c. Quick Attach Installation
d. Quick Attach Valve Test
8.11.11 Variable Speed Fan Valve
a. Variable Speed Fan Valve Removal
b. Variable Speed Fan Valve Disassembly, Cleaning, Inspection and Assembly
c. Variable Speed Fan Valve Installation
d. Variable Speed Fan Valve Test
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
a. Lift Lower Cylinder
b. Extend/Retract Cylinder
c. Tilt Cylinder
d. Compensating Cylinder
a. Lift Lower Cylinder
b. Extend/Retract Cylinder
c. Tilt Cylinder
d. Compensating Cylinder
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 Prior to SN JK201000 & Prior to SN JK301000
a. Cab Schematic “A”
b. Cab Schematic “B”
c. Cab Roof, AC and Miscellaneous Schematic
d. Base Frame Schematic “A”
e. Base Frame Schematic “B”
f. Engine Schematic
g. Option Frame Schematic
h. Cables and Boom Schematic
9.4.2 SN JK201000 to Present & SN JK301000 to Present
a. Cab Schematic “A”
b. Cab Schematic “B
c. Cab Roof, AC and Miscellaneous Schematic
d. Base Frame Schematic "A"
e. Base Frame Schematic "B"
f. Engine Schematic
g. Option Frame Schematic
h. Cables and Boom Schematic
i. Product Link Schematic
j. HVAC Update
9.5 Dielectric Grease Application
9.5.1 Installation
9.5.2 Exclusions
9.6 Engine Start Circuit
9.6.1 Starter
a. Testing the Starter on the Engine
b. Starter Circuit Checks
c. Starter Removal
d. Starter Cleaning and Drying
e. Starter Periodic Maintenance
f. Starter Installation
9.7 Charging Circuit
9.7.1 Alternator
a. Alternator Removal
b. Alternator Installation
9.8 Battery
9.8.1 Battery Inspection
9.8.2 Battery Removal/Installation
a. Removal
b. Installation
9.8.3 Battery Disconnect/Connect
a. Disconnect
b. Connect
9.9 Electrical System Components
9.9.1 Back-up Alarm
a. Disassembly
b. Inspection and Replacement
9.9.2 Gauge Cluster
a. Removal
b. Installation
9.10 Window Wiper/Washer
9.10.1 Windshield Wiper Motor
a. Removal
b. Disassembly
c. Inspection and Replacement
d. Installation and Testing
9.10.2 Rear Window or Roof Wiper Motor (if equipped)
a. Removal
b. Disassembly
c. Inspection and Replacement
d. Installation and Testing
9.10.3 Windshield Washer Reservoir and Pump
a. Removal
b. Disassembly
c. Installation and Testing
9.11 Cab Heater/AC and Fan
9.11.1 Cab Heater/AC Controls
a. Cab Heater Controls Removal
b. Disassembly
c. Installation and Testing
9.12 Switches, Solenoids and Senders
9.12.1 Ignition Key Switch
a. Ignition Switch Removal
b. Disassembly
c. Inspection and Replacement
d. Ignition Switch Installation
9.12.2 Dash Switches
a. Switch Removal
b. Disassembly
c. Inspection and Replacement
d. Switch Installation
9.12.3 Fuel Level Indicator and Fuel Level Sender
a. Fuel Level Indicator Testing
b. Fuel Level Circuit Tests
9.12.4 Hourmeter
9.12.5 Coolant Temperature Sender
a. Coolant Temperature Sender Removal
b. Coolant Temperature Sender Inspection and Replacement
c. Coolant Temperature Sender Installation and Testing
9.12.6 Oil Pressure Sender
a. Oil Pressure Sender Removal
b. Oil Pressure Sender Inspection and Replacement
c. Oil Pressure Sender Installation and Testing
9.13 Load Stability Indicator System (LSI)
9.13.1 Load Stability Indicator
9.13.2 LSI Sensor
a. LSI Sensor Removal
b. LSI Sensor Installation
9.13.3 LSI Boom Sensors
a. LSI Boom Sensor Removal
b. LSI Sensor Boom Installation
9.13.4 LSI Modules
a. LSI Module Removal
b. LSI Module Installation
9.13.5 LSI System Calibration
a. Standard Calibration
b. Field Calibration
9.13.6 LSI-CAN Check PT
9.13.7 500 Hour - LSI UGM Calibration Check
9.14 Analyzer (CE & AUS)
9.14.1 Hand Held Analyzer
9.14.2 Analyzer Usage
9.14.3 Analyzer Software - Version P1.1
9.15 Analyzer Software Accessibility
9.15.1 Access Level
9.15.2 Diagnostics
9.15.3 Machine Set-up
9.15.4 Personalities
9.15.5 Operator Tools
9.15.6 Calibrations
9.16 Diagnostic Trouble Codes (DTC) on Ground Module
9.16.1 Gauge Fault Code Display
9.16.2 Fault Codes
9.17 Engine Diagnostic Trouble Code
9.17.1 Gauge Fault Code Display 

