Models
TL642
TL943
S/N TBK00100 & After
S/N TBL00100 & After
31200292
Revised
June 18, 2013
EFFECTIVITY PAGE
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4 Fluids and Lubricant Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.5 Service and Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Section 3
Boom ........................................................... 3-1
3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Boom System - Three Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Complete Boom Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.5 Boom Section Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.6 Extend/Retract Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.7 Push Beam - Extend/Retract Cylinder Removal/Installation . . . . . . . . . . . . . . . . . . . . . 3-16
3.8 Boom Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.9 Boom Head - Mounted Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.10 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.11 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.12 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.13 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.15 Push Beam Temporary Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
TL642, TL943 i
Section Subject Page
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Axles, Drive Shafts, Wheels and Tires Component Terminology . . . . . . . . . . . . . . . . . . 5-2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.7 Towing a Disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Section 6
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Transmission Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5 Torque Convertor Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Section 7
Engine ........................................................... 7-1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.8 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.10 Engine Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.6 Engine Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.7 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.8 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
ii TL642, TL943
Section Subject Page
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.3 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.6 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.7 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.8 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.9 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.10 Cab Heater/AC and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.11 Switches, Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.12 Gauges and Display Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.13 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9.14 Hand Held Analyzer(S/N TBL01599 & After including TBL01551 & TBL01585) . . . . . . 9-38
9.15 Engine Diagnostic and Event Codes (S/N TBK01167 & After including TBK01162;
S/N TBL01599 & After including TBL01551 & TBL01585) . . . . . . . . . . . . . . . . . . . . . . 9-47
iv TL642, TL943
Section 1
Safety Practices
Contents
1.6.4 Operational Hazards PRESSURE TESTING: When conducting any test, only
use test equipment that is correctly calibrated and in good
ENGINE: Stop the engine before performing any service
condition. Use the correct equipment in the proper
unless specifically instructed otherwise.
manner, and make changes or repairs as indicated by the
VENTILATION: Avoid prolonged engine operation in test procedure to achieve the desired result.
enclosed areas without adequate ventilation.
LEAVING MACHINE: Lower the forks or attachment to
SOFT SURFACES AND SLOPES: NEVER work on a the ground before leaving the machine.
machine that is parked on a soft surface or slope. The
TIRES: Always keep tires inflated to the proper pressure
machine must be on a hard level surface, with the wheels
to help prevent tipover. DO NOT over-inflate tires.
blocked before performing any service.
NEVER use mismatched tire types, sizes or ply ratings.
FLUID TEMPERATURE: NEVER work on a machine
Always use matched sets according to machine
when the engine, cooling or hydraulic systems are hot.
specifications.
Hot components and fluids can cause severe burns.
Allow systems to cool before proceeding. MAJOR COMPONENTS: Never alter, remove, or
substitute any items such as counterweights, tires,
FLUID PRESSURE: Before loosening any hydraulic or
batteries or other items that may reduce or affect the
diesel fuel component, hose or tube, turn the engine
overall weight or stability of the machine.
OFF. Wear heavy, protective gloves and eye protection.
NEVER check for leaks using any part of your body; use BATTERY: DO NOT charge a frozen battery.Charging a
a piece of cardboard or wood instead. If injured, seek frozen battery may cause it to explode. Allow the battery
medical attention immediately. Diesel fluid leaking under to thaw before jump-starting or connecting a battery
pressure can explode. Hydraulic fluid and diesel fuel charger.
leaking under pressure can penetrate the skin, cause
infection, gangrene and other serious personal injury. 1.7 SAFETY DECALS
Relieve all pressure before disconnecting any
Check that all safety decals are present and readable on
component, part, line or hose. Slowly loosen parts and
the machine. Refer to the Operation & Maintenance
allow release of residual pressure before removing any
Manual supplied with machine for information.
part or component. Before starting the engine or applying
pressure, use components, parts, hoses and pipes that
are in good condition, connected properly and are
tightened to the proper torque. Capture fluid in an
appropriate container and dispose of in accordance with
prevailing environmental regulations.
RADIATOR CAP: The cooling system is under pressure,
and escaping coolant can cause severe burns and eye
injury. To prevent personal injury, NEVER remove the
radiator cap while the cooling system is hot. Wear safety
glasses. Turn the radiator cap to the first stop and allow
pressure to escape before removing the cap completely.
Failure to follow the safety practices could result in death
or serious injury.
FLUID FLAMABILTITY: DO NOT service the fuel or
hydraulic systems near an open flame, sparks or smoking
materials.
NEVER drain or store fluids in an open container. Engine
fuel and hydraulic fluid are flammable and can cause a
fire and/or explosion.
DO NOT mix gasoline or alcohol with diesel fuel. The
mixture can cause an explosion.
1
MAL0500
MY3141
MY3151
MY3161
MY3400
Torque
Torque (Loctite®
Tensile Torque TM
Clamp Torque (Loctite® 262 242 or 271TM
TM
Size Pitch Stress (Dry or Loctite®
Load (Lub) OR Vibra- OR Vibra-
Area 263TM)
TITETM 131) TITETM 111 or
140)
Torque
Torque (Lub OR Loctite® Torque
Tensile
Clamp (Dry or Loctite® 242TM or 271TM OR (Loctite® 262TM OR
Size Pitch Stress
Load 263TM) Vibra-TITE TM 111 or Vibra-TITE TM 131)
Area
K = 0.20 140) K=0.15
K= 0.18
Torque
Torque
Torque (Lub OR Loctite®
Tensile TM TM (Loctite® 262TM
Clamp Load (Dry or Loctite® 242 or 271
Size Pitch Stress OR Vibra-TITE TM
See Note 4 263TM) OR Vibra-TITE TM
Area 131)
K = .17 111 or 140)
K = .15
K = .16
3 0.5 5.03
3.5 0.6 6.78
4 0.7 8.78
5 0.8 14.20
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 54
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 220.0 900 845 790
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.
MY3191
2.3 SPECIFICATIONS
TL642 TL943
First Gear 3.4 mph (5,5 km/h) 2.9 mph (4,7 km/h)
Second Gear 6.1 mph (9,7 km/h) 5.2 mph (8,4 km/h)
Third Gear 13.7 mph (22,0 km/h) 11.4 mph (18,3 km/h)
Fourth Gear 20.4 mph (32,8 km/h) 17.5 mph (28,2 km/h)
Battery
Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free
Quantity 1
Reserve Capacity 1000 Cold Cranking Amps @ 0° F (-18° C)
Group/Series Group 31
Alternator (with Optional A/C) 12V, 65 Amps (12V, 105 Amps)
Alternator (Tier III) 12V, 100 Amps
2.3.6 Tires
Note: Standard wheel lug nut torque is 350-400 lb-ft (475-542 Nm).
Note: Pressure for foam filled tires are for initial fill ONLY.
Minimum Ply/
Size Tire Type Fill Type Pressure
Star Rating
Pneumatic 65 psi (4,5 bar)
13.00 x 24 G2/L2 Bias Ply Traction 12 Ply
Foam - Approx 542 lb (246 kg) 65 psi (4,5 bar)
Pneumatic 65 psi (4,5 bar)
13.00 x 24 G3/L3 Bias Ply Rock 12 Ply
Foam - Approx 542 lb (246 kg) 65 psi (4,5 bar)
Pneumatic 70 psi (4,8 bar)
13.00 x 24 G2/L-2 Radial 1 Star
Foam - Approx 542 lb (246 kg) 75 psi (5,1 bar)
13.00 x 24 Solid - 799 lb (362,4 kg)
Pneumatic 58 psi (4,0 bar)
15.50 x 25 G2/L2 Bias Ply Traction 12 Ply
Foam - Approx 600 lb (272 kg) 58 psi (4,0 bar)
Pneumatic 65 psi (4,5 bar)
15.50 x 25 G3/L3 Bias Ply Rock 12 Ply
Foam - Approx 600 lb (272 kg) 58 psi (4,0 bar)
Pneumatic 70 psi (4,8 bar)
15.50 x 25 G2/L2 Radial 1 Star
Foam - Approx 600 lb (272 kg) 73 psi (5,0 bar)
Pneumatic 76 psi (5,2 bar)
370/75x28 DuraForce 14 Ply
Foam - Approx 464 lb (210 kg) 73 psi (5,0 bar)
a. Fluids
Axle Differential* CAT Gear Oil (GO) SAE 80W-90 -10 120 -23 49
and Wheel End CAT Gear Oil (GO) SAE 85W-140 10 120 -12 59
CAT TDTO-TMS CAT TDTO-TMS -4 122 -20 50
SAE 0W-20 -40 104 -40 40
SAE 0W-30 -40 104 -40 40
SAE 5W-30 -22 104 -30 40
CAT TDTO
SAE 5W-40 -22 104 -30 40
CAT TDTO-TMS
Hydraulic System SAE 10W -4 104 -20 40
CAT Arctic TDTO SYN
SAE 30 50 122 10 50
Commercial TO-4
SAE 10W-30 -4 104 -20 40
SAE 15W-40 5 122 -15 50
CAT TDTO-TMS -4 122 -20 50
Boom Wear Pad
CAT Advanced 3Moly NLGI Grade 2 -4 104 -20 40
Grease
Cylinder and Axle
CAT Multipurpose NLGI Grade 2 -22 104 -30 40
Grease
Note: Friction Modifier (CAT Brake Oil Additive P/N 197-0017) required for axle differentials, see Section b,
“Capacities”.
b. Capacities
EVERY
10
Check Fuel Air Filter Check Engine Check Hydraulic Check Tire
Level Restriction Oil Level Oil Level Condition &
Indicator Pressure
Check Additional
Transmission Checks -
Oil Level Section
OMM 8
1st
50
LB/F
T (N
m)
Check Wheel
Lug Nut
Torque
EVERY
50
1st
250
EVERY
250
EVERY
500
LB/F
T (N
m)
Note: Engine oil and filter service interval can be extended. See Engine Manual for details.
EVERY
1000
EVERY
1500
a. 50 Hour
EVERY
50
2
2 B
B
B
B 2
2 2
B B 2
B B
2 B 2
2
2
2 2
2
2
4
2
2
IF EQUIPPED
OAL0321
b. 250 Hour
EVERY
250
2
2 B
B
B
B 2
2
B
2 B B B
2 2 2
2 2
2 2
IF EQUIPPED
OAL0912
c. 1000 Hour
EVERY
1000
B B
IF EQUIPPED
OAL2680
Contents
SECOND BOOM
SECTION
EXTEND CHAIN
(INSIDE BOOM)
FIRST BOOM
SECTION
THIRD BOOM
SECTION
HOSE SHEAVE
(INSIDE BOOM) MY0112
PIVOT PIN
WARNING
NEVER weld or drill the boom unless approved in
writing by the manufacturer. The structural integrity of
the boom will be impaired if subjected to any repair
involving welding or drilling.
3.4 COMPLETE BOOM REMOVAL/ 14. Lift the boom assembly from the machine and lower
INSTALLATION onto suitable supports.
15. Remove the Do Not Operate Tags from both the all open hoses, tubes and/or fittings to prevent dirt
ignition key switch and the steering wheel. and debris from entering the hydraulic system.
16. Install the previously removed attachment to the 4. Slowly loosen and remove the extend/retract
quick coupler assembly. Refer to Section 3.9, “Boom cylinder counterbalance valve (3). Plug (M27x1.5)
Head - Mounted Winch.” the open port on the extend/retract cylinder to
prevent dirt and debris from entering the hydraulic
3.5 BOOM SECTION REMOVAL/ system.
INSTALLATION 5. Remove the retaining clips from the extend/retract
cylinder mounting pin (4), remove the extend/retract
cylinder pin.
3.5.1 Second and Third Boom Section
Removal 6. Remove the four mounting bolts securing the strong
back (5) to the first boom section.
Note: Refer to Section 3.13.2, 3.15. “Push Beam
Temporary Brackets,” for diagrams of the Temporary 7. Remove the strong back (5) from the rear of the
Extend Bracket and Temporary Retract Bracket boom.
designed to hold the chains in place on the push beam 8. Remove the right or left side wear pads, shims and
during disassembly and reassembly. backing plates (6) from the rear of the second boom
These brackets are NOT a purchasable part and must be section. Label and tag each set of wear pads being
manufactured locally. removed.
They are solely designed to aid in the removal and 9. Remove the top wear pads, shims and backing
installation of the push beam assembly. plates (7) from the rear of the second boom section.
Label and tag each set of wear pads being removed.
Note: Refer to Section 8.8, “Hydraulic Cylinders.” for
general tilt cylinder removal. 8 11
5
8
4
MY3860
TL943 10. Loosen and remove the four bolts (8) securing the
3 retract chain anchor plate (9).
11. Between the bottom front of the first and second
2 2 boom sections, feed a rope or wire to the retract
6 6 chain anchor plate and secure to the second or third
boom section.
12. Disconnect both tilt tubes (10) and (if equipped) both
auxiliary tubes from the fittings on the hose retainer
brackets (11) at the bottom front inside the boom.
Plug the tube ends to prevent dirt and debris from
MY3851
entering the hydraulic system.
13. Disconnect both tilt hoses (not shown) and (if
2. Remove the locknut, jam nut and six belleville
equipped) both auxiliary hoses from the hose
washers (1) from the extend chain clevis rod at the
retainer brackets at the bottom front inside the boom.
rear of the boom.
Plug the hose ends to prevent dirt and debris from
3. Loosen and remove both extend/retract cylinder entering the hydraulic system.
tubes (2) from the rear of the boom. Cap and/or plug
14. Loosen and remove the hose retainer brackets (11)
and (if equipped) both auxiliary take-up brackets.
15. Between the bottom front of the first and second 1. Loosen and remove the tilt cylinder hose guide (1)
boom sections, feed a rope or wire to both tilt hoses and if equipped, the auxiliary hose guide from the
(not shown) and (if equipped) both auxiliary hoses rear of the third second section.
and secure to the second or third boom section.
Note: The hose guide mounting bolts also hold the push
16. Place a suitable sling around the second boom pin beams in place.
section. Slowly pull the second and third boom
sections approximately 25% out of the first boom 2. Loosen and remove all retract chain sheave
section. Lower the second and third boom sections components (2) and the hydraulic hose rollers and
onto a suitable support. components.
Note: Offset the extend chain rod to the left or right of
the push beam assembly allowing the push beam to be
raised enough to allow the removal of the chain and
12 hose sheaves.
13 12
13
12 12
4 3
MY3840
5
17. Remove all wear pads, shims and backing plates
(12) from the front inside of the first boom section. 6 MY4070
8 7
1 1
MY4110
6. Loosen and remove the tilt hose and auxiliary hose 12. Relocate the sling or using two slings for better
retainers (7 & 8) from the front of the third boom stability, balance the third boom section and slowly
section. pull the third boon section out of the second boom
10 10 section. Lower the third boom section onto suitable
supports.
CAUTION
The complete push beam assembly weighs over
1,200 lb (545 kg).
9 9
MY3890
10 11
7. Loosen the Temporary Extend Chain Bracket (9).
8. Apply CAT Thread Lubricant to the clevis mounting
pin (10).
9. Lift the push beam and install the pin and retaining
clips (10) securing the clevis to the third boom
section.
10. Remove the Temporary Retract Chain Bracket (11). 15 15
14 14
MY3890
4. Lower the third boom section onto a suitable 14. Secure the retract chain, tilt cylinder hoses and if
support, relocate one sling and insert the third boom equipped, auxiliary hoses to the bottom of the boom
section assembly approximately 75% into the head with rope or wire.
second boom section.
Note: Keep the retract and extend chain free of any dirt
and/or contaminates.
3
15. Remove the Temporary Extend Chain Bracket.
4 4
5 5 7
1
4 2 2 4
MY3870
11 11
12 12 17
16 16
15 15
MY3880 MY3880
20. Align the push beam bores with the second boom 24. Install the previously removed wear pad and spacer
section bores and install the previously removed (15) on the bottom rear of the second boom section.
pins (11). Snug mounting bolts. Shim as needed AFTER boom
section is installed. Refer to Section 3.10.2, “Wear
Note: Verify the cross holes in push beam pins align
Pad Installation and Lubrication,” for detailed
with holes in each pin bore on the second boom section.
information.
21. Install the previously removed tilt cylinder hose guide 25. Install the previously removed wear pad and spacer
(12) and if equipped, the auxiliary hose guide at the (16) on the left or right side of the second boom
rear of the third boom section using the existing section. Snug mounting bolts. Shim as needed
hardware. Torque as required. AFTER boom section is installed. Refer to Section
14 14 3.10.2, “Wear Pad Installation and Lubrication,” for
detailed information.
26. Install the previously removed counterbalance valve
(17). Torque to 44 lb-ft (59,7 Nm).
27. Torque all wear pad mounting bolts as required.
11
4 4
3 9 9
5 5 MY3990
9. Install the previously removed wear pads, spacers 16. Install the previously removed wear pad and spacer
and shims at both sides on the front of the first boom (12) on the left or right side of the second boom
section (5). Snug mounting bolts. section. Snug mounting bolts. Shim as needed
AFTER boom section is installed. Refer to Section
3.10.2, “Wear Pad Installation and Lubrication,” for
detailed information.
17. Install the previously removed wear pad and spacer
(13) on the top of the second boom section. Snug
mounting bolts. Shim as needed AFTER boom
section is installed. Refer to Section 3.10.2, “Wear
7 MY3980
7 6 Pad Installation and Lubrication,” for detailed
10. Install the anchor plate (6) using existing hardware information.
(7) into the first boom section. Torque as required.
8. Remove the extend chain locknut and jamnut (6) 2. Connect the extend chain to the wire or rope at the
from the strong back. rear of the boom.
3. Slowly pull the wire or rope guiding the extend chain
over the push beam, around the extend chain
sheave, under the push beam and stopping at the
extend chain/retract chain clevis.
4. Remove the wire or rope secured to the extend
chain.
CAUTION
The complete push beam - extend/retract cylinder
TL943
assembly weighs over 1,200 lb (545 kg).
section.
MY3851
16
15
11 11
14
10 10
13
12
9 9 MY3930
15. Loosen and remove the four bolts (12), guide bar
(13) and chain retainer (14) from the front of the
push beam.
16. Disconnect the extend chain (15) from the anchor
MAL1290 rod (16) and lay flat on the bottom of the third boom
section. Remove the anchor rod (16) from the front
Note: Disconnecting one or both extend/retract of the boom.
hydraulic tubes (9) may be required to gain access to the
Note: It may be necessary to lift the extend /retract
hose guide mounting bolts. After removing both hose
cylinder through the access holes in the sides of the third
guides, re-connect one or both extend/retract hydraulic
boom section to remove the chain retainer (14).
tubes BEFORE proceeding.
10. Loosen and remove the tilt cylinder hose guide (10)
and if equipped, the auxiliary hose guide from the 19
rear of the third second section.
20
Note: The hose guide mounting bolts also hold the push
pin beams in place. 20
18
11. Remove the left and right push beam pins (11). 20
12. Start the machine and SLOWLY extend the extend/
retract cylinder 1 - 2 ft (305 - 609 mm) or until the 17 17
push beam assembly can be accessed through the
front of the third boom section.
Note: Only the push beam - extend/retract cylinder MAL1290
assembly should move during this procedure.
17. At the rear of the boom, remove both retaining clips
(17) from the extend/retract cylinder pin (18).
NOTICE Remove the extend/retract cylinder pin from the
strong back (19).
The extend chain rod will move toward the front of
18. Loosen and remove the eight bolts (20) from the
boom. Do Not allow the rod to come into contact with
strong back (19). Remove the strong back.
the chain and/or chain roller.
19. Remove both extend/retract cylinder hydraulic tubes.
13. Shut machine OFF. Plug the tube ends and cap the fittings to prevent dirt
14. Properly disconnect the battery. and debris from entering the hydraulic system.
2
NOTICE 3
2
Guide the push beam - extend/retract cylinder
4 4
assembly over the top of the retract chain anchor at
the rear of the third boom section being careful not to
damage any components.
22. Relocate the sling or using two slings for better MAL1290
stability, balance the push beam - extend/retract
5. Install the strong back (1) with the previously
cylinder assembly and slowly pull the push beam -
removed hardware (2) and torque as required.
extend/retract cylinder assembly out of the boom
assembly. Lower the push beam - extend/retract 6. Align the extend/retract cylinder bore with the strong
cylinder assembly onto suitable supports. back bores and install the extend/retract cylinder pin
(3) and secure with the retaining clips (4).
23. Remove the extend/retract cylinder as required.
7. Install the anchor rod through the front of the boom
3.7.2 Push Beam - Extend/Retract Cylinder assembly.
Installation
6
1. Clean and lubricate the bottom and sides of the third
boom section where the push beam guide bar 5
travels.
2. Place a sling or using two slings for better stability, 8
lift and slowly push the push beam - extend/retract
cylinder assembly approximately half way into the 7
boom head assembly. Lower the push beam onto a
suitable support.
3. Relocate the sling and slowly insert the push beam - 9
extend/retract cylinder assembly into the front of the
MY3930
boom assembly.
8. Connect the extend chain (5) to the anchor rod (6).
NOTICE 9. Install the guide bar (7) and chain retainer (8) to the
front of the push beam with the previously removed
Guide the push beam - extend/retract cylinder hardware (9).
assembly over the top of the retract chain anchor at
the rear of the third boom section being careful not to 10. Properly connect the battery.
damage any components. 11. Start the machine and SLOWLY retract the extend/
retract cylinder until the push beam assembly bores
4. Remove the plugs and caps from the extend/retract can be aligned with boom sections access bores.
cylinder hydraulic tubes. Install both extend/retract
cylinder hydraulic tubes. 12. Properly disconnect the battery.
11 11
TL943
18 17
MY3861
MAL1290 17. Remove the rope or wire from the retract chain (16).
13. Install both push beam pins (10) being careful to 18. Install the belleville washers (17) to the retract chain
align the pin mounting bolt holes. clevis (16) as previously removed at the bottom front
of the first boom section.
