Caterpillar TH255/TH255C Tele-handler Factory Service & Shop Manual
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Model:
Complete workshop repair service manual with Wlectrical Wiring Diagrams for Caterpillar TH255 / TH255C Tele-handler. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.
These Caterpillar TH255/TH255C Tele-handler manuals (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.
Deutz TCD2.9 Engine (TH255C) Training.pdf
31200362 - Operation & Maintenance Manual (Model TH255).pdf
31200363 - Parts Manual (Model TH255).pdf
31200364 - Service Manual (Model TH255).pdf
31200451 - Service Manual Axle (Models TH255, TH255C).pdf
31200459 - Manuel d'utilisation et de maintenance (Modèle TH255).pdf
31200460 - Manual del operador y de mantenimiento (Modelo TH255).pdf
31200721 - Parts Manual (Model TH255C).pdf
31200746 (SEBU9291) - Operation & Maintenance Manual (Model TH255C).pdf
31200872 (SFBU9291) - Manuel d’utilisation et de maintenance (Modèle TH255C).pdf
31200873 (SSBU9291) - Manual del operador y de mantenimiento (Modelo TH255C).pdf
31200927 - Service Manual (Model TH255C).pdf
31200934 - Engine Parts Manual (Model TH255C).pdf
31200980 - Engine Service Manual (Model TH255C).pdf
31211008 - Axle Service Manual (Models TH255, TH255C).pdf
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31200362 - Operation & Maintenance Manual (Model TH255)...2
31200362_F_TH255_CAT_OMM...2
Revision Log...4
Read This First...5
Table of Contents...8
Section 1 - General Safety Practices...12
1.1 Hazard Classification System...12
Safety Alert System and Safety Signal Words...12
1.2 General Precautions...12
1.3 Operation Safety...13
Electrical Hazards...13
Tip Over Hazard...14
Travel Hazard...17
Load Falling Hazard...18
Lifting Personnel...19
Driving Hazards On Slopes...20
Pinch Points and Crush Hazards...21
Fall Hazard...23
Chemical Hazards...24
Section 2 - Pre-Operation and Inspection...26
2.1 Pre-Operation Check and Inspection...26
2.2 Safety Decals...29
ASME (ANSI, if equipped)...29
ISO (CE & AUS) (ANSI, if equipped)...31
2.3 Walk-Around Inspection...33
2.4 Warm-Up and Operational Checks...35
Warm-Up Check...35
Operational Check...35
2.5 Operator Cab...36
2.6 Windows...37
Cab Door Window (if equipped)...37
Rear Window...38
Section 3 - Controls and Indicators...40
3.1 General...40
3.2 Controls...41
Park Brake...43
Parking Procedure...44
Ignition...45
Transmission Control Lever...46
Load Stability Indicator - LSI (CE & AUS)...47
LSI Override Switch (CE & AUS)...50
Instrument Panel...51
Steering Column Adjuster (if equipped)...52
Joystick...53
Right Hand Console...55
Accessory Control Lever (if equipped)...57
3.3 Steer Modes...58
Steer Mode Change...58
3.4 Operator Seat...59
Adjustments...59
Seat Belt...60
3.5 Boom Angle and Extension Indicators...61
Section 4 - Operation...62
4.1 Engine...62
Starting the Engine...62
Battery Boosted Starting...63
Normal Engine Operation...64
Shut-Down Procedure...64
4.2 Operating with a Non-Suspended Load...65
Lift Load Safely...65
Before Picking Up a Load...65
Transporting a Load...66
Leveling Procedure...66
Placing a Load...67
Disengaging a Load...67
4.3 Operating with a Suspended Load (ANSI & CE)...68
Lift Load Safely...68
Picking Up a Suspended Load...68
Transporting a Suspended Load...69
Leveling Procedure...69
Placing a Suspended Load...70
Disengaging a Suspended Load...70
4.4 Road Operation (CE)...71
4.5 Loading and Securing for Transport...72
Tiedown...72
Lifting...73
Section 5 - Attachments and Hitches...74
5.1 Approved Attachments...74
5.2 Unapproved Attachments...74
5.3 JLG Supplied Attachments...75
5.4 Telehandler/Attachment/Fork Capacity...77
5.5 Use of the Load Chart...78
Capacity Indicator Locations...78
Sample Load Chart (ANSI & CE)...79
Sample Load Chart (AUS)...80
Example...81
5.6 Attachment Installation...82
Standard Quick Coupler...82
Universal Quick Coupler (UQC)...85
5.7 Hydraulic Operated Attachment...87
5.8 Adjusting/Moving Forks...88
5.9 Attachment Operation...89
Carriage w/Forks...91
Fork Mounted Hook (ANSI & CE)...92
Rotate/Side Tilt Carriage...93
Side Shift Carriage...95
Bucket...97
Grapple Bucket...99
Material Handling Arm (ANSI & CE)...101
5.10 Hitches...102
Pin Hitch...102
Adjustable Pin Hitch...103
Adjustable Auto Hitch...104
Section 6 - Emergency Procedures...106
6.1 Towing a Disabled Product...106
Moving Short Distances...106
Moving Longer Distances...106
6.2 Emergency Lowering of Boom...107
6.3 Emergency Exit from Enclosed Cab...107
Section 7 - Lubrication and Maintenance...108
7.1 Introduction...108
Clothing and Safety Gear...108
7.2 General Maintenance Instructions...109
7.3 Service and Maintenance Schedule...110
10 & 1st 50 & 50 Hour Maintenance Schedule...110
1st 250, 250 & 500 Hour Maintenance Schedule...111
1000 Hour Maintenance Schedule...112
7.4 Lubrication Schedules...113
250 Hour Lubrication Schedule...113
7.5 Operator Maintenance Instructions...115
Fuel System...115
Engine Oil...117
Hydraulic Oil...118
Tires...119
Air Intake System...121
Engine Cooling System...123
Battery...124
Brake System...125
Windshield Washer System (if equipped)...126
Section 8 - Additional Checks...128
8.1 General...128
8.2 Load Stability Indicator System (CE & AUS)...128
Section 9 - Specifications...130
9.1 Product Specifications...130
Fluids...130
Capacities...131
Tires...131
Performance...132
Dimensions...133
Declaration of Vibration (CE)...134
Noise Emission Level (CE)...134
Index...136
Inspection, Maintenance and Repair Log...140
31200363 - Parts Manual (Model TH255)...146
31200363_L_TH255_ CAT_Parts...146
Effectivity Page...148
Table of Contents...150
SMCS Codes - TELEHANDLER...154
Section 1 Frame & Attaching Parts...160
Figure 1-1 Frame Shrouding & Attaching Parts...161
Figure 1-2 Frame Covers, Shrouding & Attaching Parts...167
Figure 1-3 Engine Pod Insulation...171
Figure 1-4 Axle & Fender Installation...173
Figure 1-5 Hitches...175
Figure 1-6 License Plate Holder Installation...179
Figure 1-7 Rear Engine Cover...183
Section 2 Boom...186
Figure 2-1 Boom Assembly - Components...187
Figure 2-2 Boom Assembly - Pads, Shims & Spacers...189
Figure 2-3 Boom Pin Installation...191
Figure 2-4 Quick Coupler...193
Figure 2-5 Universal Quick Coupler...195
Section 3 Attachments...198
Figure 3-1 Standard Carriage...199
Figure 3-2 Universal Standard Carriage...201
Figure 3-3 Rotate/Side Tilt Carriage...203
Figure 3-4 Universal Rotate/Side Tilt Carriage...205
Figure 3-5 Universal Side Shift Carriage...207
Figure 3-6 Forks...209
Figure 3-7 Grapple Bucket...211
Figure 3-8 Light Material Bucket...215
Figure 3-9 Fork Mounted Hook...217
Figure 3-10 Universal Quick Coupler Adapter...219
Section 4 Engine & Attaching Parts...222
Figure 4-1 Engine Installation...223
Figure 4-2 Engine Assembly...227
Figure 4-3 Cat Engine...229
Figure 4-4 Cat Engine...231
Figure 4-5 Radiator/Oil Cooler Installation...233
Figure 4-6 Air Cleaner Installation...235
Figure 4-7 Exhaust Installation...237
Section 5 Drive Train...240
Figure 5-1 Front Axle Assembly...241
Figure 5-2 Front Differential & Central Housing...243
Figure 5-3 Front Hub Reduction...247
Figure 5-4 Front Brakes...249
Figure 5-5 Front Steering Components...251
Figure 5-6 Rear Axle Assembly...253
Figure 5-7 Rear Differential...255
Figure 5-8 Rear Hub Reduction & Central Housing...257
Figure 5-9 Rear Steering Components...261
Figure 5-10 Drive Shaft Installation...263
Figure 5-11 Tires & Rims...265
Section 6 Cab...270
Figure 6-1 Cab Installation...271
Figure 6-2 Open Cab...277
Figure 6-3 Enclosed Cab Installation...279
Figure 6-4 Rear Hinged Window Installation...283
Figure 6-5 Suspension Seat...285
Figure 6-6 Wiper Installation...287
Figure 6-7 Heater & AC Installation - Cab...289
Figure 6-8 Heater & AC Installation - Engine Pod...293
Figure 6-9 Overhead Console...295
Section 7 Controls...300
Figure 7-1 Boom Joystick...301
Figure 7-2 Steering Column & Attaching Parts...303
Figure 7-3 Accelerator Pedal Assembly...305
Figure 7-4 Brake Assembly...307
Section 8 Hydraulic Circuits...310
Figure 8-1 Supply Circuit...311
Figure 8-2 Dump Circuit...315
Figure 8-3 Steer Select...319
Figure 8-4 Service/Park Brake...321
Figure 8-5 Boom Joystick...323
Figure 8-6 Lift Cylinder...331
Figure 8-7 Extend/Retract Cylinder...335
Figure 8-8 Tilt & Compensating...337
Figure 8-9 Auxiliary Hydraulics...339
Figure 8-10 Rear Auxiliary Hydraulics...343
Figure 8-11 Auxiliary Hydraulics Pressure Relief...347
Section 9 Hydraulic Components...354
Figure 9-1 Lift Cylinder...355
Figure 9-2 Extend/Retract Cylinder...359
Figure 9-3 Tilt Cylinder...361
Figure 9-4 Compensating Cylinder...363
Figure 9-5 Hydraulic Quick Coupler Cylinder...365
Figure 9-6 Rotate/Side Tilt Cylinder & Grapple Bucket Cylinder...367
Figure 9-7 Universal Side Shift Cylinder...369
Figure 9-8 Main Control Valve...371
Figure 9-9 Front Drive Motor...373
Figure 9-10 Hydrostatic Transmission...375
Figure 9-11 Divertor Valve...377
Figure 9-12 Steering Select Valve...381
Figure 9-13 Blocking Valve...385
Figure 9-14 Pilot Select Valve...387
Figure 9-15 Brake Valves...391
Figure 9-16 LSI Valve...393
Figure 9-17 Auxiliary Hydraulic Pressure Relief Valve...395
Section 10 Electrical...398
Figure 10-1 Electrical Installation...399
Figure 10-2 Road Lights Installation...403
Figure 10-3 Work Lights Installation...407
Figure 10-4 Cab Switches...411
Figure 10-5 Cab Fuse Holder...413
Figure 10-6 Frame Base Harness...415
Figure 10-7 Frame Option Harness...421
Figure 10-8 Cab Harness...429
Figure 10-9 Cab Roof Harness...439
Figure 10-10 Roof Worklights Harness...443
Figure 10-11 Boom Worklights Harness...447
Figure 10-12 AC System Harness...449
Figure 10-13 Boom Aux Harness...451
Figure 10-14 LSI Timer Installation...453
Figure 10-15 Speedometer Installation...455
Figure 10-16 LSI Installation...457
Figure 10-17 LSI Axle Sensor & Boom Proximity Sensor Installation...459
Figure 10-18 Function Cutout Jump Harness...461
Figure 10-19 Valve Jumper Harness...463
Section 11 Decals...466
Figure 11-1 Decal Installation...467
Maintenance parts list...474
Part Number Index...478
003-6271 6-25...478
0100020 1-5...478
010-3647 4-13...478
0275506CP 5-27...478
0275507CP 5-27...478
033-0695 6-4...478
0642216 2-11...478
0701010 2-5...478
0S-1613 1-5...478
1001080228 5-28...478
1001080533 8-29...478
1001080599 8-11...478
1001080658CP 5-27...478
1001080659CP 5-27...478
1001080662CP 5-27...478
1001080663CP 5-27...478
1001081218CP 5-27...478
1001081219CP 5-27...478
1001081220CP 5-27...478
1001081221CP 5-27...478
1001081222 5-27...478
1001112556CP 5-27...478
1001112557CP 5-27...478
1001112558CP 5-27...478
1001119669 10-29...478
1001135671CP 5-27...478
1001135672CP 5-27...478
1001135673CP 5-27...478
1001135674CP 5-27...478
1001135676CP 5-27...478
1001135677CP 5-27...478
1001135762 8-37...478
101-4411 3-19...478
102-8801 10-45...478
105-3478 4-7, 8-3...478
10700730 1-21...478
10733183 4-15...478
113-0919 6-5...478
113-8490 10-17, 10-19, 10-22...478
113-8491 10-17, 10-19, 10-22...478
113-8492 10-17...478
114-3913 6-5...478
115-2422 10-3...478
122-1010 2-3...478
122-1084 6-11, 6-15...478
122-4401 10-36...478
124-3548 10-17...478
128-2016 10-17...478
128-5016 10-49...478
131-5879 2-11...478
132-7551 2-11...478
136-5488 10-49, 10-51...478
140-9037 7-5...478
141-2759 10-17, 10-19, 10-22...478
141-2760 10-17, 10-19, 10-22...478
142-8828 1-10...478
144-0195 6-6...478
146-8438 1-6, 2-3...478
148-8313 8-3, 8-11...478
148-8339 8-7, 8-9...478
153-0088 8-31...478
153-8498 1-21...478
154-3197 6-5...478
155-1165 6-6, 7-7...478
160-8500 7-9...478
166-2560 2-11...478
169-0705 10-28...478
169-0706 10-28, 10-29...478
176-1477 10-19, 10-22...478
178-9983 6-5...478
179-4324 8-23, 8-25, 10-3...478
185-4633 11-6...478
187-0789 10-11...478
192-0089 1-9...478
192-2645 2-11...478
195-6754 2-11...478
196-2412 10-49...478
196-2413 10-22...478
197-7429 10-22...478
197-7430 10-22...478
1N-5998 1-5...478
1P-0545 11-6...478
202-3643 8-11, 8-31...478
202-5397 10-25, 10-29...478
204-6195 10-22...478
208-8469 1-6, 4-7, 10-3, 10-11...478
211-0089 1-5...478
213-2243 11-5...478
213-8350 10-43, 10-45...478
213-8351 10-43, 10-45...478
2145005 8-3...478
2145010 5-3...478
2145016 8-3...478
217-5888 10-25, 10-28, 10-36, 10-41, 10-63...478
217-5892 10-35, 10-40...478
217-5893 10-23, 10-25, 10-28, 10-35, 10-36, 10-40, 10-41, 10-63...478
223-8819 10-4...478
226-6494 9-25, 9-27...478
230-4011 10-19, 10-22...478
231-3761 1-4...478
232-2551 4-9...478
238-8247 10-19, 10-22...478
241-6603 11-6...478
247-8195 10-29...478
252-1436 3-13...478
252-1438 3-13...478
252-1454 3-13...478
252-1456 3-13...478
253-8113 10-28...478
254-9046 4-15...478
272-2838 10-36, 10-40...478
272-2840 10-19, 10-22...478
272-3089 6-25...478
272-6538 9-37, 9-39, 9-43...478
281-0791 1-10, 1-11, 1-17, 1-19...478
281-5863 8-23, 8-25...478
295-8469 8-35, 8-37...478
296-7319 1-17...478
297-7012 4-3, 6-25, 8-35, 8-37, 10-3...478
297-7022 1-15, 1-23, 8-29, 8-31...478
297-7030 1-23, 8-27...478
297-7032 6-25...478
297-7077 1-9...478
298-0402 4-7...478
298-0414 8-27, 8-31...478
298-0462 8-3, 8-11...478
298-0463 8-29...478
298-0464 8-29, 8-35, 8-37, 8-39...478
298-0466 8-7, 8-9, 8-23, 8-25, 8-27, 8-31...478
298-0468 8-7, 8-9...478
298-0470 8-3...478
298-0471 2-9, 5-3, 8-3, 8-9...478
298-0473 8-3, 8-11, 8-31, 8-41...478
298-0474 8-7...478
298-0475 8-35, 8-39...478
298-0476 8-7, 8-9...478
298-0488 2-9...478
298-0492 8-9, 8-41...478
298-0494 8-7, 8-9...478
298-0496 8-3, 8-7, 8-39, 8-41...478
298-0497 8-29...478
298-0498 8-39...478
298-0507 8-39...478
298-0508 8-35, 8-39...478
298-0547 10-7...478
298-0549 1-5...478
298-0552 1-6, 1-9, 10-7...478
298-0553 10-3...478
298-0556 11-5...478
298-0576 11-5...478
298-1540 1-10...478
298-1579 1-15, 4-13...478
298-1580 2-7, 2-9, 2-11, 8-4...478
298-1581 6-27, 7-9...478
298-1586 4-13...478
298-1588 8-41...478
