Service 31200364 09-11-08 TH255 Global English

Service Manual
Model
TH255
S/N TBS00100 & After
31200364
Original
September 11, 2008
EFFECTIVITY PAGE
September 11, 2008 - A - Original Issue Of Manual
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
2.5 Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
2.6 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
Section 3
Boom ........................................................... 3.1
3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
3.9 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
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 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
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
Section 6
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
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
6.7 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Section 7
Engine: CAT C4.4DIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
7.12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
8.9 Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
8.10 Front Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
8.11 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
8.12 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.24
ii TH255
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.3 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.4 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.5 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
9.6 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
9.7 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
9.8 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
9.9 Window Wiper/Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
9.10 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.11 Switches, Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
TH255 iii
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
TH255 1.1
Safety Practices
1.1 INTRODUCTION 1.2 DISCLAIMER

This service manual provides general directions for All information in this manual is based on the latest
accomplishing service and repair procedures. Following product information available at the time of publication.
the procedures in this manual will help assure safety and The manufacturer reserves the right to make changes
equipment reliability. and improvements to its products, and to discontinue the
Read, understand and follow the information in this manufacture of any product, at its discretion at any time
manual, and obey all locally approved safety practices, without public notice or obligation.
procedures, rules, codes, regulations and laws.
These instructions cannot cover all details or variations in
the equipment, procedures, or processes described, nor 1.3 OPERATION & MAINTENANCE
provide directions for meeting every possible contingency MANUAL
during operation, maintenance, or testing. When additional
information is desired consult the local Caterpillar dealer. The mechanic must not operate the machine until the
Operation & Maintenance Manual has been read &
Many factors contribute to unsafe conditions: carelessness,
understood, training has been accomplished and
fatigue, overload, inattentiveness, unfamiliarity, even
operation of the machine has been completed under the
drugs and alcohol, among others. For optimal safety,
supervision of an experienced and qualified operator.
encourage everyone to think, and to act, safely.
An Operation & Maintenance Manual is supplied with
Appropriate service methods and proper repair
each machine and must be kept in the manual holder
procedures are essential for the safety of the individual
located in the cab. In the event that the Operation &
doing the work, for the safety of the operator, and for the
Maintenance Manual is missing, consult the local
safe, reliable operation of the machine. All references to
Caterpillar dealer before proceeding.
the right side, left side, front and rear are given from the
operator’s seat looking in a forward direction.
Supplementary information is available from the
manufacturer in the form of Service Bulletins, Service 1.4 DO NOT OPERATE TAGS
Campaigns, Service Training Schools, the service
website, other literature, and through updates to the Place Do Not Operate Tags on the ignition key switch
manual itself. and the steering wheel before attempting to perform any
service or maintenance. Remove key and disconnect
battery leads.
1.2 TH255
Safety Practices
1.5 SAFETY INFORMATION 1.6 SAFETY INSTRUCTIONS

To avoid possible death or injury, carefully read, Following are general safety statements to consider before
understand and comply with all safety messages. performing maintenance procedures on the telehandler.
In the event of an accident, know where to obtain medical Additional statements related to specific tasks and
assistance and how to use a first-aid kit and fire procedures are located throughout this manual and are
extinguisher/fire suppression system. Keep emergency listed prior to any work instructions to provide safety
telephone numbers (fire department, ambulance, rescue information before the potential of a hazard occurs.
squad/paramedics, police department, etc.) nearby. If For all safety messages, carefully read, understand and
working alone, check with another person routinely to follow the instructions before proceeding.
help assure personal safety.
1.6.1 Personal Hazards
1.5.1 Safety Alert System and Signal Words PERSONAL SAFETY GEAR: Wear all the protective
clothing and personal safety gear necessary to perform
DANGER the job safely. This might include heavy gloves, safety
glasses or goggles, filter mask or respirator, safety shoes
or a hard hat.
DANGER indicates an imminently hazardous situation LIFTING: NEVER lift a heavy object without the help of at
which, if not avoided, will result in death or serious injury. least one assistant or a suitable sling and hoist.
1.6.2 Equipment Hazards

WARNING LIFTING OF EQUIPMENT: Before using any lifting
equipment (chains, slings, brackets, hooks, etc.), verify
that it is of the proper capacity, in good working order, and
WARNING indicates a potentially hazardous situation is properly attached.
which, if not avoided, could result in death or serious
NEVER stand or otherwise become positioned under a
injury.
suspended load or under raised equipment. The load or
equipment could fall or tip.
CAUTION DO NOT use a hoist, jack or jack stands only to support
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load.
CAUTION indicates a potentially hazardous situation HAND TOOLS: Always use the proper tool for the job;
which, if not avoided, may result in minor or moderate keep tools clean and in good working order, and use
injury. special service tools only as recommended.
TH255 1.3
Safety Practices
1.6.3 General Hazards appropriate container and dispose of in accordance with

prevailing environmental regulations.
SOLVENTS: Only use approved solvents that are known
to be safe for use. RADIATOR CAP: The cooling system is under pressure,
and escaping coolant can cause severe burns and eye
HOUSEKEEPING: Keep the work area and operator’s
injury. To prevent personal injury, NEVER remove the
cab clean, and remove all hazards (debris, oil, tools, etc.).
radiator cap while the cooling system is hot. Wear safety
FIRST AID: Immediately clean, dress and report all injuries glasses. Turn the radiator cap to the first stop and allow
(cuts, abrasions, burns, etc.), no matter how minor the pressure to escape before removing the cap completely.
injury may seem. Know the location of a First Aid Kit, and Failure to follow the safety practices could result in death
know how to use it. or serious injury.
CLEANLINESS: Wear eye protection, and clean all FLUID FLAMABILTITY: DO NOT service the fuel or
components with a high-pressure or steam cleaner hydraulic systems near an open flame, sparks or smoking
before attempting service. materials.
When removing hydraulic components, plug hose ends NEVER drain or store fluids in an open container. Engine
and connections to prevent excess leakage and fuel and hydraulic fluid are flammable and can cause a
contamination. Place a suitable catch basin beneath the fire and/or explosion.
machine to capture fluid run-off.
DO NOT mix gasoline or alcohol with diesel fuel. The
Check and obey all Federal, State and/or Local mixture can cause an explosion.
regulations regarding waste storage, disposal and
PRESSURE TESTING: When conducting any test, only
recycling.
use test equipment that is correctly calibrated and in good
condition. Use the correct equipment in the proper
1.6.4 Operational Hazards manner, and make changes or repairs as indicated by the
ENGINE: Stop the engine before performing any service test procedure to achieve the desired result.
unless specifically instructed otherwise. LEAVING MACHINE: Lower the forks or attachment to
VENTILATION: Avoid prolonged engine operation in the ground before leaving the machine.
enclosed areas without adequate ventilation. TIRES: Always keep tires inflated to the proper pressure
SOFT SURFACES AND SLOPES: NEVER work on a to help prevent tipover. DO NOT over-inflate tires.
machine that is parked on a soft surface or slope. The NEVER use mismatched tire types, sizes or ply ratings.
machine must be on a hard level surface, with the wheels Always use matched sets according to machine
blocked before performing any service. specifications.
FLUID TEMPERATURE: NEVER work on a machine MAJOR COMPONENTS: Never alter, remove, or
when the engine, cooling or hydraulic systems are hot. substitute any items such as counterweights, tires,
Hot components and fluids can cause severe burns. batteries or other items that may reduce or affect the
Allow systems to cool before proceeding. overall weight or stability of the machine.
FLUID PRESSURE: Before loosening any hydraulic or BATTERY: DO NOT charge a frozen battery. Charging a
diesel fuel component, hose or tube, turn the engine frozen battery may cause it to explode. Allow the battery
OFF. Wear heavy, protective gloves and eye protection. to thaw before jump-starting or connecting a battery
NEVER check for leaks using any part of your body; use charger.
a piece of cardboard or wood instead. If injured, seek
medical attention immediately. Diesel fluid leaking under
1.7 SAFETY DECALS
pressure can explode. Hydraulic fluid and diesel fuel
leaking under pressure can penetrate the skin, cause Check that all safety decals are present and readable on
infection, gangrene and other serious personal injury. the machine. Refer to the Operation & Maintenance
Relieve all pressure before disconnecting any Manual supplied with machine for information.
component, part, line or hose. Slowly loosen parts and
allow release of residual pressure before removing any
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
1.4 TH255
Section 2
General Information and Specifications
Contents

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.3.1 Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.3.2 Hydraulic Cylinder Performance Specifications. . . . . . . . . . . . . . . . . . . . . 2.10
2.3.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.3.4 Engine Performance Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.3.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
2.5 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
2.5.1 10,1st 50 & 50 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 2.14
2.5.2 1st 250, 250, 500 & 1000 Hour Maintenance Schedule . . . . . . . . . . . . . . 2.14
2.6 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
2.6.1 250 Hour Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
TH255 2.1
2.1 REPLACEMENT PARTS AND

WARRANTY INFORMATION
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.
EARLY PRODUCTION ONLY
CURRENT PRODUCTION
MY2350
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 manufacturerr.
2.2 TH255
2.2 TORQUES
2.2.1 SAE Fastener Torque Chart
(CAT THREADLOCK OR
(DRY) (CAT HIGH STRENGTH CAT HIGH STRENGTH
THREADLOCK) THREADLOCK)
MAM1325
SAE GRADE 5 SAE GRADE 8
TH255 2.3

(Continued)
(CAT THREADLOCK OR
MAM1324
2.4 TH255

(Continued)
(CAT THREADLOCK OR
(CAT HIGH STRENGTH CAT HIGH STRENGTH
MAM1323
TH255 2.5
2.2.2 Metric Fastener Torque Chart
(CAT THREADLOCK OR
MAM1322
METRIC CLASS 8.8 METRIC CLASS 10.9
2.6 TH255

(Continued)
(CAT THREADLOCK OR
MAM1321
TH255 2.7

(Continued)
(CAT THREADLOCK
(CAT HIGH
OR CAT HIGH
STRENGTH
STRENGTH
THREADLOCK)
THREADLOCK)
MAM1320
2.8 TH255
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.
TH255 2.9
2.3 SPECIFICATIONS
2.3.1 Travel Speed
12 x 16.5 Tires (Standard) 26 kmph (16 mph)

14 x 17.5 Tires 29 kmph (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 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 BCI Group 31
Alternator 12V, 75 Amps
Starter 12V, 3,0 KW Type EV (Gear Reduction)
2.10 TH255
2.3.4 Engine Performance Specifications
Description
Engine Make/Model CAT C4.4DIT
Low Idle 900 ±50 rpm
High Idle 2335 ±50 rpm (ANSI) - 2005 to 2090 RPM (CE)
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.
Size Tire Type Minimum Ply/ 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)
TH255 2.11
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 & Glycol
Fuel #2 Diesel Low Sulfur
Air Conditioning Refrigerant R-134a Tetrafluorethane
2.12 TH255
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 - Front 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 0,7 kg (1.6 lb)
TH255 2.13
2.5 MAINTENANCE SCHEDULES 2.5.2 1st 250, 250, 500 & 1000 Hour
Maintenance Schedule
2.5.1 10,1st 50 & 50 Hour Maintenance
Schedule
1st
250
EVERY
10
Change Axle Change Wheel
Differential Oil End Oil
Check Fuel Check Engine Check Hydraulic Check Tire

Level Oil Level Oil Level Condition &
Pressure
EVERY
250
1st
50
LB/FT
(Nm) Check Boom Lubrication Check Axle Check Wheel Check
Wear Pads Schedule Differential Oil End Oil Levels Fan Belt
Level
Check Wheel
Lug Nut
Torque
EVERY
EVERY 500
50 LB/FT
(Nm)
Change Fuel Change Engine Change Check Wheel

Filter Oil and Air Filter Lug Nut
Filter Elements Torque
Drain Fuel/ Check Engine Check Check Check Brake
Water Coolant Level Air Filter Battery Fluid Level
Separator
EVERY
1000
Check Washer
Fluid Level
(if equipped)
MY2560
Change Axle Change Wheel Change Check Change

Differential Oil End Oil Hydraulic Hydraulic Tank Transmission
Fluid & Filters Cap Filter
Change
Engine Coolant
MY2570
2.14 TH255
2.6 LUBRICATION SCHEDULE
2.6.1 250 Hour Lubrication Schedule
EVERY
250
MY2580
TH255 2.15
This Page Intentionally Left Blank
2.16 TH255
Section 3
Boom
Contents

3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.4.10 Extend/Retract Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.5 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
3.5.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
3.5.2 Boom Wear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
3.5.3 Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
3.6 Quick Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.6.1 Quick Coupler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.6.2 Quick Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.7 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
3.8 Boom Prop (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
3.8.1 Installation and Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
3.9 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3.9.1 Equipment and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3.9.2 Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
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 2. Be sure there is enough room in front of the machine
to allow the boom sections to be removed. Park the
machine on a hard, level surface, fully retract the
WARNING boom, lower the boom, place the transmission
control lever in (N) NEUTRAL, engage the park
DO NOT service the machine without following all brake and shut the engine OFF.
safety precautions as outlined in the “Safety 3. Place a Do Not Operate Tag on both the ignition key
Practices” section of this manual. Failure to follow the switch and the steering wheel, stating that the
safety practices could result in death or serious injury. machine should not be operated.
4. Remove the battery negative (-) cable from the
3.3 BOOM SYSTEM - TWO SECTION battery negative (-) terminal.
BOOM
5. Open the engine cover. Allow the system fluids to
cool.
3.3.1 Boom System Description 6. Remove the quick coupler assembly. Refer to
The boom operates via an interchange among the Section 3.6.1, “Quick Coupler Removal.”
electrical, hydraulic and mechanical systems. Components 7. Label and disconnect the tilt hoses and (if equipped)
involved include the joystick, tilt cylinder, extend/retract auxiliary hydraulic hoses attached to the machine at
cylinder, lift/lower cylinder, compensating cylinder, the boom head. Plug and cap the hose ends to
electronic sensors, various pivots, supporting hardware prevent dirt and debris from entering the hydraulic
and other components. system.
8. Label and disconnect the extend/retract hydraulic
3.4 BOOM ASSEMBLY MAINTENANCE tubes on the extend/retract cylinder at the rear of the
boom.
The boom assembly consists of the first and second
section booms and supporting hardware. 9. Tag or identify each hose to the corresponding fitting
it was removed from.
Note: Before removing the boom or boom section, the
carriage or any other attachment must be removed from 10. Remove the top and side wear pads from the rear of
the quick coupler. the second boom section.
Before beginning, conduct a visual inspection of the Note: Tag each pad, backing plate, shim and bolts from
machine and work area, and review the task about to be each location.
undertaken. Read, understand and follow these
instructions.
During service of the boom, perform the following:
1. Check wear pads. (Refer to Section 3.5.1, “Wear 1
Pad Inspection.”)
2. Apply grease at all lubrication points (grease fittings).
(Refer to Section 2.6, “Lubrication Schedule.”) 2
3. Check for proper operation by operating all boom
functions through their full ranges of motion several
times. MY1960
Depending on your particular circumstance, the following 11. Remove the lock bolt and nut (1) from the rear of the
procedures explain the removal/installation of individual extend/retract cylinder.
boom sections or removal/installation of the complete 12. Remove the extend/retract cylinder mounting pin (2).
boom.
13. Support the front of the boom by placing a sling
3.4.1 Second Boom Section Removal behind the boom head. Pull the second boom
section out of the first boom section approximately
1. Remove any attachment from the quick coupler 15 cm to 20 cm (6 in to 8 in).
assembly.
14. Pull the tilt hoses and (if equipped) auxiliary
hydraulic hoses through the rear of the boom.
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 7. 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 8. Remove the lock bolt and pivot pin (4) from rear of
3.5.1, “Wear Pad Inspection.”) first boom section.
9. Lift the first boom section off machine and set on
3.4.2 First Boom Section Removal 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. 10. 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 11. Inspect hoses, hardware, wear pads, mounting
cylinder pin. 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 12. 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
boom wear surfaces lubricated properly. Lubrication of
5. Support the first boom section by placing a sling at
the boom wear surfaces is also recommended when the
the balance point of the section.
machine is stored, to help prevent rusting.
1
1. Park the machine on a hard, level surface, place the
transmission control lever in (N) NEUTRAL, engage
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.
2 3. Remove the battery negative (-) cable from the
MY1970 battery negative (-) terminal.
6. Support the lift/lower cylinder and remove the lock cool.
bolt (1) and then the rod end pin (2). Lower the lift/
lower cylinder onto the frame rails. Note: Grease the boom pivot bore, compensating
cylinder rod ends, lift/lower cylinder rod end and pins
before installing.
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 Cat 2. Using suitable slings, balance the second boom
Threadlock 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 Cat Threadlock 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
auxiliary hoses through the channel above the
6 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)
auxiliary hoses. Attach both sets to their appropriate
7. With the sling still in place, install the rod end of the fittings until wrench-tight. Mark the fitting, then
lift/lower cylinder, pin and lock bolt. Apply Cat torque to specification. Refer to Section 2.2.3,
Threadlock and torque to 90 Nm (66 lb-ft). “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 9. Connect the battery negative (-) cable to the battery
cylinder bores can be aligned for easier pin installation. negative (-) terminal.
8. Remove the sling. 10. Start the engine and operate all boom functions
9. Temporarily install the battery negative (-) cable to several times to bleed any air out of the hydraulic
the battery negative (-) terminal. system. Check for fluid leaks. Check the hydraulic
fluid level in the tank and add fluid as required.
10. Start the machine and lower the first boom section to
a level position. 11. Clean up all debris, hydraulic fluid, etc., in, on, near
and around the machine.
Note: DO NOT activate ANY boom function other than
the boom lift function. Activating the extend/retract, tilt or 12. Close and secure the engine cover.
auxiliary function could cause hydraulic oil to spray onto
the machine and/or surrounding areas. 3.4.5 Complete Boom Removal
11. Shut the engine OFF. 1. Remove any attachment from the quick coupler
assembly.
battery negative (-) terminal. 2. Be sure there is enough room in front of the machine
to allow the boom sections to be removed. Park the
machine on a hard, level surface, fully retract the
3.4.4 Second Boom Section Installation
boom, Raise the boom to allow access to the lift
Note: Lubrication of the boom wear surfaces with CAT cylinder and the comp cylinder pivot pins, place the
Advanced 3Moly grease is recommended to keep the transmission control lever in (N) NEUTRAL, engage
boom wear surfaces lubricated properly. Lubrication of the park brake and shut the engine OFF.
TH255 3.5
Boom
4. Remove the battery negative (-) cable from the cylinder pin. Remove the tilt cylinder pin and lower
battery negative (-) terminal. the tilt cylinder out of the boom head.
5. Open the engine cover. Allow the system fluids to 2. Remove the extend /retract tubes from the extend /
cool. retract cylinder from the rear of the boom.
6. Remove the quick coupler assembly. Refer to 3. If equipped, unscrew the auxiliary hoses. Plug the
Section 3.6.1, “Quick Coupler Removal.” hose ends to prevent dirt and debris from entering
7. Support the boom by placing a sling around the the hydraulic system.
boom head. Support the lift/lower cylinder and Note: Tag or identify each hose to the corresponding
remove the lock bolt and then the rod end pin. Lower fitting it was removed from.
the lift/lower cylinder onto the frame rails.
8. Label and disconnect the tilt and auxiliary hydraulic
hoses attached to the machine at the tubes on top of
the boom. Plug and cap the hose ends to prevent
dirt and debris from entering the hydraulic system.
9. Label and disconnect the extend/retract hydraulic
hoses at the tubes on the side of the boom.
Note: Tag or identify each hose to the corresponding
fitting it was removed from.
MY1990
1 3
4. Remove the lock nut, bolt and pin from rod end of
the extend/retract cylinder.
2
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
bolts and remove all the wear pads, backing plates
and shims from the rear outside of the second
section boom and the front inside of the first section
boom. Tag each pad, backing plate, shim and bolts
MY1980
from each location.
6. Carefully pull the tilt and auxiliary hydraulic hoses (3)
10. Remove the lock bolt and pin (1) from the rod end of through the rear of the first boom section.
the compensating cylinder on the first boom section.
Rest the cylinder on the machine frame.
11. Lower the boom to a level position and place a WARNING
suitable support under the rear of the boom. NEVER weld or drill the boom unless approved in
Reposition the slings to each end of the boom. writing by the manufacturer. The structural integrity of
12. Remove the lock bolt and pivot pin (2) from rear of the boom will be impaired if subjected to any repair
first boom section. involving welding or drilling. Failure to comply could
13. Lift the complete boom off machine and set on level result in death or severe personal injury.
ground or supports being careful not to damage the 7. Pull out the remainder of the second boom section.
tubes on the bottom of the boom.
8. Inspect the boom and welds. Consult the local
3.4.6 Second Boom Section Removal Caterpillar dealer if structural damage is detected.
9. Inspect hoses, hardware, wear pads, mounting
1. At the boom head, attach a sling around the tilt
points and other components visible with the first
cylinder. Remove both hoses from tilt cylinder. Plug
boom section. Replace any item if damaged.
the hose ends and cap the tilt cylinder fittings to
prevent dirt and debris from entering the hydraulic 10. Inspect all wear pads for wear. (Refer to Section
system. Remove the clip from barrel end of tilt 3.5.1, “Wear Pad Inspection.”)
3.6 TH255
Boom
3.4.7 Second Boom Section Installation 12. Uncap and reconnect the tilt and auxiliary hoses and
attach to their appropriate locations.
1. If previously removed, insert the extend/retract
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 Cat Threadlock 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 Cat Threadlock to all wear pad bolts prior to machine is stored, to help prevent rusting.
installing wear pads.
1. Park the machine on a hard, level surface, place the
3. Grease the inside of the first boom section on areas transmission control lever in (N) NEUTRAL, engage
where the second boom section wear pads will slide. the park brake and shut the engine OFF.
4. Using a suitable sling, carefully slide the second 2. Place a Do Not Operate Tag on both the ignition key
boom section 1 m to 1.5 m (3 ft to 4 ft) into the front switch and the steering wheel, stating that the
of the first boom section. Set the second boom machine should not be operated.
section head onto suitable supports and reset sling
under the boom head of the second section.
cool.
Carefully slide the second section into the first
section. Leave 15 cm to 20 cm (6 in to 8 in) of the 4. Disconnect the battery negative (-) cable from the
second section out to be able to install wear pads in battery negative (-) terminal.
front of the first boom section. Note: Grease the boom pivot bore, compensating
5. With the sling still under the boom head, install the cylinder rod ends, lift/lower cylinder rod end and pins
top wear pads, washers and bolts in the front of the before installing.
first boom section. Apply Cat Threadlock 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 Cat
Apply Cat Threadlock and torque to 90 Nm (66 lb-ft).
Threadlock and torque to 90 Nm (66 lb-ft).
Install the left and right side front wear pads, backing
plates, shims and bolts in the front of the first boom 6. With the sling still in place, install the compensating
section. Apply Cat Threadlock and torque to 90 Nm cylinder, pin (5) and lock bolt. Apply Cat Threadlock
(66 lb-ft). and torque to 90 Nm (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).
Note: Lubrication of the boom wear surfaces with CAT 4
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
8. Slide the tilt and auxiliary hoses between the boom MY1980
sections.
7. With the sling still in place, install the rod end of the
9. Insert the pin and secure the rod end of the extend/ lift/lower cylinder, pin and lock bolt. Apply Cat
retract cylinder in place with the bolt and locknut. Threadlock and torque to 90 Nm (66 lb-ft).
10. Install both tubes to the rear of the extend/retract
Note: Raising the boom up or down with the sling may
cylinder.
be necessary so the boom, compensating and lift/lower
11. Lift the tilt cylinder into place and insert the pins and cylinder bores can be aligned for easier pin installation.
clips to secure the cylinder to the boom head.
TH255 3.7
Boom
8. Uncap and reconnect the extend/retract cylinder 3.4.9 Extend/Retract Cylinder Removal
fittings and plugs from extend/retract cylinder tubes
1. Remove any attachment from the quick coupler
and tighten until wrench-tight. Mark the fitting, then
assembly. Refer to Section 3.6, “Quick Coupler
torque to specification. Refer to Section 2.2.3,
Assembly.”
“Hydraulic Hose Torque Chart.”
2. Park the machine on a hard, level surface, extend
the boom to gain access to the extend/retract
auxiliary hoses. Attach both sets to their appropriate
cylinder pin in the second boom section
fittings until wrench-tight. Mark the fitting, then attach
(approximately 1 m (3 ft), level the boom assembly,
both sets to there appropriate fitting and torque to
place the transmission control lever in (N)
specification. Refer to Section 2.2.3, “Hydraulic
NEUTRAL, engage the park brake and shut the
Hose Torque Chart.”
engine OFF.
10. Connect the battery negative (-) cable to the battery
negative (-) terminal. Note: The boom must be properly aligned (level) with
the access hole at the rear of the frame to allow removal
11. Start the engine and operate all boom functions of the extend/retract cylinder barrel mounting pin.
several times to bleed any air out of the hydraulic
system. Check for fluid leaks. Check the hydraulic 3. Place a Do Not Operate Tag on both the ignition key
fluid level in the tank and add fluid as required. switch and the steering wheel, stating that the
1 cool.
battery negative (-) terminal.
MY2000
12. Check clearance (1) between the tilt hoses (and if