ENGINE SERVICE REPAIR MANUAL:

Effectivity
Foreword
TOC
Section 1 JLG Safety Practices
1.1 Introduction
1.2 Disclaimer
1.3 Operation & Maintenance Manual
1.4 Do Not Operate Tags
1.5 Safety Information
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 Safety information / User information
2.1 General
2.2 Specifications
2.2.1 Accident prevention and safety regulations
2.2.2 Cleanliness instructions and measures for working with common rail systems
2.2.3 Additional information and measures for the handling of exhaust aftertreatment systems
2.2.4 Disposal regulations
2.3 Operation Manual And Service Manual
2.4 Explanation Of Symbols
Section 3 Disassembly and Assembly
3.1 Oil Measuring Device
3.1.1 Oil Measuring Device Removal
3.2 Crankcase Breather
3.3 Lubricating Oil Pan
3.3.1 Lubricating Oil Pan Removal
3.3.2 Lubricating Oil Pan Installation
3.3.3 Technical Data
3.4 Flywheel
3.4.1 Flywheel Removal
3.4.2 Flywheel Installation
3.4.3 Technical Data
3.5 V-belt Pulley Add-on
3.6 V-belt Pulley Add-on Fastening Parts
3.7 Cylinder Head Cover (Engine 441-9208)
3.7.1 Cylinder Head Cover Removal
3.7.2 Cylinder Head Cover Installation
3.7.3 Technical Data
3.8 Cylinder Head Cover (Engine 441-9209)
3.8.1 Cylinder Head Cover Removal
3.8.2 Cylinder Head Cover Installation
3.8.3 Technical Data
3.9 Heat Protection Plate (Engine 441-9208)
3.10 Lubricating Oil Cooler
3.10.1 Lubricating Oil Cooler Removal
3.10.2 Lubricating Oil Cooler Installation
3.10.3 Technical Data
3.11 Lubricating Oil Filter
3.12 Injector (Engine 441-9208)
3.12.1 Injector Removal
3.12.2 Injector Installation
3.12.3 Technical Data
3.13 Injector (Engine 441-9209)
3.13.1 Injector Removal
3.13.2 Injector Installation
3.13.3 Technical Data
3.14 Fuel Supply Pump
3.15 Fuel Pipes
3.15.1 High-pressure Line Removal
3.15.2 Injection Pipes Removal
3.15.3 Rail Removal
3.15.4 Pressure Sensor Removal
3.15.5 Pressure Sensor Installation
3.15.6 Pressure Limiting Valve Removal
3.15.7 Pressure Limiting Valve Installation
3.15.8 Mounting Rail
3.15.9 Injection Pipes Installation
3.15.10 High-pressure Line Installation
3.15.11 Technical Data
3.16 Exhaust Turbocharger Intake Nozzle
3.17 Charge Air Manifold
3.18 Charge Air Line
3.19 Coolant Pump Fastening Parts
3.19.1 V-rib Belt Pulley Removal
3.19.2 V-rib Belt Pulley Installation
3.20 Thermostat Test
3.20.1 Thermostat Test In Removed State
3.20.2 Technical Data
3.21 Thermostat
3.21.1 Thermostat Removal
3.21.2 Thermostat Installation
3.21.3 Technical Data
3.22 Exhaust Gas Recirculation Line
3.23 Exhaust Pipe
3.23.1 Exhaust Line Removal
3.23.2 Installing Exhaust Line
3.23.3 Technical Data
3.24 Flutter Valve
3.24.1 Flutter Valve Removal
3.24.2 Flutter Valve Installation
3.24.3 Technical Data
3.25 Exhaust Gas Turbocharger
3.25.1 Turbocharger Removal
3.25.2 Turbocharger Installation
3.25.3 Technical Data
3.26 Lubricating Oil Line
3.26.1 Lubricating Oil Line Removal
3.26.2 Lubricating Oil Line Installation
3.26.3 Technical Data
3.27 Lubricating Oil Return Line
3.27.1 Oil Return Line Removal
3.27.2 Oil Return Line Installation
3.27.3 Technical Data
3.28 V-Belt Pulley (parts to generator)
3.29 Generator Parts
3.30 Generator
3.30.1 Generator Removal
3.30.2 Generator Installation
3.30.3 Technical Data
3.31 Starter
3.31.1 Starter Removal
3.31.2 Starter Installation
3.31.3 Technical Data
3.32 Cable Harness Fastening Parts
3.33 Cable Harness Fastening Parts (Engine 441-9208)
3.34 Impulse Transmitter (Crankshaft)
3.34.1 Impulse Transmitter Removal
3.34.2 Impulse Transmitter Installation
3.34.3 Technical Data
3.35 Temperature Sensor
3.36 Oil Pressure Transmitter
3.37 Connection Housing
3.37.1 Connection Housing Removal
3.37.2 Connection Housing Installation
3.37.3 Technical Data
3.38 Start-aid Glow Plugs
3.38.1 Glow Plugs Removal
3.38.2 Glow Plugs Installation
3.38.3 Technical Data
3.39 Exhaust Gas Treatment Inlet Module (Engine 441-9208)
3.40 Holder (Engine 441-9208)
3.41 Assembly Material Compensator Structure (Engine 441-9208)
Section 4 Special Tools
4.1 Tools
4.1.1 Pump (P/N 449-2474)
4.1.2 Assembly Pliers
4.1.3 Measuring Device (P/N 449-2482)
4.1.4 Torx Tool Set
4.1.5 Rotation Angle Disc (P/N 449-2484)
4.1.6 Check Designation (P/N 449-2485)
4.1.7 Fitting Tool (P/N 449-2487)
4.1.8 Check Designation (P/N 449-2488)
4.1.9 Pliers (P/N 449-2489)
4.1.10 Socket Wrench Insert
4.1.11 Plug (P/N 449-2493)
4.1.12 Assembly Tool
4.1.13 Key (P/N 449-2496)
4.1.14 Lever Tool (P/N 449-2497)
4.1.15 Disassembly Tool
4.1.16 Assembly Device (P/N 449-2500)
Section 5 Engine Electrical Schematic
5.1 Power Harness
5.2 Equipment Harness
Section 6 Wire Sensor Troubleshooting
6.1 Engine Sensor Test
6.2 Engine Sensor Circuit Test
6.3 Signal Wire Test
Section 7 Diagnostics

