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Service Manual

Model
TH255
S/N TBS00100 & After

31200364

Revised
February 8, 2012
EFFECTIVITY PAGE

September 11, 2008 - A - Original Issue Of Manual


February 8, 2012 - B - Revised pages 1.3, 2.14 - 2.17, 3.4 - 3.6, 3.8, 4.2, 5.12, 5.13, 8.9, 8.10, 8.19 - 8.21, 8.27, 8.28,
8.33, 9.12 - 9.17, 9.33 - 9.47

31200364 TH255 a
EFFECTIVITY PAGE

b TH255 31200364
SECTION CONTENTS
Section Subject Page

Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.5 Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.6 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Section 3
Boom ........................................................... 3-1
3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Boom System - Two Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.6 Quick Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.7 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.8 Boom Prop (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.9 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.5 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.6 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

TH255 i
Section Subject Page

Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.5 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.6 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.7 Steering Angle Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.8 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.9 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Section 6
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.6 Transmission Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Section 7
Engine ........................................................... 7-1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.5 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.6 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.7 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.8 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.9 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.10 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.11 Engine Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5 Hoses, Tube Lines, Fittings, Etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.6 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.7 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.8 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.9 Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.10 Front Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.11 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.12 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29

ii TH255
Section Subject Page

Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.3 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.5 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
9.6 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.7 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.8 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.9 Window Wiper/Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.10 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.11 Switches, Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.12 Load Stability System (CE & AUS) Before S/N TBS00627 . . . . . . . . . . . . . . . . . . . . . . 9-33
9.13 Load Stability System (CE & AUS) S/N TBS00627 & After . . . . . . . . . . . . . . . . . . . . . . 9-35
9.14 Hand Held Analyzer (CE & AUS) S/N TBS00627 & After . . . . . . . . . . . . . . . . . . . . . . . 9-41

TH255 iii
Section Subject Page

iv TH255
Section 1
Safety Practices

Contents

PARAGRAPH TITLE PAGE


1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

TH255 1-1
Safety Practices

1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS


This service manual provides general directions for Place Do Not Operate Tags on the ignition key switch
accomplishing service and repair procedures. Following and the steering wheel before attempting to perform any
the procedures in this manual will help assure safety and service or maintenance. Remove key and disconnect
equipment reliability. battery leads.
Read, understand and follow the information in this
manual, and obey all locally approved safety practices, 1.5 SAFETY INFORMATION
procedures, rules, codes, regulations and laws.
To avoid possible death or injury, carefully read,
These instructions cannot cover all details or variations in understand and comply with all safety messages.
the equipment, procedures, or processes described, nor
provide directions for meeting every possible contingency In the event of an accident, know where to obtain medical
during operation, maintenance, or testing. When additional assistance and how to use a first-aid kit and fire
information is desired consult the local Caterpillar dealer. extinguisher/fire suppression system. Keep emergency
telephone numbers (fire department, ambulance, rescue
Many factors contribute to unsafe conditions: carelessness, squad/paramedics, police department, etc.) nearby. If
fatigue, overload, inattentiveness, unfamiliarity, even working alone, check with another person routinely to
drugs and alcohol, among others. For optimal safety, help assure personal safety.
encourage everyone to think, and to act, safely.
Appropriate service methods and proper repair 1.5.1 Safety Alert System and Signal Words
procedures are essential for the safety of the individual
doing the work, for the safety of the operator, and for the
safe, reliable operation of the machine. All references to
the right side, left side, front and rear are given from the
DANGER
operator’s seat looking in a forward direction.
Supplementary information is available from the DANGER indicates an imminently hazardous situation
manufacturer in the form of Service Bulletins, Service which, if not avoided, will result in death or serious injury.
Campaigns, Service Training Schools, the service
website, other literature, and through updates to the
manual itself. WARNING
1.2 DISCLAIMER
WARNING indicates a potentially hazardous situation
All information in this manual is based on the latest which, if not avoided, could result in death or serious
product information available at the time of publication. injury.
The manufacturer reserves the right to make changes
and improvements to its products, and to discontinue the
manufacture of any product, at its discretion at any time CAUTION
without public notice or obligation.

1.3 OPERATION & MAINTENANCE CAUTION indicates a potentially hazardous situation


MANUAL which, if not avoided, may result in minor or moderate
injury.
The mechanic must not operate the machine until the
Operation & Maintenance Manual has been read &
understood, training has been accomplished and
operation of the machine has been completed under the
supervision of an experienced and qualified operator.
An Operation & Maintenance Manual is supplied with
each machine and must be kept in the manual holder
located in the cab. In the event that the Operation &
Maintenance Manual is missing, consult your local
service distributor before proceeding.
1-2 TH255
Safety Practices

1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards


SOLVENTS: Only use approved solvents that are known
Following are general safety statements to consider before
to be safe for use.
performing maintenance procedures on the telehandler.
Additional statements related to specific tasks and HOUSEKEEPING: Keep the work area and operator’s
procedures are located throughout this manual and are cab clean, and remove all hazards (debris, oil, tools, etc.).
listed prior to any work instructions to provide safety FIRST AID: Immediately clean, dress and report all injuries
information before the potential of a hazard occurs. (cuts, abrasions, burns, etc.), no matter how minor the
For all safety messages, carefully read, understand and injury may seem. Know the location of a First Aid Kit, and
follow the instructions before proceeding. know how to use it.
CLEANLINESS: Wear eye protection, and clean all
1.6.1 Personal Hazards components with a high-pressure or steam cleaner
PERSONAL SAFETY GEAR: Wear all the protective before attempting service.
clothing and personal safety gear necessary to perform When removing hydraulic components, plug hose ends
the job safely. This might include heavy gloves, safety and connections to prevent excess leakage and
glasses or goggles, filter mask or respirator, safety shoes contamination. Place a suitable catch basin beneath the
or a hard hat. machine to capture fluid run-off.
LIFTING: NEVER lift a heavy object without the help of at It is good practice to avoid pressure-washing electrical/
least one assistant or a suitable sling and hoist. electronic components. In the event pressure-washing
the machine is needed, ensure the machine is shut down
1.6.2 Equipment Hazards before pressure-washing. Should pressure-washing be
utilized to wash areas containing electrical/electronic
LIFTING OF EQUIPMENT: Before using any lifting
components, it is recommended a maximum pressure of
equipment (chains, slings, brackets, hooks, etc.), verify
52 bar (750 psi) at a minimum distance of 30,5 cm (12 in)
that it is of the proper capacity, in good working order, and
away from these components. If electrical/electronic
is properly attached.
components are sprayed, spraying must not be direct and
NEVER stand or otherwise become positioned under a for brief time periods to avoid heavy saturation,
suspended load or under raised equipment. The load or
Check and obey all Federal, State and/or Local
equipment could fall or tip.
regulations regarding waste storage, disposal and
DO NOT use a hoist, jack or jack stands only to support recycling.
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load.
HAND TOOLS: Always use the proper tool for the job;
keep tools clean and in good working order, and use
special service tools only as recommended.

TH255 1-3
Safety Practices

1.6.4 Operational Hazards PRESSURE TESTING: When conducting any test, only
use test equipment that is correctly calibrated and in good
ENGINE: Stop the engine before performing any service
condition. Use the correct equipment in the proper
unless specifically instructed otherwise.
manner, and make changes or repairs as indicated by the
VENTILATION: Avoid prolonged engine operation in test procedure to achieve the desired result.
enclosed areas without adequate ventilation.
LEAVING MACHINE: Lower the forks or attachment to
SOFT SURFACES AND SLOPES: NEVER work on a the ground before leaving the machine.
machine that is parked on a soft surface or slope. The
TIRES: Always keep tires inflated to the proper pressure
machine must be on a hard level surface, with the wheels
to help prevent tipover. DO NOT over-inflate tires.
blocked before performing any service.
NEVER use mismatched tire types, sizes or ply ratings.
FLUID TEMPERATURE: NEVER work on a machine
Always use matched sets according to machine
when the engine, cooling or hydraulic systems are hot.
specifications.
Hot components and fluids can cause severe burns.
Allow systems to cool before proceeding. MAJOR COMPONENTS: Never alter, remove, or
substitute any items such as counterweights, tires,
FLUID PRESSURE: Before loosening any hydraulic or
batteries or other items that may reduce or affect the
diesel fuel component, hose or tube, turn the engine
overall weight or stability of the machine.
OFF. Wear heavy, protective gloves and eye protection.
NEVER check for leaks using any part of your body; use BATTERY: DO NOT charge a frozen battery. Charging a
a piece of cardboard or wood instead. If injured, seek frozen battery may cause it to explode. Allow the battery
medical attention immediately. Diesel fluid leaking under to thaw before jump-starting or connecting a battery
pressure can explode. Hydraulic fluid and diesel fuel charger.
leaking under pressure can penetrate the skin, cause
infection, gangrene and other serious personal injury. 1.7 SAFETY DECALS
Relieve all pressure before disconnecting any
Check that all safety decals are present and readable on
component, part, line or hose. Slowly loosen parts and
the machine. Refer to the Operation & Maintenance
allow release of residual pressure before removing any
Manual supplied with machine for information.
part or component. Before starting the engine or applying
pressure, use components, parts, hoses and pipes that
are in good condition, connected properly and are
tightened to the proper torque. Capture fluid in an
appropriate container and dispose of in accordance with
prevailing environmental regulations.
RADIATOR CAP: The cooling system is under pressure,
and escaping coolant can cause severe burns and eye
injury. To prevent personal injury, NEVER remove the
radiator cap while the cooling system is hot. Wear safety
glasses. Turn the radiator cap to the first stop and allow
pressure to escape before removing the cap completely.
Failure to follow the safety practices could result in death
or serious injury.
FLUID FLAMABILTITY: DO NOT service the fuel or
hydraulic systems near an open flame, sparks or smoking
materials.
NEVER drain or store fluids in an open container. Engine
fuel and hydraulic fluid are flammable and can cause a
fire and/or explosion.
DO NOT mix gasoline or alcohol with diesel fuel. The
mixture can cause an explosion.

1-4 TH255
Section 2
General Information and Specifications

Contents

PARAGRAPH TITLE PAGE


2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.2.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.1 Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.2 Hydraulic Cylinder Performance Specifications. . . . . . . . . . . . . . . . . . . . . 2-11
2.3.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.4 Engine Performance Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.3.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.5 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.5.1 10,1st 50 & 50 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.5.2 1st 250, 250 & 500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . 2-16
2.5.3 1000 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.6 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.6.1 250 Hour Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

TH255 2-1
General Information and Specifications

2.1 REPLACEMENT PARTS AND


WARRANTY INFORMATION
EARLY PRODUCTION ONLY

CURRENT PRODUCTION

MY2350

Before ordering parts or initiating service inquiries, make


note of the machine serial number. The machine serial
number plate (1) is located as indicated in the figure.
Note: The replacement of any part on this machine with
any other than factory authorized replacement parts can
adversely affect the performance, durability, or safety of
the machine, and will void the warranty. JLG disclaims
liability for any claims or damages, whether regarding
property damage, personal injury or death arising out of
the use of unauthorized replacement parts.
A warranty registration form must be filled out by the local
Caterpillar dealer, signed by the purchaser and returned to
the manufacturer when the machine is sold and/or put
into use.
Registration activates the warranty period and helps to
assure that warranty claims are promptly processed. To
guarantee full warranty service, verify that the local
Caterpillar dealer has returned the business reply card of
the warranty registration form to the manufacturer.

2-2 TH255
General Information and Specifications

2.2 TORQUES

2.2.1 SAE Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)


SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
Torque
Tensile Torque Torque (Loctite® 242TM or 271TM
Size TPI Bolt Dia Clamp Load TM
(Loctite® 262TM or Vibra-
Stress Area (Dry) Lubricated OR Vibra-TITE 111 or
TITETM 131)
140)
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

MY3141

TH255 2-3
General Information and Specifications

2.2.1 SAE Fastener Torque Chart


(Continued)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*


Torque Torque
Torque
Tensile (Loctite® 242TM or 271TM (Loctite® 262TM or Vibra-
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
Stress Area
K= 0.20 OR Vibra-TITE TM 111 or TITETM 131)
140) K=.18 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

MY3151

2-4 TH255
General Information and Specifications

2.2.1 SAE Fastener Torque Chart


(Continued)

SOCKET HEAD CAP SCREWS


Magni Coating (Ref 4150701)*
Torque
Torque
(Loctite® 242TM or 271TM
Tensile Clamp Load Torque (Loctite® 262TM
Size TPI Bolt Dia
Stress Area See Note 4 (Dry) K = .17 OR Vibra-TITE TM 111 or TM
or Vibra-TITE 131)
140 OR Precoat 85® K=0.15
K=0.16
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

MY3161

TH255 2-5
General Information and Specifications

2.2.2 Metric Fastener Torque Chart

SOCKET HEAD CAP SCREWS


Zinc Yellow Chromate Fasteners (Ref 4150707)*
Torque
Torque
Torque (Loctite® 242TM or 271TM
Tensile Clamp Load (Loctite® 262TM
Size TPI Bolt Dia
Stress Area See Note 4
(Dry) OR Vibra-TITE TM 111 or TM
or Vibra-TITE 131)
K = .20 140 OR Precoat 85® K=0.15
K=0.18
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

MY3400

2-6 TH255
General Information and Specifications

2.2.2 Metric Fastener Torque Chart


(Continued)

CLASS 8.8 METRIC BOLTS


CLASS 8 METRIC NUTS

Torque
Torque (Loctite®
Tensile Torque
Clamp Torque (Loctite® 262TM 242TM or 271TM
SizePITCH Stress (Dry or Loctite®
Load (Lub) OR Vibra- OR Vibra-
Area 263TM)
TITETM 131) TITETM 111 or
140)

Sq mm KN [N.m] [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4


3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
MY3171 *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.

TH255 2-7
General Information and Specifications

2.2.2 Metric Fastener Torque Chart


(Continued)

CLASS 10.9 METRIC BOLTS


CLASS 10 METRIC NUTS
CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

Torque
Torque (Lub OR Loctite® Torque
Tensile
Clamp (Dry or Loctite® 242 or 271TM OR
TM
(Loctite® 262TM OR
SizePITCH Stress
Load 263TM) Vibra-TITE TM 111 or Vibra-TITE TM 131)
Area
K = 0.20 140) K=0.15
K= 0.18

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 3.13


3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25.2 22.7 18.9
8 1.25 36.60 22.8 36.5 32.8 27.4
10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
MY3181 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.

2-8 TH255
General Information and Specifications

2.2.2 Metric Fastener Torque Chart


(Continued)

Magni Coating (Ref 4150701)*

CLASS 12.9 SOCKET HEAD CAP SCREWS


M6 AND ABOVE*

Torque
Torque
Torque (Lub OR Loctite®
Tensile TM TM (Loctite® 262TM
Clamp Load (Dry or Loctite® 242 or 271
SizePITCH Stress OR Vibra-TITE TM
See Note 4 263TM) OR Vibra-TITE TM
Area 131)
K = .17 111 or 140)
K = .15
K = .16

Sq mm kN [N.m] [N.m] [N.m]

3 0.5 5.03
3.5 0.6 6.78
4 0.7 8.78
5 0.8 14.20
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 54
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 220.0 900 845 790
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.

MY3191

TH255 2-9
General Information and Specifications

2.2.3 Hydraulic Hose Torque Chart Flats Method:


1. If equipped, lubricate o-ring with hydraulic oil. Hand
O-Ring Face Seal & JIC Torque Chart tighten the swivel nut until no lateral movement of
the swivel nut can be detected. Average hand torque
Size ORFS JIC Flats Method
is 4 Nm (3 lb-ft).
18 Nm 18 Nm 2. Mark a dot on one of the swivel nut flats and another
4 1.5 to 1.75
(13 lb-ft) (13 lb-ft) dot in line on the hex of the adapter it’s connecting
31 Nm 31 Nm to.
6 1 to 1.5
(23 lb-ft) (23 lb-ft) 3. Use the double wrench method while tightening to
54 Nm 54 Nm avoid hose twist.
8 1.5 to 1.75
(40 lb-ft) (40 lb-ft) 4. After the connection has been properly tightened,
mark a straight line across the connecting parts, not
81 Nm 81 Nm
10 1.5 to 1.75 covering the dots indicating that the connection has
(60 lb-ft) (60 lb-ft)
been properly tightened.
100 Nm 115 Nm
12 1.0 to 1.5
(136 lb-ft) (85 lb-ft)
156 Nm 156 Nm
16 .75 to 1.0
(115 lb-ft) (115 lb-ft)
230 Nm 230 Nm
20 .75 to 1.0
(170 lb-ft) (170 lb-ft)
271 Nm 271 Nm
24 .75 to 1.0
(200 lb-ft) (200 lb-ft)
366 Nm
32 N/A .75 to 1.0
(270 lb-ft)

Note: By definition the “Flats Method“ will contain some


variance. Use the “Flats Method” only when accessibility
with a torque wrench is not possible.
Torque Wrench:
1. Identify the appropriate application and refer to the
above chart for the correct torque value.
2. If equipped, lubricate o-ring with hydraulic oil. Hand
tighten the swivel nut until no lateral movement of
the swivel nut can be detected. Average hand torque
is 4 Nm (3 lb-ft).
3. Use the double wrench method while tightening to
avoid hose twist.
4. Torque wrench must be held at the center of the grip.
Apply constant force until it clicks.
5. After the connection has been properly tightened,
mark a straight line across the connecting parts
indicating that the connection has been properly
tightened.

2-10 TH255
General Information and Specifications

2.3 SPECIFICATIONS

2.3.1 Travel Speed

12 x 16.5 Tires (Standard) 26 km/h (16 mph)


14 x 17.5 Tires 29 km/h (18 mph)

2.3.2 Hydraulic Cylinder Performance Specifications


Note: Machine with no load, engine at full throttle, hydraulic oil above 54° C (130° F) minimum, engine at operating
temperature.

Function Approximate Times (sec.)


Boom Extend (Boom Level) 6
Boom Retract 4
Boom Lift 6
Boom Lower 4
Quick Coupler - UP 2
Quick Coupler - DOWN 2

2.3.3 Electrical System


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

Battery
Type, Rating 12V, Negative (-) Ground, Tapered Top Post, Maintenance Free
Quantity 1
Reserve Capacity 1000 Cold Cranking Amps @ -18° C (0° F)
Group/Series Group 31
Alternator 12V, 75 Amps
Starter 12V, 3,0 KW Type EV (Gear Reduction)

TH255 2-11
General Information and Specifications

2.3.4 Engine Performance Specifications

Description
Engine Make/Model CAT C4.4DIT
Low Idle 900 ±50 rpm
High Idle 2285-2385 rpm (ANSI) - 2005-2090 RPM (CE & AUS)
Horsepower 84 BHP/ 64,5 kW @ 2200 rpm
Fuel Delivery Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and Safety Elements
Average Fuel Consumption (dependant on load/duty) 6,1 I/hr (1.6 gal/hr)

2.3.5 Tires
Note: Standard wheel lug nut torque is 220 lb-ft (300 Nm).
Note: Pressures for Foam filled tires are for initial fill ONLY.

Minimum Ply/
Size Tire Type Fill Type Pressure
Star Rating
Pneumatic 5,5 bar (80 psi)
12.00 x 16.5 NHS Bias - 12 Ply
Foam - Approx. 100 kg (220 lb) 5,5 bar (80 psi)
Pneumatic 4,8 bar (70 psi)
14.00 x 17.5 NHS Bias - 10 Ply
Foam - Approx. 100 kg (220 lb) 4,8 bar (70 psi)

2-12 TH255
General Information and Specifications

2.4 FLUIDS, LUBRICANTS AND CAPACITIES

a. Fluids

Ambient Temperature Range


Compartment
Type and Classification Viscosities °C °F
or System
Min Max Min Max
SAE 0W-20 -40 10 -40 50
SAE 0W-30 -40 30 -40 86
Cat DEO Multigrade SAE 0W-40 -40 40 -40 104
Cat DEO SYN
Engine SAE 5W-30 -30 30 -22 86
Cat Arctic DEO SYN
Crankcase SAE 5W-40 -30 50 -22 122
Cat ECF-1
SAE 10W-30 -18 40 0 104
API CG-4 Multigrade
SAE 10W-40 -18 50 0 122
SAE 15W-40 -9.5 50 15 122
SAE 0W-20 -40 40 -40 104
SAE 0W-30 -40 40 -40 104
SAE 5W-30 -30 40 -22 104
Hydraulic Cat TDTO
SAE 5W-40 -30 40 -22 104
System, Brake Cat TDTO-TMS
Reservoir, Axle SAE 10W -20 40 -4 104
Differentials and Cat Arctic TDTO SYN
SAE 30 10 50 50 122
Wheel Ends Commercial TO-4
SAE 10W-30 -20 40 -4 104
SAE 15W-40 -15 50 5 122
Cat TDTO-TMS -20 50 -4 122
Boom Wear Pad
Cat Advanced 3Moly NLGI Grade 2 -20 40 -4 104
Grease
Cylinder and
Cat Multipurpose NLGI Grade 2 -30 40 -22 104
Axle Grease
Engine Coolant Cat DEAC 50/50 Mix - Water and Glycol
Fuel #2 Diesel Low Sulfur
Air Conditioning Refrigerant R-134a Tetrafluorethane

TH255 2-13
General Information and Specifications

b. Capacities

Engine Crankcase Oil


Capacity w/Filter Change 9,1 liters (9.6 quarts)
Fuel Tank
Capacity 91 liters (24 gallons)
Cooling System
System Capacity 13,8 liters (14.6 quarts)
Overflow Bottle Capacity 0,6 liters (0.6 quarts)
Hydraulic System
System Capacity 90 liters (23.5 gallons)
Reservoir Capacity to FULL Mark 61 liters (16 gallons)
Auxiliary Hydraulic Circuit Max Flow 75,7 lpm (20 gpm)
Brake System
System Capacity 0,7 liters (0.7 quarts)
Axles
Differential Housing Capacity 3,4 liters (3.6 quarts)
Wheel End Capacity 0,3 liters (10 ounces)
Front Axle Drop Box 0,6 liters (21 ounces)
Air Conditioning System (if equipped)
System Capacity 1134 g (2.5 lb)

2-14 TH255
General Information and Specifications

2.5 MAINTENANCE SCHEDULES

2.5.1 10,1st 50 & 50 Hour Maintenance


Schedule

EVERY
10

Check Fuel Check Engine Check Hydraulic Check Tire


Level Oil Level Oil Level Condition &
Pressure

1st
50
LB/F
T (N
m)

Check Wheel
Lug Nut
Torque

EVERY
50

Drain Fuel/ Check Engine Check Check Check Brake


Water Coolant Level Air Filter Battery Fluid Level
Separator

Check Washer
Fluid Level
(if equipped)
MU7670

TH255 2-15
General Information and Specifications

2.5.2 1st 250, 250 & 500 Hour Maintenance


Schedule

1st
250

Change Axle Change Wheel Change Front


Differential Oil End Oil Axle Drop
Box Oil

EVERY
250

Check Boom Lubrication Check Axle Check Wheel Check Front


Wear Pads Schedule Differential Oil End Oil Levels Axle Drop
Level Box Oil Level

Check
Fan Belt

EVERY
500
LB/F
T (N
m)

Change Fuel Change Engine Change Check Wheel Check LSI


Filter Oil and Air Filter Lug Nut Calibration
Filter Elements Torque
MU7680

2-16 TH255
General Information and Specifications

2.5.3 1000 Hour Maintenance Schedule

EVERY
1000

Change Axle Change Wheel Change Front Change Check


Differential Oil End Oil Axle Drop Hydraulic Hydraulic Tank
Box Oil Fluid & Filters Cap

Change Change
Transmission Engine Coolant
Filter
MU7690

TH255 2-17
General Information and Specifications

2.6 LUBRICATION SCHEDULE

2.6.1 250 Hour Lubrication Schedule

EVERY
250

MY2580

2-18 TH255
Section 3
Boom

Contents

PARAGRAPH TITLE PAGE


3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Boom System - Two Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4.1 Second Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4.2 First Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4.3 First Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4.4 Second Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4.5 Complete Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4.6 Second Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.4.7 Second Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4.8 Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4.9 Extend/Retract Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.4.10 Extend/Retract Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.2 Wear Pad Installation and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.3 Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.6 Quick Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.6.1 Quick Coupler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.6.2 Quick Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.7 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.8 Boom Prop (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.8.1 Installation and Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.9 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.9.1 Equipment and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.9.2 Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

TH255 3-1
Boom

3.1 BOOM SYSTEM COMPONENT


TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the boom system.
The following illustration identifies the components that
are referred to throughout this section.

COMPENSATING
CYLINDER

FIRST
BOOM
SECTION

SECOND
BOOM PIVOT PIN
SECTION

TILT
CYLINDER

EXTEND/RETRACT
CYLINDER

AUXILIARY HYDRAULIC
QUICK CONNECTS

MY1940

QUICK
COUPLER

3-2 TH255
Boom

3.2 SAFETY INFORMATION machine on a hard, level surface, fully retract the
boom, lower the boom, place the transmission
control lever in (N) NEUTRAL, engage the park
WARNING brake and shut the engine OFF.
3. Place a Do Not Operate Tag on both the ignition key
DO NOT service the machine without following all switch and the steering wheel, stating that the
safety precautions as outlined in the “Safety machine should not be operated.
Practices” section of this manual.
4. Properly disconnect the battery.
3.3 BOOM SYSTEM - TWO SECTION 5. Open the engine cover. Allow the system fluids to
cool.
BOOM
6. Remove the quick coupler assembly. Refer to
Section 3.6.1, “Quick Coupler Removal.”
3.3.1 Boom System Description
7. Label and disconnect the tilt hoses and (if equipped)
The boom operates via an interchange among the auxiliary hydraulic hoses attached to the machine at
electrical, hydraulic and mechanical systems. Components the boom head. Plug and cap the hose ends to
involved include the joystick, tilt cylinder, extend/retract prevent dirt and debris from entering the hydraulic
cylinder, lift/lower cylinder, compensating cylinder, system.
electronic sensors, various pivots, supporting hardware
and other components. 8. Label and disconnect the extend/retract hydraulic
tubes on the extend/retract cylinder at the rear of the
boom.
3.4 BOOM ASSEMBLY MAINTENANCE
9. Tag or identify each hose to the corresponding fitting
The boom assembly consists of the first and second it was removed from.
section booms and supporting hardware. 10. Remove the top and side wear pads from the rear of
Note: Before removing the boom or boom section, the the second boom section.
carriage or any other attachment must be removed from Note: Tag each pad, backing plate, shim and bolts from
the quick coupler. each location.
Before beginning, conduct a visual inspection of the
machine and work area, and review the task about to be
undertaken. Read, understand and follow these
instructions.
During service of the boom, perform the following: 1
1. Check wear pads. (Refer to Section 3.5.1, “Wear
Pad Inspection.”)
2
2. Apply grease at all lubrication points (grease fittings).
(Refer to Section 2.6, “Lubrication Schedule.”)
3. Check for proper operation by operating all boom MY1960
functions through their full ranges of motion several
times. 11. Remove the lock bolt and nut (1) from the rear of the
Depending on your particular circumstance, the following extend/retract cylinder.
procedures explain the removal/installation of individual 12. Remove the extend/retract cylinder mounting pin (2).
boom sections or removal/installation of the complete
13. Support the front of the boom by placing a sling
boom.
behind the boom head. Pull the second boom
section out of the first boom section approximately
3.4.1 Second Boom Section Removal 15 cm to 20 cm (6 in to 8 in).
1. Remove any attachment from the quick coupler 14. Pull the tilt hoses and (if equipped) auxiliary
assembly. hydraulic hoses through the rear of the boom.
2. Be sure there is enough room in front of the machine
to allow the boom sections to be removed. Park the

TH255 3-3
Boom

15. Remove the top, side and bottom wear pads from
the front of the first boom section.
3
Note: Tag each pad, backing plate, shim and bolts from
each location.
16. Pull the second boom section halfway out of the first
boom section, reposition the sling, balancing the
second boom section and remove from the first 4
boom section.
17. Set the second boom section on suitable stands to
begin tear down.
18. Inspect the boom and welds. Consult the local
Caterpillar dealer if structural damage is detected. MY1980

19. Inspect hoses, hardware, wear pads, mounting


8. Remove the lock bolt and pin (3) from the rod end of
points and other components visible with the first
the compensating cylinder on the first boom section.
boom section. Replace any item if damaged.
Rest the cylinder on the machine frame.
20. Inspect all wear pads for wear. (Refer to Section
9. Remove the lock bolt and pivot pin (4) from rear of
3.5.1, “Wear Pad Inspection.”)
first boom section.
3.4.2 First Boom Section Removal 10. Lift the first boom section off machine and set on
level ground or supports being careful not to damage
1. Temporarily install the battery negative (-) cable to the tubes on the bottom of the boom.
the battery negative (-) terminal.
11. Inspect the boom and welds. Consult the local
2. Start the machine and raise the first boom section to Caterpillar dealer if structural damage is detected.
gain access to the lift cylinder pin and the comp
cylinder pin. 12. Inspect hoses, hardware, wear pads, mounting
points and other components visible within the first
Note: DO NOT activate ANY boom function other than boom section. Replace any item if damaged.
the boom lift function. Activating the extend/retract, tilt or
13. Inspect all wear pads for wear. (Refer to Section
auxiliary function could cause hydraulic oil to spray onto
3.5.1, “Wear Pad Inspection.”)
the machine and/or surrounding areas.
3. Shut the engine OFF. 3.4.3 First Boom Section Installation
4. Remove the battery negative (-) cable from the Note: Lubrication of the boom wear surfaces with CAT
battery negative (-) terminal. Advanced 3Moly grease is recommended to keep the
5. Support the first boom section by placing a sling at boom wear surfaces lubricated properly. Lubrication of
the balance point of the section. the boom wear surfaces is also recommended when the
6. If equipped, disconnect the LSI boom proximity machine is stored, to help prevent rusting.
sensor at the rear of the first boom section. 1. Park the machine on a hard, level surface, place the
transmission control lever in (N) NEUTRAL, engage
1
the park brake and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Properly disconnect the battery.
4. Open the engine cover. Allow the system fluids to
2 cool.
MY1970
Note: Grease the boom pivot bore, compensating
7. Support the lift/lower cylinder and remove the lock cylinder rod ends, lift/lower cylinder rod end and pins
bolt (1) and then the rod end pin (2). Lower the lift/ before installing.
lower cylinder onto the frame rails.