298-1612 2-3...478
298-1638 8-11...478
298-1656 8-4, 8-7, 8-9, 8-13...478
298-1746 6-7...478
298-1857 5-9, 5-19, 5-20...478
298-1863 5-9, 5-19...478
298-1864 1-15, 5-19...478
298-1865 5-9, 5-19...478
298-1878 5-11...478
298-1880 5-11...478
298-6828 8-31...478
298-6870 10-3...478
298-7030 6-7...478
298-7082 7-3...478
298-7341 3-5...478
298-7343 4-17...478
298-7355 8-3, 8-7, 8-15, 8-19, 8-21, 9-41...478
298-7356 8-15, 8-17, 8-19, 8-21...478
298-7358 8-7, 8-9, 8-15, 8-17, 8-19, 8-41, 8-43...478
298-7363 1-4, 1-5, 2-3, 4-3, 6-6, 8-3, 8-19, 8-35, 8-37, 10-3, 10-4, 10-7, 10-11, 10-57, 10-63...478
298-7364 1-4, 1-6, 1-9, 1-15, 4-13, 6-25, 7-9, 8-13, 8-27...478
298-7365 2-9, 4-3, 8-7, 8-9, 10-3...478
298-7366 6-25, 11-5...478
298-7367 1-9, 2-7...478
298-7368 1-19...478
298-7369 1-9, 1-11, 2-11...478
298-7372 6-25, 8-19...478
298-7373 1-6...478
298-7374 1-5, 1-23, 4-13, 6-25, 8-35, 8-39...478
298-7377 10-3...478
298-7378 7-9, 10-3...478
298-7380 2-9, 10-3...478
298-7383 2-11...478
298-7387 4-7...478
298-7393 4-7...478
298-7394 1-4, 1-15...478
298-7395 6-6...478
298-7842 8-41...478
298-7845 8-31...478
298-7846 1-23, 8-27, 8-29...478
298-7868 5-9, 5-19...478
298-7873 5-11...478
298-7900 10-3, 10-57...478
298-7971 10-3, 10-11...478
298-7972 10-3, 10-11...478
298-7981 1-9...478
298-7987 6-6, 10-7...478
298-8051 1-19...478
298-8052 1-9, 1-11, 1-21...478
298-8435 4-3...478
298-8438 11-4...478
298-8581 6-7...478
298-8668 1-5...478
298-8669 6-17...478
298-8726 6-17...478
298-8743 11-5...478
299-0197 5-20...478
299-0209 7-3...478
299-0210 7-3...478
299-0309 4-3...479
299-0312 10-19, 10-22...479
299-0334 1-10...479
299-0350 10-19...479
299-0353 4-13...479
299-0354 6-5, 11-5...479
299-0471 8-39...479
299-0498 7-3...479
299-0508 5-17...479
299-0611 9-39...479
299-0821 5-6, 5-20...479
299-0834 7-3...479
299-0903 9-39...479
299-0912 4-13...479
299-0921 6-17...479
299-0922 6-17...479
299-0924 6-17...479
299-0925 6-17...479
299-0928 6-17...479
299-0949 1-23, 8-27, 8-29, 8-31...479
299-0953 7-3...479
299-0967 7-3...479
299-0986 7-3...479
299-6637 6-17...479
299-7096 10-19...479
299-7103 5-9, 5-11, 5-19, 5-20...479
299-7106 10-41...479
299-7107 10-19, 10-23, 10-28, 10-35, 10-40, 10-41...479
299-7134 5-5, 5-9, 5-19...479
299-7156 5-5, 5-9, 5-19...479
299-7161 5-6, 5-20...479
2F-0951 7-7...479
2L-1701 3-13...479
300-6078 2-11, 3-7, 3-15, 8-35, 8-37...479
300-6079 2-11, 3-7, 3-15, 8-35, 8-37...479
300-6095 8-31...479
300-6096 8-3, 8-23, 8-37...479
300-6101 10-11...479
300-6103 2-9, 2-11, 3-7, 8-35, 8-37...479
301-9752 3-13...479
303-4754 8-7, 8-9, 8-11, 8-31...479
303-4758 4-3, 8-7, 8-9...479
303-4759 8-4...479
303-4760 8-31, 8-41...479
303-4782 3-3, 3-5...479
303-4787 10-11...479
303-4788 1-9, 9-19, 10-7...479
303-4790 4-17...479
303-4795 6-25...479
303-4796 8-27...479
303-4911 1-25...479
303-4939 11-4...479
303-4940 11-4...479
303-4941 11-4...479
303-4942 11-4...479
303-4943 11-4...479
303-4944 11-4...479
303-4945 11-4...479
303-4946 11-4...479
303-4947 11-4...479
303-4948 11-4...479
303-4949 11-4...479
303-4950 11-4...479
303-4955 10-7...479
303-4956 10-7...479
303-4957 3-3, 3-5...479
303-4960 11-4...479
303-4962 11-4...479
303-4969 10-12, 10-25, 10-28, 10-29, 10-49, 10-63, 10-67...479
303-4975 10-7...479
303-4976 10-7...479
303-4988 3-3, 3-5...479
303-8559 5-3...479
303-8586 6-12...479
303-8599 6-25...479
303-8609 9-19...479
303-8636 6-12...479
304-2250 9-19...479
304-2270 9-19...479
304-2271 9-19...479
304-2294 9-19...479
304-2295 9-19...479
304-2606 10-55...479
304-2626 6-17...479
304-2648 6-11...479
304-3181 6-11...479
304-3813 9-19...479
304-4555 1-5...479
304-4564 9-19...479
305-2107 10-7, 10-8...479
305-2108 10-7, 10-8...479
305-2109 10-7, 10-8...479
305-5426 5-9, 5-20...479
305-5449 10-19, 10-22, 10-25, 10-28, 10-29, 10-36, 10-41, 10-49...479
305-5450 10-19, 10-22, 10-36, 10-40...479
305-5503 10-28, 10-29...479
307-7359 1-4...479
308-9131 1-6...479
3090601 10-11...479
309-2832 1-9...479
309-2835 1-4, 1-9, 1-21...479
309-2837 1-9...479
309-2838 1-5...479
309-2839 1-5...479
309-2840 1-9...479
309-2841 1-5...479
309-2843 1-5...479
309-2845 1-9...479
309-2849 1-5...479
309-2850 1-5...479
309-2852 1-5...479
309-2853 1-21...479
309-2924 2-7...479
309-2925 4-13...479
309-2927 5-3...479
309-2928 5-15...479
309-2929 5-3...479
309-2937 4-7...479
309-2938 9-23...479
309-2939 8-3...479
309-2940 2-7...479
309-2941 2-7...479
309-2955 2-7...479
309-2958 10-25...479
309-2959 9-3...479
309-2960 9-11...479
309-2963 8-3...479
309-2964 8-3, 8-13...479
309-2966 8-3...479
309-2971 5-3, 8-13...479
309-2972 4-7...479
309-2973 9-21...479
309-2975 1-15...479
309-2976 5-25...479
309-2978 2-11, 4-7...479
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415-3063 10-63...485
415-3064 10-63...485
415-3068 6-27...485
415-3205 6-4...485
415-3208 6-4...485
415-3209 6-28...485
415-3214 1-5...485
415-3216 1-5...485
415-3217 2-3...485
416-1013 1-5...485
418-0027 4-3...485
418-3397 6-5...485
418-4416 8-21...485
418-4417 8-21...485
418-4522 8-21...485
418-4523 8-17, 8-21...485
418-5164 1-5...485
418-7445 10-22...485
419-0442 11-4...485
419-0443 11-4...485
419-0668 6-28...485
419-3619 10-40...485
419-3620 10-28...485
419-4525 6-23...485
419-4548 6-22...485
420-2325 2-3...485
420-3170 2-3...485
421-2306 11-5...485
421-5496 10-4...485
421-5531 6-7...485
421-5532 2-3...485
421-6077 9-39...485
421-6256 4-13...485
421-7700 6-22...485
421-9179 9-37...485
422-1390 6-4...485
422-4199 6-27...485
422-4316 11-6...485
422-6478 4-3...485
422-7078 10-65...485
422-7173 6-4...485
422-7174 6-4...485
422-7175 6-4...485
422-7176 6-4...485
422-7178 6-5...485
422-7180 6-23...485
423-1218 4-3...485
423-1317 9-37...485
423-2467 6-7...485
430-5089 10-3...485
430-8646 6-7...485
430-8647 6-7...485
430-8648 6-7...485
430-8649 6-6...485
430-8650 6-6...485
436-2901 5-11...485
437-1924 2-9...485
437-1925 2-9...485
437-7751 4-3...485
438-0878 6-5...485
442-5213 11-5...485
443-3877 6-19...485
443-3878 6-19...485
443-5811 6-22...485
443-5812 6-22...485
443-5813 6-22...485
443-6295 10-7...485
443-6296 1-9...485
443-8071 5-27...485
444-1538 6-27...485
444-1539 6-27...485
444-1540 6-27...485
445-1422 8-37...485
445-1423 8-31...485
445-1424 8-37...485
445-1425 8-37...485
445-1426 8-37...485
445-1427 8-37...485
446-5517 9-5...485
446-5518 9-5...485
447-0427 1-17...485
447-0436 1-17...485
447-0437 1-17...485
447-0438 1-17...485
447-0439 1-11, 1-17...485
447-0440 1-17...485
447-7966 7-9...485
448-3126 11-5...485
448-4869 9-31...485
448-8388 6-19...485
449-2077 6-7...485
449-2078 6-7...485
449-2079 6-7...485
449-2080 6-7...485
449-2082 7-5...485
449-2083 6-27...485
449-2373 5-9...485
449-2944 9-37...485
449-2968 9-37...485
449-2974 9-37...485
449-2975 9-37...485
449-5795 9-19...485
450-0307 9-27...485
450-5971 9-15...485
451-7853 10-49, 10-63...485
4520259 5-28...485
4520658CP 5-27...485
4520659CP 5-27...485
452-7079 10-63...485
453-0130 1-17...485
454-3968 10-63...485
456-1554 10-35, 10-40...485
456-1565 10-25...485
456-1567 10-22, 10-35, 10-40...485
456-1577 10-22, 10-25, 10-29...485
456-1584 10-22...485
456-1585 10-45...485
456-1591 10-41...485
456-8195 10-22...485
457-8027 10-29, 10-57...485
459-3497 10-17...485
460-2707 10-41...485
460-4116 10-23, 10-28, 10-29, 10-35...485
464-0613 5-28...485
464-3816 8-23, 8-25...485
465-7068 6-25...485
469-8699 1-10...485
471-2121 6-7...485
472-0024 1-9...486
472-7921 10-45...486
473-3652 10-28...486
473-3669 10-28...486
476-8913 5-27...486
477-0034 8-13...486
477-1014 1-10...486
477-1688 5-11...486
477-1735 5-9...486
477-3345 10-28...486
477-9071 6-17...486
477-9617 1-5...486
478-0587 6-19...486
478-2148 6-12...486
478-3796 7-5...486
478-7732 10-28...486
481-7832 1-6...486
482-2805 1-9...486
484-1870 9-31...486
484-9740 10-65...486
484-9763 6-28...486
485-2777 1-23...486
493-2997 2-11...486
493-8930 5-9, 5-19...486
494-0253 6-6, 6-19...486
4B-5276 1-9, 2-11...486
4M-0061 1-4, 1-6, 1-9...486
4M-5281 1-4, 1-5, 7-9, 10-63...486
4M-5282 10-57...486
4M-6425 1-6, 7-9...486
501-3071 8-31...486
501-3076 8-31...486
501-3077 8-31, 10-67...486
501-3078 8-31...486
502-2015 6-5...486
502-2017 6-7...486
502-2020 6-23...486
506-3879 10-63...486
506-3880 10-63...486
506-9057 10-4...486
507-3154 5-27...486
507-4959 10-28, 10-29...486
507-9260 10-7...486
507-9262 6-19...486
507-9308 7-9...486
507-9498 6-5...486
508-4536 6-23...486
508-8837 1-10...486
509-6496 1-10...486
509-7069 6-12...486
512-0345 10-17...486
512-0346 10-17...486
512-0347 10-35, 10-40...486
512-0348 10-36, 10-41...486
512-0354 10-35, 10-40...486
518-2966 1-11...486
518-9756 6-17...486
519-7024 6-23...486
527-9833 2-11...486
527-9834 2-11...486
527-9835 2-11...486
527-9836 2-11...486
5C-2890 3-19...486
5C-9553 3-19...486
5D-0353 2-9, 7-5...486
5J-5314 8-11...486
5K-9107 4-3, 4-13, 8-7, 8-9...486
5L-4126 1-23, 6-15...486
5P-0767 4-7, 6-22, 6-25...486
5P-1507 4-3...486
5P-2675 7-9...486
5P-4116 3-19...486
5P-4135 1-15...486
5P-7590 1-5...486
5P-8500 6-5...486
5P-9938 8-35, 8-39, 10-3...486
5S-0003 6-7...486
5S-7349 10-3...486
5S-7383 8-31...486
5W-4957 10-36...486
5W-5038 6-5...486
5W-8686 10-7...486
6C-3220 6-6...486
6I-0646 6-25...486
6K-8178 4-3...486
6K-9632 6-19...486
6T-6506 10-40...486
6T-7929 10-41...486
6V-0413 4-13, 6-25...486
6V-4432 2-9, 2-11...486
6V-6945 1-15...486
6V-7744 2-11...486
6V-8182 1-9, 1-15, 6-6...486
6V-8188 1-5, 4-3...486
6V-8213 8-37...486
6V-8225 10-11...486
6V-8801 1-5, 10-3...486
6V-8918 2-9...486
6V-9188 1-17, 1-19...486
6V-9189 10-7...486
70021164 5-19...486
7012953 9-33...486
7029300 5-19...486
7D-5473 10-63...486
7D-5962 4-3...486
7N-0718 10-4...486
7R-2751 10-22...486
7X-0265 8-15, 8-19...486
7X-0274 9-19...486
7X-0290 2-3...486
7X-0332 1-5, 2-7...486
7X-0336 2-7...486
7X-0340 1-5...486
7X-0345 4-7...486
7X-0347 1-19...486
7X-0352 3-3, 3-5...486
7X-0370 6-6...486
7X-0371 6-7...486
7X-0375 1-15...486
7X-0440 1-4, 1-9, 8-13, 8-27, 8-29, 8-31, 10-7...486
7X-0449 6-6...486
7X-2538 3-3, 3-5...486
7X-2619 2-9...486
7X-3178 8-19...486
7X-3327 2-7...486
7X-7729 2-11...486
80474017 4-15...486
80604019 10-29...486
80604023 10-35, 10-36, 10-40...486
8770016 8-3...486
8C-3121 1-6, 8-29, 8-31...486
8C-8585 2-5...486
8C-8988 5-3, 5-15...486
8F-9866 11-6...486
8H-3127 6-5, 7-3...486
8H-5505 6-5...486
8T-0289 8-23, 8-25...486
8T-0328 1-10, 1-11...486
8T-4121 2-5, 4-3, 4-15, 6-25, 10-3, 10-61...486
8T-4123 2-11...486
8T-4137 4-3, 6-25...486
8T-4138 4-7, 6-5...486
8T-4177 4-7...486
8T-4182 4-7...486
8T-4185 2-5...486
8T-4189 3-19, 4-7, 4-15...486
8T-4190 3-13...486
8T-4191 4-3...486
8T-4195 2-5, 4-7...486
8T-4196 4-15...486
8T-4198 2-11...486
8T-4199 1-10, 1-17...486
8T-4200 10-3...486
8T-4205 1-6, 10-11...486
8T-4223 4-3, 6-7, 6-25...486
8T-4224 1-10, 10-3, 10-7...486
8T-4956 4-3...486
8T-7008 1-5...486
8T-8730 10-22, 10-23, 10-25, 10-28, 10-29, 10-35, 10-36, 10-40, 10-41, 10-49, 10-67...486
8T-8737 10-12, 10-22, 10-23, 10-25, 10-28, 10-29, 10-30, 10-35, 10-36, 10-40, 10-41...486
8T-8908 7-9...486
8T-9368 4-3, 8-3, 8-41...486
8T-9379 8-9...486
8T-9394 6-27...486
90027471 1-5...486
90027473 6-6...486
91143223 9-21...486
91514118 1-15, 5-19...486
9D-3868 6-5...486
9S-2087 5-27...486
9S-7382 8-31...486
9W-0844 10-25, 10-28, 10-29...486
9X-2480 4-17...486
9X-8257 1-17, 4-7...486
9X-8483 9-21...486
31200364 - Service Manual (Model TH255)...490
31200364_B_CAT_TH255_Service Manual ...490
Effectivity Page...492
Table of Contents...494
Section 1 Safety Practices...498
1.1 Introduction...499
1.2 Disclaimer...499
1.3 Operation & Maintenance Manual...499
1.4 Do Not Operate Tags...499
1.5 Safety Information...499
1.5.1 Safety Alert System and Signal Words...499
1.6 Safety Instructions...500
1.6.1 Personal Hazards...500
1.6.2 Equipment Hazards...500
1.6.3 General Hazards...500
1.6.4 Operational Hazards...501
1.7 Safety Decals...501
Section 2 General Information and Specifications...502
2.1 Replacement Parts and Warranty Information...503
2.2 Torques...504
2.2.1 SAE Fastener Torque Chart...504
2.2.2 Metric Fastener Torque Chart...507
2.2.3 Hydraulic Hose Torque Chart...511
2.3 Specifications...512
2.3.1 Travel Speed...512
2.3.2 Hydraulic Cylinder Performance Specifications...512
2.3.3 Electrical System...512
2.3.4 Engine Performance Specifications...513
2.3.5 Tires...513
2.4 Fluids, Lubricants and Capacities...514
2.5 Maintenance Schedules...516
2.5.1 10,1st 50 & 50 Hour Maintenance Schedule...516
2.5.2 1st 250, 250 & 500 Hour Maintenance Schedule...517
2.5.3 1000 Hour Maintenance Schedule...518
2.6 Lubrication Schedule...519
2.6.1 250 Hour Lubrication Schedule...519
Section 3 Boom...520
3.1 Boom System Component Terminology...521
3.2 Safety Information...522
3.3 Boom System - Two Section Boom...522
3.3.1 Boom System Description...522
3.4 Boom Assembly Maintenance...522
3.4.1 Second Boom Section Removal...522
3.4.2 First Boom Section Removal...523
3.4.3 First Boom Section Installation...523
3.4.4 Second Boom Section Installation...524
3.4.5 Complete Boom Removal...524
3.4.6 Second Boom Section Removal...525
3.4.7 Second Boom Section Installation...526
3.4.8 Boom Installation...526
3.4.9 Extend/Retract Cylinder Removal...527
3.4.10 Extend/Retract Cylinder Installation...528
3.5 Boom Wear Pads...529
3.5.1 Wear Pad Inspection...529
3.5.2 Wear Pad Installation and Lubrication...529
3.5.3 Boom Wear Pad Lubrication...529
3.6 Quick Coupler Assembly...530
3.6.1 Quick Coupler Removal...530
3.6.2 Quick Coupler Installation...530
3.7 Forks...531
3.8 Boom Prop (If Equipped)...531
3.8.1 Installation and Removal Procedures...531
3.9 Emergency Boom Lowering Procedure...532
3.9.1 Equipment and Supplies Required...532
3.9.2 Lowering Procedure...532
3.10 Troubleshooting...534
Section 4 Cab and Covers...538
4.1 Operator Cab and Covers Component Terminology...539
4.2 Safety Information...540
4.3 Operator Cab...540