Note: Disconnecting one or both extend/retract
19. Install the adjusting and jamnut (18) to the retract
hydraulic tubes (11) may be required to gain access to
chain clevis (16) at the bottom front of the first boom
the hose guide mounting bolts. After installing both hose
section.
guides, re-connect one or both extend/retract hydraulic
tubes BEFORE preceding. Note: Note the position of the belleville washer for
reassembly.
14. Install the tilt cylinder hose guide (12) and the
auxiliary hose guide from the rear of the third second
section.
14 20
TL642
15 13
TL943
19
MAL1310
24. Adjust the chain as needed. Refer to Section 3.8, 6. At the bottom front of the boom, check dimension “B”
“Boom Adjustments.” 1.634 in (41,5 mm) on the retract chain clevis.
25. Install the cover on the rear of the boom.
26. Close and secure the engine cover.
27. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
1 3 4
MAL2560 2
5. At the boom head, check dimension “A” 11.625 to
11.938 in (295,2 to 303,2 mm).
B MAL2550
1. Remove the lock nut (1) from the retract chain clevis
(2).
2. Set the retract chain adjustment nut face (3) flush
with the end of the retract clevis.
3. Verify the belleville washers (4) are in the correct
order as shown. Remove the retract chain
adjustment nut (3) and correct if required.
B MAL2600
7 6 7 6
5 5
MAL2570 C MAL2570 C
4. Remove the extend chain lock nut (5) and loosen 8. With dimension “A” less than 11.625 in
adjustment nut (6) until the belleville washers (7) are (295,2 mm), verify the extend rod Belleville washers
free to turn on the extend rod. and the retract chain Belleville washers are loose.
5. Verify the belleville washers (7) are in the correct Tighten the extend chain rod adjusting nut (6) until
order as shown. Remove the extend chain dimension “A” is 12.125 to 12.250 in
adjustment nut (6) and correct if required. (307,9 to 311 mm).
9. Install and temporarily tighten the extend chain lock
Note: Belleville washers are shown in the un-
nut (5).
compressed state.
A
1 3 4
B MAL2550
10. Tighten the retract chain adjustment nut (3) until the
belleville washers (4) compress to a measured
distance of “B” 1.634 in (41,5 mm). Do Not
MAL2560
Overtighten.
11. Install and temporarily tighten the retract chain lock
6. Check dimension “A” 11.625 to 11.938 in nut (1).
(295,2 to 303,2 mm). 12. Start the machine and at low idle, fully extend and
7. If dimension “A” is greater than 11.625 in retract the boom three times. Verify boom is fully
(295,2 mm), push the third section boom IN until retracted and level. Shut machine Off.
dimension “A” is less than 11.625 in (295,2 mm). 13. Verify dimension “A” 11.625 to 11.938 in
(295 to 303 mm). Verify dimension “C” is not less
than 2.857in (72,5 mm).
Note: Re-adjust boom if dimensions “A” & “C” are not
met. Contact the local Caterpillar Dealer if the procedure
cannot be obtained.
14. Loosen the retract chain lock nut and the extend rod
lock and apply Loctite® 242TM.
15. Torque each retract chain lock nut (3) and extend
chain lock nut (6) without adding any additional
spring load. Torque each lock nut to 100 lb-ft
(135 Nm).
1 3 4
MAL2560 2
5. At the boom head, check dimension “A”
17.000 to 17.312 in (421,8 to 439,7 mm).
B MAL2590
1. Remove the lock nut (1) from the retract chain clevis
(2).
2. Set the retract chain adjustment nut face (3) flush
with the end of the retract clevis.
3. Verify the belleville washers (4) are in the correct
order as shown. Remove the retract chain
adjustment nut (3) and correct if required.
B MAL2620
7 6 7 6
5 5
MAL2580 C MAL2580 C
4. Remove the extend chain lock nut (5) and loosen the 8. With dimension “A” less than 17.000 in (421,8 mm),
adjustment nut (6) until the belleville washers (7) are verify the extend rod Belleville washers and retract
free to turn on the extend rod. chain Belleville washers are loose. Tighten the
5. Verify the belleville washers (7) are in the correct extend chain rod adjusting nut (6) until dimension “A”
order as shown. Remove the extend chain is 17.500 to 17.625 in (444,5 to 447,6 mm).
adjustment nut (6) and correct if required. 9. Install and temporarily tighten the extend chain lock
nut (5).
Note: Belleville washers are shown in the un-
compressed state.
A
1 3 4
B MAL2590
10. Tighten the retract chain adjustment nut (3) until the
belleville washers (4) compress to a measured
distance of “B” 2.561 in (65,0 mm). Do Not
Overtighten.
MAL2560
11. Install and temporarily tighten the retract chain lock
6. Check dimension “A” 17.000 to 17.312 in nut (1).
(421,8 to 439,7 mm). 12. Start the machine and at low idle, fully extend and
7. If dimension “A” is greater than 17.000 in retract the boom three times. Verify boom is fully
(421,8 mm), push the third section boom IN until retracted and level. Shut machine Off.
dimension “A” is less than 17.000 in (421,8 mm). 13. Verify dimension “A” 17.000 to 17.312 in
(421,8 to 439,7 mm). Verify dimension “C” is not less
than 3.069 in (77,9 mm).
Note: Re-adjust boom if dimensions “A” & “C” are not
met. Contact the local Caterpillar Dealer if the procedure
cannot be obtained.
14. Apply Loctite® 242TM to the retract chain lock nut and
the extend rod lock nut.
15. Torque the retract chain lock nut (1) and extend 3.10 BOOM WEAR PADS
chain lock nut (5) without adding any additional
spring load. Torque each lock nut to 100 lb-ft The wear pads on this machine are flat rectangular wear
(135 Nm). pads with metal inserts.
A total of 30 wear pads are installed on the boom sections
3.9 BOOM HEAD - MOUNTED WINCH of the TL642 and TL943 machines.
Ma2070
6 Inspect all wear pads for wear. If the angle indicators (1)
on the end of the wear pads are visible, the wear pads
can be reused. If the wear pads show uneven wear (front
4 to back), they should be replaced. Replace wear pads as
5 a set if worn or damaged.
• Maintain a total boom section clearance of 3.11 BOOM EXTEND AND RETRACT
0.070-0.130 in (1,78-3,30 mm) both the horizontal CHAINS
and vertical directions.
A
3.11.1 Boom Chain Inspection
B
WARNING
MY3620 Worn pins, stretched or cracked links or corrosive
• The length of the wear pad bolt depends on the environments can cause chain failure. A chain failure
number of shims, spacers and washers being used. could result in uncontrolled boom movement, loss of
load or machine instability.
• The thickness of each threaded wear pad insert is
0.312 in (7,92 mm)(A). Under normal operating conditions the boom chains will
• The bolt length should be determined by measuring need to be inspected every 250 hours of operation. The
the distance from the face of the insert to the face of retract chains need to be exposed and inspected every
the boom (B) including any spacer, shim(s) and 1000 hours of operation. Environmental conditions and
washer(s). dynamic impulse/shock loads can drastically affect
• Bolt thread engagement in the wear pad insert normal operating conditions and require more frequent
should be 0.275 ± 0.040 in (6,98 ± 1,0 mm). inspection intervals.
• One or two hardened washers are to be used on Environments in which material handling vehicles
each wear pad bolt except where noted otherwise. operate can vary widely from outdoor moisture to
DO NOT use more than two hardened washers. temperature to mildly corrosive or highly corrosive
• Use only one hardened washer if mounting bolts are industrial atmospheres, in addition to abrasive
recessed. exposures such as sand and grit. Some effects can be
as follows:
• Wear Pad Bolt Torque:
3/8-24 Bolt, 32-37 lb-ft (43-50 Nm) • Moisture - Corrosive rusting reduces chain
3/8-24 Hollow Bolt, 15-17 lb-ft (20-23 Nm) strength by pitting and cracking.
1/2-20 Bolt, 76-86 lb-ft (103-116 Nm)
• Temperature - Low temperature reduces chain
1/2 - 20 Hollow Bolt, 45-50 lb-ft (61-68 Nm)
strength by embrittlement. Going in and out of
• Torque wear pad bolts after shimming is completed. cold storage results in moisture from
• Lubricate the face and pockets of each wear pad condensation.
after being installed.
• Chemical Solutions or Vapors - Corrosive attack
Boom Section Wear Pad Pathway Lubrication: on the chain components and/or the mechanical
• Clean and lightly grease all wear pad pathways with connections between the chain components.
Mystik Tetrimoly grease. Cracking can be (and often is) microscopic.
Going from microscopic cracking to complete
• Clean and lightly grease the push beam guide bar failure can be either abrupt or may require an
pathways with Mystik Tetrimoly grease. extended period of time.
• Abrasives - Accelerated wearing and scoring of
the articulating members of the chain (pins and
plates), with a corresponding reduction in chain
strength. Due to the inaccessibility of the bearing
surfaces (pin surfaces and plate apertures),
wear and scoring are not readily noticeable to
the naked eye.
MY1360
If possible, safely remove and/or secure the load on a. Retract the boom as follows:
the machine before starting the boom lowering 1. If equipped with Personal Work Platform, rescue
procedure. If load cannot be removed, the machine occupants prior to performing procedure.
load chart MUST be followed.
2. Properly support the boom before attempting to
proceed with the emergency boom lowering
3.13.1 Equipment and Supplies Required procedure.
Auxiliary Hydraulic Power Supply: 3. Place a Do Not Operate Tag on both the ignition key
• Portable hydraulic unit or another machine with switch and steering wheel.
an auxiliary hydraulic power supply with a 4. Properly support the boom as required.
capacity to hold up to 22 gal (83 L) of hydraulic
5. Place a suitable receptacle under the tube/hose
oil from the machine during lowering process.
connections.
Note: If another machine is being used, the hydraulic 6. Remove the plastic cover from the main control
reservoir must be drained to accept a minimum of 22 gal
valve.
(83 L) of hydraulic oil before attempting this procedure.
• Standard Mechanic Tools.
WARNING
NOTICE Loss of hydraulic oil is limited to the amount trapped
within each tube/hose. Slowly loosen each hydraulic
EQUIPMENT DAMAGE. Auxiliary Hydraulic Power tube/hose fitting to release any possible hydraulic oil
Supply hydraulic oil must be compatible with hydraulic pressure that may be trapped between the main
oil shown in Section 2.4, “Fluids and Lubricant control valve and the counterbalance valve of the
Capacities.” extend/retract cylinder or the lift/lower cylinder.
3.14 TROUBLESHOOTING
This section provides an easy reference guide covering
the most common problems that occur during operation
of the boom.
2. 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 3.10, “Boom
Wear Pads.”
6. 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.
9. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8.4, “Hydraulic
operate. operating properly. Circuits.”
10. Excessive chain wear. 1. Improper chain adjustment. 1. Adjust to correct tension. Refer
to Section 3.8, “Boom
Adjustments.”- Replace chains
as needed.
5.00
3.125 Tube I.D. 1.3125in - O.D. 2.0in
0.1875
0.250
0.50 0.875
2.0
SEE NOTE A 1.3125
1/4
6.875
7.00
1.50
3/16
X Y
4.0
5.00
1.50
3.125
0.1875
3/16 2.0
1.0
3/16
0.50 0.875
2.0
0.50 1.50
Drill 0.3125 Thru
2.50
0.50 3.0
A36 STEEL RECOMMENDED
3.0
ALL WELDS SHALL CONFORM TO AWS D1.1
ALL DIMENSIONS ARE IN INCHES MY4100
Contents
FRAME LEVEL
INDICATOR
STEERING WHEEL
BOOM CONTROL
JOYSTICK
INSTRUMENT PANEL
OUTRIGGER CONTROLS
(IF EQUIPPED)
AUXILIARY
HYDRAULICS
CONTROLLER
IGNITION
SWITCH
SERVICE BRAKE
PEDAL MAL0200
ACCELERATOR
PEDAL
BOOM CONTROL
STEERING WHEEL JOYSTICK
IGNITION
SWITCH
SERVICE BRAKE
PEDAL
MAL1190
ACCELERATOR
PEDAL
WARNING 4
DO NOT weld, grind, drill, repair or modify the cab in
any way. Any modification or damage to cab structural
components requires cab replacement. Refer to the
Operation & Maintenance Manual.
1
To help ensure optimum safety, protection and
performance, replace the cab if it is damaged. Refer to
the appropriate parts manual for ordering information.
Note: DO NOT disassemble the orbitrol valve. The c. Service Brake Pedal Removal
orbitrol valve is not serviceable and must be replaced in
1. Park the machine on a firm, level surface, level the
its entirety, if defective.
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
b. Orbitrol Valve Installation
position, engage the parking brake and turn the
1. Secure the steering valve to the steering column engine OFF.
with four hex-flange capscrews and four 2. Place a Do Not Operate Tag on both the ignition key
lockwashers. switch and steering wheel.
2. Install the steering column through the dash panel 3. Open the engine cover. Allow the system fluids to
opening. Position steering valve to its original cool.
orientation in the cab.
4. Properly disconnect the battery.
3. Install the travel select lever, connect the instrument
panel harness connector, install the steering wheel
assembly. Torque the steering wheel nut to 29-34 lb-ft
(39-46 Nm).
4. Install new o-rings into the steering valve fittings.
Lubricate the o-rings with clean hydraulic oil.
5. Uncap and connect the previously labeled load
sense hose to the steering valve.
3
6. Uncap and connect the remaining previously labeled 1
four hoses to the steering valve.
Note: If necessary, install the main dash panel. Refer to
Section 9.12, “Gauges and Display Monitor.”
2
7. Properly connect the battery.
8. Carefully examine all connections one last time MY0141
before engine start-up. Rectify any faulty conditions.
5. Remove the bolt and lockwasher (1) securing the
9. Start the engine and check the operation of steering
service brake pedal pivot pin (2).
system. Check for hydraulic fluid leaks. Check the
hydraulic fluid level in the tank and add fluid as 6. Pull the pivot pin from the service brake pedal
required. bracket (3).
10. Close and secure the engine cover. 7. Remove the service brake pedal from the cab.
11. Remove the Do Not Operate Tags from both the
d. Service Brake Pedal Installation
ignition key switch and the steering wheel.
1. Position the service brake pedal in its mounting
c. Steering Test location within the cab.
Conduct a pressure check of the steering hydraulic 2. Secure the brake pedal into position with the pivot pin.
circuits at the main control valve. Refer to Section 8.3.1, 3. Be sure the brake pedal has the correct range of motion.
“Pressure Checks and Adjustments.” Secure pivot pin with bolt and lockwasher.
4. Properly connect the battery.
4.3.2 Service Brake Pedal
5. Close and secure the engine cover.
a. Brake Valve Removal 6. Remove the Do Not Operate Tags from both the
Refer to Section 8.7.2, “Service Brake Valve,” for removal ignition key switch and the steering wheel.
information.
11 11 MAL0940
4.3.7 Heater/Air Conditioning System 11. Remove the bolts securing the seat riser weldment
(if equipped) to the cab. Remove the riser weldment.
Note: If machine is equipped with air conditioning, HEATER WITH AIR 3 5
DO NOT loosen or disconnect any air conditioning hoses CONDITIONING SHOWN
until the air conditioning system has been properly
drained by the local Caterpillar dealer or certified air
conditioning service center.
Note: When the engine is initially started, run it briefly at 5. Place a funnel at the base of the radiator to channel
low idle and check the machine for any visual sign of the drained coolant into the container. Loosen the
fluid leakage. STOP the engine immediately if any drain petcock and allow the coolant to drain.
leakage is noted, and make any necessary repairs 6. Transfer the coolant to a container with a cover, and
before continuing. label as “Used Antifreeze.” Dispose of the used
10. Wait for the engine to cool and check the coolant coolant at an approved recycling facility.
level. Add coolant as required to bring the coolant to 7. Tighten the radiator drain petcock.
the proper level.
8. Disconnect the cab heater hoses. Refer to Section
11. Remove the Do Not Operate Tags from both the 4.3.7, “Heater/Air Conditioning System (if
ignition key switch and the steering wheel. equipped).”
9. Remove the necessary dash panels to gain access
4.4 CAB REMOVAL to the electrical wiring connections. Label and
disconnect the harnesses. Push the harness
connectors through the opening in the cab.
WARNING 10. If equipped, remove the boom joystick from is
The protection offered by this ROPS/FOPS will be mounting position. Refer to Section 4.3.4, “Boom
impaired if subjected to any modification or structural Joystick.” Label, disconnect and cap all hydraulic
damage, at which time replacement is necessary. hoses attached to the boom joystick. Cap all fittings
ROPS/FOPS must be properly installed using and openings to keep dirt and debris from entering
fasteners of correct size and grade, and torqued to the hydraulic system.
their specified value. 11. Remove the frame level and attachment tilt and
auxiliary control joystick. Refer to Section 4.3.5,
Note: To help ensure safety and optimum performance,
“Frame Level, Auxiliary Hydraulic (if equipped) and
replace the cab if it is damaged. Refer to the appropriate
Outrigger Joysticks.” Label, disconnect and cap all
parts manual for ordering information.
hydraulic hoses attached to the joystick. Cap all
Inspect the cab, its welds and mounts. If modification, fittings and openings to keep dirt and debris from
damage, a cracked weld and/or fatigued metal is entering the hydraulic system.
discovered, replace the cab. Contact the local Caterpillar 12. Label, disconnect and cap all hydraulic hoses
dealer with any questions about the suitability or attached to the steering orbitrol valve. Cap all fittings
condition of a cab. and openings to keep dirt and debris from entering
Note: Remove and label cab components as needed the hydraulic system.
before removing the cab from the machine. Label, 13. Label, disconnect and cap all hydraulic hoses
disconnect and cap hydraulic hoses. Transfer cab parts attached to the steering orbitrol valve. Cap all fittings
to the replacement cab after the replacement cab is and openings to keep dirt and debris from entering
securely mounted on the machine. the hydraulic system.
1. Park the machine on a firm, level surface. Allow 14. Label, disconnect and cap all hydraulic hoses
sufficient overhead and side clearance for cab attached to the service brake valve. Cap all fittings
removal. Level the machine, fully retract the boom, and openings to keep dirt and debris from entering
lower the boom, place the travel select lever in the the hydraulic system.
(N) NEUTRAL position, engage the park brake and 15. Push all the hydraulic hoses through the opening in
shut the engine OFF. the cab.
2. Block all four wheels to help prevent the machine 16. Disconnect the throttle cable from the throttle
from moving. Assure that there is sufficient overhead assembly. Refer to Section 4.3.3, “Throttle Pedal.”
and side clearance for cab removal.
17. Disconnect the engine air filter and hydraulic oil
3. Open the engine cover. Allow the system fluids to reservoir breather from their brackets at the top of
cool. the cab. Move the air filter and breather clear from
4. Properly disconnect the battery. the cab so they do not become damaged during cab
removal.
18. Remove the fuel tank from the cab. Refer to Section 24. Carefully begin to lift the cab. Stop and check that all
7.6.2, “Fuel Tank.” wiring, hydraulic hoses and fasteners are
1 2 disconnected or removed.
25. When all wiring, hydraulic hoses and fasteners are
disconnected or removed, carefully and slowly lift the
cab and remove it from the frame. Readjust the
position of the sling as needed to help balance the
cab during removal.
26. When the cab is completely clear of the machine,
carefully lower it to the ground. Block up or support
the cab so that it does not move or fall. Assure that
no personnel enter the cab while it is being removed
from the machine.
3
27. Inspect the condition of the fittings, clamps, hydraulic
hoses, etc. Replace parts as indicated by their
condition.
19. Open Cab: Route a sling with a minimum lifting 28. Inspect and replace other machine parts that are
capacity of 1000 lb (453 kg) under the inner four exposed with the cab removed. Repair or replace as
braces (1) and behind the center cross support required.
above the wind shield or install two lifting eye bolts
(2) in the threaded holes on the roof of the cab
4.5 CAB INSTALLATION
above the B pillars (15).
20. Enclosed Cab: Install two lifting eye bolts (14) in the 1. Block all four wheels to help prevent the machine
threaded holes on the roof of the cab above the B from moving. Assure that there is sufficient overhead
pillars (3). and side clearance for cab installation.
1 2
4 4
4. Use a hoist or overhead crane and sling attached to 14. Fill the cooling system completely with coolant,
the cab. Carefully begin to align the cab with the allowing time for the coolant to fill the engine block.
mounting holes in the frame. Stop and check that The cooling system capacity is listed in Section 2.4,
wiring, hydraulic hoses, cables, etc., will not be “Fluids and Lubricant Capacities.”
pinched or damaged as the cab is positioned. 15. Properly connect the battery.
Readjust the position of the sling as needed to help
balance the cab during installation. 16. 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.
Note: 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.
4 4
17. 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.
18. Install the mirrors and all other cab components as
needed, if removed.
19. Close and secure the engine cover.
20. Unblock the wheels.
21. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
5 5
5. Install the four cab-to-frame mount bolts, washers and
nuts (5). Torque to 280-305 lb-ft (379-414 Nm).
6. Install the two cab side mount bolts washers and
nuts (4). Torque to 680-720 lb-ft (922-976 Nm).
7. Install the engine air filter and hydraulic oil reservoir
breather to their brackets at the top of the cab.
8. Install the throttle cable to the throttle pedal
assembly. Refer to Section 4.3.3, “Throttle Pedal.”
9. Pull all the hydraulic hoses and electrical wires
through the cab.
10. Uncap and reconnect the previously labeled
hydraulic hoses to their appropriate locations.
11. Reconnect the previously labeled electrical
connections to their appropriate locations.
12. For machines equipped with the heater option,
reconnect the heater hoses to the cab heater. Refer
to Section 4.3.7, “Heater/Air Conditioning System (if
equipped).”