3-4 TH255
Boom

5. Using suitable slings, balance the first boom section, 1. If previously removed, install the extend/retract
lift and carefully guide the boom into place. Align the cylinder into the rear of the second boom section.
frame pivot bore with the boom assembly pivot bore. Pin and clip the barrel end of the cylinder in place.
Install boom pivot pin (5) and lock bolt. Apply 2. Using suitable slings, balance the second boom
Loctite® 242TM and torque to 90 Nm (66 lb-ft). section, lift and carefully guide the boom into place.
6. With the sling still in place, install the compensating 3. Install the wear pads, shims and bolts to their proper
cylinder, pin (6) and lock bolt. Apply Loctite® 242TM location at the front inside of the first boom section.
and torque to 90 Nm (66 lb-ft). DO NOT tighten the wear pads at this time.
4. Feed the tilt cylinder hoses and if equipped, the
6 auxiliary hoses through the channel above the
extend/retract cylinder.
5. Install the wear pads, shims and bolts previously
removed from the rear of the second boom section.
5
DO NOT tighten the wear pads at this time.
6. Uncap and reconnect the extend/retract cylinder
fittings and plugs from extend/retract cylinder tubes
and tighten until wrench-tight. Mark the fitting, then
torque to specification. Refer to Section 2.2.3,
“Hydraulic Hose Torque Chart.”
MY1980
7. Uncap and reconnect the tilt hoses and (if equipped)
7. With the sling still in place, install the rod end of the auxiliary hoses. Attach both sets to their appropriate
lift/lower cylinder, pin and lock bolt. Apply Loctite® fittings until wrench-tight. Mark the fitting, then
242TM and torque to 90 Nm (66 lb-ft). torque to specification. Refer to Section 2.2.3,
“Hydraulic Hose Torque Chart.”
Note: Raising the boom up or down with the sling may
8. Adjust and shim each wear pad as needed.
be necessary so the boom, compensating and lift/lower
cylinder bores can be aligned for easier pin installation. 9. Properly connect the battery.
8. If equipped, connect the LSI boom proximity sensor 10. Start the engine and operate all boom functions
at the rear of the first boom section. several times to bleed any air out of the hydraulic
system. Check for fluid leaks. Check the hydraulic
9. Remove the sling. fluid level in the tank and add fluid as required.
10. Temporarily install the battery negative (-) cable to 11. Clean up all debris, hydraulic fluid, etc., in, on, near
the battery negative (-) terminal. and around the machine.
11. Start the machine and lower the first boom section to 12. Close and secure the engine cover.
a level position.
Note: DO NOT activate ANY boom function other than 3.4.5 Complete Boom Removal
the boom lift function. Activating the extend/retract, tilt or 1. Remove any attachment from the quick coupler
auxiliary function could cause hydraulic oil to spray onto assembly.
the machine and/or surrounding areas.
2. Be sure there is enough room in front of the machine
12. Shut the engine OFF. to allow the boom sections to be removed. Park the
13. Remove the battery negative (-) cable from the machine on a hard, level surface, fully retract the
battery negative (-) terminal. boom, Raise the boom to allow access to the lift
cylinder and the comp cylinder pivot pins, place the
3.4.4 Second Boom Section Installation transmission control lever in (N) NEUTRAL, engage
the park brake and shut the engine OFF.
Note: Lubrication of the boom wear surfaces with CAT
Advanced 3Moly grease is recommended to keep the 3. Place a Do Not Operate Tag on both the ignition key
boom wear surfaces lubricated properly. Lubrication of switch and the steering wheel, stating that the
the boom wear surfaces is also recommended when the machine should not be operated.
machine is stored, to help prevent rusting. 4. Properly disconnect the battery.

TH255 3-5
Boom

5. Open the engine cover. Allow the system fluids to 3.4.6 Second Boom Section Removal
cool.
1. At the boom head, attach a sling around the tilt
6. Remove the quick coupler assembly. Refer to cylinder. Remove both hoses from tilt cylinder. Plug
Section 3.6.1, “Quick Coupler Removal.” the hose ends and cap the tilt cylinder fittings to
7. Support the boom by placing a sling around the prevent dirt and debris from entering the hydraulic
boom head. Support the lift/lower cylinder and system. Remove the clip from barrel end of tilt
remove the lock bolt and then the rod end pin. Lower cylinder pin. Remove the tilt cylinder pin and lower
the lift/lower cylinder onto the frame rails. the tilt cylinder out of the boom head.
8. Label and disconnect the tilt and auxiliary hydraulic 2. Remove the extend /retract tubes from the extend /
hoses attached to the machine at the tubes on top of retract cylinder from the rear of the boom.
the boom. Plug and cap the hose ends to prevent 3. If equipped, unscrew the auxiliary hoses. Plug the
dirt and debris from entering the hydraulic system. hose ends to prevent dirt and debris from entering
9. Label and disconnect the extend/retract hydraulic the hydraulic system.
hoses at the tubes on the side of the boom. Note: Tag or identify each hose to the corresponding
10. If equipped, disconnect the LSI boom proximity fitting it was removed from.
sensor at the rear of the first boom section.
Note: Tag or identify each hose to the corresponding
fitting it was removed from.

2
MY1990

4. Remove the lock nut, bolt and pin from rod end of
the extend/retract cylinder.
MY1980 5. Pull the second boom section out 15 cm to 20 cm
(6 in to 8 in) to be able to loosen and remove all the
11. Remove the lock bolt and pin (1) from the rod end of bolts and remove all the wear pads, backing plates
the compensating cylinder on the first boom section. and shims from the rear outside of the second
Rest the cylinder on the machine frame. section boom and the front inside of the first section
12. Lower the boom to a level position and place a boom. Tag each pad, backing plate, shim and bolts
suitable support under the rear of the boom. from each location.
Reposition the slings to each end of the boom. 6. Carefully pull the tilt and auxiliary hydraulic hoses (3)
13. Remove the lock bolt and pivot pin (2) from rear of through the rear of the first boom section.
first boom section.
14. Lift the complete boom off machine and set on level
ground or supports being careful not to damage the
WARNING
tubes on the bottom of the boom. NEVER weld or drill the boom unless approved in
writing by the manufacturer. The structural integrity of
the boom will be impaired if subjected to any repair
involving welding or drilling.

7. Pull out the remainder of the second boom section.


8. Inspect the boom and welds. Consult the local
Caterpillar dealer if structural damage is detected.

3-6 TH255
Boom

9. Inspect hoses, hardware, wear pads, mounting 9. Insert the pin and secure the rod end of the extend/
points and other components visible with the first retract cylinder in place with the bolt and locknut.
boom section. Replace any item if damaged. 10. Install both tubes to the rear of the extend/retract
10. Inspect all wear pads for wear. (Refer to Section cylinder.
3.5.1, “Wear Pad Inspection.”) 11. Lift the tilt cylinder into place and insert the pins and
clips to secure the cylinder to the boom head.
3.4.7 Second Boom Section Installation
12. Uncap and reconnect the tilt and auxiliary hoses and
1. If previously removed, insert the extend/retract attach to their appropriate locations.
cylinder through the rear of the second boom section
and attach the pin and clip to the barrel end. 3.4.8 Boom Installation
2. Install the bottom rear wear pads, washers and bolts Note: Lubrication of the boom wear surfaces with CAT
into the second boom section. Apply Loctite® 242TM Advanced 3Moly grease is recommended to keep the
and torque to 90 Nm (66 lb-ft). boom wear surfaces lubricated properly. Lubrication of
Note: Apply Loctite® 242TM to all wear pad bolts prior to the boom wear surfaces is also recommended when the
installing wear pads. machine is stored, to help prevent rusting.

3. Grease the inside of the first boom section on areas 1. Park the machine on a hard, level surface, place the
where the second boom section wear pads will slide. transmission control lever in (N) NEUTRAL, engage
the park brake and shut the engine OFF.
4. Using a suitable sling, carefully slide the second
boom section 1 m to 1.5 m (3 ft to 4 ft) into the front 2. Place a Do Not Operate Tag on both the ignition key
of the first boom section. Set the second boom switch and the steering wheel, stating that the
section head onto suitable supports and reset sling machine should not be operated.
under the boom head of the second section. 3. Open the engine cover. Allow the system fluids to
Carefully slide the second section into the first cool.
section. Leave 15 cm to 20 cm (6 in to 8 in) of the 4. Properly disconnect the battery.
second section out to be able to install wear pads in
front of the first boom section. Note: Grease the boom pivot bore, compensating
cylinder rod ends, lift/lower cylinder rod end and pins
5. With the sling still under the boom head, install the
before installing.
top wear pads, washers and bolts in the front of the
first boom section. Apply Loctite® 242TM and torque 5. Using suitable slings, balance the boom assembly,
to 90 Nm (66 lb-ft). Raise the second boom section lift and carefully guide the boom into place. Align the
and install the bottom wear pads, backing plates, frame pivot bore with the boom assembly pivot bore.
shims and bolts in the front of the first boom section Install boom pivot pin (4) and lock bolt. Apply
Apply Loctite® 242TM and torque to 90 Nm (66 lb-ft). Loctite® 242TM and torque to 90 Nm (66 lb-ft).
Install the left and right side front wear pads, backing 6. With the sling still in place, install the compensating
plates, shims and bolts in the front of the first boom cylinder, pin (5) and lock bolt. Apply Loctite® 242TM
section. Apply Loctite® 242TM and torque to 90 Nm and torque to 90 Nm (66 lb-ft).
(66 lb-ft).
6. Install the top rear left and right side wear pads,
backing plate and bolts (do not shim or tighten bolts).
Install the left and right side rear wear pads, backing
plates and bolts, do not shim or tighten bolts).
4
Note: Lubrication of the boom wear surfaces with CAT
Advanced 3Moly grease is recommended to keep the
boom wear surfaces lubricated properly.
7. Tighten all rear wear pad bolts after ensuring the
minimum gap requirements have been met. Refer to
Section 3.5.1, “Wear Pad Inspection.” 5
MY1980
8. Slide the tilt and auxiliary hoses between the boom
sections.

TH255 3-7
Boom

7. With the sling still in place, install the rod end of the 3.4.9 Extend/Retract Cylinder Removal
lift/lower cylinder, pin and lock bolt. Apply Loctite®
1. Remove any attachment from the quick coupler
242TM and torque to 90 Nm (66 lb-ft).
assembly. Refer to Section 3.6, “Quick Coupler
Note: Raising the boom up or down with the sling may Assembly.”
be necessary so the boom, compensating and lift/lower 2. Park the machine on a hard, level surface, extend
cylinder bores can be aligned for easier pin installation. the boom to gain access to the extend/retract
8. Uncap and reconnect the extend/retract cylinder cylinder pin in the second boom section
fittings and plugs from extend/retract cylinder tubes (approximately 1 m (3 ft), level the boom assembly,
and tighten until wrench-tight. Mark the fitting, then place the transmission control lever in (N)
torque to specification. Refer to Section 2.2.3, NEUTRAL, engage the park brake and shut the
“Hydraulic Hose Torque Chart.” engine OFF.
9. Uncap and reconnect the tilt hoses and (if equipped) Note: The boom must be properly aligned (level) with
auxiliary hoses. Attach both sets to their appropriate the access hole at the rear of the frame to allow removal
fittings until wrench-tight. Mark the fitting, then attach of the extend/retract cylinder barrel mounting pin.
both sets to there appropriate fitting and torque to
3. Place a Do Not Operate Tag on both the ignition key
specification. Refer to Section 2.2.3, “Hydraulic
switch and the steering wheel, stating that the
Hose Torque Chart.”
machine should not be operated.
10. If equipped, connect the LSI boom proximity sensor
4. Open the engine cover. Allow the system fluids to
at the rear of the first boom section.
cool.
11. Properly connect the battery.
5. Properly disconnect the battery.
12. Start the engine and operate all boom functions
several times to bleed any air out of the hydraulic
system. Check for fluid leaks. Check the hydraulic
fluid level in the tank and add fluid as required.

1 2

MY2680

6. Remove the cylinder rod eye retaining clips and


MY2000
mounting pin (2) at the side of the second boom
section.
13. Check clearance (1) between the tilt hoses (and if
equipped) auxiliary hoses and the front of the
extend/retract cylinder trunnion. There should be
approximately 12,7 mm (1/2 in.) of clearance.
14. If adjustment is needed, loosen the tilt tubes (and if
equipped) auxiliary tubes. Move tubes to achieve the
proper clearance.
15. Clean up all debris, hydraulic fluid, etc., in, on, near
and around the machine.
16. Close and secure the engine cover.

3-8 TH255
Boom

3.4.10 Extend/Retract Cylinder Installation


4 1. Using a suitable sling, carefully install the extend/
retract cylinder into the rear of the boom and line up
the barrel end of the cylinder with the pin bores on
the first boom section.
Note: The tilt hoses and (if equipped) the auxiliary
hoses may need to be moved during installation of the
extend/retract cylinder.
2. Install the mounting pin (5), spacers and washers
3 through the frame access hole on the chassis and
the first boom section bore and cylinder barrel.
Secure with retaining clips.
3. Remove the plugs in the bottom of the extend/retract
5 cylinder and install the previously removed fittings.
MY2670
4. Uncap and connect the tubes to the previously
labeled fittings at the extend/retract cylinder. Apply
7. Loosen and remove the hose clamps and cover Loctite® 242TM to the fittings.
plate (3) from the rear of the boom assembly. 5. Uncap and reconnect the tilt hoses and (if equipped)
8. Label and disconnect the tilt and (if equipped) auxiliary hoses (4) to their appropriate fittings until
auxiliary hydraulic hoses attached to the machine at wrench-tight. Mark the fitting and torque to
the tubes on top of the boom (4). Plug and cap the specification. Refer to Section 2.2.3, “Hydraulic
hose ends to prevent dirt and debris from entering Hose Torque Chart.”
the hydraulic system. 6. Install the cover plate and hose clamps (3) at the
9. Loosen and remove the extend/retract cylinder tubes rear of the boom assembly.
at the rear of the first boom section. Plug the tube 7. Properly connect the battery.
ends to prevent dirt and debris from entering the
hydraulic system. 8. Start the machine and extend the extend/retract
cylinder until the rod eye of the cylinder aligns with
10. Loosen and remove both fittings from the bottom of the pin bore in the second boom section.
the extend/retract cylinder barrel. Plug the openings
in the extend/retract cylinder barrel. 9. Shut the engine OFF.

11. Loosen and remove the locking bolt on the cylinder 10. Install the mounting pin through the side of the
barrel mounting pin. second boom section (2) and secure with the
retaining clips.
12. Remove the cylinder barrel pin (5). Note the location
of the spacers and washers. 11. Start the machine and cycle the extend/retract
cylinder to bleed any air out of the hydraulic system.
13. Attach a sling or other suitable lifting device to the Check for fluid leaks or any alignment problems.
extend/retract cylinder and carefully pull the extend/ Check the hydraulic fluid level in the tank and add
retract cylinder free of the machine through the rear fluid as required.
of the boom/chassis assembly.
Note: The tilt hoses and if equipped, the auxiliary hoses
may need to be moved during removal of the extend/
retract cylinder.
14. Place the extend/retract cylinder in a designated
area for the next operation.

TH255 3-9
Boom

3.5 BOOM WEAR PADS • Maintain a total boom section clearance of


0.070-0.130 in (1,78-3,30 mm) both the horizontal
A total of 14 wear pads are installed on the boom. and vertical directions.
A
Twelve of the fourteen wear pads on this boom are flat
rectangular wear pads with metal inserts. Two wear pads
on the bottom of the second section boom are channeled B
for tilt hose and auxiliary hose clearance.

3.5.1 Wear Pad Inspection MY3620

1 1 • The length of the wear pad bolt depends on the


number of shims, spacers and washers being used.
• The thickness of each threaded wear pad insert is
0.312 in (7,92 mm)(A).
Ma2070 • The bolt length should be determined by measuring
the distance from the face of the insert to the face of
Inspect all wear pads for wear. If the angle indicators (1) the boom (B) including any spacer, shim(s) and
on the end of the wear pads are visible, the wear pads washer(s).
can be reused. If the wear pads show uneven wear (front
• Bolt thread engagement in the wear pad insert
to back), they should be replaced. Replace wear pads as should be 0.275 ± 0.040 in (6,98 ± 1,0 mm).
a set if worn or damaged.
• One or two hardened washers are to be used on
each wear pad bolt except where noted otherwise.
3.5.2 Wear Pad Installation and Lubrication DO NOT use more than two hardened washers.
Note: Inspect all wear pads. Replace as necessary. • Use only one hardened washer if mounting bolts are
recessed.
The following wear pad procedure must be followed to
insure the proper wear pad installation: • Wear Pad Bolt Torque:
3/8-24 Bolt, 32-37 lb-ft (43-50 Nm)
• The wear pad inserts and mounting bolts MUST be 3/8-24 Hollow Bolt, 15-17 lb-ft (20-23 Nm)
clean from any grease, oil or other contaminates 1/2-20 Bolt, 76-86 lb-ft (103-116 Nm)
before applying Loctite® 242TM and installing 1/2 - 20 Hollow Bolt, 45-50 lb-ft (61-68 Nm)
mounting bolts. • Torque wear pad bolts after shimming is completed.
• Apply Loctite® 242TM to all wear pad mounting bolts. • Lubricate the face and pockets of each wear pad
after being installed.
3
3.5.3 Boom Wear Pad Lubrication
After replacing any wear pads or after prolonged periods
2 of inoperation, lubrication of the boom wear surfaces with
Cat Advanced 3Moly is recommended to keep the boom
1
wear surfaces lubricated properly. Lubrication of the
boom wear surfaces is also recommended when the
machine is stored, to help prevent rusting.
Note: The first shim under the pad needs to contain
MAM1390
holes, instead of slots.

• A spacer (1) with holes must be used before any


shim (2) is used.
• If required, a shim (2) must inserted between the
spacer (1) and wear pad support plate, block or
boom section (3).
• The number of shims can vary at each shim point.
• The bottom wear pads must be shimmed equally on
each side.

3-10 TH255
Boom

3.6 QUICK COUPLER ASSEMBLY 3.6.2 Quick Coupler Installation


1. Line up the quick coupler between the mounts on the
3.6.1 Quick Coupler Removal boom head. The quick coupler should be centered in
the boom head.
1. Park the machine on a firm, level surface. Place the
transmission control lever in (N) NEUTRAL, engage 2. Coat the quick coupler pivot pin (17) with an anti-
the park brake switch. seize compound. Insert the quick coupler pivot pin
through the quick coupler and boom head. Align the
2. Place a Do Not Operate Tag on both the ignition key
pivot pin and quick coupler. Install the lock bolt (16).
switch and the steering wheel, stating that the
Torque to 97 Nm (72 lb-ft).
machine should not be operated.
3. Align the quick coupler with the tilt cylinder rod end
3. Open the engine cover. Allow the system fluids to
and insert the tilt cylinder pin (15). Align the tilt
cool.
cylinder pin and quick coupler. Install the lock bolt
4. Properly disconnect the battery. (14). Torque to 97 Nm (72 lb-ft).
4. If equipped, uncap and reconnect the hydraulic quick
coupler device hoses (13) to the valve on the left
side of the boom head.
5. Properly connect the battery.
6. Clean up all debris, hydraulic fluid, etc., in, on, near
13
and around the machine.
7. Close and secure the engine cover.

16
17
14
15
MY2660

5. If equipped with a hydraulic quick coupler device,


remove both hydraulic hoses (13) from the valve on
the left side of the boom head. Plug and cap the
hose ends to prevent dirt and debris from entering
the hydraulic system.
6. Remove the lock bolt (14) holding the tilt cylinder rod
end pin (15) to the quick coupler assembly. Remove
the tilt cylinder pin.
7. Support the quick coupler assembly. Remove the
lock bolt (16) holding the quick coupler pin (17) to
the quick coupler assembly. Remove the pin from the
quick coupler assembly from either side.
8. Inspect the above pin for nicks or surface corrosion.
Use fine emery cloth to fix minor nicks or corrosion.
If damaged or if it cannot be repaired the pin must be
replaced.

TH255 3-11
Boom

3.7 FORKS 3.8 BOOM PROP (IF EQUIPPED)


Forks should be cleaned and inspected prior to being
attached to carriage. If the following criteria is not met, 3.8.1 Installation and Removal Procedures
forks must be removed from service immediately.
Daily Inspection WARNING
A raised boom can fall if a hydraulic component is
6 removed. Remove any load, retract the boom and
install the boom prop or a suitable supporting stand
9
before working under a raised boom.
10 7
8
a. Prop Installation
5 1. Park the machine on a firm, level surface. Place the
4
transmission control lever in (N) NEUTRAL, engage
14 the park brake switch.
2. Raise the boom to an angle of approximately 20
degrees. Shut engine OFF.
3. Place a Do Not Operate Tag on both the ignition key
13 11 switch and the steering wheel, stating that the
machine should not be operated.
12 MH6460
4. Before installing the boom prop, inspect the prop for
1. Inspect forks (4) for cracks, paying special attention damage. Do not use if the prop is damaged or if the
to heel (5) and mounting tubes (6). o-rings are damaged or missing.
2. Inspect forks for broken or bent tips (7) and twisted
blades (8) and shanks (9).
Yearly Inspection
1. Straightness of the upper face of blade (8) and the
front face of shank (9) should not exceed 0.5 percent
of the length of blade or height of shank.
2. Angle (10) between upper face of blade and front 3
face of shank should not exceed 93 degrees.
3. Thickness of blade (13) and shank (14) should not 2
be reduced to 90 percent of original thickness.
1
Note: Contact the local Caterpillar dealer with fork part
number to find the manufactured dimensions of the fork 2
blade.
4. Ensure fork length (12) is adequate for intended MAM1280
loads.
5. Install the boom prop (1) onto the lift/lower cylinder.
5. Fork markings should be legible, re-stamp if Install o-rings (2). Align lift cylinder lock so the o-
required. rings are on the bottom side of the lift/lower cylinder
6. Compare fork tips (11) when mounted on a carriage. rod.
Maximum difference in height of fork tips is 3 percent 6. Start the engine and SLOWLY lower the boom until
of the length of the blade (13). there is a clearance of 6 mm (0.25 in) between the
end of the boom prop and the lift/lower cylinder rod
end (3).

3-12 TH255
Boom

7. Shut engine OFF. 3.9.1 Equipment and Supplies Required


Auxiliary Hydraulic Power Supply:
NOTICE • Portable hydraulic unit or another machine with
an auxiliary hydraulic power supply with a capac-
EQUIPMENT DAMAGE. DO NOT operate with the ity to hold up to 11,4 L (3 gal) of hydraulic oil from
boom prop in place. Damage to the boom prop and/or the machine during lowering process.
the lift/lower cylinder could occur.

b. Prop Removal
NOTICE
1. If needed, start machine and slowly raise the boom EQUIPMENT DAMAGE. Auxiliary Hydraulic Power
until the boom prop is clear of the lift/lower rod end. Supply hydraulic oil must be compatible with hydraulic
2. Remove the o-rings (2) and boom prop (1) from the oil shown in Section 2.4, “Fluids, Lubricants and
cylinder. Return the boom prop to the proper location Capacities.”
and secure. Hoses:
3. Lower boom, shut engine OFF. • Two Hydraulic Hoses - Approximately 3,0 m
(10 ft) each, with a minimum I.D. of
3.9 EMERGENCY BOOM LOWERING 9,5 mm (0.375 in.) and a minimum rating of
PROCEDURE 275,8 bar (4000 psi).
Fittings:
In case of an emergency, engine, hydraulic or electrical
failure, use the following procedure to retract and/or lower • Two 25,4 mm (1 in.) - 14 ORFS Caps
the boom. • Two 25,4 mm (1 in.) - 14 ORFS Plugs
Note: Machine extend/retract and lift/lower hoses are -
WARNING 14 ORFS. The adaptor size may vary depending on the
hose ends of the auxiliary hydraulic power supply.
To avoid instability of the machine, the extend/retract
cylinder MUST BE fully retracted prior to retracting 3.9.2 Lowering Procedure
the lift cylinder. If circumstances prevent retraction of
the extend/retract cylinder first, lower the lift cylinder a. Retract the boom as follows:
the minimum amount necessary and resume
retraction of the extend/retract cylinder as soon as 1. Place a suitable receptacle under the hose
possible. connections.

4&5

MAP0040
VIEW FROM LEFT SIDE

2. Locate the extend/retract cylinder connection (4 & 5)


along the left side of the boom where the hoses from
the valve connect to the steel tube.

TH255 3-13
Boom

3. Label and disconnect the hoses from the steel tubes 2. Label and disconnect the lift/lower cylinder hoses
along the left side of the boom. Install plugs in hoses (6 & 7) from the main control valve. Install plugs in
to prevent fluid loss. Cap all fittings and openings to hoses to prevent fluid loss. Cap all fittings and
keep dirt & debris from entering the hydraulic openings to keep dirt & debris from entering the
system. hydraulic system.
Note: Loss of hydraulic oil is limited to the amount Note: Loss of hydraulic oil is limited to the amount
trapped within each hose. trapped within each hose.
4. Using the hoses and fittings specified previously, 3. Using the hoses and fittings specified, connect the
connect the jumper hoses between the auxiliary hoses between the auxiliary hydraulic power supply
hydraulic power supply and the steel tubes (4 & 5) and the hoses removed from the main control valve
connected to the extend/retract cylinder of the lift/lower section of the affected machine. Hose (7) is
affected machine. Ensure that the supply and return the supply (lower) and hose (6) is the return.
lines are installed in the proper order to ensure that Connect the hoses in the proper order to ensure that
the cylinder is retracted, not extended. the boom is lowered, not raised.
5. Use the auxiliary power supply to retract the extend/ 4. Use the auxiliary power supply to retract the lift
retract cylinder. cylinder.
6. Loosen and remove the jumper hoses and reconnect 5. After the boom has been lowered, loosen and
the extend/retract cylinder hoses. remove the jumper hoses and reconnect the lift/
7. Transfer any hydraulic oil into a suitable, covered lower cylinder hoses at the main control valve.
container, and label the container as “Used Oil.” 6. Transfer any hydraulic oil into a suitable, covered
Dispose of used oil at an approved recycling facility. container, and label the container as “Used Oil.”
8. Clean up all debris, hydraulic fluid, etc., in, on, near Dispose of used oil at an approved recycling facility.
and around the machine. 7. Clean up all debris, hydraulic fluid, etc., in, on, near
and around the machine.
b. Lower the boom as follows:
1. Place a suitable receptacle under the main control
valve.

