Service Manual

31211036_A_TL1055D, TL1255D_CAT_Service
Service Manual
Models
TL642D, TL943D,
TL1055D, TL1255D
SN ML800150 to Present, SN MLJ00150 to Present,
SN MLG00150 to Present, SN MLD00150 to Present,
SN ML500150 to Present, SN ML700150 to Present,
SN MNT00150 to Present, SN MYW00150 to Present
31211036
UENR6276-04
Revised
January 08, 2018
EFFECTIVITY PAGE
DATE REVISION DESCRIPTION

June 24, 2015 A Original Issue Of Manual.
September 22, 2015 B Added TL642D and TL943D model information.
March 18, 2016 C Revised page 3-33, 8-29, 9-4, 9-6, 9-8, 9-48, 9-136.
September 02, 2016 D Revised pages 2-5, 2-9 thru 2-13, 2-35 thru 2-82, 3-25 thru 3-31, 4-7 thru 4-10,
6-4 thru 6-6, 8-10 thru 19, 9-17 thru 9-50, 9-68 thru 9-100.
January 08, 2018 E Revise pages 2-9, 2-10, 3-34, 3-38 thru 3-41, 7-9 thru 7-12, 8-8, 8-10 thru 8-17, 8-21,
9-17 thru 9-27
TL642D, TL943D, TL1055D, TL1255D 31211036 i

EFFECTIVITY PAGE
ii 31211036 TL642D, TL943D, TL1055D, TL1255D

SECTION CONTENTS
Section Subject Page
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Maintenance Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.4 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
2.5 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
2.6 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
2.7 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
2.8 Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35
Section 3
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Boom Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.4 Boom Assembly Maintenance - TL642D, TL943D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.5 Third Boom Section Removal/Installation Only - TL642D, TL943D. . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
3.6 Boom Assembly Maintenance - TL1055D, TL1255D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
3.7 Fourth Boom Section Removal/Installation Only - TL1055D, TL1255D. . . . . . . . . . . . . . . . . . . . . . .3-25
3.8 Hose Carrier Assembly - TL1055D, TL1255D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
3.9 Boom Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
3.10 Boom Sections Adjustment - TL642D, TL943D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
3.11 Boom Sections Adjustment - TL1055D, TL1255D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
3.12 Boom Extend and Retract Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
3.13 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
3.14 Quick Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36
3.15 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
3.16 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
3.17 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42
Section 4
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Operator Cab Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operator Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4.5 Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
TL642D, TL943D, TL1055D, TL1255D 31211036 iii

SECTION CONTENTS
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Axle, Drive Shaft and Wheel Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3 Axle Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4 Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.5 Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6 Steering Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.7 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.8 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.9 Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.10 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Section 6
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5 Transmission Cooler Thermal By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.6 Torque Convertor Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Section 7
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 Engine Introduction and Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.3 Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4 Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.6 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.7 Engine Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.3 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.6 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.7 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.8 Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
8.9 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.10 Rear Axle Stabilization (RAS) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
8.11 Precision Gravity Lower System (PGLS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
8.12 Boom Ride Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
8.13 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
iv 31211036 TL642D, TL943D, TL1055D, TL1255D

SECTION CONTENTS
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Electrical Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.3 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.4 Power Distribution Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.5 Electrical System Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-17
9.6 Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-38
9.7 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-41
9.8 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-43
9.9 Electrical Master Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-44
9.10 Window Wiper System (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-45
9.11 Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-49
9.12 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-53
9.13 Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-55
9.14 Analyzer Software Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-58
9.15 Multifunction Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-70
9.16 Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-88
9.17 Machine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-89
9.18 Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-173
TL642D, TL943D, TL1055D, TL1255D 31211036 v

SECTION CONTENTS
vi 31211036 TL642D, TL943D, TL1055D, TL1255D

Section 1
Safety Practices
Contents
PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5.1 Safety Alert System and Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.1 Personal Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.2 Equipment Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
TL642D, TL943D, TL1055D, TL1255D 31211036 1-1

Safety Practices
1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

This service manual provides general directions for Place Do Not Operate Tags on the ignition key switch and
accomplishing service and repair procedures. Following the the steering wheel before attempting to perform any service
procedures in this manual will help assure safety and or maintenance. Remove key and disconnect battery leads.
equipment reliability.
Read, understand and follow the information in this manual, 1.5 SAFETY INFORMATION
and obey all locally approved safety practices, procedures,
To avoid possible death or injury, carefully read, understand
rules, codes, regulations and laws.
and comply with all safety messages.
These instructions cannot cover all details or variations in
In the event of an accident, know where to obtain medical
the equipment, procedures, or processes described, nor
assistance and how to use a first aid kit and fire extinguisher/
provide directions for meeting every possible contingency
fire suppression system. Keep emergency telephone
during operation, maintenance, or testing. When additional
numbers (fire department, ambulance, rescue squad/
information is desired consult the local Caterpillar dealer.
paramedics, police department, etc.) nearby. If working
Many factors contribute to unsafe conditions: carelessness, alone, check with another person routinely to help assure
fatigue, overload, inattentiveness, unfamiliarity, even drugs personal safety.
and alcohol, among others. For optimal safety, encourage
everyone to think, and to act, safely. 1.5.1 Safety Alert System and Signal Words
Appropriate service methods and proper repair procedures
are essential for the safety of the individual doing the work,
for the safety of the operator, and for the safe, reliable DANGER
operation of the machine. All references to the right side, left
side, front and rear are given from the operator seat looking in
a forward direction. DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
Supplementary information is available on SIS Web.
1.2 DISCLAIMER WARNING

All information in this manual is based on the latest product
information available at the time of publication. The
WARNING indicates a potentially hazardous situation
manufacturer reserves the right to make changes and
which, if not avoided, could result in death or serious injury.
improvements to its products, and to discontinue the
manufacture of any product, at its discretion at any time
without public notice or obligation.
CAUTION
1.3 OPERATION & MAINTENANCE MANUAL
The mechanic must not operate the machine until the CAUTION indicates a potentially hazardous situation which,
Operation & Maintenance Manual has been read and if not avoided, may result in minor or moderate injury.
understood, training has been accomplished and operation
of the machine has been completed under the supervision
of an experienced and qualified operator.
An Operation & Maintenance Manual is supplied with each
machine and must be kept in the manual holder located in
the cab. In the event that the Operation & Maintenance
Manual is missing, consult the local Caterpillar dealer before
proceeding.
1-2 31211036 TL642D, TL943D, TL1055D, TL1255D

Safety Practices
1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards

SOLVENTS: Only use approved solvents that are known to be
Following are general safety statements to consider before
safe for use.
performing maintenance procedures on the telehandler.
Additional statements related to specific tasks and HOUSEKEEPING: Keep the work area and operator cab clean,
procedures are located throughout this manual and are and remove all hazards (debris, oil, tools, etc.).
listed prior to any work instructions to provide safety
FIRST AID: Immediately clean, dress and report all injuries
information before the potential of a hazard occurs.
(cuts, abrasions, burns, etc.), no matter how minor the injury
For all safety messages, carefully read, understand and may seem. Know the location of a First Aid Kit, and know
follow the instructions before proceeding. how to use it.
CLEANLINESS: Wear eye protection, and clean all
1.6.1 Personal Hazards components with a high pressure or steam cleaner before
PERSONAL SAFETY GEAR: Wear all the protective clothing attempting service.
and personal safety gear necessary to perform the job safely.
When removing hydraulic components, plug hose ends and
This might include heavy gloves, safety glasses or goggles,
connections to prevent excess leakage and contamination.
filter mask or respirator, safety shoes or a hard hat.
Place a suitable catch basin beneath the machine to capture
LIFTING: NEVER lift a heavy object without the help of at fluid run off.
least one assistant or a suitable sling and hoist.
It is good practice to avoid pressure-washing electrical/
electronic components. In the event pressure-washing the
1.6.2 Equipment Hazards machine is needed, ensure the machine is shut down before
LIFTING OF EQUIPMENT: Before using any lifting equipment pressure-washing. Should pressure-washing be utilized to
(chains, slings, brackets, hooks, etc.), verify that it is of the wash areas containing electrical/electronic components, it is
proper capacity, in good working order, and is properly recommended a maximum pressure of 750 psi (52 bar) at a
attached. minimum distance of 12 in (30,5 cm) away from these
components. If electrical/electronic components are
NEVER stand or otherwise become positioned under a
sprayed, spraying must not be direct and for brief time
suspended load or under raised equipment. The load or
periods to avoid heavy saturation.
equipment could fall or tip.
Check and obey all Federal, State and/or Local regulations
DO NOT use a hoist, jack or jack stands only to support
regarding waste storage, disposal and recycling.
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load.
HAND TOOLS: Always use the proper tool for the job; keep
tools clean and in good working order, and use special
service tools only as recommended.
TL642D, TL943D, TL1055D, TL1255D 31211036 1-3

Safety Practices
1.6.4 Operational Hazards NEVER drain or store fluids in an open container. Engine fuel
and hydraulic fluid are flammable and can cause a fire
ENGINE: Stop the engine before performing any service
and/or explosion.
unless specifically instructed otherwise.
DO NOT mix gasoline or alcohol with diesel fuel.
VENTILATION: Avoid prolonged engine operation in
The mixture can cause an explosion.
enclosed areas without adequate ventilation.
PRESSURE TESTING: When conducting any test, only use test
SOFT SURFACES AND SLOPES: NEVER work on a machine
equipment that is correctly calibrated and in good
that is parked on a soft surface or slope. The machine must
condition. Use the correct equipment in the proper manner,
be on a hard level surface, with the wheels blocked before
and make changes or repairs as indicated by the test
performing any service.
procedure to achieve the desired result.
FLUID TEMPERATURE: NEVER work on a machine when the
LEAVING MACHINE: Lower the forks or attachment to the
engine, cooling or hydraulic systems are hot. Hot
ground before leaving the machine.
components and fluids can cause severe burns. Allow
systems to cool before proceeding. TIRES: Always keep tires inflated to the proper pressure to
help prevent tipover. DO NOT over inflate tires.
FLUID PRESSURE: Before loosening any hydraulic or diesel
fuel component, hose or tube, turn the engine OFF. Wear NEVER use mismatched tire types, sizes or ply ratings.
heavy, protective gloves and eye protection. NEVER check Always use matched sets according to machine
for leaks using any part of your body; use a piece of specifications.
cardboard or wood instead. If injured, seek medical
MAJOR COMPONENTS: Never alter, remove, or substitute
attention immediately. Diesel fluid leaking under pressure
any items such as counterweights, tires, batteries or other
can explode. Hydraulic fluid and diesel fuel leaking under
items that may reduce or affect the overall weight or
pressure can penetrate the skin, cause infection, gangrene
stability of the machine.
and other serious personal injury.
BATTERY: DO NOT charge a frozen battery. Charging a
Engine fuel lines are pressurized. DO NOT attempt repairs
frozen battery may cause it to explode. Allow the battery to
unless specific training has been completed. Refer to the
thaw before jump starting or connecting a battery charger.
engine manufacturers’ manual for specific details
concerning the fuel system.
1.7 SAFETY DECALS
Relieve all pressure before disconnecting any component,
part, line or hose. Slowly loosen parts and allow release of Check that all safety decals are present and readable on the
residual pressure before removing any part or component. machine. Refer to the Operation & Maintenance Manual
Before starting the engine or applying pressure, use supplied with machine for information.
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.
COOLING SYSTEM CAP: The cooling system is under
pressure, and escaping coolant can cause severe burns and
eye injury. To prevent personal injury, NEVER remove the
coolant system cap while the cooling system is hot. Wear
safety glasses. Turn the coolant system 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.
Properly disconnect battery(s) prior to service the fuel or
hydraulic systems.
FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic
systems near an open flame, sparks or smoking materials.
1-4 31211036 TL642D, TL943D, TL1055D, TL1255D

Section 2
General Information and Specifications
Contents

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.1 Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.3 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.4 Steering Angle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.5 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.6 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.2.7 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.3 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.3.1 Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.3.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4.1 Every 10 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4.2 First 50 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4.3 Every 50 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.4.4 First 250 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.4.5 Every 250 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.4.6 First 500 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.4.7 Every 500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.4.8 Every 750 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.4.9 Every 1000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.4.10 Every 1500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.4.11 Every 2000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.5 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.5.1 50 Hour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.5.2 250 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.5.3 1000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2.6 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.7 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2.7.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2.7.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
TL642D, TL943D, TL1055D, TL1255D 31211036 2-1

2.8 Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . 2-35

2.8.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
2.8.2 Assembly Instructions for American Standard Pipe Thread Tapered Connections 2-37
2.8.3 Assembly Instructions for British Standard Pipe Thread Tapered Connections. 2-39
2.8.4 Assembly Instructions for 37° (JIC) Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
2.8.5 Assembly Instructions for 45° SAE Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2.8.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings. . . . . . . . . . . . . . . . . . . 2-44
2.8.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) . . 2-46
2.8.8 Assembly Instructions for Bulkhead (BH) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
2.8.9 Assembly Instructions for O-Ring Boss (ORB) Fittings . . . . . . . . . . . . . . . . . . . . . . . . 2-52
2.8.10 Assembly Instructions for Adjustable Port End Metric Fittings . . . . . . . . . . . . . . . . 2-60
2.8.11 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends . . . . . . . . . 2-68
2.8.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings . . . . . . . . . . . . . . . . 2-70
2.8.13 Assembly Instructions for Flange Connections (FL61 and FL62) . . . . . . . . . . . . . . 2-78
2.8.14 Double Wrench Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
2.8.15 FFWR and TFFT Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
2.8.16 Adjustable Stud End Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
2.8.17 O-ring Installation (Replacement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
2-2 31211036 TL642D, TL943D, TL1055D, TL1255D

2.1 REPLACEMENT PARTS AND WARRANTY

INFORMATION
Before ordering parts or initiating service inquiries, make

note of the machine serial number. The machine serial
number plate (1) is located on the frame behind the left
front tire.
Note: The replacement of any part on this machine with any
other than factory authorized replacement parts can adversely
affect the performance, durability, or safety of the machine,
and will void the warranty. Caterpillar disclaims liability for
any claims or damages, whether regarding property damage,
personal injury or death arising out of the use of unauthorized
replacement parts.
A warranty registration form must be filled out by the local
Caterpillar dealer.
Registration activates the warranty period and helps to
assure that warranty claims are promptly processed to
guarantee full warranty service.
TL642D, TL943D, TL1055D, TL1255D 31211036 2-3

2.2 SPECIFICATIONS
2.2.1 Travel Speed
AVERAGE MAXIMUM SPEED - FORWARD AVERAGE MAXIMUM SPEED - REVERSE

MODEL
(miles per hour) (miles per hour)
TL1055D, TL1055D,
TL642D TL943D TL642D TL943D
TL1255D TL1255D
First Gear 3.3 3.1 3.2 3.3 3.0 3.2
Second Gear 6.3 5.9 6.2 6.3 5.9 6.2
Third Gear 14.1 13.5 14.2 14.2 13.5 14.2
Fourth Gear 19.5 18.5 20.5 - - -
2.2.2 Hydraulic Cylinder Performance

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

FUNCTION
TL642D TL943D TL1055D TL1255D
Boom Extend (Boom Level) 13.5 - 18.2 14.4 - 18.5 18.3 - 21.3 18.3 - 21.3
Boom Retract (Boom Level) 9.5 - 12.5 12.5 - 16.1 15.3 - 17.9 15.3 - 17.9
Boom Lift 12.5 - 16.5 9 - 11 14.3 - 15.8 15.9 - 18.6
Boom Lower 8 - 12 8 - 10 12.4 - 13.8 13.7 - 16
Attachment Tilt Forward 4 - 4.4 3.5 - 5.5 4.9 - 5.8 5.2 - 6.1
Attachment Tilt Rearward 3.9 - 4.3 3.5 - 5.5 5.1 - 6.0 5.4 - 6.3
Frame Level - Full Right to Left 8.5 - 10.7 9 - 12.7 8.8 - 11.3 8.8 - 11.3
Frame Level - Full Left to Right 8.5 - 10.7 9 - 12.7 8.8 - 11.3 8.8 - 11.3
Outrigger - Both Down 7.5 - 8.5 4.0 - 4.7 4.0 - 4.7 4.0 - 4.7
Outrigger - Both Up 5.7 - 6.5 3.9 - 4.5 3.9 - 4.5 3.9 - 4.5
Outrigger - Single Down 4.0 - 4.5 2.6 - 3.0 2.6 - 3.4 2.6 - 3.0
Outrigger - Single Up 3.0 - 3.5 3.0 - 3.5 3.0 - 3.5 3.0 - 3.5
2.2.3 Cylinder Drift
Maximum Rod Travel

Cylinder
(loaded or unloaded)
Lift/Lower Cylinder 0.125 in (3.2 mm) per hour
Extend/Retract Cylinder 0.125 in (3.2 mm) per hour
Attachment Tilt Cylinder 0.125 in (3.2 mm) per hour
2-4 31211036 TL642D, TL943D, TL1055D, TL1255D

2.2.4 Steering Angle Specifications
Model Angle (in Degree)

TL642D, TL943D 55
TL1055D, TL1255D 45
2.2.5 Electrical System
Description Standard Dual/Arctic

Battery
12 V, Negative (-) Ground, 12 V, Negative (-) Ground,
Type, Rating
Maintenance Free Maintenance Free
Quantity 1 2
Reserve Capacity Minutes @ 80° F (27° C) 160 160
Cold Cranking Amps @ 0° F (-18° C) 1000 1000
Group/Series Group 31 Group 31
Alternator 12V, 120 Amps 12V, 120 Amps
Starter 12V, 4.2 KW, LHS 12V, 4.2 KW, LHS
TL642D, TL943D, TL1055D, TL1255D 31211036 2-5

2.2.6 Engine Performance Specifications
a. TL642D, TL943D
SN ML800150 to Present
SN MLJ00150 to Present
Specifications
Description
TL642D TL943D
Engine Make/Model CAT C3.4B T4F CAT C3.4B T4F
Displacement 207 in³ (3,4 liters) 207 in³ (3,4 liters)
Low Idle 950 rpm 950 rpm
High Idle 2310 rpm 2310 rpm
Horsepower 100.57 HP (75 kW) @ 2200 rpm 111.30 HP (83 kW) @ 2200 rpm
Peak Torque 309.77 lb-ft (420 Nm) @ 1400 rpm 339.28 lb-ft (460 Nm) @ 1400 rpm
Fuel Delivery Fuel Injection Fuel Injection
Dry Type, Replaceable Primary and Safety Dry Type, Replaceable Primary and Safety
Air Cleaner
Elements Elements
SN MLG00150 to Present
SN MLD00150 to Present
Specifications
Description
TL642D TL943D
Engine Make/Model CAT C4.4 LRC CAT C4.4 LRC
Displacement 269 in³ (4,4 liters) 269 in³ (4,4 liters)
Low Idle 950 rpm 950 rpm
High Idle 2320 rpm 2320 rpm
Horsepower 99.91 HP (74,5 kW) @ 2200 rpm 110.09 HP (82,1 kW) @ 2200 rpm
Peak Torque 309.77 lb-ft (420 Nm) @ 1400 rpm 358.45 lb-ft (486 Nm) @ 1400 rpm
Fuel Delivery Fuel Injection Fuel Injection
Dry Type, Replaceable Primary and Safety Dry Type, Replaceable Primary and Safety
Air Cleaner
Elements Elements
2-6 31211036 TL642D, TL943D, TL1055D, TL1255D

b. TL1055D, TL1255D
Specifications
Description
TL1055D, TL1255D
Engine Make/Model CAT C4.4
Displacement 269 in³ (4,4 liters)
Low Idle 950 rpm
High Idle 2330 rpm
Horsepower 142 HP (106 kW) @ 2200 rpm
Peak Torque 413 lb-ft (560 Nm) @ 1400 rpm
Fuel Delivery Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and Safety Elements
SN MNT00150 to Present
SN MYW00150 to Present
Specifications
Description
TL1055D, TL1255D
Engine Make/Model CAT C4.4 LRC
Displacement 269 in³ (4,4 liters)
Low Idle 950 rpm
High Idle 2320 rpm
Horsepower 142 HP (106 kW) @ 2200 rpm
Peak Torque 412 lb-ft (558 Nm) @ 1400 rpm
Fuel Delivery Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and Safety Elements
TL642D, TL943D, TL1055D, TL1255D 31211036 2-7

2.2.7 Tires
Note: Wheel lug nut torque is 350-400 lb-ft (474-542 Nm).
Note: Pressures for foam filled tires are for initial fill ONLY.
a. TL642D
Minimum Ply/
Size Tire Type Fill Type Pressure
Star Rating
Foam Approx 464 lb (210 kg)
370/75-28 DuraForce 14 Ply
Pneumatic 76 psi (5,25 Bar)
16 Ply Pneumatic 80 psi (5,5 Bar)
13.00 - 24 G-2
12 Ply Foam Approx 542 lb (246 kg)
b. TL943D
Minimum Ply/
Star Rating
370/75-28 DuraForce 14 Ply
14.00 - 24 G-2
c. TL1055D
Minimum Ply/
Star Rating
400/75-28 DuraForce MH 16 Ply
14.00-24 G-2
d. TL1255D
Minimum Ply/
Star Rating
400/75-28 DuraForce MH 16 Ply
17.5-25 G2
2-8 31211036 TL642D, TL943D, TL1055D, TL1255D

2.3 FLUID AND LUBRICANT CAPACITIES
2.3.1 Fluids
Ambient Temperature
Range
Compartment or System Type and Classification Viscosities
°F °C
Min Max Min Max
SAE 15W-40 14 118 -10 48
CAT DEO ULS
Engine Crankcase SAE 10W-30 -4 104 -20 40
API CJ-4
SAE 0W-40 -40 118 -40 48
SAE 50 50 118 10 48
SAE 30 32 95 0 35
Transmission and Transfer
CAT TDTO SAE 10W 0 95 -18 35
Case
SAE 5W-30 -22 68 -30 20
SAE 0W-30 -40 68 -40 20
CAT Gear Oil (GO)* SAE 80W-90 -4 118 -20 48
CAT TDTO-TMS* CAT TDTO-TMS -4 118 -20 48
API GL4 with SAE90
Axle Differential and Wheel 32 118 0 48
LS Additives SAE90LS
End
or 80W-90 -4 118 -20 48
API GL5 with 75W-90 -40 118 -40 48
LS Additives 75W -40 50 -40 10
SAE 15W-40 5 118 -15 48
SAE 10W-30 -4 104 -20 40
SAE 30 50 118 10 48
CAT TDTO SAE 10W -4 104 -20 40
CAT TDTO-TMS
Hydraulic System SAE 5W-40 -22 104 -30 40
CAT Arctic TDTO SYN
commercial TO-4 SAE 5W-30 -22 104 -30 40
SAE 0W-30 -40 104 -40 40
SAE 0W-20 -40 104 -40 40
CAT TDTO-TMS -4 118 -20 48
Boom Wear Pad Grease Extreme Pressure Grease NLGI Grade 000 -31 118 -15 48
NLGI Grade 2 EP
or
Grease Fittings Extreme Pressure Grease 5 122 -15 50
NLGI Grade 3 EP with Moly
Additive
Boom Chain Lubricant Gear Oil 80W-90 -40 115 -40 46
CAT DEAC 50/50 Mix Standard
Engine Coolant
(Glycol and Water) 60/40 Mix Cold Weather
EN 590
ASTM D 975 Grade 1-D Ultra Low Sulfur
Fuel
ASTM D 975 Grade 2-D (S <15mg/kg)
(Maximum B5 Biodiesel)
Diesel Exhaust Fluid ISO22241-1 32.5% Urea
Brake Fluid Mobil ATF-D/M -40 118 -40 48
Air Conditioning Refrigerant R-143-a Tetrafluoroethane
Note: *Friction Modifier (197-0017) required for axle differentials, see Section 2.3.2, “Capacities”.
TL642D, TL943D, TL1055D, TL1255D 31211036 2-9
Ambient Temperature
Range
Compartment or System Type and Classification Viscosities
°F °C
Min Max Min Max
SAE 15W-40 14 118 -10 48
CAT DEO
Engine Crankcase SAE 10W-30 -4 104 -20 40
API CI-4
SAE 0W-40 -40 118 -40 48
SAE 50 50 118 10 48
SAE 30 32 95 0 35
Transmission and Transfer Case CAT TDTO SAE 10W 0 95 -18 35
SAE 5W-30 -22 68 -30 20
SAE 0W-30 -40 68 -40 20
CAT Gear Oil (GO)* SAE 80W-90 -4 118 -20 48
CAT TDTO-TMS* CAT TDTO-TMS -4 118 -20 48
API GL4 with SAE90
32 118 0 48
Axle Differential and Wheel End LS Additives SAE90LS
or 80W-90 -4 118 -20 48
API GL5 with 75W-90 -40 118 -40 48
LS Additives 75W -40 50 -40 10
SAE 15W-40 5 118 -15 48
SAE 10W-30 -4 104 -20 40
SAE 30 50 118 10 48
CAT TDTO SAE 10W -4 104 -20 40
CAT TDTO-TMS
Hydraulic System SAE 5W-40 -22 104 -30 40
CAT Arctic TDTO SYN
commercial TO-4 SAE 5W-30 -22 104 -30 40
SAE 0W-30 -40 104 -40 40
SAE 0W-20 -40 104 -40 40
CAT TDTO-TMS -4 118 -20 48
Boom Wear Pad Grease Extreme Pressure Grease NLGI Grade 000 -31 118 -15 48
NLGI Grade 2 EP
or
Grease Fittings Extreme Pressure Grease NLGI Grade 3 EP 5 122 -15 50
with Moly
Additive
Boom Chain Lubricant Gear Oil 80W-90 -40 115 -40 46
CAT DEAC 50/50 Mix Standard
Engine Coolant
(Glycol and Water) 60/40 Mix Cold Weather
EN 590
ASTM D 975 Grade 1-D Low Sulfur
Fuel
ASTM D 975 Grade 2-D (S<500mg/kg)
(Maximum B5 Biodiesel)
Brake Fluid Mobil ATF-D/M -40 118 -40 48
Air Conditioning Refrigerant R-143-a Tetrafluoroethane
Note: *Friction Modifier (197-0017) required for axle differentials, see Section 2.3.2, “Capacities”.
2-10 31211036 TL642D, TL943D, TL1055D, TL1255D

2.3.2 Capacities
a. TL642D
Engine Crankcase Oil

Capacity with Filter Change 8.3 quarts (7,9 liters)
Fuel Tank
Capacity 38.3 gallons (145 liters)
Diesel Exhaust Fluid (DEF) Tank (SN ML800150 to Present)
Capacity 5.7 gallons (21,5 liters)
Cooling System
System Capacity 6.0 gallons (22,6 liters)
Hydraulic System
System Capacity
No Outriggers 40.2 gallons (152 liters)
With Outriggers 41.7 gallons (158 liters)
Reservoir Capacity to Full Mark 23.8 gallons (90 liters)
Transmission
Capacity including Cooler and Lines 18 quarts (17 liters)
Capacity with Filter Change 14 quarts (13,2 liters)
Transfer Case
Capacity 3.2 quarts (3,0 liters)
Axles
Differential Housing Capacity
Front 7.6 quarts (7,2 liters)
Rear 7.1 quarts (6,7 liters)
Friction Modifier (197-0017) - Required for axle differentials
Not to Exceed 12.2 ounce (360 milliliter)
(Must be premixed with axle fluid)
Wheel End Capacity
Front 1.2quarts (1,1 liters)
Air Conditioning System (If equipped)
System Capacity 2.6 lb (1,2 kilogram)
Brake Fluid
Capacity 1.1 quarts (1,0 liter)
TL642D, TL943D, TL1055D, TL1255D 31211036 2-11

b. TL943D

Fuel Tank
Diesel Exhaust Fluid (DEF) Tank (SN MLJ00150 to Present)
Cooling System
Hydraulic System
System Capacity
No Outriggers 46.5 gallons (176 liters)
With Outriggers 48.6 gallons (184 liters)
Transmission
Transfer Case
Axles
Front 13.2 quarts(12,5 liters)
Not to Exceed 24 ounce (710 milliliter)
Wheel End Capacity
Brake Fluid
2-12 31211036 TL642D, TL943D, TL1055D, TL1255D

c. TL1055D, TL1255D

Fuel Tank
Diesel Exhaust Fluid (DEF) Tank (SN ML500150 to Present, SN ML700150 to Present)
Cooling System
Hydraulic System
System Capacity
TL1055D 48.6 gallons (184 liters)
TL1255D 49.9 gallons (189 liters)
Transmission
Transfer Case
Axles
Front 15 quarts (14,2 liters)
Rear 14 quarts (13,2 liters)
Not to Exceed 24 ounce (710 milliliter)
Wheel End Capacity
Brake Fluid
TL642D, TL943D, TL1055D, TL1255D 31211036 2-13

2.4 SERVICE AND MAINTENANCE

SCHEDULES
2.4.1 Every 10 Hours
OC0880 OC0890 OC0950 OC0910 OC0920
Check Fuel Level Check Tire Check Air Cleaner Check Engine Check Hydraulic
Condition and Oil Level Oil Level
Pressure
OC0930 OC0940 OC0900
Check Check DEF Level Check Brake

(SN ML800150 to Present
Transmission Oil SN MLJ00150 to Present Fluid Level
Level SN ML700150 to Present)
2.4.2 First 50 Hours
OC0990 OC1000
Check Wheel Lug Check Boom

Nut Torque Chain Tension
2-14 31211036 TL642D, TL943D, TL1055D, TL1255D

G
MP
OC1010 OC0960 OC0970 OC1020 OC1030
Lubrication Drain Fuel/Water Check Engine Check Washer Check Cab Filter
Schedule Separator Coolant Level Fluid
OC1040 OC1050
Change Axle Oil Change Wheel

End Oil
G
MP
OC1010 OC1090 OC1080 OC1160 OC1130
Lubrication Check Boom Wear Check Boom Check Fan Belt Check Wheel End
Schedule Pads Chains Oil Level
OC1100 OC1110
Check Transfer Check Axle Oil

Case Fluid Level Level
TL642D, TL943D, TL1055D, TL1255D 31211036 2-15

OC1140 OC1060
Change Engine Oil Change Transfer

and Filter Case Fluid
RAS
OC1220 OC0990 OC1170 OC1150 OC1120
Change Fuel Filters Check Wheel Lug Change Engine Check Battery Check RAS System
Not Torque Oil and Filter
(SN MLG00150 to Present
SN MYW00150 to Present)
OC1180 OC1190
Change Hydraulic Change Hydraulic

Tank Breather Filters
2-16 31211036 TL642D, TL943D, TL1055D, TL1255D

OC1000 OC1060 OC1200 OC1040 OC1210
Check Boom Chain Change Transfer Check Air Intake Change Axle Oil Check Park Brake
Tension Case Fluid System
G
MP
OC1070 OC1050 OC1010
Change Change Wheel End Lubrication

Transmission Fluid Oil Schedule
and Filter
Note: If using fully synthetic oil, metal engine oil filter and fuel consumption is less than 11.4 liter per hour (3 gallon per hour), oil change intervals
are 1,000 hours. If any of the following are present, conventional oil, plastic engine oil filter or fuel consumption is greater than 11.4 liter per hour (3
gallon per hour), oil change intervals are 500 hours.
OC1260 OC1240 OC1230
Change DEF Pump Change Engine Change Hydraulic Change Crankcase

Filter Coolant Fluid and Filters Vent Filter
(SN ML800150 to Present (SN ML800150 to Present
SN MLJ00150 to Present SN MLJ00150 to Present
SN ML500150 to Present SN ML500150 to Present
SN ML700150 to Present) SN ML700150 to Present)
OC1250 OC1310
Change DEF Clean Engine DEF

Tank Filter Strainer
(SN ML800150 to Present (SN ML800150 to Present
SN MLJ00150 to Present SN MLJ00150 to Present)
SN ML700150 to Present)
TL642D, TL943D, TL1055D, TL1255D 31211036 2-17

2.5 LUBRICATION SCHEDULE
2.5.1 50 Hour
a. TL642D, TL943D
OC0011
2-18 31211036 TL642D, TL943D, TL1055D, TL1255D

b. TL1055D, TL1255D
B B
B
B
B
B
OD1301
TL642D, TL943D, TL1055D, TL1255D 31211036 2-19

2.5.2 250 Hour
a. TL642D, TL943D
OC0021
2-20 31211036 TL642D, TL943D, TL1055D, TL1255D

b. TL1055D, TL1255D
OD1311
TL642D, TL943D, TL1055D, TL1255D 31211036 2-21

2.5.3 1000 Hour
a. TL642D, TL943D
OC0031
2-22 31211036 TL642D, TL943D, TL1055D, TL1255D

b. TL1055D, TL1255D
OD1321
TL642D, TL943D, TL1055D, TL1255D 31211036 2-23

2.6 THREAD LOCKING COMPOUND
Loctite® ND Industries Description

242™ Vibra-TITE™ 121 Medium Strength (Blue)
243™ Vibra-TITE™ 122 Medium Strength (Blue)
271™ Vibra-TITE™ 140 High Strength (Red)
262™ Vibra-TITE™ 131 Medium - High Strength (Red)
Loctite® 243™ can be substituted in place of Loctite® 242™. Vibra-TITE™ 122 can be substituted in place of Vibra-TITE™ 121.
2-24 31211036 TL642D, TL943D, TL1055D, TL1255D

2.7 TORQUE CHARTS
2.7.1 SAE Fastener Torque Chart
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
Tensile (Loctite® 242™ or Torque
Clamp Torque Torque
Size TPI Bolt Dia Stress 271™ or (Loctite® 262™ or
Load (Dry) Lubricated
Area Vibra-TITE™ Vibra-TITE™ 131)
111 or 140)
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
TL642D, TL943D, TL1055D, TL1255D 31211036 2-25

2.7.1 SAE Fastener Torque Chart (Continued)
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque (Loctite® 242™ or 271™
Tensile Clamp (Loctite® 262™ or
Size TPI Bolt Dia (Dry or Loctite® 263)
Stress Area Load or Vibra-TITE™ 111 or Vibra-TITE™ 131)
K=0.20
140) K=0.18 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
2-26 31211036 TL642D, TL943D, TL1055D, TL1255D

Values for Magni Coating Fasteners (Ref 4150701)

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque Torque
Size TPI Bolt Dia (Dry)
K=0.17
140) K=0.16 K=0.15
4 40 0.1120 0.00604 380 7 0.8
48 0.1120 0.00661 420 8 0.9
6 32 0.1380 0.00909 580 14 1.5
40 0.1380 0.01015 610 14 1.6
8 32 0.1640 0.01400 900 25 2.8
36 0.1640 0.01474 940 26 2.9
10 24 0.1900 0.01750 1120 36 4.1
32 0.1900 0.02000 1285 42 4.7
1/4 20 0.2500 0.0318 2020 86 9.7 80 9
28 0.2500 0.0364 2320 99 11.1 95 11
5/16 18 0.3125 0.0524 3340 15 20 14 19 15 20
24 0.3125 0.0580 3700 15 20 15 21 15 20
3/8 16 0.3750 0.0775 4940 25 35 25 34 25 34
24 0.3750 0.0878 5600 30 40 28 38 25 34
7/16 14 0.4375 0.1063 6800 40 55 40 54 35 48
20 0.4375 0.1187 7550 45 60 44 60 40 54
1/2 13 0.5000 0.1419 9050 65 90 60 82 55 75
20 0.5000 0.1599 10700 75 100 71 97 65 88
9/16 12 0.5625 0.1820 11600 90 120 87 118 80 109
18 0.5625 0.2030 12950 105 145 97 132 90 122
5/8 11 0.6250 0.2260 14400 130 175 120 163 115 156
18 0.6250 0.2560 16300 145 195 136 185 125 170
3/4 10 0.7500 0.3340 21300 225 305 213 290 200 272
16 0.7500 0.3730 23800 255 345 238 324 225 306
7/8 9 0.8750 0.4620 29400 365 495 343 466 320 435
14 0.8750 0.5090 32400 400 545 378 514 355 483
1 8 1.0000 0.6060 38600 545 740 515 700 480 653
12 1.0000 0.6630 42200 600 815 563 765 530 721
1 1/8 7 1.1250 0.7630 42300 675 920 635 863 595 809
12 1.1250 0.8560 47500 755 1025 713 969 670 911
1 1/4 7 1.2500 0.9690 53800 955 1300 897 1219 840 1142
12 1.2500 1.0730 59600 1055 1435 993 1351 930 1265
1 3/8 6 1.3750 1.1550 64100 1250 1700 1175 1598 1100 1496
12 1.3750 1.3150 73000 1420 1930 1338 1820 1255 1707
1 1/2 6 1.5000 1.4050 78000 1660 2260 1560 2122 1465 1992
12 1.5000 1.5800 87700 1865 2535 1754 2385 1645 2237
TL642D, TL943D, TL1055D, TL1255D 31211036 2-27


SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Size TPI Bolt Dia (Dry or Loctite® 263)
K=0.17
140) K=0.16 K=0.15
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 37 4
10 24 0.1900 0.01750 1580 51 6
32 0.1900 0.02000 1800 58 7
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
2-28 31211036 TL642D, TL943D, TL1055D, TL1255D


SOCKET HEAD CAP SCREWS
Torque
Torque
Clamp (Loctite® 242™ or 271™
Tensile Torque (Loctite® 262™ or
Size TPI Bolt Dia Load See or Vibra-TITE™ 111 or
Stress Area (Dry) K=0.17 Vibra-TITE™ 131)
Note 4 140) or Precoat® 85
K=0.15
K=0.16
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
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.
TL642D, TL943D, TL1055D, TL1255D 31211036 2-29

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

SOCKET HEAD CAP SCREWS
Torque
Torque
Clamp (Loctite® 242™ or 271™
Tensile Torque (Loctite® 262™ or
Size TPI Bolt Dia Load See or Vibra-TITE™ 111 or
Stress Area (Dry) K=0.17 Vibra-TITE™ 131)
Note 4 140) or Precoat® 85
K=0.15
K=0.16
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
2-30 31211036 TL642D, TL943D, TL1055D, TL1255D

2.7.2 Metric Fastener Torque Chart

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque
Torque
Clamp Torque (Loctite® 262™ or (Loctite® 242™ or
Tensile
Size Pitch Load See (Dry or Loctite® Torque (Lube) 271™ or 271™ or
Stress Area
Note 4 263™) Vibra-TITE™ 121
Vibra-TITE™ 131)
or 141)
Sq mm KN [N.m] [N.m] [N.m]
3 0.5 5.03 2.19 1.3 1.0 1.2 1.4
3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290
TL642D, TL943D, TL1055D, TL1255D 31211036 2-31

2.7.2 Metric Fastener Torque Chart (Continued)

CLASS 10.9 METRIC (HEX HEAD) BOLTS,
CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
Torque
Torque
Torque (Lube or Loctite®
Tensile Stress Clamp Load (Loctite® 262™ or
Size Pitch (Dry or Loctite® 263™) 242™ or 271™ or
Area See Note 4 Vibra-TITE™ 131)
K=0.20 Vibra-TITE™ 111 or
K=0.15
140) K=0.18
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25 23 19
8 1.25 36.60 22.8 37 33 27
10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395
2-32 31211036 TL642D, TL943D, TL1055D, TL1255D

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque
(Lube or Loctite® Torque
Torque (Loctite® 262™ or
Tensile Stress Clamp Load
Area See Note 4 Vibra-TITE™ 111 or Vibra-TITE™ 131)
K=0.17
140) K=0.15
K=0.16
3 0.5 5.03 2.19 1.1 1.1 1.0
3.5 0.6 6.78 2.95 1.8 1.7 1.5
4 0.7 8.78 3.82 2.6 2.4 2.3
5 0.8 14.20 6.18 5.3 4.9 4.6
6 1 20.10 8.74 9 8.4 7.9
7 1 28.90 12.6 15 14 13
8 1.25 36.60 15.9 22 20 19
10 1.5 58.00 25.2 43 40 38
12 1.75 84.30 36.7 75 70 66
14 2 115 50.0 119 110 105
16 2 157 68.3 186 175 165
18 2.5 192 83.5 256 240 225
20 2.5 245 106.5 362 340 320
22 2.5 303 132.0 494 465 435
24 3 353 153.5 627 590 555
27 3 459 199.5 916 860 810
30 3.5 561 244.0 1245 1170 1100
33 3.5 694 302.0 1694 1595 1495
36 4 817 355.5 2176 2050 1920
42 4.5 1120 487.0 3477 3275 3070
TL642D, TL943D, TL1055D, TL1255D 31211036 2-33

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS,
CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE*
Torque
Torque
Torque (Lube or Loctite®
Tensile Stress Clamp Load (Loctite® 262™ or
Area See Note 4 Vibra-TITE™ 131)
K=0.17 Vibra-TITE™ 111 or
K=0.15
140) K=0.18
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5 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 55
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 3 353 222.0 905 850 800
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
2-34 31211036 TL642D, TL943D, TL1055D, TL1255D

2.8 HYDRAULIC CONNECTION ASSEMBLY SAE - 45° flare per SAE J512
AND TORQUE SPECIFICATION
2.8.1 Definitions
a. Tapered Thread Types
NPTF - National tapered fuel (dry seal) per SAE J476/J512

MAE9030
ORFS - O-ring face seal per SAE J1453
MAE9000 MAE9040
MBTL - Metric flareless bite type fitting, pressure rating L

BSPT - British standard pipe tapered per ISO7-1
(medium) per ISO 8434, DIN 2353
MBTS - Metric flareless bite type fitting, pressure rating S (high)
per ISO 8434, DIN 2353
MAE9050
MAE9010
BH - Bulkhead connection – JIC, ORFS, MBTL, or MBTS types

b. Straight Thread Types, Tube and Hose Connections
JIC - 37° flare per SAE J514
MAE9060
MAE9020
c. Straight Thread Types, Port Connections
ORB - O-ring boss per SAE J1926, ISO 11926
TL642D, TL943D, TL1055D, TL1255D 31211036 2-35

MPP - Metric pipe parallel o-ring boss per SAE J2244, d. Flange Connection Types
ISO 6149, DIN 3852
FL61 - Code 61 flange per SAE J518, ISO 6162
FL62 - Code 62 flange per SAE J518, ISO 6162
MAE9070
MAE9090
MFF - Metric flat face port per ISO 9974-1
BSPP - British standard parallel pipe per ISO 1179-1, e. Tightening Methods
DIN 3852-2
Torque - Application of a twisting force to the applicable
connection by use of a precise measurement instrument
(i.e. torque wrench).
Finger Tight (Hand Tight) - The point where the connector
will no longer thread onto the mating part when tightened
by hand or fingers. Finger Tight is relative to user strength
and will have some variance. The average torque applied by
this method is 4 Nm (3 ft-lbs).
TFFT - Turns From Finger Tight; Application of a preload to a
connection by first tightening the connection by
hand (fingers) and applying an additional rotation counted
by a defined number of turns by use of a tool.
FFWR (Flat method) - Flats From Wrench Resistance;
Application of a preload to a connection by tightening to
the point of initial wrench resistance and turning the nut a
MAE9080 described number of flats. A flat is one side of the hexagonal
tube nut and equates to 1/6 of a turn.
f. Assembly and Torque Specifications

Prior to selecting the appropriate torque from the tables
within this section, it is necessary to properly identify the
connector being installed.
g. General Tube Type Fitting Assembly Instructions

1. Take precautions to ensure that fittings and mating
components are not damaged during storage, handling
or assembly. Nicks and scratches in sealing surfaces can
create a path for leaks which could lead to component
contamination and/or failure.
2. When making a connection to tubing, compression or
flare, inspect the tube in the area of the fitting
attachment to ensure that the tube has not been
damaged.
2-36 31211036 TL642D, TL943D, TL1055D, TL1255D

3. The assembly process is one of the leading causes for 6. Refer to the appropriate section in this manual for more
contamination in air and hydraulic systems. specific instructions and procedures for each type of
Contamination can prevent proper tightening of fittings fitting connection.
and adapters from occurring.
a. Avoid using dirty or oily rags when handling fittings. 2.8.2 Assembly Instructions for American
Standard Pipe Thread Tapered
b. If fittings are disassembled, they should be cleaned
and inspected for damage. Replace fittings as
Connections
necessary before reinstalling. 1. Inspect components to ensure male and female port
c. Sealing compounds should be applied where threads are free of rust, splits, dirt, foreign matter, or
specified; however, care should be taken not to burrs.
introduce sealant into the system. 2. Apply a suitable thread sealant, such as Loctite 567, to
d. Avoid applying sealant to the area of the threads the male pipe threads if not already applied. Ensure the
where the sealant will be forced into the system. first 1 to 2 threads are uncovered to prevent system
This is generally the first two threads of a fitting. contamination.
e. Sealant should only be applied to the male threads. 3. Assemble connection hand tight.
f. Straight thread fittings do not require sealants. 4. Mark fittings, male and female
O-rings or washers are provided for sealing.
g. When replacing or installing an o-ring, care is to be
taken while transferring the o-ring over the threads
as it may become nicked or torn. When replacing an NOTICE
o-ring on a fitting, the use of a thread protector is
recommended. Over tightening may cause deformation of the pipe
fitting and damage to the joining fitting, flange or
h. When installing fittings with o-rings, lubrication
component may occur.
shall be used to prevent scuffing or tearing of the
o-ring. Refer to Section 2.8.17, “O-ring Installation
(Replacement)”, for procedure.
4. Take care to identify the material of parts to apply the
correct torque values. NOTICE
a. Verify the material designation in the table headings
Never back off (loosen) pipe threaded connectors to
b. If specifications are given only for steel fittings and achieve alignment. Meet the minimum required turns
components, the values for alternate materials shall and use the last turn for alignment.
be as follows:
Aluminum and Brass - reduce steel values by 35% 5. Rotate male fitting the number of turns as per below
Stainless Steel - Use the upper limit for steel. mentioned table. Refer to Section 2.8.15, “FFWR and
5. To achieve the specified torque, the torque wrench is to TFFT Methods”, for procedure.
be held perpendicular to the axis of rotation.
Note: TFFT values provided in below mentioned table are
applicable for the following material configurations:
a. Steel fittings with steel mating components
b. Steel fittings with aluminum or brass mating
components
c. Aluminum or brass fittings with steel mating
components
d. Aluminum or brass fittings with aluminum or brass
mating components.
MAE9100
TL642D, TL943D, TL1055D, TL1255D 31211036 2-37

a. NPTF Pipe Thread
MAE9110
TYPE/FITTING IDENTIFICATION
Turns From Finger Tight
Thread Size ØA*
Material Dash Size (TFFT)**
(UNF) (in) (mm)
2 1/8 - 27 0.40 10.24 2 to 3
4 1/4 - 18 0.54 13.61 2 to 3
STEEL, ALUMINUM, OR 6 3/8 - 18 0.67 17.05 2 to 3
BRASS FITTINGS
8 1/2 - 14 0.84 21.22 2 to 3
WITH STEEL,
ALUMINUM, OR 12 3/4 - 14 1.05 26.56 2 to 3
BRASS
16 1 - 11 1/2 1.31 33.22 1.5 to 2.5
MATING
COMPONENTS 20 1 1/4 - 11 1/2 1.65 41.98 1.5 to 2.5
24 1 1/2 - 11 1/2 1.89 48.05 1.5 to 2.5
32 2 - 11 1/2 2.37 60.09 1.5 to 2.5
NOTE: * ØA thread dimension for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods”, for TFFT procedure requirements.
2-38 31211036 TL642D, TL943D, TL1055D, TL1255D

2.8.3 Assembly Instructions for British

Standard Pipe Thread Tapered
Connections
1. Inspect components to ensure male and female port
NOTICE
threads are free of rust, splits, dirt, foreign matter, or Never back off (loosen) pipe threaded connectors to
burrs. achieve alignment. Meet the minimum required turns
2. Apply a suitable thread sealant, such as Loctite 567, to and use the last turn for alignment.
the male pipe threads if not already applied. Ensure the
5. Rotate male fitting the number of turns as per below
first 1 to 2 threads are uncovered to prevent system
mention table.
contamination.
3. Assemble connection hand tight. Note: TFFT values provided in below table are applicable for
the following material configurations:
4. Mark fittings, male and female.
a. Steel fittings with steel mating components
NOTICE b. Steel fittings with aluminum or brass mating

components
c. Aluminum or brass fittings with steel mating
Over tightening may cause deformation of the pipe
components
fitting and damage to the joining fitting, flange or
component may occur. d. Aluminum or brass fittings with aluminum or brass
mating components.
a. BSPT Pipe Thread
MAE9120
Turns From Finger Tight
Thread Size ØA* (TFFT)**
Material Dash Size
(BSPT) (in) (mm)
2 1/8 - 28 0.38 9.73 2 to 3
4 1/4 - 19 0.52 13.16 2 to 3
STEEL, ALUMINUM, OR
BRASS FITTINGS 6 3/8 - 19 0.66 16.66 2 to 3
WITH STEEL, 8 1/2 - 14 0.83 20.96 2 to 3
ALUMINUM, OR 12 3/4 - 14 1.04 26.44 2 to 3
BRASS 16 1 - 11 1.31 33.25 1.5 to 2.5
MATING
20 1 1/4 - 11 1.65 41.91 1.5 to 2.5
COMPONENTS
24 1 1/2 - 11 1.88 47.80 1.5 to 2.5
32 2 - 11 2.35 59.61 1.5 to 2.5
NOTE: * ØA thread dimension for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods”, for TFFT procedure requirements.
TL642D, TL943D, TL1055D, TL1255D 31211036 2-39

2.8.4 Assembly Instructions for 37° (JIC) Flare 2. Align tube to fitting and start threads by hand.
Fittings
1. Inspect the flare for obvious visual squareness and
concentricity issues with the tube OD. Ensure that
NOTICE
surface is smooth, free of rust, weld and brazing splatter, The torque method should NOT be used on lubricated or
splits, dirt, foreign matter, or burrs. If necessary, replace oily fittings. No lubrication or sealant is required. The
fitting or adapter. lubrication would cause increased clamping force and
cause fitting damage.
NOTICE 3. Torque assembly to value listed in below mentioned
table while using the Double Wrench Method.
DO NOT force a misaligned or short hose/tube into
alignment. It puts undesirable strain onto the joint Note: Torque values provided in below table are segregated
eventually leading to leakage. based on the material configuration of the connection.
a. 37° Flare (JIC) Thread - Steel
MAE9130
TYPE/FITTING IDENTIFICATION Flats From

Thread ØA* ØB* [Ft-Lb] [Nm] Wrench
Dash Size Resistance
Material Size (F.F.W.R)**
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.28 7.00 0.31 7.75 6 7 7 8 9 10 --

3 3/8-24 0.34 8.60 0.37 9.50 8 9 10 11 12 14 --
4 7/16-20 0.39 10.00 0.44 11.10 13 14 14 18 19 19 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 14 15 15 19 20 21 1 to 1-1/2
6 9/16-18 0.51 13.00 0.56 14.30 22 23 24 30 31 33 1 to 1-1/2
STEEL FITTINGS
WITH STEEL 8 3/4-16 0.69 17.60 0.75 19.10 42 44 46 57 60 63 1-1/2 to 1-3/4
MATING
10 7/8-14 0.81 20.50 0.87 22.20 60 63 66 81 85 89 1 to 1-1/2
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 0.97 24.60 1.06 27.00 84 88 92 114 120 125 1 to 1-1/2
THREADS
14 1 3/16-12 1.11 28.30 1.19 30.10 100 105 110 136 142 149 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 118 124 130 160 168 176 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 168 176 185 228 239 251 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 195 205 215 264 278 291 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 265 278 292 359 377 395 3/4 to 1
NOTE: * ØA and ØB thread dimensions for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods”, for FFWR procedure requirements.
2-40 31211036 TL642D, TL943D, TL1055D, TL1255D

b. 37° Flare (JIC) Thread - Aluminum Brass
MAE9130
TYPE/FITTING IDENTIFICATION Flats From

Thread ØA* ØB* [Ft-Lb] [Nm] Wrench
Dash Size Resistance
Material Size (F.F.W.R)**
2 5/16-24 0.28 7.00 0.31 7.75 4 4 5 5 6 7 --

3 3/8-24 0.34 8.60 0.37 9.50 5 6 7 7 8 9 --
4 7/16-20 0.39 10.00 0.44 11.10 8 9 9 11 12 13 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 9 10 10 12 13 14 1 to 1-1/2
ALUMINUM/BRASS 6 9/16-18 0.51 13.00 0.56 14.30 14 15 16 19 20 21 1 to 1-1/2

FITTINGS OR
8 3/4-16 0.69 17.60 0.75 19.10 27 29 30 37 39 41 1-1/2 to 1-3/4
ALUMINUM/BRASS
MATING 10 7/8-14 0.81 20.50 0.87 22.20 39 41 43 53 56 58 1 to 1-1/2
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 0.97 24.60 1.06 27.00 55 57 60 74 78 81 1 to 1-1/2
THREADS 14 1 3/16-12 1.11 28.30 1.19 30.10 65 68 72 88 93 97 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 77 81 84 104 109 114 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 109 115 120 148 155 163 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 127 133 139 172 180 189 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 172 181 189 234 245 257 3/4 to 1

TL642D, TL943D, TL1055D, TL1255D 31211036 2-41

2.8.5 Assembly Instructions for 45° SAE Flare

Fittings
1. Inspect the flare for obvious visual squareness and
concentricity issues with the tube OD. Ensure that
surface is smooth, free of rust, weld and brazing splatter,
splits, dirt, foreign matter, or burrs. If necessary, replace
fitting or adapter.
NOTICE
DO NOT force a misaligned or short hose/tube into
alignment. It puts undesirable strain onto the joint
eventually leading to leakage.
2. Align tube to fitting.

