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Caterpillar TH255C Service Manual 31200927
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Caterpillar TH255C Service Manual 31200927

$30.00

  • Type Of Manual: Service Manual
  • Manual ID: 31200927
  • Number of Pages: 272
  • Size: 26.5MB
  • Format: PDF
Category:
  • Model List:

    • TH255C
  • 1. _E_TH255C_CAT_Service
  • 1.1. Effectivity Page
  • 1.2. Table of Contents
  • 1.3. Section 1 Safety Practices
  • 1.3.1. Introduction
  • 1.3.2. Disclaimer
  • 1.3.3. Operation Maintenance Manual
  • 1.3.4. Do Not Operate Tags
  • 1.3.5. Safety Information
  • 1.3.5.1. Safety Alert System and Signal Words
  • 1.3.6. Safety Instructions
  • 1.3.6.1. Personal Hazards
  • 1.3.6.2. Equipment Hazards
  • 1.3.6.3. General Hazards
  • 1.3.6.4. Operational Hazards
  • 1.3.7. Safety Decals
  • 1.4. Section 2 General Information and Specifications
  • 1.4.1. Replacement Parts and Warranty Information
  • 1.4.2. Specifications
  • 1.4.2.1. Travel Speed
  • 1.4.2.2. Hydraulic Cylinder Performance Specifications
  • 1.4.2.3. Electrical System
  • 1.4.2.4. Steering Angle Specification
  • 1.4.2.5. Engine Performance Specifications
  • 1.4.2.6. Tires
  • 1.4.3. Fluids, Lubricants and Capacities
  • 1.4.3.1. Fluids
  • 1.4.3.2. Capacities
  • 1.4.4. Maintenance Schedule
  • 1.4.4.1. ,1st 50 50 Hour Maintenance Schedule
  • 1.4.4.2. t 250, 250 500 Hour Maintenance Schedule
  • 1.4.4.3. 1500 Hour Maintenance Schedule
  • 1.4.5. Lubrication Schedule
  • 1.4.5.1. Hour Lubrication Schedule
  • 1.4.6. Thread Locking Compound
  • 1.4.7. Torque Charts
  • 1.4.7.1. SAE Fastener Torque Chart
  • 1.4.7.2. Metric Fastener Torque Chart
  • 1.4.8. Hydraulic Connection Assembly and Torque Specification
  • 1.4.8.1. Definitions
  • 1.4.8.2. Assembly Instructions for American Standard Pipe Thread Tapered Connections
  • 1.4.8.3. Assembly Instructions for British Standard Pipe Thread Tapered Connections
  • 1.4.8.4. Assembly Instructions for 37 (JIC) Flare Fittings
  • 1.4.8.5. Assembly Instructions for 45 SAE Flare Fittings
  • 1.4.8.6. Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
  • 1.4.8.7. Assembly Instructions for DIN 24 Flare Bite Type Fittings (MBTL and MBTS)
  • 1.4.8.8. Assembly Instructions for Bulkhead (BH) Fittings
  • 1.4.8.9. Assembly Instructions for O-Ring Boss (ORB) Fittings
  • 1.4.8.10. Assembly Instructions for Adjustable Port End Metric Fittings
  • 1.4.8.11. Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends
  • 1.4.8.12. Assembly Instructions for Adjustable Port End (BSPP) Fittings
  • 1.4.8.13. Assembly Instructions for Flange Connections (FL61 and FL62)
  • 1.4.8.14. Double Wrench Method
  • 1.4.8.15. FFWR and TFFT Methods
  • 1.4.8.16. Adjustable Stud End Assembly
  • 1.4.8.17. O-ring Installation (Replacement)
  • 1.5. Section 3 Boom
  • 1.5.1. Boom System Component Terminology