7
MY3000

3-14 TH255
Boom

3.10 TROUBLESHOOTING
This section provides an easy reference guide covering
the most common problems that occur during operation
of the boom.

Problem Possible Causes Remedy


1. Boom will not extend or 1. Broken hydraulic hose(s) or 1. Locate break, replace hose(s)
retract. tube(s) and/or connections or tube(s), tighten connections.
leaking.

2. Extend/Retract hydraulic system 2. Refer to Section 8.7, “Hydraulic


not operating properly. Schematic.”

3. Faulty extend/retract cylinder. 3. Repair cylinder (Refer to Section


8.12, “Hydraulic Cylinders.”)

2. Boom will not fully extend. 1. Extend/retract hydraulic system 1. Refer to Section 8.7, “Hydraulic
not operating properly. Schematic.”

3. Boom shifts to right or left 1. Boom side wear pads 1. Shim wear pads to correct gap.
when extending. improperly shimmed or worn. Replace wear pads as needed.
Refer to Section 3.5.2, “Wear
Pad Installation and
Lubrication.”

4. Excessive pivot pin noise 1. Insufficient lubrication. 1. Lubricate at regular intervals.


and/or wear. (Refer to Section 2.6,
“Lubrication Schedule.”)
Replace worn pins as needed.

2. Worn bushing(s). 2. Replace bushing(s) and


lubricate at regular intervals
(Refer to Section 2.6,
“Lubrication Schedule.”)

5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s)
and/or connection leaks. or tube(s), tighten connections.

2. Lift/lower hydraulic system not 2. Refer to Section 8.7, “Hydraulic


operating properly. Schematic.”

3. Faulty lift cylinder. 3. Repair cylinder. (Refer to


Section 8.12, “Hydraulic
Cylinders.”)

4. Seized boom pivot pin bushing. 4. Replace bushing.

TH255 3-15
Boom

Problem Possible Causes Remedy


6. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and
correct as needed. Refer to
Section 3.5.2, “Wear Pad
Installation and Lubrication.”

2. Rapid cycle times with heavy 2. Reduce cycle times.


loads.

3. Contaminated, corroded or 3. Remove contamination and/or


rusted wear pad sliding corrosion from wear pad sliding
surfaces. surfaces and lubricate. If the
surfaces cannot be
reconditioned, replace the boom
section(s).

4. Operating in extremely dusty/ 4. Clean equipment frequently.


abrasive conditions.

7. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8.7, “Hydraulic
operate. operating properly. Schematic.”

3-16 TH255
Boom

TH255 3-17
Boom

3-18 TH255
Section 4
Cab and Covers

Contents

PARAGRAPH TITLE PAGE


4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.1 Operator Cab Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Cab Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4.1 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4.2 Steering Column/Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.4.3 Brake Pedal and Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.4.4 Throttle Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4.5 Throttle Cable Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.6 High Idle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.7 Joystick Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4.8 Windshield Wiper Assembly (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4.9 Windshield Washer Assembly (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4.10 Heater/Defroster System (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.5 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.6 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

TH255 4-1
Cab and Covers

4.1 OPERATOR CAB AND COVERS


COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the machine cab and
covers. The following illustration identifies the
components that are referred to throughout this section.

LED INDICATOR (CE & AUS)


ACCESSORY CONTROL LEVER
SPEEDOMETER (CE & AUS) (IF EQUIPPED)
FRAME LEVEL
INDICATOR JOYSTICK
LONGITUDINAL LEVEL
HORN BUTTON INDICATOR (AUS)

RIGHT HAND CONSOLE


STEERING WHEEL
POWER OUTLET

INSTRUMENT
PANEL

PARK BRAKE SWITCH


(ANSI)
LSI OVERRIDE SWITCH
(CE & AUS)
TRANSMISSION
CONTROL LEVER

QUICK COUPLER SWITCH


(IF EQUIPPED)

TILT STEERING COLUMN


(IF EQUIPPED)
SERVICE BRAKE PEDAL
IGNITION SWITCH

ACCELERATOR PEDAL

PARK BRAKE LEVER MU7700


(CE & AUS)

4-2 TH255
Cab and Covers

4.2 SAFETY INFORMATION 4.4 CAB COMPONENTS

4.4.1 Steering Wheel


WARNING
a. Steering Wheel Removal
DO NOT service the machine without following all
safety precautions as outlined in the “Safety 1. Park the machine on a firm, level surface, fully
Practices” section of this manual. retract the boom, lower the boom, place the
transmission control lever in (N) NEUTRAL, engage
4.3 OPERATOR CAB the park brake and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
4.3.1 Operator Cab Description switch and the steering wheel, stating that the
machine should not be operated.
The welded metal cab features a modular design, allowing
3. Open the engine covers. Allow the system fluids to
for a relatively quick, simple exchange of the entire cab
cool.
and/or component parts. The cab is bolted directly to the
frame. 4. Properly disconnect the battery.
The operator cab is a protective structure. The cab itself 1
contains rollover protective and falling object protective 3
structures (ROPS/FOPS) for the operator.

WARNING
DO NOT weld, grind, drill, repair or modify the cab in
any way. Any modification or damage to cab structural
components requires cab replacement.

To help ensure optimum safety, protection and


performance, replace the cab if it is damaged. Refer to
the appropriate parts manual for ordering information.
The cab contains the seat, operating controls, numerous 2
panels, steering and brake components, and more.
MAH0430
Covers and mirrors on the machine exist for safety,
5. Carefully pry the center button (1) out of the steering
protection and appearance. They are relatively simple to
wheel.
remove and replace.
6. Mark the steering wheel and shaft to ensure proper
4.3.2 Serial Number Decal installation. Remove the nut (2) securing the steering
wheel (3) to the splined steering column shaft.
The cab serial number decal is located inside the cab,
under the seat. Information specified on the serial 7. Use a steering wheel puller to remove the steering
number plate includes the cab model number, the cab wheel (3) from the splined shaft.
serial number and other data. Write this information down
in a convenient location to use in cab correspondence. b. Steering Wheel Installation
1. Install the steering wheel (3) onto the splined
steering column shaft.
2. Secure the steering wheel with the nut (2).
3. Press the center button (1) onto the steering wheel.
4. Properly connect the battery.
5. Close and secure the engine covers.

TH255 4-3
Cab and Covers

4.4.2 Steering Column/Valve Replacement b. Steering Column and Valve Installation


1. Install the four hex-flange capscrews (three if machine
a. Steering Column and Valve Removal
is equipped with tilt column) through the steering
1. Park the machine on a firm, level surface, fully column, mounting bracket and into the top of the
retract the boom, lower the boom, place the orbitrol valve.
transmission control lever in (N) NEUTRAL, engage
Note: ALWAYS use new o-rings when servicing the
the park brake and shut the engine OFF.
machine.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the 2. Uncap and if needed, install new o-rings into the
machine should not be operated. fittings. Lubricate the o-rings with clean hydraulic oil.

3. Open the engine covers. Allow the system fluids to 3. Uncap and reconnect the previously labeled
cool. hydraulic hoses to their appropriate locations.

4. Properly disconnect the battery. 4. Install the dash cover.


5. Install the steering column cover.

1 6. Install the steering wheel (Refer to Section 4.4.1,


“Steering Wheel.”), accessory lever and
transmission control lever.
3 7. Properly connect the battery.
2
8. Carefully examine all connections one last time
before engine start-up. Rectify any faulty conditions.
9. Start the engine and check the operation of all
4 controls. Check for fluid leaks. Check the hydraulic
fluid level in the tank and add fluid as required.
6
10. Clean up all debris, hydraulic fluid, etc., in, on, near
5
and around the machine.
11. Close and secure the engine covers.
MY2440
c. Power Steering Test
5. Remove the steering wheel (1) (Refer to Section
4.4.1, “Steering Wheel.”), transmission control lever Conduct a pressure check of the steering hydraulic
(2) and accessory lever (if equipped)(3). circuits at the test port on the implement pump. Refer to
Section 8.6.5, “Steering Pressure Checking.”
6. Loosen and remove the steering column cover.
7. Loosen and remove the dash cover. 4.4.3 Brake Pedal and Valve
8. Label, disconnect and cap the hydraulic hoses (4)
and fittings on the steering orbitrol valve (5). a. Brake Valve Removal
9. Remove the four hex-flange capscrews (6)(three if Refer to Section 8.11.2, a. “Service Brake Valve
machine is equipped with tilt column) connecting the Removal,” for removal information.
orbitrol valve to the steering column.
10. Pull the steering column assembly and orbitrol valve b. Brake Valve Installation
from the machine cab. Refer to Section 8.11.2, b. “Service Brake Valve
Note: DO NOT disassemble the steering orbitrol valve. Installation,” for installation information.
The steering orbitrol valve is not serviceable and must
be replaced in its entirety, if defective. c. Service Brake Pedal Removal
1. Park the machine on a firm, level surface, fully
retract the boom, lower the boom, place the
transmission control lever in (N) NEUTRAL, engage
the park brake and shut the engine OFF.

4-4 TH255
Cab and Covers

2. Place a Do Not Operate Tag on both the ignition key 4.4.4 Throttle Pedal Replacement
switch and the steering wheel, stating that the
machine should not be operated. a. Throttle Pedal Removal
3. Open the engine covers. Allow the system fluids to 1. Park the machine on a firm, level surface, fully
cool. retract the boom, lower the boom, place the
4. Properly disconnect the battery. transmission control lever in (N) NEUTRAL, engage
the park brake and shut the engine OFF.
5. Remove the lower dash cover.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
should not be operated.
3. Open the engine covers. Allow the system fluids to
6 cool.
4. Properly disconnect the battery.

7
9

10

10

MY2400 8
6. Remove the clip/pin (6) from the brake plunger fork 10
link.
7. Remove the pin (7) and the return spring securing
the service brake pedal to the cab. MY2360

8. Remove the service brake pedal from the cab. 5. Remove the nut from the end of the throttle cable (8).

d. Service Brake Pedal Installation 6. Loosen the hex jam nut and flat washer (9) securing
the throttle cable to the throttle pedal assembly.
1. Position the service brake pedal in its mounting
7. Remove three capscrews, three lockwashers and
location within the cab.
three washers (10) securing the throttle pedal
2. Install the brake pedal being careful to reposition the assembly to the cab frame.
brake plunger yoke. Install the return spring and pin.
8. Remove the throttle pedal assembly from the cab.
Install clip/pin in brake plunger fork link.
3. Adjust the brake pedal as needed. b. Throttle Pedal Installation
4. Install and secure the lower dash cover. 1. Align the throttle pedal assembly with its mount
5. Properly connect the battery. holes under the cab dash.
6. Close and secure the engine covers. 2. Install three capscrews (10) securing the throttle
pedal assembly to the mount. Torque the capscrews
to 12 Nm (9 lb-ft).
3. Tighten the hex jam nut and flat washer (9) securing
the throttle cable to the throttle pedal assembly.
4. Install the nut to the end of the throttle cable (8).
5. Properly connect the battery.
6. Close and secure the engine cover.

TH255 4-5
Cab and Covers

4.4.5 Throttle Cable Adjustment CE & AUS Machines


1. Start the machine and allow engine to low idle for
1 5 approximately 30 seconds.
2. Verify low idle (850-950 rpm). Low idle is a factory
non-adjustable setting.
3. Bring engine to full throttle. If high idle rpm is greater
4
than or equal to 2340 rpm, a thick throttle stop will
need to be installed. If high idle rpm is less than
2 2340 rpm, a thin throttle stop will need to be
3
installed.
4. Return engine to low idle and shut engine OFF.
MY2360

1. With the engine OFF, lightly depress the accelerator


pedal (3) to the full-throttle position.
2. Block the accelerator pedal to the full throttle position,
check the throttle position on the fuel injector pump on 6
the engine. The throttle lever should be bottomed
against the limit-stop screw.
3. If there is an adjustment needed, return to the cab
and adjust the throttle cable (4) so the lever on the
fuel injector pump bottoms against the limit-stop just
before the throttle pedal bottoms against the limit-
MY2940
stop (5) in the cab.
4. Remove the block holding the throttle before starting 5. Allow the engine to cool. Install proper throttle stop
machine. (6) and verify high idle is correct.
6. Restart engine, bring engine to high idle. High idle
4.4.6 High Idle Adjustment must be between 2005 and 2090 rpm.
Note: Engine coolant temperature must be between Note: For the proper throttle stop, contact the local
10 and 38° C (50 and 100° F). Caterpillar dealer.
ANSI Machines
1. Start the machine and allow engine to low idle for
approximately 30 seconds.
NOTICE
2. Verify low idle (850-950 rpm). Low idle is a factory During the full throttle check:
non-adjustable setting. • DO NOT operate any hydraulic function.
3. Bring engine to full throttle. If high idle rpm is not • DO NOT steer or apply any pressure to the
2285-2385 rpm, readjust the throttle cable at the steering wheel.
throttle pedal in the cab.
• Keep the transmission in (N) NEUTRAL.

WARNING
Avoid breathing exhaust fumes, and prevent engine
operation from becoming a cause of toxic emissions.

4-6 TH255
Cab and Covers

6. Properly connect the battery.


7. Start the engine and test the boom joystick for
WARNING proper functions.

Exhaust system components reach high temperatures 4.4.8 Windshield Wiper Assembly
and can cause severe burns. DO NOT come into (If Equipped)
contact with hot exhaust system components.
Refer to Section 9.9.1, “Windshield Wiper Motor,” for
removal and installation information.
4.4.7 Joystick Replacement
4.4.9 Windshield Washer Assembly
a. Joystick Removal
(If Equipped)
1. Park the machine on a firm, level surface, fully Refer to Section 9.9.3, “Windshield Washer Reservoir
retract the boom, raise the boom, place the and Pump,” for removal and installation information.
transmission control lever in (N) NEUTRAL, engage
the park brake and shut the engine OFF.
4.4.10 Heater/Defroster System (If Equipped)
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine a. Heater Assembly Removal
should not be operated.
1. Park the machine on a firm, level surface, fully
3. Support the boom by installing the lift cylinder lock or retract the boom, lower the boom, place the
a suitable support. transmission control lever in (N) NEUTRAL, engage
4. Open the engine covers. Allow the system fluids to the park brake and shut the engine OFF.
cool. 2. Place a Do Not Operate Tag on both the ignition key
5. Properly disconnect the battery. switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine covers. Allow the system fluids to
cool.
4. Properly disconnect the battery.
7
5. Place a suitable container beneath the radiator drain
plug or petcock. Slowly turn the cap on the coolant
overflow bottle to allow any pressure to escape.
Remove the overflow bottle cap.
8 6. Place a funnel at the base of the radiator to channel
6
the drained coolant into the container. Open the
MY2410 radiator drain plug or petcock and allow the coolant
to drain. Replace the drain plug, or close the
6. Label, disconnect and cap the hydraulic hoses and petcock.
electrical connections (6) to the joystick.
7. Transfer the coolant into a suitable, covered
7. Lift the rubber boot (7) from base of the joystick and container, and label as "Used Coolant". Dispose of
remove the four capscrews (8). used coolant at an approved recycling facility.
8. Remove the joystick.
Note: Label all hoses to ensure correct installation.
b. Joystick Installation
1. Uncap and reconnect the previously labeled
hydraulic hoses to their appropriate locations.
2. Reconnect the electrical connections.
3. Install the four capscrews in the joystick base.
4. Re-seat the rubber boot to the joystick base.
5. Remove the lift cylinder lock if previously installed.

TH255 4-7
Cab and Covers

9. Check the coolant level. Add or remove fluid as


required.
10. Close and secure the engine covers.

4.5 CAB REMOVAL

WARNING
The protection offered by this ROPS/FOPS will be
impaired if subjected to any modification or structural
damage, at which time replacement is necessary.
ROPS/FOPS must be properly installed using
fasteners or correct size and grade, and torqued to
their specified value.

9 Note: To help ensure safety and optimum performance,


MY2430 replace the cab if it is damaged. Refer to the appropriate
10
parts manual for ordering information.
8. Remove the front cover to expose the heater/
defroster element (9). Inspect the cab, its welds and mounts. If modification,
damage, a cracked weld and/or fatigued metal is
9. Loosen the hose clamps and disconnect the two discovered, replace the cab. Contact the local Caterpillar
heater hoses. dealer with any questions about the suitability or
10. Remove the capscrews, nuts and lockwashers condition of a cab.
securing the heater assembly to the cab.
Note: Remove and label cab components as needed
11. Carefully pull out the heater assembly (10). Label before removing the cab from the machine. Label,
and disconnect the wiring harness connections at disconnect and cap hydraulic hoses. Transfer cab parts
the blower. to the replacement cab after the replacement cab is
12. Remove the heater assembly. securely mounted on the machine.
1. Park the machine on a firm, level surface, fully
b. Heater Assembly Installation retract the boom, lower the boom, place the
1. Install the heater assembly (10) to its original transmission control lever in (N) NEUTRAL, engage
orientation. the park brake and shut the engine OFF.
2. Connect the wiring harness connections at the 2. Block all four wheels to help prevent the machine
blower. from moving. Assure that there is sufficient overhead
and side clearance for cab removal.
3. Install the capscrews, nuts and lockwashers to
secure the heater assembly to the cab. 3. Open the engine cover. Allow the system fluids to
cool.
4. Reconnect the two heater hoses.
4. Properly disconnect the battery.
5. Refill the cooling system at the coolant overflow
bottle with a 50/50 mixture of ethylene glycol and 5. If equipped with a cab heater, Refer to Section
water allowing time for the coolant to fill the engine 4.4.10, b. “Heater Assembly Installation.”
block. See Section 2.4, “Fluids, Lubricants and 6. Working underneath the cab, label, disconnect and
Capacities,” for system capacities. cap all hydraulic hoses at the cab fittings. Cap all
6. Properly connect the battery. fittings and openings to keep dirt & debris from
entering the hydraulic system.
7. Start the engine, run it briefly at low idle and check
the machine for any visual sign of fluid leakage. 7. In the cab, disconnect the throttle cable at the
STOP the machine immediately if any leakage is throttle lever bracket. Route the cable away from the
noted, and make any necessary repairs before cab to prevent damage during removal.
continuing.
8. Install the front cover (9) in the cab.

4-8 TH255
Cab and Covers

8. Label and disconnect the cab harness connectors. 4.6 CAB INSTALLATION
Move the harnesses clear of the cab to prevent
damage during cab removal. 1. Block all four wheels to help prevent the machine
9. Install four lifting eye bolts with a minimal lifting from moving. Assure that there is sufficient overhead
capacity of 363 kg (800 lb.) in the existing holes at and side clearance for cab installation.
the top corners of the cab (1). 2. Attach a sling with minimal lifting capacity of 363 kg
10. Use a hoist or overhead crane and sling with a (800 lb.) through the previously installed eye bolts.
minimal lifting capacity of 363 kg (800 lb.) attached 3. Use a hoist or overhead crane and sling attached to
to the four lifting eye bolts. DO NOT attempt to lift the the cab. Carefully begin to align the cab with the
cab at this point. mounting holes in the frame. Stop and check that
11. Remove the bolts (2), washers and nuts securing the wiring, hydraulic hoses, cables, etc., will not be
cab to the frame. pinched or damaged as the cab is positioned. Take
special note of the fuel fill tube as well. Readjust the
1 position of the sling as needed to help balance the
cab during installation.
1 4. Install the cab-to-frame bolts, washers and nuts (2).
Torque the upper cab bolts to 461 Nm (340 lb-ft).
Torque the lower cab bolts to 719 Nm (530 lb-ft).
5. Remove the eye bolts from the top of the cab (1).
6. Connect the throttle cable to the throttle bracket in
the cab.
7. Uncap and reconnect the hydraulic hoses at the cab
locations.
8. Secure the throttle cable to the hydraulic hoses
using nylon ties.
2 9. Install the cab-to-wiring harness connectors on side
of the cab.
MY2420 10. Uncap and connect the heater hoses to the engine.
Secure with hose clamps.
12. Remove the mirrors and all other cab components
11. If equipped with a cab heater, Refer to Section
as needed, if not previously removed.
4.4.10, “Heater/Defroster System (If Equipped).”
13. When all wiring, hydraulic hoses and fasteners are
12. Properly connect the battery.
disconnected or removed, carefully and slowly lift the
cab and remove it from the frame. Readjust the 13. Carefully examine all cab components, fasteners,
position of the sling as needed to help balance the etc., one last time before engine start-up. Rectify any
cab during removal. faulty conditions.
14. When the cab is completely clear of the machine, 14. Start the engine and check the operation of all controls.
carefully lower it to the ground. Block up or support Check for hydraulic fluid leaks. Check the hydraulic
the cab so that it does not move or fall. Assure that fluid level in the tank and add fluid as required
no personnel enter the cab while it is being removed
from the machine.
15. Inspect the condition of the fittings, clamps, hydraulic
NOTICE
hoses, etc. Replace parts as indicated by their When the engine is initially started, run it briefly at low
condition. idle and check the machine for any visual sign of fluid
16. Inspect and replace other machine parts that are leakage. STOP the engine immediately if any leakage
exposed with the cab removed. Repair or replace as is noted, and make any necessary repairs before
required. continuing.

TH255 4-9
Cab and Covers

15. If equipped with optional heater, operate engine until


operating temperature is achieved ensuring that the
thermostat has opened.
16. Turn engine off and wait for the engine to cool and
check the coolant level. Add coolant to the overflow
bottle as required to bring the coolant to the proper
level.
17. Install the protective cover to the front of the cab.
18. Install the mirrors and all other components as
needed, if removed.
19. Unblock the wheels
20. Close and secure the engine cover.

WARNING
Avoid breathing exhaust fumes, and prevent engine
operation from becoming a cause of toxic emissions.

4-10 TH255
Section 5
Axles, Drive Shafts, Wheels and Tires

Contents

PARAGRAPH TITLE PAGE


5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.3 Axle Internal Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.4 Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.5 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4.6 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.4.7 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . 5-6
5.5 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5.1 Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.6 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.6.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5-10
5.6.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . 5-11
5.7 Steering Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.8 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.8.1 Brake Disc Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.9 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.9.1 Equipment and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.9.2 Towing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

TH255 5-1
Axles, Drive Shafts, Wheels and Tires

5.1 AXLE, DRIVE SHAFT AND WHEEL


COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the axles, drive shafts,
wheels and tires. The following illustration identifies the
components that are referred to throughout this section.

FRONT AXLE
ASSEMBLY

REAR STEERING
DRIVE SHAFT CYLINDER

FRONT STEERING
CYLINDER

FRONT AXLE WHEEL


HUBS (2)

MY2070

REAR AXLE
ASSEMBLY

REAR AXLE WHEEL


HUBS (2)

5-2 TH255
Axles, Drive Shafts, Wheels and Tires

5.2 SAFETY INFORMATION 5.4.4 Axle Maintenance


CLEANING: Clean parts with machined or ground
surfaces (such as gears, bearings and shafts) with
WARNING emulsion cleaners or petroleum-based cleaners. DO
NOT steam clean internal components and the interior of
DO NOT service the machine without following all
the planetary hub and axle housing. Water can cause
safety precautions as outlined in the “Safety Practices”
corrosion of critical parts. Rust contamination in the
section of this manual.
lubricant can cause gear and bearing failure. Remove old
gasket material from all surfaces.
5.3 GENERAL INFORMATION
DRYING: Use clean, lintless towels to dry components
after cleaning. DO NOT dry bearings by spinning them
Before performing any inspection, maintenance or
with compressed air; this can damage mating surfaces
service operation, thoroughly clean the unit. The axles
due to lack of lubrication. After drying, coat components
and drive shafts should be checked and repaired only by
with oil or a rust-preventive chemical to help protect them
experienced service technicians who are aware of all
from corrosion. If storing components for a prolonged
safety instructions and particular component features.
period, wrap them in wax paper.
Use suitable products to thoroughly clean all
PERIODIC OPERATION REQUIREMENT: Every two
disassembled mechanical parts to help prevent personal
weeks, drive the machine far enough to cause the drive-
injury to the worker and prevent damage to the parts.
train components to make several complete revolutions.
Carefully inspect the integrity of all moving parts
This will help ensure that internal components receive
(bearings, yokes, tubes, gears, shafts, etc.) and fasteners
lubrication to minimize deterioration caused by
(nuts, bolts, washers, etc.) as they are subject to major
environmental factors such as high humidity.
stress and wear.
SUBMERSION: If the machine has been exposed to
5.4 AXLE ASSEMBLIES water deep enough to cover the hubs, disassemble the
wheel ends and inspect for water damage and
contamination. If the carrier housing was submerged in
5.4.1 Axle Serial Number Plate water, especially if the water level was above the vent
The front and rear axle serial number plate is located on tube (breather), drain the axle and inspect internal parts
the inside of each axle on the right side of the center for water damage and contamination. Before assembling
section. Information on the serial number plate is required and refilling the unit with the specified lubricant(s), clean,
in correspondence regarding the axle. examine and replace damaged parts as necessary.
Supply information from the axle serial number plate
when communicating about an axle assembly or axle
components.

5.4.2 Axle Specifications


General axle specifications are found in Section 2,
“General Information and Specifications.”

5.4.3 Axle Internal Service


Detailed axle service instructions (covering the axle,
differential, brakes and wheel-end safety, repair,
disassembly, reassembly, adjustment and
troubleshooting information) are provided in the Axle
Disassembly & Assembly Manual (P/N 31200451).

TH255 5-3
Axles, Drive Shafts, Wheels and Tires

5.4.5 Axle Removal

2 3
WARNING
An improperly supported machine can fall, causing
death or severe personal injury. Safely raise and
adequately support the machine so that it will remain
stable and in place before attempting to remove an axle.
The front and rear axle assemblies differ in that the front 5 MY2080
axle assembly is equipped with a drop box, hydraulic
4 4
drive pump, parking brake mechanism and a limited-slip
feature; the rear axle has none of these. The following 6. If the axle will be disassembled after removal, place
steps outline a typical axle removal procedure, suitable a suitable receptacle under the axle (1), drop box (2)
for either the front or the rear axle assembly. and wheel hubs (3) drain plugs (4). Remove the
Cleanliness is extremely important. Before attempting to drain plugs and allow the axle oil to drain into the
remove the axle, thoroughly clean the machine. Avoid receptacle. Transfer the used axle oil into a suitable
spraying water or cleaning solution on the stabilizer covered container, and label the container as "Used
solenoids and other electrical components. If using a Oil." Dispose of the used oil at an approved recycling
steam cleaner, seal all openings before steam cleaning. facility.
Note: Clear the work area of all debris, unnecessary 7. Label, disconnect and cap the steering and brake
personnel, etc. Allow sufficient space to raise the lines at the axle. Wipe up any spilled oil.
machine and to remove the axle. 8. Block the front and rear of both tires on the axle that
1. Park the machine on a firm, level surface, fully is not being removed. Ensure that the machine will
retract the boom, lower the boom, place the remain in place during axle removal before
transmission control lever in (N) NEUTRAL, engage proceeding.
the park brake and shut the engine OFF. 9. Raise the machine using a suitable jack or hoist.
2. Place a Do Not Operate Tag on both the ignition key Place suitable supports under both sides of the
switch and steering wheel, stating that the machine frame and lower the machine onto the supports.
should not be operated. Ensure that the machine will remain in place during
axle removal.
3. Open the engine covers. Allow the system fluids to
cool. 10. Support the axle that is being removed with a suitable
jack, hoist or overhead crane and sling. DO NOT
4. Properly disconnect the battery. raise the axle or the machine.
5. If the axle will be disassembled after removal, the oil 11. Mark and remove both wheel and tire assemblies
will have to be drained. Loosen the breather to from the axle that is being removed. (Refer to
release possible internal pressure, then tighten Section 5.6.1, “Removing Wheel and Tire Assembly
breather with a torque wrench to 12 Nm (9 lb-ft). from Machine.”)
1
5 Note: The wheel and tire assemblies must be re-installed
later with the directional tread pattern “arrows” facing in
the direction of forward travel.
12. Remove the drive shaft assembly. (Refer to Section
5.5.3, “Drive Shaft Removal.”)
13. Remove the capscrews, locknuts and axle plates
securing the axle to the frame.