equipped) auxiliary hoses and the front of the 2
extend/retract cylinder trunnion. There should be
approximately 12,7 mm (1/2 in.) of clearance.
13. If adjustment is needed, loosen the tilt tubes (and if
MY2680
equipped) auxiliary tubes. Move tubes to achieve the
proper clearance.
6. Remove the cylinder rod eye retaining clips and
14. Clean up all debris, hydraulic fluid, etc., in, on, near
mounting pin (2) at the side of the second boom
section.
15. Close and secure the engine cover.
3.8 TH255
Boom
3.4.10 Extend/Retract Cylinder Installation

1. Using a suitable sling, carefully install the extend/
4 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
through the frame access hole on the chassis and
3
the first boom section bore and cylinder barrel.
Secure with retaining clips.
3. Remove the plugs in the bottom of the extend/retract
cylinder and install the previously removed fittings.
5
4. Uncap and connect the tubes to the previously
MY2670 labeled fittings at the extend/retract cylinder. Apply
Loctite 545® to the fittings.
7. Loosen and remove the hose clamps and cover
plate (3) from the rear of the boom assembly.
auxiliary hoses (4) to their appropriate fittings until
8. Label and disconnect the tilt and (if equipped) wrench-tight. Mark the fitting and torque to
auxiliary hydraulic hoses attached to the machine at specification. Refer to Section 2.2.3, “Hydraulic
the tubes on top of the boom (4). Plug and cap the Hose Torque Chart.”
hose ends to prevent dirt and debris from entering
6. Install the cover plate and hose clamps (3) at the
the hydraulic system.
rear of the boom assembly.
9. Loosen and remove the extend/retract cylinder tubes
at the rear of the first boom section. Plug the tube
negative (-) terminal.
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

A total of 14 wear pads are installed on the boom.
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 5
for tilt hose and auxiliary hose clearance.
3.5.1 Wear Pad Inspection

Inspect all wear pads (2) for wear. If the angle
MY2020
indicators (3) on the ends of the wear pads are visible, the
wear pads can be reused. If the pads show uneven wear
Use shims under the wear pads as required to maintain a
(front to back), they should be replaced. Replace pads as
maximum gap of 1,5 mm (0.06 in) (6) between the wear
a set if worn or damaged.
pad on the front and sides of the boom. The gap at the
rear of the boom should be no more than 3 mm (0.12 in).
3
3 Shims are available in four thicknesses, 0,5 mm (0.02 in),
1 mm (0.04 in), 1,5 mm (0.06 in) and 2,0 mm (0.08 in).
2 MA2070
3.5.2 Boom Wear Pad Replacement

When replacing a wear pad on the boom, replace both
wear pads on that side of the boom; e.g.: replace top front
left and top front right wear pads at the same time.
All wear pads are secured to the boom using different
capscrews and washers. When installing new wear pads,
MU4080
apply Cat Threadlock to all wear pad mounting
capscrews and torque to the proper specification. Refer
to Section 2.2, “Torques.”. Grease the new pads and 3.5.3 Boom Wear Pad Lubrication
surrounding area.
After replacing any wear pads or after prolonged periods
The boom wear pads are mounted on the inside of the of inoperation, lubrication of the boom wear surfaces with
first boom section (4) and the outside of the second boom Cat Advanced 3Moly is recommended to keep the boom
section (5). wear surfaces lubricated properly. Lubrication of the
boom wear surfaces is also recommended when the
Note: The first shim under the pad needs to contain
holes, instead of slots.
4
MY2010
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
pivot pin and quick coupler. Install the lock bolt (16).
Torque to 97 Nm (72 lb-ft).
3. Align the quick coupler with the tilt cylinder rod end
and insert the tilt cylinder pin (15). Align the tilt
cool.
cylinder pin and quick coupler. Install the lock bolt
4. Remove the battery negative (-) cable from the (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.
6. Clean up all debris, hydraulic fluid, etc., in, on, near
13
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. Sudden movement of the boom could
cause personal injury or death. Remove any load,
9
retract the boom and install the boom prop or a
10 7 suitable supporting stand before working under a
8
raised boom.
5
4 a. Prop Installation
14 1. Park the machine on a firm, level surface. Place the
the park brake switch.
2. Raise the boom to an angle of approximately 20
13 11 degrees. Shut engine OFF.
12 MH6460 switch and the steering wheel, stating that the
1. Inspect forks (4) for cracks, paying special attention
to heel (5) and mounting tubes (6). 4. Before installing the boom prop, inspect the prop for
damage. Do not use if the prop is damaged or if the
2. Inspect forks for broken or bent tips (7) and twisted
o-rings are damaged or missing.
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
face of shank should not exceed 93 degrees.
3. Thickness of blade (13) and shank (14) should not 3
be reduced to 90 percent of original thickness.
4. Ensure fork length (12) is adequate for intended 2
loads. 1
5. Fork markings should be legible, re-stamp if
2
required.
6. Compare fork tips (11) when mounted on a carriage.
Maximum difference in height of fork tips is 3 percent MAM1280
of the length of the blade (13).
5. Install the boom prop (1) onto the lift/lower cylinder.
Install o-rings (2). Align lift cylinder lock so the o-
rings are on the bottom side of the lift/lower cylinder
rod.
6. Start the engine and SLOWLY lower the boom until
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
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, “Hydraulic

not operating properly. System.”
3. Faulty extend/retract cylinder. 3. Repair cylinder (Refer to Section

8.12.4, “Cylinder Inspection.”)
2. Boom will not fully extend. 1. Extend/retract hydraulic system 1. Refer to Section 8, “Hydraulic
not operating properly. System.”
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, “Boom
Wear Pad Replacement.”
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, “Hydraulic

operating properly. System.”
3. Faulty lift cylinder. 3. Repair cylinder. (Refer to
Section 8.12.4, “Cylinder
Inspection.”)
4. Seized boom pivot pin bushing. 4. Replace bushing.
TH255 3.15
Boom

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, “Boom Wear Pad
Replacement.”
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, “Hydraulic
operate. operating properly. System.”
3.16 TH255
Section 4
Cab and Covers
Contents

4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . 4.2
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
locations of the major assemblies of the machine cab and
covers. The following illustration identifies the
components that are referred to throughout this section.
LSI INDICATOR (CE)

ACCESSORY CONTROL LEVER
SPEEDOMETER (CE)
(IF EQUIPPED)
FRAME LEVEL
INDICATOR JOYSTICK
HORN BUTTON RIGHT HAND CONSOLE
STEERING WHEEL
POWER OUTLET
INSTRUMENT
PANEL
PARK BRAKE
SWITCH (ANSI)
LSI OVERRIDE
SWITCH (CE)
TRANSMISSION
CONTROL LEVER
QUICK COUPLER SWITCH

(IF EQUIPPED)
TILT STEERING COLUMN

(IF EQUIPPED)
SERVICE BRAKE PEDAL
IGNITION SWITCH
ACCELERATOR PEDAL
PARK BRAKE LEVER (CE)

MY2391
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. Failure to follow the retract the boom, lower the boom, place the
safety practices could result in death or serious injury. transmission control lever in (N) NEUTRAL, engage
4.3 OPERATOR CAB 2. Place a Do Not Operate Tag on both the ignition key
4.3.1 Operator Cab Description machine should not be operated.
3. Open the engine covers. Allow the system fluids to
The welded metal cab features a modular design, allowing
cool.
for a relatively quick, simple exchange of the entire cab
and/or component parts. The cab is bolted directly to the 4. Remove the battery negative (-) cable from the
frame. battery negative (-) terminal.
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. Failure to
follow the safety practices could result in death or
serious injury.
To help ensure optimum safety, protection and

performance, replace the cab if it is damaged. Refer to 2
the appropriate parts manual for ordering information.
MAH0430
The cab contains the seat, operating controls, numerous
panels, steering and brake components, and more. 5. Carefully pry the center button (1) out of the steering
wheel.
Covers and mirrors on the machine exist for safety,
protection and appearance. They are relatively simple to 6. Mark the steering wheel and shaft to ensure proper
remove and replace. installation. Remove the nut (2) securing the steering
wheel (3) to the splined steering column shaft.
4.3.2 Serial Number Decal 7. Use a steering wheel puller to remove the steering
The cab serial number decal is located inside the cab, wheel (3) from the splined shaft.
under the seat. Information specified on the serial
number plate includes the cab model number, the cab b. Steering Wheel Installation
serial number and other data. Write this information down 1. Install the steering wheel (3) onto the splined
in a convenient location to use in cab correspondence. steering column shaft.
2. Secure the steering wheel with the nut (2).
3. Press the center button (1) onto the steering wheel.
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.
Note: ALWAYS use new o-rings when servicing the
machine.
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. Disconnect the battery negative (-) cable at the 4. Install the dash cover.
battery negative (-) terminal. 5. Install the steering column cover.
6. Install the steering wheel (Refer to Section 4.4.1,
1 “Steering Wheel.”), accessory lever and
transmission control lever.
3 negative (-) terminal.
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
controls. Check for fluid leaks. Check the hydraulic
4 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.
MY2440
c. Power Steering Test
5. Remove the steering wheel (1) (Refer to Section Conduct a pressure check of the steering hydraulic
4.4.1, “Steering Wheel.”), transmission control lever circuits at the test port on the implement pump. Refer to
(2) and accessory lever (if equipped)(3). Section 8.6.5, “Steering Pressure Checking.”
6. Loosen and remove the steering column cover.
4.4.3 Brake Pedal and Valve
7. Loosen and remove the dash cover.
8. Label, disconnect and cap the hydraulic hoses (4) a. Brake Valve Removal
and fittings on the steering orbitrol valve (5).
Refer to Section 8.11.2, a. “Service Brake Valve
Removal,” for removal information.
9. Remove the four hex-flange capscrews (6)(three if
machine is equipped with tilt column) connecting the b. Brake Valve Installation
orbitrol valve to the steering column. Refer to Section 8.11.2, b. “Service Brake Valve
10. Pull the steering column assembly and orbitrol valve Installation,” for installation information.
from the machine cab.
c. Service Brake Pedal Removal
Note: DO NOT disassemble the steering orbitrol valve.
The steering orbitrol valve is not serviceable and must 1. Park the machine on a firm, level surface, fully
be replaced in its entirety, if defective. retract the boom, lower the boom, place the
4.4 TH255
Cab and Covers
2. Place a Do Not Operate Tag on both the ignition key 4.4.4 Throttle Pedal Replacement
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. Disconnect the battery negative (-) cable at the transmission control lever in (N) NEUTRAL, engage
battery negative (-) terminal. 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.
cool.
4. Disconnect the battery negative (-) cable at the
6
7 9
10
10
8
MY2400
10
6. Remove the clip/pin (6) from the brake plunger fork
link.
7. Remove the pin (7) and the return spring securing MY2360
the service brake pedal to the cab.
5. Remove the nut from the end of the throttle cable (8).
8. Remove the service brake pedal from the cab.
6. Loosen the hex jam nut and flat washer (9) securing
d. Service Brake Pedal Installation the throttle cable to the throttle pedal assembly.
7. Remove three capscrews, three lockwashers and
1. Position the service brake pedal in its mounting
three washers (10) securing the throttle pedal
location within the cab.
assembly to the cab frame.
2. Install the brake pedal being careful to reposition the
8. Remove the throttle pedal assembly from the cab.
brake plunger yoke. Install the return spring and pin.
Install clip/pin in brake plunger fork link.
b. Throttle Pedal Installation
3. Adjust the brake pedal as needed.
1. Align the throttle pedal assembly with its mount
4. Install and secure the lower dash cover. holes under the cab dash.
5. Connect the battery negative (-) cable to the battery 2. Install three capscrews (10) securing the throttle
negative (-) terminal. pedal assembly to the mount. Torque the capscrews
6. Close and secure the engine covers. 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).
TH255 4.5
Cab and Covers
4.4.5 Throttle Cable Adjustment CE Machines

1. Start the machine and allow engine to low idle for
1 5 approximately 30 seconds.
2. Verify low idle (900 ± 50 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
the engine. The throttle lever should be bottomed 6
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-
stop (5) in the cab.
MY2940
4. Remove the block holding the throttle before starting
machine. 5. Allow the engine to cool. Install proper throttle stop
(6) and verify high idle is correct.
4.4.6 High Idle Adjustment 6. Restart engine, bring engine to high idle. High idle
Note: Engine coolant temperature must be between must be between 2005 and 2090 rpm.
10 and 38° C (50 and 100° F). Note: For the proper throttle stop, contact the local
ANSI Machines Caterpillar dealer.
1. Start the machine and allow engine to low idle for

approximately 30 seconds.
2. Verify low idle (900 ± 50 rpm). Low idle is a factory
non-adjustable setting.
NOTICE
3. Bring engine to full throttle. If high idle rpm is not During the full throttle check:
2335 ± 75 rpm, readjust the throttle cable at the • DO NOT operate any hydraulic function.
throttle pedal in the cab.
• DO NOT steer or apply any pressure to the
steering wheel.
• Keep the transmission in (N) NEUTRAL.
4.6 TH255
Cab and Covers
7. Lift the rubber boot (7) from base of the joystick and
remove the four capscrews (8).
WARNING 8. Remove the joystick.
Avoid breathing exhaust fumes, and prevent engine b. Joystick Installation

operation from becoming a cause of toxic emissions.
1. Uncap and reconnect the previously labeled
Failure to follow the safety practices could result in
hydraulic hoses to their appropriate locations.
death or serious injury.
2. Reconnect the electrical connections.
3. Install the four capscrews in the joystick base.
4. Reseat the rubber boot to the joystick base.
WARNING 5. Remove the lift cylinder lock if previously installed.
Exhaust system components reach high 6. Connect the battery negative (-) cable to the battery
temperatures and can cause severe burns. DO NOT negative (-) terminal.
come into contact with hot exhaust system
components. Failure to follow the safety practices 7. Start the engine and test the boom joystick for
could result in death or serious injury. proper functions.
4.4.8 Windshield Wiper Assembly