  • 1.5.2. Safety Information
  • 1.5.3. Two Section Boom System
  • 1.5.3.1. Boom System Description
  • 1.5.4. Boom Assembly Maintenance
  • 1.5.4.1. Complete Boom Removal
  • 1.5.4.2. Complete Boom Installation
  • 1.5.4.3. Second Boom Section Removal
  • 1.5.4.4. Second Boom Section Installation
  • 1.5.4.5. Tilt and Auxiliary Hose Replacement
  • 1.5.4.6. Tilt and Auxiliary Hose Installation
  • 1.5.4.7. Extend/Retract Cylinder Removal
  • 1.5.4.8. Extend/Retract Cylinder Installation
  • 1.5.5. Boom Wear Pads
  • 1.5.5.1. Wear Pad Inspection
  • 1.5.5.2. Wear Pad Installation and Lubrication
  • 1.5.5.3. Boom Wear Pad Lubrication
  • 1.5.6. Quick Coupler Assembly
  • 1.5.6.1. Quick Coupler Assembly Removal
  • 1.5.6.2. Quick Coupler Assembly Installation
  • 1.5.7. Forks
  • 1.5.8. Boom Prop (If Equipped)
  • 1.5.8.1. Prop Installation
  • 1.5.8.2. Prop Removal
  • 1.5.9. Emergency Boom Lowering Procedure
  • 1.5.9.1. Equipment and Supplies Required
  • 1.5.9.2. Lowering Procedure
  • 1.5.10. Troubleshooting
  • 1.6. Section 4 Cab
  • 1.6.1. Operator Cab Component Terminology
  • 1.6.2. Safety Information
  • 1.6.3. Operator Cab
  • 1.6.3.1. Operator Cab Description
  • 1.6.3.2. Serial Number Decal
  • 1.6.4. Cab Components
  • 1.6.4.1. Steering Wheel
  • 1.6.4.2. Steering Column/Valve Replacement
  • 1.6.4.3. Brake Pedal and Valve
  • 1.6.4.4. Accelerator Pedal Replacement
  • 1.6.4.5. Joystick Replacement
  • 1.6.4.6. Windshield Wiper Assembly (if equipped)
  • 1.6.4.7. Windshield Washer Assembly (if equipped)
  • 1.6.4.8. Heater System (if equipped)
  • 1.6.4.9. Heater and A/C System (if equipped)
  • 1.6.4.10. Air Filter System (if equipped)
  • 1.6.5. Cab Removal
  • 1.6.6. Cab Installation
  • 1.7. Section 5 Axles, Drive Shafts, Wheels and Tires
  • 1.7.1. Axle, Drive Shaft and Wheel Component Terminology
  • 1.7.2. Safety Information
  • 1.7.3. General Information
  • 1.7.4. Axle Assemblies
  • 1.7.4.1. Axle Serial Number Plate
  • 1.7.4.2. Axle Specifications
  • 1.7.4.3. Axle Internal Service
  • 1.7.4.4. Axle Maintenance
  • 1.7.4.5. Axle Removal
  • 1.7.4.6. Axle Installation
  • 1.7.4.7. Axle Assembly and Drive Shaft Troubleshooting
  • 1.7.4.8. Steering System Purge Procedure
  • 1.7.5. Drive Shafts
  • 1.7.5.1. Drive Shaft Inspection
  • 1.7.5.2. Drive Shaft Maintenance
  • 1.7.5.3. Drive Shaft Removal
  • 1.7.5.4. Drive Shaft Cleaning and Drying
  • 1.7.5.5. Drive Shaft Installation
  • 1.7.6. Wheels and Tires
  • 1.7.6.1. Removing Wheel and Tire Assembly from Machine
  • 1.7.6.2. Installing Wheel and Tire Assembly onto Machine
  • 1.7.7. Steering Angle Adjustment
  • 1.7.8. Brakes
  • 1.7.8.1. Brake Disc Inspection
  • 1.7.9. Towing a Disabled Machine
  • 1.7.9.1. Equipment and Supplies Required
  • 1.7.9.2. Towing Procedure
  • 1.7.9.3. Steering System Purge Procedure
  • 1.8. Section 6 Transmission