4.3.1 Operator Cab Description...540
4.3.2 Serial Number Decal...540
4.4 Cab Components...540
4.4.1 Steering Wheel...540
4.4.2 Steering Column/Valve Replacement...541
4.4.3 Brake Pedal and Valve...541
4.4.4 Throttle Pedal Replacement...542
4.4.5 Throttle Cable Adjustment...543
4.4.6 High Idle Adjustment...543
4.4.7 Joystick Replacement...544
4.4.8 Windshield Wiper Assembly (If Equipped)...544
4.4.9 Windshield Washer Assembly (If Equipped)...544
4.4.10 Heater/Defroster System (If Equipped)...544
4.5 Cab Removal...545
4.6 Cab Installation...546
Section 5 Axles, Drive Shafts, Wheels and Tires...548
5.1 Axle, Drive Shaft and Wheel Component Terminology...549
5.2 Safety Information...550
5.3 General Information...550
5.4 Axle Assemblies...550
5.4.1 Axle Serial Number Plate...550
5.4.2 Axle Specifications...550
5.4.3 Axle Internal Service...550
5.4.4 Axle Maintenance...550
5.4.5 Axle Removal...551
5.4.6 Axle Installation...552
5.4.7 Axle Assembly and Drive Shaft Troubleshooting...553
5.5 Drive Shafts...556
5.5.1 Drive Shaft Inspection...556
5.5.2 Drive Shaft Maintenance...556
5.5.3 Drive Shaft Removal...556
5.5.4 Drive Shaft Cleaning and Drying...556
5.5.5 Drive Shaft Installation...556
5.6 Wheels and Tires...557
5.6.1 Removing Wheel and Tire Assembly from Machine...557
5.6.2 Installing Wheel and Tire Assembly onto Machine...558
5.7 Steering Angle Adjustment...558
5.8 Brakes...558
5.8.1 Brake Disc Inspection...558
5.9 Towing a Disabled Machine...559
5.9.1 Equipment and Supplies Required...559
5.9.2 Towing Procedure...559
Section 6 Transmission...562
6.1 Transmission Assembly Component Terminology...563
6.2 Safety Information...564
6.3 Transmission Description...564
6.4 Transmission Specifications...564
6.4.1 Transmission Maintenance...564
6.5 Transmission Replacement...564
6.5.1 Transmission Removal...564
6.5.2 Transmission Disassembly...565
6.5.3 Transmission Installation...565
6.5.4 After Transmission Replacement...565
6.6 Transmission Filter Replacement...566
6.6.1 Filter Removal...566
6.6.2 Filter Installation...566
Section 7 Engine...568
7.1 Introduction...569
7.1.1 Disclaimer and Scope...569
7.1.2 Component Terminology...569
7.2 Safety Information...571
7.3 Engine Serial Number...571
7.4 Specifications and Maintenance Information...571
7.5 Engine Cooling System...571
7.5.1 Radiator Pressure Cap...571
7.5.2 Radiator/Oil Cooler and Coolant Heater Replacement...571
7.6 Engine Electrical System...572
7.7 Fuel System...572
7.7.1 Diesel Fuel...572
7.7.2 Fuel/Hydraulic Oil Tank...573
7.7.3 After Fuel System Service...573
7.8 Engine Exhaust System...574
7.8.1 Exhaust System Removal...574
7.8.2 Exhaust System Installation...574
7.9 Air Cleaner Assembly...575
7.9.1 Air Cleaner Assembly Removal...575
7.9.2 Air Cleaner Assembly Installation...575
7.10 Engine Replacement...575
7.10.1 Engine Removal...575
7.10.2 Engine Disassembly, Inspection and Service...576
7.10.3 Engine Installation...576
7.11 Engine Coupler...578
7.11.1 Coupler Removal...578
7.11.2 Coupler Installation...578
7.12 Troubleshooting...578
Section 8 Hydraulic System...580
8.1 Hydraulic Component Terminology...582
8.2 Safety Information...583
8.3 General Information...583
8.4 Specifications...583
8.5 Hoses, Tube Lines, Fittings, Etc...583
8.5.1 Replacement Considerations...583
8.5.2 Hose, Tube, Line and Fitting Replacement...583
8.6 Hydraulic Pressure Diagnosis...584
8.6.1 Pressure Checks and Adjustments...584
8.6.2 Main Control Valve Pressure Checking...584
8.6.3 Charge Pressure Checking...585
8.6.4 Boom Function Pressure Checking...585
8.6.5 Steering Pressure Checking...585
8.7 Hydraulic Schematic...586
8.7.1 Before S/N TBS00627...586
8.7.2 S/N TBS00627 & After...588
8.7.3 Options...590
8.8 Hydraulic Reservoir...592
8.8.1 Pressurized Hydraulic Oil Fill Cap...592
8.8.2 Hydraulic Oil Reservoir Draining...592
8.8.3 Hydraulic Oil Reservoir Filling...592
8.9 Hydraulic System Pump...592
8.9.1 Implement Pump Replacement...592
8.10 Front Drive Motor...593
8.11 Control Valves...594
8.11.1 Main Control Valve...594
8.11.2 Service Brake Valve...595
8.11.3 Parking Brake Valve (ANSI)...597
8.11.4 Hand Brake Valve (CE & AUS)...598
8.11.5 Steering Orbitrol Valve...599
8.11.6 Pilot Select Valve...599
8.11.7 Inching Valve...600
8.11.8 Priority Valve...602
8.11.9 Steer Select Valve...603
8.11.10 Joystick Enable Valve...604
8.11.11 Decompression Valve...605
8.11.12 Quick Attach Valve...606
8.11.13 Load Stability Indicator Valve (CE & AUS)...607
8.12 Hydraulic Cylinders...608
8.12.1 General Cylinder Removal Instructions...608
8.12.2 General Cylinder Disassembly...608
8.12.3 Cylinder Cleaning Instructions...609
8.12.4 Cylinder Inspection...610
8.12.5 General Cylinder Assembly...610
8.12.6 General Cylinder Installation...611
8.12.7 Steering Cylinders...611
8.12.8 Hydraulic Cylinder Torque Specifications...612
Section 9 Electrical System...614
9.1 Electrical Component Terminology...616
9.2 Safety Information...617
9.3 Fuses and Relays...617
9.3.1 Engine Compartment Relays and Fuses...617
9.3.2 Cab Compartment Fuses and Relays...617
9.3.3 Power Distribution Module...618
9.3.4 Cab Fuses / Relays...619
9.4 Electrical System Schematics...620
9.4.1 Before S/N TBS00627...620
9.4.2 S/N TBS00627 & After...625
9.5 Circuit Breakdowns...631
9.5.1 Charge Circuit Breakdown...631
9.5.2 Start Circuit Breakdown...632
9.5.3 Constant Power Circuit Breakdown...633
9.5.4 Drive Circuit Breakdown...634
9.6 Engine Start Circuit...635
9.6.1 Starter...635
9.7 Charging Circuit...636
9.7.1 Alternator...636
9.8 Electrical System Components...637
9.8.1 Back-up Alarm...637
9.8.2 Instrument Cluster...637
9.8.3 Speedometer...638
9.9 Window Wiper/Washer...639
9.9.1 Windshield Wiper Motor...639
9.9.2 Rear Window or Roof Wiper Motor (if equipped)...640
9.9.3 Windshield Washer Reservoir and Pump...640
9.10 Cab Heater and Fan...641
9.10.1 Cab Heater Controls...641
9.11 Switches, Solenoids and Senders...642
9.11.1 Ignition Key Switch...642
9.11.2 Dash Switches...642
9.11.3 Fuel Level Indicator and Fuel Level Sender...643
9.11.4 Hourmeter...643
9.11.5 Coolant Temperature Sender...643
9.11.6 Fuel Shut-off Solenoid...644
9.11.7 Oil Pressure Sender...645
9.12 Load Stability System (CE & AUS) Before S/N TBS00627...646
9.12.1 Load Stability Indicator...646
9.12.2 Load Stability Indicator...646
9.12.3 Load Stability Sensor...647
9.13 Load Stability System (CE & AUS) S/N TBS00627 & After...648
9.13.1 LSI Axle Sensor...649
9.13.2 LSI Boom Sensors...649
9.13.3 LSI Modules...650
9.13.4 LSI System Calibration...651
9.13.5 LSI-CAN Check PT...653
9.13.6 500 Hour - LSI UGM Calibration Check...653
9.14 Hand Held Analyzer (CE & AUS) S/N TBS00627 & After...654
9.14.1 Analyzer Usage...654
9.14.2 Analyzer Software - Version 1.2...655
9.14.3 Diagnostic Trouble Codes (DTC) on Ground Module...656
31200451 - Service Manual Axle (Models TH255, TH255C)...664
31200451_B_TH255,TH255C Axle_CAT_Service...664
Effectivity...666
TOC...668
Section 1 Safety Practices...674
1.1 Introduction...674
1.2 Disclaimer...674
1.3 Operation & Maintenance Manual...674
1.4 Do Not Operate Tags...674
1.5 Safety Information...674
1.6 Safety Alert System and Signal Words...675
1.7 Safety Instructions...675
1.8 Safety Decals...677
Section 2 General Information and Specifications...678
2.1 Introduction...678
2.2 Specifications...679
2.3 Conversion Tables...680
2.4 Torque Specifications...681
2.5 Maintenance...683
2.6 Safety Precautions...686
Section 3 Planetary Reduction 1:6 and Steering Case...688
3.1 Exploded View...688
3.2 Planetary Reduction - 1.6 and Steering Case - Disassembly...689
3.3 Planetary Reduction - 1.6 and Steering Case - Assembly...695
Section 4 Steering Cylinder...704
4.1 Exploded View...704
4.2 Steering Cylinder - Disassembly...705
4.3 Steering Cylinder - Assembly...708
Section 5 Brake: Service Brake, Negative Brake, 45% Locked & 100% Locked...716
5.1 Exploded View...716
5.2 Brake Working Conditions...717
5.3 Emergency Release Instructions...721
5.4 Reset of Fails Safe Brake Function...721
5.5 Brake: Service Brake, Negative Brake, 45% Locked & 100% Locked- Disassembly...722
5.6 Brake: Service Brake, Negative Brake, 45% Locked & 100% Locked - Assembly...728
5.7 Brake Piston Gap Check...737
Section 6 Brake: Negative Brake 4 Cup Springs Version...738
6.1 Exploded View...738
6.2 Brake: Negative Brake 4 Cup Springs Version - Disassembly...739
6.3 Brake: Negative Brake 4 Cup Springs Version - Assembly...740
Section 7 Normal Preloaded Differential Unit (Old Version)...742
7.1 Exploded View...742
7.2 Normal Preloaded Differential Unit (Old Version) - Disassembly...743
7.3 Normal Preloaded Differential Unit (Old Version) - Assembly...747
Section 8 Normal Preloaded Differential Unit (Intermediate Version)...752
8.1 Exploded View...752
8.2 Normal Preloaded Differential Unit (Intermediate Version) - Disassembly...753
8.3 Normal Preloaded Differential Unit (Intermediate Version) - Assembly...757
Section 9 Normal Preloaded Differential Unit (Last Version)...760
9.1 Exploded View...760
9.2 Normal Preloaded Differential Unit (Last Version) - Disassembly...761
9.3 Normal Preloaded Differential Unit (Last Version) - Assembly...764
Section 10 Flanged Reduction Gear 603 Type: Integral 603 Input Gear...768
10.1 Exploded View...768
10.2 Flanged Reduction Gear 603 Type: Integral 603 Input Gear - Disassembly...769
10.3 Flanged Reduction Gear 603 Type: Integral 603 Input Gear - Assembly...772
Section 11 Bevel Pinion: Normal Flange and Nut Revolution Counter Version...776
11.1 Exploded View...776
11.2 Bevel Pinion: Normal Flange and Nut Revolution Counter Version- Disassembly...777
11.3 Bevel Pinion: Normal Flange and Nut Revolution Counter Version - Assembly...780
Section 12 Ring and Pinion Adjusting: Step for Preloaded Differential...788
12.1 Exploded View...788
12.2 Ring and Pinion Adjusting: Step for Preloaded Differential - Install and Adjust...789
Section 13 Swinging Support...792
13.1 Exploded View...792
13.2 Swinging Support - Disassembly...793
13.3 Swinging Support - Assembly...795
Section 14 Planetary Reduction: 1:4, 23...798
14.1 Exploded View...798
14.2 Planetary Reduction: 1:4, 23 - Disassembly...799
14.3 Planetary Reduction: 1:4, 23 - Assembly...800
Section 15 Brake: Incoming Disc Brake...802
15.1 Exploded View...802
15.2 Brake: Incoming Disc Brake - Disassembly...803
15.3 Brake: Incoming Disc Brake - Assembly...805
15.4 Checking Wear and Replacing the Braking Pads...807
Section 16 Brake: Service and Mechanical Parking Brake...808
16.1 Exploded View...808
16.2 Brake: Incoming Disc Brake - Disassembly...809
16.3 Brake: Incoming Disc Brake - Assembly...815
Section 17 Brake: Parking Brake and Differential Hydraulic 100%...822
17.1 Exploded View...822
17.2 Brake: Incoming Disc Brake- Disassembly...823
17.3 Brake: Incoming Disc Brake- Assembly...826
Section 18 Differential With Block to Spheres 100% (Old Version)...828
18.1 Exploded View...828
18.2 Differential With Block to Spheres 100% (Old Version) - Disassembly...829
18.3 Differential With Block to Spheres 100% (Old Version) - Assembly...834
Section 19 Differential With Block to Spheres 100% (Last Version)...838
19.1 Exploded View...838
19.2 Differential With Block to Spheres 100% (Last Version)- Disassembly...839
19.3 Differential With Block to Spheres 100% (Last Version)- Assembly...842
Section 20 Normal Differential (Old Version)...846
20.1 Exploded View...846
20.2 Normal Differential (Old Version) - Disassembly...847
20.3 Normal Differential (Old Version) - Assembly...850
Section 21 Normal Differential (Last Version)...854
21.1 Exploded View...854
21.2 Normal Differential (Last Version) - Disassembly...855
21.3 Normal Differential (Last Version) - Assembly...859
Section 22 Limited Slip Differential Unit 45% (Old Version)...862
22.1 Exploded View...862
22.2 Limited Slip Differential Unit 45% (Old Version) - Disassembly...863
22.3 Limited Slip Differential Unit 45% (Old Version) - Assembly...866
Section 23 Limited Slip Differential Unit 45% (Last Version)...870
23.1 Exploded View...870
23.2 Limited Slip Differential Unit 45% (Last Version) - Disassembly...871
23.3 Limited Slip Differential Unit 45% (Last Version) - Assembly...873
Section 24 Preloaded Limited Slip Differential Unit 45% Unit (Old Version)...878
24.1 Exploded View...878
24.2 Preloaded Limited Slip Differential Unit 45% Unit (Old Version) - Disassembly...879
24.3 Preloaded Limited Slip Differential Unit 45% Unit (Old Version) - Disassembly...883
Section 25 Preloaded Limited Slip Differential Unit 45%(Intermediate Version)...888
25.1 Exploded View...888
25.2 Preloaded Limited Slip Differential Unit45% (Intermediate Version) - Disassembly...889
25.3 Preloaded Limited Slip Differential Unit 45%(Intermediate Version) - Assembly...894
Section 26 Preloaded Limited Slip Differential Unit 45%(Last Version)...898
26.1 Exploded View...898
26.2 Preloaded Limited Slip Differential Unit 45%(Last Version) - Disassembly...899
26.3 Preloaded Limited Slip Differential Unit 45%(Last Version) - Assembly...902
Section 27 Bevel Pinion: Flanged to Reduction Gear 603...906
27.1 Exploded View...906
27.2 Bevel Pinion: Flanged to Reduction Gear 603 - Disassembly...907
27.3 Bevel Pinion: Flanged to Reduction Gear 603 - Assembly...909
Section 28 Ring and Pinion Adjusting: Version Pinion Cover and Single Arm...914
28.1 Exploded View...914
28.2 Ring and Pinion Adjusting: Version Pinion Cover and Single Arm - Install and Adjust...915
Section 29 Ring and Pinion Adjusting: Version Pinion Integral and Double Arm...920
29.1 Exploded View...920
29.2 Ring and Pinion Adjusting: Version Pinion Integral and Double Arm - install and Adjust...921
Section 30 Special Tools...924
30.1 T1...924
30.2 T2...925
30.3 T3...926
30.4 T4...927
30.5 T5...928
30.6 T6...929
30.7 T7...930
30.8 T8...931
30.9 T9...932
30.10 T10...933