3. Tighten fitting by hand until hand tight.
NOTICE
The torque method should NOT be used on lubricated or
oily fittings. No lubrication or sealant is required. The
lubrication would cause increased clamping force and
Torque fitting to value listed in below table while using the

Double Wrench Method outlined in this section.
Note: Torque values provided in below table are segregated
based on the material configuration of the connection.
‘Aluminum/brass fittings or aluminum/brass mating
components’ indicate either the following material
configurations:
a. Steel fittings with aluminum or brass mating
components
b. Aluminum or brass fittings with steel mating
components
c. Aluminum or brass fittings with aluminum or brass
mating components.
2-42 31211036 TL642D, TL943D, TL1055D, TL1255D

a. 45° Flare (SAE)
MAE9140
STEEL
TYPE/FITTING IDENTIFICATION TORQUE

Thread ØA* ØB* [Ft-Lb] [Nm]
Dash Size
Material Size
4 7/16-20 0.39 9.90 0.44 11.10 13 14 14 18 19 19

STEEL FITTINGS
6 5/8-18 0.56 14.30 0.63 15.90 22 23 24 30 31 33
WITH STEEL MATING
COMPONENTS; 8 3/4-16 0.69 17.50 0.75 19.10 42 44 46 57 60 62
UN-LUBRICATED
THREADS 10 7/8-14 0.81 20.60 0.87 22.20 60 63 66 81 85 89
12 1 1/16-14 0.98 25.00 1.06 27.00 84 88 92 114 119 125
ALUMINUM BRASS

Thread ØA* ØB* [Ft-Lb] [Nm]
Dash Size
Material Size
ALUMINUM/BRASS 4 7/16-20 0.39 9.90 0.44 11.10 8 9 9 11 12 12

FITTINGS OR 6 5/8-18 0.56 14.30 0.63 15.90 14 15 15 19 20 20
ALUMINUM/BRASS
MATING 8 3/4-16 0.69 17.50 0.75 19.10 27 29 30 37 39 41
COMPONENTS;
UN-LUBRICATED 10 7/8-14 0.81 20.60 0.87 22.20 39 41 43 53 56 58
THREADS
12 1 1/16-14 0.98 25.00 1.06 27.00 55 58 61 75 79 83
TL642D, TL943D, TL1055D, TL1255D 31211036 2-43

2.8.6 Assembly Instructions for O-Ring Face

Seal (ORFS) Fittings
1. Ensure proper o-ring is installed. If o-ring is missing
install per o-ring Installation (replacement). Refer to
Section 2.8.17, “O-ring Installation (Replacement),”, for
procedure.
2. Ensure that surface is smooth, free of rust, weld and
brazing splatter, splits, dirt, foreign matter, or burrs. If
necessary, replace fitting or adapter.
NOTICE
Care to be taken when lubricating o-ring. Avoid adding
oil to the threaded connection of the fitting. The
3. Pre-lubricate the o-ring with hydraulic oil.

4. Place the tube assembly against the fitting body so that
the flat face comes in contact with the o-ring. Hand
thread the nut onto the fitting body.
5. Torque nut to value listed in below mentioned table
while using the Double Wrench Method. Refer to
Section 2.8.15, “FFWR and TFFT Methods,”, for
procedure if using the FFWR method.
Note: Torque values provided in below table are segregated
based on the material configuration of the connection.
Aluminum/brass fittings or aluminum/brass mating
components’ indicate either the following
material configurations:
a. Steel fittings with aluminum or brass mating
components
b. Aluminum or brass fittings with steel mating
components
c. Aluminum or brass fittings with aluminum or brass
mating components.
2-44 31211036 TL642D, TL943D, TL1055D, TL1255D

a. O-ring Face Seal (ORFS)
MAE9150
STEEL

Thread
Dash ØA* ØB* [Ft-Lb] [Nm] Tube Swivel &
Material Size
Size Nuts Hose Ends
4 9/16-18 0.51 13.00 0.56 14.20 18 19 20 25 26 27 1/4 to 1/2 1/2 to 3/4
6 11/16-16 0.63 15.90 0.69 17.50 30 32 33 40 43 45 1/4 to 1/2 1/2 to 3/4
STEEL FITTINGS 8 13/16-16 0.75 19.10 0.81 20.60 40 42 44 55 57 60 1/4 to 1/2 1/2 to 3/4
WITH 10 1-14 0.94 23.80 1.00 25.40 60 63 66 81 85 89 1/4 to 1/2 1/2 to 3/4
STEEL MATING
12 1 3/16-12 1.11 28.20 1.19 30.10 85 90 94 115 122 127 1/4 to 1/2 1/2 to 3/4
COMPONENTS;
UN-LUBRICATED 16 1 7/16-12 1.34 34.15 1.44 36.50 110 116 121 149 157 164 1/4 to 1/2 1/2 to 3/4
THREADS 20 1 11/16-12 1.59 40.50 1.69 42.90 150 158 165 203 214 224 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 230 242 253 312 328 343 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 375 394 413 508 534 560 1/4 to 1/2 1/2 to 3/4

ALUMINUM/BRASS
FLATS FROM
WRENCH
RESISTANCE
(F.F.W.R)**
Thread
ØA* ØB* [Ft-Lb] [Nm]
Dash Size Tube Swivel &
Material
Size Nuts Hose Ends
4 9/16-18 0.51 13.00 0.56 14.20 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4

6 11/16-16 0.63 15.90 0.69 17.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4
ALUMINUM/BRASS 8 13/16-16 0.75 19.10 0.81 20.60 26 28 29 35 38 39 1/4 to 1/2 1/2 to 3/4
FITTINGS OR
ALUMINUM/BRASS 10 1-14 0.94 23.80 1.00 25.40 39 41 43 53 56 58 1/4 to 1/2 1/2 to 3/4
MATING 12 1 3/16-12 1.11 28.20 1.19 30.10 55 58 61 75 79 83 1/4 to 1/2 1/2 to 3/4
COMPONENT;
16 1 7/16-12 1.34 34.15 1.44 36.50 72 76 79 98 103 107 1/4 to 1/2 1/2 to 3/4
UN-LUBRICATED
THREADS 20 1 11/16-12 1.59 40.50 1.69 42.90 98 103 108 133 140 146 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4

TL642D, TL943D, TL1055D, TL1255D 31211036 2-45

2.8.7 Assembly Instructions for DIN 24° Flare

Bite Type Fittings (MBTL and MBTS)
NOTICE
A non-square tube end can cause improperly seated
fittings and leakage.
6. Inspect the components to ensure free of
contamination, external damage, rust, splits, dirt,
foreign matter, or burrs. Ensure tube end is visibly
square. If necessary, replace fitting or tube.
7. Lubricate thread and cone of fitting body or hardened
pre-assembly tool, as well as the progressive ring and
nut threads.
8. Slip nut and progressive ring over tube, assuring that
they are in the proper orientation.
9. Push the tube end into the coupling body.
10. Slide collet into position and tighten until finger tight.
Mark nut and tube in the finger-tight position. Tighten
nut to the number of flats listed while using the Double
Wrench Method. The tube must not turn with the nut.
2-46 31211036 TL642D, TL943D, TL1055D, TL1255D

a. DIN 24° CONE (MBTL & MBTS)
MAE9160
DIN 24° CONE FLARELESS BITE FITTING

(WITH OR WITHOUT O-RING)
Tube Thread Torque Flats From
ØA* ØB* C* ØD*
O.D. M Size [Ft-Lb] [Nm] Wrench
Material Type
Resistance
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
6 M12 x 1.5 10.50 12.00 7.00 6.20 1.5 to 1.75
8 M14 x 1.5 12.50 14.00 7.00 8.20 1.5 to 1.75
FFWR is the recommended method of
10 M16 x 1.5 14.50 16.00 7.00 10.20 fitting assembly. 1.5 to 1.75
DIN 12 M18 x 1.5 16.50 18.00 7.00 12.20 1.5 to 1.75
Torque values are application specific
24° CONE 15 M22 x 1.5 20.50 22.00 7.00 15.20 due to variability in the fitting supplier, 1.5 to 1.75
FLARELESS coating, lubrication, and other physical
BITE (MBTL) 18 M26 x 1.5 24.50 26.00 7.50 18.20 characteristic of the connection. 1.5 to 1.75
FITTING 22 M30 x 2 27.90 30.00 7.50 22.20 1.5 to 1.75
Consult Engineering on the
28 M36 x 2 33.90 36.00 7.50 28.20 generation of torque values for the 1.5 to 1.75
particular application.
35 M45 x 2 42.90 45.00 10.50 35.30 1.5 to 1.75
42 M52 x 2 49.90 52.00 11.00 42.30 1.5 to 1.75
STEEL Tube Thread Torque Flats From

ØA* ØB* C* ØD*
FITTINGS WITH O.D. M Size [Ft-Lb] [Nm] Wrench
Type
STEEL MATING Resistance
COMPONENTS (mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
6 M14 x 1.5 12.50 14.00 7.00 6.20 1.5 to 1.75

FFWR is the recommended method of
8 M16 x 1.5 14.50 16.00 7.00 8.20 1.5 to 1.75
fitting assembly.
10 M18 x 1.5 16.50 18.00 7.50 10.20 1.5 to 1.75
DIN 12 M20 x 1.5 18.50 20.00 7.50 12.20 Torque values are application specific 1.5 to 1.75
24° CONE 14 M22 x 1.5 20.50 22.00 8.00 14.20 due to variability in the fitting supplier, 1.5 to 1.75
FLARELESS coating, lubrication, and other physical
16 M24 x 1.5 22.50 24.00 8.50 16.20 characteristics of the connection. 1.5 to 1.75
BITE (MBTS)
FITTING 20 M30 x 2 27.90 30.00 10.50 20.20 1.5 to 1.75
25 M36 x 2 33.90 36.00 12.00 25.20 Consult Engineering on the 1.5 to 1.75
generation of torque values for the
30 M42 x 2 39.90 42.00 13.50 30.20 1.5 to 1.75
particular application.
38 M52 x 2 49.90 52.00 16.00 38.30 1.5 to 1.75
NOTE: * ØA, ØB,C, & ØD thread dimensions for reference only.

TL642D, TL943D, TL1055D, TL1255D 31211036 2-47

2.8.8 Assembly Instructions for Bulkhead (BH)

Fittings
1. Ensure that threads and surface are free of rust, weld
and brazing splatter, splits, burrs or other foreign
material. If necessary, replace fitting or adapter.
2. Remove the locknut from the bulkhead assembly.
3. Insert the bulkhead side of the fitting into the panel or
bulkhead bracket opening.
4. Hand thread the locknut onto the bulkhead end of the
fitting body.
5. Torque nut onto fitting while using the Double Wrench
Method.
2-48 31211036 TL642D, TL943D, TL1055D, TL1255D

a. Bulkhead Fittings (BH) - INCH
MAE9170
FASTENING JAM NUT

FOR BULKHEAD CONNECTORS
Thread Torque
Dash Size
Material Type [Ft-Lb] [Nm]
Size
(UNF) Min Nom Max Min Nom Max
4 9/16-18 15 16 17 20 22 23
6 11/16-16 25 27 28 34 37 38
8 13/16-16 55 58 61 75 79 83
O-RING FACE 10 1-14 85 90 94 115 122 127
SEAL (ORFS)
12 1 3/16-12 135 142 149 183 193 202
BULKHEAD
FITTING 14 1 5/16-12 170 179 187 230 243 254
16 1 7/16-12 200 210 220 271 285 298
20 1 11/16-12 245 258 270 332 350 366
24 2-12 270 284 297 366 385 403
Thread Torque
Dash Size
Type [Ft-Lb] [Nm]
Size
STEEL (UNF) Min Nom Max Min Nom Max
FITTINGS 3 3/8-24 8 9 9 11 12 12
4 7/16-20 13 14 14 18 19 19
5 1/2-20 20 21 22 27 28 30
6 9/16-18 25 27 28 34 37 38
8 3/4-16 50 53 55 68 72 75
37° FLARE (JLIC) 10 7/8-14 85 90 94 115 122 127
BULKHEAD
12 1 1/16-12 135 142 149 183 193 202
FITTING
14 1 3/16-12 170 179 187 230 243 254
16 1 5/16-12 200 210 220 271 285 298
20 1 5/8-12 245 258 270 332 350 366
24 1 7/8-12 270 284 297 366 385 403
32 2 1/2-12 310 326 341 420 442 462
TL642D, TL943D, TL1055D, TL1255D 31211036 2-49

b. Bulkhead Fittings (BH) - METRIC
MAE9180
FASTENING JAM NUT

FOR BULKHEAD CONNECTORS
Connecting Thread Torque
Material Type Tube O.D. M Size [Ft-Lb] [Nm]
(mm) (metric) Min Nom Max Min Nom Max
6 M12 x 1.5 14 15 16 19 20 22
8 M14 x 1.5 17 18 19 23 24 26
10 M16 x 1.5 22 23 24 30 31 33
12 M18 x 1.5 35 37 39 47 50 53
DIN 24° CONE
FLARELESS BITE 15 M22 x 1.5 44 47 50 60 64 68
(MBTL) BULKHEAD 18 M26 x 1.5 70 75 80 95 102 108
FITTING
22 M30 x 2 115 120 125 156 163 169
28 M36 x 2 150 157 164 203 213 222
35 M45 x 2 155 162 169 210 220 229
42 M52 x 2 220 230 240 298 312 325
Connecting Thread Torque
STEEL Tube O.D. M Size
Type [Ft-Lb] [Nm]
FITTINGS
(mm) (metric) Min Nom Max Min Nom Max
6 M14 x 1.5 17 15 16 23 20 22
8 M16 x 1.5 22 18 19 30 24 26
10 M18 x 1.5 35 23 24 47 31 33
12 M20 x 1.5 40 35 37 54 47 50
DIN 24° CONE
FLARELESS BITE 14 M22 x 1.5 44 47 50 60 64 68
(MBTS) BULKHEAD 16 M24 x 1.5 70 75 80 95 102 108
FITTING 20 M30 x 2 115 120 125 156 163 169
25 M36 x 2 150 157 164 203 213 222
30 M42 x 2 155 162 169 210 220 229
38 M52 x 2 220 230 240 298 312 325
2-50 31211036 TL642D, TL943D, TL1055D, TL1255D

This Page Intentionally Left Blank
TL642D, TL943D, TL1055D, TL1255D 31211036 2-51

2.8.9 Assembly Instructions for O-Ring Boss

(ORB) Fittings
1. Inspect components to ensure that male and female
port threads are free of rust, splits, dirt, foreign matter,
or burrs.
2. Ensure proper o-ring is installed. If o-ring is missing
install per o-ring Installation (replacement). Refer to
Section 2.8.17, “O-ring Installation (Replacement),”, for
procedure.
NOTICE

4. For non-adjustable and plugs, thread the fitting by hand
until contact.
5. For adjustable fittings, refer to Section 2.8.16,
“Adjustable Stud End Assembly,”, for proper assembly.
6. Torque the fitting or nut to value while using the
Double Wrench Method.
a. The table headings identify the straight thread
o-ring port and the type on the other side of the
fitting. The torque will be applied to the straight
thread o-ring port.
b. Torque values are segregated based on the material
configuration of the connection. ‘Aluminum/brass
fittings or aluminum/brass mating components’
indicate either the following material
configurations:
• Steel fittings with aluminum or brass mating
components
• Aluminum or brass fittings with steel mating
components
• Aluminum or brass fittings with aluminum or brass
mating components.
7. Inspect to ensure the o-ring is not pinched and the
washer is seated flat on the counter bore of the port.
2-52 31211036 TL642D, TL943D, TL1055D, TL1255D

a. O-ring Boss (ORB) - Table 1 of 6
MAE9190
HEX TYPE PLUGS & STUD ENDS

WITH 37° (JIC) OR L SERIES DIN (MBTL) OPPOSITE END
Thread Torque
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
STEEL FITTINGS 6 9/16-18 0.56 14.28 29 31 32 40 42 43
WITH STEEL 8 3/4-16 0.75 19.10 52 55 57 70 75 77
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
4 7/16-20 0.44 11.11 14 15 16 19 20 22
5 1/2-20 0.50 12.70 15 16 17 20 22 23
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
NOTE: 1. * ØA thread OD dimension for reference only.

2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.
TL642D, TL943D, TL1055D, TL1255D 31211036 2-53

b. O-ring Boss (ORB) - Table 2 of 6
MAE9190
STUD ENDS
WITH (ORFS) OR S ERIES DIN (MBTS) OPPOSITE END
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
STEEL FITTINGS 6 9/16-18 0.56 14.28 29 31 32 40 42 43
WITH STEEL 8 3/4-16 0.75 19.10 52 55 57 70 75 77
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
4 7/16-20 0.44 11.11 14 15 16 19 20 22
5 1/2-20 0.50 12.70 15 16 17 20 22 23
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

2-54 31211036 TL642D, TL943D, TL1055D, TL1255D

c. O-ring Boss (ORB) - Table 3 of 6
MAE9210
ADJUSTABLE STUD END

WITH 37° (JIC) OR L SERIES DIN (MBTL) OPPOSITE END
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
STEEL FITTINGS 6 9/16-18 0.56 14.28 29 31 32 40 42 43
WITH STEEL 8 3/4-16 0.75 19.10 52 55 57 70 75 77
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
4 7/16-20 0.44 11.11 14 15 16 19 20 22
5 1/2-20 0.50 12.70 15 16 17 20 22 23
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

TL642D, TL943D, TL1055D, TL1255D 31211036 2-55

d. O-ring Boss (ORB) - Table 4 of 6
MAE9220
ADJUSTABLE STUD END

WITH (ORFS) OR S SERIES DIN (MBTS) OPPOSITE END
Thread Torque
ØA*
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 15 16 17 20 22 23
5 1/2-20 0.50 12.70 30 32 33 40 43 45
STEEL FITTINGS 6 9/16-18 0.56 14.28 35 37 39 46 50 53
WITH STEEL 8 3/4-16 0.75 19.10 60 63 66 80 85 89
MATING
10 7/8-14 0.87 22.22 100 105 110 135 142 149
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 10 11 11 14 15 15
5 1/2-20 0.50 12.70 20 21 21 27 28 28
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 23 24 24 31 33 33
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 39 41 43 53 56 58
MATING 10 7/8-14 0.87 22.22 65 69 72 88 94 98
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

2-56 31211036 TL642D, TL943D, TL1055D, TL1255D

e. O-ring Boss (ORB) - Table 5 of 6
MAE9230
TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (30) (32) (33) 3 4 4
3 3/8-24 0.37 9.52 (55) (58) (61) 6 7 7
4 7/16-20 0.44 11.11 10 11 11 14 15 15
5 1/2-20 0.50 12.70 14 15 16 19 20 22
STEEL FITTINGS 6 9/16-18 0.56 14.28 34 36 38 46 49 52
WITH STEEL 8 3/4-16 0.75 19.10 60 63 66 80 85 89
MATING
10 7/8-14 0.87 22.22 100 105 110 135 142 149
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (20) (21) (21) 2 2 2
3 3/8-24 0.37 9.52 (36) (38) (40) 4 4 5
4 7/16-20 0.44 11.11 6 7 7 8 9 9
5 1/2-20 0.50 12.70 9 10 10 12 14 14
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 22 24 25 30 33 34
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 39 41 43 53 56 58
MATING 10 7/8-14 0.87 22.22 65 69 72 88 94 98
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

TL642D, TL943D, TL1055D, TL1255D 31211036 2-57

f. O-ring Boss (ORB) - Table 6 of 6
MAE9240
ZERO LEAK GOLD®

HOLLOW HEX PLUGS
Thread Torque
ØA*
2 5/16-24 0.31 7.93 2 3 4 3 4 5
3 3/8-24 0.37 9.52 3 4 5 4 5 7
4 7/16-20 0.44 11.11 7 8 9 9 11 12
5 1/2-20 0.50 12.70 9 10 11 12 14 15
6 9/16-18 0.56 14.28 11 12 13 15 16 18
STEEL FITTINGS WITH
STEEL MATING 8 3/4-16 0.75 19.10 28 30 32 38 41 43
COMPONENTS; 10 7/8-14 0.87 22.22 46 48 50 62 65 68
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
THREADS
14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30 Fitting size greater than -12 not typically specified on
Caterpillar applications.
20 1 5/8-12 1.63 41.30
Consult specific service procedure if
24 1 7/8-12 1.87 47.60 encountered.
32 2 1/2-12 2.50 63.50
Thread Torque
ØA*
2 5/16-24 0.31 7.93 2 3 4 3 4 5
3 3/8-24 0.37 9.52 3 4 5 4 5 7
4 7/16-20 0.44 11.11 7 8 9 9 11 12
5 1/2-20 0.50 12.70 9 10 11 12 14 15
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 11 12 13 15 16 18
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 28 30 32 38 41 43
MATING 10 7/8-14 0.87 22.22 46 48 50 62 65 68
COMPONENTS; 12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30 Fitting size greater than -12 not typically specified on
Caterpillar applications.
20 1 5/8-12 1.63 41.30
Consult specific service procedure if
24 1 7/8-12 1.87 47.60 encountered.
32 2 1/2-12 2.50 63.50

2-58 31211036 TL642D, TL943D, TL1055D, TL1255D

TL642D, TL943D, TL1055D, TL1255D 31211036 2-59

2.8.10 Assembly Instructions for Adjustable

Port End Metric Fittings
threads and surfaces are free of rust, splits, dirt, foreign
matter, or burrs.
2. If o-ring is not pre-installed, install proper size, taking
care not to damage it. Refer to Section 2.8.17, “O-ring
Installation (Replacement)”, for procedure.
NOTICE

4. For non-adjustable fittings and plugs, thread the fitting
by hand until contact.
a. The table headings identify the Metric port and the
type on the other side of the fitting. The torque will
be applied to the Metric port.
configurations:
components
components
mating components.
2-60 31211036 TL642D, TL943D, TL1055D, TL1255D

a. Metric Flat Face Port (MFF) L Series - Table 1 of 3
MAE9260
MAE9250
FORM A (SEALING WASHER) FORM B (CUTTING FACE)

TYPE/FITTING STUD ENDS STUD ENDS
IDENTIFICATION WITH 37° (JIC) or L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)
OPPOSITE END OPPOSITE END
Thread Connecting Torque Torque
Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 7 8 8 9 11 11 13 14 14 18 19 19
M12x1.5 8 15 16 17 20 22 23 22 23 24 30 31 33
M14x1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
STEEL FITTINGS
M16x1.5 12 33 35 36 45 47 49 48 51 53 65 69 72
WITH STEEL
MATING M18x1.5 15 41 43 45 55 58 61 59 62 65 80 84 88
COMPONENTS; M22x1.5 18 48 51 53 65 69 72 103 108 113 140 146 153
UN-LUBRICATED
M27x2 22 66 70 73 90 95 99 140 147 154 190 199 209
THREADS
M33x2 28 111 117 122 150 159 165 251 264 276 340 358 374
M42x2 35 177 186 195 240 252 264 369 388 406 500 526 550
M48x2 42 214 225 235 290 305 319 465 489 512 630 663 694
Material M Size Tube O.D

[Ft-Lb] [Nm] [Ft-Lb] [Nm]
M10x1 6 4 5 5 5 7 7 8 9 9 11 12 12
M12x1.5 8 10 11 11 14 15 15 14 15 16 19 20 22
ALUMINUM/BRASS
M14x1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
FITTINGS OR M16x1.5 12 21 22 23 28 30 31 31 33 34 42 45 46
ALUMINUM/BRASS M18x1.5 15 27 28 29 37 38 39 38 40 42 52 54 57
MATING
COMPONENTS; M22x1.5 18 31 33 34 42 45 46 67 70 73 91 95 99
UN-LUBRICATED M27x2 22 43 45 47 58 61 64 91 96 100 123 130 136
THREADS
M33x2 28 72 76 79 98 103 107 163 171 179 221 232 243
M42x2 35 115 121 127 156 164 172 240 252 264 325 342 358
M48x2 42 139 146 153 188 198 207 302 318 332 409 431 450
TL642D, TL943D, TL1055D, TL1255D 31211036 2-61

b. Metric Flat Face Port (MFF) L Series - Table 2 of 3
MAE9280
MAE9270

IDENTIFICATION WITH 37° (JIC) OR L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)

M10x1 6 13 14 14 18 19 19 13 14 15 18 19 20
M12x1.5 8 18 19 20 25 26 27 18 19 20 25 26 28
M14x1.5 10 33 35 36 45 47 49 30 31 32 40 42 44
STEEL FITTINGS
WITH STEEL M16x1.5 12 41 43 45 55 58 61 41 43 45 55 58 61
MATING M18x1.5 15 52 55 57 70 75 77 52 54 57 70 74 77
COMPONENTS; M22x1.5 18 92 97 101 125 132 137 66 70 73 90 95 99
UN-LUBRICATED M27x2 22 133 140 146 180 190 198 133 139 146 180 189 198
THREADS
M33x2 28 229 241 252 310 327 342 229 240 252 310 326 341
M42x2 35 332 349 365 450 473 495 332 348 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594

(UNF) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12
M12x1.5 8 12 13 13 16 18 18 12 13 13 16 18 18
ALUMINUM/ M14x1.5 10 21 22 23 28 30 31 19 20 21 26 27 29
BRASS FITTINGS
OR ALUMINUM/ M16x1.5 12 27 28 29 37 38 39 26 28 29 36 38 39
BRASS M18x1.5 15 34 36 37 46 49 50 34 35 37 46 48 50
MATING M22x1.5 18 60 63 66 81 85 89 43 45 47 59 61 64
COMPONENTS; M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
2-62 31211036 TL642D, TL943D, TL1055D, TL1255D

c. Metric Flat Face Port (MFF) L Series - Table 3 of 3
MAE9310
MAE9290 MAE9300
HIGH PRESSURE BANJO

BANJO FITTINGS FORM E (EOLASTIC
TYPE/FITTING FITTINGS
WITH L SERIES DIN (MBTL) SEALING RING)
IDENTIFICATION WITH L SERIES DIN (MBTL)
OPPOSITE END HOLLOW HEX PLUGS
OPPOSITE END
Thread Connecting Torque Torque Torque
Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 13 14 14 18 19 19 13 14 14 18 19 19 9 10 10 12 14 14
M12x1.5 8 26 28 29 35 38 39 33 35 36 45 47 49 18 19 20 25 26 27
M14x1.5 10 37 39 41 50 53 56 41 43 45 55 58 61 26 28 29 35 38 39
STEEL FITTINGS
M16x1.5 12 44 46 48 60 62 65 59 62 65 80 84 88 41 43 45 55 58 61
WITH STEEL
MATING M18x1.5 15 59 62 65 80 84 88 74 78 81 100 106 110 48 51 53 65 69 72
COMPONENTS; M22x1.5 18 89 94 98 120 127 133 103 108 113 140 146 153 66 70 73 90 95 99
UN-LUBRICATED
M27x2 22 96 101 106 130 137 144 236 248 260 320 336 353 100 105 110 135 142 149
THREADS
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 166 175 183 225 237 248
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 266 280 293 360 380 397
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 266 280 293 360 380 397
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
M12x1.5 8 17 18 19 23 24 26 21 22 23 28 30 31 12 13 13 16 18 18
ALUMINUM/ M14x1.5 10 24 26 27 33 35 37 27 28 29 37 38 39 17 18 19 23 24 26
BRASS FITTINGS
M16x1.5 12 29 30 31 39 41 42 38 40 42 52 54 57 27 28 29 37 38 39
OR ALUMINUM/
BRASS M18x1.5 15 38 40 42 52 54 57 48 51 53 65 69 72 31 33 34 42 45 46
MATING M22x1.5 18 58 61 64 79 83 87 67 70 73 91 95 99 43 45 47 58 61 64
COMPONENTS;
M27x2 22 62 66 69 84 89 94 153 161 169 207 218 229 65 69 72 88 94 98
UN-LUBRICATED
THREADS M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 108 114 119 146 155 161
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 173 182 190 235 247 258
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 173 182 190 235 247 258
TL642D, TL943D, TL1055D, TL1255D 31211036 2-63

d. Metric Flat Face Port (MFF) S Series - Table 1 of 3
MAE9320 MAE9330

IDENTIFICATION WITH (ORFS) OR S SERIES DIN (MBTS) WITH (ORFS) OR S SERIES DIN (MBTS)

Material M Size Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
M12x1.5 6 15 16 17 20 22 23 26 28 29 35 38 39
M14x1.5 8 26 28 29 35 38 39 41 43 45 55 58 61
M16x1.5 10 33 35 36 45 47 49 52 55 57 70 75 77
STEEL FITTINGS
M18x1.5 12 41 43 45 55 58 61 81 85 89 110 115 121
WITH STEEL
MATING M20x1.5 14 41 43 45 55 58 61 111 117 122 150 159 165
COMPONENTS; M22x1.5 16 48 51 53 65 69 72 125 132 138 170 179 187
UN-LUBRICATED
M27x2 20 66 70 73 89 95 99 199 209 219 270 283 297
THREADS
M33x2 25 111 117 122 150 159 165 302 317 332 410 430 450
M42x2 30 177 186 195 240 252 264 398 418 438 540 567 594
M48x2 38 214 225 235 290 305 319 516 542 568 700 735 770

M12x1.5 6 10 11 11 14 15 15 17 18 19 23 24 26
M14x1.5 8 17 18 19 23 24 26 27 28 29 37 38 39
ALUMINUM/ M16x1.5 10 21 22 23 28 30 31 34 36 37 46 49 50
BRASS FITTINGS
M18x1.5 12 27 28 29 37 38 39 53 56 58 72 76 79
OR ALUMINUM/
BRASS M20x1.5 14 27 28 29 37 38 39 72 76 79 98 103 107
MATING M22x1.5 16 31 33 34 42 45 46 81 86 90 110 117 122
COMPONENTS;
M27x2 20 43 45 47 58 61 64 129 136 142 175 184 193
UN-LUBRICATED
THREADS M33x2 25 72 76 79 98 103 107 196 206 216 266 279 293
M42x2 30 115 121 127 156 164 172 259 272 285 351 369 386
M48x2 38 139 146 153 188 198 207 335 352 369 454 477 500
2-64 31211036 TL642D, TL943D, TL1055D, TL1255D

e. Metric Flat Face Port (MFF) S Series - Table 2 of 3
MAE9350
MAE9340

IDENTIFICATION WITH (ORFS) OR S SERIES DIN (MBTS) WITH (ORFS) OR S SERIES DIN (MBTS)

M10x1 6 26 28 29 35 38 39 26 28 29 35 38 39
M12x1.5 8 33 35 36 45 47 49 41 43 45 55 58 61
M14x1.5 10 52 55 57 70 75 77 52 55 57 70 75 77
STEEL FITTINGS
M16x1.5 12 66 70 73 90 95 99 66 70 73 90 95 99
WITH STEEL
MATING M18x1.5 15 92 97 101 125 132 137 92 97 101 125 132 137
COMPONENTS; M22x1.5 18 100 105 110 135 142 149 100 105 110 135 142 149
UN-LUBRICATED
M27x2 22 133 140 146 180 190 198 133 140 146 180 190 198
THREADS
M33x2 28 229 241 252 310 327 342 229 241 252 310 327 342
M42x2 35 332 349 365 450 473 495 332 349 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594

M10x1 6 17 18 19 23 24 26 17 18 19 23 24 26
M12x1.5 8 21 23 23 29 31 32 27 28 29 37 38 39
ALUMINUM/ M14x1.5 10 34 36 37 46 49 50 34 36 37 46 49 50
BRASS FITTINGS
M16x1.5 12 43 45 47 58 61 64 43 45 47 58 61 64
OR ALUMINUM/
BRASS M18x1.5 15 60 63 66 81 85 89 60 63 66 81 85 89
MATING M22x1.5 18 65 69 72 88 94 98 65 69 72 88 94 98
COMPONENTS;
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
TL642D, TL943D, TL1055D, TL1255D 31211036 2-65

f. Metric Flat Face Port (MFF) S Series - Table 3 of 3
MAE9310
MAE9290 MAE9300
HIGH PRESSURE BANJO

TYPE/FITTING FITTINGS
WITH S SERIES DIN (MBTS) SEALING RING)
IDENTIFICATION WITH S SERIES DIN (MBTS)
OPPOSITE END

M10x1 6 26 28 29 35 38 39 33 35 36 45 47 49 -- -- -- -- -- --
M12x1.5 8 37 39 41 50 53 56 41 43 45 55 58 61 -- -- -- -- -- --
M14x1.5 10 44 46 48 60 62 65 59 62 65 80 84 88 -- -- -- -- -- --
STEEL FITTINGS
M16x1.5 12 59 62 65 80 84 88 74 78 81 100 106 110 -- -- -- -- -- --
WITH STEEL
MATING M18x1.5 15 81 85 89 110 115 121 92 97 101 125 132 137 59 62 65 80 84 88
COMPONENTS; M22x1.5 18 89 94 98 120 127 133 100 105 110 135 142 149 -- -- -- -- -- --
UN-LUBRICATED
M27x2 22 100 105 110 135 142 149 236 248 260 320 336 353 -- -- -- -- -- --
THREADS
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 -- -- -- -- -- --
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 -- -- -- -- -- --

M10x1 6 17 18 19 23 24 26 21 22 23 28 30 31 -- -- -- -- -- --
M12x1.5 8 24 26 27 33 35 37 27 28 29 37 38 39 -- -- -- -- -- --
ALUMINUM/
BRASS M14x1.5 10 29 30 31 39 41 42 38 40 42 52 54 57 -- -- -- -- -- --
FITTINGS OR M16x1.5 12 38 40 42 52 54 57 48 51 53 65 69 72 -- -- -- -- -- --
ALUMINUM/ M18x1.5 15 53 56 58 72 76 79 60 63 66 81 85 89 38 40 42 52 54 57
BRASS
MATING M22x1.5 18 58 61 64 79 83 87 65 69 72 88 94 98 -- -- -- -- -- --
COMPONENTS; M27x2 22 65 69 72 88 94 98 153 161 169 207 218 229 -- -- -- -- -- --
UN-LUBRICATED M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 -- -- -- -- -- --
THREADS
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 -- -- -- -- -- --
2-66 31211036 TL642D, TL943D, TL1055D, TL1255D

TL642D, TL943D, TL1055D, TL1255D 31211036 2-67

2.8.11 Assembly Instructions for Metric ISO

6149 Port Assembly Stud Ends
matter, or burrs.
2. If o-ring is not pre installed, install proper size, taking
Installation (Replacement),”.
NOTICE

a. The table headings identify the Metric port and the
be applied to the Metric port.
configurations:
components
components
mating components.
2-68 31211036 TL642D, TL943D, TL1055D, TL1255D

a. Metric Pipe Parallel O-Ring Boss (MPP)
MAE9370 MAE9380
MAE9360
TYPE/FITTING STUD ENDS WITH 37° (JIC) OR L SERIES STUD ENDS WITH (ORFS) OR S SERIES
IDENTIFICATION DIN (MBTL) OPPOSITE END DIN (MBTS) OPPOSITE END

M8 x 1 4 6 7 7 8 9 9 8 9 9 10 12 12
M10 x 1 6 11 12 12 15 16 16 15 16 17 20 22 23
M12 x 1.5 8 18 19 20 25 26 27 26 28 29 35 38 39
M14 x 1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
M16 x 1.5 12 30 32 33 40 43 45 41 43 45 55 58 61
STEEL FITTINGS M18 x 1.5 15 33 35 36 45 47 49 52 55 57 70 75 77
WITH STEEL M20 x 1.5 -- -- -- -- -- -- -- 59 62 65 80 84 88
MATING
M22 x 1.5 18 44 46 48 60 62 65 74 78 81 100 106 110
COMPONENTS;
UN-LUBRICATED M27 x 2 22 74 78 81 100 106 110 125 132 138 170 179 187
THREADS M30 x 2 -- 95 100 105 130 136 142 175 184 193 237 249 262
M33 x 2 25 120 126 132 160 171 179 230 242 253 310 328 343
M38 x 2 -- 135 142 149 183 193 202 235 247 259 319 335 351
M42 x 2 30 155 163 171 210 221 232 245 258 270 330 350 366
M48 x 2 38 190 200 209 260 271 283 310 326 341 420 442 462
M60 x 2 50 230 242 253 315 328 343 370 389 407 500 527 552
M8 x 1 4 4 5 5 5 7 7 5 6 6 7 8 8
M10 x 1 6 7 8 8 9 11 11 10 11 11 14 15 15
M12 x 1.5 8 12 13 13 16 18 18 17 18 19 23 24 26
M14 x 1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
ALUMINUM/ M16 x 1.5 12 20 21 21 27 28 28 27 28 29 37 38 39
BRASS FITTINGS M18 x 1.5 15 21 22 23 28 30 31 34 36 37 46 49 50
OR ALUMINUM/ M20 x 1.5 -- -- -- -- -- -- -- 30 40 42 41 54 57
BRASS
M22 x 1.5 18 29 30 31 39 41 42 48 51 53 65 69 72
MATING
COMPONENTS; M27 x 2 22 48 51 53 65 69 72 81 86 90 110 117 122
UN-LUBRICATED M30 x 2 -- 62 65 68 84 88 92 114 120 125 155 163 169
THREADS M33 x 2 25 78 82 86 106 111 117 150 157 164 203 213 222
M38 x 2 -- 88 93 97 119 126 132 153 161 168 207 218 228
M42 x 2 30 101 106 111 137 144 150 159 168 176 216 228 239
M48 x 2 38 124 130 136 168 176 184 202 212 222 274 287 301
M60 x 2 50 150 157 164 203 213 222 241 253 265 327 343 359
TL642D, TL943D, TL1055D, TL1255D 31211036 2-69

2.8.12 Assembly Instructions for Adjustable

Port End (BSPP) Fittings
matter, or burrs.
2. If o-ring is not pre installed, install proper size, taking
Installation (Replacement)”, for instructions.
NOTICE

“Adjustable Stud End Assembly”, for proper assembly.
a. The table headings identify the BSPP port and the
be applied to the BSPP port.
configurations:
components
components
mating components.
2-70 31211036 TL642D, TL943D, TL1055D, TL1255D

a. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
MAE9390 MAE9400
FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)

TYPE/FITTING STUD ENDS WITH 37° (JIC) or STUD ENDS
IDENTIFICATION L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)
Torque Torque
Connecting
BSPP
Tube O.D.
Material Thread [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 7 8 8 9 11 11 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
STEEL FITTINGS G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
WITH STEEL G 3/8A 12 33 35 36 45 47 49 52 55 57 70 75 77
MATING G 1/2A 15 48 51 53 65 69 72 103 108 113 140 146 153
COMPONENTS; G 1/2A 18 48 51 53 65 69 72 74 78 81 100 106 110
UN-LUBRICATED G 3/4A 22 66 70 73 90 95 99 133 140 146 180 190 198
THREADS G 1A 28 111 117 122 150 159 165 243 255 267 330 346 362
G 1-1/4A 35 177 186 195 240 252 264 398 418 438 540 567 594
G 1-1/2A 42 214 225 235 290 305 319 465 489 512 630 663 694
Connecting Torque Torque

BSPP
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
G 1/8A 6 4 5 5 5 7 7 8 9 9 11 12 12
ALUMINUM/ G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
BRASS FITTINGS G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
OR ALUMINUM/ G 3/8A 12 21 22 23 28 30 31 34 36 37 46 49 50
BRASS
G 1/2A 15 31 33 34 42 45 46 67 70 73 91 95 99
MATING
COMPONENTS; G 1/2A 18 31 33 34 42 45 46 48 51 53 65 69 72
UN-LUBRICATED G 3/4A 22 42 45 47 57 61 64 86 91 95 117 123 129
THREADS G 1A 28 72 76 79 98 103 107 158 166 174 214 225 236
G 1-1/4A 35 115 121 127 156 164 172 259 272 285 351 369 386
NOTE: ** Non typical for Straight Male Stud Fittings, reference only.
TL642D, TL943D, TL1055D, TL1255D 31211036 2-71

b. British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3
MAE9410 MAE9420
FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)

TYPE/FITTING
STUD ENDS WITH 37° (JIC) OR STUD ENDS WITH 37° (JIC) OR
IDENTIFICATION
L SERIES DIN (MBTL) OPPOSITE END L SERIES DIN (MBTL) OPPOSITE END

BSPP
G Size
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
STEEL FITTINGS G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
WITH STEEL G 3/8A 12 52 55 57 70 75 77 52 55 57 70 75 77
MATING G 1/2A 15 66 70 73 90 95 99 66 70 73 90 95 99
COMPONENTS; G 1/2A 18 66 70 73 90 95 99 66 70 73 90 95 99
UN-LUBRICATED G 3/4A 22 133 140 146 180 190 198 133 140 146 180 190 198
THREADS G 1A 28 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 35 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 42 398 418 438 540 567 594 398 418 438 540 567 594

BSPP
G Size
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12
ALUMINUM/ G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
BRASS FITTINGS G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
OR ALUMINUM/ G 3/8A 12 34 36 37 46 49 50 34 36 37 46 49 50
BRASS
G 1/2A 15 43 45 47 58 61 64 43 45 47 58 61 64
MATING
COMPONENTS; G 1/2A 18 43 45 47 58 61 64 43 45 47 58 61 64
UN-LUBRICATED G 3/4A 22 86 91 95 117 123 129 86 91 95 117 123 129
THREADS G 1A 28 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 35 216 227 237 293 308 321 216 227 237 293 308 321
2-72 31211036 TL642D, TL943D, TL1055D, TL1255D

c. British Standard Parallel Pipe Port (BSPP) L Series - Table 3 of 3
MAE9310
MAE9290 MAE9300
HIGH PRESSURE BANJO

TYPE/FITTING FITTINGS WITH
WITH S SERIES DIN (MBTS) SEALING RING)
IDENTIFICATION S SERIES DIN (MBTS)
OPPOSITE END
Torque Torque Torque
BSPP Connecting
Material Thread Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19 10 11 11 13 15 15
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
G 1/4A 10 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
STEEL FITTINGS
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 44 46 48 60 62 65
WITH STEEL
MATING G 1/2A 15 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
COMPONENTS; G 1/2A 18 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
UN-LUBRICATED
G 3/4A 22 92 97 101 125 132 137 170 179 187 230 243 254 103 108 113 140 146 153
THREADS
G 1A 28 -- -- -- -- -- -- 236 248 260 320 336 353 148 156 163 200 212 221
G 1-1/4A 35 -- -- -- -- -- -- 398 418 438 540 567 594 295 313.5 332 400 425 450
G 1-1/2A 42 -- -- -- -- -- -- 516 542 568 700 735 770 332 349 365 450 473 495
BSPP Connecting
Material Thread Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
G 1/4A 8 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
ALUMINUM/
BRASS G 1/4A 10 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
FITTINGS OR G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 29 30 31 39 41 42
ALUMINUM/ G 1/2A 15 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
BRASS
MATING G 1/2A 18 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
COMPONENTS; G 3/4A 22 60 63 66 81 85 89 111 117 122 150 159 165 67 70 73 91 95 99
UN-LUBRICATED G 1A 28 -- -- -- -- -- -- 153 161 169 207 218 229 96 101 106 130 137 144
THREADS
G 1-1/4A 35 -- -- -- -- -- -- 259 272 285 351 369 386 216 227 237 293 308 321
G 1-1/2A 42 -- -- -- -- -- -- 335 352 369 454 477 500 216 227 237 293 308 321
TL642D, TL943D, TL1055D, TL1255D 31211036 2-73

d. British Standard Parallel Pipe Port (BSPP) S Series - Table 1 of 3
MAE9430 MAE9440
FORM A** (SEALING WASHER) FORM B** (CUTTING FACE)

TYPE/FITTING
STUD ENDS WITH (ORFS) OR STUD ENDS WITH (ORFS) OR
IDENTIFICATION
S SERIES DIN (MBTS) OPPOSITE END S SERIES DIN (MBTS) OPPOSITE END
BSPP Connecting Torque Torque

G Size (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 26 28 29 35 38 39 41 43 45 55 58 61
G 1/4A 8 26 28 29 35 38 39 41 43 45 55 58 61
G 3/8A 10 33 35 36 45 47 49 66 70 73 90 95 99
STEEL FITTINGS
G 3/8A 12 33 35 36 45 47 49 66 70 73 90 95 99
WITH STEEL
MATING G 1/2A 14 48 51 53 65 69 72 111 117 122 150 159 165
COMPONENTS; G 1/2A 16 48 51 53 65 69 72 96 101 106 130 137 144
UN-LUBRICATED
G 3/4A 20 66 70 73 90 95 99 199 209 219 270 283 297
THREADS
G 1A 25 111 117 122 150 159 165 251 264 276 340 358 374
G 1-1/4A 30 177 186 195 240 252 264 398 418 438 540 567 594
G 1-1/2A 38 214 225 235 290 305 319 516 542 568 700 735 770
BSPP Connecting Torque Torque
G Size (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 17 18 19 23 24 26 27 28 29 37 38 39
G 1/4A 8 17 18 19 23 24 26 27 28 29 37 38 39
ALUMINUM/ G 3/8A 10 21 22 23 28 30 31 43 45 47 58 61 64
BRASS FITTINGS
G 3/8A 12 21 22 23 28 30 31 43 45 47 58 61 64
OR ALUMINUM/
BRASS G 1/2A 14 31 33 34 42 45 46 72 76 79 98 103 107
MATING G 1/2A 16 31 33 34 42 45 46 62 66 69 84 89 94
COMPONENTS;
G 3/4A 20 43 45 47 58 61 64 129 136 142 175 184 193
UN-LUBRICATED
THREADS G 1A 25 72 76 79 98 103 107 163 171 179 221 232 243
G 1-1/4A 30 115 121 127 156 164 172 259 272 285 351 369 386
G 1-1/2A 38 139 146 153 188 198 207 335 352 369 454 477 500
2-74 31211036 TL642D, TL943D, TL1055D, TL1255D

e. British Standard Parallel Pipe Port (BSPP) S Series - Table 2 of 3
MAE9460
MAE9450
FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING

TYPE/FITTING STUD ENDS AND HEX TYPE PLUGS RING) STUD ENDS & ADJUSTABLE
IDENTIFICATION WITH (ORFS) or S SERIES DIN (MBTS) STUD ENDS WITH (ORFS) OR
OPPOSITE END S SERIES DIN (MBTS) OPPOSITE END

BSPP
G Size
G 1/4A 6 41 43 45 55 58 61 26 28 29 35 38 39
G 1/4A 8 41 43 45 55 58 61 26 28 29 35 38 39
G 3/8A 10 59 62 65 80 84 88 52 55 57 70 75 77
STEEL FITTINGS
G 3/8A 12 59 62 65 80 84 88 52 55 57 70 75 77
WITH STEEL
MATING G 1/2A 14 85 90 94 115 122 127 66 70 73 90 95 99
COMPONENTS; G 1/2A 16 85 90 94 115 122 127 66 70 73 90 95 99
UN-LUBRICATED
G 3/4A 20 133 140 146 180 190 198 133 140 146 180 190 198
THREADS
G 1A 25 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 30 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 38 398 418 438 540 567 594 398 418 438 540 567 594

BSPP
G Size
G 1/4A 6 27 28 29 37 38 39 17 18 19 23 24 26
G 1/4A 8 27 28 29 37 38 39 17 18 19 23 24 26
ALUMINUM/ G 3/8A 10 38 40 42 52 54 57 34 36 37 46 49 50
BRASS FITTINGS
G 3/8A 12 38 40 42 52 54 57 34 36 37 46 49 50
OR ALUMINUM/
BRASS G 1/2A 14 55 58 61 75 79 83 43 45 47 58 61 64
MATING G 1/2A 16 55 58 61 75 79 83 43 45 47 58 61 64
COMPONENTS;
G 3/4A 20 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS G 1A 25 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 30 216 227 237 293 308 321 216 227 237 293 308 321
G 1-1/2A 38 259 272 285 351 369 386 259 272 285 351 369 386
NOTE: * Typical for Straight Male Stud Fittings

***Typical for Adjustable Fittings.
TL642D, TL943D, TL1055D, TL1255D 31211036 2-75

f. British Standard Parallel Pipe Port (BSPP) L Series - Table 3 of 3
MAE9290 MAE9300
MAE9470
BANJO FITTINGS HIGH PRESSURE BANJO

TYPE/FITTING JIS/BSPP O-RING
WITH S SERIES DIN (MBTS) FITTINGS WITH S SERIES
IDENTIFICATION ONLY
OPPOSITE END DIN (MBTS) OPPOSITE END

BSPP Connecting
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
G 1/4A 6 30 32 33 40 43 45 33 35 36 45 47 49
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49
G 3/8A 10 48 51 53 65 69 72 52 55 57 70 75 77 Fitting type not typically
STEEL FITTINGS
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 specified on Caterpillar
WITH STEEL
G 1/2A 14 66 70 73 90 95 99 89 94 98 120 127 133 applications.
MATING
COMPONENTS; G 1/2A 16 66 70 73 90 95 99 89 94 98 120 127 133 Refer to the specific
UN-LUBRICATED
G 3/4A 20 92 97 101 125 132 137 170 179 187 230 243 254 procedure
THREADS
G 1A 25 -- -- -- -- -- -- 236 248 260 320 336 353 in this Service Manual.
G 1-1/4A 30 -- -- -- -- -- -- 398 418 438 540 567 594
G 1-1/2A 38 -- -- -- -- -- -- 516 542 568 700 735 770
BSPP Connecting
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
G 1/4A 6 20 21 21 27 28 28 22 22 23 30 30 31
G 1/4A 8 20 21 21 27 28 28 22 22 23 30 30 31
ALUMINUM/ G 3/8A 10 31 33 34 42 45 46 34 36 37 46 49 50 Fitting type not typically
BRASS FITTINGS
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 specified on Caterpillar
OR ALUMINUM/
G 1/2A 14 43 45 47 58 61 64 58 61 64 79 83 87 applications.
BRASS
MATING G 1/2A 16 43 45 47 58 61 64 58 61 64 79 83 87 Refer to the
COMPONENTS;
G 3/4A 20 60 63 66 81 85 89 111 117 122 150 159 165 specific procedure in
UN-LUBRICATED
G 1A 25 -- -- -- -- -- -- 153 161 169 207 218 229 this Service Manual.
THREADS
G 1-1/4A 30 -- -- -- -- -- -- 259 272 285 351 369 386
G 1-1/2A 38 -- -- -- -- -- -- 335 352 368 454 477 499
2-76 31211036 TL642D, TL943D, TL1055D, TL1255D