AXLE SERVICE REPAIR MANUAL 1:

Effectivity
TOC
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
1.6 Safety Alert System and Signal Words
1.7 Safety Instructions
1.8 Safety Decals
Section 2 General Information and Specifications
2.1 Introduction
2.2 Specifications
2.3 Conversion Tables
2.4 Torque Specifications
2.5 Maintenance
2.6 Safety Precautions
Section 3 Planetary Reduction 1:6 and The Steering Case
3.1 Exploded View
3.2 Planetary Reduction - 1.6 and steering Case - Disassembly
3.3 Planetary Reduction - 1.6 and steering Case - Assembly
Section 4 Steering Cylinder
4.1 Exploded View
4.2 Steering Cylinder - Disassembly
4.3 Steering Cylinder - Assembly
Section 5 Limited Slip Differential Unit 45% (Old Version)
5.1 Exploded View
5.2 Limited Slip Differential Unit 45% (Old Version) - Disassembly
5.3 Limited Slip Differential Unit 45% (Old Version) - Assembly
Section 6 Limited Slip Differential Unit 45% (Last Version)
6.1 Exploded View
6.2 Limited Slip Differential Unit 45% (Last Version) - Disassembly
6.3 Limited Slip Differential Unit 45% (Last Version) - Assembly
Section 7 Bevel Pinion
7.1 Exploded View
7.2 Bevel Pinion - Disassembly
7.3 Bevel Pinion - Install and Adjust
Section 8 Ring and Pinion Adjusting: Version Pinion Cover and Single Arm
8.1 Exploded View
8.2 Ring and Pinion Adjusting: Version Pinion Cover and Single Arm - Install and Adjust
Section 9 Special Tools

