Caterpillar TH255/TH255C Axle Service Manual
SN TBS00100 to Present
SN JK200150 to Present
SN JK300150 to Present
Print No: 31200451, Revised 2014
Type of machine: Telehandler
Language and Format: English/PDF
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The Service Manual will give you complete information on repair, servicing and preventative maintenance for Caterpillar TH255/TH255C Axle.
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Table of contents:
Section 1 – SAFETY PRACTICES
1.1 Introduction
1.2 Disclaimer
1.3 Operation & Maintenance Manual
1.4 Do Not Operate Tags
1.5 Safety Information
1.6 Safety Alert System and Signal Words
1.7 Safety Instructions
1.8 Safety Decals
Section 2 – GENERAL INFORMATION AND SPECIFICATIONS
2.1 Introduction
2.2 Specifications
2.3 Conversion Tables
2.4 Torque Specifications
2.5 Maintenance
2.6 Safety Precautions
Section 3 – PLANETARY REDUCTION 1:6 AND STEERING CASE
3.1 Exploded View
3.2 Planetary Reduction – 1.6 and Steering Case – Disassembly
3.3 Planetary Reduction – 1.6 and Steering Case – Assembly
Section 4 – STEERING CYLINDER
4.1 Exploded View
4.2 Steering Cylinder – Disassembly
4.3 Steering Cylinder – Assembly
Section 5 – BRAKE: SERVICE BRAKE, NEGATIVE BRAKE, 45% LOCKED & 100% LOCKED
5.1 Exploded View
5.2 Brake Working Conditions
5.3 Emergency Release Instructions
5.4 Reset of Fails Safe Brake Function
5.5 Brake: Service Brake, Negative Brake, 45% Locked & 100% Locked- Disassembly
5.6 Brake: Service Brake, Negative Brake, 45% Locked & 100% Locked – Assembly
5.7 Brake Piston Gap Check
Section 6 – BRAKE: NEGATIVE BRAKE 4 CUP SPRINGS VERSION
6.1 Exploded View
6.2 Brake: Negative Brake 4 Cup Springs Version – Disassembly
6.3 Brake: Negative Brake 4 Cup Springs Version – Assembly
Section 7 – NORMAL PRELOADED DIFFERENTIAL UNIT (Old Version)
7.1 Exploded View
7.2 Normal Preloaded Differential Unit (Old Version) – Disassembly
7.3 Normal Preloaded Differential Unit (Old Version) – Assembly
Section 8 – NORMAL PRELOADED DIFFERENTIAL UNIT (Intermediate Version)
8.1 Exploded View
8.2 Normal Preloaded Differential Unit (Intermediate Version) – Disassembly
8.3 Normal Preloaded Differential Unit (Intermediate Version) – Assembly
Section 9 – NORMAL PRELOADED DIFFERENTIAL UNIT (Last Version)
9.1 Exploded View
9.2 Normal Preloaded Differential Unit (Last Version) – Disassembly
9.3 Normal Preloaded Differential Unit (Last Version) – Assembly
Section 10 – FLANGED REDUCTION GEAR 603 TYPE: INTEGRAL 603 INPUT GEAR
10.1 Exploded View
10.2 Flanged Reduction Gear 603 Type: Integral 603 Input Gear – Disassembly
10.3 Flanged Reduction Gear 603 Type: Integral 603 Input Gear – Assembly
Section 11 – BEVEL PINION: NORMAL FLANGE AND NUT REVOLUTION COUNTER VERSION
11.1 Exploded View
11.2 Bevel Pinion: Normal Flange and Nut Revolution Counter Version- Disassembly
11.3 Bevel Pinion: Normal Flange and Nut Revolution Counter Version – Assembly
Section 12 – RING AND PINION ADJUSTING: STEP FOR PRELOADED DIFFERENTIAL
12.1 Exploded View
12.2 Ring and Pinion Adjusting: Step for Preloaded Differential – Install and Adjust
Section 13 – SWINGING SUPPORT
13.1 Exploded View
13.2 Swinging Support – Disassembly
13.3 Swinging Support – Assembly
Section 14 – PLANETARY REDUCTION: 1:4, 23
14.1 Exploded View
14.2 Planetary Reduction: 1:4, 23 – Disassembly