TL642D, TL943D, TL1055D, TL1255D 31211036 2-77

2.8.13 Assembly Instructions for Flange

Connections (FL61 and FL62)
1. Ensure sealing surfaces are free of rust, splits, scratches,
dirt, foreign matter, or burrs.
2. Pre-lubricate the O-ring with hydraulic oil.
3. Position flange and clamp halves.
4. Place lock washers on bolt and bolt through clamp
halves.
5. Tighten all bolts by hand.
6. Torque bolts in diagonal sequence in two or more
increments to the torque listed.
2-78 31211036 TL642D, TL943D, TL1055D, TL1255D

a. Flange Code (FL61 & FL62) - Inch Fasteners
MAE9480
STEEL 4-BOLT FLANGE SAE J518
(INCH FASTENERS)
Fastener Torque for Fastener Torque for
Inch Bolt Flanges Equipped with Flanges Equipped with
Flange Flange
A* Thread GRADE 5 Screws GRADE 8 Screws
Type SAE Size
Size
Dash [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10 5/16-18 18 19 19 24 25 26 24 25 26 32 34 35
12 0.75 19 1.88 47.75 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
16 1.00 25 2.06 52.32 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
20 1.25 32 2.31 58.67 7/16-14 52 54 57 70 74 77 68 71 75 92 97 101
CODE 61 24 1.50 38 2.75 69.85 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
SPLIT
32 2.00 51 3.06 77.72 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
FLANGE
(FL61) 40 2.50 64 3.50 88.90 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
48 3.00 76 4.19 106.43 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
56 3.50 89 4.75 120.65 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
64 4.00 102 5.13 130.30 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
80 5.00 127 6.00 152.40 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
Inch Bolt Fastener Torque for Flanges Fastener Torque for Flanges
Flange Flange Equipped with GRADE 5 Screws Equipped with GRADE 8 Screws
A* Thread
Type SAE Size
Size
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 40.39 5/16-18 -- -- -- -- -- -- 24 25 26 32 34 35
12 0.75 19 2.00 50.80 3/8-16 -- -- -- -- -- -- 44 46 49 60 63 66
CODE 62 16 1.00 25 2.25 57.15 7/16-14 -- -- -- -- -- -- 68 71 75 92 97 101
SPLIT
20 1.25 32 2.62 66.55 1/2-13 -- -- -- -- -- -- 111 116 122 150 158 165
FLANGE
(FL62) 20 1.25 32 2.62 66.55 -- -- -- -- -- -- -- -- -- -- -- -- --
24 1.50 38 3.12 79.25 5/8-11 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 3/4-10 -- -- -- -- -- -- 332 348 365 450 473 495
NOTE: * A dimension for reference only.
TL642D, TL943D, TL1055D, TL1255D 31211036 2-79

b. Flange Code (FL61 & FL62) - Metric Fasteners
MAE9480
TYPE/FITTING STEEL 4-BOLT FLANGE SAE J518

IDENTIFICATION (INCH FASTENERS)
Inch Fastener Torque for Fastener Torque for
Bolt Flanges Equipped with Flanges Equipped with
Flange Flange Size A* Thread
Type SAE CLASS 8.8 Screws CLASS 10.9 Screws
Size
Size (in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10
12 0.75 19 1.88 47.75 M8 x 1.25 18 19 19 24 25 26 18 19 19 24 25 26
16 1.00 25 2.06 52.32 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
20 1.25 32 2.31 58.67 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
CODE 61 24 1.50 38 2.75 69.85 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
SPLIT
32 2.00 51 3.06 77.72 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
FLANGE
(FL61) 40 2.50 64 3.50 88.90 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
48 3.00 76 4.19 106.43 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
56 3.50 89 4.75 120.65 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
64 4.00 102 5.13 130.30 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
80 5.00 127 6.00 152.40 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
Inch Fastener Torque for Fastener Torque for
Bolt Flanges Equipped with Flanges Equipped with
Flange Flange Size A* Thread
Type SAE GRADE 5 Screws GRADE 8 Screws
Size
Size (in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 40.39 M8 x 1.25 -- -- -- -- -- -- 24 25 26 32 34 35
12 0.75 19 2.00 50.80 M10 x 1.5 -- -- -- -- -- -- 52 54 57 70 74 77
CODE 62 16 1.00 25 2.25 57.15 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
SPLIT
20 1.25 32 2.62 66.55 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
FLANGE
(FL62) 20 1.25 32 2.62 66.55 M14 x 2 -- -- -- -- -- -- 133 139 146 180 189 198
24 1.50 38 3.12 79.25 M16 x 2 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 M20 x 2.5 -- -- -- -- -- -- 406 426 446 550 578 605
NOTE: * A dimension for reference only.
2-80 31211036 TL642D, TL943D, TL1055D, TL1255D

2.8.14 Double Wrench Method

To prevent undesired hose or connector rotation, two
wrenches must be used; one torque wrench and one
back- up wrench. If two wrenches are not used,
inadvertent component rotation may occur which
absorbs torque and causes improper joint load and leads
to leaks. For hose connections, the ‘layline’ printed on the
hose is a good indicator of proper hose installation. A
twisted lay-line usually indicates the hose is twisted.
Double Wrench Method to Prevent Hose Twist
MAE9490
TL642D, TL943D, TL1055D, TL1255D 31211036 2-81

2.8.15 FFWR and TFFT Methods 2.8.16 Adjustable Stud End Assembly
1. FFWR (Flats from Wrench Resistance Method) For Adjustable Stud End Connections; the following
a. Tighten the swivel nut to the mating fitting until no assembly steps are to be performed:
lateral movement of the swivel nut can be detected; a. Lubricate the o-ring with a light coat of hydraulic oil.
finger tight condition.
b. Position #1 – The o-ring should be located in the
b. Mark a dot on one of the swivel hex nut flats and groove adjacent to the face of the back-up washer.
another dot in line on the connecting tube adapter. The washer and o-ring should be positioned at the
c. Use the double wrench method per Appendix A, extreme top end of the groove as shown.
turn the swivel nut to tighten. The nut is to be c. Position #2 – Position the locknut to just touch the
rotated clockwise the number of hex flats. back-up washer as shown. The locknut in this
d. After the connection has been properly tightened, position will eliminate potential back up washer.
mark a straight line across the connecting parts, not
covering the dots, to indicate the connection has 2.8.17 O-ring Installation (Replacement)
been properly tightened.
Care must be taken when installing o-rings over threads dur-
FFWR Method
ing replacement or installation. O-rings could become
nicked or torn. A damaged o-ring could lead to leakage
problems.
1. Inspect o-ring for tears or nicks. If any are found replace
o-ring.
2. Ensure proper o-ring to be installed. Many o-rings look
the same but are of different material, different
hardness, or are slightly different diameters or widths.
3. Use a thread protector when replacing o-rings on
MAE9500
fittings.
2. TFFT (Turns from Finger Tight Method) 4. In ORB; ensure o-ring is properly seated in groove. On
straight threads, ensure o-ring is seated all the way past
a. Tighten the swivel nut to the mating fitting until no the threads prior to installation.
lateral movement of the swivel nut can be detected;
finger tight condition. 5. Inspect o-ring for any visible nicks or tears. Replace if
b. Mark a dot on one of the swivel hex nut flats and found.
another dot in line on the connecting tube adapter.
c. Use the double wrench method per Appendix A,
turn the swivel nut to tighten. The nut is to be
rotated clockwise the number of turns.
d. After the connection has been properly tightened,
mark a straight line across the connecting parts, not
covering the dots, to indicate the connection has
been properly tightened.
2-82 31211036 TL642D, TL943D, TL1055D, TL1255D

Section 3
Boom
Contents

3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.1.1 TL642D, TL943D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.1.2 TL1055D, TL1255D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2 Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2.1 Boom System Operation - TL642D, TL943D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2.2 Boom System Operation - TL1055D, TL1255D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Boom Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.1 Complete Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.2 Complete Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.4 Boom Assembly Maintenance - TL642D, TL943D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.1 Second and Third Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.2 Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.4.3 Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4.4 Second and Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.5 Third Boom Section Removal/Installation Only - TL642D, TL943D. . . . . . . . . . . . . . . . . 3-15
3.5.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.5.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6 Boom Assembly Maintenance - TL1055D, TL1255D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.6.1 Second, Third and Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.6.2 Third and Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.6.3 Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.6.4 Hose Carrier Removal - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.6.5 Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.6.6 Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.6.7 Second, Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.7 Fourth Boom Section Removal/Installation Only - TL1055D, TL1255D . . . . . . . . . . . . . 3-25
3.7.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.7.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.8 Hose Carrier Assembly - TL1055D, TL1255D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.8.1 Hose Carrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.8.2 Hose Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.9 Boom Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.10 Boom Sections Adjustment - TL642D, TL943D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.10.1 Chain Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.11 Boom Sections Adjustment - TL1055D, TL1255D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.11.1 Chain Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
TL642D, TL943D, TL1055D, TL1255D 31211036 3-1

Boom
3.12 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3.12.1 Boom Chain Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.12.2 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.12.3 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.12.4 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.13 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.13.1 Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.13.2 Boom Wear Pad Installation, Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.14 Quick Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3.14.1 Quick Coupler Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3.14.2 Quick Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.15 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.16 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.16.1 Equipment and Supplies Required without Precision Gravity Lower System (PGLS)3-38
3.16.2 Lowering Procedure without Precision Gravity Lower System (PGLS) . . . . . . . . . 3-38
3.16.3 Equipment and Supplies Required with Precision Gravity Lower System (PGLS) 3-39
3.16.4 Lowering Procedure with Precision Gravity Lower System (PGLS). . . . . . . . . . . . . 3-40
3.17 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3-2 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
3.1 BOOM SYSTEM COMPONENT

TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that the
operator/mechanic be familiar with the name and location
of the major assemblies of the boom system. The following
illustration identifies the components that are referred to
throughout this section.
Refer to Section 2, “General Information and Specifications”,
for torque values as required.
3.1.1 TL642D, TL943D
EXTEND/RETRACT
CYLINDER
RETRACT CHAIN
(INSIDE BOOM)
EXTEND CHAINS
(INSIDE BOOM) THIRD
BOOM
SECTION
FIRST BOOM
SECTION
SECOND
BOOM QUICK
SECTION COUPLER
TILT CYLINDER
(INSIDE BOOM HEAD)
AUXILIARY
CONNECTION
MAG1430
TL642D, TL943D, TL1055D, TL1255D 31211036 3-3

Boom
3.1.2 TL1055D, TL1255D
EXTEND/RETRACT
CYLINDER
EXTEND CHAINS
(INSIDE BOOM)
THIRD
BOOM
SECTION
FOURTH
RETRACT CHAIN BOOM
(INSIDE BOOM) SECTION
FIRST BOOM
SECTION
QUICK
SECOND COUPLER
BOOM
SECTION
TILT CYLINDER
(INSIDE BOOM HEAD)
AUXILIARY
CONNECTIONS
MAG0510
3-4 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
3.2 BOOM SYSTEM 3.2.2 Boom System Operation - TL1055D,

TL1255D
3.2.1 Boom System Operation - TL642D, The four section boom consists of the first, second, third and
TL943D fourth assemblies with double third section extend chains,
a single fourth section extend chain, a single third and
The three section boom consists of the first, second and
fourth section retract chains.
third assemblies with first and second section extend chains
and a single first and second section retract chain. As the extend/retract cylinder, which is anchored at the front
of the second boom section, and the rear of the first boom
As the extend/retract cylinder, which is anchored at the front
section begins to extend, it forces the second boom section
of the second boom section, and the rear of the first boom
out of the first boom section.
section begins to extend, it forces the second boom section
out of the first boom section. The first, second, third and fourth boom sections are
connected by extend and retract chains. These chains are
The first, second and third boom sections are connected by
routed around sheaves on the second and third boom
extend and retract chains. These chains are routed around
sections. As the second and third boom sections are forced
sheaves on the front and the rear of second boom section.
out, the extend chains pull the third and fourth boom
As the extend/retract cylinder is forced out hydraulically, the
sections out of the second boom section.
third boom section is pulled out by the extend chain(s).
As hydraulic pressure is applied to the retract port on the
As hydraulic pressure is applied to the retract port on the
extend/retract cylinder, the second boom section is pulled
extend/retract cylinder, the retract chain pulls the third
back into the first boom section, and the retract chains pulls
boom section back into the second boom section.
the third and fourth boom sections back into the second
This mechanical linkage formed by the chains and boom section.
supporting hardware, extends and retracts the third boom
This mechanical linkage formed by the chains and
section into the second boom section at the same rate.
supporting hardware, extends and retracts the third and
The first boom section does not extend or retract, but lifts fourth boom sections at the same rate.
and lowers via action of the lift cylinder.
The first boom section does not extend or retract, but lifts
and lowers via action of the lift cylinder.
TL642D, TL943D, TL1055D, TL1255D 31211036 3-5

Boom
3.3 BOOM REMOVAL/INSTALLATION 12. Lower the boom assembly to level.

13. Place a sling around the first boom section at the
3.3.1 Complete Boom Removal balance points.
While the boom sections can be separated from each other

on the machine, it is more efficient to remove the complete
boom assembly from the machine and place it on suitable
supports for separation.
Note: When removing a complete boom assembly use a hoist
or crane with a minimum lift capacity of 10,000 lbs (4536 kg).
1. Remove any attachment from the quick coupler
assembly. Refer to Operation & Maintenance Manual.
2. Remove the quick coupler assembly. Refer to
Section 3.14.1, “Quick Coupler Removal”.
3. Park the machine on a hard, level surface, fully retract
the boom, raise the boom assembly to access lift/lower
MD0460
cylinder pin and the compensation cylinder pin, place 5 4 6
the transmission in (N) NEUTRAL, engage the park brake
and shut the engine OFF. 14. Label, disconnect and cap the extend/retract cylinder
4. Place a Do Not Operate Tag on both the ignition key hoses (4). Cap all fittings and openings to keep dirt and
switch and the steering wheel. debris from entering the hydraulic system.
5. Open the engine cover. Allow the system fluids to cool. 15. Label, disconnect and cap the tilt hoses (5) and auxiliary
hoses (6). Cap all fittings and openings to keep dirt and
6. Properly disconnect the battery. Refer Section 9.8,
debris from entering the hydraulic system.
“Battery” for procedure.
16. Label and disconnect all electrical connections to the
7. Close engine cover to access lift/lower cylinder pin and
boom assembly.
the compensation cylinder pin.
17. Raise the boom assembly to allow the removal of the
8. Properly support the boom assembly using a hoist or
boom assembly pivot pin (3).
crane.
18. Confirm that the boom assembly is balanced with the
9. Remove boom angle sensor arm. Refer to Section 9.11.6,
sling and remove the boom assembly pivot pins.
“Boom Angle Sensor”.
19. Lift the boom assembly from the machine and lower
onto suitable supports.
3
1 3.3.2 Complete Boom Installation
1. Park the machine on a hard, level surface, place the
transmission 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.
MD0450
2
10. Remove the pin (1) from the rod end of the lift/lower
cylinder being careful not to drop the cylinder. Lower
the cylinder to a secure position.
11. Remove the pin (2) from the rod end of the
compensation cylinder being careful not to drop the
cylinder. Lower the cylinder to a secure position.
3-6 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
10. Remove slings and/or supports from the boom

1 assembly.
11. Start the engine and operate all boom functions several
times to bleed any air out of the hydraulic system. Check
3 for fluid leaks. Check the hydraulic fluid level in the tank
and add fluid as required.
12. Lower the boom assembly and shut engine OFF.
13. Clean up all debris, hydraulic fluid, etc., in, on, near and
around the machine.
MD0450
2
3. Using suitable slings, balance the boom assembly, lift

and carefully guide the boom into place. Align the
frame pivot bores with the boom assembly pivot bores.
Install boom pivot pin and lock bolt (1).
4. With the sling still in place, install the compensating
cylinder, pin and lock bolts (2).
5. With the sling still in place, install the rod end of the
lift/lower cylinder, pin and lock bolt (3).
Note: Raising the boom up or down with the sling may be
necessary so the boom, compensating and lift/lower cylinder
bores can be aligned for easier pin installation.
MD0460
5 4 6
6. Uncap and connect the previously labeled
extend/retract cylinder hoses (4) to the appropriate
tube connection.
7. Uncap and connect the previously labeled tilt hoses (5)
and auxiliary hoses (6) to the appropriate tube
connection.
8. Connect all electrical connections to the boom
assembly.
9. Install the boom angle sensor arm. Refer to
Section 9.11.6, “Boom Angle Sensor”.
TL642D, TL943D, TL1055D, TL1255D 31211036 3-7

Boom
3.4 BOOM ASSEMBLY MAINTENANCE - 3.4.1 Second and Third Boom Section Removal
TL642D, TL943D 1. Verify the boom assembly is set on stable, secure and
suitable supports.
While the boom sections can be separated from each other
boom assembly from the machine and place it on suitable 4 6
supports for separation. Refer section 'Boom removal/
Installation'.
1
These instructions must be completed in sequence. The
second and third boom sections are removed from the first
boom section. The third boom section is removed from the 3
second boom section. 2
Note: Before removing the boom section, the carriage or any
other attachment must be removed from the quick coupler. 5
Before beginning, conduct a visual inspection of the

4
machine and work area, and review the task about to be
undertaken. Read, understand and follow these instructions.
During service of the boom, perform the following:
1. Check wear pads (Refer to Section 3.13.1, “Wear Pad MAG1440
Inspection”).
2. Check chain rollers.
2. Remove front cover (5) and rear cover (6).
3. Apply grease at all lubrication points (grease fittings).
3. Properly support the extend/retract cylinder (1) using a
(Refer to Section 2.5, “Lubrication Schedule”).
hoist or crane.
4. Check for proper operation by operating all boom
4. Label, disconnect and cap the extend/retract cylinder
functions through their full ranges of motion several
hoses (2) from the extend/retract cylinder. Cap all
times.
fittings and openings to prevent dirt and debris from
Depending on your particular circumstance, the following entering the hydraulic system.
procedures explain the removal/installation of individual
5. Loosen and remove the Extend/Retract cylinder
boom sections or removal/installation of the complete
strap (3).
boom.
6. Remove one retaining ring from the mounting pin (4) at
each end of the extend/retract cylinder.
WARNING 7. Remove each mounting pin and remove the extend/
NEVER modify the boom by welding or drilling unless retract cylinder and place in a secure location.
approved in writing by the manufacturer. The structural
integrity of the boom will be impaired if subjected to any
repair involving welding or drilling.
3-8 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
TL642D
8 10
8
7
12
7
9
11
MAG1450
13
TL943D
MAG1470
8. Label, disconnect and cap the tilt circuit hoses (7) from
the tilt cylinder at the front of the third boom section. If 11
equipped, label, disconnect and cap the auxiliary circuit
hoses (8) from the fittings at the top front of the third
boom section. Cap all fittings and openings to prevent 12
dirt and debris from entering the hydraulic system.
9. Place a sling through the opening at the top of the
boom head and around the tilt cylinder and remove the 11
retaining rings and pin (9) at the barrel end of the tilt 10
cylinder. Lower the tilt cylinder and place in a secure
location.
13 MAG0230
Note: Before removing the extend chains, measure and note

the distance between the face of the jam nut to the end of the
chain clevis. This measurement will be used when reassembling
the boom.
10. Loosen and remove the lock nut and jam nut (10) on the
retract chain at the front of the first boom section.
11. Loosen and remove the lock nuts and jam nuts (11) on
the extend chains at the front of the first boom section.
12. Label, disconnect and cap both tilt hoses (12) and both
auxiliary hoses (13) from the tubes attached to the first
boom section. Cap all fittings to prevent dirt and debris
from entering the hydraulic system.
13. Pull both tilt hoses (12) and both auxiliary hoses (13)
through the rear of the first boom section.
TL642D, TL943D, TL1055D, TL1255D 31211036 3-9

Boom
16. Using a sling around the front of the second boom

section, lift and slide the two boom sections 75% of the
way out of the first boom section. Set the boom head
down on a suitable support, then center the sling to be
able to balance the two boom sections being removed.
Carefully pull the two boom sections the remainder of
the way out of the first boom section and set the two
boom sections down on suitable supports.
17. Remove the retract chain from the inside of the first
boom section. Clean and inspect chain. Replace if
damaged.
18. Inspect the boom and welds. Consult your Caterpillar
14 dealer if structural damage is detected.
15 19. Inspect hoses, hardware, wear pads, mounting points,
chains and other components visible with the first
boom section. Replace any item if damaged. (Refer to
Section 3.12, “Boom Extend and Retract Chains” and
MAG1500 Section 3.13.1, “Wear Pad Inspection”).
Note: It is recommended that if any chain or hose is damaged
14. Remove the clip and pin (14) from the retract chain
then ALL chains or hoses are replaced.
clevis that is attached to the rear of the third section
boom. Lay the retract chain (15) over the rear of the first
boom section. 3.4.2 Third Boom Section Removal
1. Verify the boom assembly is setting on stable, secure
and suitable supports.
TL642D
16
21
20
19
18
MAG1460
15. Pull the second and third section booms out

MAG1510
6 in to 8 in (152 mm to 203 mm) and remove all the wear 17
pads, shims and backing plates from the front inside of
the first section boom (16). Label all parts for
installation.
3-10 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
TL943D 9. Inspect the boom and welds. Consult your local

authorized service distributor if structural damage is
detected.
10. Inspect hardware, wear pads, mounting points, chains
and other components visible with the second boom
section. Replace any item if damaged. (Refer to
21 Section 3.13.1, “Wear Pad Inspection”).
20
18
3.4.3 Third Boom Section Installation
Note: Shim all wear pads. Refer to Section 3.13, “Boom Wear
Pads”. Final adjustments of the wear pads may required after
19 the boom assembly is installed on the machine and hydraulic
power is available.
MAG1651
1. Install the extend chains on the bottom inside of second
boom section. Lay the extend chain the length of
17
second boom section.
Note: Removal of the retract chain roller from the rear of the 2. Grease the inside second boom section on areas where
second boom section may be required to access the extend the third boom section wear pads will slide.
chain clevis assemblies. 3. Using a suitable sling, balance the third boom section
2. At the rear of the boom, loosen and remove the hose and carefully slide 3 ft to 4 ft (914 mm to 1219 mm) into
bracket assembly attached to the third boom section the front of the second boom section. Set the third
securing tilt hoses (20) and the auxiliary hoses (21). boom section head onto suitable support and reset
sling under the boom head of the third boom section.
3. Loosen and remove the mounting bolt(s) (17) and Carefully slide the third boom section into the second
bracket (18) securing each extend chain clevis(es) (19). boom section. Leave 6 ft to 8 ft (1829 mm to 2438 mm)
4. Fasten a rope/wire to each extend chain clevis(es). of the third boom section out to be able to install wear
5. Pull the third boom section out pads in front of the second boom section.
6 in to 8 in (152 mm to 203 mm). Remove the top wear 4. With the sling still under boom head install the bottom
pads, shims and backing plate from the second boom front wear pads and backing plates on the second
section. Label and tag each set of wear pads being boom section. Lower the third boom section and install
removed. the top front and side wear pads and backing plates on
6. Remove the side wear pads, shims and backing plates the second boom section. DO NOT shim or tighten
from either side of the rear of the second boom section. bolts at this time.
Label and tag each set of wear pads being removed.
7. Place a sling around the front of the third boom section.
Lift and slide the two boom sections 75% of the way out
of the second boom section. Set the boom head down
on a suitable support, then center the sling to be able to
balance the third boom sections being removed.
Carefully pull the third boom section the remainder of
the way out of the second boom section and set the
third boom sections down on suitable supports.
8. Remove the extend chains from bottom of second
damaged.
TL642D, TL943D, TL1055D, TL1255D 31211036 3-11

Boom
TL642D Note: Grease wear pads, bores and pins during assembly.
Note: Shim wear pads as needed to maintain an even gap
between the wear pads and the next boom section. The
number of shims can vary at each shim point.
6. Shim all wear pads on the rear of the third boom section
and front of the second boom section.Refer to
Section 3.13, “Boom Wear Pads”.
21
20 7. Retract the third boom section the remainder of the
way into the second boom section.
19
8. At the rear of the boom, install the hose bracket (22) to
the third boom section.
3.4.4 Second and Third Boom Section

Installation
18
the boom assembly is installed on the machine and hydraulic
MAG1510
power is available.
17
TL943D
22
21
20
18 14
15
19
MAG1500
MAG1651 1. Install the retract chain (15) to bottom front inside of

17
the first boom section. Install the lock nut and jam nut.
Lay the retract chain over the rear of the first boom
5. Secure each extend chain clevis(es) (18) with the section.
previously removed bracket (19) and mounting Note: Keep the retract chain, tilt and auxiliary hoses centered
bolt(s) (17). Torque as required. in the first boom section while installing the second boom
Note: Installation of the retract chain roller from the rear of the section into the first boom section.
second boom section may be required if removed to access the 2. Grease the inside first boom section on areas where the
extend chain clevis assemblies. second boom section wear pads will slide.
3-12 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
3. Using a suitable sling, balance the second and third TL642D

boom sections and carefully slide
3 ft - 4 ft (914 mm - 1219 mm) into the front of the first
boom section. Set the second and third boom sections
onto a suitable support and reset sling under the boom 10
head of the third boom section. Carefully slide the
second and third boom sections into the first boom
section. Leave 6 in - 8 in (152 mm - 203 mm) of the 12
second boom section out to be able to install wear pads
in front of the first boom section.
4. With the sling still under the third boom section, install 11
the bottom front wear pads and backing plates on the
first boom section. Lower the third boom section and
install the top front and side wear pads and backing MAG1450
plates on the first boom section. DO NOT shim or 13
tighten bolts at this time.
TL943D
5. Retract the second and third boom sections the
remainder of the way into the first boom section.
Note: Shim wear pads as needed to maintain an even gap 11
6. Shim all wear pads on the rear of the second boom
section and front of the first boom section. Torque as 12
required Refer to Section 3.13, “Boom Wear Pads”.
11
10
13 MAG0230
7. Attach the retract chain (10) at the bottom front of the

first boom section. Install the lock nut and jam nut.
8. Attach the extend chains (11) at the bottom front of the
first boom section. Install the lock nut and jam nut.
9. Feed the tilt hoses (12) and auxiliary hoses (13)
between the second and first boom sections. Verify
both sets of hoses are run through the opening at the
bottom front of the first boom section and parallel with
the retract chain.
10. Connect the tilt hoses (12) and auxiliary hoses (13) to
the tubes mounted at the bottom front of the first
boom section.
TL642D, TL943D, TL1055D, TL1255D 31211036 3-13

Boom
13. Remove the plugs from the fittings on the tilt cylinder
and the caps from the tilt hoses from the hose carrier.
Install both tilt hoses (7). Torque as required.
14. Remove the plugs from the auxiliary fittings and the
caps from the auxiliary hoses from the hose carrier.
Install both auxiliary hoses (8). Torque as required.
4
6
14
15 3
2
5
MAG1500
4
11. Attach the retract chain (15), pins and clips to the
clevises (14) at the rear of the second boom section.
Note: Adjust all extend chains using the measurement taken in MAG1440
the beginning of the tear down procedure. Depending on the
extent of the parts being replaced, the above measurement is to 15. Attach a sling around a balance point on the extend/
be used as a starting point ONLY. retract cylinder (1) and carefully set on top of the first
boom section.
Note: Grease extend/retract cylinder barrel end bore and rod
end bore and pins before installing.
16. Align the extend/retract cylinder barrel end with bore at
8 rear of the first boom section. Install the pin and
8
retaining clip (4).
7
17. Align the extend/retract cylinder rod end with bore at
7 front of the second boom section. Install the pin and
9 retaining clip (4).
18. Install extend/retract cylinder strap (3). Torque as
required.
19. Uncap and connect the previously labeled extend/
retract cylinder hoses (2) to the extend/retract cylinder.
Note: Torque extend and retract chains lock and jam nuts to
85 - 92 lb-ft (115 - 125 Nm).
MAG1470 20. Install front cover (5) and rear cover (6).
12. Using a suitable sling around the barrel end of the tilt
cylinder, raise the tilt cylinder into boom head. Align the
tilt cylinder barrel end bore with the boom head bore
and install the tilt cylinder pin and retaining clips (9).
Note: Grease tilt cylinder barrel end bore and pin before
installing.
3-14 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
3.5 THIRD BOOM SECTION REMOVAL/ Note: Removal of the retract chain roller from the rear of the
INSTALLATION ONLY - TL642D, TL943D second boom section may be required to access the extend
chain clevis assemblies.
3.5.1 Removal 6. Loosen and remove the mounting bolt(s) (4) and
bracket (5) securing each extend chain clevis(es) (6).
7. Fasten a rope/wire to each extend chain clevis(es).
8. Remove all wear pads, shims and backing plates from
the front of the second boom section. Label and tag
each set of wear pads being removed.
1 9. Place a sling around the front of the third boom section.
Lift and slide the two boom sections 75% of the way out
of the second boom section. Set the boom head down
on a suitable support, then center the sling to be able to
balance the third boom sections being removed.
Carefully pull the third boom section the remainder of
the way out of the second boom section and set the
MAG1450 third boom sections down on suitable supports.
2
1. Label, disconnect and cap both tilt hoses (1) and both 3.5.2 Installation
auxiliary hoses (2) from the tubes attached to the first Note: Shim all wear pads. Final adjustments of the wear pads
boom section. Cap all fittings to prevent dirt and debris may required after the boom assembly is installed on the
from entering the hydraulic system. machine and hydraulic power is available. Refer to
2. Secure a rope/wire to both tilt hoses (1) and both Section 3.13, “Boom Wear Pads”.
auxiliary hoses (2). 1. Using a suitable sling, balance the third boom section
and carefully slide 3 ft to 4 ft (914 mm to 1219 mm) into
the front of the second boom section. Set the third
boom section head onto suitable support and reset
sling under the boom head of the third boom section.
Feed the tilt hoses and auxiliary hoses through the front
of the second boom section. Carefully slide the third
8 boom section into the second boom section. Leave
9
6 ft to 8 ft (1829 mm to 2438 mm) of the third boom
10
section out to be able to install wear pads in front of the
7 second boom section.
2. With the sling still under boom head install the bottom
4 front wear pads and backing plates on the second
boom section. Lower the third boom section and install
5 the top front and side wear pads and backing plates on
3
the second boom section. Tighten as required.
6
3. Install the hose bracket assembly (8) to the third boom
section.
MAG1500
4. At the rear of the boom, secure a rope/wire to both tilt
hoses (7) and both auxiliary hoses (8). Pull the hoses
3. At the rear of the boom, remove hose bracket between the first and second boom sections.
assembly (8) from the third boom section. 5. At the bottom front of the boom, remove the caps from
4. Pull both tilt hoses and both auxiliary hoses through the both tilt hoses (9) and both auxiliary hoses (10).
rear of the first boom section. Connect each hose to the previously labeled tubes
attached to the third boom section.
5. Disconnect the retract chain clevis (7) from the rear of
the third boom section. 6. Connect the extend chain clevis (6) to the rear of the
third boom section.
TL642D, TL943D, TL1055D, TL1255D 31211036 3-15
Boom
7. Connect the retract chain clevis (7) from the rear of the 3.6.1 Second, Third and Fourth Boom Section
third boom section. Removal
1. Verify the boom assembly is set on stable, secure and
3.6 BOOM ASSEMBLY MAINTENANCE - suitable supports.
TL1055D, TL1255D
While the boom sections can be separated from each other 1
boom assembly from the machine and place it on suitable
supports for separation. 2
These instructions must be completed in sequence. The 3
second, third and fourth boom sections are removed from 4
the first boom section. The third and fourth boom sections
are removed from the second boom section. The fourth
boom section is removed from the third boom section.
Note: Before removing the boom section, the carriage or any 4
other attachment must be removed from the quick coupler.
Before beginning, conduct a visual inspection of the
machine and work area, and review the task about to be
undertaken. Read, understand and follow these instructions.
During service of the boom, perform the following:
1. Check wear pads (Refer to Section 3.13.1, “Wear Pad
Inspection”). 2. Properly support the extend/retract cylinder (1) using a
2. Check chain rollers. hoist or crane.
3. Apply grease at all lubrication points (grease fittings). 3. Label, disconnect and cap the extend/retract cylinder
(Refer to Section 2.5, “Lubrication Schedule”). hoses (2) from the extend/retract cylinder. Cap all
fittings and openings to prevent dirt and debris from
4. Check for proper operation by operating all boom
entering the hydraulic system.
functions through their full ranges of motion several
times. 4. Loosen and remove the extend/retract cylinder
strap (3).
Depending on your particular circumstance, the following
procedures explain the removal/installation of individual 5. Remove one retaining ring from the mounting pin (4) at
boom sections or removal/installation of the complete each end of the extend/retract cylinder.
boom. 6. Remove each mounting pin and remove the
extend/retract cylinder and place in a secure location.
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.
3-16 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
10. Loosen and remove the lock nut and jam nut (8) on the
retract chain at the front of the first boom section.
11. Loosen and remove the lock nut and jam nuts (9) on the
6 6 extend chains at the front of the first boom section.
12. Label, disconnect and cap both tilt hoses (10) and both
5 auxiliary hoses (11) from the tubes attached to the first
boom section. Cap all fittings to prevent dirt and debris
from entering the hydraulic system.
7
13. Pull both tilt hoses (10) and both auxiliary hoses (11)
through the rear of the first boom section.
5
MAG0600
7. Label, disconnect and cap the tilt circuit hoses (5) from
the tilt cylinder at the front of the fourth boom section.
If equipped, label, disconnect and cap the auxiliary
circuit hoses (6) from the fittings at the top front of the
fourth boom section. Cap all fittings and openings to
prevent dirt and debris from entering the hydraulic 12
system.
8. Place a sling through the opening at the top of the
boom head and around the tilt cylinder and remove the
retaining rings and pin (7) at the barrel end of the tilt
cylinder. Lower the tilt cylinder and place in a secure
location. 13 MD0350
9. Loosen and remove the rear cover assembly from the
rear of the first boom section. 14. Remove the clip and pin (12) from the retract chain
clevis that is attached to the rear of the third section
Note: Before removing the extend chains, measure and note boom. Lay the retract chain (13) over the rear of the first
the distance between the face of the jam nut to the end of the boom section.
chain clevis. This measurement will be used when reassembling
the boom.
10
9
11 8
TL642D, TL943D, TL1055D, TL1255D 31211036 3-17

Boom
3.6.2 Third and Fourth Boom Section Removal

14
17
16
15. Pull the second, third and fourth section booms out
6 in to 8 in (152 mm to 203 mm) and remove all the wear
pads, shims and backing plates from the front inside of
MD0371
the first section boom (14). Label all parts for 15
installation.
16. Using a sling around the front of the second boom Note: Removal of the retract chain roller from the rear of the
section, lift and slide the three boom sections 75% of second boom section may be required to access the extend
the way out of the first boom section. Set the boom chain clevis assemblies.
head down on a suitable support, then center the sling 2. Loosen and remove the mounting bolts (15) and
to be able to balance the three boom sections being bracket (16) securing each extend chain clevises (17).
removed. Carefully pull the three boom sections the
3. Fasten a rope/wire to each extend chain clevis.
remainder of the way out of the first boom section and
set the three boom sections down on suitable supports.
17. Remove the retract chain from the inside of the first
damaged.
18. Inspect the boom and welds. Consult your local
detected.
19. Inspect hoses, hardware, wear pads, mounting
points, chains and other components visible with the
first boom section. Replace any item if damaged. (Refer
to Section 3.12, “Boom Extend and Retract Chains” and
Section 3.13.1, “Wear Pad Inspection”).
3-18 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
12. It is recommended that if any chain or hose is damaged

19 that ALL chains or hoses are replaced.
3.6.3 Fourth Boom Section Removal

20
18
22
23
21
4. At the top front of the second boom section (18),

remove the jam nuts and nuts and washers from the
extend chain clevis (19).
5. At the top front of the second boom section (18),
remove the jam nuts and nuts and washers from the
Retract Chain Clevis (20).
6. Pull the third boom section out
6 in to 8 in (152 mm to 203 mm). Remove the top wear MD0390
pads, shims and backing plate from the second boom 24 25 24
section. Label and tag each set of wear pads being
removed. 2. At the rear of the boom, loosen and remove the hose
7. Remove the side wear pads, shims and backing plates brackets attached to the third boom section securing
from either side of the rear of the second boom section. tilt hoses (21) and the auxiliary hoses (22).
Label and tag each set of wear pads being removed. 3. Remove the clip and pin from the retract chain
8. Place a sling around the front of the third boom section. clevis (23) that is attached to the rear of the fourth
Lift and slide the two boom sections 75% of the way out section boom. Lay the retract chain over the rear of the
of the second boom section. Set the boom head down third boom section.
on a suitable support, then center the sling to be able to 4. Remove the retract chain from top of third boom
balance the two boom sections being removed. section. Clean and inspect chain. Replace if damaged.
Carefully pull the two boom sections the remainder of 5. Loosen and remove the bolts (24) securing the hose
the way out of the second boom section and set the bracket (25) to the third boom section.
two boom sections down on suitable supports.
9. Remove the extend chains from bottom of second
damaged.
10. Inspect the boom and welds. Consult your local
detected.
11. Inspect hardware, wear pads, mounting points, chains
and other components visible with the second boom
section. Replace any item if damaged. (Refer to
TL642D, TL943D, TL1055D, TL1255D 31211036 3-19

Boom
29
27
28 26
MD0410
10. Remove the extend chain (29) from top of fourth boom
section. Clean and inspect chain. Replace if damaged.
6. At the top front of the third boom section (26), lay the 11. Inspect the boom and welds. Consult your local
extend chain and clevis (27) over the front of the fourth authorized service distributor if structural damage is
boom section (28). detected.
7. Remove the top wear pads, shims and backing plate 12. Inspect hardware, wear pads, mounting points, chains
from the third boom section. Label and tag each set of and other components visible with the fourth boom
wear pads being removed. section. Replace any item if damaged. (Refer to
8. Remove all wear pads, shims and backing plates from
the front of the third boom section. Label and tag each
set of wear pads being removed. Note: It is recommended that if any chain or hose is damaged
9. Place a sling around the front of the fourth boom then ALL chains or hoses are replaced.
section. Lift and slide the two boom sections 75% of the
way out of the third boom section. Set the boom head 3.6.4 Hose Carrier Removal - Installation
down on a suitable support, then center the sling to be Refer to Section 3.8, “Hose Carrier Assembly - TL1055D,
able to balance the two boom sections being removed. TL1255D”, for detailed hose carrier removal and installation.
Carefully pull the fourth boom section the remainder of
the way out of the third boom section and set the fourth
boom section down on suitable supports.
3-20 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
3.6.5 Fourth Boom Section Installation

Note: Shimming of the wear pads. Final adjustments of the
wear pads may required after the boom assembly is installed 27
on the machine and hydraulic power is available. Refer to
Section 3.13, “Boom Wear Pads”.
29 26

MD0410 number of shims can vary at each shim point.
1. Install the extend chain (29) on the top rear of fourth 6. Shim all wear pads on the front of the third boom
boom section. Lay the extend chain the length of fourth section.Refer to Section 3.13, “Boom Wear Pads”.
boom section. 7. Lay the extend chain and clevis (27) over the top of the
2. Grease the inside third boom section on area’s where third boom section (26).
the fourth boom section wear pads will slide.
3. Using a suitable sling, balance the fourth boom section 22
and carefully slide 3 ft to 4 ft (914 mm to 1219 mm) into 23
21
the front of the third boom section. Set the fourth boom 36
section head onto suitable support and reset sling
under the boom head of the fourth boom section.
Carefully slide the fourth boom section into the third
boom section. Leave 6 ft to 8 ft (1829 mm to 2438 mm)
of the fourth boom section out to be able to install wear
pads in front of the third boom section.
4. With the sling still under boom head install the bottom
front wear pads and backing plates on the third boom
section. Lower the fourth boom section and install the
top front and side wear pads and backing plates on the
third boom section. DO NOT shim or tighten bolts at
this time.
Note: Grease wear pads, bores and pins during assembly.
5. Retract the fourth boom section the remainder of the
way into the third boom section. MD0390
25
8. Lay the retract chain (36) the length of third boom

section.
9. Install the pin and clip to the retract chain clevis (23) to
the top rear of the fourth section boom.
TL642D, TL943D, TL1055D, TL1255D 31211036 3-21
Boom
10. At the rear of the boom, install the tilt hoses Note: Installation of the retract chain roller from the rear of the
bracket (21), auxiliary hoses bracket (22) and tray second boom section may be required if removed to access the
support (25) to the third boom section. extend chain clevis assemblies.
5. Secure the retract chain clevis (20) to the top front of
3.6.6 Third and Fourth Boom Section the second boom section (18) with the previously
Installation removed jam and lock nuts.
Note: Shim all wear pads. Refer to Section 3.13, “Boom Wear 6. Secure the extend chain clevis to the top front of the
Pads”. Final adjustments of the wear pads may required after second boom section (19) with the previously removed
the boom assembly is installed on the machine and hydraulic jam and lock nuts.
power is available.
1. Install the extend chains on the bottom inside of second
boom section. Lay the extend chain the length of
19
20
17
18
16
MD0371
15
7. Secure each extend chain clevises (17) with the
previously removed bracket (16) and mounting
bolts (15). Torque as required.
2. Grease the inside second boom section on areas where
the third boom section wear pads will slide. Note: Grease wear pads, bores and pins during assembly.
3. Using a suitable sling, balance the third and fourth Note: Shim wear pads as needed to maintain an even gap
boom sections and carefully slide 3 ft - 4 ft (914 mm- between the wear pads and the next boom section. The
1219 mm) into the front of the second boom section. number of shims can vary at each shim point.
Set the third and fourth boom sections onto a suitable
support and reset the sling under the boom head of the 8. Shim all wear pads on the rear of the third boom section
fourth boom section. Carefully slide the third and fourth and front of the second boom section. Refer to
boom sections into the second boom section. Leave Section 3.13, “Boom Wear Pads”.
6 in - 8 in (152 mm - 203 mm) of the third boom section
out to be able to install the wear pads in the front of the
4. With the sling still under third boom section, install the
bottom front wear pads and backing plates on the
second boom section. Lower the third boom section
and install the top front and side wear pads and backing
plates on the second boom section. DO NOT shim or
3-22 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
3.6.7 Second, Third and Fourth Boom Section 4. With the sling still under the third boom section, install
Installation the bottom front wear pads and backing plates on the
first boom section. Lower the third boom section and
install the top front and side wear pads and backing
plates on the first boom section. DO NOT shim or
the boom assembly is installed on the machine and hydraulic
power is available.
5. Retract the second, third and fourth boom sections the
remainder of the way into the first boom section.
6. Shim all wear pads on the rear of the second boom
section and front of the first boom section. Torque as
required.Refer to Section 3.13, “Boom Wear Pads”.
10
13 MD0350
9
1. Install the retract chain (13) to bottom front inside of
the first boom section. Install the lock nut and jam nut.
11 8
Lay the retract chain over the rear of the first boom
section. 7. Attach the retract chain (8) at the bottom front of the
Note: Keep the retract chain, tilt and auxiliary hoses centered first boom section. Install the lock nut and jam nut.
in the first boom section while installing the second boom 8. Attach the extend chains (9) at the bottom front of the
section into the first boom section. first boom section. Install the lock nut and jam nut.
2. Grease the inside first boom section on areas where the 9. Feed the tilt hoses (10) and auxiliary hoses (11)
second boom section wear pads will slide. between the second and first boom sections. Verify
3. Using a suitable sling, balance the second, third and both sets of hoses are run through the opening at the
fourth boom sections and carefully slide bottom front of the first boom section and parallel with
3 ft - 4 ft (914 mm - 1219 mm) into the front of the first the retract chain.
boom section. Set the second, third and fourth boom 10. Connect the tilt hoses (10) and auxiliary hoses (11) to
sections onto a suitable support and reset sling under the tubes mounted at the bottom front of the first
the boom head of the fourth boom section. Carefully boom section.
slide the second, third and fourth boom sections into
the first boom section. Leave
6 in - 8 in (152 mm - 203 mm) of the second boom
section out to be able to install wear pads in front of the
first boom section.
TL642D, TL943D, TL1055D, TL1255D 31211036 3-23

Boom
Note: Grease tilt cylinder barrel end bore and pin before
installing.
13. Remove the plugs from the fittings on the tilt cylinder
and the caps from the tilt hoses from the hose carrier.
Install both tilt hoses (5). Torque as required.
14. Remove the plugs from the auxiliary fittings and the
caps from the auxiliary hoses from the hose carrier.
Install both auxiliary hoses (6). Torque as required.
2 4
12 3
4
13 MD0350
11. Attach the retract chain (13), pins and clips to the
clevises (12) at the rear of the second boom section.
Note: Adjust all extend chains using the measurement taken in
the beginning of the tear down procedure. Depending on the
extent of the parts being replaced, the above measurement is to
be used as a starting point ONLY.
15. Attach a sling around a balance point on the
extend/retract cylinder (1) and carefully set on top of
the first boom section.
Note: Grease extend/retract cylinder barrel end bore and rod
6 6 end bore and pins before installing.
16. Align the extend/retract cylinder barrel end with bore at
5 rear of the first boom section. Install the pin and
retaining clip (4).
7
17. Align the extend/retract cylinder rod end with bore at
5 front of the second boom section. Install the pin and
retaining clip (4).
18. Install extend/retract cylinder strap (3). Torque as
required.
19. Uncap and connect the previously labeled extend/
retract cylinder hoses (2) to the extend/retract cylinder.
Note: Torque extend and retract chains lock and jam nuts to
MAG0600 85 - 92 lb-ft (115 - 125 Nm).
12. Using a suitable sling around the barrel end of the tilt
cylinder, raise the tilt cylinder into boom head. Align the
tilt cylinder barrel end bore with the boom head bore
and install the tilt cylinder pin and retaining clips (7).
3-24 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
3.7 FOURTH BOOM SECTION REMOVAL/

INSTALLATION ONLY - TL1055D, 6
TL1255D
5
3.7.1 Removal 9
1. Start machine, level and extend boom until the side and 8
bottom front wear pad bolts on the third boom section
are accessible. Shut machine OFF.
3 4
2
MD1400 MD0361
2. Remove the tilt tubes clamp (1) and the auxiliary tubes 5. At the top front of the second boom section, remove
clamp (2). the lock nut and adjusting nut (5) from the extend chain
3. Label, disconnect and cap both tilt hoses (3) and both clevis and lay the extend chain and clevis (6) on top of
auxiliary hoses (4) from the tubes attached to the first the fourth boom section (7).
boom section. Cap all fittings to prevent dirt and debris 6. Remove the locking bolt, pin and sheave (8) from the
from entering the hydraulic system. top front of the third boom section.
4. If equipped, disconnect the electrical connection at the 7. At the top front of the second boom section, loosen the
bottom rear of the first boom section.Secure a lock nut and adjusting nut from the retract chain
rope/wire to both tilt hoses (3), both auxiliary clevis(9).
hoses (4) and if equipped, the electrical cable.
8. Remove the top wear pads, shims and backing plates
from the front of the third boom section. Label and tag
each set of wear pads being removed.
9. Place a sling around the front of the fourth boom
section and raise the fourth boom section to allow the
removal of the bottom front wear pads, shims and
backing plates.
10. Remove all side and bottom wear pads, shims and
backing plates from the front of the third boom section.
Label and tag each set of wear pads being removed.
TL642D, TL943D, TL1055D, TL1255D 31211036 3-25

Boom
3.7.2 Installation
1. Using a suitable sling, balance the fourth boom section
10
and feed the tilt hoses, auxiliary hoses and if equipped,
the electrical cable through the front of the third boom
section. Carefully slide 3 ft to 4 ft (914 mm to 1219 mm)
into the front of the third boom section. Set the fourth
Boom section head onto suitable support and reset
sling under the boom head of the fourth boom section.
Carefully slide the fourth boom section into the third
boom section. Leave approximately 1ft (305 mm) of the
11
fourth boom section out to be able to install wear pads
in front of the third boom section.
12 2. With the sling still under boom head install the bottom
13 front wear pads and backing plates on the third boom
section. Lower the fourth boom section and install the
14 top front and side wear pads and backing plates on the
third boom section. Tighten as required.
3. Remove caps and connect the auxiliary circuit hoses to
MD0420 the backside of the bulkhead at the front of the fourth
boom section.
4. At the rear of the boom, secure a rope/wire to both tilt
hoses (3), both auxiliary hoses (4) and if equipped, the
11. Disconnect the retract chain clevis (10) from the rear of
electrical cable. Pull the hoses between the first and
the fourth boom section.
second boom sections. Remove the rope/wire from
12. At the rear of the boom, remove the tilt hose clamp (11) both tilt hoses, both auxiliary hoses.
and auxiliary hose clamp (12) from the third boom
5. At the bottom front of the boom, remove the caps from
section.
both tilt hoses (3) and both auxiliary hoses (4). Connect
13. Remove the two right side bolts and two top left bolts each hose to the previously labeled tubes attached to
securing the hose carrier bracket (13) to the rear side of the bottom of the first boom section.
the third boom section.
6. Install the tilt tubes clamp (1) and the auxiliary tubes
14. Pull the hose carrier back and remove the four bolts clamp (2).
securing the hose carrier bracket to the hose carrier(14).
7. If equipped, secure the electrical cable to the tilt
Remove bracket.
cylinder tube tubes attached to the first boom section.
15. Pull both tilt hoses, both auxiliary hoses and if
8. Connect the extend chain clevis (10) to the rear of the
equipped, the electrical cable from between the first
fourth boom section.
and second boom sections through the rear of the first
boom section. 9. Install the hose carrier bracket (13) by pulling the hose
carrier back and install the four bolts securing the hose
16. Lift and slide the fourth boom section 75% of the way
carrier bracket to the hose carrier (14).
out of the third boom section. Set the boom head down
on a suitable support, then center the sling to balance 10. Install the two right side bolts and two top left bolts
the fourth boom section. Carefully pull the fourth boom securing the hose carrier bracket (13) to the rear side of
section the remainder of the way out of the third boom the third boom section.
section and set down on suitable supports. 11. Install the tilt hose clamp (11) and auxiliary hose clamp
(12) from the third boom section.
12. Install the sheave, pin and locking bolt (8) from the top
front of the third boom section.
13. At the top front of the second boom section, install the
extend chain and clevis (1). Install the adjusting nut and
lock nut the lock nut to the extend chain clevis (5).
3-26 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
14. Refer to Section 3.10, “Boom Sections Adjustment - 3.8 HOSE CARRIER ASSEMBLY - TL1055D,
TL642D, TL943D”, for detailed chain and boom section TL1255D
adjustment.
Note: Removal and installation of the hose carrier can also be
performed after the fourth boom section has been removed.
3.8.1 Hose Carrier Removal

1. Refer to Section 3.6.3, “Fourth Boom Section Removal”,
for detailed removal instructions.
2
1
MD0431
2. Label, disconnect and plug the tilt circuit hoses (1) from
the tilt cylinder at the front of the fourth boom section.
3. Remove the two bolts securing the auxiliary hose
bulkhead (2) to the fourth boom section. Pull the
bulkhead forward to aid in removal of the auxiliary
hoses.
4. Label, disconnect and plug the auxiliary circuit hoses (3)
from the back side of the bulkhead at the front of the
fourth boom section.
TL642D, TL943D, TL1055D, TL1255D 31211036 3-27