AXLE SERVICE REPAIR MANUAL 2:

Effectivity
TOC
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
1.6 Safety Alert System and Signal Words
1.7 Safety Instructions
1.8 Safety Decals
Section 2 General Information and Specifications
2.1 Introduction
2.2 Specifications
2.3 Conversion Tables
2.4 Torque Specifications
2.5 Maintenance
2.6 Safety Precautions
Section 3 Planetary Reduction 1:6 and Steering Case
3.1 Exploded View
3.2 Planetary Reduction - 1.6 and Steering Case - Disassembly
3.3 Planetary Reduction - 1.6 and Steering Case - Assembly
Section 4 Steering Cylinder
4.1 Exploded View
4.2 Steering Cylinder - Disassembly
4.3 Steering Cylinder - Assembly
Section 5 Brake: Service Brake, Negative Brake, 45% Locked & 100% Locked
5.1 Exploded View
5.2 Brake Working Conditions
5.3 Emergency Release Instructions
5.4 Reset of Fails Safe Brake Function
5.5 Brake: Service Brake, Negative Brake, 45% Locked & 100% Locked- Disassembly
5.6 Brake: Service Brake, Negative Brake, 45% Locked & 100% Locked - Assembly
5.7 Brake Piston Gap Check
Section 6 Brake: Negative Brake 4 Cup Springs Version
6.1 Exploded View
6.2 Brake: Negative Brake 4 Cup Springs Version - Disassembly
6.3 Brake: Negative Brake 4 Cup Springs Version - Assembly
Section 7 Normal Preloaded Differential Unit (Old Version)
7.1 Exploded View
7.2 Normal Preloaded Differential Unit (Old Version) - Disassembly
7.3 Normal Preloaded Differential Unit (Old Version) - Assembly
Section 8 Normal Preloaded Differential Unit (Intermediate Version)
8.1 Exploded View
8.2 Normal Preloaded Differential Unit (Intermediate Version) - Disassembly
8.3 Normal Preloaded Differential Unit (Intermediate Version) - Assembly
Section 9 Normal Preloaded Differential Unit (Last Version)
9.1 Exploded View
9.2 Normal Preloaded Differential Unit (Last Version) - Disassembly
9.3 Normal Preloaded Differential Unit (Last Version) - Assembly
Section 10 Flanged Reduction Gear 603 Type: Integral 603 Input Gear
10.1 Exploded View
10.2 Flanged Reduction Gear 603 Type: Integral 603 Input Gear - Disassembly
10.3 Flanged Reduction Gear 603 Type: Integral 603 Input Gear - Assembly
Section 11 Bevel Pinion: Normal Flange and Nut Revolution Counter Version
11.1 Exploded View
11.2 Bevel Pinion: Normal Flange and Nut Revolution Counter Version- Disassembly
11.3 Bevel Pinion: Normal Flange and Nut Revolution Counter Version - Assembly
Section 12 Ring and Pinion Adjusting: Step for Preloaded Differential
12.1 Exploded View
12.2 Ring and Pinion Adjusting: Step for Preloaded Differential - Install and Adjust
Section 13 Swinging Support
13.1 Exploded View
13.2 Swinging Support - Disassembly
13.3 Swinging Support - Assembly
Section 14 Planetary Reduction: 1:4, 23
14.1 Exploded View
14.2 Planetary Reduction: 1:4, 23 - Disassembly
14.3 Planetary Reduction: 1:4, 23 - Assembly
Section 15 Brake: Incoming Disc Brake
15.1 Exploded View
15.2 Brake: Incoming Disc Brake - Disassembly
15.3 Brake: Incoming Disc Brake - Assembly