13. Install the fuel tank to the cab. Refer to Section 7.6.2,
“Fuel Tank.”
Contents
REAR STEERING
CYLINDER
TRANSMISSION
DROP BOX
REAR AXLE
ASSEMBLY
FRONT AXLE
ASSEMBLY
FRONT AXLE WHEEL MY0570
HUBS
5.3.5 Axle Removal 8. Place a suitable receptacle under the axle drain
plugs (1) and wheel hubs drain plugs (2). Remove
The front and rear axle assemblies differ in that the front
the drain plugs and allow the axle oil to drain into the
axle assembly is equipped with a parking brake
receptacle. If necessary, rotate both wheel hubs and
mechanism and a limited-slip feature; the rear axle has
allow the wheel hub oil to drain into the receptacle.
neither. The following steps outline a typical axle removal
procedure, suitable for either the front or the rear axle 9. Transfer the used oil into a suitable covered
assembly. container, and label the container as “Used Oil.”
Dispose of used oil at an approved recycling facility.
Cleanliness is extremely important. Before attempting to
remove the axle, thoroughly clean the machine. Avoid 10. Label, disconnect and cap the steering and brake
spraying water or cleaning solution on electrical lines at the axle. Wipe up any spilled oil.
components. If using a steam cleaner, seal all openings 11. Support the axle that is being removed with a suitable
before steam cleaning. jack, hoist or overhead crane and sling. DO NOT
Note: Clear the work area of all debris, unnecessary raise the axle or the machine.
personnel, etc. Allow sufficient space to raise the Note: The wheel and tire assemblies must be re-installed
machine and to remove the axle. later with the directional tread pattern “arrows” facing in
1. Park the machine on a firm, level surface, level the the direction of forward travel.
machine, fully retract the boom, lower the boom, 12. Remove the drive shaft assembly. Refer to Section
place the travel select lever in the (N) NEUTRAL 5.4.3, “Drive Shaft Removal.”
position, engage the parking brake, straighten all
13. On the front axle remove the capscrew and locknuts
wheels and shut the engine OFF.
securing the lower position cylinder-mount pin to the
2. Place a Do Not Operate Tag on both the ignition key front cylinder. Tap the cylinder mount pin out, and
switch and steering wheel. move the cylinder to prevent it from interfering with
3. Open the engine cover. Allow the system fluids to axle removal.
cool. 14. Remove the bolts and locknuts securing the axle to
4. Properly disconnect the battery. the frame.
5. Block the front and rear of both tires on the axle that 15. Remove the axles from the machine using the jack,
is not being removed. Ensure that the machine will hoist or overhead crane and sling supporting the
remain in place during axle removal before axle. DO NOT raise or otherwise disturb the
proceeding. machine while removing the axle. Balance the axle
and prevent it from tipping, turning or falling while
6. Raise the machine using a suitable jack or hoist.
removing it from beneath the machine. Place the
Place suitable supports under both sides of the
axle on a suitable support or holding stand.
frame and lower the machine onto the supports.
Ensure that the machine will remain in place during
axle removal.
5.3.6 Axle Installation
7. Remove both wheel and tire assemblies from the 1. Before proceeding, ensure that the machine will
axle that is being removed. (Refer to Section 5.5.1, remain in place during axle installation. Block the
“Removing Wheel and Tire Assembly from front and rear of both tires on the axle that is already
Machine.”) installed on the machine.
2. If applicable, raise the machine using a suitable jack
or hoist. Place suitable supports beneath the frame
and lower the machine onto the supports, allowing
enough room for axle installation. Ensure that the
machine will remain in place during axle installation.
MY4180
2 1 1 1 2
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. with hydraulic oil. Refer to
Section 2.4, “Fluids and
Lubricant Capacities.”
3. Vibration or intermittent noise 1. Drive shaft universal joint 1. Tighten capscrews to correct
when traveling. assembly(ies) incorrectly torque.
tightened.
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 130 Nm
(96 lb-ft).
2. Axle and/or wheel end housings 2. Drain axle and fill to correct level
filled with incorrect oil or oil with hydraulic oil. Refer to
contaminated or oil level low. Section 2.4, “Fluids and
Lubricant Capacities.”
8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to Section 8.4, “Hydraulic
operating properly. Circuits.”
9. Slow steering response. 1. Steering (hydraulic) system not 1. Refer to Section 8.4, “Hydraulic
operating properly. Circuits.”
10. Excessive noise when brakes 1. Brake discs worn. 1. Check brake discs for wear.
are engaged. Refer to Section 2.4, “Fluids and
Lubricant Capacities.”
11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to Section 8.7.3, “Service
operating properly. Brake Bleeding.”
12. Brakes will not hold the 1. Brake discs worn. 1. Check brake discs for wear.
machine or braking power Refer to Section 5.3.3, “Axle
reduced. Internal Service.”
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.
5.5.2 Installing Wheel and Tire Assembly 6. Remove the Do Not Operate Tags from both the
onto Machine ignition key switch and the steering wheel.
Note: The wheel and tire assemblies must be installed
with the directional tread pattern “arrows” facing in the 5.6 BRAKES
direction of forward travel.
Check the brake disks for wear every 1,000 hours of
operation or yearly.
For more information on brake disk inspection, refer to
Tread “arrows” must point the appropriate axle repair manual.
forward
MAH0460
5
5 MZ1020
Contents
Transmission Filter
SHIFT SOLENOIDS
SHIFT SOLENOIDS
OAL0010
OIL DRAIN PLUG
WARNING WARNING
DO NOT service the machine without following all NEVER lift a transmission alone; enlist the help of at
safety precautions as outlined in Section 1, “Safety least one assistant or use a suitable hoist or overhead
Practices,” of this manual. crane and sling with a minimum lifting capacity of
1000 lb (454 kg).
6.2 TRANSMISSION SERIAL NUMBER
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
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 steering wheel.
3. Open the engine cover. Allow the system fluids to cool.
4. Remove engine cover to allow easier access to the
1 transmission.
5. Drain the hydraulic oil reservoir. Refer to Section
MY5550 8.5.1, “Hydraulic Oil Reservoir Draining.”
6. Properly disconnect the battery.
The transmission serial number plate is located on the
front of the transmission behind the oil dipstick. 7. Thoroughly clean the transmission and surrounding
Information on the serial number plate is required in area, including all hoses and fittings, before
correspondence regarding the transmission. proceeding.
11. Remove air cleaner unit and intake tubes. switch, and inlet and outlet cooler hose fittings.
12. Remove the hydraulic pump. Refer to Section 8.6.1, Cover all transmission openings.
“Pump Replacement.” 29. Remove the transmission oil filter (3) and dispose of
13. Label and disconnect the transmission temperature properly. Clean the filter mounting surface. Cover or
switch connector and shift solenoid wiring harness cap the oil filter mount.
connectors. 30. If transmission oil is suspect to contamination or
14. Label, disconnect and cap the transmission oil torque converter is damaged, remove the converter
cooler inlet and outlet hoses at the transmission. The and flex plate from the transmission.
transmission oil cooler outlet hose, routed to the 31. Remove the bolt and washers holding the converter
lower radiator fitting, is located on the top of the to the flex plate.
transmission. The transmission oil cooler inlet hose,
routed to the upper radiator fitting, is located on top 6.4.2 Transmission Inspection and Internal
of the transmission. Repair
15. Remove the access plug from side of the engine bell If replacing the entire transmission, transfer the
housing. This will allow access to remove the eight transmission temperature switch to the replacement
bolts holding the flex plate to the engine flywheel. transmission. The gear shift solenoids are included with a
16. Turn the engine over slowly by hand and align each new transmission.
of the eight flex plate bolts to be accessed. Remove
them one at a time. 6.4.3 Transmission Installation
17. Wipe up any spilled hydraulic and transmission oil.
18. Connect a lifting strap or chain to the lifting eye at
the top of the transmission, and to a suitable hoist or
WARNING
overhead crane. Operate the hoist or crane to NEVER lift a transmission alone; enlist the help of at
remove slack from the chain, but DO NOT raise the least one assistant or use a suitable hoist or overhead
transmission at this time. crane and sling with a minimum lifting capacity of
1000 lb (454 kg).
19. Place blocks under rear of engine for support
BEFORE transmission mounts are removed. 1. Install both rear transmission mounts on the
20. Place blocks under the transmission to help support transmission. Torque capscrews to 66 lb-ft (89 Nm).
it during removal. 2. Install two guide studs near the top of the bell
21. Remove both rear transmission mount bolts and housing holes.
lockwashers securing the transmission mount to the 3. Use a hoist or overhead crane and sling attached to
frame. the lifting eye at the top of the transmission. Raise
22. Remove the bolts and washers holding the and position the transmission within the chassis.
transmission to the engine. 4. Align the torque converter, align the transmission
23. Remove the capscrews and lockwashers securing bolt holes with the two studs in the bell housing.
each rear transmission mount to the transmission. Install the eight bolts and washers and torque to
53 lb-ft (72 Nm). Remove the two alignment studs
24. Remove the transmission mounts from the machine. and install and torque the last two transmission
25. Inspect the rubber mounts. Replace the mounts if mounting bolts.
damaged. 5. Install the two rear transmission mounting bolts on
26. Carefully remove the transmission from the machine. the frame with two capscrews and two lockwashers.
Avoid causing damage to the transmission or Apply Loctite® 242TM to the transmission mount bolts
surrounding parts. and torque to 220 lb-ft (298 Nm).
27. Lift the transmission clear of the machine, and lower 6. Turn the engine over slowly by hand and align each
it onto suitable supports or secure it to a stand built of the eight flex plate bolts to be accessed. Install
especially for transmission or engine service. Secure them one at a time. Torque to 26-29 lb-ft (35-39 Nm).
the transmission so that it will not move or fall. Replace access plug.
28. Remove any external transmission components as 7. Remove the hoist or overhead crane and sling.
required, including the transmission temperature
7 8
6.6 TROUBLESHOOTING
This section provides an easy reference guide covering
the most common problems that may occur during
operation of the transmission.
Note: Contact your local Service Department if internal
transmission repair is required during the warranty
period.
The transmission should be checked, serviced and
repaired only by experienced service technicians who are
aware of all safety instructions and particular component
features.
3. Low clutch pressure. 1. Incorrect oil level. 1. Fill transmission to correct level
with hydraulic oil. Refer to
Section 2.4, “Fluids and
Lubricant Capacities.”
2. Main pressure valve stuck open. 2. Clean the valve spool and
housing.
4. Lack of power. 1. Park or service brake dragging. 1. Refer to Section 8.4, “Hydraulic
Circuits.”
6. Grinding or “clunking” noise 1. Oil level too low. 1. Fill oil to correct level. Refer to
from transmission. Section 2.4, “Fluids and
Lubricant Capacities.”
Contents
7.1 INTRODUCTION
3054C
TL642 - BEFORE S/N TBK01167 EXCLUDING TBK01162
TL943 - BEFORE S/N TBL01599 EXCLUDING TBL01551 & TBL01585
TURBOCHARGER
4.4C
TL642 - S/N TBK01167 & AFTER INCLUDING TBK01162
TL943 - S/N TBL01599 & AFTER INCLUDING TBL01551 & TBL01585
TURBOCHARGER
MAL0970
• Parts Manual (P/N SEBP4124) 6. Place a funnel at the base of the radiator to channel
the drained coolant into the container. Loosen the
• Schematic - Electrical (P/N RENR9964) drain plug and slowly remove to allow the coolant to
• Troubleshooting (P/N SENR9969) drain. Transfer the coolant into a properly labeled
container. Dispose of properly if coolant needs to be
• Torque Specifications (SENR 3130) replaced. Replace the radiator drain plug.
7. Disconnect the Engine Water Temperature Sender.
b. Thermostat Installation
1. Install the engine thermostat, thermostat gasket and
thermostat housing. Secure with the two capscrews.
2. Connect the Engine Water Temperature sender.
3. Properly connect the battery.
4. Open the radiator cap, and fill the radiator
completely with a 50/50 mixture of ethylene glycol
and water. Add the coolant solution at a maximum TL642 - S/N TBK01167 & AFTER INCLUDING TBK01162
rate of 1.3 gallons per minute (5 liters per minute). TL943 - S/N TBL01599 & AFTER INCLUDING TBL01551 & TBL01585
MAL1010
5. Slowly turn the radiator cap to the first stop and allow 5. Uncap and connect transmission inlet and outlet
any pressure to escape. Remove the radiator cap. hoses to the radiator.
6. Place a suitable container beneath the radiator 6. At the lower radiator return hose, and with the clamp
drain. installed over the hose, work the hose onto the
radiator, and tighten the clamp.
7. Place a funnel at the base of the radiator to channel
the drained coolant into a container. Loosen the 7. At the upper radiator hose, and with the clamp
drain cock and slowly remove to allow the coolant to installed over the hose, work the hose onto the
drain. Transfer the coolant into a properly labeled radiator, and tighten the clamp.
container. Dispose of properly if coolant needs to be 8. Open the radiator cap and fill the radiator completely
replaced. Tighten the radiator drain cock. with a 50/50 mixture of ethylene glycol and water.
8. Loosen the radiator clamp on the top radiator hose. Add the coolant solution at a maximum rate of 1.3
Work the hose off the radiator. Position the hose out gallons per minute (5 liters per minute). Replace and
of the way to allow radiator removal, or remove the tighten the radiator cap. Refer to Section 2.4, “Fluids
hose from the engine. Inspect the hose, and replace and Lubricant Capacities,” for proper capacities.
if necessary. 9. Properly connect the battery.
9. Loosen the clamp on the radiator return (lower) 10. Run the engine to operating temperature. Visually
hose. Work the hose off the radiator. Position the check for leaks with the engine running. Check the
hose out of the way to allow radiator removal, or coolant level in the overflow bottle and fill, or drain,
remove the hose from the engine. Inspect the hose, as necessary.
and replace if necessary. 11. Close and secure the engine cover.
10. Label, disconnect and cap the hoses on the oil 12. Remove the Do Not Operate Tags from both the
cooler. ignition key switch and the steering wheel.
11. Remove the radiator fan shroud.
12. Remove the radiator bracket. 7.5 ENGINE ELECTRICAL SYSTEM
13. Remove the nuts and washers from the radiator The engine electrical system, including the starter,
mounts. alternator and primary wiring, is described in Section 9.5,
14. Carefully lift the radiator/oil cooler out of the engine “Electrical System Schematics.”
compartment.
Note: If more clearance is needed to remove the
radiator, the engine fan may be removed for easier
access.
1. Have a dry chemical (Class B) fire extinguisher near 7. Check fuel tank for leaks.
the work area. 8. Properly connect the battery.
2. Remove the fuel or oil tank drain plug, and safely 9. Close and secure the engine cover.
drain any fuel into a suitable container. Dispose of
fuel properly. 10. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
3. Clean the fuel tank with a high-pressure washer, or
flush the tank with hot water for five minutes and 7.6.3 After Fuel System Service
drain the water. Dispose of contaminated water
properly. 1. Drain and flush the fuel tank if it was contaminated.
4. Add a diesel fuel emulsifying agent to the tank. Refer 2. Vent air from the fuel system in accordance with the
to the manufacturer’s instructions for the correct instructions found in the appropriate Operation &
emulsifying agent-to-water mixture ratio. Refill the Maintenance Manual.
tank with water, and agitate the mixture for 10 3. Fill the fuel tank with fresh, clean diesel fuel as required.
minutes. Drain the tank completely. Dispose of
contaminated water properly. 7.7 ENGINE EXHAUST SYSTEM
5. Refill the fuel tank with water until it overflows.
Completely flush the tank with water. Empty the fuel
7.7.1 Exhaust System Removal
tank, and allow it to dry completely.
1. Park the machine on a firm, level surface, level the
d. Assembly machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
The fuel level indicator can be removed and reused on the position, engage the parking brake, and shut the
new replacement tank. Dispose of the old tank according engine OFF.
to local regulations concerning hazardous materials
disposal regulations. 2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel.
e. Inspection 3. Open the engine cover. Allow the system fluids to
cool.
Note: If a leak is suspected in the fuel tank, contact your
local Service Department. 4. Properly disconnect the battery.
1. Inspect the fuel tank thoroughly for any cracks,
slices, leaks or other damage.
2. With the fuel tank removed from the machine, plug
all openings except one elbow fitting. Install the
elbow fitting, and apply approximately 1-1.5 psi
(7-10 kPa) of air pressure through the elbow. Check
the reservoir for leaks by applying a soap solution to
the exterior and look for bubbles to appear at the
cracked or damaged area. OAL0060
11. Remove the exhaust heat shield (if equipped). 7.8.1 Air Cleaner Assembly Removal
1. Park the machine on a firm, level surface, level the
7.7.2 Exhaust System Installation machine, fully retract the boom, lower the boom,
Note: Keep all clamps loosened until entire exhaust place the travel select lever in the (N) NEUTRAL
system is in place. position, engage the parking brake, and shut the
engine OFF.
1. Install the exhaust pipe with a new seal to the
exhaust manifold. 2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel.
Note: Replace the nuts and the exhaust manifold studs
if damaged. 3. Open the engine cover. Allow the system fluids to
cool.
2. Install the exhaust pipe clamp.
4. Properly disconnect the battery.
3. Install the muffler to the exhaust pipe and bolt the
muffler to the frame.
4. Install the clamp securing the muffler to the exhaust
pipe.
5. Install the clamp securing the muffler to the tail pipe.
6. Install the exhaust heat shield (if equipped).
7. Adjust the muffler, exhaust and tail pipes for proper
clearance then tighten all clamps.
8. Install the heat shield attached to the engine.
9. Properly connect the battery.
10. Start engine and check for exhaust leaks at all
exhaust connections. Adjust or repair as needed.
11. Close and secure the engine cover. MAL1020
12. Remove the Do Not Operate Tags from both the 5. Remove the clamp securing the air intake elbow to
ignition key switch and the steering wheel. the air cleaner assembly. Lift the air intake elbow off
the air cleaner.
7.8 AIR CLEANER ASSEMBLY
6. Remove the capscrews and nuts securing the air
cleaner mounting bracket to the air cleaner mounting
NEVER run the engine with only the inner safety 7.8.2 Air Cleaner Assembly Installation
element installed. Note: Apply Loctite® 242TM to the capscrew threads
before installation.
Note: Refer to the appropriate Operation &
Maintenance Manual for your machine for the correct 1. With the air cleaner assembly attached, install the air
element change procedure. cleaner mounting bracket using capscrews and nuts.
TL642 - Before S/N TBK01167 excluding TBK01162 2. Place the loosened clamps over the air outlet elbow
and install elbow on the air cleaner assembly.
TL943 - Before S/N TBL01599 excluding TBL01551 &
TBL01585 3. Adjust and tighten both clamps before starting the
machine.
4. Properly connect the battery.
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
12. Mark the location of the throttle cable at the throttle 22. Remove the ten bolts holding the transmission to the
cable mount. Loosen jam nuts and remove. engine. Slightly lift and pull the engine out of the
machine. Have an assistant ensure that the engine
clears all frame components during removal.
23. Place engine on a flat, level surface.
14. Connect all the labeled wire harness connections on 29. Close and secure the engine cover.
the engine. 30. Remove the Do Not Operate Tags from both the
15. Install both heater hoses to the engine and tighten ignition key switch and the steering wheel.
clamps (if equipped).
16. Install the complete radiator assembly. Refer to
Section 7.4.3, “Radiator/Oil Cooler and
Replacement.”
17. Install the engine cover and adjust.
18. Install the battery and connect the positive (+) and
negative (-) cables.
19. Check that all hydraulic system, electrical system,
cooling system, fuel system and exhaust system
connections are correct and connected tightly.
20. From within the cab, lightly depress the throttle pedal
to full-throttle position. As needed, adjust the limit-
stop screw until it touches the pedal bracket.
Note: Have an assistant stand by with a Class B fire
extinguisher.
21. Start the engine and run to normal operating
temperature then shut off the engine. While the
engine is cooling, check for leaks.
22. Allow the engine to cool. Check the radiator coolant
level, and top off with a 50/50 mixture of ethylene
glycol and water. Add the coolant solution at a
maximum rate of 1.3 gallons per minute (5 liters per
minute). Replace the radiator cap.
23. 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.
Note: During the full throttle check:
• DO NOT operate any hydraulic function.
• DO NOT steer or apply any pressure to the steering
wheel.
• Keep the transmission in (N) NEUTRAL.
24. Obtain and connect an appropriate engine analyzer
or tachometer. Check the engine rpm at full throttle.
If the rpm is not 2675-2750, readjust the throttle
limit-stop screw at the throttle pedal within the cab.
25. Purge the hydraulic system of air by operating all
boom functions through their entire range of motion
several times. Check the hydraulic oil level.
26. Check for proper operation of all components.
27. Turn the engine OFF.
28. Install the oil pan cover underneath the engine
compartment.