Boom
2. Carefully slide the hose carrier into the rear of the fourth
boom section.
4
3. Install the four bolts securing the hose carrier
5
bracket (7) to the bottom of the fourth boom section.
4. Install the hose carrier bracket tray support (6) to the
rear sides of the fourth boom section.
5. Carefully feed the tilt hoses, auxiliary hoses and if
equipped the electrical cable through the appropriate
hose channels at the top rear of the fourth boom
section.
6. Remove the plugs from the auxiliary circuit hoses (3)
and connect to the fittings on the back side of the
bulkhead (2) at the front of the fourth boom section.
7. Secure the auxiliary hose bulkhead (2) to the fourth
boom section with the previously removed hardware.
8. Remove the plugs from the tilt circuit hoses (1) and
6 MD1380 connect to the fittings on the tilt cylinder at the front of
the fourth boom section.
7
9. Install the tilt hoses clamp (5) and auxiliary hoses
Note: Side plate removed for clarity. clamp (4) to the rear sides of the fourth boom section.
5. Remove the tilt hose clamp (4) and auxiliary hose 10. Refer to Section 3.7, “Fourth Boom Section Removal/
clamp(5) from the rear sides of the fourth boom section. Installation Only - TL1055D, TL1255D”.
6. Remove the hose carrier bracket tray support (6) from
the rear sides of the fourth boom section.
7. Remove the four bolts securing the hose carrier
bracket (7) from the bottom of the fourth boom section.
8. Carefully pull the hose carrier the out of the rear fourth
boom section and set down on suitable supports.
9. Secure the tilt hoses, the auxiliary hoses and if equipped
the electrical cable with nylon ties. Remove tilt and/or
auxiliary hoses if required.
3.8.2 Hose Carrier Installation

Note: If replacing the tilt hoses and/or auxiliary hoses, label the
new hoses according to the hoses being replaced.
1. Verify the auxiliary hose length from the end of the hose
fitting to the face of the hose carrier is
193.0 in (4902,0 mm).
Verify the tilt hose length from the end of the hose
fitting to the face of the hose carrier is
200.0 in (5080,0 mm).
3-28 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
3.9 BOOM CHAIN REMOVAL/INSTALLATION

TL642D TL943D
The removal of the extend and/or retract chains can only be 2
accomplished by disassembling the boom sections.
Refer to respective boom removal and installation sections.
3.10 BOOM SECTIONS ADJUSTMENT -

TL642D, TL943D
2 1
MAG2130
3.10.1 Chain Adjustments 2 1
The chains are adjusted by tightening and/or backing off

the adjusting nuts at the threaded end of the chains. The 4. Loosen the locknuts on the extend and retract chains.
opposite chain adjusting nut usually must be loosened
whenever this procedure is performed.
1. Park the machine on a firm, level surface, fully retract
and raise the boom to a horizontal (level) position, place
switch. B
MAG1721
5. Set the “SAG” in the chains to the following dimensions:

For TL642D,
B. 4.84 - 5.03 in (123 - 128 mm)
For TL943D,
B. 3.46 - 3.66 in (88 - 93 mm)
6. Tighten adjusting nut (1) to move the 3rd boom section
in.
Tighten adjusting nuts (2) to move the 3rd boom
section out.
7. Tighten the extend and retract chain locknuts to
A MAG1640 86 lb-ft (120 Nm) against the adjusting nut.
2. The boom is properly adjusted whenever the following Note: Ensure that there is a minimum of one full thread of the
parameters are met. clevis showing beyond the lock nut.
TL642D, 8. Start the machine and retract boom fully. Check
A. 1.45 - 1.85 in (37 - 47 mm) dimensions (A).
9. Start the machine and cycle the extend-retract cylinder
TL943D, a minimum of three times to verify dimensions (A).
A. 0.62 - 1.02 in (16 - 26 mm)
3. If adjustments are needed:
Start the machine and fully extend the boom, then
retract the boom 2.0 in (50 mm).
TL642D, TL943D, TL1055D, TL1255D 31211036 3-29

Boom
3.11 BOOM SECTIONS ADJUSTMENT -

TL1055D, TL1255D
3.11.1 Chain Adjustments C

The chains are adjusted by tightening and/or backing off
the adjusting nuts at the threaded end of the chains. The
opposite chain adjusting nut usually must be loosened
whenever this procedure is performed.
1. Park the machine on a firm, level surface, fully retract D
and raise the boom to a horizontal (level) position, place
switch.
MD1111
5. Set the “SAG” in the chains to the following dimensions:

For TL1055D,
C. 3.94 - 4.13 in (100 - 105 mm)
D. 5.20 - 5.39 in (132 - 137 mm)
For TL1255D,
C. 5.16 - 5.35 in (131 -136 mm)
D. 6.42 - 6.61 in (163 -168 mm)
A
B MD1100
2. The boom is properly adjusted whenever the following

parameters are met.
A. 5.8 - 6.2 in (148 -158 mm)
B. 2.2 - 2.6 in (56 - 66 mm)
3. If adjustments are needed:
Start the machine and fully extend the boom, then
retract the boom 2.0 in (50 mm).
2
MD1120
4 3
4. Loosen the locknuts on the extend and retract chains.
3-30 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
3 3.12 BOOM EXTEND AND RETRACT CHAINS
3.12.1 Boom Chain Inspection
WARNING
3 Worn pins, stretched or cracked links or corrosive
1 environments can cause chain failure. A chain failure
could result in uncontrolled boom movement, loss of
load or machine instability.
Under normal operating conditions the boom chains will
3 need to be inspected every 250 hours of operation. The
retract chains need to be exposed and inspected every
2
1000 hours of operation. Refer to the Service Manual for the
4 proper procedure. Environmental conditions and dynamic
impulse/shock loads can drastically affect normal operating
conditions and require more frequent inspection intervals.
Environments in which material handling vehicles operate
can vary widely from outdoor moisture to temperature to
mildly corrosive or highly corrosive industrial
3 atmospheres, in addition to abrasive exposures such as sand
MD1410
and grit. Some effects can be as follows:
6. Tighten adjusting nut (1) to move the 4th boom section • Moisture - Corrosive rusting reduces chain strength
out. by pitting and cracking.
Tighten adjusting nut (2) to move the 4th boom section
in. • Temperature - Low temperature reduces chain
strength by embrittlement. Going in and out of
Tighten adjusting nut (3) to move the 3rd boom section
cold storage results in moisture from condensation.
in.
Tighten adjusting nuts (4) to move the 3rd boom • Chemical Solutions or Vapors - Corrosive attack on
section out. the chain components and/or the mechanical
connections between the chain components.
7. Tighten the extend and retract chain lock nuts to Cracking can be (and often is) microscopic. Going
86 lb-ft (120 Nm) against the adjusting nut. from microscopic cracking to complete failure can
Note: Ensure that there is a minimum of one full thread of the be either abrupt or may require an extended period
of time.
clevis showing beyond the lock nut.
• Abrasives - Accelerated wearing and scoring of the
8. Start the machine and retract boom fully. Check articulating members of the chain (pins and plates),
dimensions (A and B). with a corresponding reduction in chain strength.
9. Start the machine and cycle the extend-retract cylinder Due to the inaccessibility of the bearing surfaces
a minimum of three times to verify dimensions (pin surfaces and plate apertures), wear and scoring
(A and B). are not readily noticeable to the naked eye.
Following are some examples of dynamic shock loading
which can impose abnormal loads above the endurance
limit of a leaf chain.
• High velocity movement of load, followed by
sudden, abrupt stops.
• Carrying loads in suspension over irregular surfaces
such as railroad tracks, potholes, and rough terrain.
• Attempting to “inch” loads which are beyond the
rated capacity of the vehicle.
TL642D, TL943D, TL1055D, TL1255D 31211036 3-31

Boom
The above load cycles and environmental conditions make it Edge Wear
impossible to predict chain life. It is therefore necessary to
conduct frequent inspections until replacement life can be
predicted.
The boom chain’s normal life expectancy can be expressed 1 2
as a maximum percent of elongation. This is generally 3%.
As the chain flexes back and forth over the sheave, the
bearing joints (pins and inside link plates) gradually incur
wear due to articulation.
MZ1463
3.12.2 Inspection Guidelines Check the chain for wear on the link plate edges caused
by running back and forth over the sheave. The
a. Extend Chain maximum reduction of material should not exceed 5%.
Measure and compare to a normal link plate height by
1. Park the machine on a firm, level surface, raise the boom measuring a portion of chain that does not run over the
to a horizontal (level) position, place the transmission in sheave. If the measured plate height (1) is 5% less than
(N) NEUTRAL, engage the park brake switch. the normal plate height (2), discard and replace the
2. Fully extend the boom until the extend chain is taut. chain.
Shut the engine off. Elongation
3. The extend chain will be visible for inspection with the It is important to measure the chain in the section that
vehicle in this state. moves over the sheaves because it receives the most
4. While doing the chain inspection, check all chain clevis frequent articulation. Measuring the chain near its clevis
ends, pins for distortion or cracking and sheaves for terminals could give an inaccurate reading. The ends of
the chains, near the clevis terminal, will not have flexed
bearing wear or grooving from the chain.
as frequently, if at all, as the middle of the chains.
b. Retract Chains It is best to measure in 12 pin increments from pin
center to pin center. For example, if the links are
1. Park the machine on a firm, level surface, raise the boom 25 mm (1 in) from pin center to pin center, the distance
to a horizontal (level) position, place the transmission in should be 305 mm (12 in). If the links are 19 mm (75 in)
(N) NEUTRAL, engage the park brake switch. apart, the distance after 12 pins should be
2. Fully retract the boom. Shut the engine off. 229 mm (9 in).
3. Both retract chain clevises and pins will be visible in this

state.
3
4. Limited visual inspection of the retract chains is
possible. For complete retract chain inspection, the 4
retract chains must be removed from the boom. Refer to
Section 3.4, “Boom Assembly Maintenance - TL642D,
TL943D” and Section 3.6, “Boom Assembly Maintenance
- TL1055D, TL1255D”.
5. Inspect the chains for the following conditions:
MY1360
If the distance measured (3) is 3% greater than the

normal length (4), discard and replace the chain.
3-32 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
Distorted or Battered Link Plates Cracked Plates

Inspect the chains very carefully, front and back as well
85 as side to side, for any evidence of cracked plates. If any
one crack is discovered, the chain should be replaced in
its entirety.
It is important, however to determine the cause of the
crack before installing a new chain so the condition
does not repeat itself.
The types of cracks are:
MZ1466
• Fatigue Cracking - Fatigue
Distorted or battered link plates (5) on a leaf chain can cause cracks (9) are a result of 9
repeated cyclic loading
tight joints and prevent flexing.
beyond the chain’s MZ1467
Turning or Protruding Pins endurance limit.
Highly loaded chain, operating with inadequate • Stress Corrosion
lubrication can generate abnormal frictional forces Cracking - The outside
between pin and link plates. When chain is allowed to link plates are 10
operate in this condition, a pin or series of pins, can particularly MZ1468
begin to twist out of a chain, resulting in failure. susceptible to stress

corrosion cracking (10).
• Corrosion Fatigue Cracking - Corrosion fatigue
cracks are very similar to fatigue cracks in
appearance. Corrosion fatigue is the combined
7 action of an aggressive environment and cyclic
6 stress.
8
Other Modes of Failure
MZ1465
• Ultimate Strength Failure -
These types of failures are
Examine the pin head rivets to determine if 11
caused by overloads far in
the “VEE” flats are still in correct alignment (6). Chain
excess of the design load. MZ1469
with rotated/displaced heads (7) or abnormal pin
Either fractured plates (11) or
protrusion (8) should be replaced immediately. 12
enlarged holes (12) can occur.
DO NOT attempt to repair the chain by welding or If either of these failures
MZ1470
driving the pin(s) back into the chain. Once the press fit occurs, the chain should be
integrity between outside plates and pins has been replaced immediately.
altered, it cannot be restored.
• Tight Joints -
Any wear pattern on the pin heads or the sides of the All joints in
link plates indicates misalignment in the system. This the chain
condition damages the chain as well as increases should flex
frictional loading and should be corrected. freely. Tight
13 MZ1471
joints (13)
resist flexing.
If the problem is caused by dirt or foreign substance
packed in the joints, clean and lubricate thoroughly
before re-installing the chain.
If the problem is caused by corrosion and rust or bent
pins, replace the chain.
TL642D, TL943D, TL1055D, TL1255D 31211036 3-33

Boom
3.12.3 Expose Chains for Inspection 3.12.4 Chain Lubrication

After inspection and before being returned to service,
c. Extend Chain chains must be lubricated with gear oil. Refer to Section 2.3,
1. Park the machine on a firm, level surface. Place the “Fluid and Lubricant Capacities”, for detailed Information.
transmission in (N) NEUTRAL, engage the park brake The lubricant must penetrate the chain joint to prevent
switch and raise the boom to a horizontal (level) wear. Applying lubricant to the external surfaces will
position. prevent rust, but the chains should be articulated to make
2. Fully extend the boom until the extend chain is taut. sure the lubricant penetrates to the working surfaces
between the pins and links.
Shut the engine OFF.
The extend chain will be visible for inspection with the To prepare the chain for lubrication, the chain plates should
be brushed with a stiff brush or wire brush to clear the space
machine in this state.
between the plates so that lubricant can penetrate to the
While doing the chain inspection, check all chain clevis ends working surfaces.
for distortion or cracking and sheaves for bearing wear or
Lubricant may be applied with a narrow paint brush or
grooving from the chain. directly poured on, but the chain should be well flooded
If during the inspection, if any chain is found to be damaged with lubricant and the boom should be extended and
or stretched, the chain must be replaced. It is recommended retracted to be sure that the lubricant penetrates to the
that when any chain is replaced, that all the chains and working surfaces. All surplus lubricant should be wiped
clevises be replaced at the same time. away from the external surfaces. DO NOT use a solvent for
this wiping operation.
d. Retract Chains Regular application of lubricant is necessary to make sure
that all working surfaces are adequately lubricated. In
The retract chains are only partially visible through the rear extremely dusty conditions, it may be necessary to lubricate
of the boom with all the sections retracted. It is possible to the chains more often. Refer to Section 2.4, “Service and
see a section of the retract chain as the boom is slowly Maintenance Schedules” and Section 2.5, “Lubrication
extended. If during the inspection, if any chain is found to be Schedule”, for detailed information.
damaged or stretched, the chain must be replaced. It is
Lubrication of chains on vehicles working consistently in
recommended that when any chain is replaced, that all the
extreme hot or cold conditions requires special
chains and clevises be replaced at the same time. consideration. Contact the Caterpillar dealer for guidance.
Refer to Section 3.12, “Boom Extend and Retract Chains”.
Note: DO NOT attempt to repair a chain. Replace a stretched
or damaged chain with a new part. Always replace both the
chain and the clevis. It is recommended that when any chain is
replaced, that all chains and clevis’ be replaced at the same
time.
3-34 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
3.13 BOOM WEAR PADS 3.13.2 Boom Wear Pad Installation, Lubrication
The boom has been factory lubricated for proper wear pad
The boom wear pads are flat rectangular plastic blocks with
break-in and will normally require minor further lubrication.
metal inserts.
However, after replacing any wear pad(s), or after prolonged
periods of inoperation, lubrication of the boom wear surfaces
3.13.1 Wear Pad Inspection is recommended to keep the boom wear surfaces lubricated
1 properly. Refer to Section 2.3, “Fluid and Lubricant
Capacities”, for appropriate lubricants to be used.
Lubrication of the boom wear surfaces is also recommended
when the machine is stored, to help prevent rusting.
The following wear pad procedure must be followed to
insure the proper wear pad installation:
• Maintain a total boom section clearance between the
1 side/top wear pad(s) and the next boom section (2) is
0.019 - 0.059 in (0,5 - 1,5 mm).
MAE2120
• The wear pad inserts and mounting bolts MUST be
clean before mounting bolts are installed.
1. Park the machine on a firm, level surface. Place the
transmission in (N) NEUTRAL, engage the park brake • Refer to Section 2.6, “Thread Locking Compound”.
switch, retract and level the boom.
2. Inspect all wear pads for wear. If the angle indicators (1)
5
on the ends of the wear pads are not visible, or show
uneven wear, they should be replaced. Always replace
pads as a set. 4
MAM1390
• A spacer (3) with holes must be used before any

2 shim (4) is used.
• A shim (4) must inserted between the spacer (3) and
wear pad support plate, block or boom section (5).
• The number of shims can vary at each shim point.
MZ7661 • The bottom wear pads must be shimmed equally on
3. Measure all side and top wear pads for proper clearance. each side.
Acceptable total gap between the side/top wear pad(s) A
and the next boom section (2) is
0.019 - 0.059 in (0,5 -1,5 mm).
4. Shim each wear pad to within the above measurement B
if required.
MD1130
• The length of the wear pad bolt depends on the

number of shims, spacers and washers being used.
• The bolt length can be ± 0.004 in (±1,0 mm) from the
face of the insert.
TL642D, TL943D, TL1055D, TL1255D 31211036 3-35

Boom
• The bolt length should be determined by measuring 3.14 QUICK COUPLER

the distance from the face of the insert to the face of the
boom (B) including any spacer, shim(s) and washer(s).
• One or two hardened washers are to be used on each 3.14.1 Quick Coupler Removal
wear pad bolt except where noted otherwise. 1. Tilt coupler rearward to access coupler pin and lower to
DO NOT use more than two hardened washers. ground. Set park brake and turn off engine.
• Use only one hardened washer if mounting bolts are
recessed.
• Torque wear pad bolts as required.
• Lubricate the face and pockets of each wear pad after
being installed.
Boom Section Wear Pad Pathway Lubrication:
• Clean and lightly grease all wear pad pathways with
Multipurpose Grease.
• Clean and lightly grease the hose carrier guide bar 3
pathway with Multipurpose Grease.
1
3
2 MAG0520
6 5
2. If equipped, remove cover (5), clamp (7) and disconnect

the hydraulic attachment hoses (6) to the quick
disconnect fittings on the left side of the boom head.
3. Remove the bolt and washer (1) securing the rod end
tilt cylinder pin to the quick coupler assembly. Remove
the rod end pin (2).
3-36 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
4. Support the quick coupler assembly. Remove the bolt 3.15 FORKS
and nut (3) securing the quick coupler assembly to the
boom head. Remove the pin (4) from the quick coupler Forks should be cleaned and inspected prior to being
assembly. attached to carriage. If the following criteria is not met, forks
5. Inspect the above pins for nicks or surface corrosion. must be removed from service immediately.
Use fine emery cloth to fix minor nicks or corrosion. If
damaged or if it cannot be repaired the pin must be 3
replaced.
6
3.14.2 Quick Coupler Installation 5
7 4
1. Refer to Section 2.6, “Thread Locking Compound”.
2. Assemble the quick coupler to the boom head. Line up 2
the quick coupler between the mounts on the boom 1
head. The quick coupler should be centered in the
boom head. 6
3. Coat the quick coupler pivot pin with Anti-Seize Lube.
Insert the quick coupler pivot pin (9) through the quick
coupler and boom head. Secure with the previously 9
5
removed bolt and nut (8).
4. Align the quick coupler with the rod end tilt cylinder 8 MH6460
and insert the coupler pin (7). Secure with the
previously removed bolt and washer (8). Daily Inspection
5. If equipped, reconnect the hydraulic attachment hoses 1. Inspect forks (1) for cracks, paying special attention to
to the quick disconnect fittings on the left side of the heel (2) and mounting tubes (3).
boom head. 2. Inspect forks for broken or bent tips (4) and twisted
blades (5) and shanks (6).
Yearly Inspection
1. Straightness of the upper face of blade (5) and the front
face of shank (6) should not exceed 0.5 percent of the
length of blade or height of shank.
2. Angle (7) between upper face of blade and front face of
shank should not exceed 93 degrees.
3. Thickness of blade (5) and shank (6) should not be
reduced to 90 percent of original thickness.
Note: Contact the local Caterpillar dealer with the fork part
number to find the manufactured dimensions of the fork blade.
4. Ensure fork length (8) is adequate for intended loads.
5. Fork markings should be legible, re-stamp if required.
6. Compare fork tips (9) when mounted on a carriage.
Maximum difference in height of fork tips is 3 percent of
the length of the blade (8).
TL642D, TL943D, TL1055D, TL1255D 31211036 3-37

Boom
3.16 EMERGENCY BOOM LOWERING 3.16.2 Lowering Procedure without Precision

PROCEDURE Gravity Lower System (PGLS)
a. Retract the boom as follows:

WARNING 1. Remove the rear cover from the machine.
To avoid instability of the machine, the extend/retract 2. Place a suitable receptacle under the main control valve.
cylinder MUST BE fully retracted prior to retracting the
lift cylinder. If circumstances prevent retraction of the
extend/retract cylinder first, lower the lift cylinder the
minimum amount necessary and resume retraction of
the extend/retract cylinder as soon as possible.
3.16.1 Equipment and Supplies Required

without Precision Gravity Lower System
(PGLS)
4
Auxiliary Hydraulic Power Supply:
• Portable hydraulic unit or another machine with an
auxiliary hydraulic power supply with a capacity to 3
hold up to 9 gal (35 L) of hydraulic oil from the 2
machine during lowering process.
NOTICE 1
EQUIPMENT DAMAGE. Auxiliary Hydraulic Power
Supply hydraulic oil must be compatible with hydraulic
oil shown in Section 2.3, “Fluid and Lubricant Capacities”.
MD0471
Hoses: VIEW FROM REAR OF FRAME
• Two Hydraulic Hoses - Approximately 10 ft (3,0 m)

3. Label and disconnect the extend/retract cylinder
each, with a minimum I.D. of 0.375 in (9,5 mm) and a
hoses (1 and 2) from the main control valve. Install
minimum rating of 4000 psi(275,8 bar).
plugs in hoses to prevent fluid loss. Cap all fittings and
Fittings: openings to keep dirt and debris from entering the
• Two - ORFS/ORB 10 - 10 Caps hydraulic system.
• Two - ORFS/ORB 10 - 10 Plugs Note: Loss of hydraulic oil is limited to the amount trapped
Adaptors: within each hose.
• Two - ORFS/ORB 10 - 10 Adaptors 4. Using the hoses and fittings specified, connect the
hoses between the auxiliary hydraulic power supply
Note: Machine extend/retract and lift/lower hoses are - 8ORFS. and the hoses removed from the main control valve
The adaptor size may vary depending on the hose ends of the extend/retract section of the affected machine.
auxiliary hydraulic power supply.
5. Retract hose (2) is the supply and extend hose (1) is the
return. Connect the hoses in the proper order to ensure
that the cylinder is retracted, not extended.
6. Use the auxiliary power supply to retract the extend/
retract cylinder.
7. Loosen and remove the jumper hoses and reconnect
the extend/retract cylinder hoses.
8. Transfer any hydraulic oil into a suitable, covered
container, and label the container as “Used Oil”. Dispose
of used oil at an approved recycling facility.
3-38 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
9. Clean up all debris, hydraulic fluid, etc., in, on, near and 3.16.3 Equipment and Supplies Required with
around the machine. Precision Gravity Lower System (PGLS)
Auxiliary Hydraulic Power Supply:
b. Lower the boom as follows:
• Primary Portable hydraulic unit or another machine
1. Place a suitable receptacle under the main control valve. with an auxiliary hydraulic power supply with the
2. Label and disconnect the lift/lower cylinder capacity to hold up to 9 gal (35 L) of hydraulic oil
hoses (3 and 4) from the main control valve. Install from the machine during lowering process.
plugs in hoses to prevent fluid loss. Cap all fittings and • Secondary Portable hydraulic unit or compressed
openings to keep dirt and debris from entering the air source capable of producing, regulating and
hydraulic system. releasing pressure between 87 psi (6 bar) - 216 psi
Note: Loss of hydraulic oil is limited to the amount trapped (15 bar) of hydraulic pressure. A pressure gauge to
within each hose. monitor, vent and/or release applied pressure.
3. Using the hoses and fittings specified, connect the Note: A secondary portable hydraulic unit is required to
hoses between the auxiliary hydraulic power supply produce the required pilot pressure to aid in the lowering of the
and the hoses removed from the main control valve lift/ boom when equipped with PGLS.
lower section of the affected machine.
4. Hose (4) is the supply (lower) and hose (3) is the return.
Connect the hoses in the proper order to ensure that
NOTICE
the boom is lowered, not raised. EQUIPMENT DAMAGE. Auxiliary Hydraulic Power
Supply hydraulic oil must be compatible with hydraulic
5. Use the auxiliary power supply to lower the boom.
oil shown in Section 2.3, “Fluid and Lubricant Capacities”.
the lift/lower cylinder hoses. Hoses:
7. Transfer any hydraulic oil into a suitable, covered • Two Hydraulic Hoses - Approximately 10 ft (3,0 m)
container, and label the container as “Used Oil”. Dispose each, with a minimum I.D. of 0.375 in (9,5 mm) and a
of used oil at an approved recycling facility. minimum rating of 4000 psi(275,8 bar).
8. Clean up all debris, hydraulic fluid, etc., in, on, near and Fittings:
around the machine. • Two - ORFS/ORB 10 - 10 Caps
9. Install the previously removed rear cover. • Two - ORFS/ORB 10 - 10 Plugs
• One -ORFS/ORB 4-6 Cap
Adaptors:
• Two - ORFS/ORB 10 - 10 Adaptors
• One -ORFS/ORB 4-6 Tee
Note: Machine extend/retract and lift/lower hoses are - 8ORFS.
The adaptor size may vary depending on the hose ends of the
auxiliary hydraulic power supply.
TL642D, TL943D, TL1055D, TL1255D 31211036 3-39

Boom
3.16.4 Lowering Procedure with Precision 9. Clean up all debris, hydraulic fluid, etc., in, on, near and
Gravity Lower System (PGLS) around the machine.
a. Retract the boom as follows: b. Lower the boom as follows:

1. Remove the rear cover from the machine. 1. Place a suitable receptacle under the main control valve.
2. Place a suitable receptacle under the main control valve. 6
5
MD1470
2. Disconnect the PGLS pilot hose (5) from the main

MD0471
VIEW FROM REAR OF FRAME control valve. Install cap to the main control valve pilot
port fitting (6) to prevent fluid loss and keep dirt and
3. Label and disconnect the extend/retract cylinder debris from entering the hydraulic system.
hoses (1 & 2) from the main control valve. Install plugs
Note: Loss of hydraulic oil is limited to the amount trapped
in hoses to prevent fluid loss. Cap all fittings and
within each hose.
openings to keep dirt and debris from entering the
hydraulic system. 3. Connect the specified tee fitting to the PGLS pilot
hose (5) removed from the main control valve lift/lower
pilot port section of the affected machine.
within each hose.
4. Connect the secondary auxiliary power supply and a
4. Using the hoses and fittings specified, connect the digital pressure gauge to the open ends of the
hoses between the primary auxiliary hydraulic power previously installed tee fitting.
supply and the hoses removed from the main control
valve extend/retract section of the affected machine. Note: PGLS pilot pressure is NOT to exceed 216 psi (15 bar).
5. Retract hose (2) is the supply and extend hose (1) is the 5. Use the secondary auxiliary power supply, slowly apply
return. Connect the hoses in the proper order to ensure pressure to the PGLS pilot port hose. Do Not exceed 216
that the cylinder is retracted, not extended. psi (15 bar). To slow or stop the rate of decent, use the
6. Use the primary auxiliary power supply to retract the vent or release feature of the secondary power supply
extend/retract cylinder. to decrease the pilot pressure below 87 psi (6 bar).
7. Loosen and remove the jumper hoses and reconnect Note: If the boom fails to lower to a safe level when
the extend/retract cylinder hoses. following Step B, continue directly to Step C.
8. Transfer any hydraulic oil into a suitable, covered 6. With the boom lowered, relieve all PGLS pilot pressure,
container, and label the container as “Used Oil”. Dispose loosen and remove the secondary auxiliary power
of used oil at an approved recycling facility. supply, pressure gauge and tee fitting. Remove the cap
3-40 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom
from the main control valve pilot port fitting (6) and 6. Use the secondary auxiliary power supply, slowly apply
reconnect the PGLS pilot hose (5). pressure to the PGLS pilot port on the main control
7. Transfer any hydraulic oil into a suitable, covered valve.
container, and label the container as “Used Oil”. Dispose Note: PGLS pilot pressure is NOT to exceed 216 psi (15 bar).
7. Use the primary auxiliary power supply to lower the
8. Clean up all debris, hydraulic fluid, etc., in, on, near and boom.
around the machine.
8. With the boom lowered, relieve all PGLS pilot pressure,
9. Install the previously removed rear cover. loosen and remove the secondary auxiliary power
supply, pressure gauge, tee fitting and reconnect the
c. Lower the boom as follows (If Required): PGLS pilot hose (5) to the main control valve pilot port
1. Place a suitable receptacle under the main control valve. fitting (6).
6
the lift/lower cylinder hoses (3 & 4).
5
10. Transfer any hydraulic oil into a suitable, covered
container, and label the container as “Used Oil”. Dispose
11. Clean up all debris, hydraulic fluid, etc., in, on, near and
4 around the machine.
12. Install the previously removed rear cover.
MD1520
2. Relieve all PGLS pilot pressure (5) from the previously

installed secondary auxiliary hydraulic power supply.
3. Label and disconnect the lift/lower cylinder
hoses (3 and 4) from the main control valve. Install
plugs in hoses to prevent fluid loss. Cap all fittings and
openings to keep dirt and debris from entering the
hydraulic system.
within each hose.
4. Using the hoses and fittings specified, connect the
hoses between the primary auxiliary hydraulic power
supply and the hoses removed from the main control
valve lift/lower section of the affected machine.
5. Hose (4) is the supply (lower) and hose (3) is the return.
Connect the hoses in the proper order to ensure that
the boom is lowered, not raised.
TL642D, TL943D, TL1055D, TL1255D 31211036 3-41

Boom
3.17 TROUBLESHOOTING
This section provides an easy reference guide covering the
most common problems that occur during operation of the
boom.
Problem Possible Causes Remedy

1. Boom will not extend or retract. 1. Broken hydraulic hose(s) or 1. Locate break, replace hose(s) or
tube(s) and/or connections tube(s), tighten connections.
leaking. 2. Refer to Section 8.5, “Hydraulic
2. Extend/retract hydraulic system Circuits”.
not operating properly. 3. Repair cylinder. Refer to
3. Faulty extend/retract cylinder. Section 8.13.1, “General Cylinder
4. Electrical System not operating Removal Instructions”.
properly. 4. Refer to Section 9.5, “Electrical
System Schematics”.
2. Boom shifts to right or left when 1. Boom side wear pads improperly 1. Shim wear pads to correct gap.
extending. shimmed or worn. Replace wear pads as needed.
Refer to Section 3.13, “Boom Wear
Pads”.
3. Excessive pivot pin noise and/or 1. Insufficient lubrication. 1. Lubricate at regular intervals.
wear. Refer to Section 2.5, “Lubrication
Schedule”. Replace worn pins as
needed.
2. Worn bearing(s). 2. Replace bearing(s) and lubricate

at regular intervals. Refer to
Section 2.5, “Lubrication
Schedule”.
4. Excessive compensation 1. Insufficient lubrication. 1. Lubricate at regular intervals.

cylinder pivot pin noise and/or Refer to Section 2.5, “Lubrication
wear. Schedule”. Replace worn pins as
needed.
2. Worn bushing(s). 2. Replace bushing(s) and lubricate

at regular intervals.
5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s) or
and/or connection leaks. tube(s), tighten connections.
2. Lift/lower hydraulic system not 2. Refer to Section 8.5, “Hydraulic
operating properly. Circuits”.
3. Faulty lift/lower cylinder. 3. Repair cylinder. Refer to
4. Seized boom pivot pin bushing. Section 8.13.1, “General Cylinder
Removal Instructions”.
5. Electrical System not operating
properly. 4. Replace bushing.
5. Refer to Section 9.5, “Electrical
3-42 31211036 TL642D, TL943D, TL1055D, TL1255D

Boom

6. Drooping chain, or jerky boom 1. Chain(s) tension not properly 1. Adjust chain(s).
extend or retract functions. adjusted.
2. Chain(s) stretched or binding. 2. Replace chains as needed. Refer to

Section 3.3, “Boom Removal/
Installation”.
3. Wear pads loose, contaminated, 3. Replace wear pad. Refer to

excessively worn or damaged. Section 3.13, “Boom Wear Pads”
4. Contaminated, corroded or rusted 4. Remove contamination and/or

wear pad sliding surfaces. corrosion from wear pad sliding
surfaces and lubricate.If the
surfaces cannot be reconditioned,
replace the boom section(s)
5. Extend/Retract hydraulic system 5. Refer to Section 8.5, “Hydraulic

not operating properly. Circuits”.
6. Damaged boom section. 6. Replace the damaged boom

section.
7. Excessive Lift/Lower cylinder 1. Insufficient lubrication. 1. Lubricate at regular intervals.

pivot pin noise and/or wear. Refer to Section 2.4, “Service and
Maintenance Schedules”. Replace
worn pins as needed. Refer to
Section 8.13.1, “General Cylinder
Removal Instructions”.
2. Worn self-aligning bushing(s). 2. Replace bushing(s) and lubricate

at regular intervals. Refer to
Section 2.5, “Lubrication
Schedule”.
8. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct
as needed. Refer to Section 3.13,
“Boom Wear Pads”.
2. Rapid cycle times with heavy 2. Reduce cycle times.

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

wear pad sliding surfaces. corrosion from wear pad sliding
surfaces and lubricate. If the
surfaces cannot be reconditioned,
replace the boom section(s).
4. Operating in extremely dusty/ 4. Clean equipment frequently.

abrasive conditions.
9. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8.5, “Hydraulic
operate. operating properly. Circuits”.
TL642D, TL943D, TL1055D, TL1255D 31211036 3-43

Boom

10. Excessive chain wear. 1. Improper chain adjustment. 1. Adjust to correct tension. Refer to
Section 3.12, “Boom Extend and
Retract Chains” - Replace chains as
needed.
2. Chain sheave(s) not properly 2. Lubricate chain sheave. Refer to

lubricated. Section 2.4, “Service and
Maintenance Schedules”.
3. Chain sheave(s) not rotating 3. Lubricate chain sheave. Refer to

freely. Section 2.4, “Service and
Maintenance Schedules”. Repair
or replace chain sheave(s) as
needed.
4. Improper chain lubrication. 4. Lubricate at regular intervals.

Refer to Section 2.4, “Service and
Maintenance Schedules”. Replace
chains as needed.
3-44 31211036 TL642D, TL943D, TL1055D, TL1255D

Section 4
Cab
Contents

4.1 Operator Cab Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 Operator Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.2 Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.1 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.2 Steering Column/Orbital Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.3 Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.4 Electronic Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.5 Joystick Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.6 Window Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.7 Heater System (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.8 Heater and Air Conditioning System (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
TL642D, TL943D, TL1055D, TL1255D 31211036 4-1

Cab
4.1 OPERATOR CAB COMPONENT

TERMINOLOGY
To understand safety, operation and maintenance
operator/mechanic be familiar with names and locations of
major assemblies of machine cab. The following illustration
identifies components that are referred to throughout this
section.
FRAME LEVEL
INDICATOR
STEERING
WHEEL MULTIFUNCTIONAL
DISPLAY PANEL
INSTRUMENT (IF EQUIPPED)
PANEL DISPLAY
TRANSMISSION
CONTROL LEVER ACCESSORY CONTROL
LEVER
LEFT DASH RIGHT DASH
CONTROL PANEL CONTROL PANEL
JOYSTICK
IGNITION
SWITCH
PARK BRAKE FRAME LEVEL

SWITCH SWITCH
ACCELERATOR
PEDAL
OUTRIGGER
SERVICE BRAKE CONTROLS
PEDAL (IF EQUIPPED)
MAG1410
4-2 31211036 TL642D, TL943D, TL1055D, TL1255D

Cab
4.2 OPERATOR CAB 4.3 CAB COMPONENTS
4.3.1 Steering Wheel

WARNING a. Steering Wheel Removal
DO NOT service the machine without following all safety 1. Park machine on a firm, level surface, level machine,
precautions as outlined in the Section 1, “Safety fully retract boom, lower boom, place transmission in
Practices”, section of this manual. (N) NEUTRAL, engage park brake and shut engine OFF.
2. Place a Do Not Operate Tag on both ignition key switch
4.2.1 Operator Cab Safety and steering wheel.
3. Open engine covers. Allow system fluids to cool.
WARNING 4. Properly disconnect the battery. Refer Section 9.8,
“Battery”, for procedure.
The protection offered by this ROPS/FOPS will be
impaired if subjected to any modification or structural 1
damage, at which time replacement is necessary. 2
ROPS/FOPS must be properly installed using fasteners of
correct size, grade, and torqued to their specified value.
WARNING
DO NOT weld, grind, drill, repair or modify the cab in any
way. Any modification or damage to cab structural
3
components requires cab replacement.
Refer to the appropriate parts manual for ordering
information. 4
4.2.2 Serial Number Plate

The cab serial number plate is located on the left side of the 5. Carefully pry horn button (1) out of steering wheel (2).
cab, below the seat. Information specified on the serial
6. Remove horn wire (3) from back of horn button.
number plate includes the cab model number, the cab serial
number and other data. Write this information down in a 7. Mark steering wheel and shaft to ensure proper
convenient location to use in cab correspondence. installation. Remove nut (4) securing the steering
wheel (2) to splined steering column shaft.
8. Use a steering wheel puller to remove steering wheel (2)
from splined shaft.
b. Steering Wheel Installation

1. Install steering wheel (2) onto splined steering column
shaft.
2. Secure steering wheel with nut (4). Torque as required.
3. Connect the previously removed horn connector (3).
4. Press the horn button (1) onto steering wheel.
5. Properly connect the battery. Refer Section 9.8,
6. Close and secure engine covers.
7. Remove Do Not Operate Tag from ignition key switch
and steering wheel.
TL642D, TL943D, TL1055D, TL1255D 31211036 4-3

Cab
4.3.2 Steering Column/Orbital Valve 9. If equipped, remove windshield washer assembly (8),
heater cover and heater assembly (9). Refer to
a. Steering Column and Orbital Valve Removal Section 4.3.7, “Heater System (if equipped)”.
1. Park machine on a firm, level surface, level machine, 10. Slowly turn surge tank cap to first stop and allow any
fully retract boom, lower boom, place transmission in pressure to escape. Remove surge tank cap.
(N) NEUTRAL, engage park brake and shut engine OFF. 11. Place a suitable container beneath radiator drain.
2. Place a Do Not Operate Tag on both ignition key switch 12. Place a funnel at base of radiator to channel drained
and steering wheel. coolant into a container. Open drain plug and slowly
3. Open engine cover. Allow system fluids to cool. remove to allow coolant to drain. Transfer coolant into a
properly labeled container. Dispose of properly if
coolant needs replaced. Replace surge tank cap. Close
radiator drain plug.
5. Remove lower dash panel in cab.
5
10 MD0580
13. Label, disconnect and cap hydraulic tubes (10) attached

6 to orbital valve.
MAE2760
6. If equipped, remove the windshield wiper assembly (5).

7. Remove cab air filter cover (6).
8. Remove access covers from front of cab (7).
9
MD0570
4-4 31211036 TL642D, TL943D, TL1055D, TL1255D

Cab
14. Remove steering wheel. Refer to Section 4.3.1, “Steering 5. Install previously removed steering wheel. Refer to
Wheel”. Section 4.3.1, “Steering Wheel”, for detailed installation
instructions.
11
6. If equipped, install heater (8) and windshield washer
assembly (9).
7. Open surge tank cap and fill the radiator completely
with coolant. Replace and tighten surge tank cap. Refer
to Section 2.3, “Fluid and Lubricant Capacities”, for
proper capacities.
9. Start engine and check operation of steering system.
Check for hydraulic fluid leaks. Check hydraulic fluid
level in tank and add fluid as required.
10. Install access covers to front of cab.
11. Install lower dash panel in cab.
12. Close and secure engine cover.
12 13 10 13. Remove Do Not Operate Tag from ignition key switch
15. Disconnect and remove the transmission control and steering wheel.
lever (11), and if equipped accessory control lever.
Disconnect control lever(s) harness from the main cab c. Steering Test
harness. Conduct a pressure check of the steering hydraulic circuits.
16. Label, disconnect and cap hydraulic tubes (10) attached Refer to Section 8.4.1, “Pressure Checks and Adjustments”.
to orbital valve.
17. Remove four bolts (12) securing orbital valve
bracket (13) to cab.
18. Remove the steering column assembly through the
dash panel opening.
19. Lift rubber cover and remove four bolts securing orbital
valve bracket (13) and steering column.
Note: DO NOT disassemble orbital valve. The orbital valve is
not serviceable and must be replaced in its entirety, if defective.
b. Steering Column and Orbital Valve Installation

1. Secure the steering column to bracket and valve with
previously removed hardware. Torque as required.
2. Install orbital assembly to original orientation in cab.
Secure with the previously remove four bolts (12).
Torque as required.
3. Install transmission control lever, and if equipped,
accessory control lever. Connect control lever(s) harness
connector to main cab harness and install steering wheel
assembly.
4. Uncap and connect previously labeled hydraulic hoses
to orbital valve.
TL642D, TL943D, TL1055D, TL1255D 31211036 4-5

Cab
4.3.3 Service Brake 11. Place a funnel at base of radiator to channel drained
coolant into a container. Open drain plug and slowly
a. Brake Valve Removal remove to allow coolant to drain. Transfer coolant into a
Refer to Section 8.9.3, “Service Brake Valve”, for removal
information.
b. Brake Valve Installation
Refer to Section 8.9.3, “Service Brake Valve”, for installation
information.
4.3.4 Electronic Throttle Pedal
a. Throttle Pedal Removal

1. Park machine on a firm, level surface, level machine fully
retract boom, lower boom, place transmission in
(N) NEUTRAL, engage park brake and shut engine OFF. 14 MD0600
2. Place a Do Not Operate Tag on both ignition key switch 12. Remove hardware (14) securing pedal assembly.
and steering wheel.
15
5
16
7
MD0590
13. Disconnect electrical connection (15) to pedal

assembly (16).
14. Remove throttle pedal assembly from cab.
6 b. Throttle Pedal Installation

MAE2760
1. Position throttle pedal in its mounting location in cab.
5. If equipped, remove the windshield wiper assembly (5). 2. Reconnect electrical connection to pedal assembly.
6. Remove cab air filter cover (6). 3. Secure throttle pedal into position with previously used
7. Remove access covers from front of cab (7). hardware (14).
8. If equipped, remove heater and windshield washer 4. If equipped, install heater and windshield washer
assembly. assembly.
9. Slowly turn surge tank cap to first stop and allow any 5. Open surge tank cap and fill the radiator completely
pressure to escape. Remove surge tank cap. with coolant. Replace and tighten surge tank cap. Refer
10. Place a suitable container beneath radiator drain.
proper capacities.
6. Install protective covers.
4-6 31211036 TL642D, TL943D, TL1055D, TL1255D

Cab
7. Properly connect the battery. Refer Section 9.8, b. Joystick Assembly Installation
1. Connect previously labeled electrical connectors
8. Close and secure engine cover. to joystick.
9. Remove Do Not Operate Tag from ignition key switch 2. Secure joystick assembly to cab using previously
and the steering wheel. removed hardware.
3. Seat rubber boot to joystick base.
4.3.5 Joystick Assembly
a. Joystick Assembly Removal “Battery”, for procedure.
1. Park machine on a firm, level surface, level machine fully 5. Test joystick functions.
retract boom, lower boom, place transmission in 6. Close and secure engine cover.
(N) NEUTRAL, engage park brake and shut engine OFF. 7. Remove Do Not Operate Tag from ignition key switch
2. Place a Do Not Operate Tag on both ignition key switch and steering wheel.
and steering wheel.
3. Open engine cover. Allow system fluids to cool. 4.3.6 Window Wiper Assembly
4. Properly disconnect the battery. Refer Section 9.8, Refer to Section 9.10, “Window Wiper System (if equipped)”,
“Battery”, for procedure. for removal and installation information.
4.3.7 Heater System (if equipped)
a. Removal
1. Park machine on a firm, level surface, level machine fully
(N) NEUTRAL, engage park brake and shut engine OFF.
and steering wheel.
17 4. Properly disconnect the battery. Refer Section 9.8,
5. Place a suitable container beneath radiator. Slowly turn
surge tank cap and allow any pressure to escape.
18 Remove surge tank cap.
6. Place a funnel at base of radiator to channel drained
coolant into container. Remove drain plug and allow
coolant to drain.
19
MD0610
7. Transfer coolant to a container with a cover, and label as
5. Raise rubber boot (17) from base of joystick. “Used Coolant”. Dispose of used coolant at an approved
recycling facility.
6. Remove hardware securing joystick assembly (18).
8. Tighten radiator drain plug.
7. Lift joystick from its mounting position.
8. Label and disconnect electrical connector (19) attached
to joystick.
9. Remove joystick assembly.
TL642D, TL943D, TL1055D, TL1255D 31211036 4-7

Cab
20
MD0620
9. Remove heater cover (20) inside cab.

5
21
22
MAE3810
6
13. Label and disconnect heater (21) electrical connections.
MAE2760
14. Label and remove hoses (22) connected to heater.
15. Remove bolts securing heater assembly to cab. Remove
11. Remove access covers (6 and 7) from front of cab. heater assembly.
12. If equipped, remove windshield washer assembly.
b. Installation
1. Position heater assembly to original orientation to cab.
Secure with previously removed hardware.
2. Connect previously labeled electrical connections.
3. Connect previously labeled heater hoses to appropriate
locations.
4. If equipped, connect previously labeled air conditioning
hoses to appropriate locations.
5. Fill cooling system completely with coolant, allowing
time for the coolant to fill the engine block. The cooling
system capacity is listed in Section 2.3, “Fluid and
Lubricant Capacities”.
4-8 31211036 TL642D, TL943D, TL1055D, TL1255D

Cab
6. Properly connect the battery. Refer Section 9.8, 7. If equipped, remove windshield washer assembly.
7. Start engine, run it briefly at low idle and check machine
for any visual sign of fluid leakage.
Note: STOP engine immediately if any leakage is noted, and
make any necessary repairs before continuing.
8. Wait for engine to cool and check coolant level. Add
coolant as required to bring coolant to proper level.
9. If equipped, install windshield washer assembly. 8
10. Install protective covers.
11. Install heater cover inside cab.
12. Close and secure the engine cover.
and steering wheel.
9
MD0570
4.3.8 Heater and Air Conditioning System
(if equipped) 8. If equipped, remove windshield washer assembly (8)
and heater cover (9).
a. Removal 9. Place a suitable container beneath radiator. Slowly turn
1. Park machine on a firm, level surface, level machine, surge tank cap and allow any pressure to escape.
fully retract boom, lower boom, place transmission in Remove surge tank cap.
(N) NEUTRAL, engage park brake and shut engine OFF. 10. Place a funnel at base of radiator to channel drained
2. Place a Do Not Operate Tag on both ignition key switch coolant into container. Remove drain plug and allow
and steering wheel. coolant to drain.
3. Open engine covers. Allow system fluids to cool. 11. Transfer coolant to a container with a cover, and label as
“Used Coolant”. Dispose of used coolant at an approved
4. Properly disconnect the battery. Refer
recycling facility.
Section 9.8, “Battery”, for procedure.
12. Tighten radiator drain plug.
5
13. Drain the refrigerant from the air conditioning system.
Note: The local Caterpillar dealer or certified air conditioning
service center or personnel to perform the refrigerant removal
from the system.
6
MAE2760
5. If equipped, remove windshield wiper assembly (5).