30.11 T11...934
30.12 T12...935
30.13 T13...936
30.14 T14...937
30.15 T16...938
30.16 T17...939
30.17 T18...940
31200459 - Manuel d'utilisation et de maintenance (Modèle TH255)...944
31200459_F_TH255_French_OMM...944
Journal de révision...946
À lire en premier...947
Table des matières...950
Section 1 - Pratiques de sécurité générales...954
1.1 Système de classification des dangers...954
Système de mise en garde et termes de sécurité...954
1.2 Précautions générales...954
1.3 Sécurité de l’utilisation...955
Risques de choc électrique...955
Risque de basculement...956
Risque de déplacement...959
Risque de chute de la charge...960
Levage de personnel...961
Risques de conduite sur des pentes...962
Points de pincement et risques d’écrasement...963
Risque de chute...965
Risques chimiques...966
Section 2 - Avant la mise en service et inspection...968
2.1 Vérification et inspection avant la mise en service...968
2.2 Autocollants de sécurité...971
ASME (ANSI, le cas échéant)...971
ISO (CE et AUS) (ANSI, le cas échéant)...973
2.3 Ronde d'inspection...975
2.4 Réchauffage et vérifications de fonctionnement...977
Vérification durant le réchauffage...977
Vérification de fonctionnement...977
2.5 Cabine de l’opérateur...978
2.6 Fenêtres...979
Fenêtre de porte de cabine (le cas échéant)...979
Fenêtre arrière...980
Section 3 - Commandes et indicateurs...982
3.1 Généralités...982
3.2 Commandes...983
Frein de stationnement...985
Procédure de stationnement...986
Allumage...987
Levier de commande de la transmission...988
Indicateur de stabilité de charge - LSI (CE et AUS)...989
Interrupteur de priorité manuelle sur le LSI (CE et AUS)...992
Tableau de commande...993
Ajusteur de colonne de direction (le cas échéant)...995
Manipulateur...996
Console de droite...999
Levier de commande d'accessoire (le cas échéant)...1001
3.3 Modes de direction...1002
Changement de mode de direction...1002
3.4 Siège de l’opérateur...1003
Réglages...1003
Ceinture de sécurité...1004
3.5 Indicateurs d'angle de flèche et d'extension...1005
Section 4 - Utilisation...1006
4.1 Moteur...1006
Démarrage du moteur...1006
Démarrage à l’aide d’une batterie de renfort...1008
Fonctionnement normal du moteur...1009
Procédure d'arrêt...1009
4.2 Utilisation avec une charge non suspendue...1010
Sécurité du levage de la charge...1010
Avant de lever une charge...1010
Transport d’une charge...1011
Procédure de mise à niveau...1011
Mise en place d’une charge...1012
Désengagement d’une charge...1012
4.3 Utilisation avec une charge suspendue (ANSI et CE)...1013
Sécurité du levage de la charge...1013
Levage d’une charge suspendue...1013
Transport d’une charge suspendue...1014
Procédure de mise à niveau...1014
Mise en place d’une charge suspendue...1015
Désengagement d’une charge suspendue...1015
4.4 Utilisation sur route (CE)...1016
4.5 Chargement et fixation pour le transport...1017
Arrimage...1017
Levage...1018
Section 5 - Accessoires et attelages...1020
5.1 Accessoires approuvés...1020
5.2 Accessoires non approuvés...1020
5.3 Accessoires fournis par JLG...1021
5.4 Capacité des appareils de manutention télescopiques/accessoires/fourches...1023
5.5 Utilisation du tableau de capacités de charge...1025
Emplacements des témoins de charge...1025
Exemple de tableau de capacités de charge (ANSI et CE)...1026
Exemple de tableau de capacités de charge (AUS)...1027
Exemple...1028
5.6 Installation de l’accessoire...1029
Couplage rapide ordinaire...1029
Couplage rapide universel (Universal Quick Coupler, UQC)...1032
5.7 Accessoire hydraulique...1034
5.8 Réglage/déplacement des fourches...1035
5.9 Utilisation de l’accessoire...1036
Tablier porte-fourche avec fourches...1038
Crochet monté sur fourche (ANSI et CE)...1039
Tablier porte-fourche à rotation/inclinaison latérale...1041
Tablier porte-fourche à déport latéral...1043
Benne...1045
Benne à grappin...1047
Bras de manutention de matériaux (ANSI et CE)...1049
5.10 Attelages...1050
Attelage à goupille...1050
Attelage à goupille réglable...1051
Attelage automatique réglable...1052
Section 6 - Procédures d'urgence...1054
6.1 Remorquage d’un produit en panne...1054
Déplacement sur de courtes distances...1054
Déplacement sur de plus longues distances...1054
6.2 Abaissement d’urgence de la flèche...1055
6.3 Sortie d'urgence d'une cabine fermée...1055
Section 7 - Lubrification et maintenance...1056
7.1 Introduction...1056
Vêtements et équipement de sécurité...1056
7.2 Instructions de maintenance générale...1057
7.3 Programme d'entretien et de maintenance...1058
Programme de maintenance des 10 heures, 50 premières heures et 50 heures...1058
Programme de maintenance des 250 premières heures, 250 heures et 500 heures...1059
Programme de maintenance des 1000 heures...1060
7.4 Programmes de lubrification...1061
Programme de lubrification des 250 heures...1061
7.5 Instructions de maintenance pour l'opérateur...1062
Circuit de carburant...1062
Huile moteur...1064
Huile hydraulique...1065
Pneus...1066
Circuit d'admission d'air...1069
Circuit de refroidissement du moteur...1071
Batterie...1072
Circuit de freinage...1073
Système de lave-glace (le cas échéant)...1074
Section 8 - Vérifications supplémentaires...1076
8.1 Généralités...1076
8.2 Système d'indicateur de stabilité de charge (CE et AUS)...1076
Section 9 - Caractéristiques...1078
9.1 Caractéristiques du produit...1078
Liquides...1078
Contenances...1079
Pneus...1079
Performances...1080
Dimensions...1081
Déclaration sur les vibrations (CE)...1082
Niveau sonore (CE)...1082
Index...1084
Registre d’inspection, de maintenance et de réparation...1088
31200460 - Manual del operador y de mantenimiento (Modelo TH255)...1094
31200460_F_TH255_Spanish_OMM...1094
Registro de revisiones...1096
Leer esto primero...1097
Contenido...1100
Sección 1 - Prácticas de seguridad generales...1104
1.1 Sistema de clasificación de peligros...1104
Sistema de avisos de seguridad y mensajes de seguridad...1104
1.2 Precauciones generales...1104
1.3 Seguridad durante el funcionamiento...1105
Peligros eléctricos...1105
Riesgo de vuelcos...1106
Riesgos durante la conducción...1109
Riesgo de caída de carga...1110
Elevación de personal...1111
Riesgos durante la conducción en pendientes...1112
Riesgos de aprisionamiento y aplastamiento...1113
Riesgo de caídas...1115
Riesgos con productos químicos...1116
Sección 2 - Revisión e inspección antes del uso...1118
2.1 Revisión e inspección antes del uso...1118
2.2 Etiquetas de seguridad...1121
ASME (ANSI, en su caso)...1121
ISO (CE y AUS) (ANSI, en su caso)...1123
2.3 Inspección visual...1125
2.4 Calentamiento y revisiones funcionales...1127
Revisión de calentamiento...1127
Revisión funcional...1127
2.5 Cabina del operador...1128
2.6 Ventanas...1129
Ventana de puerta de cabina (si la tiene)...1129
Ventana trasera...1130
Sección 3 - Controles e indicadores...1132
3.1 Generalidades...1132
3.2 Controles...1133
Freno de estacionamiento...1135
Procedimiento de estacionamiento...1136
Encendido...1137
Palanca de control de la transmisión...1138
Indicador de estabilidad de carga - LSI (CE y AUS)...1139
Interruptor de anulación del LSI (CE y AUS)...1142
Tablero de instrumentos...1143
Ajustador de columna de dirección (en su caso)...1144
Palanca de control...1145
Consola derecha...1147
Palanca de control de accesorios (en su caso)...1149
3.3 Modos de dirección...1150
Cambio de modo de dirección...1150
3.4 Asiento del operador...1151
Ajustes...1151
Cinturón de seguridad...1152
3.5 Indicadores de ángulo y extensión de pluma...1153
Sección 4 - Uso...1154
4.1 Motor...1154
Arranque del motor...1154
Arranque con batería de refuerzo...1155
Funcionamiento normal del motor...1156
Procedimiento de apagado...1156
4.2 Funcionamiento con una carga no suspendida...1157
Elevación de la carga de manera segura...1157
Antes de recoger una carga...1157
Transporte de una carga...1158
Procedimiento de nivelación...1158
Colocación de una carga...1159
Descarga de la carga...1159
4.3 Funcionamiento con una carga suspendida (ANSI y CE)...1160
Elevación de la carga de manera segura...1160
Recogida de una carga suspendida...1160
Transporte de una carga suspendida...1161
Procedimiento de nivelación...1161
Colocación de una carga suspendida...1162
Descarga de una carga suspendida...1162
4.4 Funcionamiento en carretera (CE)...1163
4.5 Para cargar y asegurar la máquina para el transporte...1164
Amarre...1164
Levante...1165
Sección 5 - Accesorios y enganches...1166
5.1 Accesorios aprobados...1166
5.2 Accesorios no aprobados...1166
5.3 Accesorios suministrados por JLG...1167
5.4 Capacidad del manipulador telescópico/ accesorio/horquilla...1169
5.5 Uso de la tabla de capacidades de carga...1170
Ubicaciones de indicadores de capacidad...1170
Muestra de tabla de capacidades de carga (ANSI y CE)...1171
Muestra de tabla de capacidades de carga (AUS)...1172
Ejemplo...1173
5.6 Instalación del accesorio...1174
Acoplador rápido estándar...1174
Acoplador de conexión rápida universal (UQC)...1177
5.7 Accesorio accionado hidráulicamente...1179
5.8 Ajuste/movimiento de las horquillas...1180
5.9 Funcionamiento del accesorio...1181
Carruaje con horquillas...1183
Gancho montado en horquilla (ANSI y CE)...1184
Carruaje con rotación/inclinación lateral...1185
Carruaje con desplazamiento lateral...1187
Cucharón...1189
Cucharón con tenazas...1191
Brazo manipulador de materiales (ANSI y CE)...1193
5.10 Enganches...1194
Enganche con pasador...1194
Enganche con pasador ajustable...1195
Enganche automático ajustable...1196
Sección 6 - Procedimientos de emergencia...1198
6.1 Remolcado de un producto inhabilitado...1198
Transporte a distancias cortas...1198
Transporte a distancias más largas...1198
6.2 Bajada de emergencia de la pluma...1199
6.3 Salida de emergencia de la cabina cerrada...1199
Sección 7 - Lubricación y mantenimiento...1200
7.1 Introducción...1200
Ropa y equipo de seguridad...1200
7.2 Instrucciones de mantenimiento general...1201
7.3 Programa de servicio y mantenimiento...1202
Programa de mantenimiento de 10, primeras 50 y 50 horas...1202
Programa de mantenimiento de primeras 250, 250 y 500 horas...1203
Programa de mantenimiento de 1000 horas...1204
7.4 Programas de lubricación...1205
Programa de lubricación de 250 horas...1205
7.5 Instrucciones de mantenimiento por parte del operador...1207
Sistema de combustible...1207
Aceite del motor...1209
Aceite hidráulico...1210
Neumáticos...1211
Sistema de admisión de aire...1213
Sistema de enfriamiento del motor...1215
Batería...1216
Sistema de frenos...1217
Sistema de lavaparabrisas (en su caso)...1218
Sección 8 - Revisiones adicionales...1220
8.1 Generalidades...1220
8.2 Indicador de estabilidad de carga (CE y AUS)...1220
Sección 9 - Especificaciones...1222
9.1 Especificaciones del producto...1222
Fluidos...1222
Capacidades...1223
Neumáticos...1223
Rendimiento...1224
Dimensiones...1225
Declaración de niveles de vibración (CE)...1226
Nivel de emisión de ruido (CE)...1226
Índice...1228
Registro de inspecciones, mantenimiento y reparaciones...1232
31200721 - Parts Manual (Model TH255C)...1238
31200721_H_TH255C_CAT_Parts...1238
Effectivity Page...1240
Table of Contents...1242
SMCS CODES - TELEHANDLER...1246
Section 1 Frame & Attaching Parts...1252
Figure 1-1 Frame & Attaching Parts...1253
Figure 1-2 Covers...1259
Figure 1-3 License Plate Holder Installation...1267
Figure 1-4 Hitches...1269
Figure 1-5 Hitch Assembly...1273
Section 2 Boom...1278
Figure 2-1 Boom Assembly - Components...1279
Figure 2-2 Boom Assembly - Pads & Shims...1283
Figure 2-3 Quick Coupler...1285
Figure 2-4 Manual Quick Coupler Installation...1287
Figure 2-5 Hydraulic Quick Coupler Installation...1289
Section 3 Attachments...1292
Figure 3-1 Standard Carriage...1293
Figure 3-2 Universal Standard Carriage...1295
Figure 3-3 Side Tilt Carriage...1297
Figure 3-4 Universal Side Tilt Carriage...1299
Figure 3-5 Universal Side Shift Carriage...1301
Figure 3-6 Forks...1303
Figure 3-7 Grapple Bucket...1305
Figure 3-8 Light Material Buckets...1311
Figure 3-9 Fork Mounted Hook...1313
Figure 3-10 Universal Hitch Attachment...1315
Figure 3-11 Universal Quick Attach Lifting Hook...1317
Figure 3-12 Multi-Purpose Bucket...1319
Figure 3-13 Fork Muck Attachment (w/GRAB)...1321
Figure 3-14 Reflective Plates Installation (Forks)...1323
Figure 3-15 Reflective Plates Installation (Bucket) (Italy)...1325
Section 4 Engine & Attaching Parts...1328
Figure 4-1 Engine Installation...1329
Figure 4-2 Fuel Tank & Lines...1333
Figure 4-3 Fuel Tank and Components Installation...1335
Figure 4-4 Radiator Installation...1339
Figure 4-5 Air Cleaner Installation...1343
Figure 4-6 Exhaust Installation...1345
Figure 4-7 Engine Heater Installation...1349
Figure 4-8 Lubricity Doser Installation...1351
Figure 4-9 Precleaner Filter...1353
Section 5 Drive Train...1356
Figure 5-1 Drivetrain Installation...1357
Figure 5-2 Front Axle Assembly...1359
Figure 5-3 Central Housing & Steering...1361
Figure 5-4 Differential...1363
Figure 5-5 Hub Reduction...1367
Figure 5-6 Brakes...1369
Figure 5-7 Rear Axle Assembly...1371
Figure 5-8 Central Housing & Steering...1373
Figure 5-9 Differential...1375
Figure 5-10 Hub Reduction...1377
Figure 5-11 Fender Installation...1379
Figure 5-12 Tires & Rims...1381
Section 6 Cab...1384
Figure 6-1 Cab Installation...1385
Figure 6-2 Open Cab...1391
Figure 6-3 Enclosed Cab Installation...1393
Figure 6-4 Rear Window Installation...1397
Figure 6-5 Cab Interior...1399
Figure 6-6 Overhead Console Installation...1403
Figure 6-7 Suspension Seat...1405
Figure 6-8 Wiper Installation...1407
Figure 6-9 Heater & A/C - Cab...1409
Figure 6-10 AC Condenser Installation...1417
Figure 6-11 AC System Installation...1419
Figure 6-12 Heater Assembly...1421
Figure 6-13 Heater Assembly with AC...1423
Section 7 Controls...1426
Figure 7-1 Brake...1427
Figure 7-2 Accelerator...1431