DRIVE PLATES
RING
MZ0580
7.11 TROUBLESHOOTING
1. Battery charge low 21. Blocked fuel tank vent 43. Faulty suction pipe
2. Bad electrical connection 22. Incorrect grade of fuel 44. Restricted oil filter
3. Faulty starter motor 23. Sticking throttle or 45. Piston seizure/pick up
4. Incorrect grade of restricted movement 46. Incorrect piston height
lubricating oil 24. Exhaust pipe restriction 47. Damaged fan
5. Low cranking speed 25. Leaking cylinder head gasket 48. Faulty engine mounting
6. Fuel tank empty 26. Overheating 49. Incorrectly aligned flywheel
7. Faulty stop control operation 27. Cold running housing or incorrectly aligned
8. Fuel inlet restricted 28. Incorrect tappet adjustment flywheel
9. Faulty fuel lift pump 29. Sticking valves 50. Faulty thermostat
10. Clogged fuel filter 30. Incorrect high pressure pipes 51. Restriction in water jacket
11. Restricted air cleaner 31. Worn cylinder bores 52. Loose fan belt
12. Air in fuel system 32. Pitted valves and seats 53. Restricted radiator
13. Faulty fuel injection pump 33. Broken, worn or sticking 54. Faulty water pump
14. Faulty fuel injectors or piston ring(s) 55. Restricted breather pipe
incorrect type 34. Worn valve stems and guides 56. Damaged valve stem oil
15. Incorrect use of cold start 35. Restricted air cleaner deflectors (if fitted)
equipment 36. Worn or damaged bearings 57. Coolant level too low
16. Faulty cold start equipment 37. Insufficient oil in sump 58. Blocked sump strainer
17. Broken fuel injection 38. Inaccurate gauge 59. Broken valve spring
pump drive 39. Oil pump worn 60. Exhauster or vacuum pipe leak
18. Incorrect fuel pump timing 40. Pressure relief valve sticking open 61. Turbo impeller damaged or dirty
19. Incorrect valve timing 41. Pressure relief valve sticking closed 62. Turbo lubricating oil seal leak
20. Poor compression 42. Broken relief valve spring 63. Induction system leaks
Contents
EXTEND/RETRACT
CYLINDER COMPENSATION
(inside boom) CYLINDER
HYDRAULIC FLUID LIFT/LOWER
RESERVOIR CYLINDER
TILT CYLINDER
PRIORITY
VALVE
FO S FO
AM LB AM BS
F I L L ED 2 FI L L E 2 L
WI T H 5 4 D WI T H 5 4
MAL0340
8.2 SAFETY INFORMATION Some hydraulic functions are actuated by interfacing with
electrical system components (switches, solenoids and
sensors). When the hydraulic system is not functioning
WARNING properly, check the electrical aspect of the malfunctioning
circuit also. Refer to Section 9.6, “Circuit Breakdowns,” in
DO NOT service the machine without following all this manual.
safety precautions as outlined in Section 1, “Safety
Practices,” of this manual. 8.3 HYDRAULIC PRESSURE DIAGNOSIS
Petroleum-based hydraulic fluids are used in this
machine. The temperature of hydraulic fluid increases 8.3.1 Pressure Checks and Adjustments
during the operation of various hydraulic functions. A When diagnosing trouble in the hydraulic system, use the
heated petroleum-based hydraulic fluid presents a fire hydraulic testing information in Section 8.4.1, “Hydraulic
hazard, especially when an ignition source is present. Pressures.”
Hydraulic fluid has a flash point that ranges from
300-600° F (150-318° C) and an auto-ignition temperature In general, follow the steps below whenever conducting
of 500-750° F (262-402° C). pressure checks and performing adjustments:
Accordingly, periodically inspect all hydraulic system 1. Park the machine on a firm, level surface. Engage
components, hoses, tubes, lines, fittings, etc. Carefully the park brake, place the travel select lever in (N)
examine any deterioration and determine whether any NEUTRAL, level the boom and turn the engine OFF.
further use of the component would constitute a hazard. 2. The test port is located at the top right corner of the
If in doubt, replace the component. main control valve. Install a pressure gauge capable
Operate the hydraulic controls after the engine has of measuring at least 10% more pressure than that
stopped to relieve trapped pressure. which the circuit being checked operates under.
3. Start the engine. Operate machine functions several
Note: Residual pressure may remain in hydraulic
times to allow hydraulic oil to reach operating
cylinders, hoses, valve bodies, components, etc. If the
temperature. The hydraulic oil temperature should
hydraulic lines going to or coming from a component are
be between 100-120°F (38-49° C). If a temperature
taut, slowly and cautiously relieve (“bleed off”) pressure.
gauge or thermometer is unavailable, the hydraulic oil
Whenever you disconnect a hydraulic line, coupler, fitting reservoir should be warm to the touch.
or other component, slowly and cautiously loosen the part 4. Refer to Section 8.4.1, “Hydraulic Pressures,” for
involved. A hissing sound or slow seepage of hydraulic testing procedures.
fluid may occur in most cases. After the hissing sound
has ceased, continue removing the part. Any escaping oil 5. Fully depress the accelerator pedal if required. Place
should be directed into an appropriate container. Cap or and hold the joystick in the position needed to
otherwise block off the part to prevent further fluid seepage. operate the particular machine function being
checked. Continue holding the joystick in position
Hydraulic system maintenance will, at times, require that until pressure readings are taken.
the engine be operated. Always follow safety precautions.
6. Check the pressure gauge reading. It should read as
A major cause of hydraulic component failure is specified in the Pressure Readings column of the
contamination. Keeping the hydraulic fluid as clean as charts found in Section 8.4.1, “Hydraulic Pressures.”
possible will help avoid downtime and repairs. Sand, grit If the reading is not as specified, turn the engine
and other contaminants can damage the finely machined OFF and check other components in the system.
surfaces within hydraulic components. If operating in an Verify that all related hydraulic components and
exceptionally dirty environment, change filters and electrical switches, sensors, solenoids, etc. are
inspect the fluid more often. When servicing the system, operating correctly.
cap or plug hydraulic fittings, hoses and tube assemblies.
Plug all cylinder ports, valves and the hydraulic reservoir, 7. Adjust the relief valve by turning the adjustment
and pump openings until installation occurs. Protect screw. Turning clockwise will increase the pressure;
threads from contamination and damage. turning the screw counterclockwise will decrease the
pressure.
8. Start the engine and check the pressure again. Turn b. Adjusting Hydraulic Pressure
the engine OFF. If there is pressure reading in the
1. Shut the machine off. Remove the cap on the relief
gauge, bleed it off then disconnect or remove the
(if necessary).
pressure gauge from the machine.
2. Start the machine and loosen the jam nut on the
8.4 HYDRAULIC CIRCUITS relief. Turn the relief clockwise to increase pressure
or counter-clockwise to decrease pressure. Set to
This section covers the hydraulic circuits and includes the correct pressure.
listings for all hydraulic function pressures, where and 3. Tighten the jam nut and recheck the pressure at full
how to check those pressures and a hydraulic schematic. throttle. If the reading is within specification, shut the
Electrical and hydraulic functions are often related. Verify machine off, install the safety cap and remove the
that the electrical components of the circuit are gauge from the test port.
functioning properly whenever troubleshooting the 4. If the proper pressure cannot be set, use the
hydraulic circuit. accompanying hydraulic schematic and/or the
Always check the following before beginning to electrical schematic to help troubleshoot and correct
troubleshoot a circuit that is not functioning correctly. the problem.
1. Check the hydraulic oil level in the reservoir. Oil level
8.4.2 Tilt Circuit Port Relief Adjustment
should be to the middle of the sight glass with all
cylinders retracted. The following procedure is specific to the tilt circuit only
2. Check hoses, tubes, fittings and other hydraulic and should be performed and verified if the main and/or
components for leaks, bends, kinks, interference, etc. load sense circuits pressures are in question.
3. Check for air in the hydraulic system. Erratic machine 1. Remove any attachment from the quick coupler
performance and/or spongy cylinder operation are assembly. Refer to Section 3.9, “Boom Head -
signs of air in the hydraulic system. Mounted Winch.”
If air in the hydraulic system is suspected, you will 2. Raise the boom for access to the compensation
hear air leakage when hydraulic fittings are loosened cylinder.
and see air bubbles in the hydraulic fluid.
Loose fittings, faulty o-rings or seals, trapped oil,
leaks, system opened for service, etc., can cause air 1
in the system. Determine what is causing air to enter
the system and correct it. Bleed air from the system.
2
8.4.1 Hydraulic Pressures
a. Checking Pressures
1. Start the machine and warm the hydraulic system to
operating temperature. MY4500
7. Install a digital or a 5000 psi (345 bar) gauge to the 19. Monitor the gauge and slowly lower the boom. The
retract (1) port tee fitting on the compensation gauge should read:
cylinder. TL642: 4150 - 4450 psi (286,5 - 306,5 bar)
8. Start the machine and warm the hydraulic system to TL943: 3911 - 4211 psi (270 - 290 bar)
operating temperature. 20. If pressure is correct, proceed to step 23.
9. Tilt the forks down to allow the tilt cylinder to fully 21. The relief on the (B) port is non-adjustable and must
retract. be replaced. Replace and repeat steps 17 and 18.
10. Monitor the gauge and slowly raise the boom. The 22. Verify pressure is correct.
gauge should read: 23. Shut engine OFF.
TL642: 4150 - 4450 psi (286,5 - 306,5 bar)
TL943: 3911 - 4211 psi (270 - 290 bar) 24. Slowly remove the gauge, line and tee fitting from
the compensation cylinder (1 & 2). Reinstall each
11. If pressure is correct, proceed to step 14. hose and torque as required.
TL642 25. Install any previously removed attachment.
TL943
BEFORE S/N TBL01599 S/N TBL01599 & AFTER
B A
B
A
MAL2130
Hydraulic Adjustment
Test Port Function Used to Test Pressure Range
Circuit Location
BV 400 - 460 psi
1 Pilot Pressure High Idle - Bottom Steering, Any Mode 2
(A) (30,3 - 31,7 Bar)
Relief Valve CF1 2550 - 2650psi
2 High Idle - Bottom Steering, Any Mode 1
Cartridge (C) (176 - 183 Bar)
Main Relief EF1 3900 - 4100 psi
3 High Idle - Bottom Boom Retract 3
Valve (D) (269 - 282,7 Bar)
EF1 3650 - 3950 psi
4 Boom Extend High Idle - Bottom Boom Extend N/A
(D) (251,6 - 272 Bar)
EF1 3900 - 4100 psi
5 Boom Lift High Idle - Bottom Boom Down N/A
(D) (269 - 282,7 Bar)
EF1 2850 - 3150 psi
6 Auxiliary High Idle - Bottom Auxiliary Function N/A
(D) (196,5 - 217 Bar)
C B
2 1
MAL0900
MAL0110
d. Pressure Specifications - TL943 Before S/N TBL01599 excluding TBL01551 & TBL01585
Hydraulic Adjustment
Test Port Procedure Pressure Range
Circuit Location
Connect gauge to TP port, run engine at 500 ± 50 psi
Park Brake Pilot TP (A) 6
high idle (34,5 ± 3,4 Bar)
Connect gauge to Primary port, run
2450 ± 100 psi
Steering Primary (B) engine at high idle, bottom out function. 7
(168,9 ± 6,6 Bar)
Hold over relief and check pressure.
Connect gauge to P1 port, run engine at
1100 ± 10 psi
Service Brake P1 (C) high idle, depress brake pedal. Hold over 8
(75,8 ± 0,7 Bar)
relief and check pressure.
Boom Lift
Connect gauge to Secondary port, run
Extend/Retract 3800 ± 50 psi
Secondary (D) engine at high idle, bottom out function. 9
Frame Level (262,0 ± 13,4 Bar)
Hold over relief and check pressure.
Fork Tilt
8
A B
6
C
D
7 MAL0910
MAL0120
e. Pressure Specifications - TL943 S/N TBL01599 & After including TBL01551 & TBL01585
Note: 1. All pressures must be checked in numerical order.
Note: 2. Connect gauge to P1 port, adjust Standby Pressure to 250 psi (step 2). Adjust Main Compensator Pressure
to 3950 psi (step 3). Adjustment may require incrementally increasing Load Sense Relief Valve (adjustment
location 6) and Main Pump Compensator until a setting of 3950 psi can be observed on the gauge. Connect additional
gauge to GLS (A) port, bottom boom lift, adjust Load Sense Relief to the setting noted below.
Hydraulic Adjustment
Test Port Function Used to Test Pressure Range
Circuit Location
Load Sense GLS/PLS Bottom Boom Lift 3550 - 3650 psi
1 6
Relief (A) (see Note 2) (245 - 252 Bar)
P1 250 - 265 psi
2 Standby High Idle - No Function 1
(B) (17,2 - 18,3 Bar)
P1 3825 - 3875 psi
3 Main High Idle - Bottom Boom Lift 2
(B) (264 - 267 Bar)
JS1 500 - 550 psi
4 Pilot High Idle - Bottom Steering, Any Mode 4
(C) (34,5 - 38 Bar)
BV1 1050 - 1150 psi
5 Service Brake High Idle - Bottom Steering, Any Mode 5
(D) (72,4 - 79,3 Bar)
Priority Load GLS/PLS 2350 - 2450 psi
6 High Idle - Bottom Steering, Any Mode 3
Sense (A) (162 - 169 Bar)
GLS/PLS No 3600 - 3800 psi
7 Boom Extend High Idle - Bottom Boom Extend
(A) Adjustment (248 - 262 Bar)
GLS/PLS No 3600 - 3800 psi
8 Boom Retract High Idle - Bottom Boom Retract
(A) Adjustment (248 - 262 Bar)
GLS/PLS No 3600 - 3800 psi
9 Boom Lift High Idle - Bottom Boom Lift
(A) Adjustment (248 - 262 Bar)
GLS/PLS No 2900 - 3100 psi
10 Auxiliary High Idle - Bottom Auxiliary Function
(A) Adjustment (200 - 214 Bar)
6 5
4
HYDRAULIC
3 MANIFOLD
1
2
A
MY4361
D
C MAL0920
TL642, TL943
P
STEER SELECT
VALVE
LEGEND P T
P T
TE
QA CYLINDER
(TEST PORT)
AUXILIARY
SERVICE BRAKE HYD. PORTS
VALVE
REAR C1 C4
COMPENSATING
SERVICE CYLINDER
L R
BRAKES
JOYSTICK
P1 P2
P
LEFT RIGHT,
OUTLET DWN UP,
Hydraulic Schematic - TL642
QA EXTD. QA RET.
INLET AUXILIARY HYD.
T PORTS @ BOOM NOSE
1 2 3 4
OUTLET
SWAY CYLINDER
STEERING ORBITROL
GREEN
RED
PURPLE
YELLOW
LP T LS
.040 .050
SERVICE
BRAKE
PARK
BRAKE
AUX. HYD.
PORTS "QD'S"
THIS
LOC'N
ON STD.
MACHINE
EF1
EF CF CF1 LS JS
T 4300 3000
PSI PSI
.
A A A A A
M RETURN
PR FILTER
TILT
.
OR CV 550 PSI AUX.
25 PSI B 8=75
LIFT CROWD SWAY
.
.120 PB
450 PSI 10 MICRON
SV
BREATHER
P1 P BV TP PRIORITY/BRAKE MAIN
VALVE CONTROL VALVE
(W/O POWER BEYOND)
IMPLEMENT PUMP
1.97 CU.IN./REV
Hydraulic System
MAL0020J
8-9
8-10
8.4.3
LEFT OUTRIGGER RIGHT OUTRIGGER
CYLINDER CYLINDER
5000 5000
PSI PSI
Hydraulic System
B B
LOD ROD
PUMP TANK
T LOU ROU
P A A
PB
OUTRIGGER
SEE VALVE
SHT #1
MAIN
CONTROL VALVE
WITH POWER BEYOND
(SEE STD VALVE SHT #1
FOR REMAINING CONNECTIONS)
JOYSTICK
P
LEFT AND RIGHT
T OUTRIGGER JOYSTICK
1 2 3 4
T
YELLOW
GREEN
RED
BLUE
SEE SHT #1
JS PORT 1 2 1 2
ON PRIORITY/BRAKE VALVE
SEE SHT #1 LOD LOU ROD ROU
HYDRAULIC
OIL COOLER
RETURN
FILTER
25 PSI
B8=75
OUTRIGGER OPTION
10 MICRON
BREATHER
MAL0030J
TL642, TL943
8.4.4
TL642, TL943
PT
B1 B2
A1 A2
REAR STEERING
CYLINDER
FRONT STEERING
CYLINDER
P T STEER SELECT
VALVE
TILT CYLINDER
L R SERVICE
BRAKE VALVE
REAR JOYSTICK
5000
SERVICE PSI
BRAKES
T COMPENSATING
OUTLET 1 2 3 4
CYLINDER
.040 .050
INLET 5000
5000 PSI
PSI
STEERING ORBITROL
YELLOW
GREEN
RED
BLUE
OUTLET
LP T LS
FRONT
LOAD SERVICE
SENSE BRAKES
PARK
BRAKES
TANK
HYDRAULIC
OIL LEFT RIGHT,
COOLER
DWN UP,
QA EXTD. QA RET.
AUXILIARY
HYDRAULICS
PORTS
SECONDARY P1 BV PB
GAUGE PORT B B B B B
SV
PR CV
.030
JS 4100
P P PSI
LOAD SENSING
SIGNAL PORT 500
PSI
TP PUMP 4100 TANK
1100 PSI
2450 PSI RV
PSI T T
4100
T PSI
LIFT CROWD TILT SWAY AUX
PUMP
VALVE BLOCK
A A A A A
REAR SEC
3.19 CU IN/REV
@@2750 RPM FRONT SEC
.75 CU IN/ REV
@@2750 RPM
RETURN
FILTER
25 PSI
B8=75
10 MICRON
BREATHER
100
MESH
MAL0020
Hydraulic Schematic - TL943 Before S/N TBL01599 excluding TBL01551 & TBL01585
Hydraulic System
8-11
8-12
8.4.4
LEFT OUTRIGGER RIGHT OUTRIGGER
CYLINDER CYLINDER
5000 5000
PSI PSI
MAL0030
OPTIONAL REMOTE
HYDRAULIC QUICK ATTACH
(Continued)
Hydraulic System
B B 1
3
LOD ROD
2
PUMP TANK
QA CYLINDER
B B B B B
C2 C3
3800
LOU ROU
PSI
TANK
4100
PSI TO HYDRAULIC AUXILIARY
OIL COOLER HYD. PORTS
SHT1
4100 A A
PSI C1 C4
PUMP POWER
4100
PSI BEYOND
4100
LIFT CROWD PSI TILT SWAY AUX
P1 P2
A A A A A
JOYSTICK
P
LEFT AND RIGHT LEFT RIGHT,
T OUTRIGGER JOYSTICK DWN UP,
1 2 3 4
T QA EXTD. QA RET.
SECONDARY P1 BV PB
GAUGE PORT AUXILIARY HYD.
SV P PORTS @ BOOM NOSE
PRIMARY SECONDARY
PORT
YELLOW
GREEN
RED
BLUE
PRIMARY PORT
GAUGE
PORT
CV
SEE SHT #1
PR
.030 1 2 1 2
JS
P P
LOAD SENSING LOD LOU ROD ROU
SIGNAL PORT 500
PSI
TP
1100
2450 PSI RV
PSI T T
T
PUMP
VALVE BLOCK
RETURN
FILTER
25 PSI
B8=75
10 MICRON
BREATHER
100
MESH
OUTRIGGER OPTION
Hydraulic Schematic - TL943 Before S/N TBL01599 excluding TBL01551 & TBL01585
TL642, TL943
Hydraulic System
8.4.5 Hydraulic Schematic - TL943 S/N TBL01599 & After including TBL01551 & TBL01585
MAL1080E
a. Reservoir Removal
1. Park the machine on a firm, level surface, level the
MAL1060 machine, fully retract the boom, lower the boom,
place the transmission control lever in
The hydraulic reservoir (1) is located on the frame (N) NEUTRAL, engage the park brake and shut the
between the engine compartment and the cab. engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
8.5.1 Hydraulic Oil Reservoir Draining switch and the steering wheel.
1. Park the machine on a firm, level surface, level the 3. Open the engine cover. Allow the system fluids to
machine, fully retract the boom, lower the boom, cool.
place the transmission control lever in 4. Properly disconnect the battery.
(N) NEUTRAL, engage the park brake and shut the
engine OFF. 5. Drain the hydraulic oil reservoir. Refer to Section
8.5.1, “Hydraulic Oil Reservoir Draining.”
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel. 6. Label, disconnect and cap all hydraulic hoses
attached to the hydraulic oil reservoir. Cap all fittings
3. Open the engine cover. Allow the system fluids to and openings to keep dirt & debris from entering the
cool. hydraulic system.
4. Properly disconnect the battery. 7. Remove the bolts securing the hydraulic oil reservoir
5. Open the filler cap on the hydraulic oil reservoir. to the frame.
Remove the drain plug on the side of the hydraulic 8. Remove the hydraulic oil reservoir.
oil reservoir.
6. Transfer the used hydraulic oil into a suitable b. Disassembly
covered container, and label as "Used Oil". Dispose
The hydraulic oil reservoir is a one-piece unit and cannot
of used oil at an approved recycling facility. Clean
be disassembled. The hydraulic oil level sight- glass and
and reinstall the drain plug.
hydraulic oil filler cap can be removed and reused on the
7. Wipe up any hydraulic fluid spillage in, on, near and new replacement reservoir. Dispose of the old reservoir
around the machine and the work area. according to local regulations concerning hazardous
materials disposal.
8.5.2 Hydraulic Oil Reservoir Filling
1. Be sure the reservoir is clean and free of all debris. c. Cleaning and Drying
2. Install a new hydraulic oil filter. If contaminated hydraulic oil or foreign material is in the
tank, the tank can usually be cleaned.
3. Fill the reservoir with hydraulic oil. Refer to Section
2.4, “Fluids and Lubricant Capacities.” Note: If a leak is suspected in the hydraulic oil reservoir,
4. Properly connect the battery. contact your local Service Department.
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
e. Reservoir Installation 2
9. Close and secure the engine cover. 7. Label, disconnect and cap the hydraulic hoses
attached to the pump.
10. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel. 8. Remove the three bolts and washers securing the
pump to the transmission. Remove the o-ring
located between the transmission and the pump.
Wipe up any hydraulic oil spillage.
c. Pump Priming 12. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
moving the machine or operating any hydraulic
4 functions.
13. Inspect for leaks and check all fluid levels. The
hydraulic reservoir oil level must be to the middle of
the sight gauge.
14. Close and secure the engine cover.
15. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
MAL1350
d. Pump Test
1. Disconnect the electrical connector (4) from the Refer to Section 8.3.1, “Pressure Checks and
engine ECM. Adjustments.”