6. Remove access covers (6 and 7) from front of cab.
TL642D, TL943D, TL1055D, TL1255D 31211036 4-9

Cab
b. Installation
25
1. Install cab condenser assembly (25) to cab roof. Secure
with previously removed hardware.
2. Connect previously labeled electrical connections to
24 the condenser assembly (25).
3. Connect previously labeled hoses (24) to condenser
assembly (25).
4. Position heater and air conditioning assembly (21) to
original orientation to cab. Secure with previously
removed hardware.
5. Connect previously labeled electrical connections to
heater and air conditioning assembly.
6. Connect previously labeled heater hoses (23) to
appropriate locations.
7. Connect previously labeled air conditioning hoses (22)
to appropriate locations.
time for the coolant to fill the engine block. The cooling
system capacity is listed in Section 2.3, “Fluid and
9. Fill air conditioning system completely with refrigerant.
Refer Section 2.3, “Fluid and Lubricant Capacities”, for
refrigerant type and capacity.
22
21 Note: The local Caterpillar dealer or certified air conditioning
service center or personnel to perform the refrigerant
installation to the system.
23 11. Start engine, run it briefly at low idle and check machine
for any visual sign of fluid leakage.
MAE5310
Note: STOP engine immediately if any leakage is noted, and
14. Label and disconnect hoses (24) attached to the make any necessary repairs before continuing.
condenser assembly (25).
12. Wait for engine to cool and check coolant level. Add
15. Label and disconnect all electrical connections attached coolant as required to bring coolant to proper level.
to the condenser assembly.
13. If equipped, install windshield washer assembly.
16. Remove bolts securing the condenser assembly (25) to
14. Install protective cover.
cab roof. Remove condenser assembly from rear of the
cab roof. 15. If equipped, install windshield wiper assembly (5).
17. Label and disconnect all electrical connections attached 16. Close and secure the engine cover.
to the heater and air conditioning assembly (21). 17. Remove Do Not Operate Tag from ignition key switch
18. Label and remove hoses (22) connected to the heater and steering wheel.
and air conditioning assembly (21).
19. Label and disconnect air conditioning hoses (23)
attached to heater assembly.
20. Remove bolts securing heater assembly to cab. Remove
heater assembly.
4-10 31211036 TL642D, TL943D, TL1055D, TL1255D

Cab
4.4 CAB REMOVAL 7. Replace and tighten drain plug.
WARNING
The protection offered by this ROPS/FOPS will be
impaired if subjected to any modification or structural
damage, at which time replacement is necessary.
ROPS/FOPS must be properly installed using fasteners of
correct size and grade, and torqued to their specified
value.
Note: To help ensure safety and optimum performance,

replace cab if it is damaged. Refer to appropriate parts manual
for ordering information.
Inspect cab, its welds and mounts. If modification, damage,
a cracked weld and/or fatigued metal is discovered, replace
cab. Contact local Caterpillar dealer with any questions about
MD0640
suitability or condition of a cab. 3 2 1 4 5
Note: Remove and label cab components as needed before 8. Label and disconnect cab heater hoses (1). Refer to
removing cab from machine. Label, disconnect and cap Section 4.3.7, “Heater System (if equipped)”.
hydraulic hoses. Transfer cab parts to replacement cab after
9. Label and disconnect cab AC hoses (2). Refer to
replacement cab is securely mounted on machine.
Section 4.3.8, “Heater and Air Conditioning System (if
1. Park machine on a firm, level surface. Allow sufficient equipped)”.
overhead and side clearance for cab removal. Level 10. Label, disconnect and cap all hydraulic hoses attached
machine, fully retract boom, lower boom, place to the steering orbital valve (3). Cap all fittings and
transmission in (N) NEUTRAL, engage park brake and openings to keep dirt and debris from entering
shut engine OFF. hydraulic system.
2. Block all four wheels to help prevent machine from 11. Label, disconnect and cap all hydraulic hoses attached
moving. Assure that there is sufficient overhead and to the brake assembly (4). Cap all fittings and openings
side clearance for cab removal. to keep dirt and debris from entering hydraulic system.
3. Open engine cover. Allow system fluids to cool. 12. Label, disconnect and all electrical connections (5)
4. Properly disconnect the battery. Refer Section 9.8, attached to the cab.
5. Place a funnel at base of cooling system to channel
drained coolant into suitable container. Remove drain
plug and allow coolant to drain.
6. Transfer coolant to a container with a cover, and label as
“Used Antifreeze”. Dispose of used coolant at an
approved recycling facility.
TL642D, TL943D, TL1055D, TL1255D 31211036 4-11

Cab
16. Use a hoist or overhead crane and sling with a total

minimum lifting capacity of 1200 lb (545 kg) attached to
7 the four eye bolts. DO NOT attempt to lift the cab at this
point.
17. Remove four nuts, bolts, washers (9) securing cab to
frame.
18. Remove mirrors and all other cab components as
needed, if not previously removed.
19. When all wiring, hydraulic hoses and fasteners are
disconnected or removed, carefully and slowly lift cab
and remove it from frame. Readjust position of sling as
needed to help balance cab during removal.
20. When cab is completely clear of machine, carefully
lower it to ground. Block up or support cab so it does
not move or fall.
21. Assure that no personnel enter cab while it is being
6 6 MD0650 removed from machine.
22. Inspect and replace machine parts that are exposed
13. Remove rear cab covers (6) and securing hardware.
with cab removed. Repair or replace as required.
14. If equipped, label and disconnect the air conditioning
connections (7). Move the hoses clear of the cab to
prevent damage during cab removal.
9
MD0660
15. Install four lifting eye bolts with a total minimum lifting
capacity of 1200 lb (545 kg) in the existing lifting holes
at the top corners of the cab (8).
4-12 31211036 TL642D, TL943D, TL1055D, TL1255D

Cab
4.5 CAB INSTALLATION 14. Wait for engine to cool and check coolant level. Add
coolant as required to bring coolant to proper level.
1. Block all four wheels to help prevent machine from 15. Install protective covers to front of cab.
moving. Assure that there is sufficient overhead and
side clearance for cab installation. 16. Install the mirrors and all other cab components as
needed, if removed.
2. Attach a sling with a total minimum lifting capacity of
1200 lb (545 kg) through lifting eyes of cab. 17. Install protective cover to rear of cab.
3. Use a hoist or overhead crane and sling attached to cab. 18. Unblock wheels.
Carefully begin to align cab with mounting holes in 19. Close and secure engine cover.
frame. Stop and check that wiring, hydraulic hoses, 20. Remove Do Not Operate Tag from ignition key switch
cables, etc., will not be pinched or damaged as cab is and steering wheel.
positioned. Readjust position of sling as needed to help
balance cab during installation.
4. Install four cab to frame mount washers, bolts and nuts to
270–350 Nm (199–258 lb-ft).
5. Connect previously labeled cab harness connectors to
their appropriate locations.
6. Uncap and reconnect previously labeled hydraulic
hoses to their appropriate locations.
7. Reconnect any remaining electrical connections to their
appropriate locations.
8. Reconnect AC hoses to cab AC. Refer to Section 4.3.8,
“Heater and Air Conditioning System (if equipped)”.
9. Reconnect heater hoses to cab heater. Refer to
Section 4.3.7, “Heater System (if equipped)”.
time for coolant to fill engine block. Cooling system
capacity is listed in Section 2.3, “Fluid and Lubricant
Capacities”.
12. Carefully examine all cab components, fasteners, etc.,
before engine start-up. Rectify any faulty conditions.
13. Start engine and check operation of all controls. Check for
hydraulic fluid leaks. Check hydraulic fluid level in tank
and add fluid as required.
Note: When engine is initially started, run it briefly at low idle
and check machine for any visual sign of fluid leakage. STOP
engine immediately if any leakage is noted. Make any
necessary repairs before continuing.
TL642D, TL943D, TL1055D, TL1255D 31211036 4-13

Cab
4-14 31211036 TL642D, TL943D, TL1055D, TL1255D

Section 5
Axles, Drive Shafts, Wheels and Tires
Contents

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3 Axle Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4 Axle Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4.1 Axle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4.2 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.5 Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6 Steering Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.7 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.8 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.8.1 Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.8.2 Drive Shaft Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.8.3 Drive Shaft - TL642D, TL943D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.8.4 Drive Shaft - TL1055D, TL1255D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.9 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.9.1 Removing Wheel and Tire Assembly from Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.9.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.10 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.10.1 Manually Releasing the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.10.2 Manually Resetting the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
TL642D, TL943D, TL1055D, TL1255D 31211036 5-1

5.1 AXLE, DRIVE SHAFT AND WHEEL

COMPONENT TERMINOLOGY
operator/mechanic be familiar with the names and locations
of the major assemblies of the axles, drive shafts, wheels and
tires. The following illustration identifies the components
that are referred to throughout this section.
TL642D, TL943D
REAR AXLE
ASSEMBLY
TRANSMISSION
REAR STEERING
CYLINDER
FRONT STEERING
CYLINDER
REAR DRIVE
SHAFTS REAR AXLE WHEEL
HUBS
FRONT DRIVE
SHAFT
FRONT AXLE WHEEL

HUBS
FRONT AXLE
ASSEMBLY
MAG1520
5-2 31211036 TL642D, TL943D, TL1055D, TL1255D

TL1055D, TL1255D
REAR AXLE
ASSEMBLY
REAR STEERING
TRANSMISSION CYLINDER
CARRIER
BEARING
FRONT STEERING
CYLINDER
REAR AXLE WHEEL

HUBS
REAR DRIVE
SHAFTS
FRONT DRIVE
SHAFT
FRONT AXLE WHEEL

HUBS
FRONT AXLE
ASSEMBLY
TL642D, TL943D, TL1055D, TL1255D 31211036 5-3

5.4 AXLE REPLACEMENT

WARNING
5.4.1 Axle Removal
DO NOT service the machine without following all safety
precautions as outlined in Section 1, “Safety Practices”, of
this manual. WARNING
5.2 AXLE SERIAL NUMBER An improperly supported machine can fall. Safely raise
and adequately support the machine so that it will
Front and rear axle serial number plate is located on the remain stable and in place before attempting to remove
inside of each axle on right side of the center section. an axle.
Information on the serial number plate is required in
The front and rear axle assemblies differ in that front axle
correspondence regarding the axle.
assembly is equipped with a parking brake mechanism and
Supply information from the axle serial number plate when a limited slip feature; rear axle has neither. The following
communicating about the axle assembly or the axle steps outline a typical axle removal procedure, suitable for
components. either front or rear axle assembly.
Cleanliness is extremely important. Before attempting to
5.3 AXLE SPECIFICATIONS AND remove the axle, thoroughly clean the machine. Avoid
MAINTENANCE INFORMATION spraying water or cleaning solution on electrical
components. If using a steam cleaner, seal all openings
For axle, oil specifications and maintenance information, before steam cleaning.
refer to Section 2.3, “Fluid and Lubricant Capacities”.
Note: Clear the work area of all debris, unnecessary personnel,
Refer SIS Web for detailed axle service instructions.
etc. Allow sufficient space to raise the machine and to remove
the axle.
1. Park machine on a firm, level surface, level machine, fully
(N) NEUTRAL, engage parking brake, and shut engine
OFF.
and steering wheel.
3. Open engine cover. Allow system fluids to cool.
5. Remove bolts securing fender assembly to axle.
5-4 31211036 TL642D, TL943D, TL1055D, TL1255D

Note: The wheel and tire assemblies must be re-installed later

3 with the directional tread pattern “arrows” facing in the
4 4 direction of forward travel.
13. Remove the drive shaft assembly. Refer to Section 5.8.3,
“Drive Shaft - TL642D, TL943D” or Section 5.8.4, “Drive
Shaft - TL1055D, TL1255D”.
14. On front axle, remove capscrew and locknuts securing
lower position cylinder-mount pin to the front cylinder.
Tap the cylinder mount pin out, and move the cylinder
to prevent it from interfering with axle removal.
15. Remove bolts and locknuts securing axle to frame.
MAG1551
1 16. Remove axles from machine using jack, hoist or

overhead crane and sling supporting axle. DO NOT raise
or otherwise disturb machine while removing axle.
Balance axle and prevent it from tipping, turning or
falling while removing it from beneath machine. Place
the axle on a suitable support or holding stand.
2 5.4.2 Axle Installation

1. If applicable, raise machine using a suitable jack or hoist.
Place suitable supports beneath the frame and lower
the machine onto the supports, allowing enough room
MAG1570
for axle installation.
2. Before proceeding, ensure machine will remain in place
6. Loosen and remove the axle oil fill plug (3) and check fill during axle installation.
plugs (4).
3. Block front and rear of both tires on axle that is already
7. If axle will be disassembled after removal, place a installed on machine.
suitable receptacle under axle (1) and wheel hub (2)
4. Using a suitable jack, hoist or overhead crane and sling,
drain plugs. Remove drain plugs and allow oil to drain
remove axle from its support or holding stand. Balance
into receptacle. Transfer used oil into a suitable covered
axle and prevent it from tipping, turning or falling while
container, and label container as “Used Oil”. Dispose of
positioning it beneath machine. DO NOT raise or
used oil at an approved recycling facility.
otherwise disturb machine while installing the axle.
8. Label, disconnect and cap steering and brake lines at
5. Keep axle supported and balanced on the jack, hoist or
axle. Wipe up any spilled oil.
overhead crane and sling throughout the installation
9. Block front and rear of both tires on axle that is not procedure.
being removed. Ensure that machine will remain in
6. Position axle under frame, and align axle housings with
place during axle removal before proceeding.
holes in frame.
10. Raise machine using a suitable jack or hoist. Place
7. Refer to Section 2.6, “Thread Locking Compound”, for all
suitable supports under both sides of frame and lower
thread locking requirements.
machine onto supports. Ensure that machine will
remain in place during axle removal. 8. Install axle mounting bolts and nuts. Tighten and torque
as required.
11. Support axle that is being removed with a suitable jack,
hoist or overhead crane and sling. DO NOT raise axle or 9. Install the drive shaft assemblies. Refer to Section 5.8.3,
machine. “Drive Shaft - TL642D, TL943D” or Section 5.8.4, “Drive
12. Remove both the wheel and the tire assemblies
from the axle that is being removed. Refer to 10. If reinstalling an axle previously removed from machine,
Section 5.9.1, “Removing Wheel and Tire Assembly from position driveshaft yoke on axle according to alignment
Machine”. marks made earlier.
TL642D, TL943D, TL1055D, TL1255D 31211036 5-5

11. If installing a new axle, note position of driveshaft yoke 20. Install new o-rings into fittings. Lubricate o-rings with
at transmission. Align driveshaft yoke on axle in same clean hydraulic oil.
plane as yoke on transmission. 21. Uncap and connect steering and brake lines at their axle
12. Connect the steering and brake lines at axle. fittings.
22. Check hydraulic reservoir oil level.
3 23. Start engine. Turn steering wheel several times lock to
4 lock, operate frame tilt function several times in both
4 directions and check function of brakes. Check for
hydraulic leaks, and tighten or repair as necessary.
24. Install fender assembly. Torque as required.
MAG1551
1 and steering wheel.
13. Tighten axle oil drain plugs (1). Fill until oil level reaches Note: Service brake circuit will need to bled after axle
bottom of check fill Plug. Refer to Section 2.3, “Fluid and installation. Refer to Section 8.9.4, “Service Brake Bleeding”, for
Lubricant Capacities”, for proper oil and capacities. detailed instructions.
5.5 BRAKE INSPECTION

Detailed axle service instructions are provided in the Axle
2 Service Manual, refer to Section 5.3, “Axle Specifications and
Maintenance Information”.
5.6 STEERING ANGLE ADJUSTMENT

Detailed axle service instructions are provided in the Axle
Service Manual, refer to Section 5.3, “Axle Specifications and
Maintenance Information”. Refer to Section 2.2.4, “Steering
Angle Specifications”, for steering angle information.
MD0150
14. Rotate wheel hubs 90 degrees so wheel hub drain plug

becomes the fill plug (2). Refer to Section 2.3, “Fluid and
Lubricant Capacities”, for proper oil and capacities.
15. Install and tighten the axle oil fill plug (3) and check fill
plugs (4).
16. Install the wheel and tire assemblies. Refer to
Section 5.9.2, “Installing Wheel and Tire Assembly onto
Machine”.
17. Carefully remove jack, hoist or overhead crane and sling
supporting axle.
18. Carefully raise machine using a suitable jack or hoist.
Remove supports from beneath the frame and lower
machine to ground.
19. Remove blocks from front and rear of both tires on
other axle.
Note: ALWAYS use new o-rings when servicing machine.
5-6 31211036 TL642D, TL943D, TL1055D, TL1255D

5.7 AXLE ASSEMBLY AND DRIVE SHAFT TROUBLESHOOTING

1. Excessive axle noise while 1. Oil level too low. 1. Fill oil to correct level. Refer to
driving. Section 2.3, “Fluid and Lubricant
Capacities”.
2. Axle and/or wheel end housings 2. Drain axle and/or wheel end
filled with incorrect oil or oil level housings and fill to correct level.
low. Refer to Section 2.3, “Fluid and
3. Incorrect alignment of ring and 3. Correct alignment by adding or

pinion gears. removing shims as needed.
4. Incorrect pinion (input) shaft 4. Correct bearing preload by

bearing preload. adding or removing shims as
needed.
5. Worn or damaged bearings. 5. Replace bearings as needed.
6. Worn or broken gear teeth. 6. Replace gears as needed.
7. Contamination in the axle. 7. Drain axle and/or wheel end

housings and fill to correct level.
Refer to Section 2.3, “Fluid and
8. Axle housing damaged. 8. Replace damaged parts.
2. Intermittent noise when 1. Universal joint(s) worn or 1. Repair or replace universal joints
traveling. damaged. as needed.
2. Differential ring and/or pinion 2. Determine cause and repair as

gears damaged. needed.
3. Vibration or intermittent noise 1. Drive shaft universal joint 1. Tighten capscrews to correct
when traveling. assembly(ies) incorrectly torque.
tightened.
2. Drive shaft universal joint(s) worn 2. Repair or replace universal joints

or damaged. as needed.
3. Drive shaft(s) damaged/ 3. Replace drive shaft(s) as needed.

unbalanced.
TL642D, TL943D, TL1055D, TL1255D 31211036 5-7


4. Oil leaking from axle 1. Drain and/or inspection plugs 1. Replace o-rings as needed and
(differential housing and/or loose and/or o-rings damaged or tighten plugs to 96 lb-ft (130 Nm).
axle housings). missing.
2. Hose fittings loose. 2. Tighten fittings.
3. Axle shaft seal damaged or 3. Replace seal and/or joint coupling

missing and/or worn or damaged fork shaft (axle shaft).
shaft sealing surfaces.
4. Input shaft multi-seal ring 4. Replace multi-seal ring and/or

damaged or missing and/or worn input shaft. Adjust ring and pinion
or damaged pinion (input) shaft alignment and bearing preload as
sealing surfaces. described in the Engine Repair
Manuals.
5. Axle casing to brake housing and/ 5. Replace o-rings and seals.

or brake housing to differential
assembly o-rings and/or seals
worn or damaged.
6. Axle housing mounting nuts and 6. Tighten housing nuts and

capscrews loose. capscrews to 288 lb-ft (390 Nm).
7. Differential and/or axle housing(s) 7. Replace housing(s) as needed.

damaged.
5. Oil leaking from wheel end 1. Oil level plugs loose and/or 1. Replace o-rings as needed and
housing (planet carrier). o-rings damaged or missing. tighten plugs to 44 lb-ft (60 Nm).
2. O-ring between hub and housing 2. Replace o-ring.

(planet carrier) damaged or
missing.
3. Shaft seal damaged or missing 3. Replace seal and/or fork joint

and/or worn or damaged shaft shaft.
sealing surfaces.
4. Housing capscrews loose. 4. Tighten housing capscrews to

41 lb-ft (55 Nm).
5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).
6. Oil leaking from steering 1. Hose fittings loose. 1. Tighten fittings.

cylinder.
2. Steering cylinder o-rings and/or 2. Replace o-rings and seals.
seals worn or damaged.
3. Piston rod seal worn or damaged. 3. Replace piston rod seal.
4. Cylinder tube damaged. 4. Replace cylinder tube.
5-8 31211036 TL642D, TL943D, TL1055D, TL1255D


7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level. Refer to
Section 2.3, “Fluid and Lubricant
Capacities”.
2. Axle and/or wheel end housings 2. Drain axle and fill to correct level.
filled with incorrect oil or oil Refer to Section 2.3, “Fluid and
contaminated or oil level low. Lubricant Capacities”.
3. Dragging park brake. 3. Adjust park brake cable as

needed. Refer to Section Note:,
“Service brake circuit will need to
bled after axle installation. Refer
to Section 8.9.4, “Service Brake
Bleeding”, for detailed
instructions.”
8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to Section 8.5, “Hydraulic
2. Excessive joint housing swivel 2. Correct bearing preload by

bearing preload. adding or removing shims as
needed.
3. Worn or damaged swivel 3. Replace swivel bearings as

bearings. needed.
9. Slow steering response. 1. Steering (hydraulic) system not 1. Refer to Section 8.5, “Hydraulic
2. Steering cylinder leaking 2. Repair or replace steering cylinder

internally. as needed.
10. Excessive noise when brakes are 1. Brake discs worn. 1. Check brake discs for wear. Refer
engaged. to Section 5.5, “Brake Inspection”.
2. Brake discs damaged. 2. Replace brake discs.
11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to Section 8.5, “Hydraulic
2. Brake piston o-rings and seals 2. Replace o-rings and seals.

damaged (leaking).
12. Brakes will not hold the 1. Brake discs worn. 1. Check brake discs for wear. Refer
machine or braking power to Section 5.5, “Brake Inspection”.
reduced.
2. Brake (hydraulic) system not 2. Refer to Section 8.9.4, “Service
operating properly. Brake Bleeding”.
3. Brake piston o-rings and seals 3. Replace o-rings and seals.

damaged (leaking).
TL642D, TL943D, TL1055D, TL1255D 31211036 5-9

5.8 DRIVE SHAFTS

5
5.8.1 Drive Shaft Inspection
Inspect areas where the drive shaft flange yokes and slip
yokes mount to the drive shafts. Attempt to turn each drive 5
4
shaft in both directions. Look for excessive looseness, 6
1
missing parts, cracks or other damage. Worn or damaged
drive shafts and cross and bearing assemblies may cause an
excessive amount of vibration or noise. 2
Verify the mating surfaces between the driveshaft yoke and 4

universal joint are clean and smooth. 1
3
Refer to Section 2.5, “Lubrication Schedule”, for information 2 MAG1600
regarding the lubrication of grease fittings on the driveshaft.
7. Remove four bolts and two straps (1) securing bearing
Note: To ensure optimum performance, the driveshaft
cross to the transmission output shaft flange. Discard
assemblies are specially balanced as a unit at the factory. When
bolts.
servicing any flange yoke, slip yoke or drive shaft tube, order a
complete assembly if components are bent or damaged. Refer 8. Remove four bolts and two straps (2) securing bearing
to the appropriate parts manual for ordering information. crosses to the axle. Discard bolts.
Note: Any bolt removed from the drive shaft assembly MUST 9. Remove front drive shaft assembly (3).
be replaced. DO NOT re-torque. 10. Remove four bolts and two straps (4) securing bearing
cross to transmission output shaft flange. Discard bolts.
Note: Refer to Section 2.6, “Thread Locking Compound”, all the
thread locking requirements. 11. Remove four bolts and two straps (5) securing bearing
cross to rear axle. Discard bolts.
5.8.2 Drive Shaft Maintenance 12. Remove rear drive shaft assembly (6).
Refer to Section 2.3, “Fluid and Lubricant Capacities”, for
information regarding the lubrication of the grease fittings b. Installation
on the drive shafts. 1. Raise drive shaft assembly into position. Slip-yoke end
of drive shaft mounts toward axle. If reinstalling a drive
5.8.3 Drive Shaft - TL642D, TL943D shaft previously removed, align flange yokes according
to alignment marks made during removal.
a. Removal
Note: The yokes at both ends of the drive shaft must be in the
1. Park machine on a firm, level surface, level machine, fully same plane to help prevent excessive vibration.
(N) NEUTRAL, engage park brake and shut engine OFF. 2. Refer to Section 2.6, “Thread Locking Compound”, for all
thread locking requirements.
switch and steering wheel. 3. Install two straps and four new bolts (1) securing
bearing crosses to transmission. Torque bolts to
3. Open engine cover. Allow the system fluids to cool. 55 - 60 lb-ft (75 - 81 Nm).
4. Properly disconnect the battery. Refer Section 9.8, 4. Install two straps and four new bolts (2) securing
“Battery”, for procedure. bearing crosses to axle. Torque bolts to
5. Block the wheels. 55 - 60 lb-ft (75 - 81 Nm).
6. The drive shaft assembly is a balanced assembly. Mark 5. Install front drive shaft assembly (3).
yoke and axle, transmission and shaft and slip yoke so 6. Install two straps and four new bolts (4) securing
that these components can be returned to their original bearing crosses to the transmission. Torque bolts to
positions when reinstalled. Yokes at both ends of drive 55 - 60 lb-ft (75 - 81 Nm).
shaft must be in same plane to help prevent excessive
vibration. 7. Install two straps and four new bolts (5) securing
bearing crosses to axle. Torque bolts to
55 - 60 lb-ft (75 - 81 Nm).
5-10 31211036 TL642D, TL943D, TL1055D, TL1255D

8. Install rear drive shaft assembly (6). 11. Remove four bolts and two straps (5) securing bearing
9. Properly connect the battery. Refer Section 9.8, crosses to rear drive shaft (6) at carrier bearing. Discard
“Battery”, for procedure. bolts.
10. Close and secure the engine cover. 12. Remove rear drive shaft assembly (6).
11. Unblock the wheels. 13. Remove four bolts and two straps (7) securing bearing
cross to rear axle. Discard bolts.
12. Remove Do Not Operate Tags from both ignition key
switch and steering wheel. 14. Remove two Bolts, Nuts and Washers (8) securing carrier
bearing to frame.
5.8.4 Drive Shaft - TL1055D, TL1255D 15. Remove rear drive shaft assembly (9).
a. Removal b. Installation
1. Park machine on a firm, level surface, level machine, fully 1. Raise drive shaft assembly into position. Slip-yoke end
retract boom, lower boom, place transmission in of drive shaft mounts toward axle. If reinstalling a drive
(N) NEUTRAL, engage park brake and shut engine OFF. shaft previously removed, align flange yokes according
2. Place a Do Not Operate Tag on both the ignition key to alignment marks made during removal.
switch and steering wheel. Note: The yokes at both ends of the drive shaft must be in the
3. Open engine cover. Allow the system fluids to cool. same plane to help prevent excessive vibration.
4. Properly disconnect the battery. Refer Section 9.8, 2. Refer to Section 2.6, “Thread Locking Compound”, for all
“Battery”, for procedure. thread locking requirements.
5. Block the wheels. 3. Install two straps and four new bolts (1) securing
6. The drive shaft assembly is a balanced assembly. Mark bearing crosses to transmission. Torque bolts to
yoke and axle, transmission and shaft and slip yoke so 55 - 60 lb-ft (75 - 81 Nm).
that these components can be returned to their original 4. Install two straps and four new bolts (2) securing
positions when reinstalled. Yokes at both ends of drive bearing crosses to axle. Torque bolts to
shaft must be in same plane to help prevent excessive 55 - 60 lb-ft (75 - 81 Nm).
vibration.
5. Install front drive shaft assembly (3).
6. Install two straps and four new bolts (7) securing
8 7 bearing crosses to axle. Torque bolts to
5
55 - 60 lb-ft (75 - 81 Nm).
7. Install previously removed bolts, nuts and washers (8)
and secure the carrier bearing to frame. Torque to
9 7 59 lb-ft (80 Nm).
1 4
8. Install rear drive shaft assembly (9).
9. Install two straps and four new bolts (4) securing
2 6 5 bearing crosses to the transmission. Torque bolts to
55 - 60 lb-ft (75 - 81 Nm).
4 10. Install two straps and four new bolts (5) securing
3 1 bearing crosses to the rear axle at the carrier bearing.
2 Torque bolts to 55 - 60 lb-ft (75 - 81 Nm).
7. Remove four bolts and two straps (1) securing bearing 11. Install rear drive shaft assembly (6).
cross to the transmission output shaft flange. Discard
bolts.
crosses to the axle. Discard bolts.
14. Unblock the wheels.
9. Remove front drive shaft assembly (3).
15. Remove Do Not Operate Tags from both ignition key
switch and steering wheel.
cross to transmission output shaft flange. Discard bolts.
TL642D, TL943D, TL1055D, TL1255D 31211036 5-11

5.9 WHEELS AND TIRES 4. Place a suitable jack under axle pad closest to wheel
being removed. Raise machine and position a suitable
support beneath axle. Allow sufficient room to lower
WARNING machine onto support and to remove wheel and tire
assembly.
Mismatched tire sizes, ply ratings or mixing of tire types 5. Lower machine onto support.
(radial tires with bias-ply tires) may compromise machine
stability and may cause machine to tip over. 6. Remove lug nuts and washers in alternating pattern.
7. Remove wheel and tire assembly from machine.
It is recommended that a replacement tire to be same size,
ply and brand as originally installed. Refer to appropriate 5.9.2 Installing Wheel and Tire Assembly onto
parts manual for ordering information. If not using an Machine
approved replacement tire, It is recommended that
replacement tires have following characteristics: 1
• Equal or greater ply/load rating and size of original

• Tire tread contact width equal or greater than original
• Wheel diameter, width and offset dimensions equal to
original
• Approved for application by the tire manufacturer
(including inflation pressure and maximum tire load)
The rims installed have been designed for stability
requirements which consist of track width, tire pressure and
load capacity. Size changes such as rim width, center piece
location, larger or smaller diameter, etc., without written MZ6020
factory recommendations, may result in unsafe condition

Note: The wheel and tire assemblies must be installed with
regarding stability.
directional tread pattern “arrows” facing in direction of forward
Foam filled tires have a positive effect on the weight, travel.
stability and handling characteristics of the machine,
Note: Verify valve stems face outward on all wheel and tire
especially under load. The use of hydrofill as a tire-fill
assemblies.
substance is not recommended because of possible
environmental impact. 1. Position wheel onto studs on wheel end of axle.
Large-bore valve stems are used to help expedite tire 2. Start all lug nuts by hand to prevent cross threading.
inflation and deflation. An inner tube may be used if a tire Apply one drop of lubrication oil.
does not provide an airtight seal. Check tire inflation 1 8
pressures when the tires are cold. When mounting a tire on
the wheel, the tire must be mounted on the wheel
respective of the directional tread pattern of the tire; this 6 3
produces a left or right tire and wheel assembly.
5.9.1 Removing Wheel and Tire Assembly from

Machine 9 10
OFF. 4 5

and steering wheel. 7 2 MY4200
3. Loosen but DO NOT remove the lug nuts on the wheel 3. Tighten lug nuts in an alternating pattern as indicated in
and tire assembly to be removed. previous figure. Refer to Section 2.2.7, “Tires”, for proper
torque values.
5-12 31211036 TL642D, TL943D, TL1055D, TL1255D
4. Remove machine from supports. 8. Carefully tighten each release screw a 1/4 turn at a time
5. Remove Do Not Operate Tag from ignition key switch in sequence until all have been turned one full turn
and steering wheel. 360°.
9. Repeat Steps 1 thru 3 for other side of differential.
5.10 TOWING A DISABLED MACHINE Note: After machine has been towed to a secure location,
reactivate parking brake. Carefully follow procedures from start
5.10.1 Manually Releasing the Park Brake to finish. Contact local Caterpillar dealer if you are unsure
about any part of the procedure, or for specific instructions
1. Remove load from machine.
concerning your particular situation.
2. Fully retract the boom. Position attachment
approximately 24 in (610 mm) above the ground.
FRONT VIEW - NO OUTRIGGER
Note: If total loss of power has occurred, refer to Section 3.16,
“Emergency Boom Lowering Procedure”.
WARNING
DO NOT attempt to tow a machine that is loaded or the
boom/attachment is raised more than approximately
24 in (610 mm).
3. Place transmission in (N) NEUTRAL, engage park brake

4. Block all four wheels.
WARNING
MAG1540
Block all four wheels when preparing the machine for 2
towing to prevent any unexpected movement.
5. Remove front and rear drive shafts. Refer to Section 5.8, FRONT VIEW - WITH OUTRIGGER
“Drive Shafts”.
1 1
1 1 MD0180
6. Loosen the nuts of the screws (1) for the manual release
of the braking units. Draw the nuts back approximately
6 mm.
7. Tighten the screws until they are gently seated on the 2 MAG1060
driving plate.
TL642D, TL943D, TL1055D, TL1255D 31211036 5-13

REAR VIEW Note: Block the wheels of the machine BEFORE attempting to
release the park brake. Once the park brake is released the
machine’s park brake AND service brakes are inoperable.
5.10.2 Manually Resetting the Park Brake

Note: Block the wheels of the machine BEFORE attempting to
reset the machine’s park brake. Once the park brake is released
the machine’s park brake AND service brakes are inoperable.
1 1
3
MD0190 1 1 MD0180
10. Secure machine to a suitable towing vehicle. 1. Loosen each release screw (1), only 1/4 turn at a time, in
sequence, until each screw has lost contact with the
a. For towing or retrieval from front of machine, attach
guide pin.
towing equipment to lifting points (2) on each side
of the frame directly behind the outrigger 2. Remove screws along with nuts and seals. Replace seals,
weldments. lubricate screws with a silicone-based grease and
b. For towing or retrieval from rear of machine, attach re-install screws along with nuts.
towing equipment to the retrieval hitch (3). 3. Adjust the nut of the screw heads in relation to the arm
by 1.18 in (30 mm).
4. Repeat steps 1 thru 3 for other side of differential.
WARNING 5. After repairs to machine have been made, start machine
and check park brake and service brakes for proper
Use a vehicle of sufficient capacity to tow the machine.
function. Refer to Section 8.9.4, “Service Brake
Tow vehicle must be capable of providing braking for
Bleeding”, Section d, “Free Play Adjustment”, and
both vehicle and machine.
Section 8.9.7, “Steering Orbital Valve”.
11. Clear area of any unnecessary personnel.
12. Have an operator seated in machine operator cab.
13. Remove blocks from all four wheels.
14. Disengage machine park brake.
15. Tow machine to a secure location.
Note: Tow machine at a very slow speed.
16. After towing is complete, engage park brake.
17. Block all four wheels.
18. Reinstall front and rear drive shafts. Refer to Section 5.8,
“Drive Shafts”.
19. Repair machine as necessary.
5-14 31211036 TL642D, TL943D, TL1055D, TL1255D

Section 6
Transmission
Contents

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Transmission Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.3 Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.5 Transmission Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.5 Transmission Cooler Thermal By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.5.1 Thermal By-Pass Valve Cartridge Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.5.2 Thermal By-Pass Valve Cartridge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.6 Torque Convertor Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.6.1 Torque Convertor Diaphragm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.6.2 Torque Convertor Diaphragm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
TL642D, TL943D, TL1055D, TL1255D 31211036 6-1

Transmission
6.1 TRANSMISSION ASSEMBLY

of the major assemblies of the transmission. The following
TRANSMISSION
TORQUE FILTER
CONVERTER
TRANSFER CASE
BREATHER
BREATHER
TRANSFER CASE
OIL FILLER PLUG
TRANSFER CASE
TRANSMISSION OIL OIL DRAIN
DIPSTICK
SHIFT SOLENOIDS (E3)
TRANSMISSION OIL
DRAIN PLUG
6-2 31211036 TL642D, TL943D, TL1055D, TL1255D

Transmission
6.4 TRANSMISSION REPLACEMENT

WARNING Cleanliness is of extreme importance. Before attempting to
DO NOT service the machine without following all safety remove the transmission, thoroughly clean the exterior of
precautions as outlined in Section 1, “Safety Practices”, of the transmission to help prevent dirt from entering during
this manual. the replacement process. Avoid spraying water or cleaning
solution onto or near the transmission shift solenoids and
Note: These instructions cover only the routine maintenance, other electrical components.
removal, installation and troubleshooting of the transmission.
Refer to the local Caterpillar dealer and the applicable 6.4.1 Transmission Removal
Transmission Service Manual for assistance with
comprehensive transmission diagnosis, repair and component
replacement. WARNING
Use a suitable hoist or overhead crane and sling with a
6.2 TRANSMISSION SERIAL NUMBER minimum lifting capacity of 1000 lb (454 kg).
1. Park machine on a firm, level surface, level machine,
fully retract boom, lower boom, place transmission in
4. If not previously removed, remove the implement
pump. Refer to Section 8.8.1, “Pump Replacement”.
5. Refer to Section 7.9, “Engine Replacement”, for detailed
removal instructions.
MAG0490
The transmission serial number plate (1) is located on the

front of the transmission case behind the oil dipstick.
Information contained in the serial number is required in
correspondence with the transmission manufacturer.
6.3 SPECIFICATIONS AND MAINTENANCE

INFORMATION
For transmission, oil specifications and maintenance
information, refer to Section 2, “General Information and 2
MAG0490
Specifications”. 1
Refer to SIS Web for detailed transmission service 6. Place a suitable receptacle under transmission
instructions. drain plug (1). Remove the transmission drain plug, and
allow the transmission oil to drain into the receptacle.
Repeat the drain procedure with the transfer case (2).
7. Transfer used transmission oil into a suitable, covered
container, and label container as “Used Oil”. Dispose of
TL642D, TL943D, TL1055D, TL1255D 31211036 6-3

Transmission
used oil at an approved recycling facility. Clean and 6.4.3 Transmission Installation
reinstall the transmission and transfer case drain plugs.
WARNING
minimum lifting capacity of 1000 lb (454 kg).
1. Install two guide studs near the top of the bell housing
holes.
2. Use a hoist or overhead crane and sling attached to the
lifting eye at the top of the transmission. Raise and
position the transmission behind the engine.
3. Align the torque converter, align the transmission bolt
holes with the two studs in the bell housing. Install the
eight bolts and washers and torque to 53 lb-ft (72 Nm).
4 3 MZ7140 Remove the two alignment studs and install and torque
the last two transmission mounting bolts.
8. Remove access cover (3) from bottom of engine bell
housing (4). This will allow access to remove four bolts 4. Turn the engine over slowly by hand and align each of
holding the torque convertor diaphragm to the engine the four torque convertor diaphragm bolts through the
flywheel. access cover in the bell housing. Install them one at a
time. DO NOT fully tighten until all of the capscrews and
9. Turn the engine over slowly by hand and align each of locknuts are in place. Torque to 26 - 39 lb-ft (35 - 59 Nm).
the four torque convertor diaphragm bolts to be Replace access cover.
accessed. Remove them one at a time.
5. If previously removed, install the implement pump.
10. Connect a lifting strap or chain to lifting eye at top of Refer to Section 8.8.1, “Pump Replacement”.
transmission, and to a suitable hoist or overhead crane.
6. Refer to Section 7.9.4, “Engine/Transmission
11. Carefully remove the transmission from the engine. Installation”, for detailed installation instructions.
Avoid causing damage to the transmission or
surrounding parts. 7. Initially fill the transmission with 16 quarts (15,1 liters).
12. Lift the transmission clear of the engine, and lower it 8. Properly connect the battery. Refer to Section 9.8,
onto suitable supports or secure it to a stand built “Battery”, for procedure.
especially for transmission or engine service. Secure the 9. Check transmission fluid level. Refer to Section 6.4.5,
transmission so that it will not move or fall. “Transmission Fluid Level Check”, for procedure.
13. Drain and flush entire transmission cooling system. 10. Recheck all drain plugs, lines, connections, etc, for leaks,
14. Thoroughly clean transmission filter screens and cases, and tighten where necessary.
and replace transmission filter elements. 11. Close and secure engine cover.
12. Shut down machine. Remove the Do Not Operate tags
6.4.2 Transmission Inspection and from both the ignition key switch and steering wheel.
Internal Repair
Refer to Section 6.3, “Specifications and Maintenance 6.4.4 Transmission Fluid/Filter Replacement
Information”. Refer to Section 6.3, “Specifications and Maintenance
Information”, for procedure. Note that transmission should
be filled initially with 12 quarts (11,4 liters) during the
procedure.
6-4 31211036 TL642D, TL943D, TL1055D, TL1255D

Transmission
6.4.5 Transmission Fluid Level Check 12. Place the transmission in (N) NEUTRAL and apply the
park brake. Allow the engine to run at idle for
Note: Final transmission oil level must always be checked with
30 seconds.
engine at idle and transmission oil at operating temperature
(minimum 80°C/176°F). 13. Open the engine cover.
1. Start machine on a firm, level surface, level machine,

(N) NEUTRAL, engage park brake and run engine at idle.
2. Open the engine cover.
5
6
MAE3820
14. Verify that top of transmission oil cooler (6) is warm, to

MAG0500 determine that the bypass valve (7) has closed and oil is
3. Remove the transmission dipstick (5) and check the oil circulating through the cooler. If the top of the
level. The cold oil level after 2-3 minutes of idle should transmission oil cooler is not warm, repeat
be within the MIN and MAX oil level marks. steps 6 thru 10.
15. Remove the transmission dipstick (5) and check the oil
Note: Depending on the amount of fluid remaining in the
level. The oil level should be between the MIN and MAX
transmission oil cooler, the oil level may read slightly above the
level marks.
HOT oil top level mark at this time. The correct oil level can be
obtained after the transmission fluid is at operating 16. Add oil as required.
temperature. 17. Replace the transmission dipstick.
4. If the oil is low, add oil as required. 18. Close and secure the engine cover.
5. Replace the transmission dipstick. 19. Shut engine OFF.
7. Ensure that the front of the machine is clear of persons
or obstacles.
8. Apply the service brake and disengage the park brake.
Place the transmission in (F) FORWARD at 4th gear.
9. Stall the transmission against service brake at full
throttle a maximum of 60 seconds. If transmission
temperature warning light illuminates, go to step 12.
10. Allow the engine to run at idle for 30 seconds.
11. Repeat steps 9 and 10 three more times, or until the
transmission temperature warning light illuminates.
TL642D, TL943D, TL1055D, TL1255D 31211036 6-5

Transmission
6.5 TRANSMISSION COOLER THERMAL

BY-PASS VALVE
6.5.1 Thermal By-Pass Valve Cartridge

Removal
2 MD0220
“Battery”, for procedure. 6. Thoroughly clean the radiator and surrounding area,
including all the hoses and fittings, before proceeding.
7. Place a suitable container beneath the radiator cooler
fittings on the hydraulic cooler. Transfer any
transmission oil into a properly labeled container.
Dispose of properly.
8. Loosen and remove the cartridge (2) from the side of
the thermal by-pass valve. Plug opening to prevent dirt
and debris from entering system.
1
6.5.2 Thermal By-Pass Valve Cartridge
Installation
1. Remove the plug and install the new cartridge (2) in the
thermal by-pass valve.
2. Reinstall access cover (1) to the radiator assembly.
MD0210 4. Check transmission oil level. Refer to Section 6.4.5,
1 “Transmission Fluid Level Check”, for procedure.
5. Loosen and remove the access cover (1) at the radiator 5. Remove Do Not Operate Tag from ignition key switch
assembly. and the steering wheel.
6-6 31211036 TL642D, TL943D, TL1055D, TL1255D

Transmission
6.6 TORQUE CONVERTOR DIAPHRAGM
6.6.1 Torque Convertor Diaphragm Removal

(N) NEUTRAL, engage park brake and shut the
engine OFF.
Note: In order to remove engine drive plates, engine and
transmission must be separated.
2. Refer to Section 6.4.1, “Transmission Removal” or
Section 7.9.1, “Engine/Transmission Removal”.
MAL1950
3. Remove six bolts holding diaphragms to flywheel.

4. With the drive plate and torque converter removed,
loosen and remove the six bolts (1) and eight lock
washer holding the two diaphragm (2) to the torque
converter (3).
5. Replace both diaphragms if damaged.
6.6.2 Torque Convertor Diaphragm

Installation
1. Install two new diaphragms on torque converter with
previously removed bolts with washers.
2. Mount the diaphragm/converter assembly to
the transmission.
3. Refer to Section 6.4.3, “Transmission Installation” or
Section 7.9.4, “Engine/Transmission Installation”, for the
remainder of the installation.
TL642D, TL943D, TL1055D, TL1255D 31211036 6-7

Transmission
6-8 31211036 TL642D, TL943D, TL1055D, TL1255D

Section 7
Engine
Contents

7.1 Engine Introduction and Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4.1 Surge Tank Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4.3 Radiator Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.6.2 Diesel Exhaust Fluid (DEF) Tank (SN ML800150 to Present, SN MLJ00150 to Present,
SN ML500150 to Present, SN ML700150 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.6.3 Diesel Exhaust Fluid (DEF) System Header (SN ML800150 to Present, SN MLJ00150 to
Present, SN ML500150 to Present, SN ML700150 to Present). . . . . . . . . . . . . . . . . . 7-10
7.6.4 Diesel Exhaust Fluid (DEF) Pump Filter (SN ML800150 to Present, SN MLJ00150 to
Present, SN ML500150 to Present, SN ML700150 to Present). . . . . . . . . . . . . . . . . . 7-11
7.6.5 Diesel Exhaust Fluid (DEF) System Cleaning (SN ML800150 to Present, SN MLJ00150 to
Present, SN ML500150 to Present, SN ML700150 to Present) . . . . . . . . . . . . . . . . . 7-12
7.6.6 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.6.7 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.7.1 Exhaust System Removal TL642D, TL943D (SN ML800150 to Present, SN MLJ00150 to
Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.7.2 Exhaust System Installation TL642D,TL943D (SN ML800150 to Present, SN MLJ00150 to
Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.7.3 Exhaust System Removal TL1055D, TL1255D (SN ML500150 to Present, SN ML700150
to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.7.4 Exhaust System Installation TL1055D, TL1255D (SN ML500150 to Present, SN
ML700150 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7.7.5 Exhaust System Removal TL642D, TL943D, TL1055D, TL1255D (SN MLG00150 to
Present, SN MLD00150 to Present, SN MNT00150 to Present, SN MYW00150 to
Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7.7.6 Exhaust System Installation TL642D, TL943D, TL1055D, TL1255D (SN MLG00150 to
Present, SN MLD00150 to Present, SN MNT00150 to Present, SN MYW00150 to
Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
TL642D, TL943D, TL1055D, TL1255D 31211036 7-1

Engine
7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

7.8.1 Air Cleaner Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.8.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7.9.1 Engine/Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7.9.2 Transmission Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7.9.3 Engine Disassembly, Inspection and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7.9.4 Engine/Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7-2 31211036 TL642D, TL943D, TL1055D, TL1255D

Engine
7.1 ENGINE INTRODUCTION AND

WARNING
precautions as outlined in Section 1. “Safety Practices”, of
this manual.
WARNING
Engine fuel lines are pressurized. DO NOT attempt
repairs unless specific training has been completed.
7.1.1 Disclaimer and Scope

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

of the engine components. The following illustration
identifies the components that are referred to throughout
this section.
TL642D, TL943D, TL1055D, TL1255D 31211036 7-3

Engine
DIESEL OXIDATION CATALYST
(DOC)
SECONDARY
FUEL FILER
THERMOSTAT OIL FILTER
PRIMARY FUEL
FILTER/WATER
SEPARATOR
TURBOCHARGER
ALTERNATOR STARTER
MAG1080
WATER PUMP
TURBOCHARGER VENTILATION
FILTER
THERMOSTAT CRANKCASE
PRIMARY FUEL
FILTER/WATER
SEPARATOR
EXHAUST BACK
PRESSURE VALVE SECONDARY
FUEL FILTER
MAG0220
ENGINE CONTROL
MODULE (ECM)
WATER PUMP
FUEL INJECTOR STARTER

ALTERNATOR PUMP OIL FILTER MAG0290
THERMOSTAT
PRIMARY FUEL
FILTER/WATER
SEPARATOR
ENGINE CONTROL
MODULE (ECM)
WATER TWIN SECONDARY

PUMP FUEL FILTER
TURBOCHARGER
ALTERNATOR FUEL INJECTOR STARTER

MAG0300
PUMP OIL FILTER
7-4 31211036 TL642D, TL943D, TL1055D, TL1255D

Engine
7.2 ENGINE SERIAL NUMBER 7.4 ENGINE COOLING SYSTEM

The engine serial number is stamped on top of the engine.
Information contained in the serial number is required in
7.4.1 Surge Tank Cap
correspondence with the engine manufacturer. A 14.5 psi (1 Bar) cap is used on the surge tank. An incorrect
or malfunctioning cap can result in the loss of coolant and a
7.3 SPECIFICATIONS AND MAINTENANCE hot running engine.
INFORMATION
7.4.2 Thermostat Replacement
For engine, coolant and oil specifications, and maintenance Before considering thermostat replacement, check the
information, refer to Section 2, “General Information and coolant level, fan belt tension and instrument cluster
Specifications”. temperature indicator.
Refer to Section 9.18, “Engine Fault Codes”, for diagnostic • If engine seems to take a long time to warm
codes and descriptions. up, thermostat may be stuck in the open position
Detailed engine service instructions are provided in the and requires replacement.
following publications: • If engine runs hot, check temperature of upper
Refer to SIS Web for detailed engine service instructions. radiator hose.
• If hose is not hot, thermostat may be stuck in closed
position.
• If engine has overheated, performance may
suffer, indicating other damage including a leaking
cylinder head gasket, cracked cylinder head or block
and/or other internal engine damage.
a. Thermostat Removal
(N) NEUTRAL, engage parking brake and shut engine
OFF.
and steering wheel.
5. Slowly turn surge tank cap to first stop and allow any
pressure to escape. Remove surge tank cap.
coolant into container. Loosen the drain plug and slowly
remove to allow coolant to drain. Transfer coolant into a
coolant needs to be replaced. Replace surge tank cap.
Replace the radiator drain plug.
TL642D, TL943D, TL1055D, TL1255D 31211036 7-5

Engine
• If engine has overheated, performance may

suffer, indicating other damage including a leaking
cylinder head gasket, cracked cylinder head or block
and/or other internal engine damage.
1 a. Radiator Assembly Removal

OFF.
and steering wheel.
TYPICAL ILLUSTRATION
7. Remove capscrews securing thermostat housing (1) to
engine. 2
8. Remove thermostat housing, old gasket and
thermostat. Clean all gasket surfaces. DO NOT let any
debris into thermostat opening.
Note: ALWAYS use correct thermostat and install a new gasket.
NEVER operate engine without a thermostat or engine
damage will result.
3
b. Thermostat Installation 3
1. Install engine thermostat, thermostat gasket and

thermostat housing. Secure with the previously
removed capscrews.
4 5
2. Properly connect the battery. Refer Section 9.8, MAG0310

5. Remove hood (2), end cover (3), side skirt (4) and belly
3. Open the surge tank cap, fill system complete to the pan (5) from engine compartment.
“Full Cold” level with coolant. Replace and tighten the
surge tank cap. 6. Place a suitable receptacle under transmission drain
plug. Remove transmission drain plug and allow the
4. Run engine to operating temperature. Visually check for transmission oil to drain into receptacle.
leaks with engine running. Check coolant level in surge
tank and fill or drain as necessary. 7. Transfer used transmission oil into a suitable, covered
container and label container as “Used Oil”. Dispose of
7.4.3 Radiator Assembly Replacement used oil at an approved recycling facility. Clean and
reinstall transmission drain plug.
Before considering radiator assembly replacement for other
8. Drain hydraulic oil reservoir. Refer to Section 8.7.1,
than obvious damage, conduct a cooling system pressure
“Hydraulic Oil Reservoir Draining”.
test check coolant specific gravity, coolant level, fan belt
tension and dash panel temperature indicator. 9. Slowly turn surge tank cap to first stop and allow any
pressure to escape. Remove surge tank cap.
• If engine runs hot, check temperature of upper
radiator hose. 10. Place a suitable container beneath radiator drain.
• If hose is not hot, thermostat may be stuck in closed
position.
7-6 31211036 TL642D, TL943D, TL1055D, TL1255D

Engine

coolant into a container. Open drain plug and slowly 10
remove to allow coolant to drain. Transfer coolant into a 9
7
7
11
8
10
MD0070
14. Label and disconnect both transmission cooler

hoses (8). Cap all fittings and openings to prevent dirt
7 and debris from entering hydraulic system.
MD0050
15. Loosen and remove radiator assembly mounting
12. Label and disconnect the outer hydraulic cooler bolts, washers and (if equipped) shims. Note the
hoses (6). Cap all fittings and openings to prevent dirt number of shims being used and there location.
and debris from entering hydraulic system. 16. Label, disconnect and cap hoses attached to surge
13. Label and disconnect the fuel cooler hoses (7). Cap all tank (7). Remove surge tank and mounting plate.
fittings and openings to prevent dirt and debris from 17. Loosen and remove air intercooler tubes (9) from
entering hydraulic system. radiator assembly.
18. Loosen and remove the radiator hoses (10) from
radiator assembly.
19. Remove bolts and washers attaching the fan guard (11).
Remove fan guard.
20. Carefully lift the radiator assembly out of the engine
compartment.
Note: Fan Guard can be removed after radiator assembly is
removed and placed in a secure location.
TL642D, TL943D, TL1055D, TL1255D 31211036 7-7

Engine
b. Radiator Assembly Installation 7.5 ENGINE ELECTRICAL SYSTEM

1. Place radiator assembly in engine compartment at the
The engine electrical system, including the starter, alternator
original orientation. Secure with the previously used
and primary wiring, is described in Section 9.5, “Electrical
hardware.
2. Install the fan guard (11) with bolts and washers.
3. Uncap and connect previously labeled hoses to 7.6 FUEL SYSTEM
radiator, transmission cooler and oil cooler.
4. Fill hydraulic oil reservoir. Refer to Section 8.7.2, 7.6.1 Diesel Fuel
“Hydraulic Oil Reservoir Filling”.
Fuel represents a major portion of machine operating costs
5. Fill transmission. Refer to Section 2.3, “Fluid and and therefore must be used efficiently. ALWAYS use a
Lubricant Capacities”. premium brand of high quality, clean diesel fuel. Low cost,
6. Open surge tank cap and fill the radiator completely inferior fuel can lead to poor performance and expensive
with coolant. Replace and tighten surge tank cap. Refer engine repair.
Refer Section 2.3, “Fluid and Lubricant Capacities”, for
proper capacities.
approved fuel specification.
8. Run engine to operating temperature. Visually check for
leaks with engine running. Check all fluid levels for
correct levels.
9. Install the end cover, hood and belly pans on the engine
compartment.
and the steering wheel.
7-8 31211036 TL642D, TL943D, TL1055D, TL1255D

Engine
7.6.2 Diesel Exhaust Fluid (DEF) Tank

(SN ML800150 to Present, SN MLJ00150
to Present, SN ML500150 to Present,
The DEF tank is located at the rear of the cab below the fuel
tank.
a. DEF Tank Removal
3
OFF.
and steering wheel.
6 4
4. Properly disconnect the battery. Refer Section 9.8, 7
5
“Battery”, for procedure. TYPICAL ILLUSTRATION
7. Thoroughly clean the DEF tank and surrounding area.