15.4 Checking Wear and Replacing the Braking Pads
Section 16 Brake: Service and Mechanical Parking Brake
16.1 Exploded View
16.2 Brake: Incoming Disc Brake - Disassembly
16.3 Brake: Incoming Disc Brake - Assembly
Section 17 Brake: Parking Brake and Differential Hydraulic 100%
17.1 Exploded View
17.2 Brake: Incoming Disc Brake- Disassembly
17.3 Brake: Incoming Disc Brake- Assembly
Section 18 Differential With Block to Spheres 100% (Old Version)
18.1 Exploded View
18.2 Differential With Block to Spheres 100% (Old Version) - Disassembly
18.3 Differential With Block to Spheres 100% (Old Version) - Assembly
Section 19 Differential With Block to Spheres 100% (Last Version)
19.1 Exploded View
19.2 Differential With Block to Spheres 100% (Last Version)- Disassembly
19.3 Differential With Block to Spheres 100% (Last Version)- Assembly
Section 20 Normal Differential (Old Version)
20.1 Exploded View
20.2 Normal Differential (Old Version) - Disassembly
20.3 Normal Differential (Old Version) - Assembly
Section 21 Normal Differential (Last Version)
21.1 Exploded View
21.2 Normal Differential (Last Version) - Disassembly
21.3 Normal Differential (Last Version) - Assembly
Section 22 Limited Slip Differential Unit 45% (Old Version)
22.1 Exploded View
22.2 Limited Slip Differential Unit 45% (Old Version) - Disassembly
22.3 Limited Slip Differential Unit 45% (Old Version) - Assembly
Section 23 Limited Slip Differential Unit 45% (Last Version)
23.1 Exploded View
23.2 Limited Slip Differential Unit 45% (Last Version) - Disassembly
23.3 Limited Slip Differential Unit 45% (Last Version) - Assembly
Section 24 Preloaded Limited Slip Differential Unit 45% Unit (Old Version)
24.1 Exploded View
24.2 Preloaded Limited Slip Differential Unit 45% Unit (Old Version) - Disassembly
24.3 Preloaded Limited Slip Differential Unit 45% Unit (Old Version) - Disassembly
Section 25 Preloaded Limited Slip Differential Unit 45%(Intermediate Version)
25.1 Exploded View
25.2 Preloaded Limited Slip Differential Unit45% (Intermediate Version) - Disassembly
25.3 Preloaded Limited Slip Differential Unit 45%(Intermediate Version) - Assembly
Section 26 Preloaded Limited Slip Differential Unit 45%(Last Version)
26.1 Exploded View
26.2 Preloaded Limited Slip Differential Unit 45%(Last Version) - Disassembly
26.3 Preloaded Limited Slip Differential Unit 45%(Last Version) - Assembly
Section 27 Bevel Pinion: Flanged to Reduction Gear 603
27.1 Exploded View
27.2 Bevel Pinion: Flanged to Reduction Gear 603 - Disassembly
27.3 Bevel Pinion: Flanged to Reduction Gear 603 - Assembly
Section 28 Ring and Pinion Adjusting: Version Pinion Cover and Single Arm
28.1 Exploded View
28.2 Ring and Pinion Adjusting: Version Pinion Cover and Single Arm - Install and Adjust
Section 29 Ring and Pinion Adjusting: Version Pinion Integral and Double Arm
29.1 Exploded View
29.2 Ring and Pinion Adjusting: Version Pinion Integral and Double Arm - install and Adjust
Section 30 Special Tools 