2. Properly connect the battery.
5
7
MAL1320
8.7 CONTROL VALVES 6. Thoroughly clean the main control valve and
surrounding area, including all hoses and fittings,
before proceeding.
8.7.1 Main Control Valve
7. Drain the hydraulic fluid reservoir. Refer to Section
The main control valve is mounted on the frame behind 8.5.1, “Hydraulic Oil Reservoir Draining.”
the cab underneath a protective cover.
8. Place a suitable container to catch hydraulic fluid
The main control valve assembly consists of separate drainage beneath the frame.
working sections with their own valve assemblies, each
providing a specific hydraulic function. Note: Slowly remove the hydraulic hoses attached to
the main control valve to relieve any possible trapped
TL642
pressure in the hydraulic line.
9. Label, disconnect and cap all the hydraulic hoses,
tubes and wires at the main control valve.
10. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.
11. Remove the three bolts, washer and nuts (3)
securing the main control valve to the frame.
MAL0090
3
TL943
MAL0080
MAL0100
Disassemble each Valve Section 3. Install the proper o-rings and load sense shuttle on
the inner face of the end main control valve section.
1. Carefully separate the load sense outlet section from the
Align the next valve section over the three tie rods
lift/lower section.
and slide onto the end main control valve section.
2. Remove the o-rings from between the two sections.
4. Using the proper o-rings and load sense shuttle,
3. Carefully separate each remaining sections, being repeat step three for the remaining valve sections
careful not to lose the load sense shuttle ball. and lastly the inlet end valve section.
4. Remove both end caps from each end of the valve 5. Install the three washers and nuts on the tie rods.
sections then remove each control spool. Torque to 32 lb-ft (43 Nm) for the TL642 and to
5. Remove any check valves, compensator valves, 42 lb-ft (57 Nm) for the TL943.
anti-cavitation valves or shock valves from individual
valve section if equipped. f. Main Control Valve Installation
6. Keep all parts being removed from individual valve 1. Install the main control valve onto the frame, aligning
sections tagged and kept together. the bolts with the holes in the end sections of the
main control valve. Slide the main control valve into
c. Main Control Valve Parts Cleaning position, and tighten the bolts.
Clean all components with a suitable cleaner, such as 2. Prime the main control valve by filling the inlet
triclorethylene, before continuing. Blow dry. openings with fresh, filtered hydraulic oil from a
clean container, before attaching the hoses.
d. Main Control Valve Parts Inspection 3. Use new oiled o-rings as required. Uncap and
Inspect all parts and internal passageways for wear, connect all previously labeled hoses, clamps, etc. to
damage, etc. If inner surfaces of any component DO NOT the main control valve.
display an ultra-smooth, polished finish, or are damaged 4. Check the routing of all hoses, wiring and tubing for
in any way, replace the damaged part. Often, dirty sharp bends or interference with any rotating
hydraulic fluid causes failure of internal seals, damage to members, and install tie wraps and/or protective
the polished surfaces within the component, and wear of conduit as required. Tighten all tube and hose
and/or harm to other parts. clamps.
5. Fill the hydraulic fluid reservoir. Refer to Section
e. Main Control Valve Assembly 8.5.2, “Hydraulic Oil Reservoir Filling.”
Note: ALWAYS replace seals, o-rings, gaskets, etc., 6. Properly connect the battery.
with new parts to help ensure proper sealing and
7. Start the engine and run at approximately one-third
operation. Lubricate seals and o-rings with clean
to one-half throttle for about one minute without
hydraulic oil.
moving the machine or operating any hydraulic
functions.
Assemble each Valve Section
8. Inspect for leaks and check the level of the hydraulic
1. Reassemble any check valves, compensator valves, fluid in the reservoir. Shut the engine OFF.
anti-cavitation valves or shock valves from each
individual valve section if equipped. Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as needed.
2. Install the control spool being careful not to nick or
scratch the valve section bore or the control spool. 9. Wipe up any hydraulic fluid spillage in, on, near and
3. Install the end caps on each end of the valve section. around the machine, work area and tools.
10. Install the main control valve protective cover.
Assemble the Main Control Valve. 11. Close and secure the engine cover.
1. Place all three tie rods with the washers and nuts 12. Remove the Do Not Operate Tags from both the
through the end main control valve section. ignition key switch and the steering wheel.
2. Stand the end main control valve section on end.
a. Service Brake Valve Removal Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
1. Park the machine on a firm, level surface, level the operation. Lubricate seals and o-rings with clean
machine, fully retract the boom, lower the boom, hydraulic oil.
place the transmission control lever in (N) NEUTRAL,
engage the park brake and shut the engine OFF. 3. Use new oiled o-rings as required. Uncap and
connect the previously labeled hoses to the service
2. Place a Do Not Operate Tag on both the ignition key
brake valve.
switch and the steering wheel.
4. Check the routing of all hoses, and tubing for sharp
3. Open the engine cover. Allow the system fluids to
bends or interference with any rotating members,
cool.
and install tie wraps and/or protective conduit as
4. Properly disconnect the battery. required. Tighten all tube and hose clamps.
5. Label, disconnect and cap all hose attached to the 5. Properly connect the battery.
service brake valve.
6. Start the engine and run at approximately one-third
6. Remove the service brake pedal. Refer to Section to one-half throttle for about one minute, without
4.3.2, “Service Brake Pedal.” moving the machine or operating any hydraulic
functions.
1 7. Inspect the service brake valve and connections for
leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF.
Note: Check for leaks, and repair as required before
continuing. Add hydraulic fluid to the reservoir as
needed.
8. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
9. Close and secure the engine cover.
10. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
MAL1070
MY0150
8.7.5 Steer Select Valve b. Steer Select Manifold and Valve Disassembly,
Cleaning, Inspection and Assembly
1. Place the steer select assembly on a suitable work
surface.
2. Separate the steer select valve from the manifold by
removing the four socket head capscrews. Discard
the four o-rings.
3. Remove the solenoid valves and cartridges from the
steer select housing.
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
4 functioning properly. Check that the spring is intact.
Inspect the cartridge interior for contamination.
MY0350
6. Inspect internal passageways of the steer select
manifold and valve for wear, damage, etc. If inner
The machine can be used in the front-wheel, four-wheel
surfaces of the manifold DO NOT display an ultra-
or crab steering mode. The steer select valve (4) controls
smooth, polished finish, or components are
the direction of hydraulic fluid flow to the steering cylinder
damaged in any way, replace the manifold or
mounted on each axle. The steer select valve is attached
appropriate part. Often, dirty hydraulic fluid causes
to a mounting plate inside the frame near the left front
failure of internal seals and damage to the polished
corner of the cab.
surfaces within the secondary function manifold.
Verify the correct operation of the steer select valve
solenoids before considering replacement of the valve. Note: ALWAYS replace seals, o-rings, gaskets, etc.,
Refer to Section 9.5, “Electrical System Schematics,” and with new parts to help ensure proper sealing and
Section 9.12, “Gauges and Display Monitor.” The housing operation. Lubricate seals and o-rings with clean
of the steer select valve is not serviceable and must be hydraulic oil.
replaced if defective. 7. Install the solenoid valves and cartridges in the steer
select housing.
a. Steer Select Manifold and Valve Removal
8. Attach the steer select valve to the manifold using
1. Park the machine on a firm, level surface, level the four new, oiled o-rings and the four socket head
machine, fully retract the boom, lower the boom, capscrews.
place the transmission control lever in (N) NEUTRAL,
engage the park brake and shut the engine OFF. c. Steer Select Valve and Manifold Installation
2. Place a Do Not Operate Tag on both the ignition key 1. Install the steer select valve to the mounting plate
switch and the steering wheel. under the left front side of the frame using the two
3. Open the engine cover. Allow the system fluids to bolts.
cool. 2. Connect all the hydraulic hoses, fittings, solenoid
4. Properly disconnect the battery. wire terminal leads, etc., to the steer select valve
5. Label, disconnect and cap the hydraulic hoses and 3. Check the routing of all hoses, wiring and tubing for
the electrical plugs connected to the steering select sharp bends or interference with any rotating
valve. members, and install tie wraps and/or protective
conduit as required. Tighten all hose clamps.
6. Remove the bolts holding the steer select valve to
the mounting plate on the frame. 4. Properly connect the battery.
7. Remove the steer select manifold with the attached 5. Start the engine and run at approximately 1/3-1/2
steer select valve from the machine. throttle for about one minute without moving the
machine or operating any hydraulic functions.
8. Wipe up any hydraulic fluid spillage in, on, near and
around the machine.
6. Inspect for leaks and check the level of the hydraulic fittings to keep dirt & debris from entering the
fluid in the reservoir. Shut the engine OFF. hydraulic system.
Note: Check for leaks and repair as required before 7. Remove the bolts holding the outrigger control valve
continuing. Add hydraulic fluid to the reservoir as to the frame.
needed.
b. Outrigger Valve Installation
7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools. 1. Install the outrigger valve onto the machine frame.
8. Close and secure the engine cover. 2. Uncap and connect the previously labeled hydraulic
hoses to the outrigger valve.
9. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel. 3. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
d. Steering Test members, and install tie wraps and/or protective
conduit as required. Tighten all hose clamps.
Refer to Section 8.4.1, “Hydraulic Pressures.”
4. Properly connect the battery.
1. Conduct a pressure check of the steering hydraulic
circuit. 5. Start the engine and run at approximately 1/3-1/2
throttle for about one minute without moving the
2. Check each steering mode for proper function. machine or operating any hydraulic functions.
8.7.6 Outrigger Valve (if equipped) 6. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
a. Outrigger Valve Removal Note: Check for leaks and repair as required before
1. Park the machine on a firm, level surface, level the continuing. Add hydraulic fluid to the reservoir as
machine, fully retract the boom, raise the boom, needed.
place the transmission control lever in 7. Wipe up any hydraulic fluid spillage in, on, near and
(N) NEUTRAL, engage the park brake and shut the around the machine, work area and tools.
engine OFF.
8. Close and secure the engine cover.
2. Place a Do Not Operate Tag on both the ignition key
9. Remove the Do Not Operate Tags from both the
switch and the steering wheel.
ignition key switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
OAL0070
Note: When sliding the rod and piston assembly out of c. Cylinder Inspection
the barrel, prevent the threaded end of the barrel from
1. Inspect internal surfaces and all parts for wear,
damaging the piston. Keep the rod centered within the
damage, etc. If the inner surface of the cylinder
barrel to help prevent binding.
barrel does not display a smooth finish, or is scored
6. Carefully pull the rod assembly along with the head or damaged in any way, replace the barrel.
gland out of the cylinder barrel. 2. Remove light scratches on the piston, head gland,
7. Fasten the rod eye in a soft-jawed vise, and place a rod or inner surface of the cylinder barrel with a 400-
padded support under and near the threaded end of 600 grit emery cloth. Use the emery cloth in a rotary
the rod to prevent any damage to the rod. motion to polish out and blend the scratch(es) into
8. Remove the set screw from the piston head. the surrounding surface.
3. Check the piston rod assembly for run-out. If the rod
Note: It may be necessary to apply heat to break the
is bent, it must be replaced.
bond of the sealant between the piston and the rod
before the piston can be removed.
d. General Cylinder Assembly Instructions
Some cylinder parts are sealed with a special organic
1. Use the proper tools for specific installation tasks.
sealant and locking compound. Before attempting to
Clean tools are required for installation.
disassemble these parts, remove any accessible seals
from the area of the bonded parts. Wipe off any hydraulic 2. Install new seals, back-up rings and o-rings on the
oil, then heat the part(s) uniformly to break the bond. A piston and new seals, back-up rings, o-rings and
temperature of 300-400° F (149-204° C) will destroy the bearing on the head gland.
bond. Avoid overheating, or the parts may become Note: The extend/retract cylinder has a spacer that
distorted or damaged. Apply sufficient torque for removal MUST be installed over the rod AFTER the head gland
while the parts are still hot. The sealant often leaves a
and BEFORE the piston head.
white, powdery residue on threads and other parts, which
must be removed by brushing with a soft brass wire brush 3. Fasten the rod eye in a soft-jawed vise, and place a
prior to reassembly. padded support under and near the threaded end of
the rod to prevent any damage to the rod.
9. Remove the piston head from the rod and carefully
slide the head gland off the end of the rod. Note: Protect the finish on the cylinder rod at all times.
10. Remove all seals, back-up rings and o-rings from the Damage to the surface of the rod can cause seal failure.
piston head and all seals, back-up rings and o-rings 4. Lubricate and slide the head gland over the cylinder
from the head gland. rod. Install the piston head on to the end of the
Note: The head gland bearing will need to be inspected cylinder rod. Loctite® 243TM and install the set screw
to determine if replacement is necessary. in the piston head. Refer to Section 8.8.4, “Cylinder
Torque Specifications - TL642” or Section 8.8.5,
DO NOT attempt to salvage cylinder seals, sealing rings “Cylinder Torque Specifications - TL943” for torque
or o-rings. ALWAYS use a new, complete seal kit when specifications for the piston head and the set screw.
rebuilding hydraulic components. Consult the parts
catalog for ordering information. Note: Avoid using excess force when clamping the
cylinder barrel in a vise. Apply only enough force to hold
b. Cylinder Cleaning Instructions the cylinder barrel securely. Excessive force can
damage the cylinder barrel.
1. Discard all seals, back-up rings and o-rings. Replace
with new items from seal kit to ensure proper 5. Place the cylinder barrel in a soft-jawed vise or other
cylinder function. acceptable holding devise.
2. Clean all metal parts with an approved cleaning Note: When sliding the rod and piston assembly into the
solvent such as trichlorethylene. Carefully clean cylinder barrel, prevent the threaded end of the cylinder
cavities, grooves, threads, etc. barrel from damaging the piston head. Keep the cylinder
rod centered within the barrel to prevent binding.
Note: If a white powdery residue is present on threads
or parts, it can be removed by using a soft brass wire 6. Carefully insert the cylinder rod assembly into the
brush. Wipe clean with Loctite® Cleaner prior to cylinder barrel.
reassembly.
7. Screw the head gland into the cylinder barrel and 8.8.3 Steering Cylinders
tighten with a spanner wrench. Refer to Section
The steer cylinder is attached to each axle center
8.8.4, “Cylinder Torque Specifications - TL642” or
housing.The steer cylinder assembly can be found in
Section 8.8.5, “Cylinder Torque Specifications -
Section 5.3, “Axle Assemblies.” The steer cylinder is
TL943” for torque specifications for the head gland.
covered in the appropriate manufacturer’s axle literature.
8. If applicable, install new counter balance valve into
block on the cylinder barrel. STEERING CYLINDER
a. Lift/Lower Cylinder
Note: The capscrews for the bolt plate need to be torqued in sequence in an alternating pattern starting at 35 lb-ft to
75 lb-ft to the final 95 lb-ft. Check the final torque in a circular pattern a minimum of two times.
b. Extend/Retract Cylinder
c. Tilt Cylinder
d. Compensation Cylinder
a. Lift/Lower Cylinder
Note: The capscrews for the piston need to be torqued in sequence in an alternating pattern starting at 150 lb-ft to
300 lb-ft to the final 460 lb-ft. Check the final torque in a circular pattern a minimum of two times.
b. Extend/Retract Cylinder
c. Tilt Cylinder
d. Compensation Cylinder
Contents
POWER CONTROL
BOARD
(under dash panel)
HEATER/AC CONTROLS
(if equipped)
MAL0440
TRANSMISSION
TEMPERATURE
SWITCH
MAL0450
HEATER/AC CONTROLS
(if equipped)
POWER CONTROL
BOARD & UGM
(under dash panel)
MAL1090
ALTERNATOR
STARTER
RELAYS
TRANSMISSION
TEMPERATURE
SWITCH
COOLANT TEMPERA-
TURE SENDER
MAL1140
5
WARNING
DO NOT service the machine without following all
safety precautions as outlined in Section 1, “Safety
Practices,” of this manual. 4
MAL0460
9.4 FUSES AND RELAYS
The starter relay (2), glow plug relay (3), fuel pump relay
(4), 50 amp fuse (5) are located on the frame directly
9.4.1 Cab above the engine.
TL642 - Before S/N TBK01167 excluding TBK01162
TL943 - Before S/N TBL01599 excluding TBL01551 & TL642 - S/N TBK01167 & After including TBK01162
TBL01585 TL943 - S/N TBL01599 & After including TBL01551 &
TBL01585
1 6
9
MAL1150
fuses and sealed 12-volt relays are mounted under the The starter relay (6) and VEC control module (7) 100 amp
panel. relay(8), 60 amp fuse (9) are located on the power
distribution unit bracket in the engine compartment.
X1 X2 X3 X4
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
X5 X6 X7
X8 X9 X10
X11
R1 R2 R3 R4
X12 X13
R5 R6 R7 R8 R9
MY0391
XXXXXXX
XXXXXX
F8 F3
25 10
F15 F4
20 10
POWER DISTRIBUTION
MAL1100
FUSE/BREAKER LEGEND
No. Function Amp Rating
F1 TRANS/PARK BRK PWR 15
F2 ALTERNATOR EXCITE 5
F3 ENGINE ECU IGNITION PWR 10
F4 GAGE (INST PANEL) PWR 10
F5 SPARE ACCESSORY PWR 15
F6 AUX ELECTRIC PWR 10
F7 HORN PWR 15
F8 SPARE BATTERY PWR 25
F9 ENGINE ECU BATTERY PWR 25
F10 STEER/FRAME LEVEL PWR 10
F11 REAR AXLE STABILITY/TILT PWR 10
F12 KEY BATTERY PWR 15
F13 OPTION PWR 3 20
F14 OPTION PWR 4 20
F15 OPTION PWR 1 20
F16 OPTION PWR 2 20
d. UGM Installation
1. Attach the UGM to the cab with the previously
3 removed hardware
2. Reconnect the electrical harnesses to the UGM.
3. Install the right hand side panel to the dash with the
previously removed hardware.
4. Properly connect the battery.
MAL1110
5. Close and secure engine cover.
The UGM is located behind the right hand side panel (3)
6. Remove the Do Not Operate Tags from both the
of the dash.
ignition key switch and the steering wheel.
a. UGM Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
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.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Remove the hardware securing the right hand side
panel to the dash.
6. Disconnect the electrical harnesses attached to the
UGM.
7. Remove the bolts securing the UGM to the cab and
remove the UGM.