1 8. Disconnect electrical connection (3) on top of DEF tank.
9. Loosen clamps, label, disconnect and plug and/or cap
DEF tank coolant hoses (4).
10. Label, disconnect and plug and/or cap DEF tank fluid
hoses (5).
2
11. Remove DEF tank drain plug and transfer fluid into a
suitable container. Dispose fluid at an approved
recycling facility. Reinstall drain plug.
12. Remove the DEF hoses strap (6) from the fuel tank.
13. Remove straps (7) securing DEF tank to frame and
remove DEF tank.
b. DEF Tank Inspection
MD0100
1. If cleaning DEF tank, refer to Section 7.6.5, “Diesel
Exhaust Fluid (DEF) System Cleaning (SN ML800150 to
5. Remove fuel tank/hydraulic reservoir access cover (1). Present, SN MLJ00150 to Present, SN ML500150 to
Present, SN ML700150 to Present)”, for procedure.
6. Remove DEF tank access cover (2).
2. If replacing DEF tank, remove all components and retain
for use on replacement tank. Refer to Section 7.6.3, a.
“DEF Tank Header Removal”. Dispose of damaged DEF
tank according to local regulations concerning
hazardous material disposal.
TL642D, TL943D, TL1055D, TL1255D 31211036 7-9

Engine
c. DEF Tank Installation a. DEF Tank Header Removal

1. Install all previously removed components. Refer to 1. Refer to Section 7.6.2, “Diesel Exhaust Fluid (DEF) Tank
Section 7.6.3, b. “DEF Tank Header Installation”, for (SN ML800150 to Present, SN MLJ00150 to Present,
detailed header installation procedure. SN ML500150 to Present, SN ML700150 to Present)”, for
2. Install DEF tank and secure to frame with the previously DEF tank removal.
removed straps (7).
3. Remove plugs and/or caps from the previously labeled
DEF tank fluid hoses (5) and connect to their 8
appropriate locations. 9
4. Remove plugs and/or caps from the previously labeled
DEF tank coolant hoses (4) and connect to their
appropriate locations. Tighten clamps. 11
5. Connect electrical connection (3) on top of DEF tank.
6. Fill DEF tank according to specifications. Refer to
Section 2.3, “Fluid and Lubricant Capacities”.
7. Verify all DEF system hose connections are tight and
secure from any sharp edges, moving parts and/or 10
excessive heat.
8. Install the DEF hoses strap (6) to the fuel tank.
9. Install the fuel tank/hydraulic reservoir access cover (1).
MAG0330
10. Install the DEF tank access cover (2).
11. Properly connect battery. Refer Section 9.8, “Battery”, 2. Loosen and remove two screws (8) securing header (9)
for procedure. to the DEF tank (10).
12. Close and secure engine cover. 3. Remove the header (9) from the DEF tank and discard
13. Remove Do Not Operate Tag from ignition key switch the filter (11). Note the orientation of the header for
and steering wheel. reassembly.
b. DEF Tank Header Installation

7.6.3 Diesel Exhaust Fluid (DEF) System
Header (SN ML800150 to Present,
SN MLJ00150 to Present, SN ML500150 8
to Present, SN ML700150 to Present)
9
The header/filter of the DEF System is only required to be
removed and the filter replaced when the system
maintenance is required or is exposed to contamination. The
11
header can be cleaned and reused when cleaning and/or
replacing the DEF Tank.
MAG0330
1. Install new filter (10) to the header assembly (9).

2. Install the header assembly into the DEF tank.
7-10 31211036 TL642D, TL943D, TL1055D, TL1255D

Engine
Note: Verify the indent on the bottom of the header is located TL1055D, TL1255D
on the centering nub on the bottom of the DEF tank.
3. Orient and secure the header (9) with the previously
removed hardware (8).
4. Refer to Section 7.6.2, “Diesel Exhaust Fluid (DEF) Tank
(SN ML800150 to Present, SN MLJ00150 to Present,
SN ML500150 to Present, SN ML700150 to Present)”, for
DEF tank installation.
7.6.4 Diesel Exhaust Fluid (DEF) Pump Filter

(SN ML800150 to Present, SN MLJ00150 to
Present, SN ML500150 to Present,
The pump filter of the DEF System is only required to be
replaced when system maintenance is required or is
exposed to contamination. 12 MAG1770
a. Pump Filter Removal

5. Thoroughly clean the DEF pump (12) and surrounding
1. Park machine on a firm, level surface, level machine, fully area.
retract boom, lower boom, place transmission in TL642D, TL943D
OFF.
and steering wheel.
TL642D, TL943D 3
MAG1580
MAG1120
12
TL642D, TL943D, TL1055D, TL1255D 31211036 7-11

Engine
TL1055D, TL1255D 7.6.5 Diesel Exhaust Fluid (DEF) System

4 Cleaning (SN ML800150 to Present,
SN MLJ00150 to Present, SN ML500150 to
Present, SN ML700150 to Present)
Cleaning of the DEF System is only required when the
5 system is exposed to contamination. If DEF quality is in
question, obtain a sample from the DEF tank and place in a
clear container. DEF should be crystal clear with a light
ammonia smell. If the DEF appears cloudy, has a colored tint
or has a strong ammonia smell, it is NOT likely to be within
3
specifications.
Ensure the DEF solution is the correct specification. Cumins
recommends using only DEF solutions that maintain 32.5%
(+/- 1.5%) of urea content by weight. The urea content can
be easily checked with a Refractometer (PN 70011925). The
DEF solution must meet the requirements International
Standard ISO 22241-1 for diesel engines. There is no accept-
able substitute. For engines using Selective Catalytic Reduc-
tion (SCR) Systems, operating in the United States and
Canada, DEF certified by the American Petroleum Institute
6. For TL1055D, TL1255D: Remove the filter cover (4) (API) is recommended for use. DEF should be stored in
from DEF pump (3). sealed containers and at 23 - 77° F (-5 - 25° C). Avoid storing
7. Remove and discard the pump filter (5) from containers in direct sunlight to assure better shelf life.
DEF pump (3). a. DEF tank Cleaning
b. Pump Filter Installation 1. Refer to Section 7.6.2, “Diesel Exhaust Fluid (DEF) Tank
(SN ML800150 to Present, SN MLJ00150 to Present,
1. Wipe out the area around the filter housing. SN ML500150 to Present, SN ML700150 to Present)”, for
2. Install new DEF pump filter (5), DEF tank removal.
DEF seal assembly and filter cap. Tighten as required. 2. Refer to Section 7.6.3, “Diesel Exhaust Fluid (DEF)
3. Properly connect battery. Refer Section 9.8, “Battery”, System Header (SN ML800150 to Present, SN MLJ00150
for procedure. to Present, SN ML500150 to Present, SN ML700150 to
4. Close and secure engine cover. Present)”, for header removal.
5. Remove Do Not Operate Tag from ignition key switch 3. Remove the drain plug.
and steering wheel. 4. Thoroughly clean the DEF tank with de-ionized water.
5. Install and tighten drain plug.
6. Refer to Section 7.6.3, “Diesel Exhaust Fluid (DEF)
System Header (SN ML800150 to Present, SN MLJ00150
to Present, SN ML500150 to Present, SN ML700150 to
Present)”, for filter and header installation.
7. Refer to Section Section 7.6.2, “Diesel Exhaust Fluid
(DEF) Tank (SN ML800150 to Present, SN MLJ00150 to
Present, SN ML500150 to Present, SN ML700150 to
Present)”, for DEF tank installation.
b. DEF Pump Cleaning

1. Refer to Section 7.6.4, “Diesel Exhaust Fluid (DEF) Pump
Filter (SN ML800150 to Present, SN MLJ00150 to Present,
SN ML500150 to Present, SN ML700150 to Present)”, for
DEF pump filter cleaning procedure.
7-12 31211036 TL642D, TL943D, TL1055D, TL1255D

Engine
7.6.6 Fuel Tank 8. Support fuel tank support frame (3) with a floor jack or
suitable supports.
Note: Fuel tank is a one piece unit. It is located under the cab. If it is
determined that fuel tank must be removed, fuel must be drained 9. Remove hardware (4) securing fuel tank support frame
before tank removal. Always dispose of fuel properly. to machine frame.
a. Fuel Tank Removal 10. Carefully lower fuel tank support frame approximately
12 in (305 mm) away from cab.
11. Label, disconnect and cap fuel lines from the top of the
fuel tank. Disconnect fuel sender.
OFF. 12. Verify all hoses and electrical wires are disconnected.
2. Place a Do Not Operate Tag on both ignition key switch 13. Lower the fuel tank support frame away from the cab.
and steering wheel.
6
Note: If replacing the tank, remove all internal and external
components from the old tank, and retain for use on the
replacement tank.
Note: Have a dry chemical (Class B) fire extinguisher near the
work area.
MD0120
5. If equipped, refer to Section 7.6.2, “Diesel Exhaust Fluid 5 5
(DEF) Tank (SN ML800150 to Present, SN MLJ00150 to
14. Remove hardware and strap (5) securing fuel tank (6) to
Present, SN ML500150 to Present, SN ML700150 to
frame.
Present)”, for detailed removal instructions of the DEF
covers and tank. 15. Remove fuel tank from the frame support.
b. Disassembly
Fuel tank is a one-piece unit and cannot be disassembled.
Fuel level indicator can be removed and reused on new
replacement tank. Dispose of old tank according to local
regulations concerning hazardous materials disposal.
2
3
4
MD0110
1
6. Remove drain plug (1) from fuel tank (2) and drain fuel
into an approved and suitable container. Dispose of
fuel properly.
7. Install the fuel tank drain plug (1).
TL642D, TL943D, TL1055D, TL1255D 31211036 7-13

Engine
c. Cleaning and Drying f. Fuel Tank Installation

Clean the tank if contaminated fuel or foreign material is 1. Install the fuel tank to the support frame using the
found. previously removed straps and mounting hardware.
Note: If a leak is suspected in the fuel tank, contact the local 2. Using a floor jack, lift fuel tank and support bracket and
Caterpillar dealer. connect previously labeled fuel hoses to their
appropriate locations. Secure with clamps. Connect fuel
To clean the fuel tank: sender.
1. Have a dry chemical (Class B) fire extinguisher near work 3. Using a floor jack, lift fuel tank and support bracket to
area. their original orientation on cab.
2. Remove the fuel or oil tank drain plug and safely drain 4. Secure the fuel tank frame support with previously used
any fuel into a suitable container. Dispose of fuel hardware. Remove floor jack.
properly.
5. Fill fuel tank according to specifications. Refer to
3. Clean fuel tank with a high pressure washer or flush Section 2.3, “Fluid and Lubricant Capacities”.
tank with hot water for five minutes and drain water.
6. Check fuel tank for leaks.
Dispose of contaminated water properly.
4. Add a diesel fuel emulsifying agent to tank. Refer to
manufacturer’s instructions for correct emulsifying
agent-to-water mixture ratio. Refill tank with water and 8. Close and secure engine cover.
agitate mixture for 10 minutes. Drain tank completely. 9. Remove Do Not Operate Tag from ignition key switch
Dispose of contaminated water properly. and steering wheel.
5. Refill fuel tank with water until it overflows. Completely
flush tank with water. Empty fuel tank and allow it to dry 7.6.7 After Fuel System Service
completely. 1. Drain and flush the fuel tank if it was contaminated.
d. Assembly 2. Vent air from fuel system in accordance with

instructions found in the appropriate Operation &
Fuel level indicator can be removed and reused on new Maintenance Manual.
replacement tank. Dispose of old tank according to
3. Fill the fuel tank with fresh and clean diesel fuel as required.
local regulations concerning hazardous materials
disposal regulations.
e. Inspection
1. Inspect fuel tank thoroughly for any cracks, slices, leaks
or other damage.
2. With fuel tank removed from machine, plug all
openings except one elbow fitting. Install elbow fitting
and apply approximately 1 - 1.5 psi (7 - 10 kPa) of air
pressure through elbow. Check reservoir for leaks by
applying a soap solution to exterior and look for
bubbles to appear at cracked or damaged area.
7-14 31211036 TL642D, TL943D, TL1055D, TL1255D

Engine
7.7 ENGINE EXHAUST SYSTEM

Note: Emission Sensitive Exhaust. Assembly must be replaced 2 3
exactly as removed. Contact your local Caterpillar dealer before
removing the muffler system.
Note: When removing or installing the flex pipe assembly,
DO NOT apply excessive force to the flex section that could
over-extend, compress, or twist the flex.
7.7.1 Exhaust System Removal

TL642D, TL943D (SN ML800150 to
Present, SN MLJ00150 to Present)
OFF. 4 5 6 MAG1140
2. Place a Do Not Operate Tag on both ignition key switch 6. Loosen and remove clamps (2 and 3) at tail pipe end
and steering wheel. segment (4).
3. Open engine cover. Allow system fluids to cool. 7. Remove tail pipe segment (4).
4. Properly disconnect the battery. Refer Section 9.8, 8. Loosen and remove clamps (6) at tail pipe segment (5).
9. Remove tail pipe segment (5).
13 10
7
11
6 5
14
1
MAG0350
5. Remove belly pans (1).

9 20
21 12 MAG1160
8

Selective Catalytic Reduction (SCR) assembly (7), inlet
pipes (8) and exhaust adaptor (10).
11. Loosen and remove exhaust outlet pipe
clamp (11). Remove the exhaust outlet pipe (12).
12. Loosen, remove and discard exhaust adaptor V-band
clamp (13). Remove the exhaust adaptor (10).
TL642D, TL943D, TL1055D, TL1255D 31211036 7-15

Engine
19 18
14
13 10
7
9
11
6 5
17
14
14
15
16 9 20
21 12 MAG1160
8
MAG1810 1. Raise the SCR assembly (7 & 21) into place and secure
with the previously removed hex bolts (20).
8
2. Connect all electrical connections to the SCR assembly.
13. Note exact orientation of clamps (9 & 15). Remove
3. Install new DOC outlet clamp (18) and DOC outlet
thermal blankets (14). Loosen, remove and discard
pipe (19). Do Not tighten.
ball clamps (9).
14. Loosen exhaust pipe clamp (15). Note: Do Not remove bellows wrap and ties until after all
clamps are installed, oriented and torqued.
15. Remove exhaust pipe support clamps (16).
4. Install flex bellow (17), exhaust inlet pipe (8), ball
16. Remove inlet pipes (8) and flex bellows (17).
clamp (9) and exhaust pipe clamp (15). Refer to SIS Web
17. Loosen and remove the Diesel Oxidation Catalyst (DOC) for appropriate installation procedure.
outlet clamp (18). Remove DOC outlet pipe (19).
5. Install exhaust pipe support clamp (16).
18. Loosen and remove four hex bolts (20) from SCR
6. Connect all electrical connections to inlet pipe (8).
mounting bracket (21). Remove SCR with caution. SCR
should be properly supported when removed. 7. Install exhaust adaptor (10) to SCR assemble (7) and
secure with new exhaust adaptor V-band clamp (13).
7.7.2 Exhaust System Installation Refer SIS Web for appropriate installation procedure.
TL642D,TL943D (SN ML800150 to 8. Connect all electrical connections to the exhaust
Present, SN MLJ00150 to Present) adaptor (10).
Note: Keep all clamps loosened until entire exhaust system is in 9. Install exhaust outlet pipe (12) to exhaust
place. adaptor (10) and secure with the clamp (11). Do Not
tighten.
Note: Clamps (9, 13 and 15) and bellows flex pipe (17) MUST
be replaced if the SCR assembly is removed from the machine. 10. Install the tail pipe segment (5) to the exhaust outlet
pipe (12) with clamp (6) and secure to frame on existing
bracket.
11. Install the tail pipe segment (4) to the tail pipe
segment (5) with clamp (3) and secure to frame with
new clamp (2).
12. Properly orient new ball clamps (9) new V-band
clamp (13) and new slip joint clamp (15) for proper
thermal blanket installation. Refer to SIS Web for proper
torque procedure.
7-16 31211036 TL642D, TL943D, TL1055D, TL1255D

Engine
13. Tighten exhaust clamps (2, 3, 6, 11 and 16) to

11–13 Nm (8–9.5 lb-ft).
14
22
14 1
MAG0350
3
MAG1150
14. Install thermal blankets (14).

15. Remove bellows wrap and ties (22).
17. Start engine and check for exhaust leaks at all exhaust
connections. Adjust or repair as needed.
18. Install belly pans (1).
3
and steering wheel. 4
MD0240
7.7.3 Exhaust System Removal

TL1055D, TL1255D (SN ML500150 to 6. Remove skid plate (2).
Present, SN ML700150 to Present) 7. Loosen and remove clamps (3) at tail pipe (4).
1. Park machine on a firm, level surface, level machine, fully 8. Remove tail pipe (4).
OFF.
and steering wheel.
TL642D, TL943D, TL1055D, TL1255D 31211036 7-17

Engine
13. Remove exhaust pipe support clamps (18).

16 14. Remove inlet pipes (7 and 11) and flex bellows (12).
15
15. Loosen and remove exhaust clamp (13). Remove
exhaust pipe (14).
16. Disconnect DEF hoses (19) at DEF injector on the
EAT (6).
17. Loosen and remove four hex bolts (15) from EAT
8
mounting bracket (16). Remove EAT with caution. EAT
should be properly supported when removed.
2 5
MAG1820

Exhaust After Treatment (EAT) assembly (6), inlet
pipes (7) and exhaust outlet pipe (5).
10. Loosen and remove exhaust outlet pipe clamp (8).
Remove the exhaust outlet pipe (5).
19
13
14, 17
9
12 9
17
10
18
MAG1830
11
17
10
11. Note exact orientation of clamps (9, 10 &13). Remove

thermal blankets (17). Loosen, remove and discard ball
clamp (9) and V-clamp (13).
12. Loosen exhaust pipe clamps (10).
7-18 31211036 TL642D, TL943D, TL1055D, TL1255D

Engine
7.7.4 Exhaust System Installation 13. Install previously removed thermal blankets (17)
TL1055D, TL1255D (SN ML500150 to
Present, SN ML700150 to Present)
Note: Keep all clamps loosened until entire exhaust system is in 20
place.
Note: The clamps (8, 9 and13) and bellows flex pipe (12) MUST
be replaced if the EAT assembly is removed from the machine.
1. Raise the EAT assembly (6) into place and secure with
the previously removed hex bolts (15).
2. Connect all electrical connections to the EAT assembly.
3. Install new exhaust clamp (13) and exhaust pipe (14).
Do Not tighten.
4. Install flex bellow (12), exhaust pipe (7 and 11) and ball
clamps (9). Refer to SIS Web for appropriate installation
procedure.
5. Install exhaust pipe support clamps (18).
6. Connect all electrical connections to inlet pipe (7).
7. Install outlet exhaust pipe (5) to EAT (6) outlet and
secure with the new clamp (8). Do Not tighten. MAG1050
8. Connect all electrical connections to the outlet exhaust 14. Remove bellows wrap and ties.
pipe (5).
9. Connect DEF hoses (19) to EAT (6) DEF injector. “Battery”, for procedure.
10. Install the tail pipe (4) to the outlet exhaust pipe (5) with 16. Start engine and check for exhaust leaks at all exhaust
clamp (3) and secure to frame with clamp (3). connections. Adjust or repair as needed.
11. Torque ball clamps (9) and exhaust clamps (10). Refer to 17. Install skid plate (2).
SIS Web for appropriate procedure to torque.
18. Install belly pans (1).
12. Tighten exhaust clamps (3), (8) and (18) to
11 - 13 Nm (8 - 9.5 lb-ft).
and steering wheel.
14, 17
17
MAG1040
17
TL642D, TL943D, TL1055D, TL1255D 31211036 7-19

Engine
7.7.5 Exhaust System Removal TL1055D, TL1255D

TL642D, TL943D, TL1055D, TL1255D 2
(SN MLG00150 to Present,
SN MLD00150 to Present,
SN MNT00150 to Present,
SN MYW00150 to Present)
OFF. 2
and steering wheel.
4. Properly disconnect the battery. Refer Section 9.8, 3
“Battery”, for procedure. MD0240
6. For TL642D, TL943D:

a. Loosen and remove clamps (2 and 4) at tail pipe end
segment(3).
b. Remove tail pipe segment (3).
c. Loosen and remove clamps (5) at tail pipe
segment(6).
d. Remove tail pipe segment (6)
7. For TL1055D, TL1255D: Loosen and remove clamps (2)
at tail pipe (3).
8. Remove tail pipe (3).
TL642D, TL943D, TL1055D & TL1255D
1
MAG0350

TL642D, TL943D
7
2 12 8
4
10
15
11
9
14 13
MAG0370
9. Loosen and remove exhaust pipe clamp (13).

3 6 5 10. Remove exhaust pipe (14).
MAG1140
11. Loosen and remove clamp (10) from flex pipe
assembly (8).
7-20 31211036 TL642D, TL943D, TL1055D, TL1255D

Engine
12. Remove hardware (9) securing muffler band 7.8 AIR CLEANER ASSEMBLY
clamps (11) to muffler mounting bracket (12).
13. Carefully lower muffler (15) from machine.
14. Loosen and remove three flange nuts (7) securing flex NOTICE
pipe assembly (8). NEVER run the engine with only the inner safety element
15. Remove flex pipe assembly (8). installed.
Note: Refer to the appropriate machine Operation &

7.7.6 Exhaust System Installation Maintenance Manual for the correct element change
TL642D, TL943D, TL1055D, TL1255D procedure.
(SN MLG00150 to Present,
SN MLD00150 to Present,
7.8.1 Air Cleaner Assembly Removal
SN MNT00150 to Present,
SN MYW00150 to Present) 1. Park machine on a firm, level surface, level machine, fully
Note: Keep all clamps loosened until entire exhaust system is in
place.
OFF.
Note: The flex pipe assembly (8) MUST be replaced if removed 2. Place a Do Not Operate Tag on both ignition key switch
from the machine. and steering wheel.
1. Install new flex pipe assembly (8) to the engine with seal 3. Open engine cover. Allow system fluids to cool.
interposed in between and secure with hardware
removed earlier. Do Not tighten.
2. Install muffler (15) and secure with hardware removed
SN ML800150 to Present, SN MLJ00150 to Present,
earlier. Install clamp (10) on flex pipe assembly. Do Not
SN ML500150 to Present, SN ML700150 to Present
tighten.
3. Install exhaust pipe (14) to muffler (15) with clamp (13).
Do Not tighten. 15
4. For TL642D, TL943D:

a. Install the tail pipe segment(6) to the exhaust outlet
pipe (14) with clamp (5)and secure to frame on
existing bracket.
b. Install the tail pipe segment(3) to the tail pipe
segment(6) with clamp (4) and secure to frame with
clamp (2).
5. For TL1055D, TL1255D: Install the tail pipe (3) to the
exhaust pipe (14) and secure to frame with new
clamps (2). Do Not Tighten.
6. Adjust the muffler, tail and exhaust pipes for proper
clearance then tighten all clamps. MAG0380
7. Torque clamps (7) to 34 - 36 lb-ft (47 - 50 Nm). 12 11 13 14
8. Torque clamps (2 and 5) to 8 - 9.5 lb-ft (11 - 13 Nm).
10. Start engine and check for exhaust leaks at all exhaust
connections. Adjust or repair as needed.
11. Install belly pans.
and steering wheel.
TL642D, TL943D, TL1055D, TL1255D 31211036 7-21

Engine
SN MLG00150 to Present, SN MLD00150 to Present, 7.9 ENGINE REPLACEMENT

SN MNT00150 to Present, SN MYW00150 to Present
15
WARNING
minimum lifting capacity of 2000 lb (907 kg).
7.9.1 Engine/Transmission Removal

Note: The radiator assembly must be removed from the
machine before engine/transmission removal. Refer to
Section 7.4.3, “Radiator Assembly Replacement”. Several
additional components must be removed before engine/
transmission removal. They will be addressed in the following
procedures.
12 11 13 14
MAG0390 (N) NEUTRAL, engage parking brake and shut engine
OFF.
5. Disconnect all electrical connections. 2. Place a Do Not Operate Tag on both ignition key switch
6. Loosen and remove clamp (11) securing air intake and steering wheel.
tube (12) to air cleaner (13). Pull air intake elbow off air 3. Open engine cover. Allow system fluids to cool.
cleaner.
4. Properly disconnect battery(s).
7. Remove bolts (14) securing air cleaner straps (15) to air
cleaner (13). Remove air cleaner assembly. 1
7.8.2 Air Cleaner Assembly Installation

1. Install the air cleaner assembly (13) to the air cleaner
mounting plate and secure with the previously used
hardware.
2. Place the loosened clamp (11) over the air intake 3 3
elbow (12) and install elbow on the air cleaner
assembly. Tighten clamp.
3. Reconnect all electrical connections.
4. Properly connect the battery. Refer Section 9.8, 2 MAG0400
4
5. Close and secure engine cover. 5. Remove hood (1), belly pan (2), end covers (3) and front
cover (4) from engine compartment.
and steering wheel. 6. Properly drain hydraulic oil system. Refer to Section 8.7.
“Hydraulic Reservoir”, for detailed instructions.
7. Properly drain transmission. Refer to Section 6.4.1.
“Transmission Removal”, for detailed instructions.
8. Mark position of cover to help with cover adjustment
when being reinstalled.
9. Label, disconnect and cap/plug all hydraulic
connections on the engine/transmission.
7-22 31211036 TL642D, TL943D, TL1055D, TL1255D

Engine
Note: Engine/transmission harness is routed and attached to TL642D, TL943D, TL1055D, TL1255D
engine/transmission using hold-down clamps and plastic wire (SN MLG00150 to Present, SN MLD00150 to Present,
ties at various places on engine. Before removing SN MNT00150 to Present, SN MYW00150 to Present)
engine/transmission, ensure that harness has been completely
5
separated (disconnected) from engine/transmission. Move
harness clear of engine/transmission and with help of an
observer, ensure that engine/transmission clears the harness
during removal.
10. Label and disconnect all electrical wire connections on
engine/transmission.
TL642D, TL943D
(SN ML800150 to Present, SN MLJ00150 to Present)
6 MAG0420
11. Disconnect and cap the fuel inlet lines (5).

12. Disconnect and cap the fuel return lines (6).
13. Label and remove all clamps securing any fuel line on
engine.
14. Remove the heater hoses (7) (if equipped) and DEF tank
cooling hoses (8) (if equipped) attached to the engine.
15. Remove exhaust pipe from exhaust manifold. Refer to
Section 7.7, “Engine Exhaust System”.
6 MAG1620
8 5 Note: Emission Sensitive Exhaust. Assembly must be replaced
exactly as removed.
TL1055D, TL1255D
(SN ML500150 to Present, SN ML700150 to Present) 16. Remove air cleaner assembly. Refer to Section 7.8, “Air
7 6 Cleaner Assembly”.
8
17. Remove drive shaft assemblies. Refer to Section 5.8.
“Drive Shafts”.
MAG0410
8 5
TL642D, TL943D, TL1055D, TL1255D 31211036 7-23

Engine
TL642D, TL943D TL1055D, TL1255D

(SN ML800150 to Present, SN MLJ00150 to Present) (SN ML500150 to Present, SN ML700150 to Present,
SN MNT00150 to Present, SN MYW00150 to Present)
10
10
11
MAG1780
TL642D, TL943D
(SN MLG00150 to Present, SN MLD00150 to Present)
MAG2190
11
18. Secure engine with a lifting strap or chain from

appropriate lifting points (10). Use a suitable hoist or
overhead crane with minimum lifting capacity of
2000 lb (910 kg).
19. Loosen and remove three engine/transmission
10
mounting bolts (11).
20. Slightly lift and pull engine/transmission out of
machine. Have an assistant to ensure that
engine/transmission clears all frame components
during removal.
21. Place engine/transmission on a flat and level surface.
7.9.2 Transmission Removal/Installation

1. Refer to Section 6.4. “Transmission Replacement”, for
detailed transmission removal and installation
instructions.
MAG2200
11
7-24 31211036 TL642D, TL943D, TL1055D, TL1255D

Engine
7.9.3 Engine Disassembly, Inspection and 13. Install drive shaft assemblies. Refer to Section 5.8.3,
Service “Drive Shaft - TL642D, TL943D” and Section 5.8.4, “Drive
Engine disassembly, internal inspection, service, repair and
assembly procedures are covered in the Engine Service 14. Connect and secure all the previously labeled hydraulic
Manual. Several special engine service tools are required to hoses, fuel lines and electrical wire connections on
properly service the engine. Contact the local Caterpillar engine and transmission.
dealer for further information. 15. Install heater and cooling hoses to engine and tighten
Note: If engine is being replaced, there may be external clamps (if equipped).
components that will be required to be transferred from original 16. Properly connect battery(s).
engine to replacement engine depending upon who you purchase 17. Check that all hydraulic system, electrical
new engine from and configuration of your replacement engine. system, cooling system, fuel system and exhaust system
Refer to appropriate Engine user manual for detailed procedures connections are correct and connected tightly.
that cover transfer of original engine components to replacement
engine. Note: Have an assistant stand by with a Class B
fire extinguisher.
7.9.4 Engine/Transmission Installation 18. Check for proper fluid levels prior to startup.
Refer to Section 2.3, “Fluid and Lubricant Capacities”.
WARNING 19. Start engine and run to normal operating temperature

then shut off engine. While engine is cooling, check for
Use a suitable hoist or overhead crane and sling with a leaks.
minimum lifting capacity of 2000 lb (907 kg). 20. Allow engine to cool. Check radiator coolant level. Add
1. Attach a lifting chain to the front and rear engine lift coolant as required.
brackets and lift engine/transmission clear of the 21. Check for leaks from engine, main hydraulic pump and
ground. lines, transmission, hydraulic reservoir and fuel tank.
2. Refer to Section 2.6. “Thread Locking Compound”, for all Check levels of all fluids and lubricants. Fill as required.
thread locking requirements. 22. Check engine rpm at full throttle.
3. Lift engine/transmission and slowly push and lower into Note: During full throttle check:
engine compartment. Have an assistant ensure that
engine/transmission clears frame, hose and harness • DO NOT operate any hydraulic function.
components during engine/transmission installation. • DO NOT steer or apply any pressure to the steering
Position engine/transmission brackets over frame wheel.
mounts.
• Keep transmission in (N) NEUTRAL.
4. Align engine mount holes and install front mounting
bolts. 23. Purge the hydraulic system of air by operating all boom
functions through their entire range of motion several
5. Align engine mount holes and install rear mounting times.
bolts.
24. Check hydraulic oil level. If oil is warm, oil level should
6. Lower engine onto isolators. be visible in gauge window.
7. Install flat washer and nut on front two mounting bolts. 25. Check for proper operation of all components.
8. Remove lifting chains. 26. Turn engine OFF.
9. Torque engine/transmission mounting bolts (11) to 27. Install front cover (4), end covers (3), belly pan (2) and
178 lb-ft (241 Nm). hood (1) at the engine compartment and adjust if
10. Install air cleaner. Refer to Section 7.8, “Air Cleaner necessary.
Assembly”. 28. Close and secure engine cover.
11. Install exhaust pipe. Refer to Section 7.7, “Engine 29. Remove Do Not Operate Tag from ignition key switch
Exhaust System”. and steering wheel.
12. Install radiator assembly. Refer to Section 7.4.3,
“Radiator Assembly Replacement”.
TL642D, TL943D, TL1055D, TL1255D 31211036 7-25

Engine
7.10 TROUBLESHOOTING
Refer to Section 7.3, “Specifications and Maintenance
Information”, for detailed engine service information.
7-26 31211036 TL642D, TL943D, TL1055D, TL1255D

Section 8
Hydraulic System
Contents

8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5.1 Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.6 Hydraulic Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.6.1 TL642D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.6.2 TL943D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.6.3 TL1055D, TL1255D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.7 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.7.1 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.7.2 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.7.3 Hydraulic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.7.4 Hydraulic Oil Reservoir Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.8 Implement Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
8.8.1 Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
8.9 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.9.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.9.2 Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.9.3 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
8.9.4 Service Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
8.9.5 Service Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
8.9.6 Park Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
8.9.7 Steering Orbital Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
8.9.8 Outrigger/Frame Leveling Valve (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
8.9.9 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
8.10 Rear Axle Stabilization (RAS) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
8.10.1 Rear Axle Stabilization System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
8.11 Precision Gravity Lower System (PGLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
8.12 Boom Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
8.12.1 General Accumulator Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
8.12.2 Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
8.12.3 Pre-Charging Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
8.12.4 Checking Pre-Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
TL642D, TL943D, TL1055D, TL1255D 31211036 8-1

Hydraulic System
8.13 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

8.13.1 General Cylinder Removal Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
8.13.2 Cylinder Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
8.13.3 Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
8.13.4 Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
8-2 31211036 TL642D, TL943D, TL1055D, TL1255D

Hydraulic System
8.1 HYDRAULIC COMPONENT

TERMINOLOGY
To understand the safety, operation and service information
presented in this section, it is necessary that the
of the hydraulic components of the machine. The following
LIFT/LOWER COMPENSATION
CYLINDER CYLINDER
EXTEND/RETRACT RAS
CYLINDER SYSTEM
TILT
CYLINDER
MAIN
HYDRAULIC FLUID
CONTROL
RESERVOIR
IMPLEMENT VALVE
PUMP (HIDDEN FROM VIEW)
MAG0801
OUTRIGGER FRAME LEVEL CYLINDER

CYLINDERS (BEHIND TIRE ON RIGHT SIDE)
(IF EQUIPPED)
TL642D, TL943D, TL1055D, TL1255D 31211036 8-3

Hydraulic System
8.2 SAFETY INFORMATION Refer Section 2.4, “Service and Maintenance Schedules”, for
the appropriate maintenance intervals based on hours of
operation, but if your equipment is exposed to extremely
WARNING dirty or hostile conditions service may be required more
frequently. Always use OEM filters to assure the necessary
DO NOT service the machine without following all safety filtration requirements are met.
Some hydraulic functions are actuated by interfacing with
this manual.
electrical system components (switches, solenoids and
Petroleum-based hydraulic fluids are used in this machine. sensors). When the hydraulic system is not functioning
The temperature of hydraulic fluid increases during the properly, check the electrical aspect of the malfunctioning
operation of various hydraulic functions. A heated circuit also. Refer to Section 9.5, “Electrical System
petroleum-based hydraulic fluid presents a fire Schematics”, in this manual.
hazard, especially when an ignition source is present.
Accordingly, periodically inspect all hydraulic system
components, hoses, tubes, lines, fittings, etc. Carefully
examine any deterioration and determine whether any
further use of the component would constitute a hazard.
If in doubt, replace the component.
Whenever you disconnect a hydraulic line, coupler, fitting or
other component, slowly and cautiously loosen the part
involved. A hissing sound or slow seepage of hydraulic fluid
may occur in most cases. After the hissing sound has
ceased, continue removing the part. Any escaping oil should
be directed into an appropriate container. Cap or otherwise
block off the part to prevent further fluid seepage.
Hydraulic system maintenance will, at times, require that the
engine be operated. Always follow safety precautions.
A major cause of hydraulic component failure is
contamination. Keeping the hydraulic fluid as clean as
possible will help avoid downtime and repairs. Dirty or
contaminated hydraulic oil can damage internal
components and void the manufacturer’s warranty. When
servicing the system, cap or plug hydraulic fittings, hoses
and tube assemblies. Plug all cylinder ports, valves and the
hydraulic reservoir, and pump openings until installation
occurs. Protect threads from contamination and damage.
Manufacturer’s recommended hydraulic oil cleanliness
levels are based on the three digit ISO code for 4 micron/6
micron/14 micron particle sizes found in one ml of fluid
(reference ISO 4406: 199(E). The acceptable level is 19/17/14
or below; anything higher requires system cleaning and
filter replacement.
Note: The human eye can only distinguish particles down to
40 microns.
8-4 31211036 TL642D, TL943D, TL1055D, TL1255D

Hydraulic System
8.3 SPECIFICATIONS 8.5 HYDRAULIC CIRCUITS

Refer to Section 2.2, “Specifications”, for hydraulic system This section covers the hydraulic circuits and includes
specifications. listings for all hydraulic function pressures, where and how
to check those pressures and a hydraulic schematic.
8.4 HYDRAULIC PRESSURE DIAGNOSIS Electrical and hydraulic functions are often related. Verify
that the electrical components of the circuit are functioning
8.4.1 Pressure Checks and Adjustments properly whenever troubleshooting the hydraulic circuit.
When diagnosing trouble in the hydraulic system, use the Always check the following before beginning to
hydraulic testing information in Section 8.5.1, “Hydraulic troubleshoot a circuit that is not functioning correctly.
Pressures”.
1. Check the hydraulic oil level in the reservoir. If oil is
In general, follow the steps below whenever conducting cold, oil level should be visible in the lower gauge
pressure checks and performing adjustments: window with all cylinders retracted.
1. Park the machine on a firm, level surface. Engage the 2. Check hoses, tubes, fittings and other hydraulic
park brake, place the transmission in (N) NEUTRAL, level components for leaks, bends, kinks, interference, etc.
the boom and turn the engine OFF. 3. Check for air in the hydraulic system. Erratic machine
2. At the proper test port, install a pressure gauge capable performance and/or spongy cylinder operation are
of measuring at least 10% more pressure than that signs of air in the hydraulic system.
which the circuit being checked operates under. If air in the hydraulic system is suspected, you will hear
3. Start the engine. Operate machine functions several air leakage when hydraulic fittings are loosened and see
times to allow hydraulic oil to reach operating air bubbles in the hydraulic fluid.
temperature. The hydraulic oil temperature should be Loose fittings, faulty o-rings or seals, trapped
between 100-120° F (38-49° C). If a temperature gauge oil, leaks, system opened for service, etc., can cause air in
or thermometer is unavailable, the hydraulic oil reservoir the system. Determine what is causing air to enter the
should be warm to the touch. system and correct it. Bleed air from the system.
4. Fully depress the accelerator pedal if required. Place and
hold the joystick in the position needed to operate the 8.5.1 Hydraulic Pressures
particular machine function being checked. Continue
holding the joystick in position until pressure readings a. Checking Pressure
are taken. 1. Start the machine and warm the hydraulic system to
5. Check the pressure gauge reading. It should read as operating temperature.
specified in the Pressure Readings column of the charts 2. Shut off the machine and install a digital or a
found in Section 8.5.1, “Hydraulic Pressures”. If the 5000 psi (345 bar) gauge to the appropriate test port on
reading is not as specified, turn the engine OFF and the priority function valve.
check other components in the system. Verify that all
related hydraulic components and electrical 3. Start the machine, run the engine at idle and stall the
switches, sensors, solenoids, etc. are operating correctly. appropriate hydraulic function. Refer to
Section 8.5.1, c. “Pressure Specifications - TL642D”, for
6. Adjust the relief valve by turning the adjustment screw. the correct pressure rating.
Turning clockwise will increase the pressure; turning the
screw counterclockwise will decrease the pressure.
7. Start the engine and check the pressure again. Turn the
engine OFF. If there is pressure reading in the
gauge, bleed it off then disconnect or remove the
pressure gauge from the machine.
TL642D, TL943D, TL1055D, TL1255D 31211036 8-5

Hydraulic System
b. Adjusting Maximum Hydraulic Pressure

1. Shut the machine off.
2. Start the machine and loosen the jam nut on the relief.
Turn the relief clockwise to increase pressure or
counter-clockwise to decrease pressure. Set to the
correct pressure.
3. Tighten the jam nut and recheck the pressure. If the
reading is within specification, shut the machine off,
install the safety cap and remove the gauge from the
test port.
4. If the proper pressure cannot be set, use the
accompanying hydraulic schematic and/or the electrical
schematic to help troubleshoot and correct the
problem.
Note: DO NOT operate any other function while checking
steering pressure.
Note: The steering pressure is pre-set from the manufacturer
and cannot be adjusted.
8-6 31211036 TL642D, TL943D, TL1055D, TL1255D

Hydraulic System
c. Pressure Specifications - TL642D
PUMP RAS VALVE

MAIN CONTROL VALVE CF
Ps
R1
MAG2210
P
MAG1790
MAE23200
Note: All pressures must be checked in numerical order.
Hydraulic Test Adjustment Range/

Procedure Notes
Circuit Port Location Nominal Pressure
Connect gauge to MCV 235-290 psi
Standby P No
1 P-gauge port, Engine at low (16-20 bar) Park Brake - ON
Pressure Pressure Adjustment
idle, no hydraulic function 265 psi (18 bar)
2610-2710 psi
Steering Connect gauge to pump CF No (180-187 bar)
2 CF port Park Brake - ON
Pressure port, stall steering, high idle Adjustment 2660 psi
(183.5 bar)
Main 3770-3820 psi
P Connect gauge to P-Port, high Main relief
3 Relief (260-263.5 bar) Park Brake - ON
Pressure idle, stall boom retract adjust screw
Valve 3770 psi (260 bar)
No 3330-3615 psi
Hydraulic P Connect gauge to P-Port, high
4 Adjustment; (230-250 bar) Park Brake - ON
Aux Pressure idle, apply aux switch and hold
just check 3470 psi (240 bar)
Pilot 460-490 psi
Connect gauge to P-Port, high
5 supply Ps port PRV (32-34 bar) Park Brake - ON
idle, stall boom retract
pressure 475 psi (33 bar)
Connect gauge to R1 port, run 85-125 psi
6 RAS R1 engine at low idle, stall lift RAS (1) (6-8.5 bar) Park Brake - ON
down 100 psi (7 bar)
TL642D, TL943D, TL1055D, TL1255D 31211036 8-7

Hydraulic System
d. Pressure Specifications - TL943D, TL1055D, TL1255D
MAIN CONTROL VALVE PUMP

B
C RAS VALVE
R1
M3
MAG0700
M5
E
MAG0830
D M2
A
PRIORITY MAE23200
FUNCTION
VALVE
M4
MAG0840
M1
Note: All pressures must be checked in numerical order.

Procedure Notes
330-410 psi
Standby Connect gauge to M1 port, run
1 M1 P (B) (22,7-28,2 bar) Park Brake - ON
(1) engine at low idle, no function.
370 psi (25,5 bar)
40-90 psi
Load Connect gauge to M2 port, run
2 M2 N/A (2,75-6,25 bar) Park Brake - ON
Sense engine at low idle, no function.
65 psi (4,5 bar)
290-319 psi
(1) Standby Pressure, subtract (2)
3 Margin Calculation (20-22 bar) Park Brake - ON
LS Pressure = Margin Pressure
305 psi (21 bar)
Park Brake switch
Connect gauge to M1 port, run 750-820 psi turned OFF. Make
Standby
4 M1 engine at low idle, no function. Priority (D) (51,7-56,6 bar) sure M2, M3 & M4
(2)
Turn Park Brake OFF. 785 psi (54,1 bar) read 460-500 psi
(32-35 bar)
Main
3726-3814 psi
System Connect gauge to M1 port, run
5 M1 MCV(A) (257-263 bar) Park Brake - ON
Pressure engine at low idle, stall lift down.
3770 psi (260 bar)
Cutoff
8-8 31211036 TL642D, TL943D, TL1055D, TL1255D

Hydraulic System

Procedure Notes
330-410 psi Park Brake - ON
Connect gauge to M3 port, run
6 Pilot (1) M3 N/A (22,7-28,2 bar) Standby Pressure
engine at low idle.
370 psi (25,5 bar) Only
Connect gauge to M3 port, run 460-500 psi
Park Brake OFF
7 Pilot (2) M3 engine at low idle. Turn Park Priority (D) (32-35 bar)
Check Only
Brake OFF. 480 psi (33 bar)
Park Brake Connect gauge to M4 port, run 0-10 psi (0-0,7 bar)
8 M4 N/A Park Brake - ON
(1) engine at low idle. 0 psi (0bar)
Connect gauge to M4 port, run 460-500 psi
Park Brake Park Brake OFF
9 M4 engine at low idle. Turn Park Priority (D) (32-35 bar)
(2) Check Only
Brake OFF. 480 psi (33 bar)
Steering
2566-2711 psi Non Adjustable - LS
Priority Connect gauge to M5 port, run
10 M5 N/A (177-187 bar) Relief Pre-set in the
Load engine at low idle, stall steering.
2640 psi (182 bar) Steering Unit
Sense
Connect gauge to M2 port, run
3180-3430 psi
engine at high idle, stall auxiliary Pressure/Functional
11 Auxiliary M2 N/A (219-236,5 bar)
one direction, then stall in other Check
3305 psi (228 bar)
direction. Repeat check.
85-125 psi
Connect gauge to R1 port, run Pressure/Functional
12 RAS R1 RAS (E) (6-8,5 bar)
engine at low idle, stall lift down. Check
100 psi (7 bar)
Adjust Standby pressure as in
steps 1, 2 & 3.
Adjust Main Compensator High
Pressure Cut Off to 4206 psi
(290 bar). Note that adjustment
may require incrementally
increase Load Sense Relief Valve
(MCV A) first then Main Pump
Load 3393-3538 psi Only needed if step
Compensator until a setting of
13 Sense M2 MCV (A) (234-244 bar) 5 cannot be
4206 psi (290 bar) can be
Relief 3450 psi (238 bar) achieved
observed on the M1 gauge.
Adjust the Load Sense Relief
Valve to setting shown using
gauge in M2 port.
Once the Load Sense Relief is
adjusted to specification, the
Main Pump pressure may read
lower than 4206 psi (290 bar).
TL642D, TL943D, TL1055D, TL1255D 31211036 8-9

8.6
8-10
8.6.1
8 7 6 5 4 3 2 1
EXTEND/RETRACT TILT
LIFT
AUXILIARIES
150 / 90 / 1069.7 TL 642D 85 / 65 / 3604 TL 642D 120 / 60 / 388
TL 642D
STD AUX MALE QUICK COUPLER (M)

M F FEMALE QUICK COUPLER (F)
H H
a. No Outriggers
C1 C2 FOR OPTIONS DETAIL SEE
SHEET 3
C2 C1 350 BAR TL642D
C1 C2
180 BAR TL 642D 120 / 60 / 278 CB VALVE
PILOT RATIO: 4:1
380 BAR 150 BAR
V1 V2
380 BAR
COMP
CB VALVE
PILOT RATIO: 4:1
CB VALVE
V2 V1 PILOT RATIO: 4:1
V1 V2
Hydraulic System
G G
MAIN CONTROL VALVE A1 B1 A2 B2 A3 B3 A4 B4 LS (A5) B5 Pd

HYDRAULIC SCHEMATIC
280 bar 280 bar 240 bar 240 bar
260 bar FRAME LEVEL CYLINDER

F 420 BAR TL 642D 120 / 55 / 200 F
V2 C2
T
Pg V1 C1
420 BAR
P
CB VALVE
A B A B A B A B PILOT RATIO: 4.2:1
34 bar
LS A1 B1
Pd
E E
Ps
P Ø 1.4
INLET LIFT EXTEND/RETRACT FORK TILT AUX BY PASS OUTLET
Ø 1.0
Ø 1.6
T
FRAME LEVEL VALVE
31211036
R1 RAS VALVE
100 psi
D D
P
5000 psi
HYDRAULIC OIL B
COOLER T
bh
B8=75 CF EF
B1
25PSI BYPASS
PB VALVE
R1
C C
STEERING ORBITROL 320CC/REV
L
LS FRONT AXLE
P R s TL 642D 120 / 55 / 200
34.5CC/REV
230BAR RAS CYLINDER
p
ENGINE P T
LS
280BAR
4WS CRAB
170BAR STEERING MODE

SELECTOR VALVE
230BAR A B
P L
T
VALVE, BRAKE ASSEMBLY
B REAR AXLE B
3 MICRON
HYDRAULIC TANK
A A
8 7 6 5 4 3 2 1
MAE20240F
TL642D, TL943D, TL1055D, TL1255D

8 7 6 5 4 3 2 1
H H
MALE QUICK COUPLER (M)
FEMALE QUICK COUPLER (F) FRONT AUX CONFIGURATIONS
BOOM RIDE CONTROL
A
C D
B
STD AUX
FRONT AUX 1/2 & AUX QC LIFT CYLINDER
M F 1ST QC 2ND
FRONT AUX & AUX QC
FRONT AUX 1/2 1ST QC M F M F
TL642D, TL943D, TL1055D, TL1255D

1 2 1ST 2ND ACCUMULATOR A1 B1
M F 1.5L
M F M F
M1
50 BAR
G G
VALVE,GP-DIVERTOR-6-7 (C) 180 BAR
VALVE,DIVERTOR
380 BAR,
VALVE,DIVERTOR PILOT RATIO: 4:1
1 2
1 2 A B
1 2
A4 B4
F 280 bar 280 bar F
A1 B1
E A B E
A B
AUX
LIFT
AUX SECTION OF MAIN
CONTROL VALVE; SEE SHEET 1
31211036
LIFT SECTION OF MAIN
D D
C C
B B
A A
8 7 6 5 4 3 2 1
Hydraulic System
MAE20260F
8-11
8-12
8 7 6 5 4 3 2 1
LIFT EXTEND/RETRACT TILT

AUXILIARIES
TL 642D 85 / 65 / 3604 TL 642D 120 / 60 / 388
TL 642D 150 / 90 / 1069.7
STD AUX MALE QUICK COUPLER (M)

M F FEMALE QUICK COUPLER (F)
H FOR OPTIONS DETAIL SEE H
C1 C2
SHEET 3
C2 C1 350 BAR
b. With Outriggers
C1 C2
180 BAR CB VALVE
TL 642D 120 / 60 / 278
PILOT RATIO: 4:1
150 BAR
380 BAR
V1 V2
380 BAR
COMP
CB VALVE
PILOT RATIO: 4:1
CB VALVE
V2 V1 PILOT RATIO: 4:1
V1 V2
Hydraulic System
G G
MAIN CONTROL VALVE A1 B1 A2 B2 A3 B3 A4 B4 LS (A5) B5 Pd

280 bar 280 bar 240 bar 240 bar
260 bar
F F
OUTRIGGER CYLINDERS
LEFT RIGHT
M M FRAME LEVEL CYLINDER
T
420 BAR 420 BAR 420 BAR
Pg TL 642D 140 / 75 / 300 140 / 75 / 300
TL 642D TL 642D 120 / 55 / 200
C2 V2 V2 C2 V2 C2
P
A B A B A B A B
34 bar
C1 V1 V1 C1 V1 C1
Pd 150 BAR 150 BAR 420 BAR

E CB VALVE CB VALVE E
PILOT RATIO:4.2:1 CB VALVE
PILOT RATIO:4.2:1 PILOT RATIO:4.2:1
Ps
INLET LIFT EXTEND/RETRACT FORK TILT AUX BY PASS OUTLET
A B A B A B
LS
Ø 1.0
Ø 1.4
Ø 0.6
S
31211036
Ø 1.6
T
D D
FRAME LEVEL/STABILIZER
VALVE
P
R1 RAS VALVE
B 100 psi
T
P
HYDRAULIC OIL EF
CF
COOLER
0 psi
PB VALVE 5000 psi
C C
bh
STEERING ORBITROL 320CC/REV
B1
B8=75
L FRONT AXLE
25PSI BYPASS
R1
S
P
34.5CC/REV R
230BAR L
ENGINE P T
LS
280BAR
4WS CRAB
s
170BAR STEERING MODE

SELECTOR VALVE
p
230BAR A B RAS CYLINDER

P L
T
TL 642D 120 / 55 / 200
REAR AXLE
B B
3 MICRON
HYDRAULIC TANK
A A
8 7 6 5 4 3 2 1
MAE20250F
TL642D, TL943D, TL1055D, TL1255D

8 7 6 5 4 3 2 1
H H
TL642D, TL943D, TL1055D, TL1255D

G
EMERGENCY STEERING OPTION G
L R
280 bar 280 bar
F F
80/320 cc FLOW AMP STEERING UNIT

170 bar
E E
P T LS
TO DLS
200 Psi 5 Psi
31211036
D
D D
C C
B B
A A
8 7 6 5 4 3 2 1
Hydraulic System
MAE20270F
8-13
8-14
8.6.2

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TL943D
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Hydraulic System
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TL642D, TL943D, TL1055D, TL1255D

FEMALE QUICK COUPLER (F)
FRONT AUX CONFIGURATIONS BOOM RIDE CONTROL

A

B C1 C2
FRONT AUX 1/2 & AUX QC M1 ACCUMULATOR

STD AUX 1.5 L
TL642D, TL943D, TL1055D, TL1255D

1ST QC 2ND 50 BAR
FRONT AUX & AUX QC
FRONT AUX 1/2 1ST QC M F M F
1ST 2ND
M F ACC
M F M F
PIL T
VALVE, GP-DIVERTOR-6-7 (C) T
CONNECTED
TO MCV
SUMP
VALVE, DIVERTOR
V1 V2 VALVE CONTROL
VALVE, DIVERTOR
A4 B4
205 BAR 205 BAR A1 B1