ELECTRICAL SYSTEM

HYDRAULIC SYSTEM

PARTS MANUAL 1 (134 pages):

Effectivity Page
Table of Contents
Section 1 ENGINE
Figure 1-1 Dipstick
Figure 1-2 Breather Line
Figure 1-3 Filler Cap
Figure 1-4 Oil Pan
Figure 1-5 Fly Wheel
Figure 1-6 V-Grooved Pulley
Figure 1-7 V-Grooved Pulley
Figure 1-8 Fastenings
Figure 1-9 Valve Mechanical Cover
Figure 1-10 Heat Protecting Shield
Figure 1-11 Front Cover
Figure 1-12 Lubrication Oil Pump
Figure 1-13 Lubricant Oil Filter
Figure 1-14 Oil Cooler
Figure 1-15 Oil Filter Assembly
Figure 1-16 Oil Suction Pipe
Figure 1-17 High Pressure Pump
Figure 1-18 Fuel Injector
Figure 1-19 Fuel Supply Pump
Figure 1-20 Fuel Filter
Figure 1-21 Fuel Prefilter
Figure 1-22 Rail
Figure 1-23 High Pressure Pipe
Figure 1-24 Fuel Line
Figure 1-25 Fuel Line
Figure 1-26 Intake Pipe
Figure 1-27 Charge Air Elbow
Figure 1-28 Charge Air Pipe
Figure 1-29 Control Unit
Figure 1-30 Coolant Pump
Figure 1-31 V-Grooved Pulley
Figure 1-32 Fastenings
Figure 1-33 Thermostat
Figure 1-34 Pipe/Line/Lead
Figure 1-35 Exhaust Manifold
Figure 1-36 Pipe/Line/Lead
Figure 1-37 EGR-Module
Figure 1-38 Turbocharger
Figure 1-39 V-Grooved Pulley
Figure 1-40 Generator
Figure 1-41 Fastenings
Figure 1-42 Starter
Figure 1-43 Cap
Figure 1-44 Cable Harness
Figure 1-45 Fastenings
Figure 1-46 Cable Harness
Figure 1-47 Tacho Generator
Figure 1-48 Temperature Transmitter
Figure 1-49 Pressure Sensor
Figure 1-50 Sensor
Figure 1-51 Connection Housing
Figure 1-52 Glow Plug
Figure 1-53 Inlet
Figure 1-54 Bracket
Figure 1-55 Mounting Material
Figure 1-56 Returns Elevator
Figure 1-57 Special Tools
Maintenance Parts List
PART NUMBER INDEX  

PARTS MANUAL 2 (378 pages):

Effectivity Page
Table of Contents
SMCS CODES - TELEHANDLER
Section 1 Frame & Attaching Parts
Figure 1-1 Frame & Attaching Parts
Figure 1-2 Covers
Figure 1-3 License Plate Holder Installation
Figure 1-4 Hitches
Figure 1-5 Hitch Assembly
Figure 1-6 Mirror & Bracket Installation
Section 2 Boom
Figure 2-1 Boom Assembly - Components
Figure 2-2 Boom Assembly - Pads & Shims
Figure 2-3 Quick Coupler
Figure 2-4 Manual Quick Coupler Installation
Figure 2-5 Hydraulic Quick Coupler Installation
Section 3 Attachments
Figure 3-1 Standard Carriage
Figure 3-2 Universal Standard Carriage
Figure 3-3 Side Tilt Carriage
Figure 3-4 Universal Side Tilt Carriage
Figure 3-5 Universal Side Shift Carriage
Figure 3-6 Forks
Figure 3-7 Grapple Bucket
Figure 3-8 Light Material Buckets
Figure 3-9 Fork Mounted Hook
Figure 3-10 Universal Hitch Attachment
Figure 3-11 Universal Quick Attach Lifting Hook
Figure 3-12 Multi-Purpose Bucket
Figure 3-13 Fork Muck Attachment (w/GRAB)
Figure 3-14 Reflective Plates Installation (Forks)
Figure 3-15 Reflective Plates Installation (Bucket) (Italy)
Section 4 Engine & Attaching Parts
Figure 4-1 Engine Installation
Figure 4-2 Fuel Tank & Lines
Figure 4-3 Fuel Tank and Components Installation