MY2090
4

5-4 TH255
Axles, Drive Shafts, Wheels and Tires

14. Remove the axle from the machine using the jack, 9. Install the wheel and tire assemblies. (Refer to
hoist or overhead crane and sling supporting the Section 5.6.2, “Installing Wheel and Tire Assembly
axle. DO NOT raise or otherwise disturb the onto Machine.”)
machine while removing the axle. Balance the axle 10. Carefully remove the jack, hoist or overhead crane
and prevent it from tipping, turning or falling while and sling supporting the axle.
removing it from beneath the machine. Place the
axle on a suitable support or holding stand. 11. Carefully raise the machine using a suitable jack or
hoist. Remove the supports from beneath the frame
5.4.6 Axle Installation and lower the machine to the ground.
12. Remove the blocks from the front and rear of both
1. Before proceeding, ensure that the machine will
tires on the other axle.
remain in place during axle installation. Block the
front and rear of both tires on the axle that is already 13. Uncap and reconnect the steering and brake lines at
installed on the machine. their axle fittings. Refer to Section 8.11.2, “Service
Brake Valve,” for brake bleeding procedures.
2. If applicable, raise the machine using a suitable jack
or hoist. Place suitable supports beneath the frame 14. Check the hydraulic reservoir oil level.
and lower the machine onto the supports, allowing 15. Connect the battery negative (-) cable to the battery
enough room for axle installation. Ensure that the negative (-) terminal.
machine will remain in place during axle installation.
16. Close and secure the engine covers.
3. Using a suitable jack, hoist or overhead crane and
17. Start the engine. Turn the steering wheel several
sling, remove the axle from its support or holding
times lock to lock and check the function of the
stand. Balance the axle and prevent it from tipping,
brakes. Check for hydraulic leaks, and tighten or
turning or falling while positioning it beneath the
machine. DO NOT raise or otherwise disturb the repair as necessary.
machine while installing the axle. Keep the axle
supported and balanced on the jack, hoist or
overhead crane and sling throughout the installation
procedure.
4. Position the axle under the frame, and align with the
holes in the frame.
5. Install the axle with capscrews, locknuts and the axle
plates. Torque the front and rear axles to 569 Nm
(420 lb-ft).
6. Install the drive shaft assemblies. (Refer to Section
5.5.5, “Drive Shaft Installation.”)
7. If reinstalling an axle previously removed from the
machine, position the driveshaft yoke on the axle
according to the alignment marks made earlier. If
installing a new axle, note the position of the
driveshaft yoke at the transmission. Align the
driveshaft yoke on the axle in the same plane as the
yoke on the transmission.
8. Tighten the axle oil drain plug (4), loosen and
remove the axle oil fill plug (5). Tighten the drop box
oil drain plug (4), loosen and remove the drop box oil
fill plug (5). Fill axle with the appropriate oil. Refer to
Section 2.4, “Fluids, Lubricants and Capacities,” for
proper oil and capacities.Rotate wheel hubs 90
degrees so the drain plug (4) becomes the fill plug.
Fill wheel hubs with the appropriate oil. Refer to
Section 2.4, “Fluids, Lubricants and Capacities,” for
proper oil and capacities.

TH255 5-5
Axles, Drive Shafts, Wheels and Tires

5.4.7 Axle Assembly and Drive Shaft Troubleshooting

Problem Possible Causes Remedy


1. Excessive axle noise while 1. Oil level too low. 1. Fill oil to correct level. (Refer to
driving. Section 2.4, “Fluids, Lubricants
and Capacities.”)

2. Axle and/or wheel end housings 2. Drain axle and/or wheel end
filled with incorrect oil or oil level housings and fill to correct level.
low. (Refer to Section 2.4, “Fluids,
Lubricants and Capacities.”)

3. Incorrect alignment of ring and 3. Correct alignment by adding or


pinion gears. removing shims as needed.

4. Incorrect pinion (input) shaft 4. Correct bearing preload by


bearing preload. adding or removing shims as
needed.

5. Worn or damaged bearings. 5. Replace bearings as needed.

6. Worn or broken gear teeth. 6. Replace gears as needed.

7. Contamination in the axle. 7. Drain axle and/or wheel end


housings and fill to correct level.
(Refer to Section 2.4, “Fluids,
Lubricants and Capacities.”)

8. Axle housing damaged. 8. Replace damaged parts.

2. Intermittent noise when 1. Universal joint(s) worn or 1. Repair or replace universal


traveling. damaged. joints as needed.

2. Differential ring and/or pinion 2. Determine cause and repair as


gears damaged. needed.

3. Vibration or intermittent noise 1. Drive shaft universal joint(s) 1. Tighten capscrews to correct
when traveling. assembly incorrectly tightened. torque.

2. Drive shaft universal joint(s) 2. Repair or replace universal


worn or damaged. joints as needed.

3. Drive shaft damaged/ 3. Replace drive shaft as needed.


unbalanced.

5-6 TH255
Axles, Drive Shafts, Wheels and Tires

5.4.7 Axle Assembly and Drive Shaft Troubleshooting (Continued)

Problem Possible Causes Remedy


4. Oil leaking from axle 1. Drain plugs loose and/or o-rings 1. Replace o-rings as needed and
(differential housing and/or damaged or missing. tighten plugs 80 Nm (59 lb-ft).
axle housings).
2. Hose fittings loose. 2. Tighten fittings.

3. Axle shaft seal damaged or 3. Replace seal and/or joint


missing and/or worn or coupling fork shaft (axle shaft).
damaged shaft sealing
surfaces.

4. Input shaft multi-seal ring 4. Replace multi-seal ring and/or


damaged or missing and/or input shaft. Adjust ring and
worn or damaged pinion (input) pinion alignment and bearing
shaft sealing surfaces. preload as described in the Axle
Repair Manuals.

5. Axle casing to brake housing 5. Replace o-rings and seals.


and/or brake housing to
differential assembly o-rings
and/or seals worn or damaged.

6. Axle housing mounting nuts and 6. Tighten housing nuts and


capscrews loose. capscrews to
320 Nm (236 lb-ft).

7. Differential and/or axle 7. Replace housing(s) as needed.


housing(s) damaged.

5. Oil leaking from wheel end 1. Oil level plugs loose and/or 1. Replace o-rings as needed and
housing (planet carrier). o-rings damaged or missing. tighten plugs to 80 Nm (59 lb-ft).

2. O-ring between hub and 2. Replace o-ring.


housing (planet carrier)
damaged or missing.

3. Shaft seal damaged or missing 3. Replace seal and/or fork joint


and/or worn or damaged shaft shaft.
sealing surfaces.

4. Housing capscrews loose. 4. Tighten housing capscrews to


55 Nm (41 lb-ft).

5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).

6. Oil leaking from steering 1. Hose fittings loose. 1. Tighten fittings.


cylinder.

2. Steering cylinder o-rings and/or 2. Replace o-rings and seals.


seals worn or damaged.

3. Piston rod seal worn or 3. Replace piston rod seal.


damaged.

4. Cylinder tube damaged. 4. Replace cylinder tube.

TH255 5-7
Axles, Drive Shafts, Wheels and Tires

5.4.7 Axle Assembly and Drive Shaft Troubleshooting (Continued)

Problem Possible Causes Remedy


7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level. (Refer to
Section 2.4, “Fluids, Lubricants
and Capacities.”)

2. Axle and/or wheel end housings 2. Drain axle and/or wheel end
filled with incorrect oil or oil housing and fill to correct level.
contaminated or oil level low. (Refer to Section 2.4, “Fluids,
Lubricants and Capacities.”)

8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to the appropriate Axle
operating properly. Repair Manual.

2. Excessive joint housing swivel 2. Correct bearing preload by


bearing preload. adding or removing shims as
needed.

3. Worn or damaged swivel 3. Replace swivel bearings as


bearings. needed.

9. Slow steering response. 1. Steering (hydraulic) system not 1. Refer to the appropriate Axle
operating properly. Repair Manual.

2. Steering cylinder leaking 2. Repair or replace steering


internally. cylinder as needed.

10. Excessive noise when brakes 1. Brake discs worn. 1. Check brake discs for wear.
are engaged. Refer to appropriate Axle Repair
Manual.

2. Brake discs damaged. 2. Replace brake discs.

11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to the appropriate Axle
operating properly. Repair Manual.

2. Brake piston o-rings and seals 2. Replace o-rings and seals.


damaged (leaking).

12. Brakes will not hold the 1. Brake discs worn. 1. Check brake discs for wear.
machine or braking power Refer to the appropriate Axle
reduced. Repair Manual.

2. Brake (hydraulic) system not 2. Refer to the appropriate Axle


operating properly. Repair Manual.

3. Brake piston o-rings and seals 3. Replace o-rings and seals.


damaged (leaking).

5-8 TH255
Axles, Drive Shafts, Wheels and Tires

5.5 DRIVE SHAFTS


TO FRONT AXLE
1

5.5.1 Drive Shaft Inspection


Whenever servicing the machine, conduct a visual
inspection of the drive shaft and cross and bearing
assembly (universal joints, or U-joints). A few moments
spent doing this can help prevent further problems and
2
down time later.
Inspect area where the drive shaft flange yoke and slip 3
yoke mount to the drive shaft. Attempt to turn drive shaft
in both directions. Look for excessive looseness, missing
parts, cracks or other damage. Worn or damaged drive MAH0450
TO REAR AXLE
shaft and cross and bearing assembly may cause an
excessive amount of vibration or noise.
7. Remove the four capscrews (1) and four locknuts
Note: Any bolt removed from the drive shaft assembly securing the yoke flange (2) to the front axle flange.
MUST be replaced. Do Not re-torque 8. Remove the four capscrews securing the flange yoke
to the rear axle flange.
5.5.2 Drive Shaft Maintenance
9. Remove the drive shaft assembly (3).
Refer to Section 2.6, “Lubrication Schedule,” for
information regarding the lubrication of the grease fittings 5.5.4 Drive Shaft Cleaning and Drying
on the drive shafts.
1. Disassemble and clean all parts. Allow to dry.
5.5.3 Drive Shaft Removal 2. Remove any burrs or rough spots from all machined
surfaces. Re-clean and dry as required.
1. Park the machine on a firm, level surface, fully
retract the boom, lower the boom, place the 5.5.5 Drive Shaft Installation
transmission control lever in (N) NEUTRAL, engage
1. Raise the drive shaft assembly (3) into position. The
the park brake and shut the engine OFF.
slip-yoke end of the drive shaft mounts toward the
2. Place a Do Not Operate Tag on both the ignition key front axle. If reinstalling a drive shaft previously
switch and steering wheel, stating that the machine removed, align the flange yokes according to the
should not be operated. alignment marks made during removal.
3. Open the engine covers. Allow the system fluids to 2. Apply Loctite® 243TM to all mounting bolts.
cool.
3. Install the four capscrews (1) and four locknuts
4. Properly disconnect the battery. securing the yoke flange (2) to the front axle. Torque
5. Block the wheels. the capscrews to 139 Nm (102 lb-ft).
6. The drive shaft assembly is a balanced assembly. 4. Install the four capscrews securing the bearing
Mark the yoke and axle, transmission and the shaft crosses to the rear axle. Torque the capscrews to
and slip yoke so that these components can be 139 Nm (102 lb-ft).
returned to their original positions when reinstalled. 5. Properly connect the battery.
Yokes at both ends of the drive shaft must be in the
6. Unblock the wheels.
same plane to help prevent excessive vibration.
7. Close and secure the engine covers.
8. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.

TH255 5-9
Axles, Drive Shafts, Wheels and Tires

5.6 WHEELS AND TIRES 1

WARNING
Mismatched tire sizes, ply ratings or mixing of tire
types (radial tires with bias-ply tires) may compromise
machine stability and may cause machine to tip over.

It is recommended that a replacement tire to be the same


size, ply and brand as originally installed. Refer to the
appropriate parts manual for ordering information. If not
using an approved replacement tire, It is recommended
that replacement tires have the following characteristics:
MZ6020
• Equal or greater ply/load rating and size of original.
The wheel and tire assemblies must be installed with the
• Tire tread contact width equal or greater than
directional tread pattern “arrows” (1) facing in the
original.
direction of forward travel.
• Wheel diameter, width and offset dimensions equal
to the original. 5.6.1 Removing Wheel and Tire Assembly
• Approved for the application by the tire manufacturer from Machine
(including inflation pressure and maximum tire load). 1. Park the machine on a firm, level surface, fully
The rims installed have been designed for stability retract the boom, lower the boom, place the
requirements which consist of track width, tire pressure transmission control lever in (N) NEUTRAL, engage
and load capacity. Size changes such as rim width, the park brake and shut the engine OFF.
center piece location, larger or smaller diameter, etc., 2. Place a Do Not Operate Tag on both the ignition key
without written factory recommendations, may result in switch and steering wheel, stating that the machine
unsafe condition regarding stability. should not be operated.
Foam filled tires have a positive effect on the weight, 3. Loosen but DO NOT remove the lug nuts on the
stability and handling characteristics of the machine, wheel and tire assembly to be removed.
especially under load. The use of hydrofill as a tire-fill
substance is not recommended because of possible 4. Place a suitable jack under the axle pad closest to
environmental impact. the wheel being removed. Raise the machine and
position a suitable support beneath the axle. Allow
Large-bore valve stems are used to help expedite tire sufficient room to lower the machine onto the
inflation and deflation. An inner tube may be used if a tire support and to remove the wheel and tire assembly.
does not provide an airtight seal. Check tire inflation
pressures when the tires are cold. When mounting a tire 5. Lower the machine onto the support.
on the wheel, the tire must be mounted on the wheel 6. Remove lug nuts and washers in an alternating
respective of the directional tread pattern of the tire; this pattern.
produces a left or right tire and wheel assembly. 7. Remove the wheel and tire assembly from the
machine.

5-10 TH255
Axles, Drive Shafts, Wheels and Tires

5.6.2 Installing Wheel and Tire Assembly 5.7 STEERING ANGLE ADJUSTMENT
onto Machine
Detailed axle service instructions are provided in the Axle
Note: The wheel and tire assemblies must be installed
Disassembly & Assembly Manual (P/N 31200451).
with the directional tread pattern “arrows” facing in the
direction of forward travel.
5.8 BRAKES

TREAD “ARROWS” MUST 5.8.1 Brake Disc Inspection


POINT FORWARD
Detailed axle service instructions are provided in the Axle
Disassembly & Assembly Manual (P/N 31200451).

INSTALL TIRES ONTO


WHEELS TO ROTATE IN
PROPER DIRECTION

MAH0460

1. Position wheel onto studs on wheel end of axle.


2. Install washers on the wheel studs.
3. Start all lug nuts by hand to prevent cross threading.
DO NOT use a lubricant on threads or nuts.

3
1 5

8 7

6 2
4
OAH0990

4. Tighten lug nuts in an alternating pattern as


indicated in figure. Torque to 300 Nm (221 lb-ft).
5. Remove machine from supports.
6. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.

TH255 5-11
Axles, Drive Shafts, Wheels and Tires

5.9 TOWING A DISABLED MACHINE Fittings:


• One 9/16-18 UNF (-6) ORFS Cap
Towing a disabled machine should only be attempted
after exhausting all other options. Make every effort to • One 9/16-18 UNF (-6) ORFS Plug
repair the machine, and move it under its own power. Note: Machine axle fittings are 9/16-18 UNF (-6) ORFS.
Towing is only possible by using the “towing” feature built The adaptor size may vary depending on the hose end
into the hydrostatic pump and disengaging the park brake of the auxiliary hydraulic power supply.
on the front axle.
5.9.2 Towing Procedure
• Maximum towing distance is 60 m (200 ft).
1. Securely block all four wheels.
• Maximum towing speed is 8 kmh (5 mph).
• Maximum towing grade is 25%.
DO NOT attempt to tow a machine that is loaded or the
boom/attachment is raised above 1,2 m (4 ft).
1

WARNING
MACHINE HAS NO TOWING BRAKES. Towing
vehicle must be able to control machine at all times.
On highway towing is NOT permitted.

MY1930

WARNING 2. Loosen the jam nut and turn the forward relief valve
BLOCK ALL FOUR WHEELS TO PREVENT (1) on the hydrostatic transmission counterclockwise
MACHINE FROM MACHINE ROLL AWAY. Failure three turns.
to follow instructions could cause death or serious Note: This procedure does not alter any relief settings.
injury.
3 (Not Shown)
5.9.1 Equipment and Supplies Required

NOTICE
EQUIPMENT DAMAGE. Auxiliary Hydraulic Power
Supply hydraulic oil must be compatible with hydraulic
oil shown in Section 2.4, “Fluids, Lubricants and
Capacities.”
Auxiliary Hydraulic Power Supply: MY2050
• Portable hydraulic unit with the capability of pro- 2 3
ducing 20,7 bar (300 psi) minimum pressure to
release the park brake. 3. Connect an auxiliary hydraulic power supply to the
Hose: P1 port (2) on the front axle and apply 15-30 bar
(220-435 psi) to release the park brake.
• One Hydraulic Hose - Approximately 1,5 m
(5 ft), with a minimum I.D. of Note: DO NOT apply more than 31 bar (450 psi) to
6,3 mm (0.25 in.) and a minimum rating of release the park brake. Excessive pressure could
17 bar (250 psi). damage the axle brake system.
4. Loosen the unlocking bolts (3) located at the front
and back side of the axle housing and remove the
stop washers.

5-12 TH255
Axles, Drive Shafts, Wheels and Tires

5. Tighten the unlocking bolts, bottoming the bolts


against the axle housing.
6. Release the pressure from the auxiliary hydraulic
power supply and remove the auxiliary hydraulic
power supply
7. Carefully remove the blocking from each tire and tow
the machine to a secure location.
8. After the machine has been towed to a secure
location, block all four wheels.
9. Turn the forward relief valve (1) on the hydrostatic
transmission clockwise three turns and tighten the
jam nut.
10. Connect an auxiliary hydraulic power supply to the
P1 port (2) on the front axle and apply 15-30 bar
(220-435 psi) to release the park brake.
Note: DO NOT apply more than 31 bar (450 psi) to
release the park brake. Excessive pressure could
damage the axle brake system.
11. Loosen the unlocking bolts (3) and install the stop
washers.
12. Tighten the unlocking bolts.
13. Release the pressure from the auxiliary hydraulic
power supply and remove the auxiliary hydraulic
power supply.
14. The parking brake should now be reactivated and
the front wheels locked.
15. Remove the blocks from the four tires.
16. Verify that the parking brake works.
17. If the parking brake does not work, check all
activation operations step by step.

TH255 5-13
Axles, Drive Shafts, Wheels and Tires

This Page Intentionally Left Blank

5-14 TH255
Section 6
Transmission

Contents

PARAGRAPH TITLE PAGE


6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.1 Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5.2 Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.5.3 Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.5.4 After Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.6 Transmission Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.6.1 Filter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.6.2 Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

TH255 6-1
Transmission

6.1 TRANSMISSION ASSEMBLY


COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the transmission.
The following illustration identifies the components that
are referred to throughout this section.

HYDROSTATIC
TRANSMISSION

DIRECTIONAL
CONTROL VALVE

HYDROSTATIC
FILTER

FORWARD
RELIEF
VALVE

REVERSE
RELIEF
VALVE

MAP0010

6-2 TH255
Transmission

6.2 SAFETY INFORMATION 6.5 TRANSMISSION REPLACEMENT


Note: Contact the local Caterpillar dealer if internal
WARNING transmission repair is required during the warranty
period.
DO NOT service the machine without following all
Cleanliness is of extreme importance. Before attempting
safety precautions as outlined in the “Safety Practices”
to remove the transmission, thoroughly clean the exterior
section of this manual.
of the transmission to help prevent dirt from entering
during the replacement process. Avoid spraying water or
6.3 TRANSMISSION DESCRIPTION cleaning solution onto or near the transmission shift
solenoids and other electrical components.
Instructions in this section pertain mainly to general
specifications, towing, maintenance information, and 6.5.1 Transmission Removal
transmission removal and installation procedures. For
internal transmission service instructions and detailed 1. Park the machine on a firm, level surface, fully
specifications contact the local Caterpillar dealer for a retract the boom, lower the boom, place the
copy of the Transmission Disassembly & Assembly transmission control lever in (N) NEUTRAL, turn rear
Manual (P/N 31200456). wheels to give easier access to rear of engine
compartment, engage the park brake and shut the
More information can be obtained from the serial number
engine OFF.
plate directly mounted on the transmission. Information
specified on the serial number plate includes the 2. Place a Do Not Operate Tag on both the ignition key
transmission model number, the transmission serial switch and steering wheel, stating that the machine
number and other data. Information on the serial number should not be operated.
plate is required in correspondence regarding the 3. Open the engine covers. Allow the system fluids to
transmission. cool.
4. Properly disconnect the battery.
6.4 TRANSMISSION SPECIFICATIONS
5. Remove the air cleaner assembly.
6. Remove hood support at rear of engine.
6.4.1 Transmission Maintenance
7. Drain the hydraulic oil reservoir. Refer to Section
The transmission is a hydraulic component and requires
8.8.2, “Hydraulic Oil Reservoir Draining.”
the same maintenance as the hydraulic system. Refer to
Section 2.5, “Maintenance Schedules.” 8. Label, disconnect and cap all hydraulic hoses
attached to transmission, cap all fittings and
Performance criteria is based on full throttle engine
openings to keep dirt & debris from entering
speed unless otherwise specified or not applicable.
hydraulic system.
9. Label and disconnect all electrical connections
attached to the transmission.
10. Wipe up any spilled hydraulic oil.

TH255 6-3
Transmission

11. Vertically secure transmission with a lifting strap or 7. Reinstall the air cleaner assembly.
chain. Use a suitable hoist or overhead crane. 8. Properly connect the battery.
Operate the hoist or crane to remove slack from the
chain, but DO NOT raise the transmission at this 9. Close and secure the engine covers.
time. 10. Remove the Do Not Operate Tags from both the
12. Remove the two Allen head bolts that attach the ignition key and the steering wheel.
transmission to the engine.
6.5.4 After Transmission Replacement

WARNING 1. Install new hydraulic filters.


2. Check the hydraulic oil level and add oil as required.
The transmission may move while hoisting it out of
the chassis. Carefully move the transmission and
adjust the sling as needed. Keep fingers, hands, legs NOTICE
and other body parts clear of the transmission.
DO NOT use flushing compounds for cleaning
13. Carefully remove the transmission from the machine. purposes.
Avoid causing damage to the transmission or
surrounding parts. 3. Reassemble all components and fill the hydraulic
reservoir with clean, fresh oil. DO NOT overfill.
14. Lift the transmission clear of the machine, and lower
it onto suitable supports or secure it to a stand built 4. Run the engine for two minutes at idle to help bleed any
especially for transmission or engine service. Secure air from the hydraulic system.
the transmission so that it will not move or fall. 5. Operate all boom functions to ensure any air is
removed from the hydraulic system.
6.5.2 Transmission Disassembly 6. Retract and level the boom, recheck the level of the
Transmission disassembly, internal inspection, service, fluid in the reservoir.
repair and assembly procedures are covered in the 7. Add oil as necessary to bring the fluid level up until it
Transmission Disassembly & Assembly Manual reaches the FULL mark on the reservoir. Recheck
(P/N 31200456). the oil level when it reaches operating temperature
(83-94° C or 180-200° F).
6.5.3 Transmission Installation
8. Recheck all drain plugs, lines, connections, etc., for
leaks, and tighten where necessary.
WARNING
NEVER lift a transmission alone; enlist the help of at
least one assistant or use a suitable hoist or overhead
crane and sling. Failure to follow the safety practices
could result in death or serious injury.
1. Use a lifting strap or chain attached to a hoist or
overhead crane to position the transmission within
the chassis.
2. Insert the two Allen head bolts that attach the
transmission to the engine. Torque to 210 Nm
(154 lb-ft).
3. Remove the hoist or overhead crane and sling.
4. Uncap and reconnect the previously labeled hoses
and electrical connections to their appropriate
locations.
5. Fill hydraulic reservoir and bleed the system.
6. Reinstall the hood support.

6-4 TH255
Transmission

6.6 TRANSMISSION FILTER


REPLACEMENT 2 3 4 6

1
MY2450 5

8. Using a 25 mm (15/16 in.) wrench, loosen and


The hydrostatic pump filter is located on the left (inside)
remove the filter housing (2), filter (3) and spring (4).
of the pump (1).
Cleanliness is of extreme importance. Before attempting 6.6.2 Filter Installation
to remove the transmission filter, thoroughly clean the
exterior of the transmission to help prevent dirt from 1. Clean the area surrounding the hydraulic pump filter.
entering during the replacement process. Avoid spraying 2. Install a new o-ring (5) on the base of the filter
water or cleaning solution onto or near the transmission housing and lubricate the new o-ring with clean
direction solenoids and other electrical components. hydraulic oil.
3. Install the small end of the filter spring (4) into the
6.6.1 Filter Removal filter base (6).
1. Park the machine on a firm, level surface, fully 4. Install the filter (3) into the filter base (6) directly
retract the boom, lower the boom, place the behind the filter spring.
transmission control lever in (N) NEUTRAL, turn rear
5. Slowly screw the filter housing into the filter base
wheels to give easier access to rear of engine
keeping the filter and housing aligned.
compartment, engage the park brake and shut the
engine OFF. 6. Torque the filter housing to 45 Nm (33 lb-ft).
2. Place a Do Not Operate Tag on both the ignition key 7. Uncap and reconnect the previously labeled hoses
switch and steering wheel, stating that the machine to their appropriate locations.
should not be operated. 8. Fill hydraulic reservoir and bleed the system.
3. Open the engine covers. Allow the system fluids to 9. Reinstall the air cleaner assembly.
cool.
10. Properly connect the battery.
4. Properly disconnect the battery.
11. Close and secure the engine covers.
5. Remove the air cleaner assembly.
12. Remove the Do Not Operate Tags from both the
6. To allow easier access to the filter, label, disconnect ignition key and the steering wheel.
and cap all hydraulic hoses in the filter area, cap all
fittings and openings to keep dirt & debris from
entering hydraulic system.
7. Place a container or shop rags below the filter
housing to contain any spilled hydraulic oil.

TH255 6-5
Transmission

This Page Intentionally Left Blank

6-6 TH255
Section 7
Engine

Contents

PARAGRAPH TITLE PAGE


7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.5 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.5.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.5.2 Radiator/Oil Cooler and Coolant Heater Replacement . . . . . . . . . . . . . . . 7-4
7.6 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.7 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.7.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.7.2 Fuel/Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.7.3 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.8 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.8.1 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.8.2 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.9 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.9.1 Air Cleaner Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.9.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.10 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.10.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.10.2 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . 7-9
7.10.3 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.11 Engine Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.11.1 Coupler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.11.2 Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

TH255 7-1
Engine

7.1 INTRODUCTION

7.1.1 Disclaimer and Scope


These instructions are written for worldwide use. In
territories where legal requirements govern engine smoke
emission, noise, safety factors, etc., apply all instructions,
data and dimensions provided herein in such a way that
after maintenance, service and repair of the engine,
engine operation does not violate local regulations.
Note: These instructions cover only the routine
maintenance, removal, installation and troubleshooting
of the engine. For assistance with comprehensive
engine diagnosis, repair and component replacement,
contact the local Caterpillar dealer.
A gradual running-in (break-in) of a new engine is not
necessary. Full load can be applied to a new engine as
soon as the engine is put into service and the coolant
temperature is at least 60° C (140° F). Extended light-
load operation during the early life of the engine is not
recommended. DO NOT run the engine at high, no-load
speeds. DO NOT apply an overload to the engine.

7.1.2 Component Terminology


To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the engine components. The following
illustration identifies the components that are referred to
throughout this section.