PIL

31211036
A
A

AUX
LIFT
AUX SECTION OF MAIN
CONTROL VALVE; SEE SHEET 1 LIFT SECTION OF MAIN

Hydraulic System

8-15
8-16

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Hydraulic System

8-17
8-18
8.6.3
8 7 6 5 4 3 2 1
LIFT EXTEND/RETRACT TILT

TL 1255 200 / 105 / 1186 TL1255 D 120 / 75 / 3683 TL1255 D 160 / 75 / 386.4
TL 1055 190 / 100 / 1186 TL1055 D 120 / 75 / 3683 TL1055 D 150 / 75 / 386.4 AUXILIARIES
STD AUX
M F
H MALE QUICK COUPLER (M) H

C1 C2 FEMALE QUICK COUPLER (F)
FOR OPTIONS DETAIL
C1 C2 C2 C1 SEE SHEET 2
350 BAR CB VALVE
180 BAR 150 BAR COMP PILOT RATIO: 4:1
TL1255 D 160 / 75 / 292.5
380 BAR 380 BAR TL1055 D 150 / 75 / 292.5
V1 V2
C2
V2
CB VALVE CB VALVE 350 BAR
PILOT RATIO: 4:1 PILOT RATIO: 4:1
V1 V2 V2 V1
V1
C1
CB VALVE
PILOT RATIO: 8:1
Hydraulic System
G OUTRIGGER CYLINDERS FRAME LEVEL CYLINDER

G
A1 B1 A2 B2 A3 B3 A4 B4
280 bar 280 bar 280 bar 205 bar 205 bar TL1255 D 120 / 55 / 168
LEFT RIGHT
MAIN CONTROL M M
TL1055 D 120 / 55 / 168
420 BAR
TL1055D, TL1255D
VALVE TL1255 D 140 / 75 / 300 420 BAR TL1255 D 140 / 75 / 300 420 BAR
TL1055 D 140 / 75 / 300 TL1055 D 140 / 75 / 300
T1 C2 V2 V2 C2 V2 C2
LS V1 C1
B C1 V1
V1 2 C1
B B B
238 BAR 150 BAR 150 BAR 420 BAR
CB VALVE CB VALVE CB VALVE
PILOT RATIO: 4.2:1 PILOT RATIO: 4.2:1 PILOT RATIO: 4.2:1
F F
A B A B A B
LS
Ø 1.0
Ø 1.4
S Ø 0.6
A Ø 1.6
A A A
T
P1
INLET LIFT EXTEND/RETRACT TILT AUX OUTLET
EH SUMP FRAME LEVEL/STABILIZER
E SUPPLY VALVE E
PRIORITY FUNCTION
S1 LS1 VALVE EF1 EF2 LS2 S2

B R1 RAS VALVE
L r B1
100 psi
PB
31211036
T
D bh
P
Ø 0.8 mm
D p s D
5000 psi
33.3 BAR
DLS
T2 P FRONT AXLE
230 BAR R
4WS P T CRAB
STEER SELECT
M1 LS
M3 M4 T1 M5 P2 P1 PLS M2 VALVE
A B
B
DUAL THROTTLE 230 BAR L
170 BAR
0.3 CHECK VALVE
2
T TL1255 D 120 / 55 / 200
A STEERING UNIT TL1055 D 120 / 55 / 200
C 400CC/REV C
RAS CYLINDER
REAR AXLE
22 BAR
HYDRAULIC PISTON PUMP

B 290 BAR
63 CC
B ENGINE B
HOC
4 BAR
BYPASS
S L2 L1 L
B5>=1000
FILTER
3 MICRON
A FILTER A
HYDRAULIC TANK
8 7 6 5 4 3 2 1
MAG0810F
TL642D, TL943D, TL1055D, TL1255D

1 2 3 4 5 6 7 8

FEMALE QUICK COUPLER (F)
H H
FRONT AUX CONFIGURATIONS BOOM RIDE CONTROL SECONDARY STEERING
B
A
FRONT AUX & AUX QC LIFT CYLINDER

STD AUX 1ST QC
TL642D, TL943D, TL1055D, TL1255D

G M F M F G
LS
1 2 B1 A1 ACCUMULATOR
1.5L R
2.07 bar
M1 55 bar
S T
240 bar
180 BAR 0.14 bar

240 bar
VALVE,
GP-DIVERTOR-6-7 (C)
L
A B
170 bar
1 2 380 BAR,
F PILOT RATIO: 4:1 F
P
100/400 cc FLOW AMP STEERING UNIT

B A
A1 B1
A4 B4
E 205 bar 205 bar E
31211036
D D
LIFT
C AUX C
LIFT SECTION OF MAIN
AUX SECTION OF MAIN
B B
A A
Hydraulic System
1 2 3 4 5 6 7 8
MAG0820E
8-19
Hydraulic System
8.7 HYDRAULIC RESERVOIR

3
The hydraulic reservoir is located between the cab and the
frame.
MAG0700
8.7.1 Hydraulic Oil Reservoir Draining

1. Park the machine on a firm, level surface, level the 5
machine, fully retract the boom, lower the boom, place
switch and the steering wheel. MAG0760
3. Open the engine cover. Allow the system fluids to cool. 4
“Battery”, for procedure. 7. Open the filler cap (3) on the hydraulic oil reservoir.
Remove the drain plug (4) on the bottom of the
hydraulic oil reservoir.
8. Transfer the used hydraulic oil into a suitable covered
container, and label as “Used Oil”. Dispose of used oil at
an approved recycling facility. Clean and reinstall the
drain plug. Torque drain plug to 22-29 lb-ft (30-40 Nm).
2
9. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.
8.7.2 Hydraulic Oil Reservoir Filling

1. Be sure the reservoir is clean and free of all debris.
2. Install a new hydraulic oil filter. Refer to Section 8.7.3,
“Hydraulic Filter Replacement”.
3. Fill the reservoir with oil until oil level is visible in the
gauge window (5). Refer to Section 2.3, “Fluid and
1 Lubricant Capacities”.
MD0100

5. Remove fuel tank/hydraulic tank access cover (1).
6. Start machine and check all hydraulic functions for
proper operation. Check for any hydraulic oil leaks. Shut
machine OFF and check hydraulic oil level. If oil is
warm, oil level should be visible in the gauge
window (5). Add hydraulic oil if necessary.
7. Close the hydraulic oil filler cab access panel at the
bottom left rear of the cab.
8. Remove the Do Not Operate Tag from the ignition key
8-20 31211036 TL642D, TL943D, TL1055D, TL1255D

Hydraulic System
8.7.3 Hydraulic Filter Replacement 7. Be sure the filter area is clean and free of all debris.
8. Remove the hydraulic filter cap (5) on the hydraulic oil
reservoir.
6
9. Lift hydraulic filter handle and pull filter assembly from
3
the reservoir. Cover the filter opening to keep dirt and
debris from entering the hydraulic system.
10. Transfer the used hydraulic oil filter into a suitable
covered container, and label as “Used Oil”. Dispose of
used filter at an approved recycling facility.
b. Hydraulic Filter Installation

1. Apply a light coating of clean hydraulic oil to the new
5
hydraulic filter base.
2. Remove cover from hydraulic tank filter opening and
install filter. Verify filter is seated in reservoir.
3. Install hydraulic filter cap (6) and tighten by hand.
MD0680
a. Hydraulic Filter Removal
6. Start machine and check all hydraulic functions for
1. Park the machine on a firm, level surface, level the proper operation. Check for any hydraulic oil leaks. Shut
machine, fully retract the boom, lower the boom, place machine OFF and check hydraulic oil level. If oil is
the transmission in (N) NEUTRAL, engage the park brake warm, oil level should be visible in the gauge
and shut the engine OFF. window (5). Add hydraulic oil if necessary (3). Refer to
2. Place a Do Not Operate Tag on both the ignition key Section 2.3, “Fluid and Lubricant Capacities”.
switch and the steering wheel. 7. Install the cab access panels at the rear of the cab.
3. Open the engine cover. Allow the system fluids to cool. 8. Remove the Do Not Operate Tag from the ignition key
4. Properly disconnect the battery. Refer Section 9.8, switch and the steering wheel.
8.7.4 Hydraulic Oil Reservoir Removal/
Installation
If it is determined that the hydraulic oil reservoir must be
removed, the hydraulic oil must be drained before the
reservoir is removed. Always dispose of hydraulic oil
properly.
2
a. Reservoir Removal
1. Park the machine on a firm, level surface, level the
3. Open the engine cover. Allow the system fluids to cool.
1
MD0100
TL642D, TL943D, TL1055D, TL1255D 31211036 8-21
Hydraulic System
7
1
MD0100

6. Remove DEF tank access cover (2). 9. Properly support the cab.
7. Drain the hydraulic oil reservoir. Refer to Section 8.7.1, 10. Loosen and remove cab mounting bolts and pull cab
“Hydraulic Oil Reservoir Draining”. away from frame to allow removal of the hydraulic
8. Label, disconnect and cap all hydraulic hoses attached reservoir (8).
to the hydraulic oil reservoir. Cap all fittings and Note: If required, label, disconnect and cap any hydraulic
openings to keep dirt and debris from entering the hoses and/or electrical wires attached to the cab that would
hydraulic system. provide additional clearance in the removal of hydraulic tank.
Cap fittings and openings to keep dirt and debris from entering
the hydraulic system.
11. Remove hardware (7) from hydraulic reservoir (8).
Remove the hydraulic reservoir.
b. Disassembly
Dispose of the old reservoir according to local regulations
concerning hazardous materials disposal.
MD0700
1. Note the orientation of all fittings, adapters and tubes

on the hydraulic tank.
8-22 31211036 TL642D, TL943D, TL1055D, TL1255D

Hydraulic System
2. Label and remove all fittings, adapters and tubes from 9. Start machine and check all hydraulic functions for
the hydraulic tank. proper operation. Check for any hydraulic oil leaks. Shut
machine OFF and check hydraulic oil level. If oil is
c. Cleaning and Drying warm, oil level should be visible in the gauge window.
Add hydraulic oil if necessary.
If contaminated hydraulic oil or foreign material is in the
tank, the tank can usually be cleaned. 10. Remove the Do Not Operate Tag from the ignition key
To clean the hydraulic oil reservoir:
1. Have a dry chemical (Class B) fire extinguisher near the
work area.
2. Remove the hydraulic oil reservoir drain plug, and safely
drain any hydraulic oil into a suitable container. Dispose
of hydraulic oil properly.
3. Clean the hydraulic oil reservoir with a high-pressure
washer, or flush the tank with hot water for five minutes
and drain the water. Dispose of contaminated water
properly.
d. Inspection
1. Inspect the hydraulic reservoir (8) thoroughly for any
cracks, slices, leaks or other damage.
e. Assembly
1. Install the previously removed fittings, adapters and
tubes in the correct orientation.
2. Properly torque all fittings and adapters as required.
f. Reservoir Installation
1. Place the hydraulic reservoir (8) into its original
orientation.
2. Secure the hydraulic reservoir (8) to the frame with the
previous mounting hardware (7).
3. Uncap and connect the previously labeled hydraulic
hoses to their appropriate locations. Be sure all lines are
free of kinks and sharp bends.
4. Tighten previously loosened cab mounting bolts.
Torque as required.
5. Fill the reservoir with oil until oil level is visible in the
gauge window. Refer to Section 2.3, “Fluid and
6. Check the hydraulic reservoir for leaks.
TL642D, TL943D, TL1055D, TL1255D 31211036 8-23

Hydraulic System
8.8 IMPLEMENT PUMP TL943D, TL1055D, TL1255D

2
3
8.8.1 Pump Replacement 1
a. Pump Removal
5. Thoroughly clean the pump and surrounding
area, including all hoses and fittings before proceeding. MAG0770
Note: Cap all hoses as you remove them to prevent 7. Remove the four bolts and lockwashers (1) securing the
unnecessary fluid spillage. pump (2) to the adapter plate. Remove the o-ring
located between the plate and the pump. Wipe up any
6. Label, disconnect and cap the hydraulic hoses attached
hydraulic oil spillage.
to the pump.
8. If necessary, remove the four bolts securing the adapter
TL642D
plate to the transmission. Remove the adapter plate.
1 2
Note: DO NOT disassemble the operating pump. The pump is
pre-set from the manufacturer.
b. Pump Installation
1. Refer to Section 2.6, “Thread Locking Compound”, for
correct compound.
2. If the adapter plate was removed, place into position
with a new, oiled o-ring on the transmission. Secure
with the previously used hardware.
3. Place the pump and a new, oiled o-ring into position on
the adapter plate. Align the pump shaft with the
internal gear, so that the machined teeth mesh
together.
4. Align the bolt holes with the pump mount holes. Secure
the pump to the adapter plate with the two bolts and
MAG1730
washers. Torque as required.
5. Uncap and connect the previously labeled hydraulic hoses
to their appropriate locations.
Note: For TL943D, TL1055D, TL1255D - Prime the pump by
filling the case with fresh, filtered hydraulic oil from a clean
container through fill port (3) before installing hose and
flanges.
6. Fill the hydraulic reservoir. Refer to Section 8.7.2,
8-24 31211036 TL642D, TL943D, TL1055D, TL1255D

Hydraulic System
7. Check all routing of hoses and tubing for sharp bends or TL943D, TL1055D, TL1255D
interference with any rotating members. 5 4
8. Inspect for leaks and check all fluid levels. The hydraulic
reservoir oil level must be to the middle of the sight
gauge.
3
2
11. Start machine and verify proper operation. 1
c. Implement Pump Test

Refer to Section 8.4.1, “Pressure Checks and Adjustments”.
8.9 CONTROL VALVES

6
MD0720
8.9.1 Main Control Valve
The main control valve is mounted at the rear frame. The main control valve assembly (1) consists of working
sections with their own valve assemblies, each providing a
TL642D
specific hydraulic function. Those functions are:
5 4 lift/lower (2), extend/retract (3), tilt (4) and auxiliary (5).
3
a. Main Control Valve Removal
1 2 machine, fully retract the boom, lower the boom, place
7 switch and the steering wheel.
5. Remove the main control valve cover.
6. Thoroughly clean the main control valve and
6 surrounding area, including all hoses and fittings,
MAG1740 before proceeding.
7. Place a suitable container to catch hydraulic fluid
drainage beneath the frame.
8. Label, disconnect and cap all the hydraulic hoses, tubes
and wires at the main control valve. Slowly turn hose
fittings to allow any trapped pressure in the hydraulic
system to escape.
around the machine and the work area.
TL642D, TL943D, TL1055D, TL1255D 31211036 8-25

Hydraulic System
10. Support the valve and remove the four bolts securing e. Main Control Valve Assembly
the main control valve to the frame. Remove the main
Note: ALWAYS replace seals, o-rings, gaskets, etc., with new
control valve.
parts to help ensure proper sealing and operation. Lubricate
seals and o-rings with clean hydraulic oil.
b. Main Control Valve Disassembly
Assemble each Valve Section
Disassemble the Main Control Valve
1. Reassemble any check valves, compensator valves,
1. To disassemble the individual sections of the main
anti-cavitation valves or shock valves from each
control valve, remove the nuts from one end of the tie
individual valve sections if equipped.
rods.
2. Install the end caps on each end of the valve section.
2. Disassemble each section assembly as required.
Some sections include a pre-adjusted relief valve that Assemble the Main Control Valve
regulates pressure in a specific circuit.
1. If removed, install all four tie rods into the end main
Note: DO NOT adjust any of the relief valve assemblies. control valve section.
Tampering with a relief valve will irrevocably alter pressure in the
2. Stand the end main control valve section on end.
affected circuit, requiring recalibration or a new relief valve.
3. Install the proper o-rings and load sense shuttle on the
Disassemble each Valve Section inner face of the end main control valve section. Align
the next valve section over the three tie rods and slide
1. Carefully separate the load sense outlet section from the onto the end main control valve section.
next section.
4. Using the proper o-rings and load sense shuttle, repeat
2. Remove the o-rings from between the two sections. step three for the remaining valve sections and lastly
3. Carefully separate each remaining section. the inlet end valve section.
4. Remove any check valves, compensator valves, 5. For TL642D: Install the nuts on the tie rods (6), (7) and
anti-cavitation valves or shock valves from individual torque to 16 - 20 lb-ft (21.69 - 27.11 Nm) and
valve section if equipped. 29.5 - 36.5 lb-ft (40 - 49.48 Nm) respectively.
5. Keep all parts being removed from individual valve 6. For TL943D, TL1055D, TL1255D: Install the nuts on
sections tagged and kept together. the tie rods (6) and torque to 18.5 lb-ft (25 Nm).
c. Main Control Valve Parts Cleaning f. Main Control Valve Installation

Clean all components with a suitable cleaner before 1. Install the main control valve onto the frame, aligning
continuing. Blow dry. the bolts with the holes in the end sections of the main
control valve. Slide the main control valve into
d. Main Control Valve Parts Inspection position, and tighten the bolts.
Inspect all parts and internal passageways for 2. Prime the main control valve by filling the inlet
wear, damage, etc. If inner surfaces of any component openings with fresh, filtered hydraulic oil from a clean
DO NOT display an ultra-smooth, polished finish, or are container, before attaching the hoses.
damaged in any way, replace the damaged part. Often, dirty 3. Use new oiled o-rings as required. Uncap and connect
hydraulic fluid causes failure of internal seals, damage to the all hoses, clamps, etc. to the main control valve.
polished surfaces within the component, and wear of and/or
4. Check the routing of all hoses, wiring and tubing for
harm to other parts.
sharp bends or interference with any rotating
members, and install tie wraps and/or protective
conduit as required. Tighten all tube and hose clamps.
5. Fill the hydraulic oil reservoir. Refer to Section 8.7.2,
8-26 31211036 TL642D, TL943D, TL1055D, TL1255D

Hydraulic System
7. Start the engine and run at approximately one-third to 4. Properly disconnect the battery. Refer Section 9.8,
one-half throttle for about one minute without moving “Battery” for procedure.
the machine or operating any hydraulic functions. 5. Remove the priority valve access cover.
8. Inspect for leaks and check the level of the hydraulic 6. Thoroughly clean the priority valve and surrounding
fluid in the reservoir. Shut the engine OFF. area, including all hoses and fittings, before proceeding.
9. Wipe up any hydraulic fluid spillage in, on, near and 7. Place a suitable container to catch hydraulic fluid
around the machine, work area and tools. drainage beneath the frame.
10. Install main control valve cover. 8. Drain the hydraulic oil reservoir. Refer to Section 8.7.1,
11. Close and secure the engine cover. “Hydraulic Oil Reservoir Draining”.
12. Remove the Do Not Operate Tag from the ignition key 9. Label, disconnect and cap all the hydraulic hoses, tubes
switch and the steering wheel. and wires at the priority valve. Slowly turn hose fittings
to allow any trapped pressure in the hydraulic system to
g. Main Control Valve Test escape.
Conduct a pressure check of the hydraulic system in its 10. Wipe up any hydraulic fluid spillage in, on, near and
entirety. Adjust pressure(s) as required. Refer to around the machine and the work area.
Section 8.5.1, “Hydraulic Pressures”. 11. Support the valve and remove the three bolts securing
the priority valve to the frame. Remove the priority
8.9.2 Priority Valve valve.
The priority valve is mounted on the inside left frame behind
the front axle. b. Priority Valve Disassembly, Cleaning, Inspection and
Assembly
1. Place the priority valve assembly on a suitable work
surface.
2. Separate the priority valve solenoids from the spool.
Discard the o-rings.
3. Clean all components with a suitable cleaner before
inspection.
4. Inspect the solenoid cartridges for proper operation.
Check by shifting the spool to ensure that it is
functioning properly. Check that the spring is intact.
Inspect the cartridge interior for contamination.
MAG0840
The function of a priority valve is to allow hydraulic fluid flow seals and o-rings with clean hydraulic oil.
to certain functions within a hydraulic system when the
pressure is greater than or equal to a specified level. In 5. Install the solenoids in the priority valve housing.
effect, the priority valve gives priority to certain components
over less critical components. c. Priority Valve Parts Cleaning
Clean all components with a suitable cleaner before
a. Priority Valve Removal continuing. Blow dry.
machine, fully retract and lower the boom, place the
transmission in (N) NEUTRAL, engage the park brake and
shut the engine OFF.
TL642D, TL943D, TL1055D, TL1255D 31211036 8-27

Hydraulic System
d. Priority Valve Parts Inspection 8.9.3 Service Brake Valve

Inspect all parts and internal passageways for
a. Service Brake Valve Removal
wear, damage, etc. If inner surfaces of any component
DO NOT display an ultra-smooth, polished finish, or are 1. Park the machine on a firm, level surface, level the
damaged in any way, replace the damaged part. Often, dirty machine, fully retract the boom, lower the boom, place
hydraulic fluid causes failure of internal seals, damage to the the transmission in (N) NEUTRAL, engage the park brake
polished surfaces within the component, and wear of and/or and shut the engine OFF.
harm to other parts. 2. Place a Do Not Operate Tag on both the ignition key
e. Priority Valve Installation
1. Install the priority valve to the frame using the
previously removed nuts. Torque as required.
2. Connect all the hydraulic hoses, fittings, solenoid wire
terminal leads, etc., to the priority valve.
3. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
members, and install tie wraps and/or protective
conduit as required. Tighten all hose clamps.
5. Start the engine and run at approximately 1/3-1/2
throttle for about one minute without moving the 8
machine or operating any hydraulic functions.
MD0740
6. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF. 5. Remove brake pedal (8).
Note: Check for leaks and repair as required before continuing.
Add hydraulic fluid to the reservoir as needed. 9
around the machine, work area and tools.
8. Install the previously removed access cover.
10. Remove the Do Not Operate Tag from the ignition key 11
f. Priority Valve Test

Conduct a pressure check of the hydraulic system in its
entirety. Adjust pressure(s) as required. Refer to
Section 8.5.1, “Hydraulic Pressures”.
10 MAE2760

7. Remove cab air filter cover (10).
8. Remove access covers (11) from front of cab.
8-28 31211036 TL642D, TL943D, TL1055D, TL1255D

Hydraulic System
16. Remove the two bolts, nuts (17) securing the service
brake valve to the cab.
17. Remove the valve through the front of the cab.
Note: DO NOT disassemble the service brake valve. The service
brake valve is not serviceable and must be replaced in its
entirety, if defective.
12
b. Service Brake Valve Installation
1. Install the service brake valve to its original orientation
in the cab. Secure with the previously used hardware.
2. Install the service brake pedal.
13 3. Uncap and connect the previously labeled hydraulic
hoses to the service brake valve.
MD0570
4. Check the routing of all hoses, and tubing for sharp
9. If equipped, remove windshield washer assembly (12) bends or interference with any rotating members, and
and heater cover (13). install tie wraps and/or protective conduit as required.
10. Slowly turn surge tank cap to first stop and allow any Tighten all tube and hose clamps.
pressure to escape. Remove surge tank cap. 5. Fill the brake reservoir.
11. Place a suitable container beneath radiator drain. 6. Properly connect the battery. Refer Section 9.8,
12. Place a funnel at base of radiator to channel drained “Battery”, for procedure.
coolant into a container. Open drain plug and slowly 7. Start the engine and run at approximately one-third to
remove to allow coolant to drain. Transfer coolant into a one-half throttle for about one minute, without moving
properly labeled container. Dispose of properly if the machine or operating any hydraulic functions.
coolant needs replaced. Close radiator drain plug. 8. Inspect the service brake valve and connections for
13. Remove the heater/air conditioning assembly leaks, and check the level of the fluid in the reservoir.
Shut the engine OFF.
14 15 9. Wipe up any hydraulic fluid spillage in, on, near and
10. Install the cover panel in the cab.
11. Install the access covers to the outside of the cab.
17 switch and the steering wheel.
16
17 8.9.4 Service Brake Bleeding
Carefully bleed the brake lines as soon as the brake valve is
installed in the machine. Air in the system will not allow the
brakes to apply properly. There is one brake bleeder on the
brake valve and two service brake bleeders located on the
front and rear axles. Work with an assistant to perform this
procedure.
MD0730
Note: Verify brake reservoir oil is at the full mark. DO NOT
14. Remove the brake reservoir cap (14) and place a allow the brake reservoir oil to go below the minimum level
suitable container beneath brake reservoir during the bleeding procedure.
connection (15).
15. Label, disconnect and cap all hoses attached to the
service brake valve (16).
TL642D, TL943D, TL1055D, TL1255D 31211036 8-29

Hydraulic System
a. Bleeding the Master Cylinder 3. DO NOT open the brake bleeder without holding the
tubing firmly on the bleeder. There is pressure at the
1. Place the transmission in (N) NEUTRAL, engage the park
brakes. Carefully open the bleeder. Have the assistant
brake, and start the engine.
depress the brake pedal. Close the brake bleeder when
air bubbles no longer appear in the oil. Slowly release
the brake pedal. Remove the tubing from the brake
bleeder.
4. Repeat Steps 2 and 3 for the left rear brake bleeder (21).
19
18 22
MD1150
2. Open the master cylinder valve bleeder (18) and allow

the master cylinder to gravity fill and slowly depress the 23
brake pedal.
MD1140
3. Close the master cylinder valve bleeder (18) when air
bubbles no longer appear in the oil. 5. Repeat Steps 2 and 3 for the right front brake
4. Slowly release the brake pedal completely allowing oil bleeder (22).
to refill the master cylinder. 6. Repeat Steps 2 and 3 for the left front brake
5. Refill the brake reservoir (19). bleeder (23).
7. Repeat Steps 2 thru 6 three times.
b. Bleeding the Front and Rear Axles 8. Repeat Section 8.9.4, “Service Brake Bleeding”, one
1. Place the transmission in (N) NEUTRAL, engage the park additional time.
brake, and start the engine.
c. Brake System Check
1. Connect Analyzer tool
2. Start engine
3. With Analyzer, navigate to;
Diagnostics>System>Brk Pedal Prs.
4. Release park brake.
5. Pump brakes several times.
20 6. Wait approximately 10 seconds (Analyzer should read
<15 psi).
21
MD1160
2. Remove the plastic cap from the right rear brake

bleeder (20). Attach one end of a length of transparent
tubing over the brake bleeder. Place the other end of
this tubing in a suitable transparent container that is
partially filled with hydraulic oil. The end of the tubing
must be below the oil level in the container.
8-30 31211036 TL642D, TL943D, TL1055D, TL1255D

Hydraulic System
7. Apply service brakes with a single pedal press to “stop” d. Free Play Adjustment
and maintain position. There will be a defined force
change, and the Analyzer should read as follows:
Machine Pressure
CAUTION
TL642D 900 - 950 psi (62,1 - 65,5 bar) Do Not adjust when engine is off. Over-adjustment of the
free play can result in brake drag.
TL943D, TL1055D,
780 - 850 psi (53,8 - 58,6 bar)
TL1255D
B
24
28
25 26 27
MAG4010
1. Slide boot (24) up to reveal locknut (25) and

pushrod (26).
MAG4000
A 2. Start the engine. This will supply boost pressure and
ensure that pushrod (26) is fully returned to the
8. Have an assistant measure the distance (A) from the stop ring (27).
back of the pedal arm to the cab firewall. The distance 3. Loosen locknut (25) (0.67 in (17 mm)), swivel the
should be equal to or greater than the following: pushrod (26) first clockwise to shorten it (to be sure it
Machine Distance (A) was not previously over-adjusted), and then
counterclockwise to lengthen it until it contacts the
TL642D 2 in (50,8 mm)
piston (28). Use only hand effort to adjust. To achieve
TL943D, TL1055D, TL1255D 1.5 in (38,1 mm) the free play shown in image above, the
pushrod gap (B) will be 0 - 0.02 in (0 - 0,5 mm.)
4. Hold the pushrod (26) with pliers and tighten the
locknut (25). Reinstall the boot (24).
8.9.5 Service Brake Test

1. Start machine and allow to run for a minimum of one
minute. Shut machine OFF, wait five seconds and apply
service brake hard. The brake pedal should hold for a
minimum of two seconds before loosing pressure.
2. If further testing is required, refer to Section 8.5.1,
“Hydraulic Pressures” or Section 8.9.4, “Service Brake
Bleeding”.
TL642D, TL943D, TL1055D, TL1255D 31211036 8-31

Hydraulic System
8.9.6 Park Brake Bleeding 8.9.7 Steering Orbital Valve

Bleeding of the park brake is performed on the front axle The steering orbital valve is located at the base of the
only. steering wheel shaft, concealed by the front access covers.
1. Park the machine on a firm, level surface, level the The valve is not serviceable and must be replaced in it’s
machine, fully retract the boom, lower the boom, place entirety if defective. For detailed information refer to
the transmission in (N) NEUTRAL, engage the park brake Section 4.3.2, “Steering Column/Orbital Valve”.
8.9.8 Outrigger/Frame Leveling Valve (if
2. Place a Do Not Operate Tag on both the ignition key equipped)
3. Block both front wheels.
29
31
MD1140
30
MD0750
4. Remove the plastic cap from the right park brake
bleeder (29). Attach one end of a length of transparent The outrigger/frame leveling valve (31) controls the
tubing over the brake bleeder. Place the other end of direction of hydraulic fluid flow to each outrigger cylinder
this tubing in a suitable transparent container that is and the frame leveling cylinder. The outrigger/frame
partially filled with hydraulic oil. The end of the tubing leveling valve is attached inside the frame behind the front
must be below the oil level in the container. axle.
5. Start the engine and disengage park brake. Verify the correct operation of the outrigger/frame leveling
6. DO NOT open the park brake bleeder without holding valve solenoids before considering replacement of the valve.
the tubing firmly on the bleeder. Carefully open the Refer to Section 9.5, “Electrical System Schematics”. The
bleeder. body of the outrigger/frame leveling valve is not serviceable
and must be replaced if defective.
7. Switch the park brake to engage. Close the park brake
bleeder when air bubbles no longer appear in the oil
and switch the park brake switch to disengage.
8. Repeat Steps 6 and 7 if required.
9. Repeat Steps 4 thru 7 on the left park brake (30).
10. Repeat Steps 6 and 7 if required.
8-32 31211036 TL642D, TL943D, TL1055D, TL1255D

Hydraulic System
a. Outrigger/Frame Leveling Valve Removal c. Outrigger/Frame Leveling Valve Installation

1. Park the machine on a firm, level surface, level the 1. Install the outrigger/frame leveling valve to the frame
machine, fully retract the boom, raise and support the using the previously removed nuts. Torque as required.
boom, place the transmission in (N) NEUTRAL, engage 2. Connect all the hydraulic hoses, fittings, solenoid wire
the park brake, lower each outrigger and shut the engine terminal leads, etc., to the outrigger/frame leveling
OFF. valve.
2. Place a Do Not Operate Tag on both the ignition key 3. Check the routing of all hoses, wiring and tubing for
switch and the steering wheel. sharp bends or interference with any rotating
3. Open the engine cover. Allow the system fluids to cool. members, and install tie wraps and/or protective
4. Properly disconnect the battery. Refer Section 9.8, conduit as required. Tighten all hose clamps.
“Battery” for procedure. 4. Properly connect the battery. Refer Section 9.8,
5. Remove the access cover from the top front of the “Battery”, for procedure.
frame. 5. Remove boom support.
6. Label, disconnect and cap the hydraulic hoses and the 6. Start the engine and run at approximately 1/3-1/2
electrical plugs connected to the outrigger/frame throttle for about one minute without moving the
leveling valve. machine or operating any hydraulic functions.
7. From below the machine, remove the nuts holding the 7. Inspect for leaks and check the level of the hydraulic
outrigger/frame leveling valve to the frame. fluid in the reservoir. Shut the engine OFF.
8. Remove the outrigger/frame leveling valve from the Note: Check for leaks and repair as required before continuing.
machine. Wipe up any hydraulic fluid spillage Add hydraulic fluid to the reservoir as needed.
in, on, near and around the machine.
b. Outrigger/Frame Leveling Valve Disassembly, around the machine, work area and tools.
Cleaning, Inspection and Assembly 9. Install the previously removed access cover.
1. Place the outrigger/frame leveling valve assembly on a 10. Close and secure the engine cover.
suitable work surface. 11. Remove the Do Not Operate Tag from the ignition key
2. Separate the outrigger/frame leveling valve solenoids switch and the steering wheel.
from the spool. Discard the o-rings.
d. Outrigger/Frame Leveling Valve Test
inspection. Refer to Section 8.5.1, “Hydraulic Pressures”.
4. Inspect the solenoid cartridges for proper operation. 1. Conduct a pressure check of the outrigger/frame
Check by shifting the spool to ensure that it is leveling valve hydraulic circuit.
2. Check each outrigger/frame leveling valve mode for
proper function.
5. Inspect internal passageways of the steer select valve
for wear, damage, etc. If inner surfaces of the manifold
DO NOT display an ultra-smooth, polished finish, or
components are damaged in any way, replace the
manifold or appropriate part. Often, dirty hydraulic fluid
causes failure of internal seals and damage to the
polished surfaces within the secondary function
manifold.
6. Install the solenoids in the outrigger/frame leveling
valve housing.
TL642D, TL943D, TL1055D, TL1255D 31211036 8-33

Hydraulic System
8.9.9 Steer Select Valve b. Steer Select Valve Disassembly, Cleaning, Inspection
and Assembly
1. Place the steer select assembly on a suitable work
surface.
2. Separate the steer select solenoids from the spool.
Discard the o-rings.
inspection.
4. Inspect the solenoid cartridges for proper operation.
32 Check by shifting the spool to ensure that it is
5. Inspect internal passageways of the steer select valve
MD0760 for wear, damage, etc. If inner surfaces of the manifold
DO NOT display an ultra-smooth, polished finish, or
The machine can be used in the front-wheel, four-wheel or
components are damaged in any way, replace the
crab steering mode. The steer select valve (32) controls the
manifold or appropriate part. Often, dirty hydraulic fluid
direction of hydraulic fluid flow to the steering cylinder
causes failure of internal seals and damage to the
mounted on each axle. The steer select valve is attached
polished surfaces within the secondary function
inside the frame above the priority valve.
manifold.
Verify the correct operation of the steer select valve
solenoids before considering replacement of the valve. Refer
to Section 9.5, “Electrical System Schematics”. The housing
of the steer select valve is not serviceable and must be
replaced if defective. 6. Install the solenoids in the steer select housing.
a. Steer Select Valve Removal c. Steer Select Valve Installation

1. Park the machine on a firm, level surface, level the 1. Install the steer select valve to the mounting plate
machine, fully retract the boom, lower the boom, place under the left front side of the frame using the two
the transmission in (N) NEUTRAL, engage the park brake bolts.
and shut the engine OFF. 2. Connect all the hydraulic hoses, fittings, solenoid wire
2. Place a Do Not Operate Tag on both the ignition key terminal leads, etc., to the steer select valve.
switch and the steering wheel. 3. Check the routing of all hoses, wiring and tubing for
3. Open the engine cover. Allow the system fluids to cool. sharp bends or interference with any rotating
4. Properly disconnect the battery. Refer Section 9.8, members, and install tie wraps and/or protective
“Battery” for procedure. conduit as required. Tighten all hose clamps.
5. Label, disconnect and cap the hydraulic hoses and the 4. Properly connect the battery. Refer Section 9.8,
electrical plugs connected to the steering select valve. “Battery”, for procedure.
6. Remove the bolts holding the steer select valve to the 5. Start the engine and run at approximately 1/3-1/2
mounting plate on the frame. throttle for about one minute without moving the
machine or operating any hydraulic functions.
7. Remove the steer select valve from the machine. Wipe
up any hydraulic fluid spillage in, on, near and around 6. Inspect for leaks and check the level of the hydraulic
the machine. 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.
8-34 31211036 TL642D, TL943D, TL1055D, TL1255D

Hydraulic System
9. Remove the Do Not Operate Tag from the ignition key 2. Connect the analyzer to the XE port on the power
switch and the steering wheel. distribution board behind the Access Panel (1) on the
left side of the dash. Refer to Section 9.13.2, “Hand Held
d. Steering Test Analyzer”.
Refer to Section 8.5.1, “Hydraulic Pressures”. 3. Verify RAS (2) indicator is off.
1. Conduct a pressure check of the steering hydraulic 4. Place one 8 in (203 mm) high block in front of left front
circuit. tire.
2. Check each steering mode for proper function. 5. Release the park brake (3), place the transmission in
FORWARD and slowly drive onto block.
8.10 REAR AXLE STABILIZATION (RAS) 6. Stop when front left tire is resting on top of block.
SYSTEM 7. Engage park brake (3), place the transmission in
(N) NEUTRAL.
8.10.1 Rear Axle Stabilization System Test 8. Verify right front and both rear tires are in full contact
with ground.
The following procedure is required to verify the proper
operation of the Rear Axle Stabilization (RAS) System. 9. Using the frame level function, level the machine back
If any of the following test results cannot be achieved, the to 0° Frame Level Angle.
system is not functioning properly and the machine must be 10. Fully depress service brake (4), release the park
removed from service and repaired before continued brake (3) and raise the boom to 60° (5).
operation. 11. The RAS indicator should illuminate and remain ON
when the boom is at or above 40°.
12. Engage park brake (3).
5
Note: Perform the following steps at low engine idle unless
otherwise noted.
13. Navigate the analyzer to;
Diagnostics>System>Brk Pedal Prs.
14. Fully apply service brake (4), release park
6 brake (2), place transmission in (R) REVERSE 2nd gear.
15. Slowly release service brake until the analyzer reads
200 - 250 psi (13,8 - 17,2 bar).
MD1090
16. Increase engine speed to drive through the
3 2 brake, slowly backing off the eight inch high block while
retaining 200 - 250 psi (13,8 - 17,2 bar) service brake
pressure.
17. Stop machine when the left front tire is no longer
resting on the block.
18. The RAS indicator should remain ON. The rear axle
1 should remain locked while backing off the eight inch
high block and the left front tire should remain off the
ground.
19. Lower the boom to 45° (6).
4
20. With the transmission still in (R) REVERSE, slowly release
the service brake.
MAG0780
21. The rear axle lock system and RAS light should go OFF
1. Park the machine on a firm, level surface, level the with the service brake pressure less than
machine (0° Frame Level Angle), fully retract the boom, 145 psi (10 bar).
no load, place the transmission in (N) NEUTRAL, engage
the park brake.
TL642D, TL943D, TL1055D, TL1255D 31211036 8-35
Hydraulic System
22. The left front tire should return to the ground while the
machine travels in (R) REVERSE.
23. After all four tires are in full contact with the 2
ground, depress the service brake to stop the machine.
24. Place the transmission in (N) NEUTRAL, engage the park
brake.
25. Level the machine back to 0°.
26. Remove block from in front of left front tire.
27. Disconnect analyzer and replace previously removed
cover (1).
3
8.11 PRECISION GRAVITY LOWER SYSTEM
(PGLS)
MD1470
In addition to the two ports for the boom lower function

from the main control valve, there are two additional hoses
1 that are connected to the end cap port (2) and sump
port (3).
The PGLS utilizes pilot pressure from the boom lower
section of the main control valve. When the boom lower
command is initiated from the joystick, pilot pressure builds
MD1460
at the PGLS valve that is proportional to joystick position.
This pilot pressure at the PGLS valve block shifts the main
The Precision Gravity Lower System (PGLS) is a hydraulic spool in the PGLS valve. When this main spool shifts, oil is
system utilized on the boom lower function. able to flows through the PGLS valve block allowing gravity
The PGLS valve (1) mounts directly to the boom lift/lower to lower the boom.
cylinder. The speed at which the boom lowers is dictated by the pilot
pressure signal from the joystick.
Since the PGLS utilizes gravity and pilot pressure, the boom
should be lowered at low engine speed to optimize control
and boom lower speeds.
8-36 31211036 TL642D, TL943D, TL1055D, TL1255D

Hydraulic System
8.12 BOOM RIDE CONTROL TL943D
8.12.1 General Accumulator Information 3

The accumulator is a piston type accumulator.
The pneumatic accumulator is operated by compressed gas.
Gas and hydraulic oil occupy the same container. When oil
pressure rises, incoming oil compresses the gas. When oil
pressure drops, the gas expands, forcing the oil out into the
4
lift side of the lift/lower cylinder.
The gas is separated from the oil by a piston. This prevents 2
the mixing of gas and oil and keeps gas out of the hydraulic
system.
MAE23270
TL1055D, TL1255D
1
MAM1440
3
The accumulator comes “pre-charged”. If not charged, we

may need to charge the accumulator.
a. Accumulator Removal 4 2
1. Remove any attachment from the machine. Park the
machine on a firm level surface and fully retract the
boom. Raise the boom to allow sufficient work space
around the lift/lower cylinder to allow the accumulator
to be removed. Support the boom. Place the MAG0790
transmission in (N) NEUTRAL, engage the park
brake, shut the engine OFF and chock wheels. 5. Disconnect and cap or plug the hydraulic tube (2) at the
accumulator (3).
switch and the steering wheel. 6. Remove the two straps (4) securing the accumulator to
the lift/lower cylinder.
7. Remove the accumulator.
“Battery”, for procedure. 8. Wipe up any hydraulic fluid spillage in, on, near and
TL642D
b. Accumulator Installation
3 1. Secure the accumulator (3) to the lift/lower cylinder
with the two straps (4). Do Not tighten.
2. Uncap and connect the hydraulic tube (2) to the
accumulator.
4
3. Adjust accumulator and tighten hose clamps (4).
2
4. Remove the boom support.
MAG1760
TL642D, TL943D, TL1055D, TL1255D 31211036 8-37

Hydraulic System
7. Remove the Do Not Operate Tag from the ignition key Note: Make sure the nitrogen bottle, as well as the charging
switch and the steering wheel. and gauge assembly used is compatible with the schrader valve
8. Refer to Section 8.12.3, “Pre-Charging Accumulator”, for assembly on the accumulator. The nitrogen bottle and all
Accumulator pre-charging instructions. components must be rated for a pressure at least as high as the
nitrogen source. It is strongly recommended that the nitrogen
8.12.2 Accumulators bottle has a high pressure regulator.
This section covers the charging of the accumulator system. You will require an accumulator fill kit to properly charge the
accumulators. Refer to the parts manual or contact the local
The accumulator is located and mounted on the lift/lower Caterpillar dealer.
cylinder. The internal parts of the accumulator are not
serviceable. If the internal piston is leaking, or the seals on Use the following steps to properly pre-charge each
the top or bottom cap are leaking, the accumulator requires accumulator:
replacement.
The accumulator pre-charge pressure will vary depending
on the ambient temperature that the accumulator was 9
pre-charged at and the actual operating temperature of the 10
accumulator.
8.12.3 Pre-Charging Accumulator

5
WARNING 3 7
NEVER fill an accumulator with oxygen! An explosion

could result if oil and oxygen are mixed under pressure. Only 8
fill accumulator with dry nitrogen. 6 MAM1450
Pre-charged the accumulator with nitrogen gas only. 1. Thoroughly clean the top of each accumulator (3).
Nitrogen gas is free of water vapor and oxygen which makes
it harmless to internal parts and will not react if mixed with 2. Make sure the nitrogen supply is shut off.
oil under pressure. 3. Attach the accumulator fill kit (5) to the nitrogen bottle.
4. Remove the protective cap from the gas valve on the
NOTICE accumulator.
5. Back the “T” handle (6) on the accumulator fill kit all the
Never fill an accumulator with air. Air contains moisture which way out (counter-clockwise). Attach the schrader
can cause corrosion. This corrosion may damage seals and adaptor (7) to the gas valve on the accumulator. Tighten
ruin the accumulator. securely.
Never charge an accumulator to a pressure more than 6. Turn the gas valve/bleed valve (8) on the accumulator
specified. The proper pressure for the accumulator is fill kit all the way in.
725 psi (50 bar). 7. Turn the “T” handle (6) all the way in to open the valve
core on the accumulator.
8. Open the valve (9) on the nitrogen bottle.
9. Slowly adjust the regulator (10) on the nitrogen bottle
to read 725 psi (50 bar).
10. Close the main valve (9) on the nitrogen bottle.
11. Back the “T” handle (6) on the accumulator fill kit all the
way out (counter-clockwise).
8-38 31211036 TL642D, TL943D, TL1055D, TL1255D

Hydraulic System
12. Let the pre-charge on the accumulator set for 8.13 HYDRAULIC CYLINDERS
10 - 15 minutes. This will allow the gas temperature to
stabilize. If the desired pre-charged range is exceeded,
turn the “T” handle (6) all the way in. With the main 8.13.1 General Cylinder Removal Instructions
valve (9) closed on the nitrogen bottle, turn the gas 1. Remove any attachment from the machine. Park the
valve/bleeder valve (8) out to bleed pressure off the machine on a firm level surface and fully retract the
accumulator. Turn the valve all the way in and check the boom. Allow sufficient work space around the hydraulic
pressure reading on the regulator gauge. cylinder being removed. Support the boom if the
13. When the correct pressure is reached, back the “T” lift/lower cylinder is being removed. Place the
handle (6) on the accumulator fill kit all the way out transmission in (N) NEUTRAL, engage the park
(counter-clockwise). Bleed the pressure from the hose brake, shut the engine OFF and chock wheels.
by turning the gas valve/bleed valve out to relieve the 2. Place a Do Not Operate Tag on both the ignition key
pressure. switch and the steering wheel.
14. Turn the gas valve/bleed valve (8) all the way in and 3. Open the engine cover. Allow the system fluids to cool.
remove the schrader adapter (7) from the valve on the 4. Label, disconnect and cap or plug hydraulic hoses in
accumulator. relation to the cylinder.
15. Reassemble the protective cap onto the gas valve on 5. Attach a suitable sling to an appropriate lifting device
the accumulator. and to the cylinder. Make sure the device used can
actually support the cylinder.
8.12.4 Checking Pre-Charge
6. Remove the lock bolt and/or any retaining clips
a. Gas Leaks securing the cylinder pins. Remove the cylinder pins.
7. Remove the cylinder.
a. General Cylinder Disassembly

12 11
MAM1440
12
1. If an external leak is suspected, apply soapy water to the
gas valve (11) and the seams of the gas bottle (12). If
bubbles form, the accumulator has to be replaced.
2. If an internal leak is suspected, check for foaming oil in
the hydraulic reservoir and/or no accumulator action. If
any of these signs are evident, the accumulator has to
be replaced.
MZ0400
1. Clean the cylinder with a suitable cleaner before

disassembly. Remove all dirt, debris and grease from the
cylinder.
2. Clamp the barrel end of the cylinder in a soft-jawed vise
or other acceptable holding equipment if possible.
TL642D, TL943D, TL1055D, TL1255D 31211036 8-39

Hydraulic System
Some cylinder parts are assembled with a locking

compound. Before attempting to disassemble these
parts, remove any accessible seals from the area of the
WARNING bonded parts. Wipe off any hydraulic oil, then heat the
Significant pressure may be trapped inside the cylinder. part(s) uniformly to break the bond. A temperature of
Exercise caution when removing a counterbalance valve or a 149-204° C (300-400° F) will destroy the bond. Avoid
pilot-operated check valve from a cylinder. overheating, or the parts may become distorted or
damaged. Apply sufficient torque for removal while the
Note: Avoid using excessive force when clamping the cylinder parts are still hot. The sealant often leaves a white, powdery
in a vise. Apply only enough force to hold the cylinder securely. residue on threads and other parts, which must be removed
Excessive force can damage the cylinder tube. by brushing with a soft brass wire brush prior to reassembly.
3. If applicable, remove the counterbalance valve from the 9. Remove the piston head from the rod and carefully slide
side of the cylinder barrel. the head gland off the end of the rod.
Note: DO NOT tamper with or attempt to adjust the 10. Remove all seals, back-up rings and o-rings from the
counterbalance valve cartridge. If adjustment or replacement is piston head and all seals, back-up rings and o-rings
necessary, replace the counterbalance valve with a new part. from the head gland.
4. Extend the rod as required to allow access to the base of Note: The head gland bearing will need to be inspected to
the cylinder. determine if replacement is necessary.
Note: Protect the finish of the rod at all times. Damage to the DO NOT attempt to salvage cylinder seals, sealing rings or
surface of the rod can cause seal failure. o-rings. ALWAYS use a new, complete seal kit when
rebuilding hydraulic components. Consult the parts catalog
5. Using a pin spanner wrench, unscrew the head gland for ordering information.
from the tube. A considerable amount of force will be
needed to remove the head gland. Carefully slide the b. Cylinder Cleaning Instructions
head gland down along the rod toward the rod
eye, away from the cylinder barrel. 1. Discard all seals, back-up rings and o-rings. Replace with
new items from seal kit to ensure proper cylinder
Note: When sliding the rod and piston assembly out of the function.
barrel, prevent the threaded end of the barrel from damaging
2. Clean all metal parts with an approved cleaning solvent.
the piston. Keep the rod centered within the barrel to help
Carefully clean cavities, grooves, threads, etc.
prevent binding.
Note: If a white powdery residue is present on threads or
6. Carefully pull the rod assembly along with the head
parts, it can be removed by using a soft brass wire brush. Wipe
gland out of the cylinder barrel.
clean with Loctite® Cleaner prior to reassembly.
7. Fasten the rod eye in a soft-jawed vise, and place a
padded support under and near the threaded end of c. Cylinder Inspection
the rod to prevent any damage to the rod.
1. Inspect internal surfaces and all parts for wear, damage,
8. Remove the set screw from the piston head. etc. If the inner surface of the cylinder barrel does not
Note: It may be necessary to apply heat to break the bond of display a smooth finish, or is scored or damaged in any
the sealant between the piston and the rod before the piston way, replace the barrel.
can be removed. 2. Remove light scratches on the piston, head gland, rod
or inner surface of the cylinder barrel with a 400-600 grit
emery cloth. Use the emery cloth in a rotary motion to
polish out and blend the scratch(es) into the
surrounding surface.
3. Check the piston rod assembly for run-out. If the rod is
bent, it must be replaced.
8-40 31211036 TL642D, TL943D, TL1055D, TL1255D

Hydraulic System
d. General Cylinder Assembly Instructions 3. Connect the hydraulic hoses in relation to the labels or
markings made during removal.
1. Use the proper tools for specific installation tasks. Clean
tools are required for installation. 4. Before starting the machine, check fluid level of the
hydraulic fluid reservoir and if necessary fill to full mark
2. Install new seals, back-up rings and o-rings on the
with oil.
piston and new seals, back-up rings, o-rings and
bearing on the head gland. 5. Start the machine and run at low idle for about one
minute. Slowly activate hydraulic cylinder function in
Note: The extend/retract cylinder has a spacer that MUST be both directions allowing cylinder to fill with hydraulic
installed over the rod AFTER the head gland and BEFORE the oil.
piston head.
6. Inspect for leaks and check level of hydraulic fluid in
3. Fasten the rod eye in a soft-jawed vise, and place a reservoir. Add hydraulic fluid if needed. Shut the engine
padded support under and near the threaded end of OFF.
the rod to prevent any damage to the rod.
Note: Protect the finish on the cylinder rod at all times. around the machine, work area and tools.
Damage to the surface of the rod can cause seal failure. 8. Close and secure the engine cover.
4. Refer to Section 2.6, “Thread Locking Compound”, for all
thread locking requirements. 8.13.2 Cylinder Pressure Checking
5. Lubricate and slide the head gland over the cylinder Attach a 5000 psi (345 bar) gauge to the test port on the P1
rod. Install the piston head on to the end of the cylinder port on the hydraulic manifold to check the system pressure.
rod. Install the set screw in the piston head. Refer to For more information, refer to Section 8.4.1, “Pressure
Section 8.13.4, “Cylinder Torque Specifications”, for Checks and Adjustments”.
torque specifications for the piston head and the set Note: If a hydraulic cylinder pressure is greater than the main
screw. control valve pressure, increase the main control valve pressure
Note: Avoid using excess force when clamping the cylinder by adjusting the main relief. Generally, one half turn clockwise
barrel in a vise. Apply only enough force to hold the cylinder will be adequate to check an individual circuit. Activate the
barrel securely. Excessive force can damage the cylinder barrel. circuit and if pressure is obtained turn the main relief counter
clockwise one half turn. Re-check the main relief setting and
6. Place the cylinder barrel in a soft-jawed vise or other
adjust if necessary.
acceptable holding devise.
Note: When sliding the rod and piston assembly into the 8.13.3 Steering Cylinders
cylinder barrel, prevent the threaded end of the cylinder barrel
Refer to Section 5.3, “Axle Specifications and Maintenance
from damaging the piston head. Keep the cylinder rod centered
Information”, for detailed service information.
within the barrel to prevent binding.
7. Carefully insert the cylinder rod assembly into the
cylinder barrel.
8. Screw the head gland into the cylinder barrel and
tighten with a spanner wrench. Refer to Section 8.13.4,
“Cylinder Torque Specifications”, for torque
specifications for the head gland.
9. If applicable, install new counter balance valve into
block on the cylinder barrel.
e. General Cylinder Installation