Figure 4-4 Radiator Installation
Figure 4-5 Air Cleaner Installation
Figure 4-6 Exhaust Installation
Figure 4-7 Engine Heater Installation
Figure 4-8 Lubricity Doser Installation
Figure 4-9 Precleaner Filter
Section 5 Drive Train
Figure 5-1 Drivetrain Installation
Figure 5-2 Front Axle Assembly
Figure 5-3 Central Housing & Steering
Figure 5-4 Differential
Figure 5-5 Hub Reduction
Figure 5-6 Brakes
Figure 5-7 Rear Axle Assembly
Figure 5-8 Central Housing & Steering
Figure 5-9 Differential
Figure 5-10 Hub Reduction
Figure 5-11 Fender Installation
Figure 5-12 Tires & Rims
Section 6 Cab
Figure 6-1 Cab Installation
Figure 6-2 Open Cab
Figure 6-3 Enclosed Cab Installation
Figure 6-4 Rear Window Installation
Figure 6-5 Cab Interior
Figure 6-6 Overhead Console Installation
Figure 6-7 Suspension Seat
Figure 6-8 Wiper Installation
Figure 6-9 Heater & A/C - Cab
Figure 6-10 AC Condenser Installation
Figure 6-11 AC System Installation
Figure 6-12 Heater Assembly
Figure 6-13 Heater Assembly with AC
Section 7 Controls
Figure 7-1 Brake
Figure 7-2 Accelerator
Figure 7-3 Steering Column
Figure 7-4 Boom Joystick
Section 8 Hydraulic Circuits
Figure 8-1 Supply Circuit
Figure 8-2 Dump Circuit
Figure 8-3 Steer Select
Figure 8-4 Service/Park Brake
Figure 8-5 Boom Joystick
Figure 8-6 Lift Cylinder
Figure 8-7 Extend/Retract Cylinder
Figure 8-8 Tilt & Compensating
Figure 8-9 Auxiliary Hydraulics
Figure 8-10 Rear Auxiliary Hydraulics
Figure 8-11 Auxiliary Hydraulics Pressure Relief
Figure 8-12 Hydraulic Tank Breather Installation
Section 9 Hydraulic Components
Figure 9-1 Lift Cylinder
Figure 9-2 Extend/Retract Cylinder
Figure 9-3 Tilt Cylinder
Figure 9-4 Compensating Cylinder
Figure 9-5 Fork Locking Cylinder
Figure 9-6 Side Tilt Carriage Cylinder & Grapple Bucket Cylinder
Figure 9-7 Universal Side Shift Cylinder
Figure 9-8 Main Control Valve
Figure 9-9 Front Drive Motor
Figure 9-10 Hydrostatic Drive Pump
Figure 9-11 Gear Pump
Figure 9-12 Divertor Valve
Figure 9-13 Steering Select Valve
Figure 9-14 Pilot Select Valve
Figure 9-15 Brake Valves
Section 10 Electrical
Figure 10-1 Engine Compartment Electrical Installation
Figure 10-2 Boom and Frame Electrical Installation
Figure 10-3 Cab Electrical Installation
Figure 10-4 Cab Switches
Figure 10-5 Work Lights
Figure 10-6 Drive Lights
Figure 10-7 Engine Harness
Figure 10-8 Frame Harness
Figure 10-9 Frame Option Harness
Figure 10-10 Cab Harness
Figure 10-11 Cab Roof Harness
Figure 10-12 Roof Worklight Harness
Figure 10-13 Boom Worklight Harness
Figure 10-14 Beacon Worklight Harness
Figure 10-15 Boom Aux Harness
Figure 10-16 LSI Boom Sensor Harness
Figure 10-17 Mode Select Harness
Figure 10-18 Heater Jumper Harness
Figure 10-19 Valve Jumper Harness
Figure 10-20 AC Condenser Harness
Section 11 Decals
Figure 11-1 Cab & Frame Decals
Figure 11-2 Boom Decals
Maintenance parts list
Part Number Index 