4.4.7 Joystick Replacement (If Equipped)
a. Joystick Removal Refer to Section 9.9.1, “Windshield Wiper Motor,” for
removal and installation information.
1. Park the machine on a firm, level surface, fully
retract the boom, raise the boom, place the
4.4.9 Windshield Washer Assembly
(If Equipped)
2. Place a Do Not Operate Tag on both the ignition key Refer to Section 9.9.3, “Windshield Washer Reservoir
switch and steering wheel, stating that the machine and Pump,” for removal and installation information.
4.4.10 Heater/Defroster System (If Equipped)
3. Support the boom by installing the lift cylinder lock or
a suitable support. a. Heater Assembly Removal
cool.
retract the boom, lower the boom, place the
5. Disconnect the battery negative (-) cable at the transmission control lever in (N) NEUTRAL, engage
battery negative (-) terminal. the park brake and shut the engine OFF.
7 cool.
5. Place a suitable container beneath the radiator drain
8 plug or petcock. Slowly turn the cap on the coolant
6
overflow bottle to allow any pressure to escape.
MY2410 Remove the overflow bottle cap.
6. Label, disconnect and cap the hydraulic hoses and

electrical connections (6) to the joystick.
TH255 4.7
Cab and Covers
6. Place a funnel at the base of the radiator to channel 5. Refill the cooling system at the coolant overflow
the drained coolant into the container. Open the bottle with a 50/50 mixture of ethylene glycol and
radiator drain plug or petcock and allow the coolant water allowing time for the coolant to fill the engine
to drain. Replace the drain plug, or close the block. See Section 2.4, “Fluids, Lubricants and
petcock. Capacities,” for system capacities.
7. Transfer the coolant into a suitable, covered 6. Connect the battery negative (-) cable at the battery
container, and label as "Used Coolant". Dispose of negative (-) terminal.
used coolant at an approved recycling facility. 7. Start the engine, run it briefly at low idle and check
Note: Label all hoses to ensure correct installation. the machine for any visual sign of fluid leakage.
STOP the machine immediately if any leakage is
8. Remove the front cover to expose the heater/ noted, and make any necessary repairs before
defroster element (9). continuing.
9. Loosen the hose clamps and disconnect the two 8. Install the front cover (9) in the cab.
heater hoses.
9. Check the coolant level. Add or remove fluid as
required.
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,
replace the cab if it is damaged. Refer to the appropriate
MY2430
parts manual for ordering information.
10
Inspect the cab, its welds and mounts. If modification,
10. Remove the capscrews, nuts and lockwashers damage, a cracked weld and/or fatigued metal is
securing the heater assembly to the cab. discovered, replace the cab. Contact the local Caterpillar
11. Carefully pull out the heater assembly (10). Label dealer with any questions about the suitability or
and disconnect the wiring harness connections at condition of a cab.
the blower.
Note: Remove and label cab components as needed
12. Remove the heater assembly. before removing the cab from the machine. Label,
disconnect and cap hydraulic hoses. Transfer cab parts
b. Heater Assembly Installation to the replacement cab after the replacement cab is
1. Install the heater assembly (10) to its original securely mounted on the machine.
orientation. 1. Park the machine on a firm, level surface, fully
2. Connect the wiring harness connections at the retract the boom, lower the boom, place the
blower. transmission control lever in (N) NEUTRAL, engage
3. Install the capscrews, nuts and lockwashers to
secure the heater assembly to the cab. 2. Block all four wheels to help prevent the machine
from moving. Assure that there is sufficient overhead
4. Reconnect the two heater hoses.
and side clearance for cab removal.
4.8 TH255
Cab and Covers
3. Open the engine cover. Allow the system fluids to 14. When the cab is completely clear of the machine,
cool. carefully lower it to the ground. Block up or support
4. Disconnect the battery negative (-) cable at the the cab so that it does not move or fall. Assure that
battery negative (-) terminal. no personnel enter the cab while it is being removed
from the machine.
5. If equipped with a cab heater, Refer to Section
4.4.10, b. “Heater Assembly Installation.” 15. Inspect the condition of the fittings, clamps, hydraulic
hoses, etc. Replace parts as indicated by their
6. Working underneath the cab, label, disconnect and condition.
cap all hydraulic hoses at the cab fittings. Cap all
fittings and openings to keep dirt & debris from 16. Inspect and replace other machine parts that are
entering the hydraulic system. exposed with the cab removed. Repair or replace as
required.
7. In the cab, disconnect the throttle cable at the
throttle lever bracket. Route the cable away from the
4.6 CAB INSTALLATION
cab to prevent damage during removal.
8. Label and disconnect the cab harness connectors. 1. Block all four wheels to help prevent the machine
Move the harnesses clear of the cab to prevent from moving. Assure that there is sufficient overhead
damage during cab removal. and side clearance for cab installation.
9. Install four lifting eye bolts with a minimal lifting 2. Attach a sling with minimal lifting capacity of 363 kg
capacity of 363 kg (800 lb.) in the existing holes at (800 lb.) through the previously installed eye bolts.
the top corners of the cab (1). 3. Use a hoist or overhead crane and sling attached to
10. Use a hoist or overhead crane and sling with a the cab. Carefully begin to align the cab with the
minimal lifting capacity of 363 kg (800 lb.) attached mounting holes in the frame. Stop and check that
to the four lifting eye bolts. DO NOT attempt to lift the wiring, hydraulic hoses, cables, etc., will not be
cab at this point. pinched or damaged as the cab is positioned. Take
11. Remove the bolts (2), washers and nuts securing the special note of the fuel fill tube as well. Readjust the
cab to the frame. 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).
1 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.
9. Install the cab-to-wiring harness connectors on side
of the cab.
2 10. Uncap and connect the heater hoses to the engine.
Secure with hose clamps.
MY2420 11. If equipped with a cab heater, Refer to Section
4.4.10, “Heater/Defroster System (If Equipped).”
12. Remove the mirrors and all other cab components
as needed, if not previously removed. 12. Connect the battery negative (-) cable to the battery
13. When all wiring, hydraulic hoses and fasteners are
disconnected or removed, carefully and slowly lift the 13. Carefully examine all cab components, fasteners,
cab and remove it from the frame. Readjust the etc., one last time before engine start-up. Rectify any
position of the sling as needed to help balance the faulty conditions.
cab during removal.
TH255 4.9
Cab and Covers
14. Start the engine and check the operation of all controls.
Check for hydraulic fluid leaks. Check the hydraulic
fluid level in the tank and add fluid as required
NOTICE
When the engine is initially started, run it briefly at low
idle and check the machine for any visual sign of fluid
leakage. STOP the engine immediately if any leakage
is noted, and make any necessary repairs before
continuing.
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
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

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
TH255 5.1
5.1 AXLE, DRIVE SHAFT AND WHEEL

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
CYLINDER
DRIVE SHAFT
FRONT STEERING
CYLINDER
FRONT AXLE WHEEL

HUBS (2)
MY2070
REAR AXLE WHEEL REAR AXLE

HUBS (2) ASSEMBLY
5.2 TH255
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
the planetary hub and axle housing. Water can cause
safety precautions as outlined in the “Safety
corrosion of critical parts. Rust contamination in the
Practices” section of this manual. Failure to follow the
lubricant can cause gear and bearing failure. Remove old
safety practices could result in death or serious injury.
gasket material from all surfaces.
DRYING: Use clean, lintless towels to dry components
5.3 GENERAL INFORMATION after cleaning. DO NOT dry bearings by spinning them
with compressed air; this can damage mating surfaces
Before performing any inspection, maintenance or
due to lack of lubrication. After drying, coat components
service operation, thoroughly clean the unit. The axles
with oil or a rust-preventive chemical to help protect them
and drive shafts should be checked and repaired only by
from corrosion. If storing components for a prolonged
experienced service technicians who are aware of all
period, wrap them in wax paper.
safety instructions and particular component features.
PERIODIC OPERATION REQUIREMENT: Every two
Use suitable products to thoroughly clean all
weeks, drive the machine far enough to cause the drive-
disassembled mechanical parts to help prevent personal
train components to make several complete revolutions.
injury to the worker and prevent damage to the parts.
This will help ensure that internal components receive
Carefully inspect the integrity of all moving parts
lubrication to minimize deterioration caused by
(bearings, yokes, tubes, gears, shafts, etc.) and fasteners
environmental factors such as high humidity.
(nuts, bolts, washers, etc.) as they are subject to major
stress and wear. SUBMERSION: If the machine has been exposed to
water deep enough to cover the hubs, disassemble the
5.4 AXLE ASSEMBLIES wheel ends and inspect for water damage and
contamination. If the carrier housing was submerged in
water, especially if the water level was above the vent
5.4.1 Axle Serial Number Plate tube (breather), drain the axle and inspect internal parts
The front and rear axle serial number plate is located on for water damage and contamination. Before assembling
the inside of each axle on the right side of the center and refilling the unit with the specified lubricant(s), clean,
section. Information on the serial number plate is required examine and replace damaged parts as necessary.
in correspondence regarding the axle.
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
5.4.5 Axle Removal

4
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
axle assembly is equipped with a drop box, hydraulic MY2090
1
drive pump, parking brake mechanism and a limited-slip
feature; the rear axle has none of these. The following
steps outline a typical axle removal procedure, suitable
for either the front or the rear axle assembly.
Cleanliness is extremely important. Before attempting to
remove the axle, thoroughly clean the machine. Avoid
spraying water or cleaning solution on the stabilizer
solenoids and other electrical components. If using a
steam cleaner, seal all openings before steam cleaning.
Note: Clear the work area of all debris, unnecessary
personnel, etc. Allow sufficient space to raise the
MY2080
machine and to remove the axle.
2 5 3
retract the boom, lower the boom, place the 7. Label, disconnect and cap the steering and brake
transmission control lever in (N) NEUTRAL, engage lines at the axle. Wipe up any spilled oil.
8. Block the front and rear of both tires on the axle that
2. Place a Do Not Operate Tag on both the ignition key is not being removed. Ensure that the machine will
switch and steering wheel, stating that the machine remain in place during axle removal before
should not be operated. proceeding.
3. Open the engine covers. Allow the system fluids to 9. Raise the machine using a suitable jack or hoist.
cool. Place suitable supports under both sides of the
4. Disconnect the battery negative (-) cable at the frame and lower the machine onto the supports.
battery negative (-) terminal. Ensure that the machine will remain in place during
axle removal.
5. If the axle will be disassembled after removal, the oil
will have to be drained. Loosen the breather to 10. Support the axle that is being removed with a suitable
release possible internal pressure, then tighten jack, hoist or overhead crane and sling. DO NOT
breather with a torque wrench to 12 Nm (9 lb-ft). raise the axle or the machine.
6. If the axle will be disassembled after removal, place 11. Mark and remove both wheel and tire assemblies
a suitable receptacle under the axle (1), drop box (2) from the axle that is being removed. (Refer to
and wheel hubs (3) drain plugs. Remove the drain Section 5.6.1, “Removing Wheel and Tire Assembly
plugs and allow the axle oil to drain into the from Machine.”)
receptacle. Transfer the used axle oil into a suitable Note: The wheel and tire assemblies must be re-installed
covered container, and label the container as "Used later with the directional tread pattern “arrows” facing in
Oil." Dispose of the used oil at an approved recycling the direction of forward travel.
facility.
5.4 TH255
12. Remove the drive shaft assembly. (Refer to Section 8. Tighten the axle oil drain plug (1), loosen and
5.5.3, “Drive Shaft Removal.”) remove the axle oil fill plug (4). Tighten the drop box
13. Remove the capscrews, locknuts and axle plates oil drain plug (2), loosen and remove the drop box oil
securing the axle to the frame. fill plug (5). Fill axle with the appropriate oil. Refer to
Section 2.4, “Fluids, Lubricants and Capacities,” for
14. Remove the axle from the machine using the jack, proper oil and capacities.
hoist or overhead crane and sling supporting the
axle. DO NOT raise or otherwise disturb the machine 9. Rotate wheel hubs 90 degrees so the drain plug (3)
while removing the axle. Balance the axle and becomes the fill plug. Fill wheel hubs with the
prevent it from tipping, turning or falling while appropriate oil. Refer to Section 2.4, “Fluids,
removing it from beneath the machine. Place the Lubricants and Capacities,” for proper oil and
axle on a suitable support or holding stand. capacities.
10. Install the wheel and tire assemblies. (Refer to
5.4.6 Axle Installation Section 5.6.2, “Installing Wheel and Tire Assembly
onto Machine.”)
1. Before proceeding, ensure that the machine will
remain in place during axle installation. Block the 11. Carefully remove the jack, hoist or overhead crane
front and rear of both tires on the axle that is already and sling supporting the axle.
installed on the machine. 12. Carefully raise the machine using a suitable jack or
2. If applicable, raise the machine using a suitable jack hoist. Remove the supports from beneath the frame
or hoist. Place suitable supports beneath the frame and lower the machine to the ground.
and lower the machine onto the supports, allowing 13. Remove the blocks from the front and rear of both
enough room for axle installation. Ensure that the tires on the other axle.
machine will remain in place during axle installation.
14. Uncap and reconnect the steering and brake lines at
3. Using a suitable jack, hoist or overhead crane and their axle fittings. Refer to Section 8.11.2, “Service
sling, remove the axle from its support or holding Brake Valve,” for brake bleeding procedures.
stand. Balance the axle and prevent it from tipping,
15. Check the hydraulic reservoir oil level.
turning or falling while positioning it beneath the
machine. DO NOT raise or otherwise disturb the 16. Connect the battery negative (-) cable to the battery
machine while installing the axle. Keep the axle negative (-) terminal.
supported and balanced on the jack, hoist or 17. Close and secure the engine covers.
overhead crane and sling throughout the installation
18. Start the engine. Turn the steering wheel several
procedure.
times lock to lock and check the function of the
4. Position the axle under the frame, and align with the brakes. Check for hydraulic leaks, and tighten or
holes in the frame. repair as necessary.
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.
TH255 5.5
5.4.7 Axle Assembly and Drive Shaft Troubleshooting

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,
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
5.4.7 Axle Assembly and Drive Shaft Troubleshooting (Continued)

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
5.4.7 Axle Assembly and Drive Shaft Troubleshooting (Continued)

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,
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
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
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

3. Brake piston o-rings and seals 3. Replace o-rings and seals.
damaged (leaking).
5.8 TH255
5.5 DRIVE SHAFTS

TO FRONT
1 AXLE
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
down time later. 2
TO REAR
Inspect area where the drive shaft flange yoke and slip
AXLE
yoke mount to the drive shaft. Attempt to turn drive shaft 3
in both directions. Look for excessive looseness, missing
parts, cracks or other damage. Worn or damaged drive
shaft and cross and bearing assembly may cause an MAH0450
excessive amount of vibration or noise.
5.5.2 Drive Shaft Maintenance 5.5.4 Drive Shaft Cleaning and Drying
Refer to Section 2.6, “Lubrication Schedule,” for 1. Disassemble and clean all parts. Allow to dry.
information regarding the lubrication of the grease fittings 2. Remove any burrs or rough spots from all machined
on the drive shafts. surfaces. Re-clean and dry as required.
5.5.3 Drive Shaft Removal 5.5.5 Drive Shaft Installation

1. Park the machine on a firm, level surface, fully 1. Raise the drive shaft assembly (3) into position. The
retract the boom, lower the boom, place the slip-yoke end of the drive shaft mounts toward the
transmission control lever in (N) NEUTRAL, engage front axle. If reinstalling a drive shaft previously
the park brake and shut the engine OFF. removed, align the flange yokes according to the
alignment marks made during removal.
switch and steering wheel, stating that the machine Note: Yokes at both ends of the drive shaft must be in
should not be operated. the same plane to help prevent excessive vibration.
3. Open the engine covers. Allow the system fluids to 2. Install the four capscrews (1) and four locknuts
cool. securing the yoke flange (2) to the front axle. Cat
4. Disconnect the battery negative (-) cable at the Threadlock and torque the capscrews to
battery negative (-) terminal. 139 Nm (102 lb-ft).
5. The drive shaft assembly is a balanced assembly. 3. Install the four capscrews securing the bearing
Mark the yoke and axle, transmission and the shaft crosses to the rear axle. Cat Threadlock and torque
and slip yoke so that these components can be the capscrews to 139 Nm (102 lb-ft).
returned to their original positions when reinstalled. 4. Connect the battery negative (-) ground cable at the
Yokes at both ends of the drive shaft must be in the battery negative (-) terminal.
same plane to help prevent excessive vibration. 5. Close and secure the engine covers.
6. Remove the four capscrews (1) and four locknuts
securing the yoke flange (2) to the front axle flange.
7. Remove the four capscrews securing the flange yoke
to the rear axle flange.
8. Remove the drive shaft assembly (3).
TH255 5.9
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:
• Equal or greater ply/load rating and size of original.
• Tire tread contact width equal or greater than
original.
• Wheel diameter, width and offset dimensions equal
to the original.
• Approved for the application by the tire manufacturer
(including inflation pressure and maximum tire load).
The rims installed have been designed for stability MAH0890
requirements which consist of track width, tire pressure
and load capacity. Size changes such as rim width,
center piece location, larger or smaller diameter, etc., 5.6.1 Removing Wheel and Tire Assembly
without written factory recommendations, may result in from Machine
unsafe condition regarding stability.
Foam filled tires have a positive effect on the weight, retract the boom, lower the boom, place the
stability and handling characteristics of the machine, transmission control lever in (N) NEUTRAL, engage
especially under load. The use of hydrofill as a tire-fill the park brake and shut the engine OFF.
substance is not recommended because of possible
environmental impact. 2. Place a Do Not Operate Tag on both the ignition key
Large-bore valve stems are used to help expedite tire should not be operated.
inflation and deflation. An inner tube may be used if a tire
does not provide an airtight seal. Check tire inflation 3. Loosen but DO NOT remove the lug nuts on the
pressures when the tires are cold. When mounting a tire wheel and tire assembly to be removed.
on the wheel, the tire must be mounted on the wheel 4. Place a suitable jack under the axle pad closest to
respective of the directional tread pattern of the tire; this the wheel being removed. Raise the machine and
produces a left or right tire and wheel assembly. position a suitable support beneath the axle. Allow
The wheel and tire assemblies must be installed with the sufficient room to lower the machine onto the
directional tread pattern “arrows” (1) facing in the support and to remove the wheel and tire assembly.
direction of forward travel. 5. Lower the machine onto the support.
6. Remove lug nuts and washers in an alternating
pattern.
7. Remove the wheel and tire assembly from the
machine.
5.10 TH255
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
5.8.1 Brake Disc Inspection

Tread “arrows” must Detailed axle service instructions are provided in the Axle
point forward 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.
4. Tighten lug nuts in an alternating pattern as
indicated in figure. Torque to 300 Nm (221 lb-ft).
3
1 5
8 7
6 2
4
OAH0990
5. Remove machine from supports.Steering

Adjustment
TH255 5.11
5.12 TH255
Section 6
Transmission
Contents

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6.2
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
6.7 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
6.7.1 Equipment and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
6.7.2 Towing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
TH255 6.1
Transmission
6.1 TRANSMISSION ASSEMBLY

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.
Cleanliness is of extreme importance. Before attempting
to remove the transmission, thoroughly clean the exterior
of the transmission to help prevent dirt from entering
during the replacement process. Avoid spraying water or
cleaning solution onto or near the transmission shift
6.3 TRANSMISSION DESCRIPTION solenoids and other electrical components.
Instructions in this section pertain mainly to general 6.5.1 Transmission Removal

specifications, towing, maintenance information, and
transmission removal and installation procedures. For 1. Park the machine on a firm, level surface, fully
internal transmission service instructions and detailed retract the boom, lower the boom, place the
specifications contact the local Caterpillar dealer for a transmission control lever in (N) NEUTRAL, turn rear
copy of the Transmission Disassembly & Assembly wheels to give easier access to rear of engine
Manual (P/N 31200456). compartment, engage the park brake and shut the
engine OFF.
More information can be obtained from the serial number
plate directly mounted on the transmission. Information 2. Place a Do Not Operate Tag on both the ignition key
specified on the serial number plate includes the switch and steering wheel, stating that the machine
transmission model number, the transmission serial should not be operated.
number and other data. Information on the serial number 3. Open the engine covers. Allow the system fluids to
plate is required in correspondence regarding the cool.
transmission.
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.
NOTICE 10. Wipe up any spilled hydraulic oil.
DO NOT use flushing compounds for cleaning
purposes.
TH255 6.3
Transmission
11. Vertically secure transmission with a lifting strap or 6. Reinstall the hood support.
chain. Use a suitable hoist or overhead crane. 7. Reinstall the air cleaner assembly.
Operate the hoist or crane to remove slack from the
chain, but DO NOT raise the transmission at this 8. Reconnect battery cables to terminals, starting with
time. the positive (+) terminal.
12. Remove the two Allen head bolts that attach the 9. Close and secure the engine covers.
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.
Failure to follow the safety practices could result in DO NOT use flushing compounds for cleaning
death or serious injury. purposes.
13. Carefully remove the transmission from the machine. 3. Reassemble all components and fill the hydraulic
Avoid causing damage to the transmission or reservoir with clean, fresh oil. DO NOT overfill.
surrounding parts. 4. Run the engine for two minutes at idle to help bleed any
14. Lift the transmission clear of the machine, and lower air from the hydraulic system.
it onto suitable supports or secure it to a stand built 5. Operate all boom functions to ensure any air is
especially for transmission or engine service. Secure removed from the hydraulic system.
the transmission so that it will not move or fall.
6. Retract and level the boom, recheck the level of the
fluid in the reservoir.
6.5.2 Transmission Disassembly
7. Add oil as necessary to bring the fluid level up until it
Transmission disassembly, internal inspection, service, reaches the FULL mark on the reservoir. Recheck
repair and assembly procedures are covered in the the oil level when it reaches operating temperature
Transmission Disassembly & Assembly Manual (P/N (83-94° C or 180-200° F).
31200456).
8. Recheck all drain plugs, lines, connections, etc., for
leaks, and tighten where necessary.
6.5.3 Transmission Installation
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.
6.4 TH255
Transmission
6.6 TRANSMISSION FILTER 6.6.2 Filter Installation

