Description

Caterpillar TH255 2012 Service Manual

Caterpillar TH255 2012 Service Manual – you want to fix a telehandler right, you start with the factory documentation. I’ve seen too many guys grab aftermarket PDFs and then wonder why the boom doesn’t lift or the torque converter slips. That’s what happens when you trust a reprint. This is the real thing: OEM Caterpillar, revised February 8, 2012, covering serial numbers TBS00100 and after. 174 pages. Not a supplement. Not a generic write-up. Factory procedure, start to finish.

If you’re a shop owner or a home garage guy trying to keep your TH255 running, you already know the pain of guessing on a hydraulic hose torque or a cab mount bolt. That guess costs you time and sometimes a busted part. This manual takes that guess off the table. You get the exact SAE and Metric fastener torque charts from Section 2.2, the fluid capacities from Section 2.4, and the maintenance schedules so you don’t skip a 50-hour lube point. That’s the difference between a machine that works and one that sits in the yard.

Seven systems covered: Safety, General Info, Boom, Cab, Axles/Driveline, Transmission, and more. Each section opens with component terminology so you know what they call that part on the factory floor. Then it goes into removal, installation, inspection. No fluff. Just procedure.

Caterpillar TH255 2012 Service Manual: Factory Documentation

When you buy this manual, you’re getting the same document the dealer techs use. Section 1 alone is seven pages of safety practices – not warnings you can skip. That includes the Safety Alert System, Do Not Operate Tags, and decal locations. I’ve had guys argue with me that they don’t need to read safety. Those are the same guys who end up with a hydraulic oil burn or a dropped boom. Read Section 1. Every time.

Section 2 is where you’ll live. Torques for SAE and Metric fasteners, hydraulic hose torque chart, travel speeds, cylinder performance specs, electrical system data, engine specs, tire data – all on pages you can tab. Need to know the 250-hour lubrication schedule? It’s right there in 2.6.1. That schedule alone saves you from a dry U-joint on a Saturday.

Torque Specs and Fluid Capacities

The manual includes the full SAE Fastener Torque Chart and Metric Fastener Torque Chart in Section 2.2. I cannot stress this enough: do not use a generic torque chart from the internet for hydraulic fittings on a TH255. The hose torque chart in 2.2.3 is specific to Caterpillar hose ends. Over-torque a fitting and you crack the ferrule. Under-torque and you get a leak at 3,000 psi. The fluids and capacities table in Section 2.4 tells you exactly how much hyd oil, engine oil, and coolant the system holds. That’s data you don’t guess.

Does the Manual Cover the Boom System?

Yes, and it covers it in depth. Section 3 runs from page 3-1 through the boom troubleshooting guide. You get the two-section boom system description, removal and installation procedures for first and second boom sections, extend/retract cylinder service, wear pad inspection and lubrication (3.5), quick coupler removal and install, fork info, and the emergency boom lowering procedure (3.9). If you’ve ever had a TH255 boom stick in the air with a dead engine, that emergency procedure is what you need. It lists the equipment and supplies required and the exact steps to get it down safely. Don’t try that without reading Section 3.9.

Look at the Safety Section First

I mentioned it already, but I’m saying it again because people skip it. Section 1 covers personal hazards, equipment hazards, general hazards, operational hazards, and safety decals. The manual also includes a disclaimer and tells you to use the Operation & Maintenance Manual alongside this service manual. If you don’t have the OMM, get it. The service manual assumes you know how to safely block and support the machine. It tells you the steps – you have to follow them. Section 1.6.2 Equipment Hazards is particularly relevant when you’re working under a raised boom. Read it.

174 Pages of Factory Data

Count them: 174 pages. That’s enough to cover the cab and covers (Section 4) with steering wheel, column, brake pedal, throttle pedal, joystick, wiper/washer, and heater/defroster procedures. Section 5 gets into axles, drive shafts, wheels, tires, steering angle adjustment, brake disc inspection, and towing a disabled machine. Section 6 is transmission assembly component terminology – not a full rebuild, but the terminology and torque specs you need if you’re pulling the transmission. For a full factory overhaul on the engine or transmission, look at the Caterpillar C175, 3600, C8.7, C12.9 2016 Service Manual – Factory Tool Catalog or the Caterpillar 3500B 2002 Service Manual – Factory Specs. The TH255 manual gives you the base structure.

If you need parts ordering, grab the Caterpillar TH255 2011 Parts Catalog – that’s separate but works with this service manual. For understanding the transmission basics, read up on Manual Transmission principles on Wikipedia. Similarly, if you’re doing driveline work, a refresher on Manual Transmission theory helps. But the service manual’s procedure is what you follow on the job.

This is factory OEM. Not a copy. Not a reprint from a third party. The page you see is the same page the Caterpillar technician uses. If you’re serious about keeping your TH255 running without chasing leaks or stripped threads, this is the document.

FAQ

Does this manual include wiring diagrams?

Yes, Section 2.3.3 covers the electrical system specifications. However, the manual does not include full wiring schematics – that is in the electrical schematic supplement. This service manual lists component locations, wire colors, and voltage specs.

What about transmission service procedures?

Section 6 lists transmission assembly component terminology – you get the part names and basic removal/installation references. For a full overhaul with bearing clearances and clutch pack shimming, you need the separate transmission overhaul manual. The service manual does include torque specs for transmission bolts in Section 2.2.

Is this manual in printed format or digital PDF?

The digital PDF is what you get – 174 pages, fully searchable, printable. You can put it on a tablet in the shop or print specific pages for the job. It’s the same factory file, not a scan.

Can I use this manual for a TH255 with an older serial number?

This edition covers S/N TBS00100 and after. For earlier serial numbers, check the effectivity page – the original issue was September 2008, revision A. This revision B includes updates to pages 1.3, 2.14-2.17, and several others. If your machine is older, some procedures may differ. Verify with the dealer.

Stop wasting time with aftermarket guesswork. Access the Factory Manual now and get the same torque specs, the same safety notes, and the same step-by-step procedures that keep your TH255 in the field instead of the shop.