OPERATION and MAINTENANCE MANUAL 1:

Foreword
Table of contents
General
Engine description
Model
Engine illustrations
Lubricating oil diagram
Fuel diagram
Coolant diagram
Exhaust gas recirculation
Exhaust gas aftertreatment
Electrics/Electronics
Operation
Ambient conditions
Initial commissioning
Starting process
Operation monitoring
Exhaust gas aftertreatment system
Passive regeneration
Stopping process
Operating media
Lubricating oil
Fuel
Coolant
Maintenance
Maintenance schedule
Servicing and maintenance work
Lubricating oil system
Fuel system
Cooling system
Engine cleaning
Suction system
Belt drives
Electrical system
Faults
Fault table
Engine management
Transport and storage
Transport
Engine corrosion protection
Technical data
Engine and setting data
Tools 

OPERATION and MAINTENANCE MANUAL 2:

Table of Contents
Section 1 - General Safety Practices
Section 2 - Pre-Operation and Inspection
Section 3 - Controls and Indicators
Section 4 - Operation
Section 5 - Attachments and Hitches
Section 6 - Emergency Procedures
Section 7 - Lubrication and Maintenance
Section 8 - Additional Checks
Section 9 - Specifications
Section 1 - General Safety Practices
1.1 Hazard Classification System
Safety Alert System and Safety Signal Words
1.2 General Precautions
1.3 Operation Safety
Electrical Hazards
Tip Over Hazard
Travel Hazard
Load Falling Hazard
Lifting Personnel
Driving Hazards on Slopes
Pinch Points and Crush Hazards
Fall Hazard
Chemical Hazards
1.4 Product Link (if equipped)
Federal Communications Commission (FCC) Information for Users
Section 2 - Pre-Operation and Inspection
2.1 Preparation, Inspection and Maintenance
2.2 Pre-Operation Check and Inspection
2.3 Safety Decals
ANSI (if equipped)
ISO (CE & AUS) (ANSI, if equipped)
2.4 Walk-Around Inspection
2.5 Warm-Up and Operational Checks
Warm-Up Check
Operational Check
2.6 Operator Cab
2.7 Windows
Cab Door Window (if equipped)
Rear Window
Section 3 - Controls and Indicators
3.1 General
3.2 Controls
Park Brake
Parking Procedure
Ignition
Transmission Control Lever
Load Stability Indicator - LSI (CE & AUS)
LSI Override Switch (CE & AUS)
Steering Column Adjuster (if equipped)
Instrument Panel
Joystick
Right Hand Console
Accessory Control Lever (if equipped)
Reversing Fan (if equipped)
3.3 Steer Modes
Steer Mode Change
3.4 Operator Seat
Operator Presence (CE & AUS)
Adjustments
Seat Belt
3.5 Boom Angle and Extension Indicators
3.6 Reverse Sensing System
Section 4 - Operation
4.1 Engine
Starting the Engine
Cold Weather Starting
Battery Boosted Starting
Normal Engine Operation
Shut-Down Procedure
4.2 Operating with a Non-Suspended Load
Lift Load Safely
Before Picking Up a Load
Transporting a Load
Leveling Procedure
Placing a Load
Disengaging a Load
4.3 Operating with a Suspended Load (ANSI & CE)
Lift Load Safely
Picking Up a Suspended Load
Transporting a Suspended Load
Leveling Procedure
Placing a Suspended Load
Disengaging a Suspended Load
4.4 Road Operation (CE)
4.5 Loading and Securing for Transport
Tiedown
Lifting
Section 5 - Attachments and Hitches
5.1 Approved Attachments
5.2 Unapproved Attachments
5.3 JLG Supplied Attachments
5.4 Telehandler/Attachment/Fork Capacity
5.5 Use of the Load Chart
Capacity Indicator Locations
Sample Load Chart (ANSI & CE)
Sample Load Chart (AUS)
Example
5.6 Attachment Installation
Standard Quick Coupler
Universal Quick Coupler (UQC)
5.7 Hydraulic Operated Attachment
5.8 Adjusting/Moving Forks
5.9 Attachment Operation
Carriage with Forks
Fork Mounted Hook (ANSI & CE)
Rotate/Side Tilt Carriage
Side Shift Carriage
Bucket
Multipurpose Bucket
Grapple Bucket and Muck Fork Grapple
Material Handling Arm (ANSI & CE)
Coupler Mounted Hook
5.10 Hitches
Retrieval Hitch
Adjustable Auto Hitch
Pin Hitch - CUNA C
EEC Manual Pin Hitch
Section 6 - Emergency Procedures
6.1 Towing a Disabled Product
Moving Short Distances
Moving Longer Distances
6.2 Emergency Lowering of Boom
6.3 Emergency Exit from Enclosed Cab
Inside Cab
Outside Cab (if equipped)
Section 7 - Lubrication and Maintenance
7.1 Introduction
Clothing and Safety Gear
7.2 General Maintenance Instructions
7.3 Service and Maintenance Schedule
10 & 1st 50 & 50 Hour Maintenance Schedule
1st 250, 250 & 500 Hour Maintenance Schedule
1000 & 1500 Hour Maintenance Schedule
7.4 Lubrication Schedules
250 Hour Lubrication Schedule
7.5 Operator Maintenance Instructions
Fuel System
Engine Oil
Hydraulic Oil
Tires
Air Intake System
Engine Cooling System
Battery
Brake System
Windshield Washer System (if equipped)
Section 8 - Additional Checks
8.1 General
8.2 Load Stability Indicator System (CE & AUS)
8.3 Reverse Sensing System (if equipped)
Section 9 - Specifications
9.1 Product Specifications
Fluids
Capacities
Tires
Performance
Dimensions
Declaration of Vibration (CE)
Noise Emission Level (CE)
Machine Towing Capacity
Index 

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

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