Figure 7-3 Steering Column...1433
Figure 7-4 Boom Joystick...1435
Section 8 Hydraulic Circuits...1438
Figure 8-1 Supply Circuit...1439
Figure 8-2 Dump Circuit...1443
Figure 8-3 Steer Select...1447
Figure 8-4 Service/Park Brake...1449
Figure 8-5 Boom Joystick...1451
Figure 8-6 Lift Cylinder...1455
Figure 8-7 Extend/Retract Cylinder...1459
Figure 8-8 Tilt & Compensating...1461
Figure 8-9 Auxiliary Hydraulics...1463
Figure 8-10 Rear Auxiliary Hydraulics...1465
Figure 8-11 Auxiliary Hydraulics Pressure Relief...1467
Figure 8-12 Hydraulic Tank Breather Installation...1469
Section 9 Hydraulic Components...1472
Figure 9-1 Lift Cylinder...1473
Figure 9-2 Extend/Retract Cylinder...1479
Figure 9-3 Tilt Cylinder...1483
Figure 9-4 Compensating Cylinder...1487
Figure 9-5 Fork Locking Cylinder...1491
Figure 9-6 Side Tilt Carriage Cylinder & Grapple Bucket Cylinder...1493
Figure 9-7 Universal Side Shift Cylinder...1495
Figure 9-8 Main Control Valve...1497
Figure 9-9 Front Drive Motor...1499
Figure 9-10 Hydrostatic Drive Pump...1501
Figure 9-11 Gear Pump...1503
Figure 9-12 Divertor Valve...1505
Figure 9-13 Steering Select Valve...1507
Figure 9-14 Pilot Select Valve...1509
Figure 9-15 Brake Valves...1511
Section 10 Electrical...1514
Figure 10-1 Engine Compartment Electrical Installation...1515
Figure 10-2 Boom and Frame Electrical Installation...1517
Figure 10-3 Cab Electrical Installation...1523
Figure 10-4 Cab Switches...1525
Figure 10-5 Work Lights...1527
Figure 10-6 Drive Lights...1531
Figure 10-7 Engine Harness...1535
Figure 10-8 Frame Harness...1541
Figure 10-9 Frame Option Harness...1547
Figure 10-10 Cab Harness...1553
Figure 10-11 Cab Roof Harness...1565
Figure 10-12 Roof Worklight Harness...1567
Figure 10-13 Boom Worklight Harness...1569
Figure 10-14 Beacon Worklight Harness...1571
Figure 10-15 Boom Aux Harness...1573
Figure 10-16 LSI Boom Sensor Harness...1575
Figure 10-17 Mode Select Harness...1577
Figure 10-18 Heater Jumper Harness...1579
Figure 10-19 Valve Jumper Harness...1581
Figure 10-20 AC Condenser Harness...1583
Section 11 Decals...1586
Figure 11-1 Cab & Frame Decals...1587
Figure 11-2 Boom Decals...1593
Maintenance parts list...1596
Part Number Index...1598
31200746 (SEBU9291) - Operation & Maintenance Manual (Model TH255C)...1610
31200746_C_TH255C_CAT_OMM...1610
Revision Log...1612
Read This First...1613
Table of Contents...1616
Section 1 - General Safety Practices...1616
Section 2 - Pre-Operation and Inspection...1616
Section 3 - Controls and Indicators...1617
Section 4 - Operation...1617
Section 5 - Attachments and Hitches...1618
Section 6 - Emergency Procedures...1619
Section 7 - Lubrication and Maintenance...1619
Section 8 - Additional Checks...1619
Section 9 - Specifications...1620
Section 1 - General Safety Practices...1622
1.1 Hazard Classification System...1622
Safety Alert System and Safety Signal Words...1622
1.2 General Precautions...1622
1.3 Operation Safety...1623
Electrical Hazards...1623
Tip Over Hazard...1625
Travel Hazard...1628
Load Falling Hazard...1629
Lifting Personnel...1630
Driving Hazards on Slopes...1631
Pinch Points and Crush Hazards...1632
Fall Hazard...1634
Chemical Hazards...1635
1.4 Product Link (if equipped)...1636
Federal Communications Commission (FCC) Information for Users...1636
Section 2 - Pre-Operation and Inspection...1638
2.1 Preparation, Inspection and Maintenance...1638
2.2 Pre-Operation Check and Inspection...1639
2.3 Safety Decals...1641
ANSI (if equipped)...1641
ISO (CE & AUS) (ANSI, if equipped)...1644
2.4 Walk-Around Inspection...1647
2.5 Warm-Up and Operational Checks...1649
Warm-Up Check...1649
Operational Check...1649
2.6 Operator Cab...1650
2.7 Windows...1651
Cab Door Window (if equipped)...1651
Rear Window...1652
Section 3 - Controls and Indicators...1654
3.1 General...1654
3.2 Controls...1655
Park Brake...1657
Parking Procedure...1658
Ignition...1659
Transmission Control Lever...1660
Load Stability Indicator - LSI (CE & AUS)...1661
LSI Override Switch (CE & AUS)...1663
Steering Column Adjuster (if equipped)...1664
Instrument Panel...1665
Joystick...1667
Right Hand Console...1669
Accessory Control Lever (if equipped)...1671
Reversing Fan (if equipped)...1672
3.3 Steer Modes...1673
Steer Mode Change...1673
3.4 Operator Seat...1674
Operator Presence (CE & AUS)...1674
Adjustments...1675
Seat Belt...1676
3.5 Boom Angle and Extension Indicators...1677
3.6 Reverse Sensing System...1678
Section 4 - Operation...1680
4.1 Engine...1680
Starting the Engine...1680
Cold Weather Starting...1681
Battery Boosted Starting...1682
Normal Engine Operation...1683
Shut-Down Procedure...1683
4.2 Operating with a Non-Suspended Load...1684
Lift Load Safely...1684
Before Picking Up a Load...1684
Transporting a Load...1685
Leveling Procedure...1685
Placing a Load...1686
Disengaging a Load...1686
4.3 Operating with a Suspended Load (ANSI & CE)...1687
Lift Load Safely...1687
Picking Up a Suspended Load...1687
Transporting a Suspended Load...1688
Leveling Procedure...1688
Placing a Suspended Load...1689
Disengaging a Suspended Load...1689
4.4 Road Operation (CE)...1690
4.5 Loading and Securing for Transport...1691
Tiedown...1691
Lifting...1692
Section 5 - Attachments and Hitches...1694
5.1 Approved Attachments...1694
5.2 Unapproved Attachments...1694
5.3 JLG Supplied Attachments...1695
5.4 Telehandler/Attachment/Fork Capacity...1697
5.5 Use of the Load Chart...1698
Capacity Indicator Locations...1698
Sample Load Chart (ANSI & CE)...1699
Sample Load Chart (AUS)...1700
Example...1701
5.6 Attachment Installation...1702
Standard Quick Coupler...1702
Universal Quick Coupler (UQC)...1705
5.7 Hydraulic Operated Attachment...1708
5.8 Adjusting/Moving Forks...1709
5.9 Attachment Operation...1710
Carriage with Forks...1711
Fork Mounted Hook (ANSI & CE)...1712
Rotate/Side Tilt Carriage...1713
Side Shift Carriage...1715
Bucket...1717
Multipurpose Bucket...1719
Grapple Bucket and Muck Fork Grapple...1721
Material Handling Arm (ANSI & CE)...1723
Coupler Mounted Hook...1724
5.10 Hitches...1725
Retrieval Hitch...1725
Adjustable Auto Hitch...1726
Pin Hitch - CUNA C...1727
EEC Manual Pin Hitch...1728
Section 6 - Emergency Procedures...1730
6.1 Towing a Disabled Product...1730
Moving Short Distances...1730
Moving Longer Distances...1730
6.2 Emergency Lowering of Boom...1731
6.3 Emergency Exit from Enclosed Cab...1732
Inside Cab...1732
Outside Cab (if equipped)...1732
Section 7 - Lubrication and Maintenance...1734
7.1 Introduction...1734
Clothing and Safety Gear...1734
7.2 General Maintenance Instructions...1735
7.3 Service and Maintenance Schedule...1736
10 & 1st 50 & 50 Hour Maintenance Schedule...1736
1st 250, 250 & 500 Hour Maintenance Schedule...1737
1000 & 1500 Hour Maintenance Schedule...1738
7.4 Lubrication Schedules...1739
250 Hour Lubrication Schedule...1739
7.5 Operator Maintenance Instructions...1741
Fuel System...1741
Engine Oil...1743
Hydraulic Oil...1744
Tires...1745
Air Intake System...1747
Engine Cooling System...1749
Battery...1750
Brake System...1751
Windshield Washer System (if equipped)...1752
Section 8 - Additional Checks...1754
8.1 General...1754
8.2 Load Stability Indicator System (CE & AUS)...1754
8.3 Reverse Sensing System (if equipped)...1755
Section 9 - Specifications...1756
9.1 Product Specifications...1756
Fluids...1756
Capacities...1760
Tires...1761
Performance...1762
Dimensions...1763
Declaration of Vibration (CE)...1764
Noise Emission Level (CE)...1764
Machine Towing Capacity...1764
Index...1766
31200872 (SFBU9291) - Manuel d’utilisation et de maintenance (Modèle TH255C)...1776
31200872_B_TH255C_French_OMM...1776
Journal de révision...1778
À lire en premier...1779
Table des matières...1782
Section 1 - Pratiques de sécurité générales...1788
1.1 Système de classification des dangers...1788
Système de mise en garde et termes de sécurité...1788
1.2 Précautions générales...1788
1.3 Sécurité de l’utilisation...1789
Risques de choc électrique...1789
Risque de basculement...1791
Risque de déplacement...1794
Risque de chute de la charge...1795
Levage de personnel...1796
Risques de conduite en pente...1797
Points de pincement et risques d’écrasement...1798
Risque de chute...1800
Risques chimiques...1801
1.4 Product Link (le cas échéant)...1802
Informations de la Federal Communications Commission (FCC) pour les utilisateurs...1802
Section 2 - Avant la mise en service et inspection...1804
2.1 Vérification et inspection avant la mise en service...1804
2.2 Autocollants de sécurité...1807
ANSI (le cas échéant)...1807
ISO (CE et AUS) (ANSI, le cas échéant)...1810
2.3 Ronde d’inspection...1813
2.4 Vérifications durant le réchauffage et de fonctionnement...1815
Vérification durant le réchauffage...1815
Vérification de fonctionnement...1815
2.5 Cabine de l’opérateur...1816
2.6 Fenêtres...1817
Fenêtre de porte de cabine (le cas échéant)...1817
Fenêtre arrière...1818
Section 3 - Commandes et indicateurs...1820
3.1 Généralités...1820
3.2 Commandes...1821
Frein de stationnement...1823
Procédure de stationnement...1824
Allumage...1825
Levier de commande de la transmission...1826
Indicateur de stabilité de charge (LSI) (CE ET AUS)...1827
Interrupteur de priorité manuelle sur le LSI (CE ET AUS)...1829
Ajusteur de colonne de direction (le cas échéant)...1830
Tableau de commande...1831
Manipulateur...1833
Console de droite...1835
Levier de commande d’accessoire (le cas échéant)...1837
Inversion du ventilateur (le cas échéant)...1838
3.3 Modes de direction...1839
Changement de mode de direction...1839
3.4 Siège de l’opérateur...1840
Présence d’opérateur (CE ET AUS)...1840
Réglages...1841
Ceinture de sécurité...1842
3.5 Indicateurs d’angle et d’extension de flèche...1843
3.6 Système de détection en arrière...1844
Section 4 - Utilisation...1846
4.1 Moteur...1846
Démarrage du moteur...1846
Démarrage par temps froid...1847
Démarrage à l’aide d’une batterie de renfort...1848
Fonctionnement normal du moteur...1849
Procédure d’arrêt...1849
4.2 Utilisation avec une charge non suspendue...1850
Sécurité du levage de la charge...1850
Avant de lever une charge...1850
Transport d’une charge...1851
Procédure de mise à niveau...1851
Mise en place d’une charge...1852
Désengagement d’une charge...1852
4.3 Utilisation avec une charge suspendue (ANSI ET CE)...1853
Sécurité du levage de la charge...1853
Levage d’une charge suspendue...1853
Transport d’une charge suspendue...1854
Procédure de mise à niveau...1854
Mise en place d’une charge suspendue...1855
Désengagement d’une charge suspendue...1855
4.4 Utilisation sur route (CE)...1856
4.5 Chargement et fixation pour le transport...1857
Arrimage...1857
Levage...1858
Section 5 - Accessoires et attelages...1860
5.1 Accessoires approuvés...1860
5.2 Accessoires non approuvés...1860
5.3 Accessoires fournis par JLG...1861
5.4 Capacité des appareils de manutention télescopiques/ accessoires/fourches...1863
5.5 Utilisation du tableau de capacités de charge...1864
Emplacements des témoins de charge...1864
Exemple de tableau de capacités de charge (ANSI ET CE)...1865
Exemple de tableau de capacités de charge (AUS)...1866
Exemple...1867
5.6 Installation de l’accessoire...1868
Couplage rapide ordinaire...1868
Couplage rapide universel (Universal Quick Coupler, UQC)...1871
5.7 Accessoire hydraulique...1873
5.8 Réglage/déplacement des fourches...1874
5.9 Utilisation de l’accessoire...1875
Tablier porte-fourche avec fourches...1877
Crochet monté sur fourche (ANSI ET CE)...1878
Tablier porte-fourche à rotation/inclinaison latérale...1879
Tablier porte-fourche à déport latéral...1881
Benne...1883
Benne universelle...1885
Benne à grappin et fourche à fumier à grappin...1887
Bras de manutention de matériaux (ANSI ET CE)...1889
Crochet monté sur couplage...1890
5.10 Attelages...1891
Attelage d’extraction...1891
Attelage automatique réglable...1892
Attelage à goupille - CUNA C...1893
Attelage à goupille manuel CE...1894
Section 6 - Procédures d’urgence...1896
6.1 Remorquage d’un produit en panne...1896
Déplacement sur de courtes distances...1896
Déplacement sur de plus longues distances...1896
6.2 Abaissement d’urgence de la flèche...1897
6.3 Sortie d’urgence d’une cabine fermée...1898
À l’intérieur de la cabine...1898
À l’extérieur de la cabine (le cas échéant)...1898
Section 7 - Lubrification et maintenance...1900
7.1 Introduction...1900
Vêtements et équipement de sécurité...1900
7.2 Instructions de maintenance générale...1901
7.3 Programme d’entretien et de maintenance...1902
Programme de maintenance des 10 heures, des 50 premières heures et des 50 heures...1902
Programme de maintenance des 250 premières heures, 250 heures et 500 heures...1903
Programme de maintenance des 1000 et des 1500 heures...1904
7.4 Programmes de lubrification...1905
Programme de lubrification des 250 heures...1905
7.5 Instructions de maintenance pour l’opérateur...1907
Circuit de carburant...1907
Huile moteur...1909
Huile hydraulique...1910
Pneus...1911
Circuit d’admission d’air...1913
Circuit de refroidissement du moteur...1915
Batterie...1916
Circuit de freinage...1917
Système de lave-glace (le cas échéant)...1918
Section 8 - Vérifications supplémentaires...1920
8.1 Généralités...1920
8.2 Système d’indicateur de stabilité de charge (CE et AUS)...1920
8.3 Système de détection en arrière (le cas échéant)...1921
Section 9 - Caractéristiques...1922
9.1 Caractéristiques du produit...1922
Liquides...1922
Contenances...1926
Pneus...1927
Performances...1928
Dimensions...1929
Déclaration sur les vibrations (CE)...1930
Niveau sonore (CE)...1930
Capacité de remorquage...1930
Index...1932
31200873 (SSBU9291) - Manual del operador y de mantenimiento (Modelo TH255C)...1942
31200873_B_TH255C_Spanish_OMM...1942
Registro de revisiones...1944
Leer esto primero...1945
Contenido...1948
Sección 1 – Prácticas de seguridad generales...1954