REPLACEMENT 1. Clean the area surrounding the hydraulic pump filter.
The hydrostatic pump filter is located on the left (inside) 2. Install a new o-ring (5) on the base of the filter
of the pump (1). housing and lubricate the new o-ring with clean
hydraulic oil.
3. Install the small end of the filter spring (4) into the
filter base (6).
4. Install the filter (3) into the filter base (6) directly
behind the filter spring.
2 3 4 6
1
MY2450
Cleanliness is of extreme importance. Before attempting

to remove the transmission filter, thoroughly clean the
exterior of the transmission to help prevent dirt from
entering during the replacement process. Avoid spraying
water or cleaning solution onto or near the transmission
direction solenoids and other electrical components. 5
6.6.1 Filter Removal 5. Slowly screw the filter housing into the filter base
keeping the filter and housing aligned.
retract the boom, lower the boom, place the 6. Torque the filter housing to 45 Nm (33 lb-ft).
transmission control lever in (N) NEUTRAL, turn rear 7. Uncap and reconnect the previously labeled hoses
wheels to give easier access to rear of engine to their appropriate locations.
compartment, engage the park brake and shut the 8. Fill hydraulic reservoir and bleed the system.
engine OFF.
9. Reinstall the air cleaner assembly.
switch and steering wheel, stating that the machine 10. Reconnect battery cables to terminals, starting with
should not be operated. the positive (+) terminal.
3. Open the engine covers. Allow the system fluids to 11. Close and secure the engine covers.
cool.
5. Remove the air cleaner assembly.
6. To allow easier access to the filter, label, disconnect
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.
8. Using a 25 mm (15/16 in.) wrench, loosen and
remove the filter housing (2), filter (3) and spring (4).
TH255 6.5
Transmission
6.7 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 of
into the hydrostatic pump and disengaging the park brake the auxiliary hydraulic power supply.
on the front axle.
6.7.2 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. Failure to follow
instructions could cause death or serious injury.
MY1930
WARNING 2. Loosen the jam nut and turn the forward relief valve
(1) on the hydrostatic transmission counterclockwise
BLOCK ALL FOUR WHEELS TO PREVENT three turns.
MACHINE FROM MACHINE ROLL AWAY. Failure Note: This procedure does not alter any relief settings.
to follow instructions could cause death or serious
injury. 3 (Not Shown)
6.7.1 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.”
MY2050
Auxiliary Hydraulic Power Supply:
2 3
• Portable hydraulic unit with the capability of pro-
ducing 20,7 bar (300 psi) minimum pressure to 3. Connect an auxiliary hydraulic power supply to the
release the park brake. P1 port (2) on the front axle and apply 15-30 bar
Hose: (220-435 psi) to release the park brake.
• One Hydraulic Hose - Approximately 1,5 m Note: DO NOT apply more than 31 bar (450 psi) to
(5 ft), with a minimum I.D. of release the park brake. Excessive pressure could
6,3 mm (0.25 in.) and a minimum rating of damage the axle brake system.
17 bar (250 psi).
4. Loosen the unlocking bolts (3) located at the front
and back side of the axle housing and remove the
stop washers.
6.6 TH255
Transmission
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 6.7
Transmission
6.8 TH255
Section 7
Engine: CAT C4.4DIT
Contents

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
7.11.1 Coupler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
7.11.2 Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
7.12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
TH255 7.1
Engine: CAT C4.4DIT
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

locations of the engine components. The following
illustration identifies the components that are referred to
throughout this section.
7.2 TH255
Engine: CAT C4.4DIT
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: CAT C4.4DIT
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 result in the loss of coolant and a hot-running engine.
safety practices could result in death or serious injury. 7.5.2 Radiator/Oil Cooler and Coolant
Heater Replacement
7.3 ENGINE SERIAL NUMBER Before considering radiator or oil cooler replacement for
other than obvious damage, conduct a cooling system
The CAT C4.4DIT serial number is located on a tag on pressure test check the coolant specific gravity, coolant
top of the engine. Information contained in the serial level, fan belt tension and dash panel temperature
number is required in correspondence with the engine indicator.
manufacturer.
• If the engine runs hot, check the temperature of
Supply the engine serial number and/or data tag the upper radiator hose.
information when communicating about an engine or
engine components. • If the hose is not hot, the thermostat may be
stuck in the closed position.
7.4 SPECIFICATIONS AND • If the engine has overheated, performance may
MAINTENANCE INFORMATION suffer, indicating other damage including a leaking
cylinder head gasket, cracked cylinder head or
For engine, coolant and oil specifications, and block, and/or other internal engine damage.
maintenance information, refer to Section 2, “General
Information and Specifications.” a. Radiator/Oil Cooler Removal
Detailed engine service instructions are provided in the 1. Park the machine on a firm, level surface, fully
following publications: retract the boom, lower the boom, place the
• Operation and Maintenance Manual
(P/N SEBU8327)
• System Operation Testing and Adjusting
(P/N KENR6900)
• Disassembly and Assembly (P/N KENR6249)
• Specifications Manual (P/N KENR6248) cool.
4. Thoroughly clean the engine and surrounding area,
including all hoses and fittings before proceeding.
5. Disconnect the battery negative (-) cable from the
6. Remove radiator cover and support (1).
7. Slowly turn the coolant overflow bottle cap and allow
any pressure to escape. Remove the overflow bottle
cap.
8. Place a suitable container beneath the radiator
petcock.
7.4 TH255
Engine: CAT C4.4DIT
9. Place a funnel at the base of the radiator to channel b. Radiator/Oil Cooler Installation
the drained coolant into the container. Open the
1. Install the isolator mounts to the bottom of the
radiator petcock and drain the coolant into the
radiator. Insert radiator through the machine frame
funnel. Transfer the fluid into a properly labeled
and secure to the radiator mount plate with new
container. Dispose of properly if coolant needs to be
locknuts.
replaced. Close the radiator petcock.
2. Be sure the engine fan has clearance in regard to
10. Label, disconnect and cap all coolant hoses
the radiator. Install the engine cover support (1) to
attached to the radiator. Cap all fittings and openings
the frame and radiator.
to keep dirt & debris from entering the cooling
system. 3. Attach the fan safety shroud.
11. Label, disconnect and cap all hydraulic hoses 4. Uncap and reconnect the previously labeled
attached to the radiator. Cap all fittings and openings hydraulic hoses to the appropriate locations.
to keep dirt & debris from entering the hydraulic 5. Uncap and reconnect all previously labeled coolant
system. hoses to the appropriate locations.
12. Detach the fan safety shroud. 6. Fill the coolant overflow bottle with a 50/50 mixture
of ethylene glycol and water.
8. Run the engine to operating temperature. Visually
check for leaks with the engine running. Check the
coolant level in the overflow bottle and fill, or drain,
as necessary. Check the hydraulic fluid level in the
1 tank and add fluid as required.
9. Install the radiator cover.
7.6 ENGINE ELECTRICAL SYSTEM

MY1910
The engine electrical system, including the starter,
13. Remove the locknuts holding the isolator mounts at alternator and primary wiring, is described in Section 9,
the bottom of the machine. “Electrical System.”
14. Connect a lifting strap to the radiator/oil cooler and
carefully lift the radiator/oil cooler out of the engine 7.7 FUEL SYSTEM
bay.
7.7.1 Diesel Fuel
Fuel represents a major portion of machine operating
costs and therefore must be used efficiently. ALWAYS
use a premium brand of high-quality, clean diesel fuel.
Low cost, inferior fuel can lead to poor performance and
expensive engine repair.
TH255 7.5
Engine: CAT C4.4DIT
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.
c. Inspection
Use a low-sulfur content fuel with a cloud point (the
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: CAT C4.4DIT
7.8 ENGINE EXHAUST SYSTEM
7.8.1 Exhaust System Removal 7
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
position, engage the parking brake, and shut the 6
engine OFF.
switch and steering wheel, stating that the machine 8
MAM1310
cool.
4. Remove the battery negative (-) cable from the 10. Loosen and remove the clamp (6) attaching the
battery negative (-) terminal. exhaust pipe to the bracket on the side of the engine.
11. Loosen and remove the exhaust pipe flange nuts (7)
at the turbocharger.
3 2 12. Remove the exhaust and flex pipe (8) from the
3 engine compartment.
1 7.8.2 Exhaust System Installation

5 Note: Keep all clamps loosened until entire exhaust
system is in place.
1. If removed, install the exhaust flex pipe to the
exhaust pipe.
Note: Replace the nuts and the exhaust studs on the
4 turbocharger if damaged.
MAM1300
2. Install the exhaust and flex pipe (8) in place at the

5. Loosen and remove the clamp (1) connecting the turbocharger and bracket mounted on the side of the
muffler and tail pipe from the bracket on the side of engine with the previously used hardware. Torque
the frame. the flange nuts (7) on the turbo charger to 30 ±7 Nm
6. Loosen and remove the clamp (2) attaching the (22 ±5 lb-ft).
exhaust pipe to the muffler. 3. Install the exhaust pipe (5) to the flex pipe with the
7. Remove the muffler and tail pipe (3). previously used clamp.
8. Loosen and remove the clamp (4) attaching the 4. Install the muffler and tailpipe (3) to the exhaust pipe
exhaust and flex pipe to the frame. with the previously used hardware.
9. Remove the exhaust pipe (5) from the flex pipe. 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.
8. Start engine and check for exhaust leaks at all
exhaust connections. Adjust or repair as needed.
TH255 7.7
Engine: CAT C4.4DIT
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
CAUTION hardware (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. Connect the battery negative (-) cable to the battery
7.10 ENGINE REPLACEMENT
11 7.10.1 Engine Removal

MAM1310 machine should not be operated.
10 9 3. Open the engine cover. Allow the system fluids to
cool.
7.9.1 Air Cleaner Assembly Removal 4. Thoroughly clean the engine and surrounding area,
1. Park the machine on a firm, level surface, level the including all hoses and fittings before proceeding.
machine, fully retract the boom, lower the boom, 5. Disconnect the battery negative (-) cable from the
place the travel select lever in the (N) NEUTRAL battery negative (-) terminal.
position, engage the parking brake, and shut the 6. Remove the engine cover, radiator cover and engine
engine OFF. bay access cover.
2. Place a Do Not Operate Tag on both the ignition key 7. Remove front and rear engine cover supports.
should not be operated. 8. Drain hydraulic reservoir. Refer to Section 8.8.2,
“Hydraulic Oil Reservoir Draining.”
cool. 9. Drain radiator and overflow bottle. Refer to Section
7.5.2, “Radiator/Oil Cooler and Coolant Heater
4. Remove the battery negative (-) cable from the Replacement.”
10. Label, disconnect and cap all hydraulic hoses
5. Loosen the clamp (9) securing the air intake elbow to attached to engine and radiator, cap all fittings and
the air cleaner assembly. Pull the air intake elbow off plug hoses to keep dirt & debris from entering
the air cleaner. hydraulic system.
6. Remove the hardware securing the air cleaner to the 11. Disconnect the fuel inlet (1) and return lines. Install a
air cleaner mounting plate (10). Remove the air plug in the end of each line.
cleaner assembly (11).
12. Remove hydraulic and fuel filters, and filter bracket
assembly.
13. Unbolt and remove the fan safety shroud.
7.8 TH255
Engine: CAT C4.4DIT
14. Remove bolts securing the radiator and lift it clear of 7.10.2 Engine Disassembly, Inspection and
engine compartment. Refer to section Section 7.5.2, Service
“Radiator/Oil Cooler and Coolant Heater
Engine disassembly, internal inspection, service, repair
Replacement.”
and assembly procedures are covered in the CAT
15. Mark the engine fan orientation. Remove the engine C4.4DIT service manual. Several special engine service
fan. tools are required to properly service the CAT engine.
Contact the local Caterpillar dealer for further
information.
3
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
who you purchase the new engine from and the
configuration of your replacement engine. Refer to the
2 appropriate CAT user manual for detailed procedures that
cover the transfer of original engine components to the
replacement engine.
7.10.3 Engine Installation

1
Note: Refer to Section 2.2, “Torques,” for specific
fastener torque specifications.
1. Position engine in engine compartment being sure to
MY1890 line up the 4 motor mount holes. Replace bolts and
torque to 97 Nm (71 lb-ft).
16. Label and disconnect all wire connections on the
engine. 2. Connect the hydraulic reservoir fill tube.
17. Mark the location of the throttle cable (2) at the 3. Connect the exhaust pipe to the engine.
engine throttle lever. Disconnect the throttle cable. 4. Install the air cleaner assembly into the engine
18. Detach exhaust and air cleaner hoses from the compartment and attach hose to air intake.
engine. Cover air inlets to protect from dirt & debris. 5. Reconnect throttle cable (2) onto the engine, if
19. Remove air cleaner assembly from engine necessary adjust for full travel.
compartment. 6. Reattach any previously labeled wire connections on
20. Completely disconnect exhaust pipe. the engine.
21. Remove the hydraulic reservoir fill tube. 7. Attach the engine fan.
22. Secure the engine with a lifting strap or chain from 8. Reinstall the front and rear engine cover supports.
the appropriate lifting points (3). Use a suitable hoist 9. Secure the radiator with the necessary bolts and
or overhead crane. attach the fan safety shroud. Check that the fan top
23. Remove the 4 motor mount bolts that attach the clearance is adequate with regard to the radiator.
engine to the frame. Reattach the previously labeled hoses. Refer to
Section 7.5.2, “Radiator/Oil Cooler and Coolant
24. Carefully lift the engine from the machine. Avoid
Heater Replacement.” Fill with a 50/50 mixture of
causing damage to the surrounding parts.
ethylene glycol and water.
25. Lift the engine clear of the machine, and lower it onto
10. Install the filter bracket assembly. Secure the
suitable supports or stand. Secure the engine so
hydraulic and fuel filters.
that it will not move or fall.
11. Connect the fuel inlet line to the fuel filter (1) and
reconnect the return fuel line to the engine.
12. Uncap and reconnect all hydraulic hoses and fittings
to the engine and necessary hydraulic elements.
Keep hoses free of dirt & debris.
TH255 7.9
Engine: CAT C4.4DIT
13. Refill the hydraulic reservoir (Refer to the 20. Check the engine rpm at high idle. Refer to Section
appropriate Operation & Maintenance Manual for 4.4.5, “Throttle Cable Adjustment,” and Section
information concerning the hydraulic oil and filter 4.4.6, “High Idle Adjustment,” for adjustment
change). procedure.
14. Reinstall the engine cover, radiator cover and engine 21. Purge the hydraulic system of air by operating all
bay access cover. boom functions through their entire range of motion
several times. Check the hydraulic oil level.
22. Check for proper operation of all components.
23. Turn the engine OFF.
24. Install the belly pan.
25. Install the engine cover. Close and secure the cover.
2
7.11 ENGINE COUPLER
7.11.1 Coupler Removal

1. Remove Hydrostatic transmission. Refer to Section
1 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
MY1890
engine.
15. Reconnect the battery terminals, being sure to start
3. Pull off the Flywheel Cover Plate to expose the
with the positive (+) terminal.
coupler assembly (3).
16. Check that all hydraulic, electrical, cooling, fuel and
4. Remove the necessary bolts to detach the coupler
exhaust system connections are correct and
assembly.
connected tightly.
17. Run engine to normal operating temperature then shut
off the engine. While the engine is cooling, check for
leaks. 3
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 MY2550
7.11.2 Coupler Installation

During the full throttle check:
• DO NOT operate any hydraulic function. 1. Attach the coupler assembly (3) using the necessary
bolts. Torque to 210 Nm (155 lb-ft).
• DO NOT steer or apply any pressure to the
steering wheel. 2. Bolt on the Flywheel Cover Plate over the coupler
and flywheel. Torque bolts to 50 Nm (37 lb-ft).
• Keep the transmission in NEUTRAL (N).
3. Reattach the hydrostatic transmission. Follow all
guidelines in Section 6.5.3, “Transmission
Installation.”
7.10 TH255
Engine: CAT C4.4DIT
7.12 TROUBLESHOOTING
Refer to Section 7.4, “Specifications and Maintenance
Information,” for detailed engine service information or
contact the local Caterpillar dealer.
TH255 7.11
Engine: CAT C4.4DIT
7.12 TH255
Section 8
Hydraulic System
Contents

8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
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 CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
8.7.2 ANSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.7.3 Options (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
8.7.4 Options (ANSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.8 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
8.8.1 Pressurized Hydraulic Oil Fill Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
8.8.2 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
8.8.3 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
8.9 Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
8.9.1 Implement Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
8.10 Front Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
8.11 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
8.11.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
8.11.2 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
8.11.3 Parking Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
8.11.4 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
8.11.5 Pilot Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
8.11.6 Inching Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
8.11.8 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
8.11.9 Joystick Enable Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.21
8.11.10 Decompression Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.22
8.11.11 Load Stability Indicator Valve (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.23
TH255 8.1
Hydraulic System
8.12 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.24

8.12.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.24
8.12.2 General Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.24
8.12.3 Cylinder Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25
8.12.4 Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
8.12.5 General Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
8.12.6 General Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.27
8.12.7 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.27
8.12.8 Hydraulic Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 8.28
8.2 TH255
Hydraulic System
8.1 HYDRAULIC COMPONENT