7-2 TH255
Engine

THERMOSTAT FUEL FILTER

AIR CLEANER
ASSEMBLY

IMPLEMENT
PUMP

OIL FILTER
STARTER

TURBOCHARGER

ALTERNATOR

HYDROSTATIC
TRANSMISSION
FAN

ENGINE
MY1900 MOUNT
ENGINE
MOUNT

TH255 7-3
Engine

7.2 SAFETY INFORMATION 7.5 ENGINE COOLING SYSTEM

7.5.1 Radiator Pressure Cap


WARNING For a 110° C (230° F) system, use a 95 kPa (13 psi)
DO NOT service the machine without following all radiator cap. An incorrect or malfunctioning cap can
safety precautions as outlined in the “Safety Practices” result in the loss of coolant and a hot-running engine.
section of this manual.
7.5.2 Radiator/Oil Cooler and Coolant
7.3 ENGINE SERIAL NUMBER Heater Replacement
Before considering radiator or oil cooler replacement for
The CAT C4.4DIT serial number is located on a tag on other than obvious damage, conduct a cooling system
top of the engine. Information contained in the serial pressure test check the coolant specific gravity, coolant
number is required in correspondence with the engine level, fan belt tension and dash panel temperature
manufacturer. indicator.
Supply the engine serial number and/or data tag • If the engine runs hot, check the temperature of
information when communicating about an engine or the upper radiator hose.
engine components.
• If the hose is not hot, the thermostat may be
stuck in the closed position.
7.4 SPECIFICATIONS AND
MAINTENANCE INFORMATION • If the engine has overheated, performance may
suffer, indicating other damage including a leaking
For engine, coolant and oil specifications, and cylinder head gasket, cracked cylinder head or
maintenance information, refer to Section 2, “General block, and/or other internal engine damage.
Information and Specifications.”
a. Radiator/Oil Cooler Removal
Detailed engine service instructions are provided in the
following publications: 1. Park the machine on a firm, level surface, fully
retract the boom, lower the boom, place the
• Operation and Maintenance Manual
transmission control lever in (N) NEUTRAL, engage
(P/N SEBU8327)
the park brake and shut the engine OFF.
• System Operation Testing and Adjusting
2. Place a Do Not Operate Tag on both the ignition key
(P/N KENR6900)
switch and the steering wheel, stating that the
• Disassembly and Assembly (P/N KENR6249) machine should not be operated.
• Specifications Manual (P/N KENR6248) 3. Open the engine cover. Allow the system fluids to
cool.
4. Thoroughly clean the engine and surrounding area,
including all hoses and fittings before proceeding.
5. Properly disconnect the battery.

7-4 TH255
Engine

b. Radiator/Oil Cooler Installation


1. Install the isolator mounts to the bottom of the
radiator. Insert radiator through the machine frame
and secure to the radiator mount plate with new
locknuts.
2. Be sure the engine fan has clearance in regard to
the radiator. Install the engine cover support (1) to
1 the frame and radiator.
3. Attach the fan safety shroud.
4. Uncap and reconnect the previously labeled
hydraulic hoses to the appropriate locations.
5. Uncap and reconnect all previously labeled coolant
MY1910 hoses to the appropriate locations.
6. Remove radiator cover and support (1). 6. Fill the coolant overflow bottle with a 50/50 mixture
of ethylene glycol and water.
7. Slowly turn the coolant overflow bottle cap and allow
any pressure to escape. Remove the overflow bottle 7. Properly connect the battery.
cap. 8. Run the engine to operating temperature. Visually
8. Place a suitable container beneath the radiator check for leaks with the engine running. Check the
petcock. coolant level in the overflow bottle and fill, or drain,
as necessary. Check the hydraulic fluid level in the
9. Place a funnel at the base of the radiator to channel
tank and add fluid as required.
the drained coolant into the container. Open the
radiator petcock and drain the coolant into the 9. Install the radiator cover.
funnel. Transfer the fluid into a properly labeled 10. Close and secure the engine cover.
container. Dispose of properly if coolant needs to be
11. Remove the Do Not Operate Tags from both the
replaced. Close the radiator petcock.
ignition key and the steering wheel.
10. Label, disconnect and cap all coolant hoses
attached to the radiator. Cap all fittings and openings 7.6 ENGINE ELECTRICAL SYSTEM
to keep dirt & debris from entering the cooling
system. The engine electrical system, including the starter,
11. Label, disconnect and cap all hydraulic hoses alternator and primary wiring, is described in Section 9,
attached to the radiator. Cap all fittings and openings “Electrical System.”
to keep dirt & debris from entering the hydraulic
system. 7.7 FUEL SYSTEM
12. Detach the fan safety shroud.
13. Remove the locknuts holding the isolator mounts at 7.7.1 Diesel Fuel
the bottom of the machine. Fuel represents a major portion of machine operating
14. Connect a lifting strap to the radiator/oil cooler and costs and therefore must be used efficiently. ALWAYS
carefully lift the radiator/oil cooler out of the engine use a premium brand of high-quality, clean diesel fuel.
bay. Low cost, inferior fuel can lead to poor performance and
expensive engine repair.

TH255 7-5
Engine

To clean the fuel/hydraulic oil tank:


1. Have a dry chemical (Class B) fire extinguisher near
NOTICE the work area.
2. Depending on which side of the tank is contaminated
Due to the precise tolerances of diesel injection (fuel or hydraulic oil), remove the fuel or oil tank
systems, keep the fuel clean, and free of dirt and drain plug, and safely drain any fuel or hydraulic oil
water. Dirt and water in the fuel system can cause into a suitable container. Dispose of fuel or hydraulic
severe damage to both the injection pump and the oil properly.
injection nozzles. Use #2 diesel fuel with a minimum
3. Clean the fuel/hydraulic oil tank with a high-pressure
Cetane rating of 40. #2 diesel fuel gives the best
washer, or flush the tank with hot water for five
economy and performance under most operating
minutes and drain the water. Dispose of
conditions. Fuels with Cetane numbers higher than 40
contaminated water properly.
may be needed in high altitudes or extremely low
ambient temperatures to help prevent misfiring and 4. For the fuel tank side, add a diesel fuel emulsifying
excessive smoking. agent to the tank. Refer to the manufacturer’s
instructions for the correct emulsifying agent-to-
Inform the owner/operator of the machine to use #2 water mixture ratio. Refill the tank with water, and
diesel fuel, unless ambient temperatures are below 0° C agitate the mixture for 10 minutes. Drain the tank
(32° F). When temperatures are below 0° C (32° F), a completely. Dispose of contaminated water properly.
blend of #1 diesel and #2 diesel fuels (known as
5. Refill the fuel tank with water until it overflows.
“winterized” #2 diesel) may be used.
Completely flush the tank with water. Empty the fuel
Note: #1 diesel fuel may be used, however, fuel tank, and allow it to dry completely.
economy will be reduced.
Use a low-sulfur content fuel with a cloud point (the c. Inspection
temperature at which wax crystals form in diesel fuel) at Note: If a leak is suspected between the fuel and hydraulic
least 10° below the lowest expected fuel temperature. oil tank, contact the local Caterpillar dealer.
The viscosity of the fuel must be kept above 1.3 1. Inspect the fuel/hydraulic oil tank thoroughly for any
centistokes to provide adequate fuel system lubrication. cracks, slices, leaks or other damage.
Note: When using diesel fuel with a sulfur content below 2. Plug all openings except one elbow fitting. Install the
1.3 percent, the filter change interval must be reduced by elbow fitting, and apply approximately 0.07-0.10 bar
75 hours. The use of fuel with a sulfur content above (1-1.5 psi) of air pressure through the elbow. Check
1.3 percent is not recommended. the tank for leaks by applying a soap solution to the
exterior and look for bubbles to appear at the
7.7.2 Fuel/Hydraulic Oil Tank cracked or damaged area.

a. Cleaning and Drying d. Disassembly and Assembly


If contaminated fuel, hydraulic oil or foreign material is in The fuel/hydraulic oil reservoir is a one piece-unit integral
the tank, the tank can usually be cleaned. to the chassis frame and cannot be disassembled.

b. If a leak is suspected between the fuel and hydraulic oil 7.7.3 After Fuel System Service
tank, contact the local Caterpillar dealer. 1. Drain and flush the fuel tank if it was contaminated.
2. Fill the fuel tank with fresh, clean diesel fuel as required.
Note: If bleeding of the fuel system is required, contact
the local Caterpillar dealer.

7-6 TH255
Engine

7.8 ENGINE EXHAUST SYSTEM

7
7.8.1 Exhaust System Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL 6
position, engage the parking brake, and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine 8
should not be operated.
3. Open the engine cover. Allow the system fluids to MAM1310
cool.
10. Loosen and remove the clamp (6) attaching the
4. Properly disconnect the battery. exhaust pipe to the bracket on the side of the engine.

3
11. Loosen and remove the exhaust pipe flange nuts (7)
2 at the turbocharger.
3
12. Remove the exhaust and flex pipe (8) from the
1 engine compartment.

5 7.8.2 Exhaust System Installation


Note: Keep all clamps loosened until entire exhaust
system is in place.
1. If removed, install the exhaust flex pipe to the
exhaust pipe.
4
MAM1300
Note: Replace the nuts and the exhaust studs on the
turbocharger if damaged.
5. Loosen and remove the clamp (1) connecting the
muffler and tail pipe from the bracket on the side of 2. Install the exhaust and flex pipe (8) in place at the
the frame. turbocharger and bracket mounted on the side of the
6. Loosen and remove the clamp (2) attaching the engine with the previously used hardware. Torque
exhaust pipe to the muffler. the flange nuts (7) on the turbo charger to 30 ±7 Nm
(22 ±5 lb-ft).
7. Remove the muffler and tail pipe (3).
3. Install the exhaust pipe (5) to the flex pipe with the
8. Loosen and remove the clamp (4) attaching the previously used clamp.
exhaust and flex pipe to the frame.
4. Install the muffler and tailpipe (3) to the exhaust pipe
9. Remove the exhaust pipe (5) from the flex pipe. with the previously used hardware.
5. Install the muffler (3) to the frame brackets with the
previously used hardware.
6. Adjust the muffler, exhaust and tail pipes for proper
clearance then tighten all clamps.
7. Properly connect the battery.
8. Start engine and check for exhaust leaks at all
exhaust connections. Adjust or repair as needed.
9. Close and secure the engine cover.
10. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.

TH255 7-7
Engine

7.9 AIR CLEANER ASSEMBLY 7.9.2 Air Cleaner Assembly Installation


1. Install the air cleaner assembly (11) to the air cleaner
mounting plate with the previously used hardware
CAUTION (10).
NEVER run the engine with only the inner safety 2. Place the loosened clamp (9) over the air intake
element installed. elbow and install elbow on the air cleaner assembly.
3. Adjust and tighten clamps before starting the
Note: Refer to the Operation & Maintenance Manual
machine.
(P/N 31200362) for the correct element change
procedure. 4. Properly connect the battery.
5. Close and secure the engine cover.
7.9.1 Air Cleaner Assembly Removal 6. Remove the Do Not Operate Tags from both the
1. Park the machine on a firm, level surface, level the ignition key and the steering wheel.
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL 7.10 ENGINE REPLACEMENT
position, engage the parking brake, and shut the
engine OFF.
7.10.1 Engine Removal
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine 1. Park the machine on a firm, level surface, fully
should not be operated. retract the boom, lower the boom, place the
transmission control lever in (N) NEUTRAL, engage
3. Open the engine cover. Allow the system fluids to
the park brake and shut the engine OFF.
cool.
2. Place a Do Not Operate Tag on both the ignition key
4. Properly disconnect the battery.
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Thoroughly clean the engine and surrounding area,
11 including all hoses and fittings before proceeding.
5. Properly disconnect the battery.
6. Remove the engine cover, radiator cover and engine
bay access cover.
7. Remove front and rear engine cover supports.
8. Drain hydraulic reservoir. Refer to Section 8.8.2,
MAM1310 “Hydraulic Oil Reservoir Draining.”
10 9
9. Drain radiator and overflow bottle. Refer to Section
5. Loosen the clamp (9) securing the air intake elbow to 7.5.2, “Radiator/Oil Cooler and Coolant Heater
the air cleaner assembly. Pull the air intake elbow off Replacement.”
the air cleaner.
10. Label, disconnect and cap all hydraulic hoses
6. Remove the hardware securing the air cleaner to the attached to engine and radiator, cap all fittings and
air cleaner mounting plate (10). Remove the air plug hoses to keep dirt & debris from entering
cleaner assembly (11). hydraulic system.

7-8 TH255
Engine

7.10.2 Engine Disassembly, Inspection and


Service
3
Engine disassembly, internal inspection, service, repair
and assembly procedures are covered in the CAT
C4.4DIT service manual. Several special engine service
tools are required to properly service the CAT engine.
2 Contact the local Caterpillar dealer for further
information.
Note: If the engine is being replaced, there may be external
components that will be required to be transferred from the
original engine to the replacement engine depending upon
1 who you purchase the new engine from and the
configuration of your replacement engine. Refer to the
appropriate CAT user manual for detailed procedures that
cover the transfer of original engine components to the
MY1890
replacement engine.

11. Disconnect the fuel inlet (1) and return lines. Install a 7.10.3 Engine Installation
plug in the end of each line. Note: Refer to Section 2.2, “Torques,” for specific
12. Remove hydraulic and fuel filters, and filter bracket fastener torque specifications.
assembly. 1. Position engine in engine compartment being sure to
13. Unbolt and remove the fan safety shroud. line up the 4 motor mount holes. Replace bolts and
14. Remove bolts securing the radiator and lift it clear of torque to 97 Nm (71 lb-ft).
engine compartment. Refer to section Section 7.5.2, 2. Connect the hydraulic reservoir fill tube.
“Radiator/Oil Cooler and Coolant Heater 3. Connect the exhaust pipe to the engine.
Replacement.”
4. Install the air cleaner assembly into the engine
15. Mark the engine fan orientation. Remove the engine compartment and attach hose to air intake.
fan.
16. Label and disconnect all wire connections on the
engine.
17. Mark the location of the throttle cable (2) at the
engine throttle lever. Disconnect the throttle cable.
18. Detach exhaust and air cleaner hoses from the
engine. Cover air inlets to protect from dirt & debris. 2
19. Remove air cleaner assembly from engine
compartment.
20. Completely disconnect exhaust pipe.
21. Remove the hydraulic reservoir fill tube. 1
22. Secure the engine with a lifting strap or chain from
the appropriate lifting points (3). Use a suitable hoist
or overhead crane.
MY1890
23. Remove the four motor mount bolts that attach the
engine to the frame. 5. Reconnect throttle cable (2) onto the engine, if
24. Carefully lift the engine from the machine. Avoid necessary adjust for full travel.
causing damage to the surrounding parts. 6. Reattach any previously labeled wire connections on
25. Lift the engine clear of the machine, and lower it onto the engine.
suitable supports or stand. Secure the engine so 7. Attach the engine fan.
that it will not move or fall. 8. Reinstall the front and rear engine cover supports.
TH255 7-9
Engine

9. Secure the radiator with the necessary bolts and 20. Check the engine rpm at high idle. Refer to Section
attach the fan safety shroud. Check that the fan top 4.4.5, “Throttle Cable Adjustment,” and Section
clearance is adequate with regard to the radiator. 4.4.6, “High Idle Adjustment,” for adjustment
Reattach the previously labeled hoses. Refer to procedure.
Section 7.5.2, “Radiator/Oil Cooler and Coolant 21. Purge the hydraulic system of air by operating all
Heater Replacement.” Fill with a 50/50 mixture of boom functions through their entire range of motion
ethylene glycol and water. several times. Check the hydraulic oil level.
10. Install the filter bracket assembly. Secure the 22. Check for proper operation of all components.
hydraulic and fuel filters.
23. Turn the engine OFF.
11. Connect the fuel inlet line to the fuel filter (1) and
reconnect the return fuel line to the engine. 24. Install the belly pan.

12. Uncap and reconnect all hydraulic hoses and fittings 25. Install the engine cover. Close and secure the cover.
to the engine and necessary hydraulic elements. 26. Remove the Do Not Operate Tags from both the
Keep hoses free of dirt & debris. ignition key and the steering wheel.
13. Refill the hydraulic reservoir (Refer to the
appropriate Operation & Maintenance Manual for
information concerning the hydraulic oil and filter
change).
14. Reinstall the engine cover, radiator cover and engine
bay access cover.
15. Properly connect the battery.
16. Check that all hydraulic, electrical, cooling, fuel and
exhaust system connections are correct and
connected tightly.
17. Run engine to normal operating temperature then shut
off the engine. While the engine is cooling, check for
leaks.
18. Allow the engine to cool. Check the radiator coolant
level, and top off with a 50/50 mixture of ethylene
glycol and water. Replace the radiator cap.
19. Check for leaks from the engine, main hydraulic pump
and lines, transmission, hydraulic reservoir and fuel
tank. Check the levels of all fluids and lubricants. Fill
as required.

NOTICE
During the full throttle check:
• DO NOT operate any hydraulic function.
• DO NOT steer or apply any pressure to the
steering wheel.
• Keep the transmission in NEUTRAL (N).

7-10 TH255
Engine

7.11 ENGINE COUPLER 7.12 TROUBLESHOOTING


Refer to Section 7.4, “Specifications and Maintenance
7.11.1 Coupler Removal Information,” for detailed engine service information or
1. Remove Hydrostatic transmission. Refer to Section contact the local Caterpillar dealer.
6.5.1, “Transmission Removal.” Be sure to follow all
described safety guidelines.
2. After transmission has been removed, take out the
12 bolts that attach the Flywheel Cover Plate to the
engine.
3. Pull off the Flywheel Cover Plate to expose the
coupler assembly (3).

MY2550

4. Remove the necessary bolts to detach the coupler


assembly.

7.11.2 Coupler Installation


1. Attach the coupler assembly (3) using the necessary
bolts. Torque to 210 Nm (155 lb-ft).
2. Bolt on the Flywheel Cover Plate over the coupler
and flywheel. Torque bolts to 50 Nm (37 lb-ft).
3. Reattach the hydrostatic transmission. Follow all
guidelines in Section 6.5.3, “Transmission
Installation.”

TH255 7-11
Engine

This Page Intentionally Left Blank

7-12 TH255
Section 8
Hydraulic System

Contents

PARAGRAPH TITLE PAGE


8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5 Hoses, Tube Lines, Fittings, Etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5.1 Replacement Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5.2 Hose, Tube, Line and Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.6 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.6.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.6.2 Main Control Valve Pressure Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.6.3 Charge Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.6.4 Boom Function Pressure Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.6.5 Steering Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.7 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.7.1 Before S/N TBS00627. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.7.2 S/N TBS00627 & After . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
8.7.3 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.8 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.8.1 Pressurized Hydraulic Oil Fill Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.8.2 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.8.3 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.9 Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.9.1 Implement Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.10 Front Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.11 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.11.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.11.2 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8.11.3 Parking Brake Valve (ANSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.11.4 Hand Brake Valve (CU & AUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.11.5 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.11.6 Pilot Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.11.7 Inching Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.11.9 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
8.11.10 Joystick Enable Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.11.11 Decompression Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.11.12 Quick Attach Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.11.13 Load Stability Indicator Valve (CE & AUS) . . . . . . . . . . . . . . . . . . . . . . . . 8-28

TH255 8-1
Hydraulic System

8.12 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29


8.12.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
8.12.2 General Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
8.12.3 Cylinder Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
8.12.4 Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
8.12.5 General Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
8.12.6 General Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
8.12.7 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
8.12.8 Hydraulic Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 8-33

8-2 TH255
Hydraulic System

8.1 HYDRAULIC COMPONENT


TERMINOLOGY
To understand the safety, operation and service
information presented in this section, it is necessary that
the operator/mechanic be familiar with the name and
location of the hydraulic components of the machine. The
following illustration identifies the components that are
referred to throughout this section.

COMPENSATING
CYLINDER

HYDRAULIC RESERVOIR and


LIFT/LOWER CYLINDER
(UNDER BOOM)

MAIN CONTROL
JOYSTICK ENABLE
VALVE
VALVE
(UNDER BOOM)

EXTEND/RETRACT
CYLINDER

IMPLEMENT
PUMP

HYDRAULIC
FILTER HYDROSTATIC
DRIVE PUMP

TILT CYLINDER
FRONT AXLE
DRIVE MOTOR MY2530

STEERING
CYLINDER

TH255 8-3
Hydraulic System

8.2 SAFETY INFORMATION 8.4 SPECIFICATIONS


Refer to Section 2.3, “Specifications,” for hydraulic
WARNING system specifications.

DO NOT service the machine without following all 8.5 HOSES, TUBE LINES, FITTINGS, ETC.
safety precautions as outlined in the “Safety
Practices” section of this manual. There are numerous hydraulic hoses, tubes, fittings, etc.
used on this machine. Periodically inspect all of these
8.3 GENERAL INFORMATION and carefully examine any signs of wear, abrasion and/or
deterioration. Determine whether any further use of the
Petroleum-based hydraulic fluids are used in this component would constitute a hazard. If in doubt, replace
machine. The temperature of hydraulic fluid increases the component.
during the operation of various hydraulic functions. A
heated petroleum-based hydraulic fluid presents a fire 8.5.1 Replacement Considerations
hazard, especially when an ignition source is present. Conditions including, but not limited to, the following are
Accordingly, periodically inspect all hydraulic system sufficient for considering component replacement:
components, hoses, tubes, lines, fittings, etc. Carefully 1. Any evidence of hydraulic fluid leakage at the
examine any deterioration and determine whether any surface of a flexible hose or its junction with the
further use of the component would constitute a hazard. metal and couplings.
If in doubt, replace the component.
2. Any blistering or abnormal deformation to the outer
Whenever you disconnect a hydraulic line, coupler, fitting covering of a hydraulic hose.
or other component, slowly and cautiously loosen the part
involved. A hissing sound or slow seepage of hydraulic 3. Hydraulic oil leakage at any threaded or clamped
fluid may occur in most cases. After the hissing sound joint that cannot be eliminated by normal tightening
has ceased, continue removing the part. Any escaping oil or other recommended procedures.
should be directed into an appropriate container. Cap or 4. Evidence of excessive abrasion or scrubbing on the
otherwise block off the part to prevent further fluid outer surface of a hose, rigid tube, or hydraulic
seepage. fitting. Modification must be made to eliminate the
Hydraulic system maintenance will, at times, require that interference of the elements in contact with one
the engine be operated. Always follow safety precautions. another, or to otherwise protect the components
from contact with one another. Slightly moving a
A major cause of hydraulic component failure is hose or adjusting a plastic tie wrap may often be all
contamination. Keeping the hydraulic fluid as clean as that is necessary to eliminate interference; evaluate
possible will help avoid downtime and repairs. Sand, grit each situation and proceed as required by the
and other contaminants can damage the finely machined individual circumstances.
surfaces within hydraulic components. If operating in an
exceptionally dirty environment, change filters and
8.5.2 Hose, Tube, Line and Fitting
inspect the fluid more often. When servicing the system,
Replacement
cap or plug hydraulic fittings, hoses and tube assemblies.
Plug all cylinder ports, valves and the hydraulic reservoir, Before removing a hydraulic hose or component, always
and pump openings until installation occurs. Protect mark or otherwise label the related parts and the exact
threads from contamination and damage. location of the hose or component to aid in proper
reinstallation. Hydraulic fluid is a good cleaner and can
Some hydraulic functions are actuated by interfacing with
remove most liquid-ink type markings, so make sure the
electrical system components (switches, solenoids and
mark or label will remain intact. Alternative methods to
sensors). When the hydraulic system is not functioning
using markers include color-coded tie wraps, number-tag
properly, check the electrical aspect of the malfunctioning
sets, alpha-numeric stampings or markings, and suitably
circuit also.
labeled pieces of tape. Select an appropriate marking
method for the conditions and proceed accordingly.

8-4 TH255
Hydraulic System

NEVER replace a hydraulic hose or other component 6. As a last resort, adjust the appropriate relief valve, if
with a part not specifically designed for this machine. Use applicable. Turning the adjustment screw clockwise
only factory approved parts for best performance and will increase the pressure; turning the screw
safety. counterclockwise will decrease the pressure.
Removal and replacement of hoses, tube lines, fittings,
etc. usually involves straightforward procedures. When 8.6.2 Main Control Valve Pressure Checking
removing a hydraulic hose or other component, be aware
that o-rings are used throughout the hydraulic system. 1
ALWAYS replace a used o-ring with a new part.
Check all routing of hoses, wiring and tubing for sharp
bends or interference with any rotating members. Install
appropriate protective devices such as tie wraps and
conduit to help shield hoses from damage. All tube and
hose clamps must be tight.

8.6 HYDRAULIC PRESSURE DIAGNOSIS


MY2540

8.6.1 Pressure Checks and Adjustments 1. Attach 345 bar (5000 psi) gauge to the test port (1)
In general, follow the steps below whenever conducting at the rear of the implement pump to check the
pressure checks and performing adjustments: system pressure. Make sure the gauge is visible
1. Park the machine on a firm, level surface. Engage from inside the cab.
the park brake, place the transmission control lever 2. See Section 8.6, “Hydraulic Pressure Diagnosis,” for
in (N) NEUTRAL, place the neutral lock lever in the (N) start up procedure. Check the main control pressure
NEUTRAL LOCK position, level the boom and turn with the park brake on and the service brake off at
the engine OFF. full throttle. Retract a boom circuit function until the
2. Pressure tee fittings are conveniently located in each cylinder bottoms. The main control valve pressure
hydraulic circuit. Install a pressure gauge capable of should be 247-252,7 bar (3585-3665 psi) at full
measuring at least 10% more pressure than that throttle. Repeat for each boom circuit to verify the
which the circuit being checked operates under. correct main control valve pressure.

3. Start the engine. Operate machine functions several


times to allow hydraulic oil to reach operating
temperature. The hydraulic oil temperature should
be between 38-49° C (100-120° F). If a temperature
gauge or thermometer is unavailable, the hydraulic oil
reservoir should be warm to the touch.
4. Fully depress the accelerator pedal as required.
Place and hold the joystick in the position needed to
operate the particular machine function being
checked. Continue holding the joystick in position 2
until pressure readings are taken. MY2110

5. Check the pressure gauge reading. It should read as 3. If a pressure adjustment is required, adjust the main
described in the appropriate section. If the reading is relief cartridge (2) on the main control valve.
not as specified, turn the engine OFF and check Recheck pressure after any adjustment has been
other components in the system. Verify that all made.
related hydraulic components and electrical
switches, sensors, solenoids, etc. are operating
correctly.

TH255 8-5
Hydraulic System

8.6.3 Charge Pressure Checking 8.6.5 Steering Pressure Checking

3
MY2540
MY1930

1. Attach a pressure gauge to the test fitting (5) at the


1. Attach a pressure gauge to the test port (3) on the rear of the implement pump. The pressure reading
hydrostatic transmission (4) to check the system should be 182,7-189,6 bar (2650-2750 psi) with the
pressure. The pressure should be 24,1- 28,2 bar steering wheel fully turned to the steering stop in
(350-410 psi) with the engine at low idle. one direction.
2. The charge pressure relief valve is preset at the 2. There is no adjustment for steering pressure.
factory and is not adjustable.

8.6.4 Boom Function Pressure Checking


1. Attach 345 bar (5000 psi) gauge to the test port (5)
at the rear of the implement pump to check the
system pressure. Make sure the gauge is visible
from inside the cab.
2. See Section 8.6, “Hydraulic Pressure Diagnosis,” for
start up procedure. Check the boom function
pressure with the park brake on and the service
brake off at full throttle. Retract each boom circuit
function until the cylinder bottoms. Each circuit
function pressure should be 247-252,7 bar
(3585-3665 psi) at full throttle.
Note: With the machine at operating temperature, the
247-252,7 bar (3585-3665 psi) pressure reading at the
main control valve is 13,3 bar (125 psi) HIGHER than the
237,8-244,7 bar (3450-3550 psi) of each individual valve
section function. DO NOT adjust the main control valve
relief pressure below 247-252,7 bar (3585-3665 psi).
To check individual valve section pressures, install a tee
and test port between the cylinder being checked and
the corresponding valve section on the main control
valve.
The individual valve section relief valves are preset at the
factory and are not adjustable.

8-6 TH255
8.7

TH255
8.7.1

a. CE & AUS
Before S/N TBS00627
HYDRAULIC SCHEMATIC
Refer to Hydraulic Schematic Package (P/N 31200458).