1.1 Sistema de clasificación de peligros...1954
Sistema de avisos de seguridad y mensajes de seguridad...1954
1.2 Precauciones generales...1954
1.3 Seguridad durante el funcionamiento...1955
Peligros eléctricos...1955
Riesgo de vuelcos...1957
Riesgos durante la conducción...1960
Riesgo de caída de carga...1961
Elevación de personal...1962
Riesgos durante la conducción en pendientes...1963
Riesgos de aprisionamiento y aplastamiento...1964
Riesgo de caídas...1966
Riesgos con productos químicos...1967
1.4 Product Link (en su caso)...1968
Información de la Comisión Federal de Comunicaciones (FCC) para usuarios...1968
Sección 2 – Revisión e inspección antes del uso...1970
2.1 Revisión e inspección antes del uso...1970
2.2 Etiquetas de seguridad...1973
ANSI (en su caso)...1973
ISO (CE y AUS) (ANSI, en su caso)...1976
2.3 Inspección visual...1979
2.4 Calentamiento y revisiones funcionales...1981
Revisión de calentamiento...1981
Revisión funcional...1981
2.5 Cabina del operador...1982
2.6 Ventanas...1983
Ventana de puerta de cabina (en su caso)...1983
Ventana trasera...1984
Sección 3 – Controles e indicadores...1986
3.1 Generalidades...1986
3.2 Controles...1987
Freno de estacionamiento...1989
Procedimiento de estacionamiento...1990
Encendido...1991
Palanca de control de la transmisión...1992
Indicador de estabilidad de carga (LSI) (CE Y AUS)...1993
Interruptor de anulación del LSI (CE Y AUS)...1995
Ajustador de columna de dirección (en su caso)...1996
Tablero de instrumentos...1997
Palanca de control...1999
Consola derecha...2001
Palanca de control de accesorios (en su caso)...2003
Ventilador reversible (en su caso)...2004
3.3 Modos de dirección...2005
Cambio de modo de dirección...2005
3.4 Asiento del operador...2006
Presencia del operador (CE Y AUS)...2006
Ajustes...2007
Cinturón de seguridad...2008
3.5 Indicadores de ángulo y extensión de pluma...2009
3.6 Sistema sensor de retroceso...2010
Sección 4 – Funcionamiento...2012
4.1 Motor...2012
Arranque del motor...2012
Arranque en tiempo frío...2013
Arranque con batería de refuerzo...2014
Funcionamiento normal del motor...2015
Procedimiento de apagado...2015
4.2 Funcionamiento con una carga no suspendida...2016
Elevación de la carga de manera segura...2016
Antes de recoger una carga...2016
Transporte de una carga...2017
Procedimiento de nivelación...2017
Colocación de una carga...2018
Descarga de la carga...2018
4.3 Funcionamiento con una carga suspendida (ANSI Y CE)...2019
Elevación de la carga de manera segura...2019
Recogida de una carga suspendida...2019
Transporte de una carga suspendida...2020
Procedimiento de nivelación...2020
Colocación de una carga suspendida...2021
Descarga de una carga suspendida...2021
4.4 Conducción en carretera (CE)...2022
4.5 Para cargar y asegurar la máquina para el transporte...2023
Amarre...2023
Levante...2024
Sección 5 – Accesorios y enganches...2026
5.1 Accesorios aprobados...2026
5.2 Accesorios no aprobados...2026
5.3 Accesorios suministrados por JLG...2027
5.4 Capacidad del manipulador telescópico/accesorio/ horquilla...2029
5.5 Uso de la tabla de capacidades de carga...2030
Ubicación de indicadores de capacidad...2030
Muestra de tabla de capacidades de carga (ANSI Y CE)...2031
Muestra de tabla de capacidades de carga (AUS)...2032
Ejemplo...2033
5.6 Instalación del accesorio...2034
Acoplador rápido estándar...2034
Acoplador rápido universal (UQC)...2037
5.7 Accesorio accionado hidráulicamente...2039
5.8 Ajuste/movimiento de las horquillas...2040
5.9 Funcionamiento del accesorio...2041
Carruaje con horquillas...2043
Gancho montado en horquilla (ANSI Y CE)...2044
Carruaje con rotación/inclinación lateral...2045
Carruaje con desplazamiento lateral...2047
Cucharón...2049
Cucharón universal...2051
Cucharón con tenazas y horquilla para abono con tenazas...2053
Brazo manipulador de materiales (ANSI Y CE)...2055
Gancho montado en acoplador...2056
5.10 Enganches...2057
Enganche de recuperación...2057
Enganche automático ajustable...2058
Enganche con pasador CUNA C...2059
Enganche de pasador manual EEC...2060
Sección 6 – Procedimientos de emergencia...2062
6.1 Remolcado de un producto inhabilitado...2062
Transporte a distancias cortas...2062
Transporte a distancias más largas...2062
6.2 Bajada de emergencia de la pluma...2063
6.3 Salida de emergencia de la cabina cerrada...2064
Interior de la cabina...2064
Exterior de la cabina (en su caso)...2064
Sección 7 – Lubricación y mantenimiento...2066
7.1 Introducción...2066
Ropa y equipo de seguridad...2066
7.2 Instrucciones de mantenimiento general...2067
7.3 Programa de servicio y mantenimiento...2068
Programa de mantenimiento de 10, primeras 50 y 50 horas...2068
Programa de mantenimiento de primeras 250, 250 y 500 horas...2069
Programa de mantenimiento de 1000 y 1500 horas...2070
7.4 Programas de lubricación...2071
Programa de lubricación de 250 horas...2071
7.5 Instrucciones de mantenimiento por parte del operador...2073
Sistema de combustible...2073
Aceite del motor...2075
Aceite hidráulico...2076
Neumáticos...2077
Sistema de admisión de aire...2079
Sistema de enfriamiento del motor...2081
Batería...2082
Sistema de frenos...2083
Sistema de lavaparabrisas (en su caso)...2084
Sección 8 – Revisiones adicionales...2086
8.1 Generalidades...2086
8.2 Indicador de estabilidad de carga (CE y AUS)...2086
8.3 Sistema sensor de retroceso (en su caso)...2087
Sección 9 – Especificaciones...2088
9.1 Especificaciones del producto...2088
Fluidos...2088
Capacidades...2092
Neumáticos...2093
Rendimiento...2094
Dimensiones...2095
Declaración de niveles de vibración (CE)...2096
Nivel de emisión de ruido (CE)...2096
Capacidad de remolcado de la máquina...2096
Índice...2098
31200927 - Service Manual (Model TH255C)...2108
31200927_E_TH255C_CAT_Service...2108
Effectivity Page...2110
Table of Contents...2112
Section 1 Safety Practices...2116
1.1 Introduction...2117
1.2 Disclaimer...2117
1.3 Operation & Maintenance Manual...2117
1.4 Do Not Operate Tags...2117
1.5 Safety Information...2117
1.5.1 Safety Alert System and Signal Words...2117
1.6 Safety Instructions...2118
1.6.1 Personal Hazards...2118
1.6.2 Equipment Hazards...2118
1.6.3 General Hazards...2118
1.6.4 Operational Hazards...2119
1.7 Safety Decals...2119
Section 2 General Information and Specifications...2120
2.1 Replacement Parts and Warranty Information...2122
2.2 Specifications...2123
2.2.1 Travel Speed...2123
2.2.2 Hydraulic Cylinder Performance Specifications...2123
2.2.3 Electrical System...2123
2.2.4 Steering Angle Specification...2123
2.2.5 Engine Performance Specifications...2124
2.2.6 Tires...2124
2.3 Fluids, Lubricants and Capacities...2125
2.3.1 Fluids...2125
a. Prior to SN JK201000...2125
b. SN JK300150 to Present...2127
2.3.2 Capacities...2129
2.4 Maintenance Schedule...2130
2.4.1 10,1st 50 & 50 Hour Maintenance Schedule...2130
2.4.2 1st 250, 250 & 500 Hour Maintenance Schedule...2131
2.4.3 1000 & 1500 Hour Maintenance Schedule...2132
2.5 Lubrication Schedule...2133
2.5.1 250 Hour Lubrication Schedule...2133
2.6 Thread Locking Compound...2134
2.7 Torque Charts...2135
2.7.1 SAE Fastener Torque Chart...2135
2.7.2 Metric Fastener Torque Chart...2141
2.8 Hydraulic Connection Assembly and Torque Specification...2145
2.8.1 Definitions...2145
a. Tapered Thread Types...2145
b. Straight Thread Types, Tube and Hose Connections...2145
c. Straight Thread Types, Port Connections...2146
d. Flange Connection Types...2146
e. Tightening Methods...2146
f. Assembly and Torque Specifications...2146
g. General Tube Type FITTING ASSEMBLY INSTRUCTIONS...2146
2.8.2 Assembly Instructions for American Standard Pipe Thread Tapered Connections...2147
a. NPTF Pipe Thread...2148
2.8.3 Assembly Instructions for British Standard Pipe Thread Tapered Connections...2149
a. BSPT Pipe Thread...2149
2.8.4 Assembly Instructions for 37° (JIC) Flare Fittings...2150
a. 37° Flare (JIC) Thread - Steel...2150
b. 37° Flare (JIC) Thread - Aluminum Brass...2151
2.8.5 Assembly Instructions for 45° SAE Flare Fittings...2153
a. 45° Flare (SAE)...2154
2.8.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings...2155
a. O-ring Face Seal (ORFS)...2156
2.8.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)...2157
a. DIN 24° CONE (MBTL & MBTS)...2158
2.8.8 Assembly Instructions for Bulkhead (BH) Fittings...2159
a. Bulkhead Fittings (BH) - INCH...2160
b. Bulkhead Fittings (BH) - METRIC...2161
2.8.9 Assembly Instructions for O-Ring Boss (ORB) Fittings...2163
a. O-ring Boss (ORB) - Table 1 of 6...2164
b. O-ring Boss (ORB) - Table 2 of 6...2165
c. O-ring Boss (ORB) - Table 3 of 6...2166
d. O-ring Boss (ORB) - Table 4 of 6...2167
e. O-ring Boss (ORB) - Table 5 of 6...2168
f. O-ring Boss (ORB) - Table 6 of 6...2169
2.8.10 Assembly Instructions for Adjustable Port End Metric Fittings...2171
a. Metric Flat Face Port (MFF) L Series - Table 1 of 3...2172
b. Metric Flat Face Port (MFF) L Series - Table 2 of 3...2173
c. Metric Flat Face Port (MFF) L Series - Table 3 of 3...2174
d. Metric Flat Face Port (MFF) S Series - Table 1 of 3...2175
e. Metric Flat Face Port (MFF) S Series - Table 2 of 3...2176
f. Metric Flat Face Port (MFF) S Series - Table 3 of 3...2177
2.8.11 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends...2179
a. Metric Pipe Parallel O-Ring Boss (MPP)...2180
2.8.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings...2181
a. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3...2182
b. British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3...2183
c. British Standard Parallel Pipe Port (BSPP) L Series - Table 3 of 3...2184
d. British Standard Parallel Pipe Port (BSPP) S Series - Table 1 of 3...2185
e. British Standard Parallel Pipe Port (BSPP) S Series - Table 2 of 3...2186
f. British Standard Parallel Pipe Port (BSPP) L Series - Table 3 of 3...2187
2.8.13 Assembly Instructions for Flange Connections (FL61 and FL62)...2189
a. Flange Code (FL61 & FL62) - Inch Fasteners...2190
b. Flange Code (FL61 & FL62) - Metric Fasteners...2191
2.8.14 Double Wrench Method...2192
2.8.15 FFWR and TFFT Methods...2193
2.8.16 Adjustable Stud End Assembly...2193
2.8.17 O-ring Installation (Replacement)...2193
Section 3 Boom...2194
3.1 Boom System Component Terminology...2195
3.2 Safety Information...2196
3.3 Two Section Boom System...2196
3.3.1 Boom System Description...2196
3.4 Boom Assembly Maintenance...2196
3.4.1 Complete Boom Removal...2196
3.4.2 Complete Boom Installation...2198
3.4.3 Second Boom Section Removal...2199
3.4.4 Second Boom Section Installation...2200
3.4.5 Tilt and Auxiliary Hose Replacement...2200
3.4.6 Tilt and Auxiliary Hose Installation...2201
3.4.7 Extend/Retract Cylinder Removal...2202
3.4.8 Extend/Retract Cylinder Installation...2203
3.5 Boom Wear Pads...2204
3.5.1 Wear Pad Inspection...2204
3.5.2 Wear Pad Installation and Lubrication...2204
3.5.3 Boom Wear Pad Lubrication...2205
3.6 Quick Coupler Assembly...2205
3.6.1 Quick Coupler Assembly Removal...2205
3.6.2 Quick Coupler Assembly Installation...2206
3.7 Forks...2206
3.8 Boom Prop (If Equipped)...2207
3.8.1 Prop Installation...2207
3.8.2 Prop Removal...2207
3.9 Emergency Boom Lowering Procedure...2208
3.9.1 Equipment and Supplies Required...2208
3.9.2 Lowering Procedure...2208
a. Retract the boom as follows:...2208
b. Lower the boom as follows:...2209
3.10 Troubleshooting...2210
Section 4 Cab...2214
4.1 Operator Cab Component Terminology...2215
4.2 Safety Information...2216
4.3 Operator Cab...2216
4.3.1 Operator Cab Description...2216
4.3.2 Serial Number Decal...2216
4.4 Cab Components...2216
4.4.1 Steering Wheel...2216
a. Steering Wheel Removal...2216
b. Steering Wheel Installation...2216
4.4.2 Steering Column/Valve Replacement...2217
a. Steering Column and Valve Removal...2217
b. Steering Column and Valve Installation...2217
c. Power Steering Test...2217
4.4.3 Brake Pedal and Valve...2218
a. Brake Valve Removal...2218
b. Brake Valve Installation...2218
c. Service Brake Pedal Removal...2218
d. Service Brake Pedal Installation...2218
4.4.4 Accelerator Pedal Replacement...2219
a. Accelerator Pedal Removal...2219
b. Accelerator Pedal Installation...2219
4.4.5 Joystick Replacement...2220
a. Joystick Removal...2220
b. Joystick Installation...2220
4.4.6 Windshield Wiper Assembly (if equipped)...2220
4.4.7 Windshield Washer Assembly (if equipped)...2220
4.4.8 Heater System (if equipped)...2220
a. Removal...2220
b. Installation...2221
4.4.9 Heater and A/C System (if equipped)...2222
a. Removal...2222
b. Installation...2223
4.4.10 Air Filter System (if equipped)...2224
4.5 Cab Removal...2225
4.6 Cab Installation...2226
Section 5 Axles, Drive Shafts, Wheels and Tires...2228
5.1 Axle, Drive Shaft and Wheel Component Terminology...2229
5.2 Safety Information...2230
5.3 General Information...2230
5.4 Axle Assemblies...2230
5.4.1 Axle Serial Number Plate...2230
5.4.2 Axle Specifications...2230
5.4.3 Axle Internal Service...2230
5.4.4 Axle Maintenance...2230
5.4.5 Axle Removal...2231
5.4.6 Axle Installation...2232
5.4.7 Axle Assembly and Drive Shaft Troubleshooting...2233
5.4.8 Steering System Purge Procedure...2236
5.5 Drive Shafts...2237
5.5.1 Drive Shaft Inspection...2237
5.5.2 Drive Shaft Maintenance...2237
5.5.3 Drive Shaft Removal...2237
5.5.4 Drive Shaft Cleaning and Drying...2237
5.5.5 Drive Shaft Installation...2237
5.6 Wheels and Tires...2238
5.6.1 Removing Wheel and Tire Assembly from Machine...2238
5.6.2 Installing Wheel and Tire Assembly onto Machine...2239
5.7 Steering Angle Adjustment...2239
5.8 Brakes...2239
5.8.1 Brake Disc Inspection...2239
5.9 Towing a Disabled Machine...2239
5.9.1 Equipment and Supplies Required...2240
5.9.2 Towing Procedure...2240
5.9.3 Steering System Purge Procedure...2241
Section 6 Transmission...2244
6.1 Transmission Assembly Component Terminology...2245
6.2 Safety Information...2246
6.3 Transmission Description...2246