TERMINOLOGY
To understand the safety, operation and service
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.
Practices” section of this manual. Failure to follow the There are numerous hydraulic hoses, tubes, fittings, etc.
safety practices could result in death or serious injury. used on this machine. Periodically inspect all of these
and carefully examine any signs of wear, abrasion and/or
8.3 GENERAL INFORMATION deterioration. Determine whether any further use of the
component would constitute a hazard. If in doubt, replace
Petroleum-based hydraulic fluids are used in this the component.
machine. The temperature of hydraulic fluid increases
during the operation of various hydraulic functions. A 8.5.1 Replacement Considerations
heated petroleum-based hydraulic fluid presents a fire Conditions including, but not limited to, the following are
hazard, especially when an ignition source is present. sufficient for considering component replacement:
Accordingly, periodically inspect all hydraulic system 1. Any evidence of hydraulic fluid leakage at the
components, hoses, tubes, lines, fittings, etc. Carefully surface of a flexible hose or its junction with the
examine any deterioration and determine whether any metal and couplings.
further use of the component would constitute a hazard.
If in doubt, replace the component. 2. Any blistering or abnormal deformation to the outer
covering of a hydraulic hose.
Whenever you disconnect a hydraulic line, coupler, fitting
or other component, slowly and cautiously loosen the part 3. Hydraulic oil leakage at any threaded or clamped
involved. A hissing sound or slow seepage of hydraulic joint that cannot be eliminated by normal tightening
fluid may occur in most cases. After the hissing sound or other recommended procedures.
has ceased, continue removing the part. Any escaping oil 4. Evidence of excessive abrasion or scrubbing on the
should be directed into an appropriate container. Cap or outer surface of a hose, rigid tube, or hydraulic
otherwise block off the part to prevent further fluid fitting. Modification must be made to eliminate the
seepage. interference of the elements in contact with one
Hydraulic system maintenance will, at times, require that another, or to otherwise protect the components
the engine be operated. Always follow safety precautions. from contact with one another. Slightly moving a
hose or adjusting a plastic tie wrap may often be all
A major cause of hydraulic component failure is that is necessary to eliminate interference; evaluate
contamination. Keeping the hydraulic fluid as clean as each situation and proceed as required by the
possible will help avoid downtime and repairs. Sand, grit individual circumstances.
and other contaminants can damage the finely machined
surfaces within hydraulic components. If operating in an
8.5.2 Hose, Tube, Line and Fitting
exceptionally dirty environment, change filters and
Replacement
inspect the fluid more often. When servicing the system,
cap or plug hydraulic fittings, hoses and tube assemblies. Before removing a hydraulic hose or component, always
Plug all cylinder ports, valves and the hydraulic reservoir, mark or otherwise label the related parts and the exact
and pump openings until installation occurs. Protect location of the hose or component to aid in proper
threads from contamination and damage. reinstallation. Hydraulic fluid is a good cleaner and can
remove most liquid-ink type markings, so make sure the
Some hydraulic functions are actuated by interfacing with
mark or label will remain intact. Alternative methods to
electrical system components (switches, solenoids and
using markers include color-coded tie wraps, number-tag
sensors). When the hydraulic system is not functioning
sets, alpha-numeric stampings or markings, and suitably
properly, check the electrical aspect of the malfunctioning
labeled pieces of tape. Select an appropriate marking
circuit also.
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 Attach 345 bar (5000 psi) gauge to the test port (1) at the
that o-rings are used throughout the hydraulic system. rear of the implement pump to check the system
ALWAYS replace a used o-ring with a new part. pressure. Make sure the gauge is visible from inside the
Check all routing of hoses, wiring and tubing for sharp cab.
bends or interference with any rotating members. Install
appropriate protective devices such as tie wraps and 1
conduit to help shield hoses from damage. All tube and
hose clamps must be tight.
8.6 HYDRAULIC PRESSURE DIAGNOSIS
8.6.1 Pressure Checks and Adjustments

In general, follow the steps below whenever conducting
pressure checks and performing adjustments:
MY2540
1. Park the machine on a firm, level surface. Engage
the park brake, place the transmission control lever See Section 8.6, “Hydraulic Pressure Diagnosis,” for start
in (N) NEUTRAL, place the neutral lock lever in the (N) up procedure. Check the main control pressure with the
NEUTRAL LOCK position, level the boom and turn park brake on and the service brake off at full throttle.
the engine OFF. Retract a boom circuit function until the cylinder bottoms.
2. Pressure tee fittings are conveniently located in each The main control valve pressure should be 250 ± 2,8 bar
hydraulic circuit. Install a pressure gauge capable of (3625 ± 40 psi) at full throttle. Repeat for each boom
measuring at least 10% more pressure than that circuit to verify the correct main control valve pressure.
which the circuit being checked operates under.
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 2
checked. Continue holding the joystick in position MY2110
until pressure readings are taken.
If a pressure adjustment is required, adjust the main relief
5. Check the pressure gauge reading. It should read as cartridge (2) on the main control valve. Recheck pressure
described in the appropriate section. If the reading is after any adjustment has been made.
not as specified, turn the engine OFF and check
other components in the system. Verify that all
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

Attach a pressure gauge to the test port (3) on the Attach a pressure gauge to the test fitting (5) at the rear
hydrostatic transmission (4) to check the system of the implement pump. The pressure reading should be
pressure. The pressure should be 26,2 ± 2 bar 186 ± 4 bar (2700 ± 50 psi) with the steering wheel fully
(380 ± 30 psi) with the engine at low idle. turned to the steering stop in one direction.
The charge pressure relief valve is preset at the factory There is no adjustment for steering pressure.
and is not adjustable.
MY2540
3
MY1930
8.6.4 Boom Function Pressure Checking

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.
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
250 ± 2,8 bar (3625 ± 40 psi) at full throttle.
Note: With the machine at operating temperature, the
250 ± 2,8 bar (3625 ± 40 psi) pressure reading at the
main control valve is 13,3 bar (125 psi) HIGHER than the
241 bar ±4 bar (3500 ± 50 psi) of each individual valve
section function. DO NOT adjust the main control valve
relief pressure below 250 ± 2,8 bar (3625 ± 40 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
CE
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
Hydraulic System
11 FILTER, RETURN 25 VALVE, CHECK (5 PSI)

12 VALVE, INCHING
MAP0070-M
13 VALVE, STEERING 27 SENSOR, STEERING PRESSURE
14 VALVE, CHECK (55 PSI) 28 VALVE, LMI
8.7
8.8
8.7.2
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
Hydraulic System
8.7.3 Options (CE)
OPTIONAL TRAILER BRAKE
OPTIONAL REAR
AUXILIARY
OPTIONAL REAR AUX/WITH

ELECTRIC SECOND FRONT AUX
OPTIONAL SECOND
FRONT AUXILIARY
-ELECTRIC- MAP0020-M
TH255 8.9
Hydraulic System
8.7.4 Options (ANSI)
OPTIONAL REAR OPTIONAL REAR AUX/WITH

AUXILIARY ELECTRIC SECOND FRONT AUX
OPTIONAL SECOND
FRONT AUXILIARY
-ELECTRIC-
MAP0090-K
8.10 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. Start the machine. Run engine to normal operating
expelled from the filter head when system pressure temperature. Operate all hydraulic functions.
exceeds the rating of the filter head or filler cap. If the
return filter becomes plugged, return hydraulic oil will 8.9 HYDRAULIC SYSTEM PUMP
bypass the filter when pressure reaches 1,5 bar (22 psi)
and return to the reservoir unfiltered.
8.9.1 Implement Pump Replacement
Carefully examine fluid seepage or leaks from the
hydraulic reservoir to determine the exact cause. Clean a. Implement Pump Removal
the reservoir and note where any seepage occurs.
1. Park the machine on a firm, level surface, fully retract
Leaks from a cracked or damaged reservoir require that
the boom, support the boom, place the transmission
the reservoir be flushed completely with water and
control lever in (N) NEUTRAL, engage the park brake
repaired by a certified welder using approved techniques.
and shut the engine OFF.
If these conditions cannot be met, the reservoir must be
replaced in its entirety. Contact the local Caterpillar 2. Place a Do Not Operate Tag on both the ignition key
dealer should reservoir welding be required. switch and the steering wheel, stating that the
8.8.1 Pressurized Hydraulic Oil Fill Cap 3. Open the engine covers. Allow the system fluids to
The fill cap will allow the hydraulic oil reservoir to cool.
pressurize to 0,14 bar (2 psi). Inspect the condition of the 4. Drain the hydraulic oil reservoir. Refer to Section
cap seal to maintain proper reservoir pressure. 8.8.2, “Hydraulic Oil Reservoir Draining.”
5. Thoroughly clean the pump (1) and surrounding
8.8.2 Hydraulic Oil Reservoir Draining area, including all hoses and fittings before
1. Park the machine on a firm, level surface, fully proceeding.
retract the boom, support the boom, place the 6. Label, disconnect and cap all hydraulic hoses
transmission control lever in (N) NEUTRAL, engage attached to the pump, cap all fittings and plug hoses
the park brake and shut the engine OFF. to keep dirt & debris from entering the hydraulic
2. Place a Do Not Operate Tag on both the ignition key system.
cool.
4. Remove the drain plug at the bottom of the hydraulic
oil reservoir.
5. 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.
6. Wipe up any spilled hydraulic oil.
TH255 8.11
Hydraulic System
8.10 FRONT DRIVE MOTOR

For internal service instructions and detailed
specifications, contact the local Caterpillar dealer.
MY2120
1
a. Front Drive Motor Removal
MY2100
7. Remove the two bolts that hold the pump in place. transmission control lever in (N) NEUTRAL, engage
b. Implement Pump Installation 2. Place a Do Not Operate Tag on both the ignition key
1. Position pump in the mounting position. switch and the steering wheel, stating that the
Note: Use new o-rings where required. Never reuse o-
rings. 3. Open the engine covers. Allow the system fluids to
cool.
2. Use the two Allen head bolts to secure the pump into
4. Drain the hydraulic reservoir or attach a vacuum
place. Torque to 95 Nm (70 lb-ft).
adapter fitting to the reservoir fill tube to reduce oil
3. Uncap and reconnect previously labeled hydraulic spillage.
hoses to their proper locations.
5. Label and disconnect all hydraulic hoses attached to
4. Fill the hydraulic reservoir with clean, filtered the pump, cap all fittings and plug hoses to keep dirt
hydraulic oil. & debris from entering hydraulic system.
5. Prime the pump by filling the case drain port with fresh, 6. Support the motor and remove the four bolts
filtered hydraulic oil from a clean container before attaching the motor to the front axle.
installing the case drain connector and hose.
6. Check all routing of hoses and tubing for sharp b. Front Drive Motor Installation
bends or interference with any rotating members. All 1. Install the motor onto the front axle. Torque the four
tube and hose clamps must be tight. bolts to 241 Nm (178 lb-ft). Use only new seals.
7. Start the engine and run at approximately one-third 2. Uncap and reconnect the previously labeled
to one-half throttle for about one minute without hydraulic hoses to their appropriate locations.
moving the machine or operating any hydraulic
functions. 3. Fill the motor with hydraulic fluid through the fill plug
(1) before starting the machine.
8. Inspect for leaks and check all fluid levels.
4. Refill the hydraulic reservoir and inspect for leaks
Note: Check for leaks and repair as required before around the machine.
continuing. 5. Close and secure the engine covers.
c. Pump Test
1. Perform a flow meter test on the pump.
2. Check the system functions.
8.12 TH255
Hydraulic System
8.11 CONTROL VALVES b. Main Control Valve Disassembly

1. To disassemble the individual sections of the main
8.11.1 Main Control Valve control valve, remove the nuts from the end of the tie
rods. Pull the tie rods out through the sections.
The main control valve is mounted on the rear of the
machine behind the rear access panel. 2. Disassemble each section assembly as required.
The main control valve assembly consists of various Some sections include a pre-adjusted relief valve that
working sections with their own valve assemblies, each regulates pressure in a specific circuit.
providing a specific hydraulic function. The section
assemblies are the left-hand end cover (1), lift/lower (2),
tilt (3), auxiliary (4), crowd (5) and right-hand end cover
NOTICE
(6) sections. DO NOT adjust any of the relief valve assemblies!
Tampering with a relief valve will irrevocably alter
pressure in the affected circuit, requiring recalibration or
a new relief valve.
Disassemble each Valve Section
6 1. Carefully separate the end cover section from the lift/

lower section.
2. Remove the o-rings from between the two sections.
3. Carefully separate each remaining section and
1
remove all o-rings and seals.
MY2110
4. Remove any plugs, check valves, compensator
FRONT OF MACHINE 2 3 4 5
valves, anti-cavitation valves, shock valves or the
rectangular hydraulic remote positioners from each
individual valve section if equipped.
a. Main Control Valve Removal
5. Keep all parts being removed from individual valve
1. Park the machine on a firm, level surface, fully sections tagged and kept together.
transmission control lever in (N) NEUTRAL, engage c. Main Control Valve Parts Cleaning
Clean all components with a suitable cleaner, such as
2. Place a Do Not Operate Tag on both the ignition key trichlorethylene, before continuing. Blow dry.
machine should not be operated. d. Main Control Valve Parts Inspection
3. Remove the rear panel. Allow the hydraulic fluid to
Inspect all parts and internal passageways for wear,
cool.
damage, etc. If inner surfaces of any component DO NOT
4. Thoroughly clean the main control valve and display an ultra-smooth, polished finish, or are damaged
surrounding area, including all hoses and fittings, in any way, replace the damaged part. Often, dirty
before proceeding. hydraulic fluid causes failure of internal seals, damage to
5. Place a suitable container to catch hydraulic fluid the polished surfaces within the component, and wear of
drainage beneath the frame. and/or harm to other parts.
6. Label, disconnect and cap all the hydraulic hoses
e. Main Control Valve Assembly
attached to the main control valve. Cap all fittings
and openings to keep dirt & debris from entering the Note: ALWAYS replace seals, o-rings, gaskets, etc.,
hydraulic system. with new parts to help ensure proper sealing and
7. Wipe up any hydraulic fluid spillage in, on, near and operation. Lubricate seals and o-rings with clean
around the machine and the work area. hydraulic oil.
8. Remove the four bolts securing the main control

valve to the frame bracket.
TH255 8.13
Hydraulic System
Assemble each Valve Section g. Main Control Valve Test

1. Reassemble any plugs, check valves, compensator Conduct a pressure check of the hydraulic system in its
valves, anti-cavitation valves, shock valves or entirety. Adjust pressure(s) as required. Refer to Section
hydraulic remote positioners from individual valve 8.6.2, “Main Control Valve Pressure Checking.”
sections if equipped.
2. Install the end covers onto Lift/Lower and Crowd 8.11.2 Service Brake Valve
sections. The service brake valve is at the base of the steering
column support, concealed by the lower dash cover.
Assemble the Main Control Valve
The service brakes themselves are part of the front axle.
1. Place all three tie rods with the washers and nuts Refer to Section 5, “Axles, Drive Shafts, Wheels and Tires,”
through the end main control valve section. for further information.
2. Stand the end main control valve section on end.
3. Install proper o-rings on the inner face of the end
main control valve section. Align the Crowd section
over the three tie rods and slide onto the end main
control valve section.
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.
MY2160
2. Install the main control valve onto the bracket,
aligning the bolts with the holes in the end sections a. Service Brake Valve Removal
of the main control valve. Slide the main control
valve into position, and tighten the bolts. 1. Park the machine on a firm, level surface, fully
3. Prime the main control valve by filling the inlet transmission control lever in (N) NEUTRAL, engage
openings with fresh, filtered hydraulic oil from a the park brake and shut the engine OFF.
clean container, before attaching the hoses.
4. Use new oiled o-rings as required. Uncap and switch and the steering wheel, stating that the
reattach and secure all hoses, clamps, etc. to the machine should not be operated.
main control valve.
5. Check the routing of all hoses, wiring and tubing for
cool.
sharp bends or interference with any rotating
members, and install tie wraps and/or protective 4. Remove the necessary dash panels.
conduit as required. Tighten all tube and hose 5. Label, disconnect and cap the hydraulic hoses
clamps. connected to the service brake valve. Cap all fittings
6. Start the engine and run at approximately one-third and openings to keep dirt & debris from entering the
to one-half throttle for about one minute without brake system.
moving the machine or operating any hydraulic 6. Remove the bolts that mount the service brake valve
functions. to the steering column support
7. Inspect for leaks and check the level of the hydraulic Note: DO NOT disassemble the service brake valve.
fluid in the reservoir. Shut the engine OFF. The service brake valve is not serviceable and must be
8. Wipe up any hydraulic fluid spillage in, on, near and replaced in its entirety, if defective.
around the machine, work area and tools.
9. Install the rear panel.
8.14 TH255
Hydraulic System
b. Service Brake Valve Installation 1. Place the transmission control lever in

(N) NEUTRAL, engage the park brake, and start the
1. Install the service brake valve to the steering column
engine.Raise the boom to access the brake
support with the necessary hardware.
bleeders. Support boom and turn off engine.
Note: ALWAYS replace seals, o-rings, gaskets, etc., 2. Remove the plastic cap from the brake bleeder.
with new parts to help ensure proper sealing and Attach one end of a length of transparent tubing over
operation. Lubricate seals and o-rings with clean the brake bleeder. Place the other end of this tubing
hydraulic oil. in a suitable transparent container that is partially
2. Use new oiled o-rings as required. Uncap and filled with hydraulic oil. The end of the tubing must be
reconnect the previously labeled hydraulic hoses to below the oil level in the container.
the appropriate locations. 3. DO NOT open the brake bleeder without holding the
3. Check the routing of all hoses, and tubing for sharp tubing firmly on the bleeder. There is pressure at the
bends or interference with any rotating members, brakes. Have an assistant depress the brake pedal.
and install tie wraps and/or protective conduit as Carefully open the bleeder with a 12 mm wrench.
required. Tighten all tube and hose clamps Close the brake bleeder when air bubbles no longer
appear in the oil. Release the brake pedal. Remove
4. Start the engine and run at approximately one-third
the tubing from the brake bleeder.
to one-half throttle for about one minute, without
moving the machine or operating any hydraulic 4. If bleeding the service brake circuit, install a vacuum
functions. pump on the brake reservoir and remove the
remainder of the trapped air from the brake system.
5. Inspect the service brake valve and connections for
leaks, and check the brake fluid level. Shut the 5. The inching valve may also require bleeding, refer to
engine OFF. Section 8.11.6, “Inching Valve.”
6. Replace the necessary dash panels. 6. Check brake fluid level and add fluid if necessary.
Refer to Section 2.4, “Fluids, Lubricants and
7. Wipe up any hydraulic fluid spillage in, on, near and
Capacities.”
8. Close and secure the engine covers. d. Brake Performance Test
c. Service Brake Bleeding Procedure 1. Press down on the service brake pedal. The pedal
should NOT travel to the cab floor. Start the
1 machine, shift into forward, release the park brake
and slowly accelerate. Apply the service brake
carefully noting the performance of the service brake
system. If the service brakes do not safely stop the
machine, repeat the service brake bleeding
procedure.
MY2050
Carefully bleed the brake lines as soon as the brake valve