ITEM # DESCRIPTION ITEM # DESCRIPTION

1 MAIN CONTROLVALVE, W/AUX. 15 CYLINDER, LIFT


2 PUMP, HYDRAULIC (VD) 16 CYLINDER, COMP
3 PUMP, IMPLEMENT 17 CYLINDER, CROWD
4 MOTOR, HYDRAULIC 18 CYLINDER, TILT
5 VALVE, STEER SELECT 19 HYDRAULIC RESERVIOR (BUILT IN FRAME)
6 VALVE, PRIORITY 20 RADIATOR, COMBINATION W/ HYD. COOLER
7 VALVE, PILOT SELECT 21 AXLE, FRONT (SERVICE BRAKE)
8 VALVE, PARK BRAKE RELEASE 22 AXLE, FRONT (PARK BRAKE)
9 VALVE, MASTER CYL. BRAKE 23 VALVE, DECOMP
10 JOYSTICK 24 VALVE, BLOCKING
11 FILTER, RETURN 25 VALVE, CHECK (5 PSI)
Hydraulic System

12 VALVE, INCHING

MAP0070-M
13 VALVE, STEERING 27 SENSOR, STEERING PRESSURE
14 VALVE, CHECK (55 PSI) 28 VALVE, LMI

8-7
8-8
b. ANSI
Hydraulic System

ITEM # DESCRIPTION ITEM # DESCRIPTION

1 MAIN CONTROLVALVE, W/AUX. 15 CYLINDER, LIFT


2 PUMP, HYDRAULIC (VD) 16 CYLINDER, COMP
3 PUMP, IMPLEMENT 17 CYLINDER, CROWD
4 MOTOR, HYDRAULIC 18 CYLINDER, TILT
5 VALVE, STEER SELECT 19 HYDRAULIC RESERVIOR (BUILT IN FRAME)
6 VALVE, PRIORITY 20 RADIATOR, COMBINATION W/ HYD. COOLER
7 VALVE, PILOT SELECT 21 AXLE, FRONT (SERVICE BRAKE)
8 VALVE, PARK BRAKE RELEASE 22 AXLE, FRONT (PARK BRAKE)
9 VALVE, MASTER CYL. BRAKE 23 VALVE, DECOMP
10 JOYSTICK 24 VALVE, CHECK (5 PSI)
11 FILTER, RETURN

MAP0080-K
12 VALVE, INCHING
13 VALVE, STEERING
14 VALVE, CHECK (55 PSI)

TH255
TH255
8.7.2

a. CE & AUS
CYLINDER, TILT CYLINDER, CROWD VALVE, MASTER CYLINDER
CYLINDER, LIFT
JOYSTICK

V2
CYLINDER,
COMP

V1
SENSOR,
PILOT
PRESSURE

VALVE, PILOT SELECT


T MPJS3 JS3 JS1 0.047" JS4 FRONT AXLE
SERVICE BRAKE
VALVE, MAIN
CONTROL W/ AUX JS2

FRONT AXLE
TELE AUX TILT PARK BREAK
VALVE,
PARK BRAKE
S/N TBS00627 & After

RELEASE
3A 3B P8 P7 P2 P1 P3 P4 P5 P6

SENSOR, STEERING PRESSURE


VALVE, INCHING

MOTOR, HYDRAULIC

PUMP, HYDRAULIC
VARIABLE DISPLACEMENT

VALVE, VALVE, PRIORITY


COOLER CHECK

VALVE, CHECK

VALVE,
STEER
SELECT

PUMP
IMPLEMENT

FILTER,
RETURN

VALVE,
STEERING

CONTROL VALVE FUNCTIONS


PORT FUNCTION
1A LIFT (BOOM DOWN)
1B LIFT (BOOM UP)
1a LIFT PILOT (BOOM DOWN)
1b LIFT PILOT (BOOM UP)
2A TILT (FORKS DOWN)
2B TILT (FORKS UP)
2a TILT PILOT (FORKS DOWN)
2b TILT PILOT (FORKS UP)
3A AUXILIARY HYDRAULIC
Joystick Functions 3B AUXILIARY HYDRAULIC
Hydraulic System

3a AUX. PILOT
PORT FUNCTION 3b AUX. PILOT
1 LIFT (BOOM UP) 4A CROWD (BOOM RETRACT)
2 CROWD/TILT (BOOM RETRACT)/(FORKS UP) 4B CROWD (BOOM EXTEND)
3 LIFT (BOOM DOWN) 4a CROWD PILOT (BOOM RETRACT)
4 CROWD/TILT (BOOM EXTEND)/(FORKS DOWN) 4b CROWD PILOT (BOOM EXTEND)

MAM3010-B

8-9
8-10
b. ANSI
CYLINDER, TILT CYLINDER, CROWD VALVE, MASTER CYLINDER
JOYSTICK

CYLINDER, LIFT

CYLINDER,
COMP

VALVE, PILOT SELECT


T FRONT AXLE
JS4 SERVICE BRAKE
VALVE, MAIN
CONTROL W/ AUX JS2
FRONT AXLE
TELE AUX TILT PARK BREAK
Hydraulic System

VALVE,
PARK BRAKE
3A 3B P2 P1 P3 P4 P5 P6 RELEASE

VALVE, INCHING

MOTOR, HYDRAULIC

PUMP, HYDRAULIC
VARIABLE DISPLACEMENT

VALVE, VALVE, PRIORITY


COOLER CHECK

VALVE, CHECK

VALVE,
STEER
SELECT

PUMP
IMPLEMENT

FILTER,
RETURN

VALVE,
STEERING

CONTROL VALVE FUNCTIONS


PORT FUNCTION
1A LIFT (BOOM DOWN)
1B LIFT (BOOM UP)
1a LIFT PILOT (BOOM DOWN)
1b LIFT PILOT (BOOM UP)
2A TILT (FORKS DOWN)
2B TILT (FORKS UP)
2a TILT PILOT (FORKS DOWN)
2b TILT PILOT (FORKS UP)
3A AUXILIARY HYDRAULIC
Joystick Functions 3B AUXILIARY HYDRAULIC
3a AUX. PILOT
PORT FUNCTION 3b AUX. PILOT
1 LIFT (BOOM UP) 4A CROWD (BOOM RETRACT)
2 CROWD/TILT (BOOM RETRACT)/(FORKS UP) 4B CROWD (BOOM EXTEND)
3 LIFT (BOOM DOWN) 4a CROWD PILOT (BOOM RETRACT)
4 CROWD/TILT (BOOM EXTEND)/(FORKS DOWN) 4b CROWD PILOT (BOOM EXTEND)

MAM2990-C

TH255
Hydraulic System

8.7.3 Options

a. CE & AUS

OPTIONAL TRAILER BRAKE

OPTIONAL SECOND
OPTIONAL REAR FRONT AUXILIARY OPTIONAL REAR A UX/WITH
AUXILIARY -ELECTRIC- ELECTRIC SECOND FRONT AUX
MAP0021-M

TH255 8-11
Hydraulic System

b. ANSI

OPTIONAL REAR OPTIONAL REAR AUX/WITH


AUXILIARY ELECTRIC SECOND FRONT AUX

OPTIONAL SECOND
FRONT AUXILIARY
-ELECTRIC-
MAP0090-K

8-12 TH255
Hydraulic System

8.8 HYDRAULIC RESERVOIR 8.8.3 Hydraulic Oil Reservoir Filling


1. Be sure the reservoir is clean and free of all debris.
The hydraulic reservoir and fuel tank are part of the
frame. For this reason, neither tank can be removed. For 2. Install new hydraulic oil filters.
cleaning instructions, see Section 7.7.2, “Fuel/Hydraulic 3. Fill the reservoir with Cat HDO oil. Refer to Section
Oil Tank.” 2.4, “Fluids, Lubricants and Capacities.”
Occasionally, fluid may seep, leak or be more forcefully 4. Properly connect the battery.
expelled from the filter head when system pressure
5. Close and secure the battery and engine covers.
exceeds the rating of the filter head or filler cap. If the
return filter becomes plugged, return hydraulic oil will 6. Remove the Do Not Operate Tags from both the
bypass the filter when pressure reaches 1,5 bar (22 psi) ignition key and the steering wheel.
and return to the reservoir unfiltered. 7. Start the machine. Run engine to normal operating
Carefully examine fluid seepage or leaks from the temperature. Operate all hydraulic functions.
hydraulic reservoir to determine the exact cause. Clean
the reservoir and note where any seepage occurs. 8.9 HYDRAULIC SYSTEM PUMP
Leaks from a cracked or damaged reservoir require that
the reservoir be flushed completely with water and 8.9.1 Implement Pump Replacement
repaired by a certified welder using approved techniques.
If these conditions cannot be met, the reservoir must be a. Implement Pump Removal
replaced in its entirety. Contact the local Caterpillar
1. Park the machine on a firm, level surface, fully retract
dealer should reservoir welding be required.
the boom, support the boom, place the transmission
control lever in (N) NEUTRAL, engage the park brake
8.8.1 Pressurized Hydraulic Oil Fill Cap and shut the engine OFF.
The fill cap will allow the hydraulic oil reservoir to 2. Place a Do Not Operate Tag on both the ignition key
pressurize to 0,14 bar (2 psi). Inspect the condition of the switch and the steering wheel, stating that the
cap seal to maintain proper reservoir pressure. machine should not be operated.

8.8.2 Hydraulic Oil Reservoir Draining 3. Open the battery and engine covers. Allow the
system fluids to cool.
1. Park the machine on a firm, level surface, fully
retract the boom, support the boom, place the 4. Properly disconnect the battery.
transmission control lever in (N) NEUTRAL, engage 5. Drain the hydraulic oil reservoir. Refer to Section
the park brake and shut the engine OFF. 8.8.2, “Hydraulic Oil Reservoir Draining.”
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the battery and engine covers. Allow the
system fluids to cool.
4. Properly disconnect the battery.
5. Remove the drain plug at the bottom of the hydraulic
oil reservoir.
6. Transfer the used hydraulic oil into a suitable,
covered container, and label as "Used Oil". Dispose
of used oil at an approved recycling facility. Clean
and reinstall the drain plug. 1

7. Wipe up any spilled hydraulic oil.

MY2100

TH255 8-13
Hydraulic System

6. Thoroughly clean the pump (1) and surrounding 8.10 FRONT DRIVE MOTOR
area, including all hoses and fittings before
proceeding. For internal service instructions and detailed
7. Label, disconnect and cap all hydraulic hoses specifications, contact the local Caterpillar dealer.
attached to the pump, cap all fittings and plug hoses
to keep dirt & debris from entering the hydraulic a. Front Drive Motor Removal
system. 1. Park the machine on a firm, level surface, fully
8. Remove the two bolts that hold the pump in place. retract the boom, lower the boom, place the
transmission control lever in (N) NEUTRAL, engage
b. Implement Pump Installation the park brake and shut the engine OFF.
1. Position pump in the mounting position. 2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
Note: Use new o-rings where required. Never reuse o- machine should not be operated.
rings.
3. Open the battery and engine covers. Allow the
2. Use the two Allen head bolts to secure the pump into system fluids to cool.
place. Torque to 95 Nm (70 lb-ft).
4. Properly disconnect the battery.
3. Uncap and reconnect previously labeled hydraulic
5. Drain the hydraulic reservoir or attach a vacuum
hoses to their proper locations.
adapter fitting to the reservoir fill tube to reduce oil
4. Fill the hydraulic reservoir with clean, filtered spillage.
hydraulic oil.
6. Label and disconnect all hydraulic hoses attached to
5. Prime the pump by filling the case drain port with fresh, the pump, cap all fittings and plug hoses to keep dirt
filtered hydraulic oil from a clean container before & debris from entering hydraulic system.
installing the case drain connector and hose.
7. Support the motor and remove the four bolts
6. Check all routing of hoses and tubing for sharp attaching the motor to the front axle.
bends or interference with any rotating members. All
tube and hose clamps must be tight. b. Front Drive Motor Installation
7. Properly connect the battery. 1. Install the motor onto the front axle. Torque the four
8. Start the engine and run at approximately one-third bolts to 241 Nm (178 lb-ft). Use only new seals.
to one-half throttle for about one minute without 2. Uncap and reconnect the previously labeled
moving the machine or operating any hydraulic hydraulic hoses to their appropriate locations.
functions.
9. Inspect for leaks and check all fluid levels.
2
10. Close and secure the battery and engine covers.
11. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.
Note: Check for leaks and repair as required before
continuing.
MY2120
12. Close and secure the engine covers.
13. Remove the Do Not Operate Tags from both the 3. Fill the motor with hydraulic fluid through the fill plug
ignition key and the steering wheel. (2) before starting the machine.
4. Refill the hydraulic reservoir and inspect for leaks
c. Pump Test around the machine.
1. Perform a flow meter test on the pump. 5. Properly connect the battery.
2. Check the system functions. 6. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
moving the machine or operating any hydraulic
functions.

8-14 TH255
Hydraulic System

7. Inspect for leaks and check all fluid levels. 8. Label, disconnect and cap all the hydraulic hoses
8. Close and secure the battery and engine covers. attached to the main control valve. Cap all fittings
and openings to keep dirt & debris from entering the
9. Remove the Do Not Operate Tags from both the hydraulic system.
ignition key and the steering wheel.
9. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.
8.11 CONTROL VALVES
10. Remove the four bolts securing the main control
valve to the frame bracket.
8.11.1 Main Control Valve
The main control valve is mounted on the rear of the b. Main Control Valve Disassembly
machine behind the rear access panel.
1. To disassemble the individual sections of the main
control valve, remove the nuts from the end of the tie
rods. Pull the tie rods out through the sections.
2. Disassemble each section assembly as required.
Some sections include a pre-adjusted relief valve that
regulates pressure in a specific circuit.
6

NOTICE
1 DO NOT adjust any of the relief valve assemblies!
Tampering with a relief valve will irrevocably alter
MY2110
pressure in the affected circuit, requiring re-calibration or
FRONT OF MACHINE 2 3 4 5 a new relief valve.

The main control valve assembly consists of various Disassemble each Valve Section
working sections with their own valve assemblies, each
providing a specific hydraulic function. The section 1. Carefully separate the end cover section from the lift/
assemblies are the left-hand end cover (1), lift/lower (2), lower section.
tilt (3), auxiliary (4), crowd (5) and right-hand end cover 2. Remove the o-rings from between the two sections.
(6) sections.
3. Carefully separate each remaining section and
remove all o-rings and seals.
a. Main Control Valve Removal
4. Remove any plugs, check valves, compensator
1. Park the machine on a firm, level surface, fully valves, anti-cavitation valves, shock valves or the
retract the boom, lower the boom, place the rectangular hydraulic remote positioners from each
transmission control lever in (N) NEUTRAL, engage individual valve section if equipped.
the park brake and shut the engine OFF.
5. Keep all parts being removed from individual valve
2. Place a Do Not Operate Tag on both the ignition key sections tagged and kept together.
switch and the steering wheel, stating that the
machine should not be operated. c. Main Control Valve Parts Cleaning
3. Open the battery and engine covers. Allow the
Clean all components with a suitable cleaner, such as
system fluids to cool.
trichlorethylene, before continuing. Blow dry.
4. Properly disconnect the battery.
5. Remove the rear panel. Allow the hydraulic fluid to d. Main Control Valve Parts Inspection
cool. Inspect all parts and internal passageways for wear,
6. Thoroughly clean the main control valve and damage, etc. If inner surfaces of any component DO NOT
surrounding area, including all hoses and fittings, display an ultra-smooth, polished finish, or are damaged
before proceeding. in any way, replace the damaged part. Often, dirty
7. Place a suitable container to catch hydraulic fluid hydraulic fluid causes failure of internal seals, damage to
drainage beneath the frame. the polished surfaces within the component, and wear of

TH255 8-15
Hydraulic System

and/or harm to other parts. 7. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
e. Main Control Valve Assembly moving the machine or operating any hydraulic
Note: ALWAYS replace seals, o-rings, gaskets, etc., functions.
with new parts to help ensure proper sealing and 8. Inspect for leaks and check the level of the hydraulic
operation. Lubricate seals and o-rings with clean fluid in the reservoir. Shut the engine OFF.
hydraulic oil. 9. Wipe up any hydraulic fluid spillage in, on, near and
Assemble each Valve Section around the machine, work area and tools.
1. Reassemble any plugs, check valves, compensator 10. Install the rear panel.
valves, anti-cavitation valves, shock valves or 11. Close and secure the battery and engine covers.
hydraulic remote positioners from individual valve
12. Remove the Do Not Operate Tags from both the
sections if equipped.
ignition key and the steering wheel.
2. Install the end covers onto Lift/Lower and Crowd
sections. g. Main Control Valve Test

Assemble the Main Control Valve Conduct a pressure check of the hydraulic system in its
entirety. Adjust pressure(s) as required. Refer to Section
1. Place all three tie rods with the washers and nuts 8.6.2, “Main Control Valve Pressure Checking.”
through the end main control valve section.
2. Stand the end main control valve section on end. 8.11.2 Service Brake Valve
3. Install proper o-rings on the inner face of the end The service brake valve is at the base of the steering
main control valve section. Align the Crowd section column support, concealed by the lower dash cover.
over the three tie rods and slide onto the end main The service brakes themselves are part of the front axle.
control valve section. Refer to Section 5.8, “Brakes,” for further information.
4. Using proper o-rings and load sense shuttle, repeat
step three for the remaining sections.
5. Install the washers and nuts on the tie rods and
torque to 25 Nm (18.5 lb-ft).

f. Main Control Valve Installation


1. Loosely install the four main control valve mounting
bolts through bracket on the rear of the machine.
2. Install the main control valve onto the bracket,
aligning the bolts with the holes in the end sections
of the main control valve. Slide the main control
valve into position, and tighten the bolts.
3. Prime the main control valve by filling the inlet
openings with fresh, filtered hydraulic oil from a MY2160

clean container, before attaching the hoses.


a. Service Brake Valve Removal
4. Use new oiled o-rings as required. Uncap and
reattach and secure all hoses, clamps, etc. to the 1. Park the machine on a firm, level surface, fully
main control valve. retract the boom, lower the boom, place the
5. Check the routing of all hoses, wiring and tubing for transmission control lever in (N) NEUTRAL, engage
sharp bends or interference with any rotating the park brake and shut the engine OFF.
members, and install tie wraps and/or protective 2. Place a Do Not Operate Tag on both the ignition key
conduit as required. Tighten all tube and hose switch and the steering wheel, stating that the
clamps. machine should not be operated.
6. Properly connect the battery. 3. Open the battery and engine covers. Allow the
system fluids to cool.

8-16 TH255
Hydraulic System

4. Properly disconnect the battery. c. Service Brake Bleeding Procedure


5. Remove the necessary dash panels. 1
6. Label, disconnect and cap the hydraulic hoses
connected to the service brake valve. Cap all fittings
and openings to keep dirt & debris from entering the
brake system.
7. Remove the bolts that mount the service brake valve
to the steering column support.
Note: DO NOT disassemble the service brake valve.
The service brake valve is not serviceable and must be
replaced in its entirety, if defective.
MY2050

b. Service Brake Valve Installation


Carefully bleed the brake lines as soon as the brake valve
1. Install the service brake valve to the steering column is installed on the machine. Air in the system will not allow
support with the necessary hardware. the brakes to apply properly. There are two brake bleeder
locations (1) on the front axle. The outside bleeder is
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
used for the park brake circuit. The inside bleeder is used
with new parts to help ensure proper sealing and
for the service brake circuit. Work with an assistant to
operation. Lubricate seals and o-rings with clean
perform this procedure.
hydraulic oil.
1. Place the transmission control lever in
2. Use new oiled o-rings as required. Uncap and (N) NEUTRAL, engage the park brake, and start the
reconnect the previously labeled hydraulic hoses to engine.Raise the boom to access the brake
the appropriate locations. bleeders. Support boom and turn off engine.
3. Check the routing of all hoses, and tubing for sharp 2. Remove the plastic cap from the brake bleeder.
bends or interference with any rotating members, Attach one end of a length of transparent tubing over
and install tie wraps and/or protective conduit as the brake bleeder. Place the other end of this tubing
required. Tighten all tube and hose clamps. in a suitable transparent container that is partially
4. Properly connect the battery. filled with hydraulic oil. The end of the tubing must be
5. Start the engine and run at approximately one-third below the oil level in the container.
to one-half throttle for about one minute, without 3. DO NOT open the brake bleeder without holding the
moving the machine or operating any hydraulic tubing firmly on the bleeder. There is pressure at the
functions. brakes. Have an assistant depress the brake pedal.
6. Inspect the service brake valve and connections for Carefully open the bleeder with a 12 mm wrench.
leaks, and check the brake fluid level. Shut the Close the brake bleeder when air bubbles no longer
engine OFF. appear in the oil. Release the brake pedal. Remove
the tubing from the brake bleeder.
7. Replace the necessary dash panels.
4. If bleeding the service brake circuit, install a vacuum
8. Wipe up any hydraulic fluid spillage in, on, near and
pump on the brake reservoir and remove the
around the machine, work area and tools.
remainder of the trapped air from the brake system.
9. Close and secure the battery and engine covers. 5. The inching valve may also require bleeding, refer to
10. Remove the Do Not Operate Tags from both the Section 8.11.7, “Inching Valve.”
ignition key and the steering wheel. 6. Check brake fluid level and add fluid if necessary.
Refer to Section 2.4, “Fluids, Lubricants and
Capacities.”

TH255 8-17
Hydraulic System

d. Brake Performance Test 3. Clean all components with a suitable cleaner before
inspection.
1. Press down on the service brake pedal. The pedal
should NOT travel to the cab floor. Start the 4. Inspect the solenoid cartridges for proper operation.
machine, shift into forward, release the park brake Check by shifting the spool to ensure that it is
and slowly accelerate. Apply the service brake functioning properly. Check that the spring is intact.
carefully noting the performance of the service brake Inspect the cartridge interior for contamination.
system. If the service brakes do not safely stop the 5. Inspect internal passageways of the park brake
machine, repeat the service brake bleeding manifold and valve for wear, damage, etc. If inner
procedure. surfaces of the manifold DO NOT display an ultra-
smooth, polished finish, or components are
8.11.3 Parking Brake Valve (ANSI) damaged in any way, replace the manifold or
The park brake valve is located in the cab, below the seat. appropriate part. Often, dirty hydraulic fluid causes
failure of internal seals and damage to the polished
a. Park Brake Valve Removal surfaces within the unit.

1. Park the machine on a firm, level surface, fully Note: ALWAYS replace seals, o-rings, gaskets, etc.,
retract the boom, lower the boom, place the with new parts to help ensure proper sealing and
transmission control lever in (N) NEUTRAL, engage operation. Lubricate seals and o-rings with clean
the park brake and shut the engine OFF. hydraulic oil.

2. Place a Do Not Operate Tag on both the ignition key 6. Install the solenoid valves and cartridges in the park
switch and the steering wheel, stating that the brake housing.
machine should not be operated.
c. Park Brake Valve Installation
3. Open the battery and engine covers. Allow the
system fluids to cool. 1. Install the park brake valve with the two lockwashers
4. Properly disconnect the battery. and two capscrews to the cover.

5. Remove the four capscrews holding the cover below Note: ALWAYS replace seals, o-rings, gaskets, etc.,
the seat. The park brake valve is mounted on the with new parts to help ensure proper sealing and
backside of the cover. operation. Lubricate seals and o-rings with clean
hydraulic oil.
6. Label, disconnect and cap the hydraulic hoses on
each side and bottom of the park brake valve. 2. Use new oiled o-rings as required. Uncap, reattach
Disconnect and cap all hoses, fittings, etc. and secure the three hoses.
7. Remove the two capscrews, and two lockwashers 3. Check the routing of all hoses for sharp bends or
mounting the park brake valve to the cover. interference with any rotating members, and install
tie wraps and/or protective conduit as required.
b. Park Brake Valve Disassembly, Cleaning, 4. Properly connect the battery.
Inspection and Assembly
5. Start the engine and run at approximately one-third
1. Place the park brake valve on a suitable work to one-half throttle for about one minute, without
surface. moving the machine or operating any hydraulic
functions.
6. Inspect the park brake valve and connections for
1 leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF.
2 7. Install the park brake/cover with the four capscrews.
8. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
MY2150 9. Close and secure the battery and engine covers.

2. Remove the solenoid valve (1) and cartridge (2) from 10. Remove the Do Not Operate Tags from both the
the park brake housing. ignition key and the steering wheel.

8-18 TH255
Hydraulic System

d. Parking Brake Valve Test.


1. Start the machine and engage the shift lever to the
forward position. Slowly depress the throttle to mid
idle. The parking brake will not allow the machine to
move.
2. If further troubleshooting is required, refer to the
Section 8.7, “Hydraulic Schematic,” or Section 9.4,
“Electrical System Schematics.”

8.11.4 Hand Brake Valve (CE & AUS)


The hand brake valve is located in the cab, beside the
seat. MU7710

a. Hand Brake Valve Removal 2. Clean all components with a suitable cleaner before
inspection.
1. Park the machine on a firm, level surface, fully
3. Inspect internal passageways of the hand brake
retract the boom, lower the boom, place the
manifold and valve for wear, damage, etc. If inner
transmission control lever in (N) NEUTRAL, engage
surfaces of the manifold DO NOT display an ultra-
the hand brake and shut the engine OFF.
smooth, polished finish, or components are
2. Place a Do Not Operate Tag on both the ignition key damaged in any way, replace the manifold or
switch and the steering wheel, stating that the appropriate part. Often, dirty hydraulic fluid causes
machine should not be operated. failure of internal seals and damage to the polished
3. Open the battery and engine covers. Allow the surfaces within the unit.
system fluids to cool. Note: ALWAYS replace seals, o-rings, gaskets, etc.,
4. Properly disconnect the battery. with new parts to help ensure proper sealing and
5. Remove the two capscrews holding the cover below operation. Lubricate seals and o-rings with clean
the seat. The hand brake valve is mounted on the hydraulic oil.
mounting plate attached to the seat base.
c. Hand Brake Valve Installation
6. Label, disconnect and cap the hydraulic hoses on
each side and bottom of the hand brake valve. 1. Install the Hand brake valve with the four
Disconnect and cap all hoses, fittings, etc. lockwashers and capscrews to the mounting plate.
7. Remove the four capscrews and lockwashers Note: ALWAYS replace seals, o-rings, gaskets, etc.,
mounting the hand brake valve to the mounting with new parts to help ensure proper sealing and
plate. operation. Lubricate seals and o-rings with clean
hydraulic oil.
b. Hand Brake Valve Disassembly, Cleaning,
2. Use new oiled o-rings as required. Uncap, reattach
Inspection and Assembly
and secure the three hoses.
1. Place the hand brake valve on a suitable work 3. Check the routing of all hoses for sharp bends or
surface. interference with any rotating members, and install
tie wraps and/or protective conduit as required.
4. Properly connect the battery.
5. Start the engine and run at approximately one-third
to one-half throttle for about one minute, without
moving the machine or operating any hydraulic
functions.
6. Inspect the hand brake valve and connections for
leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF.
7. Install the hand brake cover with the two capscrews.

TH255 8-19
Hydraulic System

8. Wipe up any hydraulic fluid spillage in, on, near and S/N TBS00627 & After
around the machine, work area and tools. 6 7
5
9. Close and secure the battery and engine covers. 4
10. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.

d. Hand Brake Valve Test.


1. Start the machine and engage the shift lever to the
forward position. Slowly depress the throttle to mid
idle. The hand brake will not allow the machine to
5
move.
7 4
2. If further troubleshooting is required, refer to the 3 6
3 MU7720
Section 8.7, “Hydraulic Schematic,” or Section 9.4, ANSI CE & AUS
“Electrical System Schematics.”
Verify the correct operation of the pilot select valve
solenoids: boom lift/lower (3), auxiliary (4), tilt (5), boom
8.11.5 Steering Orbitrol Valve
extend/retract (6) and front auxiliary (7) before
Refer to Section 4.4.2, “Steering Column/Valve considering replacement of the valve. The housing of the
Replacement,” for details. pilot select valve is not serviceable and must be replaced
if defective.
8.11.6 Pilot Select Valve
The pilot select valve is attached to a manifold mounted a. Pilot Select Valve Removal
on a mounting plate inside the frame in front of the comp 1. Park the machine on a firm, level surface, fully
cylinder. retract the boom, lower the boom, place the
Before S/N TBS00627 transmission control lever in (N) NEUTRAL, engage
the park brake and shut the engine OFF.
4 2. Place a Do Not Operate Tag on both the ignition key
3 switch and the steering wheel, stating that the
5
machine should not be operated.
3. Open the battery and engine covers. Allow the
system fluids to cool.
4. Properly disconnect the battery.
5. Label or otherwise mark the hydraulic hoses in
relation to the pilot select valve. Disconnect and cap
all hoses, fittings, solenoid wire terminal leads, etc.
MY2170 6. Remove the capscrews that attach the valve to the
frame.
Verify the correct operation of the pilot select valve
7. Remove the pilot select valve from the machine.
solenoids: boom lift/lower (3), auxiliary (4) and tilt (5)
Wipe up any hydraulic fluid spillage in, on, near and
before considering replacement of the valve. The housing
around the machine.
of the pilot select valve is not serviceable and must be
replaced if defective.
b. Pilot Select Valve Disassembly, Cleaning,
Inspection and Assembly
1. Place the pilot select assembly on a suitable work
surface.
2. Remove the solenoid valves and cartridges (3, 4 &5)
from the steer select housing.
3. Clean all components with a suitable cleaner before
inspection.