J1 (Black) J2 (Grey)
XXXXXXXX
XXXXXXXX
MAL1120
9.5.1
DASH PANEL
GAG PWR
PARK
BRAKE
GAG PWR
LIGHT
PB LT GND
HOUR METER
DATCON
P/N 56458-10
TL642, TL943
OIL FUEL INST GND
OIL GAG
12 UDC
2
1
PARK BRAKE
B+
CARLING SWITCH
FUL GAG P/N VDD1B6AB-ARC00-000 GND
a. Cab Schematic
12V
8 7 HMTR GND HR MTR
GND 1 4
INST GND
BR SW PWR 2 5
G TEMP
CLT TMP
3 6
3
4 IN 1 GAGE
BEEDE GAG PWR
BRK SW
SHFT PWR 1
ST RLY
STEER
GAG PWR
LIGHT
REV AL
18
INST GND TRANS-E
17
STEER SELECT PRE-HEAT TRANS-D
16
CARLING SWITCH CARLING SWITCH TRANS-C
P/N V2D1B60B-AEC3V-100 15
HORN P/N VJD1S00B-AZC00-000 TRANS-A
14
CARLING SWITCH TRANS-B
8 7 8 7 INST GND 13
P/N V2D1S00B-AZC00-000 STR CRB
12
STR AW
1 1
11 TO ENGINE
4 4 SP-3
8 7 10
ALT EXC HARNESS
9
2 5 2 5 SP-2
1 4 8
SP-1
7
BAT-2
3 6 3 6 6
5 ST RLY
GP SW
2 5
FUL GAG
4
6 HORN
PRE-HEAT SWITCH INSTALLED FOR 3
3 HR MTR
CAT/PERKINS ENGINES ONLY. 2
GP SIG
BAT-1
1
PS IGN
HORN
HRN PWR
STR AW
STR PWR
STR CRB
CAB FIREWALL
TRANS
TEMP
SP-3
WARN
LIGHT SP-2
SP-1
18
17
SEALED ENDS
16
TR LT
GP SIG
15
GP SW
14
TR LT SW
13
BRK SOL
12
CLT TMP
IGNITION SWITCH 11 TO ENGINE
OIL GAG
10
ELECTRICAL SYSTEM SCHEMATICS
PS IGN HARNESS
9
STOP LT
BAT ACC 8
GND-2
7
BR SW PWR
WORK LT
6
5
STRT 4
3
PS IGN
KEY PWR
BACK LT
2
GND-1
1
KEY STRT
IGN
Before S/N TBK01167 excluding TBK01162;
PS IGN
KEY ACC
SWI-86 SW2-87a SW1-87a SW2-86 GND 85 SPARE_COIL
DEUTSCH P/N HD-36-24-18-SN
O ALT EXC
SHIFT-B A P TRANS-B
Before S/N TBL01599 excluding TBL01551 & TBL01585
TR LT B Q TR LT SW
BRK SW C R BRK SOL
KEY STRT D
SHIFT STRT E D1 S REV AL
T BACK LT
KEY ACC G
SL
GND1 GND2 GND3
SWB
U STOP LT
WL2 WL
SWB V WORK LT
D6 D7 D8 D9
HTR FAN 87 87 87 87
SW SW
87a 87a 87a 87a
86 85 86 85 86 85 86 85
30 30 30 30
FAN/HTR W/W LIGHTS ACC
TO TRANSMISSION
SHIFTER INST GND H
1
2
3
5
7
8
4
6
DEUTSCH W
P/N DT04-8P X
LOCKING WEDGE STR PWR I
W8P
GAG PWR J
HRN PWR K
SHIFT-B
TRANS-E
TRANS-C
TRANS-D
TRANS-A
KEY PWR L
SHIFT STRT
SHFT PWR 2
SHFT PWR 1
Y GND-2
M GND GND-1
MOTOROLA (25A) (25A) (25A) (10A) (25A) (30A)
D10 (10A) (10A) SPARE (15A) (10A)
MR 752 FAN/HTR W/W LIGHTS RELAYS GAGES STEER KEY HORN OPT_PWR AA BAT-2
(NOT REQUIRED) BAT
OR EQUIV
N
BATT BAT-1
WL_SWA SL_SWA
W/W_SW SPARE_BAT
MY1370
Electrical System
9-11
Electrical System
b. Engine Schematic
REV AL
18
TRANS-E
17 C
TRANS-D
DIODE
16
DEUTSCH P/N HD-34-24-18-SN
TRANS-C
15
TRANS-A
14
TRANS-B STR CRB STR CRB STEER
13 A 2W SELECT
STR CRB
12 GND-7 GND-7
TO CAB 11
STR AW B VALVE
SP-3
INSTRUMENT 10
ALT EXC
PANEL HARNESS 9
SP-2 4W
8
SP-1
7
BAT-2
DIODE
6
ST RLY
5
FUL GAG
4
HORN STR AW STR AW
3 A
HR MTR
2 GND-8 GND-8
BAT-1 B
1
ST RLY PWR
18 GND-6
17 87 85
16 GND-6
DEUTSCH P/N HD-34-24-18-PN
GP SIG
15
GP SW
STARTER
14
TR LT SW RELAY
13
BRK SOL
12
TO CAB 11
CLT TMP
OIL GAG
INSTRUMENT 10
PS IGN
PANEL HARNESS 9
STOP LT STRT SOL
8
GND-2
7
WORK LT
STARTER
6
BAT-2
MOTOR
5
BAT-1
4
GP PWR
3
BACK LT ALT BAT 1
2
GND-1 ALT BAT 2
1
- + GROUND
HORN
HORN
BATTERY
12VDC
GROUND
(AT ENGINE
POD)
ALT EXC
1 TRANS-A
TRANS-B ALT BAT 2 D+
2
TRANS-C ALT BAT 1
3 BATT W
4 TRANS-D
TRANS-E
TO TRANSMISSION 5
BRK SOL
HARNESS
6
TR LT SW ALTERNATOR
7
8 GND-9
GND-10
9
GND-11
PARK BRAKE SOLENOID
10
11 GND-12
12 GND-13
GND-13
GND-12
DIODE
GND-11
GND-10
GND-9
GND-1
GND-2
GND-7
B A
GND-8
GROUND
(AT GND-6
STARTER GND-3 GND-3 GND-3
MOTOR) BRK SOL BRK SOL
GND-5
REV AL
BACK-UP
GND-15
FUL GAG
GND-5 ALARM
GND-14
FUL GAG
A
GND-4
WORK B
LIGHT FUEL FUSE, 50 AMP GLOW PLUGS
OPTION LEVEL SLOW BLOW
A B C SENDER GP PWR GP RLY
SEALED
FP PWR
ENDS
SP-1
SP-2 GP SIG 86 30
SP-3
WORK LT
STOP LT
BACK LT
GLOW PLUG
RELAY
GND-6
MY1380
CLT TMP
PS IGN
OIL GAG
FUEL PUMP
FUEL PUMP
GND-14
PS IGN
PS IGN
HR MTR
FP PWR
GND-14
FP RLY
FP RLY
PS IGN
PS IGN
GP SW
GND-6
C
A
85
86
87
30
87A
B
B
1
1
2
2
M
FUEL
OIL WATER SOLENOID
PRESSURE TEMP. FUSE FUEL PUMP FUEL PUMP
OIL COLD START
SENDER SENDER PRESSURE SWITCH 7.5 AMP RELAY
ADVANCE
5 PSI SOLENOID
c. Transmission Schematic
TRANSMISSION
TEMPERATURE SWITCH
GND-13 TR LT SW
ZF TRANSMISSION 250°F
(RISING)
A TRANS-A
Y1 B GND-9
TRANS-A 1
TRANS-B 2
TRANS-C 3
TRANS-D 4
TRANS-B TRANS-E
A 5 TO ENGINE
Y2 B GND-9 BRK SOL
TR LT SW
6
HARNESS
7
GND-9 8
GND-10 9
TRANSMISSION
GND-11 10
A TRANS-C GND-12 11
Y3 B GND-10 GND-13 12
A TRANS-D
Y4 B GND-11
A TRANS-E
Y5 B GND-11
A BRK SOL
Y6 B GND-12
ZF/HOBBS SHIFTER
1
F 2
N 3
R 4
F 1
N 2
R 3
4
1
2
3
7
8
4
6
TRANS-C
TRANS-D
TRANS-A
TRANS-E
SHFT PWR 1
SHFT PWR 2
SHIFT-B
SHIFT STRT
SHFT PWR 2
SHFT PWR 1
SHIFT STRT
TRANS-D
TRANS-A
TRANS-C
TRANS-E
SHIFT-B
1
2
3
7
8
4
6
TRANS-E
TRANS-C
TRANS-D
TRANS-A
SHFT PWR 2
SHFT PWR 1
SHIFT-B
SHIFT STRT
CAB INSTRUMENT
PANEL HARNESS MY1400
d. Auxiliary Schematic
DASH PANEL
PARK
BRAKE
LIGHT
HOUR METER
DATCON
P/N 56458-10
OIL FUEL
12 UDC
2
1
PARK BRAKE
B+
CARLING SWITCH
P/N VDD1B6ABARC00-000 GND 12V
8 7
GND 1 4
2 5
G TEMP
3 6
3
4 IN 1 GAGE
BEEDE
STEER
LIGHT
HORN
LIGHT
STEER SELECT
CARLING SWITCH
HORN P/N VJD1S00BAZC00-000
CARLING SWITCH
P/N V2D1S00BAZC00-000
8 7
8 7 GND 85
1 4 MAST 1 4 SW1-86
8 7
SW1-87a 2 5 SW1-87a 8 7 GND 85
2 5
1 4 SIDESHIFT 3 6 SW1-86 SWING 1 4 SW2-86
5
3 6 SW2-87a 2 5 SW2-87a
2
EXTRA 3 6 SW2-86
6
3
MAST
SWING
TRANS
TEMP
WARN
LIGHT
SW1-87a
SW1-86
SW2-87a
SW2-86
MAST A BLACK
SIDESHIFT B RED
GND 85 C WHITE
SWING D GREEN
EXTRA E ORANGE
PLUG F PLUG
O
A P
B Q
ORANGE
C R
GREEN
WHITE
BLACK
PLUG
RED
E S
D1 T
10 OHM D2 D4 (10A) (15A) (15A)
30W D3 D5 OPT-1 OPT-2 OPT-3
R1
C
A
D
E
B
87 87 87 87 87
87a 87a 87a 87a 87a
86 85 86 85 86 85 86 85 86 85
WHITE
ORANGE
REV
GREEN
RED
PLUG
BLACK
OPT-1
OPT-2
30 30 30 30 30
OPT-3
87 87 87 87
HTR FAN 86
87a
85 86
87a
85 86
87a
85 86
87a
85
SW SW 30 30 30 30 "TM" EXTRA (ORANGE)
FAN/HTR W/W LIGHTS ACC
"A" OPEN
GROUND (YELLOW)
H
W
X "S" MAST (BLACK)
I
"LT" SIDESHIFT (RED)
J "RT" SWING (BLUE)
K
L
Y
M MOTOROLA GND
(25A) (25A) (25A) (10A) (10A) (10A) (25A) (15A) (10A) (30A)
D10 MR 752 FAN/HTR
OR EQUIV W/W LIGHTS RELAYS GAGES STEER SPARE KEY HORN OPT_PWR AA
N BAT
BAT
WL_SWA SL_SWA
W/W_SW SPARE_BAT
STEER
LIGHT
HORN
LIGHT
STEER SELECT
CARLING SWITCH
HORN P/N VJD1S00BAZC00-000
CARLING SWITCH QUICK COUPLER
8 7 CARLING SWITCH
P/N V2D1S00BAZC00-000
P/N VLD1CW6B-AP4-000
8 7
1 4 8 7 GND
1 4
2 5
QC PWR 1 4 QC GND
5
3 6 PWR 2 5 GND
2
6 QC PWR 3 6 QC GND
3
TRANS
TEMP
WARN
LIGHT
PLUG A BLACK
QC PWR B RED
QC PWR C WHITE
QC GND D GREEN
QC GND E ORANGE
PLUG F PLUG
PWR
GND
O
A P
B Q
ORANGE
C R
GREEN
WHITE
BLACK
PLUG
D
RED
E S
D1 T
10 OHM D2 D4 (10A) (15A) (15A)
30W D3 D5 OPT-1 OPT-2 OPT-3
C
A
D
E
B
F
R1
87 87 87 87 87
87a 87a 87a 87a 87a
86 85 86 85 86 85 86 85 86 85
WHITE
ORANGE
GREEN
RED
PLUG
BLACK
REV
OPT-1
OPT-2
30 30 30 30 30
OPT-3
87 87 87 87
HTR FAN 86
87a
85 86
87a
85 86
87a
85 86
87a
85
SW SW 30 30 30 30
QC PWR
H
1
2
W
X
I
-
-
J
K
L
Y
M MOTOROLA GND
(25A) (25A) (25A) (10A) (10A) (10A) (25A) (15A) (10A) (30A)
D10 MR 752 FAN/HTR
OR EQUIV W/W LIGHTS RELAYS GAGES STEER SPARE KEY HORN OPT_PWR AA
N BAT
BAT
WL_SWA SL_SWA
W/W_SW SPARE_BAT
MY1430
9-16
DASH PANEL
FRONT FRONT
WORK GND L1 WORK
LIGHT PARK WORK LIGHT
BRAKE LIGHT IND LT
(ON CAB) LIGHT INDICATOR (ON CAB)
HOUR METER
DATCON
P/N 56458-10
WORK LIGHT
OIL FUEL CARLING SWITCH
12 UDC P/N V1D1S00BAZC00-000
2
1
PARK BRAKE 8 7
B+
CARLING SWITCH
P/N VDD1B6ABARC00-000 1 4 GND 12V
8 7
5
GND 2
1 4
6
Work Light Schematic
2 5 3
G TEMP
3 6
3
4 IN 1 GAGE
BEEDE
Electrical System
WORK LT
LIGHT SW
A B A B
STEER
LIGHT
HORN
LIGHT
STEER SELECT
CARLING SWITCH
HORN P/N VJD1S00BAZC00-000
1 4
8 7 REV AL REV AL
18
GND L
GND L
LIGHT-1
LIGHT-2
2 5 TRANS-E 17 TRANS-E
1 4
TRANS-D 16 TRANS-D
3 6
5 TRANS-C TRANS-C
2 15
TRANS-A TRANS-A
6 14
3 TRANS-B TRANS-B
13
STR CRB STR CRB
12
STR AW STR AW
11
SP-3 SP-3
10
TRANS ALT EXC ALT EXC
9
TEMP SP-2 SP-2
WARN 8
LIGHT SP-1 SP-1
7
FRONT
BAT-2 BAT-2
6 WORK
ST RLY ST RLY LIGHT
5
FUL GAG FUL GAG
4
HORN HORN
3
HR MTR HR MTR
2
BAT-1 BAT-1
1
GND
MIRROR-LT
CAB FIREWALL
LIGHT SW LIGHT-2 A B
18
17
GND L
GND L
GND L1 16
IND LT 15
14
TR LT SW TR LT SW
13 REV AL
BRK SOL BRK SOL
12
GND
BACK-UP
WORK LT
CLT TMP CLT TMP
LIGHT SW
11 GND 1 ALARM
OIL GAG OIL GAG
MIRROR-LT
OPT-1
OPT-2
OPT-3
ELEC1
BACK LT
STOP LT
TAIL LT
GND L1
GND L
GND L
G
GND1 GND2 GND3
SL
SWB GND L A B C
STOP LT
LIGHT-1 WL2 SWB D7 D8 D9
D6
87 87 87 87
GND DL
HTR FAN 87a 87a 87a 87a
86 85 86 85 86 85 86 85
SW SW 30 30 30 30
J
K
L
Y
M MOTOROLA GND
(25A) (25A) (25A) (10A) (10A) (10A) (25A) (15A) (10A) (30A)
D10 MR 752 FAN/HTR
OR EQUIV W/W LIGHTS RELAYS GAGES STEER SPARE KEY HORN OPT_PWR AA
N BAT
BAT
IND LT
W/W_SW SPARE_BAT
DOME LT DOME LT
DOME
WORK LT LIGHT
DOME
STOP SW LIGHT
SWITCH
STOP LT
STOP SW
WORK LIGHT OPTION
MY1440
STOPLT SW
TL642, TL943
DASH PANEL
TL642, TL943
BEACON
LIGHT GND L1
(ON CAB) PARK BEACON
BRAKE LIGHT IND LT
LIGHT INDICATOR
HOUR METER
DATCON
P/N 56458-10
BEACON LIGHT
OIL FUEL CARLING SWITCH
12 UDC P/N V1D1S00BAZC00-000
2
1
PARK BRAKE 8 7
B+
CARLING SWITCH
P/N VDD1B6ABARC00-000 1 4 GND 12V
8 7
5
GND 2
1 4
6
2 5 3
G TEMP
3 6
3
4 IN 1 GAGE
BEEDE
A B
BEACON-1
BEACON SW
STEER
g. Bacon Light Schematic
LIGHT
HORN
LIGHT
STEER SELECT
CARLING SWITCH
HORN P/N VJD1S00BAZC00-000
CARLING SWITCH
8 7
P/N V2D1S00BAZC00-000
1 4
8 7
GND L
2 5
BEACON SW
1 4
3 6
5
2
6
3
TRANS
TEMP
WARN
LIGHT
O
A P
B Q
C R
D
E S
D1 T
10 OHM D2 D4 (10A) (15A) (15A)
30W D3 D5 OPT-1 OPT-2 OPT-3
R1
BEACON-1
87 87 87 87 87
87a 87a 87a 87a 87a
86 85 86 85 86 85 86 85 86 85
30 REV 30 30 30 30
ALARM WARN AUX AUX
F LT CK ELEC2 OPT
OPT-1
OPT-2
OPT-3
ELEC1
G
GND1 GND2 GND3
SL
SWB GND L
U
WL V
WL2 SWB D7 D8 D9
D6
87 87 87 87
H
W
X
I
J
K
L
Y
M MOTOROLA GND
(25A) (25A) (25A) (10A) (10A) (10A) (25A) (15A) (10A) (30A)
D10 MR 752 FAN/HTR
OR EQUIV W/W LIGHTS RELAYS GAGES STEER SPARE KEY HORN OPT_PWR AA
N BAT
BAT
WL_SWA SL_SWA
MAL0390
W/W_SW SPARE_BAT
Electrical System
9-17
TL642, TL943 9-18
MY5830
KEY BAT PWR
1
KEY/IGN
KEY START
4
KEY IGN
2
(SHIELD/020)
C
KEY ACC (CAN L/905,GREEN)
(SHIELD/020)
B
SHIELD (SHIELD/020) (CAN H/904, YELLOW)
C A
(CAN L/905, GREEN)
B (SHIELD/020)
CAN H (CAN H/904) C
3 31 30 29
A (CAN L/905,GREEN)
SHIELDED B
(CAN H/904, YELLOW)
CABLE A
(D BLU, 18 GA GXL)
FUL LVL FUL LVL
12
1
GAUGE
STONERIDGE
TRANS TMP SW
6 22 13
PLUGGED PLUGGED
6 7 8
HD34-24-31ST
DASH PANEL HARNESS
HORN
2
(RED, 18 GA GXL)
(RED, 18 GA GXL)
(RED, 18 GA GXL)
GND FAULT
17
16
ENG WARN
MAIN DASH PANEL
STEER/SWAY PWR
STR AW STR AW
10 8 9
DCLUTCH IN
ST RLY ST RLY
14
7
STEER/SWAY PWR
4
3
6
1
7
4
3
6
1
TILT DN
PARK BRAKE
DCLUTCH
STEER MODE
AUX A
AUX B
ACC MOD GND DASH GND
15 25 26 27 18 19 24
120 OHM
A
B
A
B
C
C
CAN TERMINATOR
N
AUX A
F4
F3
F2
F1
R3
R2
R1
AUX B
F4
F3
F2
F1
N4
N3
N2
N1
R4
R3
R2
R1
TILT UP
TILT DN
GEAR
GEAR
KEY IGN
DCLUTCH
GND FAULT
PK BRK SOL
DCLUTCH IN
E4, E3
E4, E2
E4, E1
E6, E3
E5, E3
E5, E2
E5, E1
Y2,Y6
Y1,Y6
Y2,Y3,Y6
Y1,Y3,Y6
Y2,Y3,Y5,Y6
Y2,Y3,Y4,Y6
Y1,Y3,Y5,Y6
Y1,Y3,Y4,Y6
(SHIELD/020)
NO SOLENOIDS INGAUGED
TRANSMISSION LEGEND
(CAN L/905,GREEN)
ACTIVATED TRANS SOLENOIDS
1
4
N
TRANS SOL Y1
2
3
TRANS SOL
TRANS SOL Y3
TRANS SOL Y6
SHIFT PWR 2
HOBBS
REVERSE SOL
PLUGGED
TRANS SOL Y5
2
3
1
4
SEE SHEET 3
N
KEY START
F
SHIFT PWR 1
TRANSMISSION SHIFTER
PLUGGED
SW4
PLUGGED
SW2
1 2 3 4 5 6 7 8 9 10 11 12
PLUGGED
26 27
F
1
4
N
SHIFT PWR 2
1 3 5 4 8 7 2 9
1 2 3 4 5 6 7 8
1
4
N
F
TRANS SOL Y6
6
TRANSMISSION SHIFTER
SW4
SW2
ON-IDLE
IVR
THR SGN/915 THR SGN/915
THR RTN/914 THR RTN/914
HD34-24-31PT
THR SUP/911 THR SUP/911
IVS IVS
SHIFTER GND ON-IDLE
WILLIAMS
(SUSPENDED)
30 31 14 15 13 29 12 17 18 19
PLUGGED 3 87a
TWIST
12 TURNS
PER FOOT
REVERSE SOL 5 86
SP-1
REVERSE
SHIFTER GND 2 85
SP-2
SP-3
11 10 20 21 22
PLUGGED PLUGGED 3 87a
25
SHIFTER GND 1 30
TRANS TMP SW TRANS TMP SW 4 87
SP BAT PWR KEY START 5 86
SP BAT PWR SHIFTER GND 2 85
TEST RELAY
WARN LIGHT
23 16 28
AC CLUTCH
24
SP-3
SP-2
SP-1
SP BAT PWR
AC CLUTCH
SP CAB GND 2
SP CAB GND 1
SP ACCY PWR
SEE
SHEET 2
a. Cab Schematic
S/N TBL01599 & After including TBL01551 & TBL01585
S/N TBK01167 & After including TBK01162; 9.5.2
Electrical System
TL642, TL943
1
TO CAB ASSEMBLY 2
(OPT)
REVERSE (OPT)
TAIL LIGHT
MY5860D
ALARM HORN QC DIVERTOR
A/C (OPT)
BU STOP TAIL TO DASH PANEL HARNESS TO CAB CONTROL HARNESS TO OPTIONS HARNESS COMPRESSOR A B C D E F VALVE
AUXILIARY
HD36-24-31PT HD36-24-31ST HD34-24-19SE
CHASSIS HARNESS CHASSIS HARNESS CHASSIS HARNESS M ELECTRIC
NEGATIVE CABLE
TO CAB FIREWALL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 A S LT RT TM
A B
BLK
RED
YEL
BLU
ORG
(-)
GRN
RED
BLK
PLUGGED
b. Chassis Schematic
A B C D
A B C D E F
MAST
BLK
YEL
BLU
RED
ORG
SP-3
SP-2
SP-1
HORN
TILT DN
HORN
SP-1
SP-2
SP-3
TILT UP
LT GND
QC GND 5
QC GND 7
SP GND 1
REVERSE
STR AW
ST RLY
AC CLUTCH
GND FAULT
AUX A
AUX B
KEY IGN
KEY ACC
STR CRB
FUL LVL
TILT UP
TILT DN
DCLUTCH
PLUGGED
CAN H/904
CAN L/905
SHIELD /020
REVERSE
IVS
ON-IDLE
IVR
KEY ACC
STOP LT
WORK LT
EXTRA
SWING
SIDESHIFT
SP BAT PWR
QC PWR 1
DASH GND
GAGE PWR
HORN PWR
SP ACCY PWR
KEY START
KEY START