is installed on the machine. Air in the system will not allow
the brakes to apply properly. There are two brake bleeder
locations (1) on the front axle. The outside bleeder is
used for the park brake circuit. The inside bleeder is used
for the service brake circuit. Work with an assistant to
perform this procedure.
TH255 8.15
Hydraulic System
8.11.3 Parking Brake Valve 5. Inspect internal passageways of the park brake
manifold and valve for wear, damage, etc. If inner
The park brake valve is located in the cab, below the seat.
surfaces of the manifold DO NOT display an ultra-
smooth, polished finish, or components are
damaged in any way, replace the manifold or
1 appropriate part. Often, dirty hydraulic fluid causes
failure of internal seals and damage to the polished
surfaces within the unit.
2 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
MY2150 hydraulic oil.
6. Install the solenoid valves and cartridges in the park
a. Park Brake Valve Removal brake housing.
retract the boom, lower the boom, place the c. Park Brake Valve Installation
transmission control lever in (N) NEUTRAL, engage 1. Install the park brake valve with the two lockwashers
the park brake and shut the engine OFF. and two capscrews to the cover.
2. Place a Do Not Operate Tag on both the ignition key Note: ALWAYS replace seals, o-rings, gaskets, etc.,
switch and the steering wheel, stating that the with new parts to help ensure proper sealing and
machine should not be operated. operation. Lubricate seals and o-rings with clean
3. Open the engine covers. Allow the system fluids to hydraulic oil.
cool. 2. Use new oiled o-rings as required. Uncap, reattach
4. Remove the four capscrews holding the cover below and secure the three hoses.
the seat. The park brake valve is mounted on the 3. Check the routing of all hoses for sharp bends or
backside of the cover. interference with any rotating members, and install
5. Label, disconnect and cap the hydraulic hoses on tie wraps and/or protective conduit as required.
each side and bottom of the park brake valve.
4. Start the engine and run at approximately one-third
Disconnect and cap all hoses, fittings, etc.
to one-half throttle for about one minute, without
6. Remove the two capscrews, and two lockwashers moving the machine or operating any hydraulic
mounting the park brake valve to the cover. functions.
b. Park Brake Valve Disassembly, Cleaning, 5. Inspect the park brake valve and connections for
Inspection and Assembly leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF.
1. Place the park brake valve on a suitable work
6. Install the park brake/cover with the four capscrews.
surface.
2. Remove the solenoid valve (1) and cartridge (2) from
the park brake housing.
8. Close and secure the engine covers
3. Clean all components with a suitable cleaner before
inspection.
d. Parking Brake Valve Test
4. Inspect the solenoid cartridges for proper operation.
Check by shifting the spool to ensure that it is 1. Start the machine and engage the shift lever to the
functioning properly. Check that the spring is intact. forward position. Slowly depress the throttle to mid
Inspect the cartridge interior for contamination. 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.”
8.16 TH255
Hydraulic System
8.11.4 Steering Orbitrol Valve 2. Remove the solenoid valves and cartridges (3, 4 &5)
from the steer select housing.
Refer to Section 4.4.2, “Steering Column/Valve
Replacement,” for details. 3. Clean all components with a suitable cleaner before
inspection.
8.11.5 Pilot Select Valve 4. Inspect the solenoid cartridges for proper operation.
The pilot select valve is attached to a manifold mounted Check by shifting the spool to ensure that it is
on a mounting plate inside the frame in front of the comp functioning properly. Check that the spring is intact.
cylinder. Inspect the cartridge interior for contamination.
5. Inspect internal passageways of the steer select
4 manifold and valve for wear, damage, etc. If inner
3
5 smooth, polished finish, or components are
appropriate part. Often, dirty hydraulic fluid causes
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
MY2170 hydraulic oil.
Verify the correct operation of the pilot select valve 6. Install the solenoid valves and cartridges in the pilot
solenoids before considering replacement of the valve select housing.
(boom lift/lower (3), auxiliary (4) and tilt (5)). The housing
of the pilot select valve is not serviceable and must be c. Pilot Select Valve Installation
replaced if defective. 1. Attach the pilot select manifold valve to the mounting
plate on the frame using the socket head capscrews.
a. Pilot Select Valve Removal
2. Connect the hydraulic hoses, fittings, solenoid wire
1. Park the machine on a firm, level surface, fully terminal leads, etc., to the pilot select valve.
retract the boom, lower the boom, place the 3. 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 clamps.
switch and the steering wheel, stating that the 4. Start the engine and run at approximately 1/3-1/2
machine should not be operated. throttle for about one minute, without moving the
3. Open the engine cover. Allow the system fluids to machine or operating any hydraulic functions.
cool. 5. Inspect for leaks and check the level of the hydraulic
4. Label or otherwise mark the hydraulic hoses in fluid in the reservoir. Shut the engine OFF.
relation to the pilot select valve. Disconnect and cap 6. Wipe up any hydraulic fluid spillage in, on, near and
all hoses, fittings, solenoid wire terminal leads, etc. around the machine, work area and tools.
5. Remove the capscrews that attach the valve to the 7. Close and secure the engine cover.
frame.
6. Remove the pilot select valve from the machine. d. Pilot Select Valve Test
Wipe up any hydraulic fluid spillage in, on, near and
1. Check boom lift/lower, auxiliary and tilt for proper
around the machine.
function.
b. Pilot Select Valve Disassembly, Cleaning, 2. If further troubleshooting is required, refer to Section
Inspection and Assembly 8.7, “Hydraulic Schematic,” or Section 9.4, “Electrical
System Schematics,” for details.
1. Place the pilot select assembly on a suitable work
surface.
TH255 8.17
Hydraulic System
8.11.6 Inching Valve 5. Inspect internal passageways of the inching valve for
wear, damage, etc. If inner surfaces of the manifold
The inching valve is attached at the front of the frame
DO NOT display an ultra-smooth, polished finish, or
directly above the steer select valve.
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.
hydraulic oil.
1
6. Install the cartridge in the inching valve housing.
MY2330
Verify the correct operation of the inching valve before c. Inching Valve Installation
considering replacement of the valve. The housing of the 1. Attach the inching valve to the mounting plate on the
inching valve is not serviceable and must be replaced if frame using the socket head capscrews.
defective.
2. Connect the hydraulic hoses, fittings, etc., to the
inching valve.
a. Inching Valve Removal
3. Check the routing of all hoses and wiring for sharp
1. Park the machine on a firm, level surface, fully bends or interference with any rotating members,
retract the boom, lower the boom, place the and install tie wraps and/or protective conduit as
transmission control lever in (N) NEUTRAL, engage required. Tighten all hose clamps.
4. Start the engine and run at approximately 1/3-1/2
2. Place a Do Not Operate Tag on both the ignition key throttle for about one minute, without moving the
switch and the steering wheel, stating that the machine or operating any hydraulic functions.
5. Inspect for leaks and check the level of the hydraulic
3. Open the engine covers. Allow the system fluids to fluid in the reservoir. Shut the engine OFF.
cool.
Note: Check for leaks and repair as required before
4. Label or otherwise mark the hydraulic hoses in
continuing. Add hydraulic fluid to the reservoir as needed.
relation to the inching valve. Disconnect and cap all
hoses, fittings, etc. 6. Wipe up any hydraulic fluid spillage in, on, near and
5. Remove the capscrews that attach the valve to the around the machine, work area and tools.
frame. 7. Close and secure the engine covers.
6. Remove the inching valve from the machine. Wipe
up any hydraulic fluid spillage in, on, near and d. Inching Valve Bleeding Procedure
around the machine. Carefully bleed the inching valve as soon as the inching
valve is installed on the machine. Air in the system will not
b. Inching Valve Disassembly, Cleaning, Inspection allow the brakes to apply properly. There is one bleeder
and Assembly location on the inching valve. Work with an assistant to
1. Place the inching valve assembly on a suitable work perform this procedure.
surface.
2. Remove the cartridge (1) from the inching valve
housing.
inspection.
4. Inspect the cartridge for proper operation. Check by
shifting the spool to ensure that it is functioning
properly. Check that the spring is intact. Inspect the
cartridge interior for contamination.
8.18 TH255
Hydraulic System
1. Place the transmission control lever in 8.11.7 Priority Valve

(N) NEUTRAL, engage the park brake, start the
.The priority valve is attached at the front of the engine
engine and lower the boom. Turn off engine.
pod frame directly behind the air cleaner.
MY2330
MY2970
2. Remove the plastic cap (2) from the inching brake

Verify the correct operation of the priority valve before
bleeder. Attach one end of a length of transparent
considering replacement of the valve. The priority valve
tubing over the bleeder. Place the other end of this
must be replaced if defective.
tubing in a suitable transparent container that is
partially filled with hydraulic oil. The end of the tubing
a. Priority Valve Removal
must be below the oil level in the container.
3. DO NOT open the bleeder without holding the tubing 1. Park the machine on a firm, level surface, fully
firmly on the bleeder. Have an assistant depress the retract the boom, lower the boom, place the
brake pedal. Carefully open the bleeder with a 10 transmission control lever in (N) NEUTRAL, engage
mm wrench. Close the bleeder when air bubbles no the park brake and shut the engine OFF.
longer appear in the oil. Release the brake pedal. 2. Place a Do Not Operate Tag on both the ignition key
Remove the tubing from the bleeder. switch and the steering wheel, stating that the
4. If brake system bleeding is required, refer to Section machine should not be operated.
8.11.2, “Service Brake Valve.” 3. Open the engine covers. Allow the system fluids to
5. Check brake fluid level and add fluid if necessary. cool.
Refer to Section 2.4, “Fluids, Lubricants and 4. Label or otherwise mark the hydraulic hoses in
Capacities.” relation to the priority valve. Disconnect and cap all
hoses, fittings, etc.
e. Inching Test 5. Remove the capscrews that attach the valve to the
1. Start the machine, engage the shift lever to the frame.
forward position and release the parking brake. 6. Remove the priority valve from the machine. Wipe up
Slowly depress the throttle to 1/2 throttle. Slowly any hydraulic fluid spillage in, on, near and around
apply the service brake. The machine will slow, but the machine.
still maintain forward movement. Continuing to
depress the service brake will disengage the inching b. Priority Valve Disassembly, Cleaning, Inspection
brake and engage the service brakes. and Assembly
2. If further troubleshooting is required, refer to Section 1. Place the priority valve assembly on a suitable work
8.7, “Hydraulic Schematic.” surface.
2. Label and remove the fittings (3) from the priority
valve housing.
inspection.
hydraulic oil.
TH255 8.19
Hydraulic System
4. Install the previously labeled fittings in the priority valve Verify the correct operation of the steer select valve
housing. solenoids before considering replacement of the valve.
The housing of the steer select valve is not serviceable
c. Priority Valve Installation and must be replaced if defective.
1. Attach the priority valve to the mounting plate on the
a. Steer Select Manifold and Valve Removal
frame using the socket head capscrews.
2. Connect the hydraulic hoses, fittings, etc., to the 1. Park the machine on a firm, level surface, fully
priority valve. retract the boom, lower the boom, place the
3. Check the routing of all hoses for sharp bends or the park brake and shut the engine OFF.
interference with any rotating members, and install
tie wraps and/or protective conduit as required. 2. Place a Do Not Operate Tag on both the ignition key
Tighten all hose clamps. switch and the steering wheel, stating that the
throttle for about one minute, without moving the 3. Open the engine cover. Allow the system fluids to
machine or operating any hydraulic functions. cool.
5. Inspect for leaks and check the level of the hydraulic 4. Label or otherwise mark the hydraulic hoses in
fluid in the reservoir. Shut the engine OFF. relation to the steer select manifold. Disconnect and
cap all hoses, fittings, solenoid wire terminal leads,
Note: Check for leaks and repair as required before etc.
5. Remove the capscrews that attach the manifold to
6. Wipe up any hydraulic fluid spillage in, on, near and the frame.
around the machine, work area and tools. 6. Remove the steer select manifold with attached steer
7. Close and secure the engine covers. select valve from the machine. Wipe up any
hydraulic fluid spillage in, on, near and around the
d. Priority Valve Test machine.
1. Start the machine and slowly depress the throttle to
b. Steer Select Valve and Manifold Disassembly,
1/2 throttle. Turn the steering and engage a boom
Cleaning, Inspection and Assembly
function. The steering will continue to respond along
with the engaged boom function. 1. Place the steer select assembly on a suitable work
2. If further troubleshooting is required, refer to Section surface.
8.7, “Hydraulic Schematic.” 2. Separate the steer select valve from the manifold by
removing the capscrews. Discard the old o-rings.
8.11.8 Steer Select Valve 3. Remove the solenoid valves and cartridges (1) from
The steer select valve is attached to inside the frame near the steer select housing.
the front drive motor. 4. Clean all components with a suitable cleaner before
inspection.
5. Inspect the solenoid cartridges for proper operation.
Check by shifting the spool to ensure that it is
functioning properly. Check that the spring is intact.
Inspect the cartridge interior for contamination.
1
6. Inspect internal passageways of the steer select
manifold and valve for wear, damage, etc. If inner
1 smooth, polished finish, or components are
appropriate part. Often, dirty hydraulic fluid causes
MY2180
8.20 TH255
Hydraulic System
Note: ALWAYS replace seals, o-rings, gaskets, etc., 8.11.9 Joystick Enable Valve
The joystick enable valve is located on top of the frame at
the left rear corner of the hydraulic reservoir.
hydraulic oil.
7. Install the solenoid valves and cartridges in the steer
select housing.
8. Attach the steer select valve to the manifold using
new, oiled o-rings and socket head capscrews.
c. Steer Select Manifold and Valve Installation

1. Attach the steer select manifold and valve to the 2
mounting plate on the frame using the socket head
capscrews. MY2380
2. Connect the hydraulic hoses, fittings, solenoid wire Verify the correct operation of the joystick enable valve
terminal leads, etc., to the steer select valve and solenoid before considering replacement of the valve.
manifold. The housing of the joystick enable valve is not
3. Check the routing of all hoses, wiring and tubing for serviceable and must be replaced if defective.
members, and install tie wraps and/or protective a. Joystick Enable Valve Removal
conduit as required. Tighten all tube and hose clamps. 1. Park the machine on a firm, level surface, fully
4. Start the engine and run at approximately 1/3-1/2 retract the boom, lower the boom, place the
throttle for about one minute, without moving the transmission control lever in (N) NEUTRAL, engage
machine or operating any hydraulic functions. the park brake and shut the engine OFF.
5. Inspect for leaks and check the level of the hydraulic 2. Place a Do Not Operate Tag on both the ignition key
fluid in the reservoir. Shut the engine OFF. switch and the steering wheel, stating that the
continuing. Add hydraulic fluid to the reservoir as needed. 3. Open the engine covers. Allow the system fluids to
cool.
around the machine, work area and tools. 4. Label or otherwise mark the hydraulic hoses in
relation to the joystick enable valve. Disconnect and
7. Close and secure the engine cover. cap all hoses, fittings, solenoid wire terminal leads,
etc.
d. Steering Test
5. Remove the capscrews that attach the valve to the
1. Start the machine and select either the 4-wheel frame.
steer or the crab steer mode.
6. Remove the joystick enable valve from the machine.
2. Turn the steering wheel until the left rear wheel is Wipe up any hydraulic fluid spillage in, on, near and
aligned with the side of the frame. around the machine.
3. Select the 2-wheel steer mode and turn the steering
wheel until the left front wheel is aligned with the b. Joystick Enable Valve Disassembly, Cleaning,
frame. Inspection and Assembly
4. With the wheel now aligned, select the desired steer 1. Place the joystick enable valve assembly on a
mode. suitable work surface.
1. If further troubleshooting is required, refer to Section 2. Remove the solenoid valve and cartridge (2) from
8.6.5, “Steering Pressure Checking,” Section 8.7, the joystick enable valve housing.
“Hydraulic Schematic,” or Section 9.4, “Electrical 3. Clean all components with a suitable cleaner before
System Schematics.” inspection.
TH255 8.21
Hydraulic System
4. Inspect the solenoid cartridge for proper operation. 8.11.10 Decompression Valve
Check by shifting the spool to ensure that it is
The decompression valve is located on the frame at the
left rear corner above the main control valve.
Inspect the cartridge interior for contamination.
5. Inspect internal passageways of the joystick enable
1
valve for 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.
operation. Lubricate seals and o-rings with clean MY2870
hydraulic oil.
DECOMPRESSION VALVE DECOMPRESSION VALVE
6. Install the solenoid valve and cartridge in the joystick BEFORE S/N TBS00227 S/N TBS00227 & AFTER
enable valve housing.
Verify the correct operation of the decompression valve
c. Joystick Enable Valve Installation solenoid before considering replacement of the valve.
1. Attach the joystick enable valve to the mounting The housing of the decompression valve is not
plate on the frame using the socket head capscrews. serviceable and must be replaced if defective.
2. Connect the hydraulic hoses, fittings, solenoid wire a. Decompression Valve Removal
terminal leads, etc., to the inching valve.
retract the boom, raise the boom, place the
members, and install tie wraps and/or protective
conduit as required. Tighten all tube and hose clamps.
throttle for about one minute, without moving the
machine or operating any hydraulic functions.
5. Inspect for leaks and check the level of the hydraulic
cool.
fluid in the reservoir. Shut the engine OFF.
4. Label or otherwise mark the hydraulic hoses in
Note: Check for leaks and repair as required before relation to the decompression valve. Disconnect and
continuing. Add hydraulic fluid to the reservoir as needed. cap all hoses, fittings, solenoid wire terminal leads,
6. Wipe up any hydraulic fluid spillage in, on, near and etc.
around the machine, work area and tools. 5. Remove the capscrews that attach the valve to the
7. Close and secure the engine covers. frame.
6. Remove the decompression valve from the machine.
d. Joystick Enable Valve Test Wipe up any hydraulic fluid spillage in, on, near and
1. Start the machine, switch the joystick enable valve to around the machine.
the ON position. The joystick will not function.
b. Decompression Valve Disassembly, Cleaning,
2. If further troubleshooting is required, refer to Section Inspection and Assembly
8.7, “Hydraulic Schematic,” or Section 9.4, “Electrical
System Schematics.” 1. Place the decompression valve assembly on a
suitable work surface.
2. Remove the solenoid valve and cartridge (1) from
the decompression valve housing.
8.22 TH255
Hydraulic System
3. Clean all components with a suitable cleaner before 8.11.11 Load Stability Indicator Valve (CE)
inspection.
The load stability indicator valve is located at the rear of
4. Inspect the solenoid cartridge for proper operation. the machine on the left inside frame rail directly below the
Check by shifting the spool to ensure that it is boom/boom pivot pin. The LSI valve is part of the LSI
functioning properly. Check that the spring is intact. System which constantly monitors the forward stability of
Inspect the cartridge interior for contamination. the machine
5. Inspect internal passageways of the decompression
valve for 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 2
hydraulic fluid causes failure of internal seals and
damage to the polished surfaces within the unit.
hydraulic oil.
MY2590
6. Install the solenoid valve and cartridge in the

Verify the correct operation of the LSI valve solenoid
decompression valve housing.
before considering replacement of the valve. Refer to
Section 9.11.8, “Load Stability Indicator.” The housing of
c. Decompression Installation
the LSI valve is not serviceable and must be replaced if
1. Attach the decompression valve to the mounting defective.
plate on the frame using the socket head capscrews.
2. Connect the hydraulic hoses, fittings, solenoid wire a. LSI Valve Removal
terminal leads, etc., to the inching valve. 1. Park the machine on a firm, level surface, fully
3. Check the routing of all hoses, wiring and tubing for retract the boom, lower the boom, place the
sharp bends or interference with any rotating transmission control lever in (N) NEUTRAL, engage
members, and install tie wraps and/or protective the park brake and shut the engine OFF.
conduit as required. Tighten all tube and hose clamps. 2. Place a Do Not Operate Tag on both the ignition key
4. Start the engine and run at approximately 1/3-1/2 switch and the steering wheel, stating that the
throttle for about one minute, without moving the machine should not be operated.
machine or operating any hydraulic functions. 3. Open the engine covers. Allow the system fluids to
5. Inspect for leaks and check the level of the hydraulic cool.
fluid in the reservoir. Shut the engine OFF. 4. Label or otherwise mark the hydraulic hoses in
Note: Check for leaks and repair as required before relation to the LSI valve. Disconnect and cap all
continuing. Add hydraulic fluid to the reservoir as needed. hoses, fittings, solenoid wire terminal leads, etc.
5. Remove the capscrews that attach the valve to the
frame.
6. Remove the LSI valve from the machine. Wipe up
any hydraulic fluid spillage in, on, near and around
the machine.
d. Decompression Valve Test
1. Turn the ignition switch to the ON position, relieve b. LSI Valve Disassembly, Cleaning, Inspection and
auxiliary system pressure by activating the Assembly
decompression switch. Disconnect and reconnect
1. Place the LSI valve assembly on a suitable work
the attachment hoses on the quick connect fittings.
surface.
2. If further troubleshooting is required, refer to Section
2. Remove the solenoid valve and cartridge (2) from
the LSI valve housing.
System Schematics.”
TH255 8.23
Hydraulic System
3. Clean all components with a suitable cleaner before 8.12 HYDRAULIC CYLINDERS
inspection.
4. Inspect the solenoid cartridge for proper operation. 8.12.1 General Cylinder Removal
Check by shifting the spool to ensure that it is Instructions
Inspect the cartridge interior for contamination. 1. Park the machine on a firm, level surface, fully
5. Inspect internal passageways of the inching valve for transmission control lever in (N) NEUTRAL, engage
wear, damage, etc. If inner surfaces of the manifold the park brake and shut the engine OFF.
DO NOT display an ultra-smooth, polished finish, or
components are damaged in any way, replace the 2. Chock the wheels.
manifold or appropriate part. Often, dirty hydraulic 3. Place a Do Not Operate Tag on both the ignition key
fluid causes failure of internal seals and damage to switch and the steering wheel, stating that the
the polished surfaces within the unit. machine should not be operated.
Note: ALWAYS replace seals, o-rings, gaskets, etc., 4. Open the engine cover. Allow the system fluids to
with new parts to help ensure proper sealing and cool.
operation. Lubricate seals and o-rings with clean 5. Label, disconnect and cap hydraulic hoses in
hydraulic oil. relation to the cylinder.
6. Install the solenoid valve and cartridge in the LSI valve 6. Attach a suitable sling to an appropriate lifting device
housing. and to the cylinder. Make sure the device used can
actually support the cylinder.
c. LSI Valve Installation
7. Remove the lock bolt and/or any retaining clips
1. Attach the LSI valve to the mounting plate on the securing the cylinder pins. Remove the cylinder pins.
frame using the socket head capscrews. 8. Remove the cylinder.
2. Connect the hydraulic hoses, fittings, solenoid wire 9. Wipe up any hydraulic fluid spillage in, on, near or
terminal leads, etc., to the inching valve. around the machine.
sharp bends or interference with any rotating 8.12.2 General Cylinder Disassembly
members, and install tie wraps and/or protective
1. Clean the cylinder with a suitable cleaner before
conduit as required. Tighten all tube and hose clamps.
disassembly. Remove all dirt, debris and grease
4. Start the engine and run at approximately 1/3-1/2 from the cylinder.
throttle for about one minute, without moving the
2. Clamp the barrel end of the cylinder in a soft-jawed
machine or operating any hydraulic functions.
vise or other acceptable holding equipment if
5. Inspect for leaks and check the level of the hydraulic possible.
fluid in the reservoir. Shut the engine OFF.
NOTICE
6. Wipe up any hydraulic fluid spillage in, on, near and Avoid using excessive force when clamping the
around the machine, work area and tools. cylinder in a vise. Apply only enough force to hold the
7. Close and secure the engine covers. cylinder securely. Excessive force can damage the
cylinder tube.
d. LSI Valve Test 3. If applicable, remove the counterbalance valve from
1. Refer to Section 9.11.8, “Load Stability Indicator,” or the side of the cylinder barrel.
Section 9.11.9, “Load Stability Sensor,”for proper
test procedures.
2. If further troubleshooting is required, refer to Section
System Schematics.”
8.24 TH255
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
temperature of 149-204° C (300-400° F) will destroy the
NOTICE 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.
9. Remove the piston head (4) from the rod (5) and
4. Extend the rod (5) to allow access to the base of the
carefully slide the head gland (6) off the end of the
cylinder.
rod.
10. Remove all seals, back-up rings and o-rings (2) from
NOTICE the piston head and all seals, back-up rings and o-
rings from the head gland.
Protect the finish on the rod at all times. Damage to the
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
DO NOT attempt to salvage cylinder seals, sealing rings
gland (6) from the barrel (1). A considerable amount
or o-rings. ALWAYS use a new, complete seal kit when
of force will be necessary to remove the head gland.
rebuilding hydraulic components. Consult the parts
Carefully slide the head gland down along the rod
manual for ordering information.
toward the rod eye end, away from the cylinder
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.
TH255 8.25
Hydraulic System
2. Clean all metal parts with an approved cleaning