8-20 TH255
Hydraulic System

4. Inspect the solenoid cartridges for proper operation. 8.11.7 Inching Valve
Check by shifting the spool to ensure that it is
The inching valve is attached at the front of the frame
functioning properly. Check that the spring is intact.
directly above the steer select valve.
Inspect the cartridge interior for contamination.
Verify the correct operation of the inching valve before
5. Inspect internal passageways of the steer select
considering replacement of the valve. The housing of the
manifold and valve for wear, damage, etc. If inner
inching valve is not serviceable and must be replaced if
surfaces of the manifold DO NOT display an ultra-
defective.
smooth, polished finish, or components are
damaged in any way, replace the manifold or
a. Inching Valve Removal
appropriate part. Often, dirty hydraulic fluid causes
failure of internal seals and damage to the polished 1. Park the machine on a firm, level surface, fully
surfaces within the unit. retract the boom, lower the boom, place the
transmission control lever in (N) NEUTRAL, engage
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
the park brake and shut the engine OFF.
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean 2. Place a Do Not Operate Tag on both the ignition key
hydraulic oil. switch and the steering wheel, stating that the
machine should not be operated.
6. Install the solenoid valves and cartridges in the pilot
select housing. 3. Open the battery and engine covers. Allow the
system fluids to cool.
c. Pilot Select Valve Installation 4. Properly disconnect the battery.
1. Attach the pilot select manifold valve to the mounting 5. Label or otherwise mark the hydraulic hoses in
plate on the frame using the socket head capscrews. relation to the inching valve. Disconnect and cap all
hoses, fittings, etc.
2. Connect the hydraulic hoses, fittings, solenoid wire
terminal leads, etc., to the pilot select valve. 6. Remove the capscrews that attach the valve to the
frame.
3. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating 7. Remove the inching valve from the machine. Wipe
members, and install tie wraps and/or protective up any hydraulic fluid spillage in, on, near and
conduit as required. Tighten all tube and hose clamps. around the machine.
4. Properly connect the battery.
b. Inching Valve Disassembly, Cleaning, Inspection
5. Start the engine and run at approximately 1/3-1/2 and Assembly
throttle for about one minute, without moving the
machine or operating any hydraulic functions. 1. Place the inching valve assembly on a suitable work
surface.
6. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
8. Close and secure the battery and engine covers.
9. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel. 1

d. Pilot Select Valve Test MY2330

1. Check boom lift/lower, auxiliary and tilt for proper 2. Remove the cartridge (1) from the inching valve
function. housing.
2. If further troubleshooting is required, refer to Section 3. Clean all components with a suitable cleaner before
8.7, “Hydraulic Schematic,” or Section 9.4, “Electrical inspection.
System Schematics,” for details.

TH255 8-21
Hydraulic System

4. Inspect the cartridge for proper operation. Check by 1. Place the transmission control lever in
shifting the spool to ensure that it is functioning (N) NEUTRAL, engage the park brake, start the
properly. Check that the spring is intact. Inspect the engine and lower the boom. Turn off engine.
cartridge interior for contamination.
5. Inspect internal passageways of the inching valve for 2
wear, damage, etc. If inner surfaces of the manifold
DO NOT display an ultra-smooth, polished finish, or
components are damaged in any way, replace the
manifold or appropriate part. Often, dirty hydraulic
fluid causes failure of internal seals and damage to
the polished surfaces within the unit.
Note: ALWAYS replace seals, o-rings, gaskets, etc., MY2330
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean 2. Remove the plastic cap (2) from the inching brake
hydraulic oil. bleeder. Attach one end of a length of transparent
tubing over the bleeder. Place the other end of this
6. Install the cartridge in the inching valve housing.
tubing in a suitable transparent container that is
partially filled with hydraulic oil. The end of the tubing
c. Inching Valve Installation
must be below the oil level in the container.
1. Attach the inching valve to the mounting plate on the 3. DO NOT open the bleeder without holding the tubing
frame using the socket head capscrews. firmly on the bleeder. Have an assistant depress the
2. Connect the hydraulic hoses, fittings, etc., to the brake pedal. Carefully open the bleeder with a 10
inching valve. mm wrench. Close the bleeder when air bubbles no
3. Check the routing of all hoses and wiring for sharp longer appear in the oil. Release the brake pedal.
bends or interference with any rotating members, Remove the tubing from the bleeder.
and install tie wraps and/or protective conduit as 4. If brake system bleeding is required, refer to Section
required. Tighten all hose clamps. 8.11.2, “Service Brake Valve.”
4. Properly connect the battery. 5. Check brake fluid level and add fluid if necessary.
5. Start the engine and run at approximately 1/3-1/2 Refer to Section 2.4, “Fluids, Lubricants and
throttle for about one minute, without moving the Capacities.”
machine or operating any hydraulic functions.
e. Inching Test
6. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF. 1. Start the machine, engage the shift lever to the
forward position and release the parking brake.
Note: Check for leaks and repair as required before Slowly depress the throttle to 1/2 throttle. Slowly
continuing. Add hydraulic fluid to the reservoir as needed. apply the service brake. The machine will slow, but
7. Wipe up any hydraulic fluid spillage in, on, near and still maintain forward movement. Continuing to
around the machine, work area and tools. depress the service brake will disengage the inching
brake and engage the service brakes.
8. Close and secure the battery and engine covers.
2. If further troubleshooting is required, refer to Section
9. Remove the Do Not Operate Tags from both the
8.7, “Hydraulic Schematic.”
ignition key and the steering wheel.

d. Inching Valve Bleeding Procedure


Carefully bleed the inching valve as soon as the inching
valve is installed on the machine. Air in the system will not
allow the brakes to apply properly. There is one bleeder
location on the inching valve. Work with an assistant to
perform this procedure.

8-22 TH255
Hydraulic System

8.11.8 Priority Valve Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
.The priority valve is attached at the front of the engine
operation. Lubricate seals and o-rings with clean
pod frame directly behind the air cleaner.
hydraulic oil.
Verify the correct operation of the priority valve before
considering replacement of the valve. The priority valve 4. Install the previously labeled fittings in the priority valve
must be replaced if defective. housing.

a. Priority Valve Removal c. Priority Valve Installation

1. Park the machine on a firm, level surface, fully 1. Attach the priority valve to the mounting plate on the
retract the boom, lower the boom, place the frame using the socket head capscrews.
transmission control lever in (N) NEUTRAL, engage 2. Connect the hydraulic hoses, fittings, etc., to the
the park brake and shut the engine OFF. priority valve.
2. Place a Do Not Operate Tag on both the ignition key 3. Check the routing of all hoses for sharp bends or
switch and the steering wheel, stating that the interference with any rotating members, and install
machine should not be operated. tie wraps and/or protective conduit as required.
3. Open the battery and engine covers. Allow the Tighten all hose clamps.
system fluids to cool. 4. Properly connect the battery.
4. Properly disconnect the battery. 5. Start the engine and run at approximately 1/3-1/2
5. Label or otherwise mark the hydraulic hoses in throttle for about one minute, without moving the
relation to the priority valve. Disconnect and cap all machine or operating any hydraulic functions.
hoses, fittings, etc. 6. Inspect for leaks and check the level of the hydraulic
6. Remove the capscrews that attach the valve to the fluid in the reservoir. Shut the engine OFF.
frame. Note: Check for leaks and repair as required before
7. Remove the priority valve from the machine. Wipe up continuing. Add hydraulic fluid to the reservoir as needed.
any hydraulic fluid spillage in, on, near and around 7. Wipe up any hydraulic fluid spillage in, on, near and
the machine. around the machine, work area and tools.

b. Priority Valve Disassembly, Cleaning, Inspection 8. Close and secure the battery and engine covers.
and Assembly 9. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.
1. Place the priority valve assembly on a suitable work
surface.
d. Priority Valve Test
1. Start the machine and slowly depress the throttle to
1/2 throttle. Turn the steering and engage a boom
function. The steering will continue to respond along
with the engaged boom function.
3
2. If further troubleshooting is required, refer to Section
8.7, “Hydraulic Schematic.”
3

MY2970

2. Label and remove the fittings (3) from the priority


valve housing.
3. Clean all components with a suitable cleaner before
inspection.

TH255 8-23
Hydraulic System

8.11.9 Steer Select Valve 3. Remove the solenoid valves and cartridges (1) from
the steer select housing.
The steer select valve is attached to inside the frame near
the front drive motor. 4. Clean all components with a suitable cleaner before
inspection.
Verify the correct operation of the steer select valve
solenoids before considering replacement of the valve. 5. Inspect the solenoid cartridges for proper operation.
The housing of the steer select valve is not serviceable Check by shifting the spool to ensure that it is
and must be replaced if defective. functioning properly. Check that the spring is intact.
Inspect the cartridge interior for contamination.
a. Steer Select Manifold and Valve Removal 6. Inspect internal passageways of the steer select
1. Park the machine on a firm, level surface, fully manifold and valve for wear, damage, etc. If inner
retract the boom, lower the boom, place the surfaces of the manifold DO NOT display an ultra-
transmission control lever in (N) NEUTRAL, engage smooth, polished finish, or components are
the park brake and shut the engine OFF. damaged in any way, replace the manifold or
appropriate part. Often, dirty hydraulic fluid causes
2. Place a Do Not Operate Tag on both the ignition key failure of internal seals and damage to the polished
switch and the steering wheel, stating that the surfaces within the unit.
machine should not be operated.
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
3. Open the battery and engine covers. Allow the
with new parts to help ensure proper sealing and
system fluids to cool.
operation. Lubricate seals and o-rings with clean
4. Properly disconnect the battery. hydraulic oil.
5. Label or otherwise mark the hydraulic hoses in 7. Install the solenoid valves and cartridges in the steer
relation to the steer select manifold. Disconnect and select housing.
cap all hoses, fittings, solenoid wire terminal leads,
etc. 8. Attach the steer select valve to the manifold using
new, oiled o-rings and socket head capscrews.
6. Remove the capscrews that attach the manifold to
the frame. c. Steer Select Manifold and Valve Installation
7. Remove the steer select manifold with attached steer
1. Attach the steer select manifold and valve to the
select valve from the machine. Wipe up any
mounting plate on the frame using the socket head
hydraulic fluid spillage in, on, near and around the
capscrews.
machine.
2. Connect the hydraulic hoses, fittings, solenoid wire
b. Steer Select Valve and Manifold Disassembly, terminal leads, etc., to the steer select valve and
Cleaning, Inspection and Assembly manifold.

1. Place the steer select assembly on a suitable work 3. Check the routing of all hoses, wiring and tubing for
surface. sharp bends or interference with any rotating
members, and install tie wraps and/or protective
2. Separate the steer select valve from the manifold by conduit as required. Tighten all tube and hose clamps.
removing the capscrews. Discard the old o-rings.
4. Properly connect the battery.
5. Start the engine and run at approximately 1/3-1/2
throttle for about one minute, without moving the
machine or operating any hydraulic functions.
6. Inspect for leaks and check the level of the hydraulic
1 fluid in the reservoir. Shut the engine OFF.
Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as needed.
1 7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
8. Close and secure the battery and engine covers.
MY2180

8-24 TH255
Hydraulic System

9. Remove the Do Not Operate Tags from both the b. Joystick Enable Valve Disassembly, Cleaning,
ignition key and the steering wheel. Inspection and Assembly
1. Place the joystick enable valve assembly on a
d. Steering Test
suitable work surface.
1. Start the machine and select either the 4-wheel
steer or the crab steer mode.
2. Turn the steering wheel until the left rear wheel is
aligned with the side of the frame.
3. Select the 2-wheel steer mode and turn the steering
wheel until the left front wheel is aligned with the
frame.
2
4. With the wheel now aligned, select the desired steer
mode.
MY2380
5. If further troubleshooting is required, refer to Section
8.6.5, “Steering Pressure Checking,” Section 8.7, 2. Remove the solenoid valve and cartridge (2) from
“Hydraulic Schematic,” or Section 9.4, “Electrical the joystick enable valve housing.
System Schematics.” 3. Clean all components with a suitable cleaner before
inspection.
8.11.10 Joystick Enable Valve
4. Inspect the solenoid cartridge for proper operation.
The joystick enable valve is located on top of the frame at Check by shifting the spool to ensure that it is
the left rear corner of the hydraulic reservoir. functioning properly. Check that the spring is intact.
Verify the correct operation of the joystick enable valve Inspect the cartridge interior for contamination.
solenoid before considering replacement of the valve. 5. Inspect internal passageways of the joystick enable
The housing of the joystick enable valve is not valve for wear, damage, etc. If inner surfaces of the
serviceable and must be replaced if defective. manifold DO NOT display an ultra-smooth, polished
finish, or components are damaged in any way,
a. Joystick Enable Valve Removal replace the manifold or appropriate part. Often, dirty
1. Park the machine on a firm, level surface, fully hydraulic fluid causes failure of internal seals and
retract the boom, lower the boom, place the damage to the polished surfaces within the unit.
transmission control lever in (N) NEUTRAL, engage Note: ALWAYS replace seals, o-rings, gaskets, etc.,
the park brake and shut the engine OFF. with new parts to help ensure proper sealing and
2. Place a Do Not Operate Tag on both the ignition key operation. Lubricate seals and o-rings with clean
switch and the steering wheel, stating that the hydraulic oil.
machine should not be operated. 6. Install the solenoid valve and cartridge in the joystick
3. Open the battery and engine covers. Allow the enable valve housing.
system fluids to cool.
4. Properly disconnect the battery. c. Joystick Enable Valve Installation

5. Label or otherwise mark the hydraulic hoses in 1. Attach the joystick enable valve to the mounting
relation to the joystick enable valve. Disconnect and plate on the frame using the socket head capscrews.
cap all hoses, fittings, solenoid wire terminal leads, 2. Connect the hydraulic hoses, fittings, solenoid wire
etc. terminal leads, etc., to the joystick enable.
6. Remove the capscrews that attach the valve to the 3. Check the routing of all hoses, wiring and tubing for
frame. sharp bends or interference with any rotating
7. Remove the joystick enable valve from the machine. members, and install tie wraps and/or protective
Wipe up any hydraulic fluid spillage in, on, near and conduit as required. Tighten all tube and hose clamps.
around the machine. 4. Properly connect the battery.

TH255 8-25
Hydraulic System

5. Start the engine and run at approximately 1/3-1/2 b. Decompression Valve Disassembly, Cleaning,
throttle for about one minute, without moving the Inspection and Assembly
machine or operating any hydraulic functions.
1. Place the decompression valve assembly on a
6. Inspect for leaks and check the level of the hydraulic suitable work surface.
fluid in the reservoir. Shut the engine OFF.
Note: Check for leaks and repair as required before 1
continuing. Add hydraulic fluid to the reservoir as needed.
7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
8. Close and secure the battery and engine covers.
9. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.

d. Joystick Enable Valve Test MY2870

1. Start the machine, switch the joystick enable valve to DECOMPRESSION VALVE DECOMPRESSION VALVE
the ON position. The joystick will not function. BEFORE S/N TBS00236 S/N TBS00236 thru TBS00626

2. If further troubleshooting is required, refer to Section


8.7, “Hydraulic Schematic,” or Section 9.4, “Electrical 2. Remove the solenoid valve and cartridge (1) from
System Schematics.” the decompression valve housing.
3. Clean all components with a suitable cleaner before
8.11.11 Decompression Valve inspection.
The decompression valve is located on the frame at the 4. Inspect the solenoid cartridge for proper operation.
left rear corner above the main control valve. Check by shifting the spool to ensure that it is
functioning properly. Check that the spring is intact.
Verify the correct operation of the decompression valve
Inspect the cartridge interior for contamination.
solenoid before considering replacement of the valve.
The housing of the decompression valve is not 5. Inspect internal passageways of the decompression
serviceable and must be replaced if defective. valve for wear, damage, etc. If inner surfaces of the
manifold DO NOT display an ultra-smooth, polished
a. Decompression Valve Removal finish, or components are damaged in any way,
replace the manifold or appropriate part. Often, dirty
1. Park the machine on a firm, level surface, fully hydraulic fluid causes failure of internal seals and
retract the boom, raise the boom, place the damage to the polished surfaces within the unit.
transmission control lever in (N) NEUTRAL, engage
the park brake and shut the engine OFF. Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
2. Place a Do Not Operate Tag on both the ignition key
operation. Lubricate seals and o-rings with clean
switch and the steering wheel, stating that the
hydraulic oil.
machine should not be operated.
3. Open the battery and engine covers. Allow the 6. Install the solenoid valve and cartridge in the
system fluids to cool. decompression valve housing.

4. Properly disconnect the battery. c. Decompression Installation


5. Label or otherwise mark the hydraulic hoses in
1. Attach the decompression valve to the mounting
relation to the decompression valve. Disconnect and
plate on the frame using the socket head capscrews.
cap all hoses, fittings, solenoid wire terminal leads,
etc. 2. Connect the hydraulic hoses, fittings, solenoid wire
terminal leads, etc., to the decompression valve.
6. Remove the capscrews that attach the valve to the
frame. 3. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
7. Remove the decompression valve from the machine.
members, and install tie wraps and/or protective
Wipe up any hydraulic fluid spillage in, on, near and
conduit as required. Tighten all tube and hose clamps.
around the machine.
8-26 TH255
Hydraulic System

4. Properly disconnect the battery.


5. Start the engine and run at approximately 1/3-1/2
throttle for about one minute, without moving the
machine or operating any hydraulic functions.
6. Inspect for leaks and check the level of the hydraulic
1
fluid in the reservoir. Shut the engine OFF. 2
Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as needed.
7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
8. Close and secure the battery and engine covers.
9. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.

d. Decompression Valve Test MU7730

1. Turn the ignition switch to the ON position, relieve 5. Label or otherwise mark the hydraulic hoses in
auxiliary system pressure by activating the relation to the quick attach valve (1). Disconnect and
decompression switch. Disconnect and reconnect cap all hoses, fittings, solenoid wire terminal leads,
the attachment hoses on the quick connect fittings. etc.
2. If further troubleshooting is required, refer to Section 6. Remove the quick attach valve from the machine.
8.7, “Hydraulic Schematic,” or Section 9.4, “Electrical Wipe up any hydraulic fluid spillage in, on, near and
System Schematics.” around the machine.

8.11.12 Quick Attach Valve b. Quick Attach Valve Disassembly, Cleaning,


Inspection and Assembly
The quick attach valve is located on the right side of the
boom head. 1. Place the quick attach valve assembly on a suitable
Verify the correct operation of the quick attach valve work surface.
solenoid before considering replacement of the valve. 2. Remove the solenoid valve and cartridge (2) from
The housing of the quick attach valve is not serviceable the quick attach valve housing.
and must be replaced if defective. 3. Clean all components with a suitable cleaner before
inspection.
a. Quick Attach Valve Removal
4. Inspect the solenoid cartridge for proper operation.
1. Park the machine on a firm, level surface, fully Check by shifting the spool to ensure that it is
retract the boom, raise the boom, place the functioning properly. Check that the spring is intact.
transmission control lever in (N) NEUTRAL, engage Inspect the cartridge interior for contamination.
the park brake and shut the engine OFF.
5. Inspect internal passageways of the decompression
2. Place a Do Not Operate Tag on both the ignition key valve for wear, damage, etc. If inner surfaces of the
switch and the steering wheel, stating that the manifold DO NOT display an ultra-smooth, polished
machine should not be operated. finish, or components are damaged in any way,
3. Open the battery and engine covers. Allow the replace the manifold or appropriate part. Often, dirty
system fluids to cool. hydraulic fluid causes failure of internal seals and
damage to the polished surfaces within the unit.
4. Properly disconnect the battery.
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
hydraulic oil.
6. Install the solenoid valve and cartridge in the quick
attach valve housing.
TH255 8-27
Hydraulic System

c. Quick Attach Installation 2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
1. Attach the quick attach valve to the fittings on the
machine should not be operated.
boom head.
3. Open the battery and engine covers. Allow the
2. Connect the hydraulic hoses, fittings, solenoid wire
system fluids to cool.
terminal leads, etc., to the quick attach.
4. Properly disconnect the battery.
3. Properly connect the battery.
5. Label or otherwise mark the hydraulic hoses in
4. Start the engine and run at approximately 1/3-1/2
relation to the LSI valve. Disconnect and cap all
throttle for about one minute, without moving the
hoses, fittings, solenoid wire terminal leads, etc.
machine or operating any hydraulic functions.
6. Remove the capscrews that attach the valve to the
5. Inspect for leaks and check the level of the hydraulic
frame.
fluid in the reservoir. Shut the engine OFF.
7. Remove the LSI valve from the machine. Wipe up
Note: Check for leaks and repair as required before any hydraulic fluid spillage in, on, near and around
continuing. Add hydraulic fluid to the reservoir as needed. the machine.
6. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools. b. LSI Valve Disassembly, Cleaning, Inspection and
Assembly
7. Close and secure the battery and engine covers.
1. Place the LSI valve assembly on a suitable work
8. Remove the Do Not Operate Tags from both the
surface.
ignition key and the steering wheel.

d. Quick Attach Valve Test


1. Turn the ignition switch to the ON position, activate
the quick attach switch to switch the auxiliary 3
position or the quick attach position.
2. If further troubleshooting is required, refer to Section
8.7, “Hydraulic Schematic,” or Section 9.4, “Electrical
System Schematics.”

8.11.13 Load Stability Indicator Valve


(CE & AUS) MY2590

Before S/N TBS00627 2. Remove the solenoid valve and cartridge (3) from
The load stability indicator valve is located at the rear of the LSI valve housing.
the machine on the left inside frame rail directly below the 3. Clean all components with a suitable cleaner before
boom/boom pivot pin. The LSI valve is part of the LSI inspection.
System which constantly monitors the forward stability of
4. Inspect the solenoid cartridge for proper operation.
the machine
Check by shifting the spool to ensure that it is
Verify the correct operation of the LSI valve solenoid functioning properly. Check that the spring is intact.
before considering replacement of the valve. Refer to Inspect the cartridge interior for contamination.
Section 9.12.1, “Load Stability Indicator.” The housing of
5. Inspect internal passageways of the inching valve for
the LSI valve is not serviceable and must be replaced if
wear, damage, etc. If inner surfaces of the manifold
defective.
DO NOT display an ultra-smooth, polished finish, or
components are damaged in any way, replace the
a. LSI Valve Removal
manifold or appropriate part. Often, dirty hydraulic
1. Park the machine on a firm, level surface, fully fluid causes failure of internal seals and damage to
retract the boom, lower the boom, place the the polished surfaces within the unit.
transmission control lever in (N) NEUTRAL, engage
the park brake and shut the engine OFF.

8-28 TH255
Hydraulic System

Note: ALWAYS replace seals, o-rings, gaskets, etc., 8.12 HYDRAULIC CYLINDERS
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
hydraulic oil. 8.12.1 General Cylinder Removal
Instructions
6. Install the solenoid valve and cartridge in the LSI valve
1. Park the machine on a firm, level surface, fully
housing.
retract the boom, lower the boom, place the
transmission control lever in (N) NEUTRAL, engage
c. LSI Valve Installation
the park brake and shut the engine OFF.
1. Attach the LSI valve to the mounting plate on the 2. Chock the wheels.
frame using the socket head capscrews.
3. Place a Do Not Operate Tag on both the ignition key
2. Connect the hydraulic hoses, fittings, solenoid wire switch and the steering wheel, stating that the
terminal leads, etc., to the LSI valve. machine should not be operated.
3. Check the routing of all hoses, wiring and tubing for 4. Open the battery and engine covers. Allow the
sharp bends or interference with any rotating system fluids to cool.
members, and install tie wraps and/or protective
conduit as required. Tighten all tube and hose clamps. 5. Properly disconnect the battery.
4. Properly connect the battery. 6. Label, disconnect and cap hydraulic hoses in
relation to the cylinder.
5. Start the engine and run at approximately 1/3-1/2
throttle for about one minute, without moving the 7. Attach a suitable sling to an appropriate lifting device
machine or operating any hydraulic functions. and to the cylinder. Make sure the device used can
actually support the cylinder.
6. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF. 8. Remove the lock bolt and/or any retaining clips
securing the cylinder pins. Remove the cylinder pins.
Note: Check for leaks and repair as required before
9. Remove the cylinder.
continuing. Add hydraulic fluid to the reservoir as needed.
10. Wipe up any hydraulic fluid spillage in, on, near or
7. Wipe up any hydraulic fluid spillage in, on, near and around the machine.
around the machine, work area and tools.
8. Close and secure the battery and engine covers. 8.12.2 General Cylinder Disassembly
9. Remove the Do Not Operate Tags from both the 1. Clean the cylinder with a suitable cleaner before
ignition key and the steering wheel. disassembly. Remove all dirt, debris and grease
from the cylinder.
d. LSI Valve Test
2. Clamp the barrel end of the cylinder in a soft-jawed
1. Refer to Section 9.12.1, “Load Stability Indicator,” or vise or other acceptable holding equipment if
Section 9.13.1, “LSI Axle Sensor,”for proper test possible.
procedures.
2. If further troubleshooting is required, refer to Section
8.7, “Hydraulic Schematic,” or Section 9.4, “Electrical
NOTICE
System Schematics.”
Avoid using excessive force when clamping the
cylinder in a vise. Apply only enough force to hold the
cylinder securely. Excessive force can damage the
cylinder tube.

3. If applicable, remove the counterbalance valve from


the side of the cylinder barrel.

TH255 8-29
Hydraulic System

1
2

3
NOTICE
When sliding the rod and piston assembly out of the
4 tube, prevent the threaded end of the tube from
damaging the piston. Keep the rod centered within the
tube to help prevent binding.

6. Carefully pull the rod assembly along with the head


gland out of the cylinder barrel.
7. Fasten the rod end in a soft-jawed vise, and put a
padded support under and near the threaded end of
the rod to help prevent damage to the rod.
1
8. Remove the set screw (3) from the piston (4).
Note: It may be necessary to apply heat to break the
bond of the sealant between the piston and the rod
2 5 before the piston can be removed.
6 Some cylinder parts are sealed with a special organic
MAH0160 sealant and locking compound. Before attempting to
disassemble these parts, remove any accessible seals
from the area of the bonded parts. Wipe off any hydraulic
oil, then heat the part(s) uniformly to break the bond. A
NOTICE temperature of 149-204° C (300-400° F) will destroy the
bond. Avoid overheating, or the parts may become
distorted or damaged. Apply sufficient torque for removal
DO NOT tamper with or attempt to adjust the while the parts are still hot. The sealant often leaves a
counterbalance valve cartridge. If adjustment is white, powdery residue on threads and other parts, which
necessary, replace the counterbalance valve with a must be removed by brushing with a soft brass wire brush
new part. prior to reassembly.
4. Extend the rod (5) to allow access to the base of the 9. Remove the piston head (4) from the rod (5) and
cylinder. carefully slide the head gland (6) off the end of the
rod.

NOTICE 10. Remove all seals, back-up rings and o-rings (2) from
the piston head and all seals, back-up rings and o-
Protect the finish on the rod at all times. Damage to the rings from the head gland.
surface of the rod can cause seal failure. Note: The head gland bearing will need to be inspected
to determine if replacement is necessary.
5. Using a pin spanner wrench, unscrew the head
gland (6) from the barrel (1). A considerable amount DO NOT attempt to salvage cylinder seals, sealing rings
of force will be necessary to remove the head gland. or o-rings. ALWAYS use a new, complete seal kit when
Carefully slide the head gland down along the rod rebuilding hydraulic components. Consult the parts
toward the rod eye end, away from the cylinder manual for ordering information.
barrel.
8.12.3 Cylinder Cleaning Instructions
1. Discard all seals, back-up rings and o-rings. Replace
with new items from complete seal kits to help
ensure proper cylinder function.

8-30 TH255
Hydraulic System

2. Clean all metal parts with an approved cleaning Note: The Crowd cylinder has a spacer that MUST be
solvent such as trichlorethylene. Carefully clean installed over the rod AFTER the head gland and
cavities, grooves, threads, etc. BEFORE the piston head.
Note: If a white powdery residue is present on threads 3. Fasten the rod eye in a soft-jawed vise, and place a
and parts, it can be removed. Clean the residue away padded support under and near the threaded end of
with a soft brass wire brush prior to reassembly, and the rod (5) to prevent any damage to the rod.
wipe clean before reinstallation.