AC CLUTCH
OPT PWR 1
QC PWR 2
OPT PWR 2
OPT PWR 3
OPT PWR 4
OPT GND 1
OPT GND 2
PK BRK SOL
SHIFT PWR 2
SP BAT PWR
SP BAT PWR
TRANS TMP SW
ENG STOP LT
TRAN/BRK PWR
TRANS SOL Y1
REVERSE SOL
TRANS SOL Y3
TRANS SOL
TRANS SOL Y5
TRANS SOL Y6
TRAN/BRK PWR
SP CAB GND 1
SP CAB GND 2
TRANS TMP SW
AUX RLYS PWR
AUX ELEC GND
WAIT TO START
STAB/TILT PWR
STEER/SWAY PWR
AC CLUTCH GND
CABLE
+ -
LT GND
REVERSE
STOP LT
WORK LT
12 VDC
QC GND 7
QC GND 5
PLUGGED
QC PWR 2
QC PWR 1
BATTERY
TO STARTER
AND ALTERNATOR
NEGATIVE CABLE
TO ENG BLOCK
BAT GND
BAT GND
BAT POS
BAT POS
A B C D E F
NEGATIVE CABLE
FLAG TO
CHASSIS FRAME
A C A C POWER DIST
BLACK-6 GRAY-5 VEC
DASH GND
A
F2 5 ALT EXC
B
ACCY-2 IGNITION-2
MAST
F5 15 SP ACCY PWR
EXTRA
SWING
C
AUX RLYS PWR
PLUGGED
F6 10
SIDESHIFT
30
87
86
85
30
87
86
85
D
87a
87a
OPT GND 1
E
AUX ELEC GND
KEY ACC
GREEN-4
F
F1 15 TRAN/BRK PWR
G
IGNITION-1 ACCY-1
OPT GND 2
H
30
87
86
85
30
87
86
85
87a
87a
SP CAB GND 1
A
SP CAB GND 2
B
SP GND 1
C
AC CLUTCH GND
D
AUX ELEC GND
E
F8
F3
F4
F9
F7
LT GND
BLUE-3
CB4
CB3
CB1
F10
CB2
F11
F12
F
STR/FUL GND
20
20
20
20
G
25
10
10
25
15
10
10
15
ACC MOD GND
H
SHIFT PWR 2
BLACK-1 GRAY-2 DCLUTCH
H G F E D C B A H G F E D C B A
A 87
TRANSMISSION DECLUTCH
86 85 RELAY
30
KEY IGN
ENG GND
GAGE PWR
HORN PWR
OPT PWR 2
OPT PWR 1
OPT PWR 3
OPT PWR 4
SP BAT PWR
SHIFTER GND
ECU IGN/012
ECU BAT/022
KEY BAT PWR
ECU GND/050
STAB/TILT PWR
STEER/SWAY PWR
STR/FUL GND
PK BRK SOL
12 TURNS
2
VLV GND PER FOOT
AUX A TWIST
PROPORTIONAL 1
HYDRALIC AUX. 2 VLV GND CABLE
VALVE AUX B
1
2
VLV GND
TILT-ON TILT UP
1
JOYSTICK VLV GND
2
VALVE TILT DN
1
THR SUP/911
THR SGN/915
THR RTN/914
2 TRANS SOL Y1
REVERSE SOL
TRANS SOL
TRANS SOL Y3
ECU GND/050
TRANS SOL Y5
PLUGGED
TRANS SOL Y6
PLUGGED
SHIELD /020
CAN H/904
CAN L/905
ST RLY
ENG GND
PLUGGED
MODE
PLUGGED
PLUGGED
ENG WARN LT
ENG STOP LT
ALT EXC
WAIT TO START LT
TRANS TMP SW
ECU IGN/012
ECU BAT/022
VALVE STR CRB
CRAB 1
STR/FUL GND
2
B
STR/FUL GND
FUEL
SNDR FUL LVL 20 7 8 1 2 13 5 14 15 16 4 19 21 22 25 26 3 28 6 10 11 12 23 24 9 17 27 29 18 23 24
A
POWER DISTRIBUTION
FUSE/BREAKER LEGEND CHASSIS HARNESS
FUSE HD34-24-29PE
20A OPTION POWER 3
FUSE 20A OPTION POWER 4 TO POWER UNIT ASSEMBLY
FUSE 20A OPTION POWER 1
VLV GND
GND FAULT
ACC MOD GND
FUSE 20A OPTION POWER 2
F1 15A TRANS/PARK BRK PWR A 87
GROUND FAULT
F2 5A ALTERNATOR EXCITE 85 86 RLY
30
F3 10A ENGINE ECU IGN PWR
F4 10A GAGE (INST PANEL) PWR
F5 15A SPARE ACCESSORY PWR
F6 10A AUX ELECTRIC PWR
F7 15A HORN PWR
F8 25A SPARE BATTERY PWR
F9 25A ENGINE ECU BAT PWR
F10 10A STEER/SWAY PWR
F11 10A R. AXLE STAB/TILT
F12 15A KEY BATTERY PWR
Electrical System
9-19
9-20
c. Engine Schematic
STARTER
PARK RELAY
CAT SUPPLIED ENGINE HARNESS BRAKE
A4E2 ECU
POWER UNIT TO CHASSIS ASSEMBLY VALVE 87 a
J2 CONNECTOR HD36-24-29SE 86
POWER UNIT HARNESS 85
TRANSMISSION LEGEND 30
RELAY
1
9
2
3
5
7
8
34
4
6
T960 BK 1 X929 BU
21
INJECTOR CYLINDER 4 RETURN
11
29
20
22
23
25
26
27
28
24
19
10
12
13
15
16
17
18
14
GEAR ACTIVATED TRANS SOLENOIDS
T954 BK 2 X923 OR 58 INJECTOR CYLINDER 4
INJECTOR CYLINDER 4 F1 Y1,Y3,Y4,Y6
NEGATIVE CABLE
TO BATTERY
TRANS SOL Y1 1
Electrical System
2
T959 BK 3 X928 GN Y1 ENG GND
A B
8 INJECTOR CYLINDER 3 RETURN F2 Y1,Y3,Y5,Y6
ST RLY
T953 BK 4 X922 WH
ENG GND
64 INJECTOR CYLINDER 3
MY5870D
TRANS SOL Y2
INJECTOR CYLINDER 3 F3 Y1,Y3,Y6 Y2 ENG GND
STRT SOL
A B
ST RLY PWR
A B
63 INJECTOR CYLINDER 2
R1 Y2,Y3,Y4,Y6
PLUGGED
ST RLY
PLUGGED
PLUGGED
CAN H/904
CAN L/905
SHIELD/020
ENG GND
ALT EXC
IVS
WAIT TO START
ON-IDLE
PLUGGED
INJECTOR CYLINDER 2 TRANS SOL Y4
Y4
PK BRK SOL
ENG GND
ENG GND
ECU IGN/012
ECU BAT/022
ECU GND/050
ENG WARN LT
THR SUP/911
THR SGN/915
THR RTN/914
R2 Y2,Y3,Y5,Y6
A B
ENG STOP LT
TRANS TMP SW
TRANS SOL Y1
REVERSE SOL
TRANS SOL Y3
TRANS SOL
TRANS SOL Y5
TRANS SOL Y6
T957 BK 3 X926 GY 35
PK BRK SOL
A B
INJECTOR CYLINDER 1 INTERNAL EXTERNAL
(3/0 AWG, BLACK)
6A/400V
A B
ZF TRANSMISSION
N1 Y6 (ONLY IF PARK BRAKE OFF)
1 T997 OR 46 IMP POWER SUPPLY (5V)
INTAKE MANIFOLD T993 BR TRANS TMP SW
2 38 IMP RETURN
PRESSURE SENSOR N2 Y6 (ONLY IF PARK BRAKE OFF)
250 F
3 X731 BU ENG GND
A B
55 IMP SIGNAL
N3 Y6 (ONLY IF PARK BRAKE OFF)
1 L730 OR 47 OIL PRESSURE SENSOR PWR (5V) N4 Y6 (ONLY IF PARK BRAKE OFF) 1
OIL PRESSURE
SENSOR 2 Y947 BR 39 OIL PRESSURE SENSOR RETURN 2
3 994 GY 56 OIL PRESSURE SENSOR SIGNAL 3
4
TRANSMISSION LEGEND TRANS SOL E1
E1 5
R997 OR ENG GND
A B
1 48 FMP SENSOR POWER SUPPLY (5V) TURNER 6
FUEL MANIFOLD
2 Y948 BR 40 FMP SENSOR GROUND TRANS SOL E2 7
STRT SOL
PRESSURE SENSOR
ST RLY PWR
3 Y946 BU 51 FMP SENSOR SIGNAL GEAR ACTIVATED TRANS SOLENOIDS E2 ENG GND 8
A B
F1 E5, E1 9
M
TRANS SOL E3
E3 10
ENG GND
A B
COOLANT TEMP 1 955 BU 43 COOLANT TEMP SIGNAL F2 E5, E2 11 ALTERNATOR
SENSOR 2 TRANS SOL E4 12
E4 ALT PWR (4 AWG, RED)
F3 E5, E3 ENG GND B+ STARTER
A B
F4 E6, E3 TRANS SOL E5 G
E5 ENG GND D+
INTAKE MANIFOLD 1 C967 BU
A B
42 IMT SIGNAL CSA RLY PWR
TEMP SENSOR 2 L731 BR 37 TEMPERATURE SENSOR RETURN R1 E4, E1 TRANS SOL E6
E6 ENG GND
A B
R2 E4, E2
CRANKSHAFT SPEED/ 1 996 GN 10 SPEED SENSOR POWER (8V) TRANS TMP SW
A
R3 E4, E3
250 F
TIMING SENSOR 2 E965 BU
TURNER TRANSMISSION
52 CRANK SPEED/TIME SENS SIG
86
N NO SOLENOIDS INGAUGED
85
1
87
F5
(3/0 AWG, RED)
SHIELDED
CABLE
CAN TERMINATOR
FUEL PUMP 1 Y950 YL 25 FUEL PUMP SOLENOID PWM SIG (CAN H/904)
A
GLOW PLUG PWR
D 945 BR 20 CDL-
DIAGNOSTIC
CONNECTOR (9 PIN) E Y793 YL 23 J1939- AMBIENT TEMPERATURE
F Y792 PK 24 J1939+ AMB SNG RTN SENSOR
B
G
H AMB SNR PWR +5V A
J AMB SNR SIG C
ENG WARN LT
ENT STOP LT
CAN H/904
CAN L/905
SHIELD/020
IVS
RTN
ECU IGN/012
THR SUP/911
THR SGN/915
ECU GND/050
WAIT TO START LT
ON-IDLE
AMB SNR PWR +5V
AMB SNR SIG
ECU BAT/022
7
8
1
2
3
9
16
15
54
33
41
40
10
45
59
20
21
22
42
56
63
60
57
35
ENGINE ECM
64 PIN
TL642, TL943
TL642, TL943
CONNECTOR PIN TAGNAME DESCRIPTION TYPE
1 KEY IGN IGNITION POWER INPUT 1 5 EXC TILT +5 ANALOG EXCITATION VOLTAGE POWER OUTPUT ACCESSORY MODULE OPTION
2 ACC MOD GND ACCESSORY MODULE GROUND POWER INPUT 2 TILT SIG A FORK TILT SIGNAL A ANALOG INPUT
3 TRIG JOYSTICK TRIGGER FOR DE-CLUTCH DIGITAL INPUT 3 TILT GND ANALOG GROUND POWER OUTPUT
4 DCLUTCH IN TRANSMISSION DE-CLUTCH INPUT DIGITAL INPUT 4 5 EXC AUX +5 ANALOG EXCITATION VOLTAGE POWER OUTPUT
5 DI2 SPARE DIGITAL INPUT DIGITAL INPUT 5 AUX SIG A AUX HYD SIGNAL A ANALOG INPUT
6 ROLLER SEL ROLLER / JOYSTICK SELECT DIGITAL INPUT 6 AUX GND ANALOG GROUND POWER OUTPUT
J1 (BLACK) J2 (GREY)
7 TILT UP TILT UP VALUE DIGITAL OUTPUT 7 TILT SIG B FORK TILT SIGNAL B ANALOG INPUT
8 TILT DN TILT DOWN VALVE DIGITAL OUTPUT 8 AUX SIG B AUX HYD SIGNAL B ANALOG INPUT
9 AUX A AUX HYD VALVE A DIGITAL OUTPUT 9 CAN H/904 CANBUS HIGH SERIAL I/O
10 AUX B AUX HYD VALVE B DIGITAL OUTPUT 10 CAN L/905 CANBUS LOW SERIAL I/O
11 DCLUTCH TRANSMISSION DE-CLUTCH OUTPUT DIGITAL OUTPUT 11 TX RS-232 TRANSMIT SERIAL OUTPUT
12 GND FAULT GND RLY FAULT SIG DIGITAL OUTPUT 12 RX RS-232 RECEIVE SERIAL INPUT
d. Auxiliary Schematic (TL943 ONLY)
CAN SHIELD
CAN L/905 1 DCLUTCH IN SEE SHEET 1
CAN H/904 IGN
2
DCLUTCH IN TILT UP
1 3
KEY IGN 4 TILT DN NOTE: FOR BASE MACHINE
2 DCLUTCH
3
TILT UP 5 OR FAILED ACCESSORY
TILT DN 6 AUX A
4 SEE SHEET 1 MODULE ONLY
DCLUTCH AUX B
7
5 ACC MOD GND
6 AUX A 8
AUX B 9
PK BRK SOL
7 PLUGGED
ACC MOD GND 10
8 PLUGGED
PLUGGED PK BRK SOL 11
9 PLUGGED
PLUGGED 10 PLUGGED 12
GND FAULT 11
GND FAULT
PLUGGED 12
PLUGGED
1
5
ACC MOD GND
TRIG TRIG 6
DCLUTCH IN TILT SIG A 3
DI2 TILT GND 2
ROLLER SEL TILT SIG B
TILT UP 4
5 EXC TILT
J1 (BLACK)
TILT DN 1
AUX A PLUGGED
7
AUX B PLUGGED
8
DCLUTCH
GND FAULT
2 3 4 5 6 7 8 9 10 11 12
5 EXC TILT
TILT SIG A
TILT GND
5 EXC AUX 5 EXC AUX 1
ACCY. MODULE
AUX SIG A AUX SIG A 3
AUX GND AUX GND 2
TILT SIG B
AUX SIG B
J2 (GREY)
AUX SIG B 4 OPTIONAL FORK TILT AND PROPORTION AUX
CAN H/904 KEY IGN 5 ON JOYSTICK W/ DE-CLUTCH TRIGGER
CAN L/905 ROLLER SEL 6
TX
RX
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4
MY5850D
JLG ANALYZER
Electrical System
9-21
9-22
BEACON WORKLIGHTS
e. Options
OPTIONS 1
2 2
3 3 STOP LT
OPTIONS VEC WORKLIGHT/
BEACON 4 STOPLIGHT
WIPER HEATER/BLOWER
S/W LT PWR SWITCH
F1 20 WIPER PWR OPTION
A 5
F5 20 HEATER PWR 6 DOME/BCN GND
30
87
86
85
30
87
86
85
B
87a
87a
KEY ACC STOP LT STOP LT
AUX ELECTRICS C
BCN PWR BCN PWR BCN PWR
1 3
F7 10
D
F8 10 D FAN PWR DOME
E
LIGHT
MY5840D
1 1 LIGHTS BCN/FAN
F6 20 DOME LT DOME LT DOME LT DOME LT
GREEN-4
F
CAB LT PWR CAB LT PWR CAB LT PWR
2 2 G
30
87
86
85
30
87
86
85
87a
87a
S/W LT PWR S/W LT PWR
4 6 2
H
S/W LT PWR
3 3 BCN LT
AUX ELEC1
SW1 86 WORK LT WORK LT DOME/BCN GND
8
BEACON
A B
A
30
87
86
85
87a
4 4 OPTION (15A) OPTION (25A)
HEATER GND
B
CAB LT GND CAB LT GND CAB LT GND
C CAB LTS
30
87
86
85
30
87
86
85
87a
87a
DOME/BCN GND DOME/BCN GND DOME/BCN GND
7 5
5 D CAB LT GND LEFT
5
A B
BLUE-3
30
87
86
85
F
87a
7 7
F4
F3
F2
SW2 86 CAB LTS
G
SW2 87A CAB LT GND RIGHT
A B
25
15
Electrical System
BLACK-1 GRAY-2
H G F E D C B A H G F E D C B A
OPTIONS
FUSE LEGEND
F1 20A WIPER PWR
WINDSHIELD
F2 5A 5A ROOF WIPER PWR WASHER
DASH BLOWER HEATER M WIPER MOTOR
F3 15A 15A OPTION PWR 2 FAN MOTOR VALVE MOTOR
F4 25A 25A OPTION PWR M
F5 20A HEATER/BLOWER PWR M M M
WIPER
F6 20A LIGHT PWR 1 2 3 4 5 6 7 8 9 10
PLUGGED
QC GND
25A OPT
F7 10A BEACON PWR H
OPT GND 1
OPT GND 2
D FAN GND
15A OPT 2
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4
AUX SW GND
MAST
LW
SWING
EXTRA
F8 10A DASH FAN PWR
SW2 86
SW1 86
15A OPT 2 GND
SW2 87A
SW1 87A
PLUGGED
PLUGGED
PLUGGED
P
SIDESHIFT
AUX SW GND
5A ROOF WIPER PWR
5A ROOF WIPER GND
A B A B C D
AUX
ELECTRIC 1 2 3 4 5 6 7 8 9 10 11 12
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
OPTION
HEATER GND
HEATER PWR
HTR CNTRL B
EMPTY
EMPTY
WASHER
WIPER HI
WIPER LO
WIPER LO
WIPER HI
WIPER PWR
WIPER PARK
WIPER PARK
WASHER
D FAN PWR
D FAN GND
HEATER HI
MAST
HEATER MED
HEATER LOW
HEATER GND
SWING
EXTRA
SW2 86
SW1 86
SW2 87A
SW1 87A
PLUGGED
PLUGGED
PLUGGED
SIDESHIFT
25A OPT
25A OPT GND
AUX SW GND
15A OPT 2
ROOF WIPER
A
B
A
OPTION
25 A
M D FAN PWR D FAN PWR
2 B
HEATER PWR HEATER PWR
WIPER PWR WIPER PWR
HEATER GND HEATER GND
OPTION
15 A
8K OHM
D FAN GND D FAN GND
PLUGGED PLUGGED
A B C D E F
HTR TEMP
BLOWER
ENCLOSED CAB A B C
(RED)
M H
OPTION A/C SWITCH RESISTOR LOCATED
L B
C
APPROX 10" BEHIND
HEATER TEMP SWITCH
FAN SW C
(ON ROOF)
HEATER PWR
M 17A M
A 87
86 85
30
(BLACK)
THERMOSTATIC
(RED/WHITE)
QUICK CONNECT SWITCH A/C PRESSURE SWITCH
1
AC CLUTCH PRS SW AC SW
2
~
SEE SHEET 1
3
AC SW
4
5 87 a
6 A/C
86 85
30 RELAY
25A OPT
25A OPT GND
25A OPT GND
OPT GND 2
PLUGGED
SIDESHIFT
OPT PWR 2
OPT PWR 3
OPT PWR 4
OPT GND 1
MAST
SWING
EXTRA
OPT PWR 1
QC PWR 1
QC GND 5
QC PWR 2
QC GND 7
KEY ACC
WORK LT
STOP LT
OPTIONS HARNESS
HD36-24-19PE
TO CHASSIS ASSEMBLY
TL642, TL943
Electrical System
30 86
ENGINE HARNESS
ST RLY PWR
87 85
STARTER
RELAY
- + GROUND
BATTERY
12VDC
GROUND
(AT ENGINE
POD)
SNSR SNSR
#1
BATT #2 ALTERNATOR
TO PCB
BAT-2
BAT-1
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
PCB D9 D5 D8 D7 D6
BATT
AA
87 87 87 87 87
SPARE
BAT
K
L
TO DASH PANEL
DASH PANEL
IGNITION SWITCH HORN
POLLACK P/N 31-610 CARLING SWITCH
P/N V2D1S00BAZC00-000
8 7
BAT ACC
1 4
STRT 5
2
6
3
IGN
HORN PWR
KEY PWR
MY0810
FUL SOL
30 86
HR MTR
ST RLY PWR
FUEL PUMP
FUEL PUMP
HR MTR
PS IGN
GP SW
PS IGN
FP PWR
PS IGN
PS IGN
FP RLY
FP RLY
PS IGN
87 85
STARTER
C
A
B
RELAY
A
85
86
87
30
87A
B
1
1
2
2
FUEL M STRT SOL STARTER
OIL GP PWR MOTOR
SOLENOID FUEL PUMP FUEL PUMP BAT-2
FUSE PRESSURE SWITCH
COLD START RELAY 5 PSI BAT-1
ADVANCE 7.5 AMP SNSR
SOLENOID ALT BAT
GP SW
GP SIG 86 30
BATTERY
12VDC
GROUND
GLOW PLG (AT ENGINE
85 87 POD)
GLOW PLUG
RELAY
SNSR SNSR
ALT EXEC
#1
BATT #2 ALTERNATOR
ALT EXEC
HR MTR
GP SIG
ST RLY
PS IGN
GP SW
BAT-2
BAT-1
ALT BAT
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
ALT EXEC
PS IGN
HR MTR
ST RLY
AA
BATT
ST RLY
HR MTR PCB
D2
TR LT SW
Q
87 O D9
87a 10 OHM
F-N-R AND 86 85 30W
TO GEAR SELECTOR 30 R1
87
TRANSMISSION G
TEMPERATURE DEUTSCH
WARN
P/N DT06-8S LT CK (15A) 87a
SWITCH 86 85
LOCKING WEDGE KEY
W8S 30
1 2 3 4 5 6 7 8
KEY STRT
GND 12V KEY ACC
ST RLY
IGNITION SWITCH
POLLACK P/N 31-610
PARK BRAKE
CARLING SWITCH
P/N VDD1B6ABARC00-000
HR MTR
TR LT
8 7
1 4
BAT ACC
KEY PWR
2 5
3 6 TRANS
TEMP
WARN STRT
LIGHT
PS IGN BR SW PWR
IGN
BR SW PWR
MY1630
ENGINE HARNESS
STRT SOL STARTER
MOTOR
SNSR
ALT BAT
- + GROUND
BATTERY
12VDC
GROUND
(AT ENGINE
POD)
SNSR SNSR
ALT EXC ALT EXC
#1
BATT #2 ALTERNATOR
ALT EXC
ALT BAT
TO PCB
DEUTSCH P/N HD-34-24-18-SN
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
PCB
DEUTSCH P/N HD-36-24-18-PN
D9
O
10 OHM
30W 87
R1 (10A)
87a GAGES
G 86 85
30
ACC
J
TO DASH PANEL
DASH PANEL
GAG PWR
OIL FUEL
12 UDC
2
1
B+
GND
G TEMP
4 IN 1 GAGE
BEEDE
MY0800
9.8 CHARGING CIRCUIT 4. Install a drive ratchet into the square hole in the
serpentine belt tensioner bracket.