14.3 Planetary Reduction: 1:4, 23 – Assembly
Section 15 – BRAKE: INCOMING DISC BRAKE
15.1 Exploded View
15.2 Brake: Incoming Disc Brake – Disassembly
15.3 Brake: Incoming Disc Brake – Assembly
15.4 Checking Wear and Replacing the Braking Pads
Section 16 – BRAKE: SERVICE AND MECHANICAL PARKING BRAKE
16.1 Exploded View
16.2 Brake: Incoming Disc Brake – Disassembly
16.3 Brake: Incoming Disc Brake – Assembly
Section 17 – BRAKE: PARKING AND DIFFERENTIAL HYDRAULIC 100%
17.1 Exploded View
17.2 Brake: Incoming Disc Brake- Disassembly
17.3 Brake: Incoming Disc Brake- Assembly
Section 18 – DIFFERENTIAL WITH BLOCK TO SPHERES 100% (Old Version)
18.1 Exploded View
18.2 Differential With Block to Spheres 100% (Old Version) – Disassembly
18.3 Differential With Block to Spheres 100% (Old Version) – Assembly
Section 19 – DIFFERENTIAL WITH BLOCK TO SPHERES 100% (Last Version)
19.1 Exploded View
19.2 Differential With Block to Spheres 100% (Last Version)- Disassembly
19.3 Differential With Block to Spheres 100% (Last Version)- Assembly
Section 20 – NORMAL DIFFERENTIAL (Old Version)
20.1 Exploded View
20.2 Normal Differential (Old Version) – Disassembly
20.3 Normal Differential (Old Version) – Assembly
Section 21 – NORMAL DIFFERENTIAL (Last Version)
21.1 Exploded View
21.2 Normal Differential (Last Version) – Disassembly
21.3 Normal Differential (Last Version) – Assembly
Section 22 – LIMITED SLIP DIFFERENTIAL UNIT 45% (Old Version)
22.1 Exploded View
22.2 Limited Slip Differential Unit 45% (Old Version) – Disassembly
22.3 Limited Slip Differential Unit 45% (Old Version) – Assembly
Section 23 – LIMITED SLIP DIFFERENTIAL UNIT 45% (Last Version)
23.1 Exploded View
23.2 Limited Slip Differential Unit 45% (Last Version) – Disassembly
23.3 Limited Slip Differential Unit 45% (Last Version) – Assembly
Section 24 – PRELOADED LIMITED SLIP DIFFERENTIAL UNIT 45% Unit (Old Version)
24.1 Exploded View
24.2 Preloaded Limited Slip Differential Unit 45% Unit (Old Version) – Disassembly
24.3 Preloaded Limited Slip Differential Unit 45% Unit (Old Version) – Disassembly
Section 25 – PRELOADED LIMITED SLIP DIFFERENTIAL UNIT 45% (Intermediate Version)
25.1 Exploded View
25.2 Preloaded Limited Slip Differential Unit45% (Intermediate Version) – Disassembly
25.3 Preloaded Limited Slip Differential Unit 45%(Intermediate Version) – Assembly
Section 26 – PRELOADED LIMITED SLIP DIFFERENTIAL UNIT 45%(Last Version)
26.1 Exploded View
26.2 Preloaded Limited Slip Differential Unit 45%(Last Version) – Disassembly
26.3 Preloaded Limited Slip Differential Unit 45%(Last Version) – Assembly
Section 27 – BEVEL PINION: FLANGED TO REDUCTION GEAR 603
27.1 Exploded View
27.2 Bevel Pinion: Flanged to Reduction Gear 603 – Disassembly
27.3 Bevel Pinion: Flanged to Reduction Gear 603 – Assembly
Section 28 – RING AND PINION ADJUSTING: VERSION PINION COVER AND SINGLE ARM
28.1 Exploded View
28.2 Ring and Pinion Adjusting: Version Pinion Cover and Single Arm – Install and Adjust
Section 29 – RING AND PINION ADJUSTING: VERSION PINION INTEGRAL AND DOUBLE ARM
29.1 Exploded View
29.2 Ring and Pinion Adjusting: Version Pinion Integral and Double Arm -install and Adjust
Section 30 – SPECIAL TOOLS
30.1 T1
30.2 T2
30.3 T3
30.4 T4
30.5 T5
30.6 T6
30.7 T7
30.8 T8
30.9 T9
30.10 T10
30.11 T11
30.12 T12
30.13 T13
30.14 T14
30.15 T16
30.16 T17
30.17 T18