8.12.4 Cylinder Inspection NOTICE


1. Inspect internal surfaces and all parts for wear, Protect the finish on the rod at all times. Damage to the
damage, etc. If the inner surface of the tube does not surface of the rod can cause seal failure.
display a smooth finish, or is scored or damaged in
any way, replace the tube. 4. Lubricate and slide the head gland (6) over the
cylinder rod (5). Install the piston head (4) on to the
2. Remove light scratches on the piston, rod or inner
surface of the tube with a 400-600 grit emery cloth. end of the cylinder rod. Loctite® 243TM and install the
Use the emery cloth in a rotary motion to polish out setscrew (3) in the piston head. Refer to Section
and blend the scratch(es) into the surrounding 8.12.8, “Hydraulic Cylinder Torque Specifications,”
surface. for tightening guidelines for the piston head and the
set screw.
3. Check the piston rod assembly for run-out. If the rod
is bent, it must be replaced.

8.12.5 General Cylinder Assembly NOTICE


1. Use the proper tools for specific installation tasks.
Clean tools are required for assembly. Avoid using excessive force when clamping the
cylinder barrel in a vise. Apply only enough force to
1 hold the cylinder barrel securely. Excessive force can
2
damage the cylinder barrel.
3 5. Place the cylinder barrel (1) in a soft-jawed vise or
other acceptable holding equipment if possible.
4

NOTICE
When sliding the rod and piston assembly into the
cylinder barrel, prevent the threaded end of the
cylinder barrel from damaging the piston head. Keep
the cylinder rod centered within the barrel to prevent
binding.
1
6. Carefully insert the cylinder rod assembly into the
tube.
7. Screw the head gland (6) into the cylinder barrel (1)
2 5 and tighten with a spanner wrench. Refer to Section
6 8.12.8, “Hydraulic Cylinder Torque Specifications,”
for tightening guidelines for the head gland.
MAH0160

8. If applicable, thread the new counterbalance valve


into the block on the cylinder barrel.
2. Install new seals, back-up rings and o-rings (2) on
the piston (4) and the head gland (6).

TH255 8-31
Hydraulic System

8.12.6 General Cylinder Installation 8.12.7 Steering Cylinders


1. Grease the bushings at the ends of the hydraulic The steering cylinders are attached to each axle center
cylinder. Using an appropriate sling, lift the cylinder housing. Detailed axle service instructions are provided
into it’s mounting position. in the Axle Disassembly & Assembly Manual
2. Align cylinder bushing and install pin, lock bolt or (P/N 31200451).
retaining clip.
3. Uncap and connect the hydraulic hoses in relation to
the labels or markings made during removal.
4. Before starting the machine, check fluid level of the
hydraulic fluid reservoir and if necessary, fill to full
mark with Cat HDO.
5. Properly connect the battery.
6. Start the machine and run at low idle for about one
minute. Slowly activate hydraulic cylinder function in
both directions allowing cylinder to fill with hydraulic
oil.
7. Inspect for leaks and check level of hydraulic fluid in
reservoir. Add hydraulic fluid if needed.
8. If no leaks are present, operate the hydraulic
function at least twenty times at full throttle to bleed
any air from the cylinder and hoses.
Note: To bleed air from the tilt cylinder, operate the tilt
function along with the lift cylinder as described above.
More operation cycles may be required to clear all air
from the system.
9. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
10. Close and secure the battery and engine covers.
11. Remove the Do Not Operate Tags from both the
ignition key and the steering wheel.

8-32 TH255
Hydraulic System

8.12.8 Hydraulic Cylinder Torque


Specifications

a. Lift Lower Cylinder

Head Piston CB Valve Valve FC Valve Set


Screw Screw
Before S/N 406-542 Nm 2440-2712 Nm 60 Nm 14-16 Nm 15 Nm
TBS00627 (300-400 lb-ft) (1800-2000 lb-ft) (44 lb-ft) (10-12 lb-ft) (11 lb-ft)
S/N TBS00627 &
406-542 Nm 2440-2712 Nm 61-67,7 Nm 27-33,8 Nm 40,6-47,5 Nm 15 Nm
After
(300-400 lb-ft) (1800-2000 lb-ft) (45-50 lb-ft) (20-25 lb-ft) (30-35 lb-ft) (11 lb-ft)
(CE & AUS Only)

b. Extend/Retract Cylinder

Head Piston Valve Valve Screw Set Screw


271-339 Nm 271-325 Nm 60 Nm 14-16 Nm (10- 81-94 Nm
(200-250 lb-ft) (200-240 lb-ft) (44 lb-ft) 12 lb-ft) (60-69 lb-ft)

c. Tilt Cylinder

Head Piston Valve Valve Screw Set Screw


406-542 Nm 1898-2034 Nm 60 Nm 14-16 Nm 15 Nm (11 lb-ft)
(300-400 lb-ft) (1400-1500 lb-ft) (44 lb-ft) (10-12 lb-ft)

d. Compensating Cylinder

Head Piston Valve Valve Screw Set Screw


406-542 Nm 1898-2034 Nm 60 Nm 14-16 Nm 15 Nm (11 lb-ft)
(300-400 lb-ft) (1400-1500 lb-ft) (44 lb-ft) (10-12 lb-ft)

Use Loctite® 262TM on all Piston Applications


Use Loctite® 242TM on all Set Screws

TH255 8-33
Hydraulic System

This Page Intentionally Left Blank

8-34 TH255
Section 9
Electrical System

Contents

PARAGRAPH TITLE PAGE


9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.3 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.3.1 Engine Compartment Relays and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.3.2 Cab Compartment Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.3.3 Power Distribution Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.3.4 Cab Fuses / Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.4 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.4.1 Before S/N TBS00627. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.4.2 S/N TBS00627 & After . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.5 Circuit Breakdowns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
9.5.1 Charge Circuit Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
9.5.2 Start Circuit Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
9.5.3 Constant Power Circuit Breakdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.5.4 Drive Circuit Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.6 Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.6.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.7 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.7.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.8 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.8.1 Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.8.2 Instrument Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.8.3 Speedometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
9.9 Window Wiper/Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.9.1 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.9.2 Rear Window or Roof Wiper Motor (if equipped) . . . . . . . . . . . . . . . . . . . 9-27
9.9.3 Windshield Washer Reservoir and Pump . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.10 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.10.1 Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28

TH255 9-1
Electrical System

9.11 Switches, Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29


9.11.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.11.2 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.11.3 Fuel Level Indicator and Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.11.4 Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.11.5 Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.11.6 Fuel Shut-off Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
9.11.7 Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
9.12 Load Stability System (CE & AUS) Before S/N TBS00627 . . . . . . . . . . . . . . . . . . 9-33
9.12.1 Load Stability Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.12.2 Load Stability Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.12.3 Load Stability Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.13 Load Stability System (CE & AUS) S/N TBS00627 & After . . . . . . . . . . . . . . . . . 9-35
9.13.1 LSI Axle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9.13.2 LSI Boom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9.13.3 LSI Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
9.13.4 LSI System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
9.13.5 LSI-CAN Check PT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
9.13.6 500 Hour - LSI UGM Calibration Check . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
9.14 Hand Held Analyzer (CE & AUS) S/N TBS00627 & After . . . . . . . . . . . . . . . . . . . 9-41
9.14.1 Analyzer Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
9.14.2 Analyzer Software - Version 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
9.14.3 Diagnostic Trouble Codes (DTC) on Ground Module . . . . . . . . . . . . . . . . 9-43

9-2 TH255
Electrical System

9.1 ELECTRICAL COMPONENT


TERMINOLOGY
To understand the safety, operation, and service
information presented in this section, it is necessary that
the operator/mechanic be familiar with the name and
location of the electrical components of the machine. The
following illustration identifies the components that are
referred to throughout this section.

BACK-UP ALARM
CAB WIRE HARNESS

HORN
RELAYS

FRAME HARNESS

FUSE BOX

ENGINE HARNESS BATTERY MY2190


CONNECTIONS

TH255 9-3
Electrical System

9.2 SAFETY INFORMATION

WARNING
DO NOT service the machine without following all
safety precautions as outlined in the “Safety
Practices” section of this manual.

9.3 FUSES AND RELAYS

9.3.1 Engine Compartment Relays and


Fuses
3 1

MY2230

There are three relays and one buss bar located on the
frame, mounted on a bracket behind the battery. The
relays control the starter (1), ignition (2) and engine
preheat (3).

9.3.2 Cab Compartment Fuses and Relays

MY2480 4

The cab fuse block (4) is located behind an access panel


at the right side of the dash.

9-4 TH255
Electrical System

9.3.3 Power Distribution Module

MAP0030

Fuse/Relay Function Amp Rating


F1 Shifter, Steer, Park Brake 15
F2 F/R Aux, QC 15
F3 Display 5
F4 Joystick 5
F5 Fuel Valve, Cold Start Advance 10
F6 Fuel Pump 7.5
F7 Back-Up Alarm, Reverse Light 15
F8 Beacon 10
F9 Spare
F10 Spare
F11 Key 10
F12 Horn 10
F13 Rear Power 15
F14 Front Worklights 10
F15 Boom Worklights 10
F16 Rear Worklights 10

R1 Worklights 35 N.O.
R2 Back-Up Alarm, Reverse Light 35 N.O.

TH255 9-5
Electrical System

9.3.4 Cab Fuses / Relays

MY2470

Fuse/Relay Function Amp Rating


F21 Hazard 10
F22 LSI Over Ride 5
F23 Dome Light - Radio 10
F24 Speedometer 5
F25 Front Washer 15
F26 Rear Roof Wiper 20
F27 Front Wiper 20
F28 HVAC Switch 30
F29 Spare
F30 Spare
F31 Right Headlight - High Beam 7.5
F32 Left Headlight - High Beam 7.5
F33 Right Headlight - Low Beam 7.5
F34 Left Headlight - Low Beam 7.5
F35 Right Marker Lights - Trailer Light Connection 7.5
F36 Left Marker Lights - License Light - Trailer Connection 7.5
F37 Turn Signal Switch 15
F38 Brake Pedal Switch 15
F39 Radio 15
F40 HVAC Switch - AC 10
X1 Flasher
R11 Park Brake Switch

9-6 TH255
Electrical System

9.4 ELECTRICAL SYSTEM SCHEMATICS


Refer to Electrical Schematic Package (P/N 31200457).

9.4.1 Before S/N TBS00627

a. Cab Schematic "A"

MAL0660-J

TH255 9-7
Electrical System

b. Cab Schematic "B"

MAL0670-J

9-8 TH255
Electrical System

c. Cab Roof Schematic

MAL0680-J

TH255 9-9
Electrical System

d. Chassis Schematic

MAL0690-J

9-10 TH255
Electrical System

e. Options Chassis Schematic

MAL0700-J

TH255 9-11
9-12
9.4.2
1 2 3 4 5 6 7 8

SWITCH,STEERSELECT

SWITCH,F/RAUX.HYD.
SWITCH,BOOMWORKLIGHTS SWITCH,FRONTWORKLIGHTS SWITCH,REARWORKLIGHTS SWITCH,BEACON
a. Cab Schematic "A"

1
2
13
14
3
15
16
6
12
11
9
10
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8

SW11

WH42
SW10
SW15
SW09

SW08

SW16

CONNECTOR,POWERSOCKET
D D
TOFRAME

062-9YEL

051-3BLU
051-5BLU
051-2BLU
051-6BLU
051-4BLU
051-7BLU
072-1BLU

061-2RED
GROUND 1

000-8-31BLK
STUD
Electrical System

000-8-26BLK
X87-6
SHEET4

062-3YEL

065-1ORG
065-4ORG
065-3ORG
065-2ORG
076-3GRN

062-3-1YEL

065-1-1ORG
065-1-1ORG
065-1-2ORG
000-8-17BLK
070-1-10BLU
000-8-18BLK
070-1-11BLU
000-8-18BLK
000-8-19BLK
070-1-11BLU
070-1-12BLU
000-8-19BLK
000-8-20BLK
070-1-12BLU
070-1-13BLU
000-8-20BLK
000-8-21BLK
070-1-13BLU
070-1-14BLU
000-8-25BLK
000-8-24BLK
070-1-17BLU
070-1-18BLU

Sheet2-[7,D]
TOCAB Sheet2-[5,D] 1 062-1YEL
6AWGBLACK
S/N TBS00627 & After

Sheet2-[7,D]
Sheet2-[8,D]
Sheet2-[8,D]
Sheet2-[7,D]
GROUND 1 Sheet2-[5,D] 2 061-5RED
STUD 3 061-4RED
X-CAB

Sheet2-[4,D]
4 062-2YEL

Sheet2-[5,D]
Sheet2-[5,D]
5 062-3YEL
6 062-4-1YEL
7 051-3BLU
8 051-5BLU
9 051-2BLU
051-6BLU
1 10 051-4BLU
000-8-3BLK 062-4-5YEL
TOCAB 2 Sheet2-[8,C] 11 062-9YEL
ROOF 051-7BLU
3 Sheet2-[1,C] 12 070-1-1BLU
WORKLIGHT 000-8-2BLK
HARNESS 4 13 076-3GRN TOBASE
072-1BLU
SHEET3 5 14 065-2-1ORG FRAME
000-8-1BLK
6 15 065-3-1ORG
S06 HARNESS
X22 16 052-1BLU
Sheet2-[3,D] 17 048-3GRY SHEET4
18 048-4-1GRY
S05
19 048-9GRY

S48

S171
C 20 048-6GRY C
21 048-7GRY
062-2-5YEL
Sheet2-[4,D] 22 048-8GRY
062-2-3YEL
TOFRAME Sheet2-[4,D] 23 048-5GRY
000-5BLK6AWGSGT
GROUND 1 24 007-1ORG
STUD

062-2-2YEL
X87-3 25 008-1ORG
SHEET4
26 076-4GRN
27 076-5GRN
Sheet2-[8,C] 28 008-2-2BLU
Sheet2-[6,B] 29 073-7BRN
30 061-2RED
31
000-6BLK10AWG X20
Sheet2-[1,B]
000-7BLK10AWG
Sheet2-[1,B]
S03

S167 000-8BLK8AWGSXL
S07
000-8-1BLK
000-8-2BLK 077-1-2ORG
Sheet2-[7,B]
000-8-3BLK
000-8-4BLK
S168 000-8-5BLK
000-8-6BLK 1.FORNORTHAMERICANCABS
S172 WITHNOHEADLIGHTSCONNECT
000-8-7BLK 065-1-2ORG
Sheet2-[4,B] 1 TOX21A.
000-8-31BLK 000-8-9BLK 062-2-2YEL
Sheet2-[4,A] 2
000-8-10BLK 070-1-19BLU 2.FORNORTHAMERICANCABS
Sheet2-[4,A] Sheet2-[1,C] 3 WITHHEADLIGHTSCONNECT
000-8-11BLK 065-4-2ORG 062-4-4YEL
Sheet2-[5,A] Sheet2-[5,D] 4 TOX21B.
000-8-12BLK
Sheet2-[5,A] X21 3.FOREUROPEANCABS
Sheet2-[4,B] NOCONNECTORREQUIRED
B B
Sheet2-[4,B] Sheet2-[1,C]

S04
Sheet2-[5,D]
Sheet2-[3,D] Sheet2-[5,D]
062-2-2YEL
Sheet2-[3,D] Sheet2-[8,C] 1
062-1YEL
048-1GRY
061-5RED
048-4GRY
077-1-1ORG
000-8-4BLK

062-2-2YEL
2
062-4-4YEL
3
1
2
3
4
5
6
1
2
HV93

SW18

1
2
3
4
5
6

062-4-4YEL
4
X21A
SW18

077-2-1ORG
077-1ORG
062-2-1YEL
077-2-2ORG
000-8-14BLK
000-8-13BLK
070-1-6BLU
070-1-7BLU
070-1-7BLU
000-8-15BLK
070-1-8BLU
000-8-15BLK
000-8-16BLK
070-1-8BLU
070-1-9BLU
IYEL
SGRY
BRED
FORG

062-3-1YEL
076-4GRN
000-8-6BLK
076-5GRN
000-8-14BLK
007-1ORG
077-1-3ORG
008-1ORG
048-2GRY
048-1GRY
062-4-3YEL
070-1-2BLU
048-6GRY
048-9GRY
000-8-8BLK
048-8GRY
077-2-2ORG
048-5GRY
048-7GRY
065-3-2ORG
048-4-2GRY
078-3WHT
065-4-1ORG
065-2-2ORG
052-1BLU
061-4RED
062-2-2YEL
1
I
S
B
F

VALVE,PARKBRAKE 062-2-2YEL
2

SW19
GD17
SW12

1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8

SW13
SW14
10
11
12
13
14
15
3
I
S
B
F

PARKBRAKEVALVEON
4
NAMACHINESONLY X21B
SW18_I 1
SW18_S 1
SW18_B 1
SW18_F 1

GND

PWR
4WSTEERLT.
SWITCH,PARKBRAKE

2WSTEERLT.

FUELGAUGE
SWITCH,QUICKCOUPLER SWITCH,HORN

HOURMETER
PARKBRAKELT.
CRABSTEERLT.
PARKBRAKESWITCH SWITCH,IGNITION
SWITCH,FNRLEVER

ENG.PRE-HEATLT.

GAUGEBACKLIGHT
ONNAMACHINESONLY

BATTERY/ALTERNATORLT.
ENG.LOWOILPRESSURELT.

ENG.HIGHCOOLANTTEMP.LT.
A LOWSTEERINGPRESSURELT. A
ALLWIRES16GA.GXLUNLESSNOTED
ELECASSY,4IN.GAUGE

1 2 3 4 5 6 7 8

MAM2930-C

TH255
9-13 TH255
MAM2940-C
A
B
C
D

1
1
RL68-R

FC65-L1

Sheet1-[1,B]
Sheet1-[4,B]
Sheet1-[8,B]

Sheet1-[1,C]
Sheet1-[8,C]
SHEET4
SHEET4
TOBATTERY

TOIGNATION
FUSEONFRAME

062-10YEL8AWGSXL

RELAYONFRAME
061-6RED10AWGSXL

062-10-2YEL
1
1

062-10-4YEL
000-6BLK
070-1-1BLU
070-1-2BLU

000-7BLK

062-14-1YEL
070-1-19BLU

062-11YEL
S170

F21_A
S169

062-10-1YEL F21_B
062-12YEL F22_A
062-10-2YEL F22_B
062-13YEL F23_A
062-10-3YEL F23_B
062-14YEL F24_A
000-7-3BLK
000-7-4BLK
000-7-2BLK
000-6-2BLK
000-6-8BLK

062-10-4YEL F24_B
062-15YEL F25_A
062-10-5YEL
000-7-1BLK14AWG
000-6-4BLK14AWG
000-6-3BLK14AWG

F25_B
062-16YEL14AWG F26_A
S166

062-10-6YEL14AWG F26_B
062-17YEL14AWG F27_A
1 062-10-7YEL14AWG F27_B
2 061-8-2RED 062-18YEL12AWG F28_A
3 071-16BLU 062-10-8YEL12AWG F28_B
4 F29_A
071-3-1BLU F29_B
SW28
071-3-3BLU F30_A
SWITCH,BRAKEPEDAL

2
2

071-2-1BLU F30_B
071-7BLU F31_A
071-3BLU F31_B
1 074-6BRN 071-8BLU F32_A
2 000-6-2BLK 071-3-1BLU
M F32_B
000-6-5BLK
FRONT

071-9BLU F33_A
WH41-F
071-2BLU F33_B
071-10BLU F34_A
1 074-7BRN 071-2-1BLU F34_B
2 000-6-5BLK 071-11BLU
M F35_A
REAR

071-1-3BLU F35_B
WH41-R
S45 071-12BLU F36_A
TANK,DUALWASHER,PUMPS

071-1-4BLU F36_B
061-7RED F37_A
061-6-1RED F37_B
061-8RED F38_A
L 1 074-2BRN14AWG S51 061-6-2RED F38_B
074-3BRN14AWG S47
HOLDER,FUSE/RELAY,CAB

H 2 061-9RED F39_A
M P 3 074-5BRN14AWG 061-6-3RED F39_B
NA

4 073-5BRN F40_A
G 5 000-6-3BLK14AWG 073-4BRN
3
3

F40_B
077-2ORG R11_85
WIPER,FRONTMOTOR

WH40
000-7-5BLK R11_86
Sheet1-[8,C] 048-3GRY R11_87
Sheet1-[3,B] 048-2GRY R11_30
ALLWIRES16GA.GXLUNLESSNOTED

Sheet1-[1,B] 077-2-1ORG R11_87a


R12_85
R12_86
R12_87
1 062-12-2YEL
R12_30
2 062-12YEL 000-7-5BLK R12_87a
3 076-9GRN 000-7-4BLK X1_31 31
4 071-13BLU X1_49 49
5 071-4BLU X1_49a 49a
6 000-8-13BLK 071-4-1BLU X1_C1 C1
FLASHER

7 000-8-7BLK 071-15BLU X1_C2 C2


8 070-1-5BLU
SWITCH,LMIOVERRIDE

070-1-6BLU FC29
SW32

4
4

Sheet1-[1,B]
Sheet1-[2,B]
Sheet1-[1,B]

2A 071-3-3BLU 076-7GRN 1
2B 000-8-9BLK Sheet1-[3,C] 062-2-5YEL
Sheet1-[4,B] 2
062-2-4YEL 3
1A 071-14BLU Sheet1-[2,D] 065-1ORG 4
1B 000-8-10BLK Sheet1-[3,C] 062-2-3YEL
Sheet1-[4,B] 5
071-17BLU Sheet1-[5,B] 065-4-2ORG
GD138 6
Sheet1-[6,B] 000-8-16BLK 7
Sheet1-[6,B] 070-1-9BLU 8
SWITCH,JOYSTICKLOCKOUT

INDICATOR,TURN,HIGHBEAM
Sheet1-[2,D] 000-8-17BLK SW36
Sheet1-[2,D] 070-1-10BLU
1A 071-15BLU 074-2-1BRN14AWG
1B 000-8-11BLK 074-4BRN14AWG
Sheet1-[4,B] 1
062-17YEL14AWG 2
2A 077-3ORG 074-1BRN14AWG 3
5

5
2B 000-8-12BLK 074-2BRN14AWG
Sheet1-[4,B] 4
074-1BRN14AWG 5

INDICATOR,TRAILER
GD139
074-3BRN14AWG 6
Sheet1-[6,D] 000-8-21BLK 7
Sheet1-[6,D] 070-1-14BLU
SWITCH,FRONTWIPER

8
000-8-22BLK SW34
070-1-15BLU
SIDELT 1 070-1BLU
LIGHTPWR 2 061-7RED
LOWHD 3 071-2BLU
HIGHHD 4 071-3BLU 074-6BRN 1
FLASHPWR 5 061-8-1RED 062-15YEL 2
LEFT 6 071-5-5BLU
S140 062-15-1YEL 3
TURNPWR 7 074-2-1BRN14AWG 4
RIGHT 8 071-4BLU 074-4BRN14AWG 5
071-6-5BLU 074-5BRN14AWG 6
SW27

SWITCH,TURNSIGNALLEVER
S141 000-8-22BLK 7
070-1-15BLU 8
SWITCH,FRONTWASHER

000-8-23BLK
SW33
070-1-16BLU

6
6

LOW 1 073-1BRN14AWG
GND 2 000-7-1BLK14AWG 062-18YEL12AWG B PWR
M HI 3 073-3BRN14AWG 073-1BRN14AWG L LOW
MED 4 073-2BRN14AWG 073-2BRN14AWG

HVACFAN
M MED.
073-3BRN14AWG
FAN

WH39-F H HI
073-4BRN C AC
1 073-6BRN
SW38-F
2 073-7BRN 073-6BRN
Sheet1-[8,C] A
073-5BRN B
WH39-AC

TBD(246)
AC
AC

000-6-8BLK C
SWITCH,HVACCONTROLWITHA/C

SW38-AC
1 062-2-4YEL 062-11YEL 1
2 077-2ORG 071-13BLU 2
3 077-1-2ORG 061-8-3RED
Sheet1-[4,B] 3
HV31 071-5-1BLU 4

7
7

071-4-1BLU 5
071-5BLU 17

VALVE,MANUALPARKBRAKE
8 062-14YEL 071-6BLU 18
7 052-2WHT 071-6-1BLU 7
SWITCH,HAZARD

6 000-6-4BLK14AWG Sheet1-[7,D] 070-1-18BLU 8


5 074-8BRN14AWG Sheet1-[6,D] 000-8-25BLK 10
074-9BRN14AWG Sheet1-[3,D] 000-8-26BLK

ROOF
4

TOCAB
SW26

OPTION

SHEET3

MANUALPARKBRAKEVALVEONCE&AUSMACHINES
3 061-9RED

HARNESS
2 062-13YEL
1 000-7-3BLK
074-9BRN14AWG 1
X50B
062-16YEL14AWG 2
074-8BRN14AWG 3
4
062-15-1YEL 5
074-7BRN 6

Sheet1-[5,B]
Sheet1-[4,C]
Sheet1-[8,C]
000-8-23BLK 7
070-1-16BLU 8
000-8-24BLK
SWITCH,REAR/ROOFWIPER
8

SW35
070-1-17BLU

8
X25
Sheet1-[7,D]
Sheet1-[7,D]

X50A
9
4
3
8
7
6
5
2
1
1

12
11
10
23
18
30
31
19

ROOF
TOCAB
FRAME

OPTION

SHEET3
SHEET5

LSI2BLK

LSI2BLK
LSI1RED

HARNESS
9 071-7BLU
8 071-8BLU
7 071-9BLU

LSI1RED

085-1BLU
HARNESS

10 077-3ORG

076-8GRN
085-1BLU
22 076-7GRN

27 052-2WHT
28 078-3WHT

16 076-8GRN
17 076-9GRN
11 071-16BLU
6 071-10BLU
5 071-11BLU
4 071-12BLU
TOOPTION

LSISHIELD
LSISHIELD
3 071-5-1BLU
2 071-6-1BLU

000-7-2BLK
12 008-2-2BLU

29 062-4-5YEL

CANHIRED
25 CANHIRED

CANLOBLK
CANSHIELD
24 CANLOBLK

LSIPWRBLU

062-12-2YEL
13 CANSHIELD

26 062-14-1YEL

LSIPWRBLU

A
B
C
D
b. Cab Schematic "B"
Electrical System
TH255 9-14
MAM2950-C
A
B
C
D

SHEET2
HARNESS

8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1

TOOPTIONCAB 10

12
11

X50A

X50B

1
1

LSI2BLK
LSI1RED

085-1BLU

061-9RED
076-8GRN

052-2WHT
062-14YEL
062-13YEL
LSISHIELD

CANHIRED

000-7-3BLK
CANLOBLK
000-7-2BLK

CANSHIELD
LSIPWRBLU
062-12-2YEL

074-8BRN14AWG
074-9BRN14AWG

000-6-4BLK14AWG

000-7-7BLK 1 -
GD30-
052-2WHT 1 S
GD30-S
SPEEDO

062-14YEL 1 +
GD30+
GAUGE,SPEEDOMETER

S173

1
2
3
2
2

S123

4 061-9RED 062-12-2YEL 1 POWER


5 000-7-6BLK
2 GROUND
6 076-8GRN 3 CUTOUTOUTPUT
7 062-13-1YEL LSI1RED 4 LSI1
S122

8 000-7-9BLK LSI2BLK 5 LSI2


MS116-GRY LSIPWRBLU 6 LSIPWR
1 CANHIRED 7 CANH
2 CANLOBLK 8 CANL
LSIDISPLAY

3 058-2BLK
GD158
120¹

4 052-4WHT
5 058-1BLK
RADIO(EUROPE)

6 052-3WHT 085-1BLU 1
7 LB183+
CUSTOMERSUPPLIED
TBD

8 000-7-10BLK 1
LSIPASSIVE

MS116-BRN LB183-
1 052-3WHT
3
3

LEFT(DX)

MS117+
1 058-1BLK
MS117-
ALLWIRES16GA.GXLUNLESSNOTED
SPEAKERS(EUROPE)
CUSTOMERSUPPLIED

1
062-13-2YEL 2
LB107
LIGHT,DOME

000-7-8BLK 1
1 052-4WHT
LB107-G
MS118+