solvent such as trichlorethylene. Carefully clean
cavities, grooves, threads, etc.
Note: If a white powdery residue is present on threads
NOTICE
and parts, it can be removed. Clean the residue away Avoid using excessive force when clamping the
with a soft brass wire brush prior to reassembly, and cylinder barrel in a vise. Apply only enough force to
wipe clean before reinstallation. hold the cylinder barrel securely. Excessive force can
damage the cylinder barrel.
8.12.4 Cylinder Inspection
5. Place the cylinder barrel (1) in a soft-jawed vise or
1. Inspect internal surfaces and all parts for wear, other acceptable holding equipment if possible.
damage, etc. If the inner surface of the tube does not
display a smooth finish, or is scored or damaged in
any way, replace the tube. NOTICE
2. Remove light scratches on the piston, rod or inner
surface of the tube with a 400-600 grit emery cloth. When sliding the rod and piston assembly into the
Use the emery cloth in a rotary motion to polish out cylinder barrel, prevent the threaded end of the
and blend the scratch(es) into the surrounding cylinder barrel from damaging the piston head. Keep
surface. the cylinder rod centered within the barrel to prevent
binding.
3. Check the piston rod assembly for run-out. If the rod
is bent, it must be replaced. 6. Carefully insert the cylinder rod assembly into the
tube.
8.12.5 General Cylinder Assembly 7. Screw the head gland (6) into the cylinder barrel (1)
1. Use the proper tools for specific installation tasks. and tighten with a spanner wrench. Refer to Section
Clean tools are required for assembly. 8.12.8, “Hydraulic Cylinder Torque Specifications,”
for tightening guidelines for the head gland.
2. Install new seals, back-up rings and o-rings (2) on
the piston (4) and the head gland (6). 8. If applicable, thread the new counterbalance valve
into the block on the cylinder barrel.
Note: The Crowd cylinder has a spacer that MUST be
installed over the rod AFTER the head gland and
BEFORE the piston head. 1
2
3. Fasten the rod eye in a soft-jawed vise, and place a
padded support under and near the threaded end of
3
the rod (5) to prevent any damage to the rod.
4
NOTICE
Protect the finish on the rod at all times. Damage to the
surface of the rod can cause seal failure.
4. Lubricate and slide the head gland (6) over the
cylinder rod (5). Install the piston head (4) on to the
end of the cylinder rod. Cat Threadlock and install
the setscrew (3) in the piston head. Refer to Section 1
8.12.8, “Hydraulic Cylinder Torque Specifications,”
for tightening guidelines for the piston head and the
set screw.
2 5
6
MAH0160
8.26 TH255
Hydraulic System
8.12.6 General Cylinder Installation

1. Grease the bushings at the ends of the hydraulic
cylinder. Using an appropriate sling, lift the cylinder
into it’s mounting position.
2. Align cylinder bushing and install pin, lock bolt or
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. 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.
6. Inspect for leaks and check level of hydraulic fluid in
reservoir. Add hydraulic fluid if needed.
7. 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.
8.12.7 Steering Cylinders

The steering cylinders are attached to each axle center
housing. Detailed axle service instructions are provided
in the Axle Disassembly & Assembly Manual (P/N
31200451).
TH255 8.27
Hydraulic System
8.12.8 Hydraulic Cylinder Torque

Specifications
Description
Extend/Retract Cylinder Set Screw 81-94 Nm (60-69 lb-ft)
All Other Cylinder Set Screws 22-25 Nm (16-18 lb-ft)
Counter Balance Valves 61-68 Nm (45-50 lb-ft)
Lift/Lower Cylinder
Head Gland 406-542 Nm (300-400 lb-ft)
Piston 2440-2712 Nm (1800-2000 lb-ft)
Extend/Retract Cylinder
Piston 271-325 Nm (200-240 lb-ft)
Tilt Cylinder
Piston 1898-2034 Nm (1400-1500 lb-ft)
Compensating Cylinder
Piston 1898-2034 Nm (1400-1500 lb-ft)
Use Cat High Strength Threadlock on all Piston Applications

Use Cat Threadlock on all Set Screws
8.28 TH255
Section 9
Electrical System
Contents

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 Cab Harness Schematic "A" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.4.2 Cab Harness Schematic "B" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
9.4.3 Cab Roof Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
9.4.4 Chassis Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
9.4.5 Options Chassis Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
9.5 Circuit Breakdowns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
9.5.1 Charge Circuit Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
9.5.2 Start Circuit Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
9.5.3 Constant Power Circuit Breakdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
9.5.4 Drive Circuit Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
9.6 Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
9.6.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
9.7 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
9.7.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
9.8 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
9.8.1 Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
9.8.2 Instrument Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
9.8.3 Speedometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
9.9 Window Wiper/Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
9.9.1 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
9.9.2 Rear Window or Roof Wiper Motor (if equipped) . . . . . . . . . . . . . . . . . . . 9.20
9.9.3 Windshield Washer Reservoir and Pump . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
9.10 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.10.1 Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
TH255 9.1
Electrical System
9.11 Switches, Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23

9.11.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
9.11.2 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
9.11.3 Fuel Level Indicator and Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . 9.23
9.11.4 Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
9.11.5 Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
9.11.6 Fuel Shut-off Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
9.11.7 Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
9.11.8 Load Stability Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9.11.9 Load Stability Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9.2 TH255
Electrical System
9.1 ELECTRICAL COMPONENT

TERMINOLOGY
To understand the safety, operation, and service
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
9.3 FUSES AND RELAYS
9.3.1 Engine Compartment Relays and

Fuses
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).
3 1
MY2230
9.3.2 Cab Compartment Fuses and Relays

The cab fuse block (4) is located behind an access panel
at the right side of the dash.
MY2480 4
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 Cab Harness Schematic "A"
SHEET 1
3096334
3184660
3184662
3176318
3184662
3176316
3099162
3176322
3096335
3176321
3176320
3176379
MAP100-H
TH255 9.7
9.8
9.4.2
SHEET 2
3176338
3178664
3176319
3178663 3176317 3178666
Electrical System
Cab Harness Schematic "B"
3178726
3178665
3178668 3178673 3099163
3178667
MAP0110-H
TH255
Electrical System
9.4.3 Cab Roof Schematic
SHEET 3
3123332
3123332
3123332
3123332
3173270
3176366
3178722
3123331
3178721
MAP0120-H
TH255 9.9
9.10
9.4.4
SHEET 4
3123294 3123299 3123298
3092849 3096324
2986870 3096326 2953368
Electrical System
Chassis Schematic
3123332
3123332
2990307
2990312
2990312 2990312
3184713
3092938
2980402
3092972
MAP0130-H
TH255
Electrical System
9.4.5 Options Chassis Schematic
SHEET 5
3123293
3209307
3093994
3034976
3034975
3034956
3034955
MAP0140-H
TH255 9.11
Electrical System
9.5 CIRCUIT BREAKDOWNS
9.5.1 Charge Circuit Breakdown
FRAME HARNESS
CAB HARNESS
MY2290
9.12 TH255
Electrical System
9.5.2 Start Circuit Breakdown
FRAME HARNESS
CAB HARNESS
MY2310
TH255 9.13
Electrical System
9.5.3 Constant Power Circuit Breakdown
2 ROOF HARNESS
CAB HARNESS B
FRAME HARNESS
CAB HARNESS
MY2301
9.14 TH255
Electrical System
9.5.4 Drive Circuit Breakdown
CAB HARNESS A
FRAME HARNESS
1
3
4
3
2
OPTIONAL FRAME HARNESS
CAB HARNESS B (CE ONLY) MY2320
TH255 9.15
Electrical System
9.6 ENGINE START CIRCUIT the drive forward to engage the flywheel may be
defective. Missing or damaged teeth on the flywheel
can also prevent the starter from cranking the
9.6.1 Starter engine.
The starter (1) is located on the left side of the engine 3. If the starter only “clicks” it may indicate that the
attached to the bell housing. battery is discharged, or that there is a loose or
corroded battery cable connection. Check the
battery state of charge and battery condition first,
then check the cables and cable connections.
4. For additional information on the starting circuit, refer
to Section 9.4.4, “Chassis Schematic.”
c. Starter Removal
Remove the starter only if it fails. To remove the starter:
1. Open the battery and engine covers.
3. Remove the wires from the solenoid stud. Remove
1 the red, positive (+) battery cable from the starter.
Label and disconnect the wire from the starter
solenoid housing stud. Record how the wires are
MY1890
installed to ensure correct installation later.
a. Testing the Starter on the Engine 4. Loosen, but DO NOT remove, the fasteners securing
the starter to the flywheel housing. Support the
If the starter does not engage when the ignition key starter securely, as it is relatively heavy and will fall if
switch is turned, check the following: not supported.
1. The transmission control lever is in (N) NEUTRAL 5. Support the starter and remove the fasteners
and the park brake switch is set. securing the starter to the engine. Remove the
2. The main fuse may be blown, requiring replacement. negative (-) ground cable from its starter mounting
Check for the cause of the blown fuse. bolt.
3. There may be a defect in the ignition key switch, 6. Remove the starter (1) from the machine.
ignition wiring or starter solenoid.
4. Check battery condition. Clean the battery posts and d. Starter Cleaning and Drying
the connectors at each end of the battery cables. 1. While the starter is being removed, wipe away any
5. Check for broken wiring and damaged insulation on grease or dirt that has accumulated around the
the wiring. Replace all broken or damaged wiring. starter mounting opening.
6. Check all connections at the starter solenoid, key 2. If reinstalling the starter, clean the exterior of the
switch and wiring harness plugs. Clean and tighten starter with an approved solvent. DO NOT submerse
all connections. the starter or allow the solvent to contact the starter
bushings.
7. If the starter still does not operate after these checks
have been performed, check the starting circuit. 3. Dry the starter with a clean, lint-free cloth.
b. Starter Circuit Checks e. Starter Periodic Maintenance
1. Check wires and connections for looseness, A starter requires no routine maintenance beyond the
corrosion, damage, etc. occasional inspection of the electrical connections, which
must be clean and tight.
2. If a “whirring” noise is heard but the engine does not
turn over, the starter is spinning but not engaging the
flywheel. The starter drive or solenoid that pushes
9.16 TH255
Electrical System
Note: DO NOT disassemble the starter. The starter is 9.7.1 Alternator

not serviceable and must be replaced in its entirety, if
defective. a. Alternator Removal
1. Open the battery and engine covers.
f. Starter Installation
2. Disconnect the positive (+) and negative (-) battery
1. Position the starter in its mounting opening on the cables at the battery terminals.
flywheel housing. Position the ground cable over the
correct starter mounting bolt. Secure the starter with 3. Label and disconnect the wires attached to the
fasteners. Torque fasteners to 43 Nm (32 lb-ft). alternator.
2. Connect the positive (+) battery cable to the upper Note: Record how the alternator is installed to ensure
solenoid stud. Install the wires to the upper solenoid correct installation later.
stud, and secure with lockwasher and nut. 4. Loosen the top mounting bolt (2), but don’t remove it
3. Connect the wire to the solenoid mounting stud. at this time. This will allow the alternator to swivel
4. Connect the battery negative (-) cable to the battery during belt removal.
5. Close and secure the battery and engine covers.
2
9.7 CHARGING CIRCUIT
Before using a battery charger, an attempt can be made
to recharge the battery by jump-starting the machine.
(Refer to the appropriate Operation & Maintenance
Manual.) Allow the engine to run, which will enable the
alternator to charge the battery.
If the engine alternator charging warning indicator
illuminates, perform the following checks:
1. Check the all battery cable connections at the 3
battery, and verify that they are clean and tight.
2. Check the external alternator wiring and
connections, and verify that they are in good
condition.
3. Check the fan belt condition and tension.
4. Verify that the alternator mounting hardware is tight. MY2200
5. Run the engine and check the alternator for noise. A

loose drive pulley, loose mounting hardware, worn or 5. Loosen the belt tensioning adjustment bolt (3) at the
dirty internal alternator bearings, a defective stator bottom of the alternator to loosen the fan drive belt.
or defective diodes can cause noise. Replace a worn 6. Remove the fan drive belt from the alternator.
or defective alternator. 7. Remove the lower mounting capscrew securing the
alternator to the lower mounting hole on the engine.
8. While supporting the alternator with one hand,
remove the upper mounting hardware from the
upper alternator mount. Remove the alternator from
the machine.
b. Alternator Installation
1. Position the alternator and align with the upper
alternator mount on the engine bracket. Insert the
upper mounting hardware through the alternator
mount. DO NOT tighten completely at this time.
TH255 9.17
Electrical System
2. Align the lower alternator mount hole with the lower 9.8.2 Instrument Cluster
mounting bracket on the engine, and insert the lower
mounting capscrew. Be sure to leave enough room
to attach the drive belt.
P
3. Attach the fan drive belt to the alternator.
4. Adjust the lower belt tensioning bolt to remove
excessive slack from the drive belt. Check for proper
fan belt deflection.
5. Reattach the previously labeled electrical wires to 00000 00 h
the alternator.
MY2210
6. Connect the positive (+) and negative (-) battery
cables to the battery terminals.
a. Removal
9.8 ELECTRICAL SYSTEM NOTICE

COMPONENTS
Static electricity can cause damage to the operator’s
instrument cluster. Avoid any manner of touching
9.8.1 Back-up Alarm (hands, tools, etc.) the printed circuit boards and
The back-up alarm is located at the rear of the machine. terminals. Disconnect the battery negative (-) cable at
its battery terminal before beginning this procedure.
When the park brake is released and the transmission Failure to comply can result in damage to the
shift control switch (transmission control lever) is shifted operator’s instrument cluster and malfunction of the
to the (R) REVERSE position, the back-up alarm will instruments and indicator lights.
automatically sound.
Place the transmission control lever in (R) REVERSE to 1. Open the battery cover.
test the back-up alarm. The back-up alarm must not 2. Disconnect the battery negative (-) cable at the
sound when the transmission control lever is in (N) battery negative (-) terminal.
NEUTRAL or (F) FORWARD. Also, with the ignition key 3. Remove the two nuts holding the instrument cluster
switch in the RUN position, the back-up alarm will sound to the dash.
when the transmission control lever is shifted into the (R)
REVERSE position. 4. Slide the instrument cluster out of the operator
console.
a. Disassembly 5. Disconnect the wiring harnesses.
DO NOT disassemble the back-up alarm. Replace a
b. Installation
defective or faulty alarm with a new part.
1. Connect the instrument cluster wiring harnesses.
b. Inspection and Replacement 2. Position the instrument cluster in the operator
Inspect the wiring harness connector and alarm terminals console.
for continuity and shorting. Test the alarm by turning the 3. Secure to the dash with two nuts.
ignition key switch to the RUN position and shifting the
4. Connect the battery negative (-) cable at the battery
transmission control lever into the REVERSE position.
The alarm should sound.
5. Close and secure the battery cover.
Replace a defective or faulty alarm with a new part.
9.18 TH255
Electrical System
9.8.3 Speedometer b. Disassembly

The speedometer (1) is located at the top right corner of DO NOT disassemble the speedometer. The
the cab A pillar directly below the Load Stability Indicator. speedometer is not serviceable. Replace speedometer if
found to be defective.
2 c. Inspection and Replacement

Inspect the speedometer terminals for continuity.
Replace speedometer if continuity is not found.
d. Installation
1. Make sure the correct Dip Switch Positions (3) are
applied to the new speedometer.
1
3
MY2500
a. Removal
1. Open the battery cover.
MY2510
battery negative (-) terminal. 2. Install the speedometer through the front of the LSI
and speedometer cover. Screw the ring on the
3. Remove the screws (2) holding the LSI and the
backside of the speedometer and tighten.
speedometer cover to the cab pillar.
3. Connect the previously labeled wire connections at
4. Label and disconnect the wire connections at the
the rear of the speedometer.
rear of the speedometer.
4. Install the screws (2) holding the LSI and the
5. Unscrew the ring on the backside of the
speedometer to the cab pillar.
speedometer and remove the unit.
5. Connect the battery negative (-) cable at the battery
Note: On the backside of the speedometer, there is a negative (-) terminal.
four digit DIP Code (3). Each of the four digits must be
installed in the new speedometer in the same order. 6. Close the battery cover.
Dip Switch Position

Tire Size
1 2 3 4
12" 1 1 0 0
14" 0 1 o o
TH255 9.19
Electrical System
9.9 WINDOW WIPER/WASHER d. Installation and Testing

1. Install all required hardware to the motor assembly.
9.9.1 Windshield Wiper Motor 2. Align motor with the mounting holes and bolt the
motor to the mounting bracket.
a. Removal
3. Connect the wiper linkage to the wiper motor shaft.
Note: It may be necessary to remove several hydraulic
hoses from under the dash in order to remove and install Note: Align the wiper linkage arm with the flat on the
the wiper motor housing. motor shaft to ensure wiper stroke covers window area,
and it does not swipe past the glass area.
4. Connect the cab harness connectors to windshield
2. Disconnect the battery negative (-) cable at the wiper motor connectors.
5. Connect the negative (-) battery cable to the battery
3. Remove the lower access panel below the negative (-) terminal.
instrument panel.
4. Disconnect the right side defroster hose from dash
panel hose connector. 7. Turn ignition key switch to the RUN position, and
operate windshield wiper in both LOW and HIGH
5. Disconnect the cab harness connectors from the speeds to ensure proper operation and that correct
wiper motor. wiper travel is achieved.
8. Install right side defroster hose to the dash panel
hose connector.
9. If previously removed, install hydraulic hoses under
the dash.
10. Install the lower dash panel.
9.9.2 Rear Window or Roof Wiper Motor