6.4 Transmission Specifications...2246
6.4.1 Transmission Maintenance...2246
6.5 Transmission Replacement...2246
6.5.1 Transmission Removal...2246
6.5.2 Transmission Disassembly...2247
6.5.3 Transmission Installation...2247
Section 7 Engine...2248
7.1 Introduction...2249
7.1.1 Disclaimer and Scope...2249
7.1.2 Component Terminology...2250
7.2 Engine Serial Number...2251
7.3 Specifications and Maintenance Information...2251
7.4 Engine Cooling System...2251
7.4.1 Surge Tank Cap...2251
7.4.2 Radiator/Oil Cooler Replacement...2251
a. Radiator/Oil Cooler Removal...2251
b. Cooler/Fan Motor Removal...2253
c. Cooler/Fan Motor Installation...2254
d. Radiator/Oil Cooler Installation...2254
7.5 Engine Electrical System...2255
7.6 Fuel System...2255
7.6.1 Diesel Fuel...2255
7.6.2 Fuel/Hydraulic Oil Tank - Prior to SN JK201000 & Prior to SN JK301000...2255
a. Cleaning and Drying...2255
b. Inspection...2255
c. Disassembly and Assembly...2255
7.6.3 Fuel Tank - SN JK201000 to Present & SN JK301000 to Present...2256
a. Fuel Tank Removal...2256
b. Cleaning and Drying...2256
c. Inspection...2256
d. Fuel Tank Installation...2256
7.6.4 After Fuel System Service...2256
7.7 Engine Exhaust System...2257
7.7.1 Exhaust System Removal...2257
7.7.2 Exhaust System Installation...2258
7.8 Air Cleaner Assembly...2258
7.8.1 Air Cleaner Assembly Removal...2258
7.8.2 Air Cleaner Assembly Installation...2259
7.9 Engine Replacement...2260
7.9.1 Engine Removal...2261
7.9.2 Engine Disassembly, Inspection and Service...2261
7.9.3 Engine Installation...2261
Section 8 Hydraulic System...2264
8.1 Hydraulic Component Terminology...2266
8.2 Safety Information...2267
8.3 General Information...2267
8.4 Specifications...2267
8.5 Hoses, Tube Lines, Fittings, Etc...2267
8.5.1 Replacement Considerations...2267
8.5.2 Hose, Tube, Line and Fitting Replacement...2268
8.6 Hydraulic Pressure Diagnosis...2268
8.6.1 Pressure Checks and Adjustments...2268
8.6.2 Main Control Valve Pressure Checking...2268
8.6.3 Charge Pressure Checking...2269
8.6.4 Boom Function Pressure Checking...2269
8.6.5 Steering Pressure Checking...2269
8.6.6 Fan Speed Pressure and Direction Checking...2269
8.7 Hydraulic Schematic...2271
8.7.1 Prior to SN JK201000 & Prior to SN JK301000...2271
a. ANSI...2271
b. CE & AUS...2273
8.7.2 SN JK201000 to Present & SN JK301000 to Present...2275
a. ANSI...2275
b. CE & AUS...2277
8.8 Hydraulic Reservoir...2279
8.8.1 Pressurized Hydraulic Oil Fill Cap...2279
8.8.2 Hydraulic Oil Reservoir Draining...2279
8.8.3 Hydraulic Oil Reservoir Filling...2279
8.8.4 Hydraulic Oil Reservoir Removal/ Installation...2279
a. Reservoir Removal...2279
b. Cleaning and Drying...2280
c. Inspection...2280
d. Reservoir Installation...2280
8.9 Hydraulic System Pump...2281
8.9.1 Implement Pump Removal...2281
8.9.2 Implement Pump Installation...2281
8.9.3 Pump Test...2281
8.10 Front Drive Motor...2282
8.10.1 Front Drive Motor Removal...2282
8.10.2 Front Drive Motor Installation...2282
8.11 Control Valves...2283
8.11.1 Main Control Valve...2283
a. Main Control Valve Removal...2283
b. Main Control Valve Disassembly...2283
c. Main Control Valve Parts Cleaning...2283
d. Main Control Valve Parts Inspection...2283
e. Main Control Valve Assembly...2284
f. Main Control Valve Installation...2284
g. Main Control Valve Test...2284
8.11.2 Service Brake Valve...2285
a. Service Brake Valve Removal...2285
b. Service Brake Valve Installation...2285
c. Service Brake Bleeding Procedure...2285
d. Brake Performance Test...2286
8.11.3 Park Brake Valve (ANSI)...2286
a. Park Brake Valve Removal...2286
b. Park Brake Valve Disassembly, Cleaning, Inspection and Assembly...2286
c. Park Brake Valve Installation...2287
d. Park Brake Bleeding Procedure...2287
e. Park Brake Valve Test...2287
8.11.4 Hand Brake Valve (CE & AUS)...2287
a. Hand Brake Valve Removal...2287
b. Hand Brake Valve Disassembly, Cleaning, Inspection and Assembly...2288
c. Hand Brake Valve Installation...2288
d. Hand Brake Valve Test...2288
8.11.5 Steering Orbital Valve...2288
8.11.6 Pilot Select Valve...2288
a. Pilot Select Valve Removal...2289
b. Pilot Select Valve Disassembly, Cleaning, Inspection and Assembly...2289
c. Pilot Select Valve Installation...2289
d. Pilot Select Valve Test...2289
8.11.7 Inching Valve...2290
a. Inching Valve Removal...2290
b. Inching Valve Disassembly, Cleaning, Inspection and Assembly...2290
c. Inching Valve Installation...2290
d. Inching Valve Bleeding Procedure...2291
e. Inching Test...2291
8.11.8 Priority Valve...2291
a. Priority Valve Removal...2291
b. Priority Valve Disassembly, Cleaning, Inspection and Assembly...2292
c. Priority Valve Installation...2292
d. Priority Valve Test...2292
8.11.9 Steer Select Valve...2293
a. Steer Select Manifold and Valve Removal...2293
b. Steer Select Valve and Manifold Disassembly, Cleaning, Inspection and Assembly...2293
c. Steer Select Manifold and Valve Installation...2293
d. Steering Test...2294
8.11.10 Quick Attach Valve...2294
a. Quick Attach Valve Removal...2294
b. Quick Attach Valve Disassembly, Cleaning, Inspection and Assembly...2294
c. Quick Attach Installation...2295
d. Quick Attach Valve Test...2295
8.11.11 Variable Speed Fan Valve...2295
a. Variable Speed Fan Valve Removal...2295
b. Variable Speed Fan Valve Disassembly, Cleaning, Inspection and Assembly...2295
c. Variable Speed Fan Valve Installation...2296
d. Variable Speed Fan Valve Test...2296
8.12 Hydraulic Cylinders...2296
8.12.1 General Cylinder Removal Instructions...2296
8.12.2 General Cylinder Disassembly...2296
8.12.3 Cylinder Cleaning Instructions...2297
8.12.4 Cylinder Inspection...2298
8.12.5 General Cylinder Assembly...2298
8.12.6 General Cylinder Installation...2299
8.12.7 Steering Cylinders...2299
8.12.8 Hydraulic Cylinder Torque Specifications...2300
a. Lift Lower Cylinder...2300
b. Extend/Retract Cylinder...2300
c. Tilt Cylinder...2300
d. Compensating Cylinder...2300
a. Lift Lower Cylinder...2301
b. Extend/Retract Cylinder...2301
c. Tilt Cylinder...2301
d. Compensating Cylinder...2301
Section 9 Electrical System...2302
9.1 Electrical Component Terminology...2304
9.2 Safety Information...2306
9.3 Fuses and Relays...2306
9.3.1 Engine Compartment Relays and Fuses...2306
9.3.2 Cab Compartment Fuses and Relays...2306
9.3.3 Power Distribution Module...2307
9.3.4 Cab Fuses / Relays...2308
9.4 Electrical System Schematics...2309
9.4.1 Prior to SN JK200786 & Prior to SN JK300163...2309
a. Cab Schematic "A"...2309
b. Cab Schematic “B”...2310
c. Cab Roof, AC and Miscellaneous Schematic...2311
d. Base Frame Schematic "A"...2312
e. Base Frame Schematic "B"...2313
f. Engine Schematic...2314
g. Option Frame Schematic...2315
h. Cables and Boom Schematic...2316
i. Product Link Schematic...2317
9.4.2 SN JK200787 to SN JK200999 & SN JK300163 to SN JK300999...2318
a. Cab Schematic “A”...2318
b. Cab Schematic “B”...2319
c. Cab Roof, AC and Miscellaneous Schematic...2320
d. Base Frame Schematic "A"...2321
e. Base Frame Schematic "B"...2322
f. Engine Schematic...2323
g. Option Frame Schematic...2324
h. Cables and Boom Schematic...2325
i. Product Link Schematic...2326
9.4.3 SN JK201000 to Present & SN JK301000 to Present...2327
a. Cab Schematic “A”...2327
b. Cab Schematic “B”...2328
c. Cab Roof, AC and Miscellaneous Schematic...2329
d. Base Frame Schematic...2330
e. Base Frame Schematic "B"...2331
f. Engine Schematic...2332
g. Option Frame Schematic...2333
h. Cables and Boom Schematic...2334
i. Product Link Schematic...2335
j. Heater and HVAC Schematic...2336
9.5 Dielectric Grease Application...2337
9.5.1 Installation...2337
9.5.2 Exclusions...2338
9.6 Engine Start Circuit...2340
9.6.1 Starter...2340
a. Testing the Starter on the Engine...2340
b. Starter Circuit Checks...2340
c. Starter Removal...2340
d. Starter Cleaning and Drying...2341
e. Starter Periodic Maintenance...2341
f. Starter Installation...2341
9.7 Charging Circuit...2342
9.7.1 Alternator...2342
a. Alternator Removal...2342
b. Alternator Installation...2342
9.8 Battery...2343
9.8.1 Battery Inspection...2343
9.8.2 Battery Removal/Installation...2343
a. Removal...2343
b. Installation...2344
9.8.3 Battery Disconnect/Connect...2344
a. Disconnect...2344
b. Connect...2344
9.9 Electrical System Components...2345
9.9.1 Back-up Alarm...2345
a. Disassembly...2345
b. Inspection and Replacement...2345
9.9.2 Gauge Cluster...2345
a. Removal...2345
b. Installation...2345
9.10 Window Wiper/Washer...2346
9.10.1 Windshield Wiper Motor...2346
a. Removal...2346
b. Disassembly...2346
c. Inspection and Replacement...2346
d. Installation and Testing...2346
9.10.2 Rear Window or Roof Wiper Motor (if equipped)...2347
a. Removal...2347
b. Disassembly...2347
c. Inspection and Replacement...2347
d. Installation and Testing...2347
9.10.3 Windshield Washer Reservoir and Pump...2347
a. Removal...2347
b. Disassembly...2348
c. Installation and Testing...2348
9.11 Cab Heater/AC and Fan...2348
9.11.1 Cab Heater/AC Controls...2348
a. Cab Heater Controls Removal...2348
b. Disassembly...2348
c. Installation and Testing...2349
9.12 Switches, Solenoids and Senders...2349
9.12.1 Ignition Key Switch...2349
a. Ignition Switch Removal...2349
b. Disassembly...2349
c. Inspection and Replacement...2349
d. Ignition Switch Installation...2350
9.12.2 Dash Switches...2350
a. Switch Removal...2350
b. Disassembly...2350
c. Inspection and Replacement...2350
d. Switch Installation...2350
9.12.3 Fuel Level Indicator and Fuel Level Sender...2350
a. Fuel Level Indicator Testing...2350
b. Fuel Level Circuit Tests...2350
9.12.4 Hourmeter...2351
9.12.5 Coolant Temperature Sender...2351
a. Coolant Temperature Sender Removal...2351
b. Coolant Temperature Sender Inspection and Replacement...2351
c. Coolant Temperature Sender Installation and Testing...2351
9.12.6 Oil Pressure Sender...2352
a. Oil Pressure Sender Removal...2352
b. Oil Pressure Sender Inspection and Replacement...2352
c. Oil Pressure Sender Installation and Testing...2352
9.13 Load Stability Indicator System (LSI)...2353
9.13.1 Load Stability Indicator...2353
9.13.2 LSI Sensor...2353
a. LSI Sensor Removal...2353
b. LSI Sensor Installation...2354
9.13.3 LSI Boom Sensors...2356
a. LSI Boom Sensor Removal...2356
b. LSI Sensor Boom Installation...2356
9.13.4 LSI Modules...2356
a. LSI Module Removal...2356
b. LSI Module Installation...2357
9.13.5 LSI System Calibration...2357
a. Standard Calibration...2357
b. Field Calibration...2359
9.13.6 LSI-CAN Check PT...2361
9.13.7 500 Hour - LSI UGM Calibration Check...2362
9.14 Analyzer (CE & AUS)...2362
9.14.1 Hand Held Analyzer...2362
9.14.2 Analyzer Usage...2362
9.14.3 Analyzer Software - Version P1.1...2363
9.15 Analyzer Software Accessibility...2364
9.15.1 Access Level...2364
9.15.2 Diagnostics...2364
9.15.3 Machine Set-up...2364
9.15.4 Personalities...2365
9.15.5 Operator Tools...2366
9.15.6 Calibrations...2367
9.16 Diagnostic Trouble Codes (DTC) on Ground Module...2368
9.16.1 Gauge Fault Code Display...2368
9.16.2 Fault Codes...2368
9.17 Engine Diagnostic Trouble Code...2372
9.17.1 Gauge Fault Code Display...2372
31200934 - Engine Parts Manual (Model TH255C)...2380
31200934_E_TH255C Engine_CAT_Parts...2380
Effectivity Page ...2382
Table of Contents ...2384
Section 1 ENGINE...2386
Figure 1-1 Dipstick...2387
Figure 1-2 Breather Line...2389
Figure 1-3 Filler Cap...2391
Figure 1-4 Oil Pan...2393
Figure 1-5 Fly Wheel...2395
Figure 1-6 V-Grooved Pulley...2397
Figure 1-7 V-Grooved Pulley...2399
Figure 1-8 Fastenings...2401
Figure 1-9 Valve Mechanical Cover...2403
Figure 1-10 Heat Protecting Shield...2405
Figure 1-11 Front Cover...2409
Figure 1-12 Lubrication Oil Pump...2411
Figure 1-13 Lubricant Oil Filter...2413
Figure 1-14 Oil Cooler...2415
Figure 1-15 Oil Filter Assembly...2417
Figure 1-16 Oil Suction Pipe...2419
Figure 1-17 High Pressure Pump...2421
Figure 1-18 Fuel Injector...2423
Figure 1-19 Fuel Supply Pump...2427
Figure 1-20 Fuel Filter...2429
Figure 1-21 Fuel Prefilter...2431
Figure 1-22 Rail...2433
Figure 1-23 High Pressure Pipe...2435
Figure 1-24 Fuel Line...2437
Figure 1-25 Fuel Line...2439
Figure 1-26 Intake Pipe...2441
Figure 1-27 Charge Air Elbow...2443
Figure 1-28 Charge Air Pipe...2445
Figure 1-29 Control Unit...2447
Figure 1-30 Coolant Pump...2449
Figure 1-31 V-Grooved Pulley...2451
Figure 1-32 Fastenings...2453
Figure 1-33 Thermostat...2455
Figure 1-34 Pipe/Line/Lead...2457
Figure 1-35 Exhaust Manifold...2459
Figure 1-36 Pipe/Line/Lead...2461
Figure 1-37 EGR-Module...2463
Figure 1-38 Turbocharger...2465
Figure 1-39 V-Grooved Pulley...2467
Figure 1-40 Generator...2469
Figure 1-41 Fastenings...2471
Figure 1-42 Starter...2473
Figure 1-43 Cap...2475
Figure 1-44 Cable Harness...2477
Figure 1-45 Fastenings...2479
Figure 1-46 Cable Harness...2481
Figure 1-47 Tacho Generator...2485
Figure 1-48 Temperature Transmitter...2487
Figure 1-49 Pressure Sensor...2489
Figure 1-50 Sensor...2491
Figure 1-51 Connection Housing...2493
Figure 1-52 Glow Plug...2495
Figure 1-53 Inlet...2497
Figure 1-54 Bracket...2499
Figure 1-55 Mounting Material...2501
Figure 1-56 Returns Elevator...2503
Figure 1-57 Special Tools...2505
Maintenance Parts List...2508
PART NUMBER INDEX...2510
31200980 - Engine Service Manual (Model TH255C)...2514
31200980_A_TH255C Engine_CAT_Service...2514
Effectivity...2516
Foreword...2518
TOC...2520
Section 1 JLG Safety Practices...2522
1.1 Introduction...2523
1.2 Disclaimer...2523
1.3 Operation & Maintenance Manual...2523
1.4 Do Not Operate Tags...2523
1.5 Safety Information...2523
1.6 Safety Instructions...2524
1.6.1 Personal Hazards...2524
1.6.2 Equipment Hazards...2524
1.6.3 General Hazards...2524
1.6.4 Operational Hazards...2525
1.7 Safety Decals...2525
Section 2 Safety information / User information...2526
2.1 General...2527
2.2 Specifications...2527
2.2.1 Accident prevention and safety regulations...2527