  • 1.8.1. Transmission Assembly Component Terminology
  • 1.8.2. Safety Information
  • 1.8.3. Transmission Description
  • 1.8.4. Transmission Specifications
  • 1.8.4.1. Transmission Maintenance
  • 1.8.5. Transmission Replacement
  • 1.8.5.1. Transmission Removal
  • 1.8.5.2. Transmission Disassembly
  • 1.8.5.3. Transmission Installation
  • 1.9. Section 7 Engine
  • 1.9.1. Introduction
  • 1.9.1.1. Disclaimer and Scope
  • 1.9.1.2. Component Terminology
  • 1.9.2. Engine Serial Number
  • 1.9.3. Specifications and Maintenance Information
  • 1.9.4. Engine Cooling System
  • 1.9.4.1. Surge Tank Cap
  • 1.9.4.2. Radiator/Oil Cooler Replacement
  • 1.9.5. Engine Electrical System
  • 1.9.6. Fuel System
  • 1.9.6.1. Diesel Fuel
  • 1.9.6.2. Fuel/Hydraulic Oil Tank – Prior to SN JK201000 Prior to SN JK301000
  • 1.9.6.3. Fuel Tank – SN JK201000 to Present SN JK301000 to Present
  • 1.9.6.4. After Fuel System Service
  • 1.9.7. Engine Exhaust System
  • 1.9.7.1. Exhaust System Removal
  • 1.9.7.2. Exhaust System Installation
  • 1.9.8. Air Cleaner Assembly
  • 1.9.8.1. Air Cleaner Assembly Removal
  • 1.9.8.2. Air Cleaner Assembly Installation
  • 1.9.9. Engine Replacement
  • 1.9.9.1. Engine Removal
  • 1.9.9.2. Engine Disassembly, Inspection and Service
  • 1.9.9.3. Engine Installation
  • 1.10. Section 8 Hydraulic System
  • 1.10.1. Hydraulic Component Terminology
  • 1.10.2. Safety Information
  • 1.10.3. General Information
  • 1.10.4. Specifications
  • 1.10.5. Hoses, Tube Lines, Fittings, Etc.
  • 1.10.5.1. Replacement Considerations
  • 1.10.5.2. Hose, Tube, Line and Fitting Replacement
  • 1.10.6. Hydraulic Pressure Diagnosis
  • 1.10.6.1. Pressure Checks and Adjustments
  • 1.10.6.2. Main Control Valve Pressure Checking
  • 1.10.6.3. Charge Pressure Checking
  • 1.10.6.4. Boom Function Pressure Checking
  • 1.10.6.5. Steering Pressure Checking
  • 1.10.6.6. Fan Speed Pressure and Direction Checking
  • 1.10.7. Hydraulic Schematic
  • 1.10.7.1. Prior to SN JK201000 Prior to SN JK301000
  • 1.10.7.2. SN JK201000 to Present SN JK301000 to Present
  • 1.10.8. Hydraulic Reservoir
  • 1.10.8.1. Pressurized Hydraulic Oil Fill Cap
  • 1.10.8.2. Hydraulic Oil Reservoir Draining
  • 1.10.8.3. Hydraulic Oil Reservoir Filling
  • 1.10.8.4. Hydraulic Oil Reservoir Removal/ Installation
  • 1.10.9. Hydraulic System Pump
  • 1.10.9.1. Implement Pump Removal
  • 1.10.9.2. Implement Pump Installation
  • 1.10.9.3. Pump Test
  • 1.10.10. Front Drive Motor
  • 1.10.10.1. Front Drive Motor Removal
  • 1.10.10.2. Front Drive Motor Installation
  • 1.10.11. Control Valves
  • 1.10.11.1. Main Control Valve
  • 1.10.11.2. Service Brake Valve
  • 1.10.11.3. Park Brake Valve (ANSI)
  • 1.10.11.4. Hand Brake Valve (CE AUS)
  • 1.10.11.5. Steering Orbital Valve
  • 1.10.11.6. Pilot Select Valve
  • 1.10.11.7. Inching Valve
  • 1.10.11.8. Priority Valve
  • 1.10.11.9. Steer Select Valve