(if equipped)
a. Removal
MY2220
6. Remove the linkage attached to the wiper motor. battery negative (-) terminal.
7. Loosen and remove the four bolts holding the wiper 3. Remove the wiper arm assembly.
motor to the mounting bracket. 4. Loosen and remove the rear wiper cover.
Note: Retain all hardware removed from the wiper 5. Disconnect the cab harness connectors from the
assembly for possible reuse on the replacement motor wiper motor.
housing.
6. Remove the wiper motor in question.
8. Remove the motor from the inside of the cab.
Note: Retain all hardware removed from the wiper
assembly for possible reuse on the replacement motor
b. Disassembly
housing.
DO NOT disassemble the motor. The motor is not
serviceable. Replace motor if found to be defective. b. Disassembly
DO NOT disassemble the motor. The motor is not
c. Inspection and Replacement
serviceable. Replace motor if found to be defective.
Inspect the motor terminals for continuity. Replace motor
if continuity is not found.
9.20 TH255
Electrical System
c. Inspection and Replacement 9.9.3 Windshield Washer Reservoir

Inspect the motor terminals for continuity. Replace motor
and Pump
if continuity is not found. The windshield washer motor and reservoir is located in
the dash area as a unit and cannot be serviced
separately.
a. Removal
3. Remove the nuts and the lockwashers from the
washer mounting studs.
4. Pull the washer reservoir out and away from the
mounting studs.
5. Rotate the washer reservoir, label and remove the
cab harness connectors from the washer reservoir
connectors.
MY2520
6. Remove the windshield washer hoses from the
reservoir.
d. Installation and Testing
b. Disassembly
1. Install all required hardware to the motor assembly.
DO NOT disassemble the pump. The pump is not
2. Align motor with the mounting holes and bolt the serviceable. Replace pump if found to be defective.
motor to the proper location.
Note: Align the wiper to ensure wiper stroke covers c. Installation and Testing
window area, and it does not swipe past the glass area. 1. Connect the windshield washer hoses to the
3. Connect the cab harness connectors to wiper motor reservoir.
connectors. 2. Connect the cab wiring harness connectors to the
4. Install rear wiper cover. reservoir connectors.
5. Install wiper arm assembly. 3. Install the reservoir tank onto the mounting studs.
6. Connect the negative (-) battery cable to the battery 4. Install the lockwashers and nuts and secure.
negative (-) terminal. 5. Fill the washer fluid reservoir with washer fluid.
7. Close and secure the battery cover. 6. Connect the battery negative (-) cable to the battery
8. Turn ignition key switch to the RUN position, and negative (-) terminal.
operate wiper to ensure proper operation and that 7. Close and secure the battery cover.
correct wiper travel is achieved.
8. Turn the ignition key switch to the RUN position and
press the washer switch. Verify that fluid is sprayed
on the windshield.
TH255 9.21
Electrical System
9.10 CAB HEATER AND FAN 5. Connect the cab harness connector to the variable
speed fan control.
9.10.1 Cab Heater Controls 6. Install the control panel screws.
Note: If the suspect component is found to be within the 7. Install the setscrew, securing the knob to the control.
heater box, the heater box must be removed as a 8. Connect the battery negative (-) cable to the battery
complete unit and replaced. For additional information negative (-) terminal.
on the removal and installation of the heater box, refer to 9. Close and secure the battery cover.
Section 4.4.10, a. “Heater Assembly Removal.”
The cab heater controls are located to the right of the
seat. The control panel consists of a variable speed fan
control knob and a temperature control knob.
a. Cab Heater Controls Removal

Note: After determining which control knob is not
functioning, remove only the suspect control knob. In
order to remove either knob, the cab heater and fan
control panel must be removed from the dash panel.
3. Remove the screws and backing locknuts from the
cab heater and fan control panel.
4. Pull the control panel out from the dash panel, and if
removing variable speed fan control, remove the cab
harness connector.
5. If removing the temperature control knob, disconnect
the cable connector and remove control knob.
6. Remove the setscrew from the variable speed fan
control knob or temperature control knob.
7. Remove the hex locknut from the suspect control
shaft.
8. Remove the control from the panel.
b. Disassembly
DO NOT disassemble the cab heater and fan controls.
The controls are not serviceable. Replace controls if
found to be defective.
c. Installation and Testing

1. Check that the variable speed fan control is in the
OFF position.
2. If installing the temperature control, attach the cable
connector to the back of the control.
3. Insert the control shaft through the panel, ensuring
that the knob is in the VERTICAL position.
4. Install the hex locknut on the shaft and tighten.
9.22 TH255
Electrical System
9.11 SWITCHES, SOLENOIDS AND 3. Align the ignition switch so that when it is in the OFF
SENDERS position, the key slot is positioned vertically (straight
up and down). Install the hex nut securing the
ignition switch to the dash. DO NOT overtighten.
9.11.1 Ignition Key Switch
4. Install the lower dash panel.
a. Ignition Switch Removal 5. Connect the battery negative (-) cable to the battery
9.11.2 Dash Switches
3. Remove lower dash panel.
4. Remove the hex nut securing the ignition key switch a. Switch Removal
to the dash. 1. Open the battery cover.
5. Reach up under the dash to work the ignition switch 2. Disconnect the battery negative (-) cable at the
and wiring out of the mounting hole. battery negative (-) terminal.
6. Disconnect the ignition switch connectors from the 3. Pull the frame out of the dash, disconnect the
cab harness connectors, and remove the switch harness connector to the switch in question and
from the machine. push the switch out of the frame.
b. Disassembly b. Disassembly
DO NOT disassemble the ignition switch. Replace a DO NOT disassemble the dash switch. Replace a
defective switch with a new part. defective switch with a new part.
c. Inspection and Replacement c. Inspection and Replacement

To determine the proper operation of the ignition key Inspect the switch terminals for continuity in both the
switch, test the wires on the back of the switch for engaged and disengaged positions. Replace a defective
continuity with an ohmmeter. or faulty switch with a new switch.
Test the ignition key switch for continuity, by checking
from the BAT terminal (1) to each of the remaining d. Switch Installation
terminals in their corresponding switch position.
1. Connect the switch to the cab harness connector.
If all terminals do not show proper continuity, replace the
2. Position the switch over the rectangular switch bezel
ignition switch.
and snap into position.
3. Replace the frame into the dash.
5. Start the machine and check the replaced switch for
proper function.
1
MY2340 9.11.3 Fuel Level Indicator and Fuel Level

Sender
d. Ignition Switch Installation a. Fuel Level Indicator Testing
1. Connect the ignition key switch to the cab harness 1. The fuel level sender wiring harness leads can be
connectors. accessed from the top of the fuel tank. Disconnect
2. Reach up and under the dash to work the ignition the fuel level sender wiring harness leads. With the
switch into the ignition switch-mounting hole on the help of an assistant, touch both harness leads
lower right side of the dash. together.
TH255 9.23
Electrical System
2. From the operator’s cab, have the assistant turn the If trouble is suspected, time the hourmeter for six minutes
ignition key switch to the RUN position. DO NOT to verify that a tenth of an hour has been recorded.
start the engine. Observe the fuel level indicator The hourmeter is built into the instrument cluster and
needle on the operator’s instrument cluster. cannot be repaired. If the hourmeter is suspect, replace
3. Turn the ignition key switch to the OFF position. The the instrument cluster.
fuel level indicator needle should return to the
EMPTY position. 9.11.5 Coolant Temperature Sender
The coolant temperature sender (2) is located on the top
b. Fuel Level Circuit Tests
of the engine below the top radiator hose.
If the fuel level indicator is suspected of giving a false
reading, perform the following checks: 2
1. If the fuel level indicator needle does not move,
check the fuel tank for fuel.
2. Check for loose or defective wiring, faulty ground
connections or corrosion on the fuel tank sender and
wiring lead.
3. If the fuel level indicator needle does not move after
the ignition key switch is turned to the RUN position,
use a test lamp to determine whether current is
flowing from the ignition switch to the fuel level
sender.
4. If the fuel level indicator does not move and a faulty
or defective fuel level sender in the fuel tank has
been ruled out and in addition, wiring and MY1890
connectors have been checked and ruled out, the
fuel level indicator is defective and the instrument a. Coolant Temperature Sender Removal
cluster must be replaced.
1. Open the battery and engine covers. Allow the
5. Check that the ignition terminal has current and that engine to cool.
the fuse in the fuse panel is not blown.
6. Check for broken, shorted, frayed, disconnected or battery negative (-) terminal.
damaged wiring between the fuel level indicator
wiring at the cab, fuse and relay panel, ignition key 3. Disconnect the wiring connector at the coolant
switch and from the fuel level sender on the fuel tank temperature sender lead.
through the wiring in the cab. 4. The coolant temperature sender is threaded into the
7. Check the fuel level sender. The resistance of the engine block. Remove the sender.
fuel level sender is 31 ohms for a full tank of fuel,
101 ohms for 1/2 tank and 255 ohms for an empty b. Coolant Temperature Sender Inspection and
tank. A defective fuel level sender in the fuel tank Replacement
may also prevent the fuel level indicator from Inspect the sender and the wiring harness connector
moving. terminals for continuity. Replace a defective or faulty
sender with a new part.
9.11.4 Hourmeter
The hourmeter is a non-repairable instrument that c. Coolant Temperature Sender Installation and
records hours of machine engine operation in tenth of an Testing
hour increments and is located in the instrument cluster. 1. Thread the coolant temperature sender into the
The hourmeter is an analog device, similar to an engine housing snugly, then connect the sender
odometer, and will display 99,999.9 hours before connector to the wiring harness connector.
resetting to zero. 2. Connect the battery negative (-) cable to the battery
9.24 TH255
Electrical System
3. Check for proper fluid level. 5. Start the engine. If the engine starts, the fuel shutoff
4. Start the engine, allow it to reach operating solenoid is functioning. If the engine fails to start, the
temperature and observe the operator’s instrument fuel shut-off solenoid may have a poor ground
cluster for warning indication. If the sender is not connection. Visually check the wiring at the fuel
defective, the problem could be elsewhere; possibly shutoff solenoid leads and/or check for continuity
in a shorted wire, improper-running engine, improper with a voltmeter as required.
or low coolant, obstructed or faulty radiator, coolant 6. Check for fuel and/or oil leakage around the solenoid.
pump, loose fan belt, defective instrument display, 7. Close and secure the battery and engine covers.
etc.
1
9.11.6 Fuel Shut-off Solenoid
The fuel shut-off solenoid (1) is located on the top of the
engine injector pump.
a. Fuel Shut-off Solenoid Removal

1. Open the battery and engine covers. Allow engine to
cool.
3. Disconnect the wiring connector at the fuel shut-off 2
solenoid lead.
4. Remove the fuel shut-off solenoid from the engine.
MY1890
b. Fuel Shut-off Solenoid Disassembly

9.11.7 Oil Pressure Sender
DO NOT disassemble a fuel shut-off solenoid. Replace a
defective fuel shut-off solenoid with a new part. The oil pressure sender (2) is located on the engine near
the oil filter.
c. Fuel Shut-off Solenoid Inspection and
Replacement a. Oil Pressure Sender Removal
Use a 12-volt DC source and ground to test the solenoid. 1. Open the battery and engine covers. Allow the
Energize the solenoid, and watch for the plunger to engine to cool.
retract. If the plunger does not retract, replace the fuel 2. Disconnect the battery negative (-) cable from the
shut-off solenoid with a new solenoid. battery negative (-) terminal.
3. Disconnect the wiring connector at the oil pressure
d. Fuel Shut-off Solenoid Installation
sender lead.
1. Clean the exterior of the fuel shut-off solenoid
4. The oil pressure sender is threaded into the engine.
engine location.
Remove the sender.
2. Install the fuel shut-off solenoid on the engine. Do
Not Over Tighten. b. Oil Pressure Sender Inspection and Replacement
3. Connect the wiring connector at the fuel shut-off Inspect the sender and the wiring harness connector
solenoid lead. terminals for continuity. Replace a defective or faulty
4. Connect the battery negative (-) cable to the battery sender with a new part.
c. Oil Pressure Sender Installation and Testing
1. Thread the oil pressure sender into the engine
housing snugly, then connect the sender connector
to the wiring harness connector.
TH255 9.25
Electrical System
2. Connect the battery negative (-) cable to the battery 9.11.9 Load Stability Sensor
The Load Stability Sensor (4) is bolted on the top right of
3. Check for proper fluid level. the rear axle.
4. Start the engine, and observe the operator’s display
4
for warning indication. If the sender is not defective,
the problem could be elsewhere; possibly in a
shorted wire, improper-running engine, low oil,
obstructed or faulty oil pump, defective instrument
display.
9.11.8 Load Stability Indicator

The Load Stability Indicator provides a visual indication
for forward stability limitations.
• Green LED will illuminate when LSI power is on.
MY2490
• LEDs progressively illuminate as a load is lifted, first
green, then yellow and finally red.
• The warning buzzer sounds as the first red LED a. Load Stability Sensor Removal
illuminates. 1. Park the machine on a firm, level surface, level the
• As the telehandler reaches its forward stability machine, fully retract the boom, lower the boom,
limitations and the second red LED illuminates, the place the transmission control lever in (N)
automatic function cut-out is activated. All functions, NEUTRAL, engage the park brake and shut the
except boom extension and lower functions are engine OFF.
disabled.
• Press warning button to disable the warning buzzer. switch and the steering wheel, stating that the
When disabled, yellow LED will illuminate. machine should not be operated.
Test the LSI at the beginning of each work shift. 3. Open the engine cover. Allow the engine to cool.
1. Fully retract and level the boom, with no load. Do not 4. Disconnect the battery negative (-) cable at the
raise the boom during this test. battery negative (-) terminal.
2. Press the test button on the LSI display. This will 5. Disconnect the LSI electrical connector.
cause all LEDs to flash on and an audible warning to 6. Loosen and remove the two bolts holding the LSI
sound. This indicates that the system is functioning assembly to the rear axle.
properly. If the test gives a different result, the
system is not functioning properly and the machine 7. Remove the sensor assembly.
must be removed from service and repaired before
continued operation. b. Load Stability Sensor Installation
Note: The Load Stability Indicator is NOT a serviceable 1. Remove any retaining compound from the sensor
item. The Load Stability Indicator must be inspected and/ area. Clean both bare metal surfaces with a
or replaced by the local Caterpillar dealer. degreasing solution and allow to dry.
2. Apply a thin film of Cat High Strength/High
Temperature Retaining Compound to the flat metal
surface of the transducer, ensuring the adhesive is
spread evenly over the entire surface.
3. Fit the transducer, ensuring the lead exits in the
corner direction. If the existing bolts are not
available, use M10 x 40mm bolts with a minimum
tensile strength of 10.9. Two washers are used.
9.26 TH255
Electrical System
Note: It is important to prevent distortion of the sensor approx. 8 seconds while the calibration point is read.
element, therefore tighten the bolts alternately a small Following successful calibration of the first point, the
amount at a time, until a value of 70 Nm (50 lb-ft) is buzzer will sound for 2 seconds, the green LED will
achieved. be turned off, and the top red LED will be on
constant.
4. Leave the machine undisturbed for a minimum of 2
hours before moving. DO NOT lift any load for 4. Place a 2000 kg (4400 lbs) test weight on the forks,
minimum of 12 hours. and place the machine on a level surface with the
rear wheels on a calibrated scale. Fully retract the
5. The transducer and area around it can be painted
boom, and raise the load approximately 305 mm (12
after 12 hours of curing.
in.) above the ground. Slowly extend the boom
6. Plug the electrical connector into the sensor horizontally until the combined weight on both rear
assembly. wheels is 318 ±9 kg (700 ±20 lbs). Stop all boom
7. Connect the battery negative (-) cable to the battery movement.
negative (-) terminal. 5. Press the TEST button on the LSI display and
8. Close and secure the engine cover. release. The top red LED should flash for approx. 8
seconds while the calibration point is read. Following
c. Load Stability Indicator System Calibration successful calibration of the second point, the
buzzer will be on constant, the red LED will be
To calibrate the LSI, certain conditions must be met: turned off, and the green power LED will be on
• The sensor must be mounted according to assembly constant.
instructions at least 12 hours before calibration. 6. Turn the ignition key to OFF. LSI is now calibrated.
• The machine control system must be powered on for
at least 10 minutes before calibration.
• The calibration shall be conducted with the standard
carriage and forks attached for the machine and
weights as necessary.
• If the machine is equipped with stabilizers, they shall
remain up for the calibration procedure.
• The machine must be on a level surface with the
wheels steered straight and park brake OFF, with the
straight driving over a distance of at least 2 meters
being the last movement before entering a
calibration point.
• The calibration must be completed within 30 minutes
after starting procedure.
Calibration procedure:
1. With the ignition key in OFF position, press and hold
TEST button on LSI display and turn ignition key to
engine START position. Release the ignition key
when engine start is achieved, but continue to hold
TEST button on LSI display until the LED power
indicator on LSI display begins to flash (approx. 2
seconds). Release TEST key within 2 seconds of
power LED flashing.
2. The lower green LED of the scale should be on
constant. Position the machine with empty
attachment with boom level and fully retracted, forks
level (not contacting the ground).
3. Press the TEST button on the LSI display and
release. The lower green LED should flash for
TH255 9.27
Electrical System
9.28 TH255

Service 31200364 09-11-08 TH255 Global English

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Service Manual

September 11, 2008 - A - Original Issue Of Manual

PARAGRAPH TITLE PAGE

1.1 INTRODUCTION 1.2 DISCLAIMER

1.5 SAFETY INFORMATION 1.6 SAFETY INSTRUCTIONS

1.6.2 Equipment Hazards

1.6.3 General Hazards appropriate container and dispose of in accordance with

PARAGRAPH TITLE PAGE

2.1 REPLACEMENT PARTS AND

EARLY PRODUCTION ONLY

Note: The replacement of any part on this machine with

2.2.1 SAE Fastener Torque Chart

SAE GRADE 5 SAE GRADE 8

2.2.1 SAE Fastener Torque Chart

SAE GRADE 5 SAE GRADE 8

2.2.1 SAE Fastener Torque Chart

SAE GRADE 5 SAE GRADE 8

2.2.2 Metric Fastener Torque Chart

METRIC CLASS 8.8 METRIC CLASS 10.9

2.2.2 Metric Fastener Torque Chart

METRIC CLASS 8.8 METRIC CLASS 10.9

2.2.2 Metric Fastener Torque Chart

METRIC CLASS 8.8 METRIC CLASS 10.9

2.2.3 Hydraulic Hose Torque Chart Flats Method:

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

2.3.1 Travel Speed

12 x 16.5 Tires (Standard) 26 kmph (16 mph)

2.3.2 Hydraulic Cylinder Performance Specifications

Function Approximate Times (sec.)

2.3.3 Electrical System

2.3.4 Engine Performance Specifications

Size Tire Type Minimum Ply/ Fill Type Pressure

2.4 FLUIDS, LUBRICANTS AND

Ambient Temperature Range

Engine Crankcase Oil

Check Fuel Check Engine Check Hydraulic Check Tire

Change Fuel Change Engine Change Check Wheel

Change Axle Change Wheel Change Check Change

2.6 LUBRICATION SCHEDULE

2.6.1 250 Hour Lubrication Schedule

This Page Intentionally Left Blank

PARAGRAPH TITLE PAGE

3.1 BOOM SYSTEM COMPONENT

12. Check clearance (1) between the tilt hoses (and if

3.4.10 Extend/Retract Cylinder Installation

3.5 BOOM WEAR PADS

3.5.1 Wear Pad Inspection

3.5.2 Boom Wear Pad Replacement

3.6 QUICK COUPLER ASSEMBLY 3.6.2 Quick Coupler Installation

5. If equipped with a hydraulic quick coupler device,

3.7 FORKS 3.8 BOOM PROP (IF EQUIPPED)

7. Shut engine OFF. 3.9.1 Equipment and Supplies Required

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

Problem Possible Causes Remedy

2. Extend/Retract hydraulic system 2. Refer to Section 8, “Hydraulic

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

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

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

2. Lift/lower hydraulic system not 2. Refer to Section 8, “Hydraulic

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

Problem Possible Causes Remedy

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

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