2.2.2 Cleanliness instructions and measures for working with common rail systems...2528
2.2.3 Additional information and measures for the handling of exhaust aftertreatment systems...2529
2.2.4 Disposal regulations...2530
2.3 Operation Manual And Service Manual...2530
2.4 Explanation Of Symbols...2531
Section 3 Disassembly and Assembly...2532
3.1 Oil Measuring Device...2535
3.1.1 Oil Measuring Device Removal...2535
3.2 Crankcase Breather...2536
3.3 Lubricating Oil Pan...2537
3.3.1 Lubricating Oil Pan Removal...2537
3.3.2 Lubricating Oil Pan Installation...2540
3.3.3 Technical Data...2542
3.4 Flywheel...2543
3.4.1 Flywheel Removal...2543
3.4.2 Flywheel Installation...2544
3.4.3 Technical Data...2545
3.5 V-belt Pulley Add-on...2546
3.6 V-belt Pulley Add-on Fastening Parts...2547
3.7 Cylinder Head Cover (Engine 441-9208)...2548
3.7.1 Cylinder Head Cover Removal...2548
3.7.2 Cylinder Head Cover Installation...2550
3.7.3 Technical Data...2551
3.8 Cylinder Head Cover (Engine 441-9209)...2552
3.8.1 Cylinder Head Cover Removal...2552
3.8.2 Cylinder Head Cover Installation...2554
3.8.3 Technical Data...2555
3.9 Heat Protection Plate (Engine 441-9208)...2556
3.10 Lubricating Oil Cooler...2557
3.10.1 Lubricating Oil Cooler Removal...2557
3.10.2 Lubricating Oil Cooler Installation...2558
3.10.3 Technical Data...2559
3.11 Lubricating Oil Filter...2560
3.12 Injector (Engine 441-9208)...2561
3.12.1 Injector Removal...2561
3.12.2 Injector Installation...2563
3.12.3 Technical Data...2566
3.13 Injector (Engine 441-9209)...2567
3.13.1 Injector Removal...2567
3.13.2 Injector Installation...2569
3.13.3 Technical Data...2572
3.14 Fuel Supply Pump...2573
3.15 Fuel Pipes...2575
3.15.1 High-pressure Line Removal...2575
3.15.2 Injection Pipes Removal...2575
3.15.3 Rail Removal...2576
3.15.4 Pressure Sensor Removal...2576
3.15.5 Pressure Sensor Installation...2577
3.15.6 Pressure Limiting Valve Removal...2577
3.15.7 Pressure Limiting Valve Installation...2578
3.15.8 Mounting Rail...2579
3.15.9 Injection Pipes Installation...2579
3.15.10 High-pressure Line Installation...2580
3.15.11 Technical Data...2582
3.16 Exhaust Turbocharger Intake Nozzle...2583
3.17 Charge Air Manifold...2584
3.18 Charge Air Line...2585
3.19 Coolant Pump Fastening Parts...2586
3.19.1 V-rib Belt Pulley Removal...2586
3.19.2 V-rib Belt Pulley Installation...2586
3.20 Thermostat Test...2587
3.20.1 Thermostat Test In Removed State...2587
3.20.2 Technical Data...2590
3.21 Thermostat...2591
3.21.1 Thermostat Removal...2591
3.21.2 Thermostat Installation...2592
3.21.3 Technical Data...2593
3.22 Exhaust Gas Recirculation Line...2594
3.23 Exhaust Pipe...2595
3.23.1 Exhaust Line Removal...2595
3.23.2 Installing Exhaust Line...2596
3.23.3 Technical Data...2597
3.24 Flutter Valve...2598
3.24.1 Flutter Valve Removal...2598
3.24.2 Flutter Valve Installation...2600
3.24.3 Technical Data...2602
3.25 Exhaust Gas Turbocharger...2603
3.25.1 Turbocharger Removal...2603
3.25.2 Turbocharger Installation...2605
3.25.3 Technical Data...2606
3.26 Lubricating Oil Line...2607
3.26.1 Lubricating Oil Line Removal...2607
3.26.2 Lubricating Oil Line Installation...2608
3.26.3 Technical Data...2610
3.27 Lubricating Oil Return Line...2611
3.27.1 Oil Return Line Removal...2611
3.27.2 Oil Return Line Installation...2613
3.27.3 Technical Data...2615
3.28 V-Belt Pulley (parts to generator)...2616
3.29 Generator Parts...2617
3.30 Generator...2618
3.30.1 Generator Removal...2618
3.30.2 Generator Installation...2620
3.30.3 Technical Data...2621
3.31 Starter...2622
3.31.1 Starter Removal...2622
3.31.2 Starter Installation...2623
3.31.3 Technical Data...2624
3.32 Cable Harness Fastening Parts...2625
3.33 Cable Harness Fastening Parts (Engine 441-9208)...2626
3.34 Impulse Transmitter (Crankshaft)...2627
3.34.1 Impulse Transmitter Removal...2627
3.34.2 Impulse Transmitter Installation...2628
3.34.3 Technical Data...2629
3.35 Temperature Sensor...2630
3.36 Oil Pressure Transmitter...2631
3.37 Connection Housing...2632
3.37.1 Connection Housing Removal...2632
3.37.2 Connection Housing Installation...2633
3.37.3 Technical Data...2634
3.38 Start-aid Glow Plugs...2635
3.38.1 Glow Plugs Removal...2635
3.38.2 Glow Plugs Installation...2636
3.38.3 Technical Data...2637
3.39 Exhaust Gas Treatment Inlet Module (Engine 441-9208)...2638
3.40 Holder (Engine 441-9208)...2640
3.41 Assembly Material Compensator Structure (Engine 441-9208)...2641
Section 4 Special Tools...2642
4.1 Tools...2643
4.1.1 Pump (P/N 449-2474)...2643
4.1.2 Assembly Pliers...2643
4.1.3 Measuring Device (P/N 449-2482)...2643
4.1.4 Torx Tool Set...2643
4.1.5 Rotation Angle Disc (P/N 449-2484)...2644
4.1.6 Check Designation (P/N 449-2485)...2644
4.1.7 Fitting Tool (P/N 449-2487)...2644
4.1.8 Check Designation (P/N 449-2488)...2644
4.1.9 Pliers (P/N 449-2489)...2645
4.1.10 Socket Wrench Insert...2645
4.1.11 Plug (P/N 449-2493)...2645
4.1.12 Assembly Tool...2645
4.1.13 Key (P/N 449-2496)...2646
4.1.14 Lever Tool (P/N 449-2497)...2646
4.1.15 Disassembly Tool...2646
4.1.16 Assembly Device (P/N 449-2500)...2646
Section 5 Engine Electrical Schematic...2648
5.1 Power Harness...2649
5.2 Equipment Harness...2650
Section 6 Wire Sensor Troubleshooting...2652
6.1 Engine Sensor Test...2653
6.2 Engine Sensor Circuit Test...2654
6.3 Signal Wire Test...2655
Section 7 Diagnostics...2656
7.1 Fault Codes...2660
7.1.1 KWP Code 45...2660
7.1.2 KWP Code 46...2661
7.1.3 KWP Code 47...2662
7.1.4 KWP Code 84...2663
7.1.5 KWP Code 85...2664
7.1.6 KWP Code 88...2665
7.1.7 KWP Code 89...2666
7.1.8 KWP Code 96...2667
7.1.9 KWP Code 97...2668
7.1.10 KWP Code 98...2669
7.1.11 KWP Code 99...2670
7.1.12 KWP Code 101...2671
7.1.13 KWP Code 121...2672
7.1.14 KWP Code 122...2673
7.1.15 KWP Code 291...2674
7.1.16 KWP Code 292...2675
7.1.17 KWP Code 305...2676
7.1.18 KWP Code 360...2677
7.1.19 KWP Code 361...2678
7.1.20 KWP Code 376...2679
7.1.21 KWP Code 377...2680
7.1.22 KWP Code 378...2681
7.1.23 KWP Code 387...2682
7.1.24 KWP Code 388...2683
7.1.25 KWP Code 389...2684
7.1.26 KWP Code 390...2685
7.1.27 KWP Code 391...2686
7.1.28 KWP Code 419...2687
7.1.29 KWP Code 420...2688
7.1.30 KWP Code 421...2689
7.1.31 KWP Code 422...2690
7.1.32 KWP Code 423...2691
7.1.33 KWP Code 464...2692
7.1.34 KWP Code 465...2693
7.1.35 KWP Code 472...2694
7.1.36 KWP Code 473...2695
7.1.37 KWP Code 474...2696
7.1.38 KWP Code 559...2697
7.1.39 KWP Code 560...2698
7.1.40 KWP Code 561...2699
7.1.41 KWP Code 562...2700
7.1.42 KWP Code 565...2701
7.1.43 KWP Code 566...2702
7.1.44 KWP Code 567...2703
7.1.45 KWP Code 568...2704
7.1.46 KWP Code 569...2705
7.1.47 KWP Code 570...2706
7.1.48 KWP Code 571...2707
7.1.49 KWP Code 580...2708
7.1.50 KWP Code 581...2709
7.1.51 KWP Code 582...2710
7.1.52 KWP Code 583...2711
7.1.53 KWP Code 592...2712
7.1.54 KWP Code 594...2713
7.1.55 KWP Code 595...2714
7.1.56 KWP Code 596...2715
7.1.57 KWP Code 597...2716
7.1.58 KWP Code 612...2717
7.1.59 KWP Code 613...2718
7.1.60 KWP Code 614...2719
7.1.61 KWP Code 615...2720
7.1.62 KWP Code 616...2721
7.1.63 KWP Code 617...2722
7.1.64 KWP Code 618...2723
7.1.65 KWP Code 619...2724
7.1.66 KWP Code 620...2725
7.1.67 KWP Code 621...2726
7.1.68 KWP Code 623...2727
7.1.69 KWP Code 624...2728
7.1.70 KWP Code 625...2729
7.1.71 KWP Code 627...2730
7.1.72 KWP Code 628...2731
7.1.73 KWP Code 637...2732
7.1.74 KWP Code 732...2733
7.1.75 KWP Code 733...2734
7.1.76 KWP Code 736...2735
7.1.77 KWP Code 737...2736
7.1.78 KWP Code 747...2737
7.1.79 KWP Code 752...2738
7.1.80 KWP Code 776...2739
7.1.81 KWP Code 777...2740
7.1.82 KWP Code 825...2741
7.1.83 KWP Code 826...2742
7.1.84 KWP Code 827...2743
7.1.85 KWP Code 828...2744
7.1.86 KWP Code 829...2745
7.1.87 KWP Code 830...2746
7.1.88 KWP Code 831...2747
7.1.89 KWP Code 832...2748
7.1.90 KWP Code 833...2749
7.1.91 KWP Code 834...2750
7.1.92 KWP Code 835...2751
7.1.93 KWP Code 836...2752
7.1.94 KWP Code 837...2753
7.1.95 KWP Code 856...2754
7.1.96 KWP Code 857...2755
7.1.97 KWP Code 858...2756
7.1.98 KWP Code 859...2757
7.1.99 KWP Code 861...2758
7.1.100 KWP Code 862...2759
7.1.101 KWP Code 864...2760
7.1.102 KWP Code 876...2761
7.1.103 KWP Code 877...2762
7.1.104 KWP Code 878...2763
7.1.105 KWP Code 935...2764
7.1.106 KWP Code 940...2765
7.1.107 KWP Code 946...2766
7.1.108 KWP Code 947...2767
7.1.109 KWP Code 948...2768
7.1.110 KWP Code 956...2769
7.1.111 KWP Code 957...2770
7.1.112 KWP Code 958...2771
7.1.113 KWP Code 959...2772
7.1.114 KWP Code 960...2773
7.1.115 KWP Code 961...2774
7.1.116 KWP Code 973...2775
7.1.117 KWP Code 974...2776
7.1.118 KWP Code 975...2777
7.1.119 KWP Code 976...2778
7.1.120 KWP Code 980...2779
7.1.121 KWP Code 994...2780
7.1.122 KWP Code 995...2781
7.1.123 KWP Code 996...2782
7.1.124 KWP Code 997...2783
7.1.125 KWP Code 1014...2784
7.1.126 KWP Code 1015...2785
7.1.127 KWP Code 1016...2786
7.1.128 KWP Code 1022...2787
7.1.129 KWP Code 1023...2788
7.1.130 KWP Code 1024...2789
7.1.131 KWP Code 1025...2790
7.1.132 KWP Code 1157...2791
7.1.133 KWP Code 1170...2792
7.1.134 KWP Code 1180...2793
7.1.135 KWP Code 1181...2794
7.1.136 KWP Code 1223...2795
7.1.137 KWP Code 1224...2796
7.1.138 KWP Code 1226...2797
7.1.139 KWP Code 1227...2798
7.1.140 KWP Code 1228...2799
7.1.141 KWP Code 1229...2800
7.1.142 KWP Code 1230...2801
7.1.143 KWP Code 1231...2802
7.1.144 KWP Code 1232...2803
7.1.145 KWP Code 1505...2804
7.1.146 KWP Code 1669...2805
7.1.147 KWP Code 1679...2806
31211008 - Axle Service Manual (Models TH255, TH255C)...2810
31211008_A_TH255,TH255C Axle_CAT_Service...2810
Effectivity...2812
TOC...2814
Section 1 Safety Practices...2816
1.1 Introduction...2816
1.2 Disclaimer...2816
1.3 Operation & Maintenance Manual...2816
1.4 Do Not Operate Tags...2816
1.5 Safety Information...2816
1.6 Safety Alert System and Signal Words...2817
1.7 Safety Instructions...2817
1.8 Safety Decals...2819
Section 2 General Information and Specifications...2820
2.1 Introduction...2820
2.2 Specifications...2821
2.3 Conversion Tables...2822
2.4 Torque Specifications...2823
2.5 Maintenance...2825
2.6 Safety Precautions...2828
Section 3 Planetary Reduction 1:6 and The Steering Case...2830
3.1 Exploded View...2830
3.2 Planetary Reduction - 1.6 and steering Case - Disassembly...2831
3.3 Planetary Reduction - 1.6 and steering Case - Assembly...2837
Section 4 Steering Cylinder...2846
4.1 Exploded View...2846
4.2 Steering Cylinder - Disassembly...2847
4.3 Steering Cylinder - Assembly...2850
Section 5 Limited Slip Differential Unit 45% (Old Version)...2858
5.1 Exploded View...2858
5.2 Limited Slip Differential Unit 45% (Old Version) - Disassembly...2859
5.3 Limited Slip Differential Unit 45% (Old Version) - Assembly...2862
Section 6 Limited Slip Differential Unit 45% (Last Version)...2866
6.1 Exploded View...2866
6.2 Limited Slip Differential Unit 45% (Last Version) - Disassembly...2867
6.3 Limited Slip Differential Unit 45% (Last Version) - Assembly...2869
Section 7 Bevel Pinion...2872
7.1 Exploded View...2872
7.2 Bevel Pinion - Disassembly...2873
7.3 Bevel Pinion - Install and Adjust...2874
Section 8 Ring and Pinion Adjusting: Version Pinion Cover and Single Arm...2880
8.1 Exploded View...2880
8.2 Ring and Pinion Adjusting: Version Pinion Cover and Single Arm - Install and Adjust...2881
Section 9 Special Tools...2886
9.1 T1...2886
9.2 T2...2887
9.3 T3...2888
9.4 T4...2889
9.5 T5...2890
9.6 T6...2891
9.7 T7...2892
9.8 T8...2893
9.9 T9...2894
9.10 T10...2895
Deutz TCD2.9 Engine (TH255C) Training...2898
CAT TH255C...2898
General Product information...2899
General Product information II...2900
General Product information III...2901
General Product information III...2902
Engine Details...2903
Engine Details...2904
Engine Details...2905
Engine Details...2906
Engine Details...2907
Engine Details...2908
Maintenance...2909
Maintenance...2910
Emissions...2911
Diesel Oxidation Catalyst (DOC)...2912
After Treatment System...2913
After Treatment System...2914
After Treatment System...2915
Lubrication System...2916
Lubrication System...2917
Lubrication System...2918
Lubrication System...2919
Lubrication System...2920
Lubrication System...2921
Lubrication System...2922
Lubrication System...2923
Cooling System...2924
Cooling System...2925
Cooling System...2926
Fuel System...2927
Fuel System...2928
Fuel System...2929
Fuel System...2930
Fuel System...2931
Fuel System...2932
Fuel System...2933
Fuel System...2934
Fuel System...2935
Fuel System...2936
Fuel System...2937
Fuel System...2938
Fuel System...2939
Fuel System...2940
Fuel System...2941
Fuel System...2942
Electrical System...2943
Electrical System...2944
Electrical System...2945
Electrical System...2946
Electrical System...2947
Diagnostic System...2948
Serdia 2010 – Start page...2949
Seria 2010 – Overview...2950
Serdia 2010 – Error Memory...2951
Serdia 2010 – DataSet Management...2952
Serdia 2010 – Actuator Test...2953
Serdia 2010 – Settings ...2954
Slide Number 58...2955
EXCERPT:
7.7.2 Exhaust System Installation
Note: Keep all clamps loosened until entire exhaust system is in place.
Note: Replace the nuts and the exhaust studs on the turbocharger if damaged.
1. Install the exhaust assembly in place at the turbocharger with the previously used hardware.
Torque the flange nuts (2) on the turbo charger to 22 ±5 lb-ft (30 ±7 Nm).
2. Install the muffler brackets (1) to the frame brackets with the previously used hardware.
3. Adjust the muffler, exhaust and tail pipes for proper clearance then tighten all clamps.
4. Properly connect the battery. Refer to Section 9.8, “Battery”, for procedure.
5. Start engine and check for exhaust leaks at all exhaust connections. Adjust or repair as needed.
6. Close and secure the engine cover.
7. Remove the Do Not Operate Tags from both the ignition key and the steering wheel.
...
Caterpillar TH255 & TH255C Tele-handler Factory Service & Shop Manual