  • 1.10.11.10. Quick Attach Valve
  • 1.10.11.11. Variable Speed Fan Valve
  • 1.10.12. Hydraulic Cylinders
  • 1.10.12.1. General Cylinder Removal Instructions
  • 1.10.12.2. General Cylinder Disassembly
  • 1.10.12.3. Cylinder Cleaning Instructions
  • 1.10.12.4. Cylinder Inspection
  • 1.10.12.5. General Cylinder Assembly
  • 1.10.12.6. General Cylinder Installation
  • 1.10.12.7. Steering Cylinders
  • 1.10.12.8. Hydraulic Cylinder Torque Specifications
  • 1.11. Section 9 Electrical System
  • 1.11.1. Electrical Component Terminology
  • 1.11.2. Safety Information
  • 1.11.3. Fuses and Relays
  • 1.11.3.1. Engine Compartment Relays and Fuses
  • 1.11.3.2. Cab Compartment Fuses and Relays
  • 1.11.3.3. Power Distribution Module
  • 1.11.3.4. Cab Fuses / Relays
  • 1.11.4. Electrical System Schematics
  • 1.11.4.1. Prior to SN JK200786 Prior to SN JK300163
  • 1.11.4.2. SN JK200787 to SN JK200999 SN JK300163 to SN JK300999
  • 1.11.4.3. SN JK201000 to Present SN JK301000 to Present
  • 1.11.5. Dielectric Grease Application
  • 1.11.5.1. Installation
  • 1.11.5.2. Exclusions
  • 1.11.6. Engine Start Circuit
  • 1.11.6.1. Starter
  • 1.11.7. Charging Circuit
  • 1.11.7.1. Alternator
  • 1.11.8. Battery
  • 1.11.8.1. Battery Inspection
  • 1.11.8.2. Battery Removal/Installation
  • 1.11.8.3. Battery Disconnect/Connect
  • 1.11.9. Electrical System Components
  • 1.11.9.1. Back-up Alarm
  • 1.11.9.2. Gauge Cluster
  • 1.11.10. Window Wiper/Washer
  • 1.11.10.1. Windshield Wiper Motor
  • 1.11.10.2. Rear Window or Roof Wiper Motor (if equipped)
  • 1.11.10.3. Windshield Washer Reservoir and Pump
  • 1.11.11. Cab Heater/AC and Fan
  • 1.11.11.1. Cab Heater/AC Controls
  • 1.11.12. Switches, Solenoids and Senders
  • 1.11.12.1. Ignition Key Switch
  • 1.11.12.2. Dash Switches
  • 1.11.12.3. Fuel Level Indicator and Fuel Level Sender
  • 1.11.12.4. Hourmeter
  • 1.11.12.5. Coolant Temperature Sender
  • 1.11.12.6. Oil Pressure Sender
  • 1.11.13. Load Stability Indicator System (LSI)
  • 1.11.13.1. Load Stability Indicator
  • 1.11.13.2. LSI Sensor
  • 1.11.13.3. LSI Boom Sensors
  • 1.11.13.4. LSI Modules
  • 1.11.13.5. LSI System Calibration
  • 1.11.13.6. LSI-CAN Check PT
  • 1.11.13.7. Hour – LSI UGM Calibration Check
  • 1.11.14. Analyzer (CE AUS)
  • 1.11.14.1. Hand Held Analyzer
  • 1.11.14.2. Analyzer Usage
  • 1.11.14.3. Analyzer Software – Version P1.1
  • 1.11.15. Analyzer Software Accessibility
  • 1.11.15.1. Access Level
  • 1.11.15.2. Diagnostics
  • 1.11.15.3. Machine Set-up
  • 1.11.15.4. Personalities
  • 1.11.15.5. Operator Tools
  • 1.11.15.6. Calibrations
  • 1.11.16. Diagnostic Trouble Codes (DTC) on Ground Module
  • 1.11.16.1. Gauge Fault Code Display
  • 1.11.16.2. Fault Codes
  • 1.11.17. Engine Diagnostic Trouble Code
  • 1.11.17.1. Gauge Fault Code Display
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