5. While lifting the automatic belt tensioner away from
2
the belt, remove the fan serpentine belt.
Note: Record how the alternator is installed to ensure
correct installation later.
6. Label and disconnect the wire leads attached to the
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 (longer) mounting hardware from
the upper alternator mount. Remove the alternator
from the machine.
b. Alternator Installation
MY0370 1. Position the alternator and align with the upper
alternator mount on the engine bracket. Insert the
Before using a battery charger, an attempt can be made upper (longer) mounting hardware through the
to recharge the battery by jump-starting the machine alternator mount. Thread the longer capscrew into
(Refer to the appropriate Operation & Maintenance the alternator front mount. DO NOT tighten
Manual). Allow the engine to run, which will enable the completely at this time.
alternator (2) to charge the battery.
2. Align the lower alternator mount hole with the lower
If the engine alternator charging warning indicator mounting bracket on the engine, and insert the lower
illuminates, perform the following checks: mounting capscrew. Tighten the lower capscrew and
1. Check all battery cable connections at the battery, upper capscrew securely.
and verify that they are clean and tight. 3. Place a drive ratchet into the square hole on the
2. Check the external alternator wiring and serpentine belt tensioner bracket. Apply pressure
connections, and verify that they are in good against the tensioner bracket and route the
condition. serpentine belt onto the alternator and engine
3. Check the fan belt condition and tension. pulleys. Release and check the tensioner pulley to
verify that it is pivoting freely in order to provide the
4. Run the engine and check the alternator for noise. A proper tension on the belt. Check for proper belt
loose drive pulley, loose mounting hardware, worn or alignment. (Refer to the appropriate Operation &
dirty internal alternator bearings, a defective stator Maintenance Manual.)
or defective diodes can cause noise. Replace a worn
or defective alternator. 4. Connect the previously labeled wire leads to the
alternator.
9.8.1 Alternator 5. Properly connect the battery.
6. Close and secure the engine cover.
a. Alternator Removal
7. Remove the Do Not Operate Tags from both the
1. Park the machine on a firm, level surface, level the ignition key switch and the steering wheel.
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake and turn the
engine OFF.
2. Open the engine cover. Allow the system fluids to
cool.
3. Properly disconnect the battery.
9.9 WINDOW WIPER/WASHER DO NOT disassemble the motor. The motor is not
WINDSHIELD WIPER MOTOR serviceable. Replace motor if found to be defective.
MY0440
b. Disassembly
9.9.1 Windshield/Rear Window Washer 2. Connect the cab wiring harness connectors to the
Reservoir reservoir connectors.
3. Install the reservoir tank onto the mounting bracket.
Note: Attach the ground strap to the lower right bolt hole
of washer bottle.
4. Install the lock washers and nuts and secure.
4 5. Fill the washer fluid reservoir with washer fluid.
6. Properly connect the battery.
7. Turn the ignition key switch to the RUN position and
press the washer switch. Verify that fluid is sprayed
on both the windshield and rear glass.
8. Close and secure the engine cover.
MY0420
9. Remove the Do Not Operate Tags from both the
The windshield washer motor and reservoir (4) is located ignition key switch and the steering wheel.
in the cab behind the seat. It is labeled as a unit and
cannot be serviced separately. 9.10 CAB HEATER/AC AND FAN
a. Removal
9.10.1 Cab Heater/AC Controls
1. Park the machine on a firm, level surface, level the
Note: If the suspect component is found to be within the
machine, fully retract the boom, lower the boom,
heater box, the heater box must be removed as a
place the transmission control lever in
complete unit and replaced.
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
a. Cab Heater/AC Controls Removal
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel. TL642 - Before S/N TBK01167 excluding TBL01162
TL943 - Before S/N TBL01599 excluding TBL01551 &
3. Open the engine cover. Allow the system fluids to TBL01585
cool.
1. Park the machine on a firm, level surface, level the
4. Properly disconnect the battery. machine, fully retract the boom, lower the boom,
5. Remove the nuts and the lock washers from the place the transmission control lever in
washer mounting bolts. (N) NEUTRAL, engage the park brake and shut the
6. Pull the washer reservoir out and away from the engine OFF.
mounting bracket. 2. Place a Do Not Operate Tag on both the ignition key
7. Rotate the washer reservoir, label and remove the switch and the steering wheel.
cab harness connectors from the washer reservoir 3. Open the engine cover. Allow the system fluids to
connectors. cool.
8. Remove the windshield washer hoses from the 4. Properly disconnect the battery.
reservoir.
b. Disassembly
DO NOT disassemble the pump. The pump is not
serviceable. Replace pump if found to be defective. 5
5. Remove the four screws (5) from the cab heater and c. Installation and Testing
fan control panel.
1. Check that the variable speed fan control is in the
6. Pull the control panel out from the dash panel and OFF position.
disconnect the variable speed fan control cab
2. Install the temperature control cable to the back of
harness connector and disconnect the temperature
the control.
cable.
3. Install the hex locknut on the shaft and tighten.
7. Remove the control from the panel.
4. Connect the cab harness connector to the variable
a. Cab Heater/AC Controls Removal speed fan control.
TL642 - S/N TBK01167 & After including TBL01162 5. Install the screws securing the control panel to the
TL943 - S/N TBL01599 & After including TBL01551 & dash panel.
TBL01585 6. Properly connect the battery.
1. Park the machine on a firm, level surface, level the 7. Turn the ignition key to the ON position and check
machine, fully retract the boom, lower the boom, the fan speeds. If further repair is needed, refer to
place the transmission control lever in Section 9.5, “Electrical System Schematics.”
(N) NEUTRAL, engage the park brake and shut the 8. Start the machine and allow engine to warm to
engine OFF. operating temperature. Check heat control at
2. Place a Do Not Operate Tag on both the ignition key different levels.
switch and the steering wheel. 9. Close and secure the engine cover.
3. Open the engine cover. Allow the system fluids to 10. Remove the Do Not Operate Tags from both the
cool. ignition key switch and the steering wheel.
4. Properly disconnect the battery.
9.11 SWITCHES, SOLENOIDS AND
SENDERS
MAL1220 9
4. Start the engine, allow it to reach operating b. Engine Oil Pressure Sender/Sensor Inspection
temperature and observe the operator instrument and Replacement
cluster for warning indication. If the sensor is not
Inspect the sender/sensor and the wiring harness
defective, the problem could be elsewhere; possibly
connector terminals for continuity. Replace a defective or
in a shorted wire, improper-running engine, improper
faulty sender/sensor with a new part.
or low coolant, obstructed or faulty radiator, coolant
pump, loose fan belt, defective instrument display,
c. Engine Oil Pressure Sender/Sensor Installation
etc.
and Testing
5. Close and secure the engine cover.
1. Thread the engine oil pressure sender/sensor into
6. Remove the Do Not Operate Tags from both the the threaded mount snugly, then connect the sender/
ignition key switch and the steering wheel. sensor connector to the wiring harness connector.
4 a. Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
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.
MAL1240
3. Open the engine cover. Allow the system fluids to
cool.
If the fuel level sender (4) is suspected of giving a false
reading, perform the following checks: 4. Properly disconnect the battery.
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, and 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
MY5560
or defective fuel level sender in the fuel tank has 5
been ruled out, and in addition, wiring and 5. Remove the seven screws (5) securing the dash
connectors have been checked and ruled out, the panel.
fuel level indicator is defective and must be replaced.
6. Label and disconnect the wires from the gauge,
5. Check that the ignition terminal has current and that remove the gauge bracket.
the fuse in the fuse panel is not blown.
7. Pull the gauge out from the dash.
6. Check for broken, shorted, frayed, disconnected or
damaged wiring between the fuel level indicator b. Disassembly
wiring at the cab, fuse and relay panel, ignition key
switch, and from the fuel level sender on the fuel DO NOT disassemble the gauge. The gauge is not
tank through the wiring in the cab. serviceable. Replace the gauge if found to be defective.
7. Check the fuel level sender. A defective fuel level c. Installation and Testing
sender in the fuel tank may also prevent the fuel
level indicator from moving. Refer to Section 9.5, 1. Install the gauge in the dash. Install the gauge
“Electrical System Schematics,” for further bracket.
information. 2. Connect the previously labeled wires to the gauge.
3. Install the dash panel with the previously used
hardware.
4. Properly connect the battery.
5. Turn the ignition to the ON position to check the including TBL01551 & TBL01585),” or contact the local
gauge values. Caterpillar dealer.
6. Close and secure the engine cover.
a. Gauge Removal
7. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel. 1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
9.12.2 3-N-1 Digital Gauge place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
TL642 - S/N TBK01167 & After including TBL01162 engine OFF.
TL943 - S/N TBL01599 & After including TBL01551 &
TBL01585 2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Remove the screws (5) securing the dash panel.
6. Label and disconnect the wires from the gauge,
remove the gauge bracket.
7. Pull the gauge out from the dash.
b. Disassembly
6
5 DO NOT disassemble the gauge. The gauge is not
MAP0300
serviceable. Replace the gauge if found to be defective.
The 3-N-1 gauge (6) is located on the center dash panel. c. Gauge Installation and Testing
The digital display in the center of the gauge displays the
operating hours, voltmeter and engine speed on the left 1. Install the gauge in the dash. Install the gauge
hand side and engine fault codes or machine diagnostic bracket.
trouble codes (DTC’s) on the right hand side. 2. Connect the previously labeled wires to the gauge.
3. Install the dash panel with the previously used
XXXXXX.X 8 hardware.
XX.X V 4. Properly connect the battery.
7 5. Turn the ignition to the ON position to check the
RPM XXXX XXX.XX gauge values.
6. Close and secure the engine cover.
7. Remove the Do Not Operate Tags from both the
XXXXXX.X XXXX ignition key switch and the steering wheel.
9
XX.X V
RPM XXXX 10
MAP0640
9.13 DASH SWITCHES If all terminals do not show proper continuity, replace the
ignition switch.
Note: For information on the front windshield wiper, rear
window wiper and washer systems, refer to Section 9.9, d. Ignition Switch Installation
“Window Wiper/Washer Windshield Wiper Motor.”
1. Connect the ignition key switch to the previously
labeled wires.
9.13.1 Ignition Key Switch
2. Align the ignition switch in the dash so that when it is
a. Ignition Switch Removal in the OFF position, the key slot is positioned vertically
(straight up and down). Install the hex nut securing
1. Park the machine on a firm, level surface, level the the ignition switch to the dash. DO NOT overtighten.
machine, fully retract the boom, lower the boom,
place the transmission control lever in 3. Install the dash panel with the previously used
(N) NEUTRAL, engage the park brake and shut the hardware.
engine OFF. 4. Properly connect the battery.
2. Place a Do Not Operate Tag on both the ignition key 5. Close and secure the engine cover.
switch and the steering wheel. 6. Remove the Do Not Operate Tags from both the
3. Open the engine cover. Allow the system fluids to ignition key switch and the steering wheel.
cool.
Note: If further information is needed, refer to Section
4. Properly disconnect the battery. 9.5, “Electrical System Schematics.”
5. Remove the screws securing the dash panel.
9.13.2 Dash Switches
6. Remove the hex nut securing the ignition key switch
to the dash.
a. Switch Removal
7. Label and disconnect the ignition switch wires and
remove the switch from the machine. 1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
b. Disassembly place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
DO NOT disassemble the ignition switch. Replace a engine OFF.
defective switch with a new part.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
c. Inspection and Replacement
3. Open the engine cover. Allow the system fluids to
To determine the proper operation of the ignition key cool.
switch, test the terminals on the back of the switch for
continuity with an ohmmeter. 4. Properly disconnect the battery.
5. Pull the frame out of the dash, disconnect the
BA
6 T AC
C harness connector to the switch in question and
push the switch out of the frame.
b. Disassembly
ACC
BAT
IG
N N
IG
MY0830
3. Properly connect the battery. 2. Position the switch it’s original orientation. Secure
with the previously used hardware.
4. Start the machine and check the replaced switch for
proper function. 3. Properly connect the battery.
5. Close and secure the engine cover. 4. Start the machine and check the replaced switch for
proper function.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel. 5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the
9.13.3 Rheostat Switch (if equipped) ignition key switch and the steering wheel.
TL642 - Before S/N TBK01167 excluding TBK01162
TL642 - S/N TBK01167 & After including TBL01162
TL943 - Before S/N TBL01599 excluding TBL01551 &
TBL01585
a. Rheostat Switch Removal
a. Rheostat Switch Removal 1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
1. Park the machine on a firm, level surface, level the
place the transmission control lever in
machine, fully retract the boom, lower the boom,
(N) NEUTRAL, engage the park brake and shut the
place the transmission control lever in
engine OFF.
(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.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel. 3. Open the engine cover. Allow the system fluids to
cool.
3. Open the engine cover. Allow the system fluids to
cool. 4. Properly disconnect the battery.
4. Properly disconnect the battery.
8
TILT SPEED
CONTROL
MAL1250
MAL1260
3 4
5 6
MAM1410
1. Cable Connector.
2. Analyzer Display Screen.
TL642, TL943
The Access Level Menu controls security for Control Module settings. Access Level 2 is the default and allows view access to all menus, except
Calibration. Access Level 1 (33271) provides view, edit and calibration authorization.
Note: The layout shows all possible analyzer screens. Please note, some screens may not be available depending upon machine configuration.
Analyzer Software Version A
MAL0890A
Electrical System
9-39
Electrical System
Fork Tilt:
AUX FUNCTION:
Cal. Fork Tilt? The technician will press the ENTER key to initiate calibration, or the
Yes: Enter, No:ESC ESC key to leave menu.
Fork Tilt Roller The technician will knurl the fork tilt roller to the +AR position and
FWD to Max press the ENTER key to confirm.
Fork Tilt Roller The the technician will release the fork tilt roller and press the ENTER
Center key to confirm.
Fork Tilt Roller The technician will knurl the fork tilt roller to the - AR position and
Calibrations: REV to Max press the ENTER key to confirm.
Fork Tilt
Fork Tilt Roller The the technician will release the fork tilt roller and press the ENTER
Center key to confirm.
Calibrations: The control system will display this message to advise that the
Complete procedure was successful. The technician will press the ESC key to
leave this menu.
Calibrations: The control system will display this message to advise that the
Failed procedure was unsuccessful. The technician will press the ESC key to
leave this menu.
Cal. Aux Hyd? The technician will press the ENTER key to initiate calibration, or the
Yes: Enter, No:ESC ESC key to leave menu.
Aux Hyd Roller The technician will knurl the auxiliary hydraulic roller to the +AR
FWD to Max position and press the ENTER key to confirm.
Aux Hyd Roller The the technician will release the auxiliary hydraulic roller and press
Center the ENTER key to confirm.
Aux Hyd Roller The technician will knurl the auxiliary hydraulic roller to the - AR
Calibrations: REV to Max position and press the ENTER key to confirm.
Aux Hydraulic
Aux Hyd Roller The the technician will release the auxiliary hydraulic roller and press
Center the ENTER key to confirm.
Calibrations: The control system will display this message to advise that the
Complete procedure was successful. The technician will press the ESC key to
leave this menu.
Calibrations: The control system will display this message to advise that the
Failed procedure was unsuccessful. The technician will press the ESC key to
leave this menu.
2125 Joystick Left Roller Not In • Fork Tilt Up & Down prevented No
The Neutral Position At
• The left roller must be in the neutral position
Power Up
(established by Calibration) when the control
system is energized or it is ignored until is
momentarily returns to neutral.
2397 Fork Tilt Joystick - • Fork Tilt Up & Down prevented Yes
Voltage Disagreement
• Analog feedback from the joystick’s tilt roller did
not agree within ±25% for 1000mS. Fork tilt up and
down will be prevented until the next power cycle.
This fault may be caused by improper wiring, a
joystick issue or a control module issue.
2398 Fork Tilt Joystick - • Fork Tilt Up & Down prevented Yes
Out Of Range High
• Analog feedback from the joystick’s tilt roller was
measured to be greater than 4.85V. Fork tilt up and
down will be prevented until the next power cycle.
This fault may be caused by improper wiring, a
joystick issue or a control module issue.
2399 Fork Tilt Joystick - • Fork Tilt Up & Down prevented Yes
Out Of Range Low
• Analog feedback from the joystick’s tilt roller was
measured to be less than 0.15V. Fork tilt up and
down will be prevented until the next power cycle.
This fault may be caused by improper wiring, a
joystick issue or a control module issue.
33191 Fork Tilt Valve - • The desired current is greater than 250mA, but the Yes
Open Circuit actual current is less then 75mA
• The fork tilt up digital output was open-circuit. This
fault may be caused by improper wiring or a
control module issue.
33193 Fork Tilt Up Valve - • The actual current is greater than 200mA, PWM is Yes
Short To Ground 95%, and the digital output driver’s diagnostic
feedback is low
• The fork tilt up digital output was shorted to
ground. This fault may be caused by improper
wiring or a control module issue.
33194 Fork Tilt Down Valve - • The desired current is greater than 250mA, but the Yes
Open Circuit actual current is less then 75mA
• The fork tilt down digital output was open-circuit.
This fault may be caused by improper wiring or a
control module issue.
33195 Fork Tilt Down Valve - • The actual current is greater than 200mA, PWM is Yes
Short To Ground 95%, and the digital output driver’s diagnostic
feedback is low
• The fork tilt down digital output was shorted to
ground. This fault may be caused by improper
wiring or a control module issue.
33196 Auxiliary Function - • The desired current is greater than 250mA, but the Yes
A Valve - Open Circuit actual current is less then 75mA
• The auxiliary hydraulic “A” or “B” digital output was
open-circuit. This fault may be caused by improper
wiring or a control module issue.
33197 Auxiliary Function - • Fork Tilt Up & Down, Auxiliary Hydraulics Yes
A/B Valve - Short To Battery functionality prevented
• The auxiliary hydraulic “A” digital output was
shorted to battery. Auxiliary hydraulics will be
prevented until the next power cycle. This fault may
be caused by improper wiring or a control module
issue.
• Active when Machine Setup’s AUX HYDRAULIC is
set to ENABLED
• The desired current is 0mA and the digital output
driver’s diagnostic feedback is low
• Low-Side Fault Relay de-energized
33199 Auxiliary Function - • The desired current is greater than 250mA, but the Yes
B Valve - Open Circuit actual current is less then 75mA
• The auxiliary hydraulic “B” digital output was open-
circuit. This fault may be caused by improper
wiring or a control module issue.
• Active when Machine Setup’s AUX HYDRAULIC is
set to ENABLED
33200 Auxiliary Function - • The actual current is greater than 200mA, PWM is Yes
B Valve - Short To Ground 95%, and the digital output driver’s diagnostic
feedback is low
• The auxiliary hydraulic “B” digital output was
shorted to ground. This fault may be caused by
improper wiring or a control module issue.
• Active when Machine Setup’s AUX HYDRAULIC is
set to ENABLED
441 Battery Voltage Too Low - • Fork Tilt Up & Down, Auxiliary Hydraulics & De- No
System Shutdown Clutch functionality prevented
• Battery voltage is less than 8.0V so the control
module has prevented associated functionality.
442 Battery Voltage Too High - • Fork Tilt Up & Down, Auxiliary Hydraulics & De- Yes
System Shutdown Clutch functionality prevented
• Battery voltage is greater than 8.0V so the control
module has prevented associated functionality.
• Low-Side Fault Relay de-energized
447 Reference Voltage Out Of • Fork Tilt Up & Down, Auxiliary Hydraulics & De- Yes
Range Clutch functionality prevented
• The control module’s +5V reference was
measured greater than 5.4V or less than 4.6V for
1000mS. Since this reference voltage supplies the
joystick(s), fork tilt and auxiliary hydraulic functions
must be prevented.
• Low-Side Fault Relay de-energized
259 Model Change - Hydraulics • Fork Tilt Up & Down, Auxiliary Hydraulics & De- Yes
Suspended - Cycle Ems Clutch functionality prevented
• The user changed the Model Selection using a
JLG Analyzer. All functions are being prevented
until the EMS is cycled.
• Machine Setup’s MODEL was changed via JLG
Analyzer
3rd Party
CDL CatET J1939 Flash
Description Device J1939
Code Code Code
Code
3rd Party
CDL CatET J1939 Flash
Description Device J1939
Code Code Code
Code
0091-03 Throttle Position Sensor Voltage Above Normal J91-03 91-03 154
0091-04 Throttle Position Sensor Voltage Below Normal J91-04 91-04 154
0100-03 Engine Oil Pressure Sensor Voltage Above Normal J100-03 100-03 157
0100-04 Engine Oil Pressure Sensor Voltage Below Normal J100-04 100-04 157
3rd Party
CDL CatET J1939 Flash
Description Device J1939
Code Code Code
Code
0262-04 5 Volt Sensor DC Power Supply Voltage Below Normal J1079-04 1079-04 516
0526-05 Turbo Wastegate Drive Current Below Normal J1188-05 1188-05 177
0526-06 Turbo Wastegate Drive Current Above Normal J1188-06 1188-06 177
0526-07 Turbo Wastegate Drive Not Responding Properly J1188-07 1188-07 177
1797-03 Fuel Rail Pressure Sensor Voltage Above Normal J157-03 157-03 159
1797-04 Fuel Rail Pressure Sensor Voltage Below Normal J157-04 157-04 159
3rd Party
CDL CatET J1939 Flash
Description Device J1939
Code Code Code
Code
2246-06 Glow Plug Start Aid Relay Current Above Normal J676-06 676-06 199
3rd Party
Event CatET J1939 Flash
Description Device J1939
Code Code Code
Code
E539-1 High Intake Manifold Air Temperature - Warning J105-15 105-15 133
E539-2 High Intake Manifold Air Temperature - Derate J105-16 105-16 133