1. Grease the bushings at the ends of the hydraulic
cylinder. Using an appropriate sling, lift the cylinder into
it’s mounting position.
2. Align cylinder bushing and install pin, lock bolt or
retaining clip.
TL642D, TL943D, TL1055D, TL1255D 31211036 8-41

Hydraulic System
8.13.4 Cylinder Torque Specifications
a. Lift/Lower Cylinder
Model Head Piston Piston Set Screw

TL642D 295 - 369 lb-ft (400-500 Nm) 2681 lb-ft (3636 Nm) NA
TL943D 220 - 258 lb-ft (300 - 350 Nm) NA 9 lb-ft (12 m)
TL1055D 1014 - 1240 lb-ft (1375 - 1681 Nm) 1269 - 1551 lb-ft (1721 - 2103 Nm) 16 - 20 lb-ft (22 - 27 Nm)
TL1255D 443 lb-ft (600 Nm) 1844 lb-ft (2500Nm) 7.3 lb-ft (10 Nm)
b. Extend/Retract Cylinder
Model Head Piston V1 Plug V2 Plug CB Valve

TL642D 220 - 258 lb-ft (300 - 350 Nm) 1115 lb-ft (1513 Nm) NA NA NA
TL943D 2212 lb-ft (3000 Nm) 2212 lb-ft (3000 Nm) NA NA NA
TL1055D,
295 - 369 lb-ft (400 - 500 Nm) 2682 lb-ft (3636 Nm) 74 lb-ft (100 Nm) 125 lb-ft (170 Nm) NA
TL1255D
c. Tilt Cylinder

73 - 295 lb-ft 44 - 52 lb-ft
TL642D 295-367 lb-ft (400 - 500 Nm) NA NA
(100 - 400 Nm) (60 - 70 Nm)
258 - 295 lb-ft 44 - 52 lb-ft
TL943D 220 - 258 lb-ft (300 - 350 Nm) NA NA
(350 - 400 Nm) (60 - 70 Nm)
TL1055D, 44 - 52 lb-ft
295 - 369 lb-ft (400 - 500 Nm) 2682 lb-ft (3636 Nm) 40 lb-ft (54 Nm) 40 lb-ft (54 Nm)
TL1255D (60 - 70 Nm)
d. Compensation Cylinder

TL642D 450 Nm 1372 lb-ft (1860Nm) NA NA NA
755 - 923 lb-ft 984 - 1186 lb-ft 31 - 38 lb-ft 31 - 38 lb-ft 30 - 37 lb-ft

TL943D
(1024 - 1251 Nm) (726 - 875 Nm) (42 - 51 Nm) (42 - 51 Nm) (41 - 50 Nm)
TL1055D, 1106 lb-ft 37 lb-ft
4056 lb-ft (5500 Nm) 44 lb-ft (60 Nm) 44 lb-ft (60 Nm)
TL1255D (1500 Nm) (50 Nm)
8-42 31211036 TL642D, TL943D, TL1055D, TL1255D

Hydraulic System
e. Frame Level Cylinder

TL1055D,
332 lb-ft (450 Nm) 295 lb-ft (400 Nm) NA NA NA
TL1255D
f. Outrigger Cylinder (If Equipped)

755 - 923 lb-ft 1041 - 1273 lb-ft 41.4 - 50.6 lb-ft 41.4 - 50.6 lb-ft 30 - 37 lb-ft
TL642D
(1024 - 1251 Nm) (1411 - 1726 Nm) (56 - 69 Nm) (56 - 69 Nm) (40 - 50 Nm)
755 - 923 lb-ft 755 - 923 lb-ft 41.4 - 50.6 lb-ft 41.4 - 50.6 lb-ft 30 - 37 lb-ft
TL943D
(1024 - 1251 Nm) (1024 - 1251 Nm) (56 - 69 Nm) (56 - 69 Nm) (40 - 50 Nm)
TL1055D, 755 - 923 lb-ft 1041 - 1273 lb-ft 41.4 - 50.6 lb-ft 41.4 - 50.6 lb-ft 30 - 37 lb-ft
TL1255D (1024 - 1251 Nm) (1411 - 1726 Nm) (56 - 69 Nm) (56 - 69 Nm) (40 - 50 Nm)
g. RAS Cylinder
Model Head Piston V1 Plug V2 Plug Relief

TL642D 332 lb-ft (450 Nm) 1033 lb-ft (1400 Nm) NA NA 25 lb-ft (34 Nm)
TL943D 332 lb-ft (450 Nm) 1033 lb-ft (1400 Nm) NA NA 25 lb-ft (34 Nm)
TL1055D,
332 lb-ft (450 Nm) 1033 lb-ft (1400 Nm) NA NA 25 lb-ft (34 Nm)
TL1255D
h. Attachment Cylinders
Attachment Head Piston V1 Plug V2 Plug

50 in Side Tilt Carriage NA NA NA NA
50 in Dual Fork Positioner
NA NA NA NA
Carriage
TL642D, TL943D, TL1055D, TL1255D 31211036 8-43

Hydraulic System
8-44 31211036 TL642D, TL943D, TL1055D, TL1255D

Section 9
Electrical System
Contents

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.1.1 General Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.4 Power Distribution Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.4.1 Cab Power Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.4.2 Frame Power Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
9.4.3 Option 1 Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.4.4 Option 2 Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
9.4.5 Engine Harness Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
9.5.1 TL642D, TL943D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
9.5.2 TL1055D, TL1255D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.6 Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
9.6.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
9.6.2 Exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9.7 Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
9.7.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
9.7.2 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
9.7.3 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
9.8 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
9.8.1 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
9.8.2 Battery Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
9.8.3 Battery Disconnect/Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
9.9 Electrical Master Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
9.9.1 Electrical Master Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
9.9.2 Electrical Master Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
9.10 Window Wiper System (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
9.10.1 Front Windshield Wiper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
9.10.2 Rear Window Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
9.10.3 Roof Window Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47
9.10.4 Washer Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
TL642D, TL943D, TL1055D, TL1255D 31211036 9-1

Electrical System
9.11 Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49

9.11.1 Transmission Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
9.11.2 Transmission Oil Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
9.11.3 Transmission Mounted Speed Sensor (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . 9-51
9.11.4 Engine Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-51
9.11.5 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52
9.11.6 Boom Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52
9.11.7 Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-53
9.12 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-53
9.12.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-53
9.12.2 Dash Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-54
9.13 Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-55
9.13.1 Analyzer Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-55
9.13.2 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-55
.............................................................................. 9-57
9.14.1 Access Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-58
9.14.2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-58
9.14.3 Machine Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-59
9.14.4 Personalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-61
9.14.5 Operator Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-66
9.14.6 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-68
9.15 Multifunction Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70
9.15.1 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70
9.15.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-71
9.15.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-72
9.15.4 Multifunction Display and Control Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-72
9.15.5 Main Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-73
9.15.6 Setup and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-85
9.15.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-87
9.16 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-88
9.17 Machine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-89
9.17.1 Help Comment (00X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-89
9.17.2 Power Up (21X). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-90
9.17.3 Platform Controls (22X0). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-94
9.17.4 Cabin Controls (23X). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-96
9.17.5 Function Prevented (25X). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-107
9.17.6 Line Contactor Open-Circuit (31x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-109
9.17.7 Line Contactor Short-Circuit (32x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-110
9.17.8 Output Drivers (33X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-111
9.17.9 Engine (43X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-131
9.17.10 Battery Supply (44X). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-135
9.17.11 Transmission and Drive System (46X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-136
9.17.12 Communications (66X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-155
9.17.13 Envelope Control (84x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-158
9.17.14 Tilt Sensor (81x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-159
9.17.15 Load Moment (85X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-160
9.17.16 Steering (86x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-166
9.17.17 Service Required (87x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-167
9.17.18 Hardware (99X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-168
9-2 31211036 TL642D, TL943D, TL1055D, TL1255D

Electrical System
9.18 Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-173

9.18.1 TL642D, TL943D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-173
9.18.2 TL1055D, TL1255D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-184
TL642D, TL943D, TL1055D, TL1255D 31211036 9-3

Electrical System
9.1 ELECTRICAL COMPONENT

TERMINOLOGY
To understand the safety, operation, and service
of the electrical components of the machine. The following
9.1.1 General Overview
BACKUP
ALARM BOOM ANGLE
SENSOR
JOYSTICK
TRANSMISSION
CONTROL LEVER
DISPLAY
PANEL
REAR FRAME CAB CONTROL

CONTROL MODULE
MODULE
CAB POWER
DISTRIBUTION
BOARD
ALTERNATOR
ECM
CONTROL
STARTER
IGNITION KEY
SWITCH
FRAME POWER
BATTERY DISTRIBUTION
DISCONNECT BOARD
HORN
BATTERY
MAG0530
FRONT FRAME CONTROL
MODULE
TYPICAL ILLUSTRATION
9-4 31211036 TL642D, TL943D, TL1055D, TL1255D

Electrical System
9.2 SPECIFICATIONS 9.4 POWER DISTRIBUTION BOARDS

Electrical system specifications are listed in
Section 2, “General Information and Specifications”.
9.4.1 Cab Power Distribution Board
Power distribution board is located in cab. For access,
9.3 SAFETY INFORMATION remove screws securing the small side panel at the left side
of the dash.
Note: Connectors XA, XB, XC, XD, XE, XF, XG, XH and XJ are
WARNING marked with pin designation.
this manual.
B+ IGN GND
9 6 3
P
XD 8 5 2
E N
7 4 1
F D M
A C XB
G B L
H K 1 4 1 4
J
XC 2 5 XG 2 5
3 6 3 6
K2
15 12 7 4 3
2 1
XF 14 11 8 5 2
4 3 XA 13 10 9 6 1
6 5
D1
1 4 7 10
XH 2 5 8 11
XE 1 2 3 4
3 6 9 12
F1 10 F6 5
F2 30 F7 5 12 9 6 3
F3 10 F8 10 XJ 11 8 5 2
10 4 1
F4 5 F9 10 7
F5 5 F10 5
F3
B+ IGN GND
MAG9870
TL642D, TL943D, TL1055D, TL1255D 31211036 9-5

Electrical System
FUSE/RELAY FUNCTION AMP RATING

F1 AUXILIARY POWER 10
F2 MODULE POWER 30
F3 DISPLAY IGNITION, JOYSTICK IGNITION, RS232 POWER 10
SWITCH IGNITION (2), HI BEAM POWER, SHIFT IGNITION, COLUMN IGNITION,

F4 5
SEAT IGNITION
F5 TELEMATICS B+ 5
F6 TELEMATICS IGNITION 5
F7 HAZARD POWER, KEY BATTERY, BRAKE POWER 5
F8 HORN B+ (3) 10
F9 REVERSE SENSOR POWER, DOME IGNITION, REAR WIPER POWER 10
F10 BEACON POWER 5
K2 HORN RELAY 15
CONNECTOR PIN FUNCTION

A KEY IGNITION
B CAN1 HIGH
C CAN1 LOW
D SPARE
E SPARE
F KEY PLAT
G IGNITION OUT
XB
H SPARE
J HVAC COMPRESSOR OUT
K REVERSE SIGNAL 2
L REVERSE SIGNAL 1
M BOOM WORK LIGHTS
N HORN OUT
P SPARE
9-6 31211036 TL642D, TL943D, TL1055D, TL1255D

Electrical System

1 B+
2 B+
3 GND
XA
4 IGNITION
5 CLEAN IGNITION
6 CLEAN IGNITION
1 REVERSE SIGNAL 1
2 REVERSE SIGNAL 2
3 HVAC COMPRESSOR OUT

XC
4 BOOM WORK LIGHTS
5 HORN SW
6 SPARE
1 RS232 RX
2 RS232 TX
3 KEY PLAT
4 CAN1 HIGH
XD 5 KEY IGNITION
6 SPARE
7 CAN1 LOW
8 SPARE
9 SPARE
1 RS232 POWER
2 RS232 RX
XE
3 RS232 TX
4 RS232 GND
1 GND
2 TELEMATICS B+
3 TELEMATICS IGNITION
XG
4 SHIELD
5 CAN 2 LOW
6 CAN2 HIGH
TL642D, TL943D, TL1055D, TL1255D 31211036 9-7

Electrical System

1 HAZARD POWER
2 HORN B+
3 REVERSE SENSOR POWER
4 KEY BATTERY
5 MARKER LT MODULE
6 DOME IGNITION
XH
7 BRAKE POWER
8 D1
9 REAR WIPER POWER
10 IGNITION OUT
11 -
12 BEACON POWER
1 SHIELD
2 CAN2 LOW
3 CAN2 HIGH
4 SEAT IGNITION
5 COLUMN IGNITION
6 SHIFT IGNITION
7 HIGH BEAM POWER
XF 8 SWITCH IGNITION
9 SWITCH IGNITION
10 JOYSTICK IGNITION
11 JOYSTICK IGNITION
12 DISPLAY IGNITION
13 MODULE POWER
14 MODULE POWER
15 AUXILIARY POWER SOCKET
XJ ALL PINS GROUND
9-8 31211036 TL642D, TL943D, TL1055D, TL1255D

Electrical System
9.4.2 Frame Power Distribution Board

Power distribution board is located to the right side of the
cab, inside the frame.
J3
J5
F5
F4
F3
J4
MEGA
MEGA
FUSE
FUSE
J1
F2
F1
J7
K3
F11
F10
F7
F9
F12
F6
F8
K2
K7
J6
K6
J2
K5
K4
K1
MD0890
TL642D, TL943D, TL1055D, TL1255D 31211036 9-9

Electrical System

F1 GLOW PLUGS 150
F2 ALTERNATOR 200
F3 REAR FRAME 80
F4 FRONT FRAME 80
F5 CAB 80
F6 ECM IGNITION 25
F7 FRAME IGNITION 15
F8 ECM B+ 30
F9 CAB B+ 25
F10 AC FANS 30
F11 STARTER 30
F12 CAB MODULE 30
K1 FRONT FRAME IGNITION 70
K2 REAR FRAME IGNITION 70
K3 SYSTEM IGNITION 70
K4 SYSTEM IGNITION 70
K5 ECM IGNITION 30
K6 AC FAN POWER 30
K7 START SIGNAL TO ENGINE (STARTER OUT) 30
HIGH POWER CONNECTIONS
LOCATION FUNCTION AMP RATING SIZE
J1 B+ 200 M10
J2 ALTERNATOR 200 M10
J3 GLOW PLUGS/ENGINE POWER 150 M10
J4 FRONT FRAME 80 M8
J5 REAR FRAME 80 M8
J6 CAB 80 M8
9-10 31211036 TL642D, TL943D, TL1055D, TL1255D

Electrical System
9.4.3 Option 1 Distribution Board

Option 1 distribution board is located in the cab. For access,
remove screws securing the small side panel to cab.
Note: Connectors XK, XL and XM are marked with pin
designation.
4 5 6
XK
K1 1 2 3
1 4 7 10
2 5 8 11
10 F11 10 F16 XL 3 6 9 12
10 F12 10 F17
10 F13 25 F18
10 F14 10 F19
12 9 6 3
11 8 5 2
25 F15 5 F20
XM 10 7 4 1
B+ IGN GND
MAE0911

F11 BOOM WORK LIGHTS 10
F12 FRONT WORK LIGHTS 10
F13 REAR WORLK LIGHTS 10
F14 REAR WIPER 10
F15 WIPER POWER 25
F16 IGNITION 10
F17 ROOF WIPER POWER 10
F18 HVAC BLOWER POWER 25
F19 ROOF WIPER POWER 10
F20 AC FANS 5
K1 LIGHTS
TL642D, TL943D, TL1055D, TL1255D 31211036 9-11

Electrical System

1 GND
2 GND
3 GND
XK
4 REAR WIPER POWER
5 WIPER POWER
6 LIGHTS ON SIGNAL
1 SW IGNITION
2 HVAC BLOWER POWER
3 ROOF WIPER POWER
4 COLUMN IGNITION
5 HVAC COMPRESSOR OUT
6 ROOF WIPER POWER

XL
7 HI BEAM IGNITION
8 AC CMD
9 IGNITION
10 BOOM WORKLIGHT POWER
11 FT WORKLIGHT POWER
12 RR WORKLIGHT POWER
XM ALL PINS GROUND
9-12 31211036 TL642D, TL943D, TL1055D, TL1255D

Electrical System
9.4.4 Option 2 Distribution Board

Option 2 distribution board is located in the cab. For access,
remove screws securing the small side panel to cab.
Note: Connectors XN, XP, XR and XS are marked with pin
designation.
B+ IGN GND
12 9 6 3
11 8 5 2
F21 10 15 F25 XR 10 7 4 1
F22 15 15 F26
F23 15 15 F27
1 4 7 10
F24 15 2 5 8 11
E
P
N XP 3 6 9 12
D
F M
XS G
A C
L
B
H K 15 12 9 6 3
J
XN 12 11 8 5 2
13 10 7 4 1
MAE0920

F21 RADIO 10
F22 AIR RIDE SEAT POWER 15
F23 RADIO B+ 15
F24 SPARE 15
F25 AUXILARY POWER 15
F26 SPARE (IGNITION SWITCH) 15
F27 SPARE 15
TL642D, TL943D, TL1055D, TL1255D 31211036 9-13

Electrical System

A SPARE
B SPARE
C CAMERA GND
D SPARE
E SPARE
F SPARE
G SPARE
XS
H SPARE
J LMIS CAN H
K LMIS CAN L
L SPARE
M SPARE
N CAMERA SIGI
P AUXILARY ELECTRIC POWER OUT
1 SPARE
2 SPARE
3 HI DISPLAY POWER
4 SW IGNITION
5 SPARE
6 SPARE
XP
7 AUXILARY ELECTRIC POWER
8 -
9 SPARE
10 RADIO IGNITION
11 RADIO B+
12 AIR RIDE SEAT POWER
XR ALL PINS GROUND
9-14 31211036 TL642D, TL943D, TL1055D, TL1255D

Electrical System

1 SPARE
2 SPARE
3 SPARE
4 SPARE
5 -
6 AUXILARY ELECTRIC POWER OUT
7 SPARE
XN 8 CAMERA GND
9 CAMERA SIGI
10 SPARE
11 SPARE
12 SPARE
13 LMIS CAN H
14 LMIS CAN L
15 SPARE
TL642D, TL943D, TL1055D, TL1255D 31211036 9-15

Electrical System
9.4.5 Engine Harness Fuses and Relays

Engine harness fuses and relays box is located inside the
engine compartment.
F1
R1
F2
F3
R2
F4
F5
R3
F6
R4
D1
R5
MAG2960

F1 DEF HEATER 15
F2 DEF SUPPLY MODULE 15
F3 DIAGNOSTIC POWER 10
F4 ECM IGNITION POWER 5
F5 ALTERNATE EXCITE POWER 5
F6 AFTER TREATMENT SENSORS POWER 10
D1 ALTERNATE EXCITE POWER 6
R1 STARTER LOCKOUT 35
R2 DEF SUPPLY MODULE 35
R3 DEF HEATER 3 35
R4 DEF HEATER 2 35
R5 DEF HEATER 1 35
9-16 31211036 TL642D, TL943D, TL1055D, TL1255D

9.5
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Electrical System
9-17
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Electrical System

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TL642D, TL943D, TL1055D, TL1255D

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Electrical System
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9-19
9-20

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9-27
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9.5.2
8 7 6 5 4 3 2 1
CONNECTS TO X269 JS224
YEL CAN1H CAN1H
GD22 2 x 4 Buss Bar A NC SHIELD NC
WHT XF-13-3 DISPLAY PWR GXL OPTION 2 HARNESS GRN CAN1L CAN1L YEL CAN1H CAN1H
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1
2
3
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10 G2 DI TYPE 3 DI TYPE 1 G2 7
WHT J1-B3 CONT AUX SW WHT J2-G3 GEAR 1 WHT J1-G3 MARKER SW WHT J1-G4-1-1 SW BACKLIGHT
9 G3 DI TYPE 1 DI TYPE 1 G3 SW513
WHT J1-B2 LO BEAM SW WHT J1-G4 SW BACKLT BLK XJ-4-1 GND
8 G4 DI TYPE 1 DO TYPE 3 G4
WHT J1-C2 HI BEAM SW WHT J2-H1 TX WHT J1-H1 CRAB STEER SWITCH S234
7 H1 RS232 TX DI TYPE 1 H1
WHT J1-G3-1 MARKER SW WHT J2-H2 RX WHT J1-H2 LEFT PWR
6 H2 RS232 RX +5V AREF H2
WHT XH-1 HAZARD PWR GXL WHT J2-H3 AUX ELECTRIC OUT WHT J1-H3 IGN RELAY 14AWG
5 H3 DI TYPE 1 DO TYPE 4 H3
WHT J2-M1 HAZARD SW BLK XJ-4-1 GND
4 H4 DI TYPE 1 DO TYPE 3 H4
WHT J1-G4-2 SW BACKLT GXL WHT J1-G4-1-1 SW BACKLIGHT
3 J1 DI TYPE 2 SW18
CONNECTS TO X97
OPTION 1 HARNESS
WHT XC-4 BOOM WORKLIGHTS 14AWG GXL CO229-J3 BLK XJ-4-2 GND GXL
F 2 J2 DI TYPE 1 7 F
WHT XC-3 HVAC COMPRESSOR OUT GXL WHT J1-G4-1-2 SW BACKLIGHT GXL
1 J3 DI TYPE 1 DI TYPE 1 A1 8
WHT J1-H1 CRAB STEER SWITCH
X36 J4 DI TYPE 1 DI TYPE 1 A2 6
a. Cab Harness Electrical Schematic 1 of 4
WHT XC-5 HORN OUT WHT XF-9 SW IGN GXL

K1 ANALYZER SUPPLY DI TYPE 1 A3 5
DO TYPE 4
WHT SW18-2-4 JUMPER GXL
K2 ANALYZER GND A4 4
BLK XG-1 GND WHT J2-K3 GEAR 4 WHT J1-G1 2W STEER SWITCH
K3 DI TYPE 1 DO TYPE 4 B1 3
STEER MODE
RED XG-2 BAT + WHT J2-K4 AUX DECOMP SW WHT J3-B2 AC CMD WHT SW18-2-4 JUMPER GXL
K4 DI TYPE 1 DI TYPE 1 B2 2
YEL XG-3 IGN WHT J2-L1 KEY IGN WHT J1-D4 AW STEER SWITCH
L1 DI TYPE 2 DO TYPE 4 B3 1
YEL CAN2H CAN2H WHT J2-L2 BRAKE SWITCH WHT XF-9-1 SW IGN GXL
L2 DI TYPE 2 DO TYPE 4 B4
GRN CAN2L CAN2L BLK J2-L3 RIGHT GND WHT J3-C1 MOD PWR
L3 AGND MASTER POWER C1
FC244-XE
FC244-XC
FC244-XG
WHT J2-L4 AC ENABLE DI TYPE 1
L4 DO TYPE 3 C2
WHT J2-M1 HAZARD SW DI TYPE 1
DI TYPE 2
J
M1 C3
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
F
E
B
A
D
C
H
X2082
G
BLK J2-M2 MOD GND 14AWG DO TYPE 4
M2 MASTER GND C4
WHT J3-D1 MOD PWR
CONNECTS TO M3 DO TYPE 3 MASTER POWER D1
TELEMATICS M4 DO TYPE 3 DI TYPE 1 D2
HARNESS X2011 N/C D3
BLK J3-D4 MOD GND
(ANALYZER) (TELEMATICS) ON SHEET 5 N/C D4
FC244-XB WHT J3-E1 MOD PWR
MASTER POWER E1
FC244-XD DI TYPE 1
1 E2
YEL CAN1H CAN1H N/C
2 4 E3
GRN CAN1L CAN1L
3 7 AI TYPE 1 E4
WHT J3-F1 MOD PWR
E 4 8 MASTER POWER F1 E
WHT XD-5 KEY IGN 14AWG
5 5 DO TYPE 4 F2
6 MAIN POWER BOARD 3 N/C F3
7 6 AI TYPE 1 F4
WHT J3-G1 MOD PWR
8 9 MASTER POWER G1
WHT J2-H1 TX
9 2 MASTER POWER G2
WHT J2-H2 RX
10 1 MASTER POWER G3
11 MASTER POWER G4
12 MASTER POWER H1
FC244-XF
13 MASTER POWER H2
WHT XF-15 AUX POWER SOCKET 14AWG GXL
14 15 MASTER POWER H3
WHT XF-14 MOD PWR 14AWG GXL S519
14 MASTER POWER H4
CONNECTS TO FRONT FRAME XB

WHT XF-13 MOD PWR 14AWG GXL
13
S520 WHT XF-9-1 SW IGN GXL
12 1
WHT XF-11 JOY IGN WHT XF-9-2 SW IGN
11 2
FC244-XA WHT XF-10 JOY IGN GXL WHT J2-K4 AUX DECOMP SW
10 3
WHT XF-9 SW IGN GXL
1 9 4
31211036
WHT XF-8 USB IGN
2 8 5
3 7 6
AUX DECOMP
WHT XF-6 SHIFT IGN GXL WHT J1-G4-1-2 SW BACKLIGHT GXL

4 6 8
BLK XJ-4-2 GND GXL
5 5 7
D WHT J1-G4-1-3 SW BACKLT D
6 4
YEL CAN2H CAN2H BLK XJ-4-3 GND SW517
3
GRN CAN2L CAN2L
2
1 1
WHT XH-12 BEACON PWR SW 14AWG GXL
2
WHT SW31-3 BEACON PWR 14AWG GXL
3
FC244-XH
4
WHT XH-1 HAZARD PWR GXL
1 5
WHT XH-4 KEY BAT 14AWG
4 6
WHT XH-7 BRAKE PWR GXL WHT J1-G4-1-3 SW BACKLT
BEACON (OPT)
7 8
BLK XJ-4-3 GND
2 7
WHT J1-G3 MARKER SW WHT J1-G4-1-4 SW BACKLT GXL
5
WHT J1-G3-1 MARKER SW BLK XJ-4-4 GND GXL SW31
8
WHT J1-H3 IGN RELAY 14AWG
10
CONNECTS TO FRONT FRAME XA

WHT XH-9 REAR WIPER POWER WHT J1-F2 FRAME LEVEL LEFT
9 1
WHT XF-9-2 SW IGN
3 2
WHT XH-6 DOME IGN GXL WHT J1-F3 FRAME LEVEL RIGHT
6 3
WHT XF-9-2 SW IGN GXL
11 4
WHT XH-12 BEACON PWR SW 14AWG GXL
12 5
6
FRAME LEVEL
WHT J1-G4-1-4 SW BACKLT GXL

8
C FC244-XJ BLK XJ-4-4 GND GXL C
7
1 SW17
BLK XJ-2 DISPLAY GND GXL
2
BLK J2-M2 MOD GND 14AWG
3 X1662 X1663
BLK XJ-4 BACKLIGHT GND GXL
4 A A
BLK XJ-5 JOY GND GXL
5 B B
BLK XJ-6 DISPLAY GND GXL
6 X1954 C C X1953
WHT SW42-3 F WKLT SW WHT SW42-3 F WKLT SW
7 1 D D 1
BLK J3-D4 MOD GND BLK XM-10 F WKLT GND BLK XM-10 F WKLT GND CONNECTS TO X1951
8 2 E E 2
BLK XJ-9 USB CHARGING GND WHT SW43-3 R WKLT SW WHT SW43-3 R WKLT SW OPTION 1 HARNESS
9 3 F F 3
BLK XJ-10 DOME GND GXL BLK XM-9 R WKLT GND BLK XM-9 R WKLT GND
10 4 G G 4
BLK XJ-11 BEACON GND 14AWG GXL
11 H H
BLK XJ-12 AUX POWER GND 14AWG GXL CONNECTS TO X1950
12 J J
OPTION 1 HARNESS
K K
L L
M M
WHT SW31-3 BEACON PWR 14AWG GXL
N N 1 BEACON
BLK XJ-11 BEACON GND 14AWG GXL
P P 2
CONNECTION
X220
(OPTION)
B B
WHT J1-D1 LEFT SIG2
WHT J1-H2 LEFT PWR
WHT J1-C1 LEFT SIG1
BLK J2-G1 LEFT GND
WHT J2-F2 RIGHT PWR
WHT J1-E1 RIGHT SIG1
BLK J2-L3 RIGHT GND
WHT J1-F1 RIGHT SIG2
X603
X604
4
1
3
2
1
3
2
4
ALL WIRES ARE 20 AWG TXL UNLESS OTHERWISE NOTED.
WHT XF-15 AUX POWER SOCKET 14AWG GXL

BLK XJ-12 AUX POWER GND 14AWG GXL
LEFT RIGHT
X236
1
2
3
BLK XJ-10 DOME GND GXL
WHT XH-6 DOME IGN GXL
WHT XF-8 USB IGN

BLK XJ-9 USB CHARGING GND
OUTRIGGER JOYSTICKS
WHT XC-5 HORN OUT

WHT XH-7 BRAKE PWR GXL
WHT J2-L2 BRAKE SWITCH
1
1
2
1
LB530
X1716-
X1716+
SW05
2
1
1
2
3
4
SN212
A A
USB CHARGING
HORN DOME LIGHT
BRAKE PEDAL
AUX POWER SOCKET

8 7 6 5 4 3 2 1
MD0790F
TL642D, TL943D, TL1055D, TL1255D

1 2 3 4 5 6 7 8
STUD CONNECTIONS TO MAIN POWER BOARD
1
1
HORN RELAY
GND
IGN
GND
GND
GND
GND
GND
87
30
87a
85
86
H MAIN POWER BOARD OPTION 1 PDB H
4
1
3
2
5
K2
(SHEET 2) (SHEET 4)
XK
HORN B+
HORN B+
HORN SW
HORN OUT
GND
XB XC 1
REVERSE SIGNAL 1 REVERSE SIGNAL 1 GND
L 1 2
REVERSE SIGNAL 2 REVERSE SIGNAL 2 GND
K 2 3
HVAC COMPRESSOR OUT HVAC COMPRESSOR OUT F14 - 10A REAR WIPER PWR REAR WIPER PWR
J 3 6
BOOM WORKLIGHTS BOOM WORKLIGHTS F15 - 25A WIPER PWR WIPER PWR
M 4 5
HORN OUT HORN SW LIGHTS ON SIGNAL
N 5 4
(SPARE) (SPARE)
H 6
IGNITION OUT
G XD
CAN1 HI CAN1 HI GND LIGHTS ON SIGNAL
B 4
CAN1 LO CAN1 LO
C 7
TL642D, TL943D, TL1055D, TL1255D

(SPARE) (SPARE)
D 8
KEY IGN KEY IGN
A 5
KEY PLAT KEY PLAT
F 3
(SPARE) (SPARE)
E 6
(SPARE) (SPARE)
G P 9 G
RS232 TX
2
RS232 RX
1
XA XL
IGN F11 - 10A BM WKLT PWR BM WKLT PWR
4 10
GND F12 - 10A FT WKLT PWR FT WKLT PWR
3 11
CLEAN IGN F13 - 10A RR WKLT PWR RR WKLT PWR
5 12
CLEAN IGN SW IGN SW IGN
6 XE 1
B+ RS232 PWR F16 - 10A COLUMN IGN COLUMN IGN
1 1 4
B+ RS232 RX HI BEAM IGN HI BEAM IGN
2 2 7
RS232 TX IGN IGN
3 9
RS232 GND F17 - 10A ROOF WIPER PWR ROOF WIPER PWR
4 6
F18 - 25A HVAC BLOWER PWR HVAC BLOWER PWR
2
F19 - 10A ROOF WIPER POWER ROOF WIPER POWER
3
HVAC COMPRESSOR OUT
5
F20 - 5A AC CMD AC CMD
XF 8
F1 - 10A AUX POWER SOCKET AUX POWER SOCKET
15
MODULE POWER MODULE POWER
14
F2 - 30A MODULE POWER MODULE POWER
13
DISPLAY IGN DISPLAY IGN
12
JOY IGN JOY IGN
F 11 F
F3 - 10A JOY IGN JOY IGN
10 XM
RS232 PWR SWITCH IGN
9 1
b. Cab Harness Electrical Schematic 2 of 4
SWITCH IGN
8 2
SWITCH IGN HI BEAM POWER
7 3
SWITCH IGN SHIFT IGN
6 4
HI BEAM POWER COLUMN IGN
5 5
SHIFT IGN SEAT IGN
4 6
COLUMN IGN SHIELD
1 7
F4 - 5A SEAT IGN CAN 2L
2 8
CAN 2H
3 9
10
11
XG 12
CAN 2H
6
F5 - 5A TELEMATICS B+ CAN 2L
5
SHIELD
4
GND
1
TELEMATICS B+
2
F6 - 5A TELEMATICS IGN TELEMATICS IGN
3
E E
XH
HAZARD PWR HAZARD PWR
1
F7 - 5A KEY BAT KEY BAT
4
BRAKE PWR BRAKE PWR
7 OPTION 2 PDB
HORN B+ HORN B+
2
F8 - 5A HORN B+ MARKER LT MODULE
5
HORN B+ D1 (SHEET 5)
8
REV SEN PWR REV SEN PWR
3
F9 - 10A DOME IGN DOME IGN
6 XS XN
REAR WIPER PWR REAR WIPER PWR (SPARE) (SPARE)
9 A 4
IGNITION OUT (SPARE) (SPARE)
10 B 11
CAMERA GND CAMERA GND
11 C 8
F10 - 5A BEACON PWR BEACON PWR CAMERA PWR CAMERA PWR
12 D 3
(SPARE) (SPARE)
E 2
(SPARE) (SPARE)
F 1
31211036
(SPARE) (SPARE)
G 7
(SPARE) (SPARE)
H 10
LMIS CAN H LMIS CAN H
XJ J 13
LMIS CAN L LMIS CAN L
1 K 14
(SPARE) (SPARE)
2 L 15
(SPARE) (SPARE)
D 3 M 12 D
CAMERA SIG1 CAMERA SIG1
4 N 9
AUX ELECTRIC PWR OUT AUX ELECTRIC PWR OUT
5 P 6
6 5
7
8
9
10
11 STUD CONNECTIONS TO MAIN POWER BOARD
12
1
1
1
B+
IGN
GND
B+
IGN
GND
1
1
1
XP
F21 - 10A RADIO IGN RADIO IGN
C 10 C
STUD CONNECTIONS TO OPTION 1 PDB F22 - 15A AIR RIDE SEAT PWR AIR RIDE SEAT PWR
12
8
STUD CONNECTIONS TO OPTION 2 PDB F23 - 15A RADIO B+ RADIO B+
11
(SPARE) (SPARE)
6
F24 - 15A (SPARE) (SPARE)
9
HI DISP PWR HI DISP PWR
3
F25 - 15A AUX ELECTRIC PWR AUX ELECTRIC PWR
7
F26 - 15A (SPARE) (SPARE)
1
SW IGN SW IGN
4
F27 - 15A REVERSE CAMERA REVERSE CAMERA
2
(SPARE) (SPARE)
5
XR
1
2
3
4
B 5
6
B
7
8
9
10
11
12
A A
1 2 3 4 5 6 7 8
MD0800F
Electrical System
9-29
c.
9-30
1 2 3 4 5 6 7 8
FAN SWITCH
A/C ON/OFF CONT AUX
FAN
WHT X100-12 FRONT WASH
PWR
LOW
MED.
HI
AC
1
WHT XK-2 WASH GND
2 M
WHT XK-2-1 GND
FRONT
WH233-F
B
L
M
H
C
1
2
3
4
5
6
7
8
1
2
3
4
5
6
8
7
Sw82
Sw58
Sw59
H H
WHT SW40-6 REAR WASH
1
WHT XK-2-1 GND
2
WASHER PUMPS
M
REAR
WH233-R
BLK XK-1 FRONT WIPER GND 14AWG
6
5
WHT X100-9 WIPE HIGH 14AWG G
4
WHT XK-5-2 WIPER PWR P
3
WHT XL-1 SW IGN

BLK XM-11-1 GND
WHT X100-10 WIPE LOW 14AWG
WHT XL-1-1 SW IGN

BLK XM-11-10 GND
2 M
WHT SW59-C HVAC PWR

WHT SW58-3 AC ON/OFF
L
BLK XM-11-9 GND

WHT X100-6 WIPE PARK
BLK XM-11-10 GND
WHT SW59-H-2 FAN H

1
WHT J1-B3 CONT AUX SW

H
WHT SW59-C HVAC PWR

FRONT WIPER
WHT J1-G4-2-9 SW BACKLT

WH51
WHT SW59-L FAN L 14AWG

WHT SW59-H FAN H 14AWG
BLK XM-11-9 GND
WHT SW59-M FAN M 14AWG

CONNECT TO "G" ON HVAC X1658
WHT XL-2-1 HVAC PWR 12AWG

2
ACTUATOR HARNESS BLK XM-11 BACKLIGHT GND
1
WHT XL-2 HVAC BLOWER PWR 12AWG

CONNECT TO "D" ON HVAC X1659
WHT XL-2-1 HVAC PWR 12AWG
1
HVAC BLOWER ACTUATOR HARNESS BLK XM-7 BLOWER GND 14AWG WHT X100-12 FRONT WASH
2 12
WHT XK-5-1 WIPER PWR 12AWG
X1657-PWR 8
Electrical System
WHT SW59-H FAN H 14AWG S1949 WHT X100-6 WIPE PARK

+VE 1 6
M WHT X100-10 WIPE LOW 14AWG
G BLK XM-8 BLOWER GND 14AWG 2 G
GND 1 WHT X100-9 WIPE HIGH 14AWG
1
X1657-GND WHT J1-E2 RT TURN SW
11
WHT SW59-L FAN L 14AWG WHT XL-4 COLUMN IGN
LOW 1 10
X1657-L WHT J1-D2 LF TURN SW
WHT SW59-M FAN M 14AWG 9
MED 1 WHT XL-7 HI BEAM IGN
X1657-M 7
WHT SW59-H-2 FAN H WHT SW29-6 ROAD LIGHTS
LIGHTS / WIPER STALK
HIGH 1 4
REGULATOR
X1657 -H WHT J1-B2 LO BEAM SW
5
X1657-TEMP 1 WHT J1-C2 HI BEAM SW
WHT SW58-3 AC ON/OFF 3
1
SW100
WHT J3-B2 AC CMD
1
AC X1657-TEMP 2
WHT J3-B2 AC CMD

15
WHT J2-L4 AC ENABLE
14
WHT XH-9 REAR WIPER POWER
13
WHT J1-B3 CONT AUX SW WHT SW40-1 REAR WIPER PARK
9 1
WHT J1-G4-2 SW BACKLT WHT SW40-2 REAR WIPER SW 14AWG
3 2
WHT J1-D2 LF TURN SW WHT XK-6 REAR WIPER PWR 14AWG
12 3
WHT J1-E2 RT TURN SW WHT XK-6-1 REAR WIPER PWR
11 4
WHT J1-B2 LO BEAM SW WHT XK-6-1 REAR WIPER PWR
F 8 5 F
WHT J1-C2 HI BEAM SW WHT SW40-6 REAR WASH
7 6
REAR WIPER
10 8
Cab Harness Electrical Schematic 3 of 4
WHT J1-G3 MARKER SW BLK XM-11-1 GND

6 7
WHT XH-1 HAZARD PWR WHT J1-G4-2-2 SW BACKLT
5
WHT J2-M1 HAZARD SWITCH BLK XM-11-2 GND SW40
4
CONNECTS TO X36
WHT XC-4 BOOM WORKLIGHTS 14AWG
2
WHT XC-3 HVAC COMPRESSOR OUT
1
TO STANDARD HARNESS
X97
WHT SW41-1 ROOF WIPER PARK
1
WHT SW41-2 ROOF WIPER SW 14AWG
X266 -XK 2
BLK XK-1 FRONT WIPER GND 14AWG WHT XL-3 ROOF WIPER PWR 14AWG
1 3
WHT XK-2 WASH GND
2 4
BLK XK-3 REAR WIPER GND 14AWG
3 5
WHT XK-6 REAR WIPER PWR 14AWG
6 6
WHT XK-5 WIPER PWR 12AWG WHT J1-G4-2-2 SW BACKLT
ROOF WIPER
5 8
WHT XK-4 LIGHTS ON SIGNAL BLK XM-11-2 GND
4 7
WHT XK-5-2 WIPER PWR WHT J1-G4-2-4 SW BACKLT
BLK XM-11-4 GND SW41
X266-XL
WHT XL-10 BM WKLT PWR 14AWG
10
WHT XL-11 FT WKLT PWR 14AWG
11
WHT XL-12 RR WKLT PWR 14AWG
E 12 E
WHT XL-1 SW IGN
1
WHT XL-4 COLUMN IGN
4
WHT XL-7 HI BEAM IGN
7
9
WHT XL-6 ROOF WIPER POWER
6
WHT XL-2 HVAC BLOWER PWR 12AWG
2
WHT XL-3 ROOF WIPER PWR 14AWG
3
WHT XC-3 HVAC COMPRESSOR OUT
5
WHT J2-L4 AC ENABLE
8
FC266-XM
1
2
3
OPTION 1 PDB
4
5
WHT XL-1-3 IGN
31211036
6 1
BLK XM-7 BLOWER GND 14AWG WHT XL-1-1 SW IGN
7 2
BLK XM-8 BLOWER GND 14AWG WHT J1-G3 MARKER SW
8 3
BLK XM-9 R WKLT GND 14AWG WHT XK-4 LIGHTS ON SIGNAL
9 4
BLK XM-10 F WKLT GND 14AWG WHT XL-1-4 IGN
10 5
BLK XM-11 BACKLIGHT GND WHT SW29-6 ROAD LIGHTS
D 11 6 D
BLK XM-12 ROOF WIPER GND 14AWG WHT XL-1-3 IGN
ROAD LIGHTS
12 8
BLK XM-11-4 GND
7
WHT XL-1-4 IGN
WHT XH-1-1 HAZARD PWR

1
WHT XH-1 HAZARD PWR
WH101 X2158 X2157 2
H WHT XH-9 REAR WIPER POWER WHT J2-M1 HAZARD SWITCH
1 1 1 3
L BLK XK-3 REAR WIPER GND 14AWG
M 2 2 2 4
WHT SW40-2 REAR WIPER SW 14AWG WHT XH-1-1 HAZARD PWR
3 3 3 5
REAR WIPER
HAZARD
P WHT SW40-1 REAR WIPER PARK

4 4 4 17
G
18
7
8
BLK XM-11-5 GND
WH264 10
H WHT XL-6 ROOF WIPER POWER WHT J1-G4-2-6 SW BACKLT
1 5 5
L BLK XM-12 ROOF WIPER GND 14AWG BLK XM-11-6 GND SW213
M 2 6 6
WHT SW41-2 ROOF WIPER SW 14AWG
C 3 7 7 C
P WHT SW41-1 ROOF WIPER PARK
ROOF WIPER
4 8 8
G
WHT SW42-3-2 F WKLT SW 14AWG

A
BLK XM-10-2 GND 14AWG
B
LB567
LF WORKLIGHT
1
WHT XL-11 FT WKLT PWR 14AWG
2
WHT SW42-3-1 F WKLT SW 14AWG
A 3
BLK XM-10-1 F WKLT GND 14AWG
B 4
LB569 5
RF WORKLIGHT
B B
6
S592
8
S572
BLK XM-11-6 GND
FRONT WORKLIGHTS
7
X1951
1 9 9
2 10 10 1
WHT XL-10 BM WKLT PWR 14AWG
3 11 11 2
WHT XC-4 BOOM WORKLIGHTS 14AWG
4 12 12 3
X1950 4
5
HARNESS BREAK 6
ALL WIRES ARE 18 AWG GXL UNLESS OTHERWISE NOTED.
8
BETWEEN RIGHT BLK XM-11-7 GND
BOOM WORKLIGHTS
7
SWITCH PANEL BLK XM-11-8 GND SW248
1
AND JOYSTICK WHT XL-12 RR WKLT PWR 14AWG
S593 2
WHT SW43-3-1 R WKLT SW 14AWG WHT SW43-3 R WKLT SW 14AWG
A 3
BLK XM-9-1 R WKLT GND 14AWG
B S594 4
LB566 5
RR WORKLIGHT
A 6
WHT J1-G4-2-8 SW BACKLT A
8
BLK XM-11-8 GND
REAR WORKLIGHTS
7
LB565 SW247
BLK XM-9-2 GND 14AWG
B
WHT SW43-3-2 R WKLT SW 14AWG
A
LR WORKLIGHT
1 2 3 4 5 6 7 8
MD0810F
TL642D, TL943D, TL1055D, TL1255D

1 2 3 4 5 6 7 8
H H
WHT XP-4 SW IGN

1
WHT XP-4-1 SW IGN
2
3
TL642D, TL943D, TL1055D, TL1255D

4
5
6
QUICK CONN
8
BLK XR-1 SW BACKLT GND
7
G WHT J1-G4-3-2 SW BACKLT G
SW272
BLK XR-1-2 GND
1
WHT XP-4-1 SW IGN
2
3
X269 4
YEL CAN2H CAN2H
1 5
GRN CAN2L CAN2L
2 6
BOOM RIDE

3 8
BLK XR-1-2 GND
4 7
5
BLK XR-1-3 GND SW270
6
7
8
9
10
11
CONNECTS TO X235
F 12 F
TO STANDARD HARNESS
d. Cab Harness Electrical Schematic 4 of 4
FC268-XN
1
2
WHT XN-3 CAMERA PWR
3
4
5 1
WHT XN-6 AUX ELECTRIC PWR OUT WHT XN-6 AUX ELECTRIC PWR OUT
6 2
WHT XP-7 AUX ELECTRIC PWR
7 3
BLK XN-8 CAMERA GND
8 4
FC268-XS WHT XN-9 CAMERA SIG1
OPTION 2 PDB 9 5
E 1 10 6 E
AUX ELECTRIC
2 11 8
BLK XR-1-3 GND
3 12 7
4 13 SW277
5 14
6 15
7
8
9
FC268-XP
10
11 12
12 10
(X1692 SH11 H5)

13
TELEMATICS READY HARNESS
8
14 11
6
9 CONNECTS TO
31211036
X1611
WHT XP-3 HI DISP PWR BLK XG-1 GND
3 X2011 1
WHT XP-7 AUX ELECTRIC PWR BLK XG-1 GND RED XG-2 BAT +
7 TELEMATICS A 2
WHT XP-1 DISPLAY IGN RED XG-2 BAT + YEL XG-3 IGN
1 B 3
WHT XP-4 SW IGN
4 X2082 C 4
WHT XN-3 CAMERA PWR
2 D
D 5 ON SHEET 2, ZONE E2 E D
F
G
YEL XG-3 IGN
H
FC268-XR
J
CONNECTS TO CAB OPTION HARNESS X1692

BLK XR-1 SW BACKLT GND
1
2
3
4
5 X1611
RED XG-2 BAT+
6 X2011 1
BLK XG-1 GND BLK XG-1 GND
7 A 2
RED XG-2 BAT+ S2114 YEL XG-3 IGN
8 B 3
S2115
9 C 4
YEL PC ETH TX+ PC ETH TX+
10 D 5
ORG PC ETH TX- PC ETH TX-
11 E 6
BLK XR-12 HI DISP GND BLU PC ETH RX+ PC ETH RX+
12 F 7
WHT PC ETH RX- PC ETH RX-
G 8
YEL XG-3 IGN
H 9
SHLD SHIELD SHIELD
J 10
YEL CAN H CAN H
11
GRN CAN L CAN L
C 12 C
MS2113 MS2112
YEL CAN H CAN H YEL CAN H CAN H
A 1
GRN CAN L CAN L YEL CAN H CAN H
B 2
YEL CAN H CAN H
C 7
GRN CAN2L CAN2L

YEL CAN2H CAN2H
YEL CAN H CAN H
8
MS1233-3 GRN CAN L CAN L
3
YEL CAN H CAN H GRN CAN L CAN L
A 4
B
A
C
2 x 4 Buss Bar
MS600-1
GRN CAN L CAN L GRN CAN L CAN L
B 5
GRN CAN L CAN L
C 6
A
B
C
A
B
C
X2110
BLK XG-1 GND PRODUCTLINK HARNESS
A
MS600-3
MS600-2
RED XG-2 BAT+
B
YEL CAN H CAN H
C X1611
GRN CAN L CAN L RED XG-2 BAT +
D X2011 1
PRODUCTLINK PL641 HARNESS BLK XG-1 GND BLK XG-1 GND
E A 2
RED XG-2 BAT + YEL XG-3 IGN
MS2088-3 F B 3
HRC YEL CAN2H CAN2H
B A G C 4 B
GRN CAN2L CAN2L
B LRC H D 5
YEL CAN2H CAN2H

GRN CAN2L CAN2L
C C C J E 6
GRN CAN1L CAN1L GRN CAN2L CAN2L
B B K F 7
YEL CAN1H CAN1H YEL CAN1H CAN1H SHLD SHIELD SHIELD YEL CAN2H CAN2H
A A A NC G 8
GRN CAN1L CAN1L WHT PC ETH RX- PC ETH RX- YEL XG-3 IGN
MS522-3 MS2088-1 B L H 9
BLU PC ETH RX+ PC ETH RX+
C M J 10
ORG PC ETH TX- PC ETH TX-
MS2088-2 N 11
YEL PC ETH TX+ PC ETH TX+
P 12
TO STANDARD HARNESS
CONNECTS TO MS522-3
ALL WIRES ARE 18 AWG GXL UNLESS OTHERWISE NOTED.
YEL CAN2H CAN2H

GRN CAN2L CAN2L
WHT XP-3 HI DISP PWR
BLK XR-12 HI DISP GND
WHT XN-9 CAMERA SIG1
BLK XN-8 CAMERA GND
WHT XP-1 DISPLAY IGN

GRN CAN1L CAN1L
YEL CAN1H CAN1H
X279
9
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
GD92
18
17
16
15
14
13
12
11
10
A A
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
GND
CONNECT TO HIGH END
CAN L
CAN H
CAN2 L
CAN2 H
VIDEO CABLE
+12V (btty pwr)
IGN - WAKE UP
ON PREMIUM DISPLAY
PREMIUM DISPLAY
1 2 3 4 5 6 7 8
Electrical System
MD0820F
9-31
9-32
1 2 3 4 5 6 7 8
REAR HARNESS
TO CAB OPT CAB HARNESS CONNECTIONS
CONNECTIONS
X867
WHT J2H4 TRANS SOL1 HARNESS
1
WHT J2G4 TRANS SOL2 XB XA RH1 RH2
2
A
B
C
D
E
F
G
H
J
K
L
M
N
P
6
5
4
3
2
1
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
WHT J1E4 TRANS SOL3 CAB OPT
3
WHT J1D4 TRANS SOL4
X872
X871
X307
X324
4
2
1
WHT J3C1 TRANS SOL5
5
ET1 WHT J1A3 TRANS SOL6
X870
6
H 7 H
8
e. Front Frame
WHT J3E2 HI TR TP SW
9
GRN CAN 1L-2 CAN 1L

YEL CAN 1H-2 CAN 1H
WHT J1C1 TR TP SN
10
11
12
B
A
C
YEL 2 IGN 6AWG SGT
MS330-1
RED 1-1 B+ 14AWG GXL
RED 1-2 B+ 14AWG GXL
BLK 0-1 GND 6AWG SGT

YEL 2-1 IGN 14AWG GXL

X865
YEL 2-5 FR IGN 14AWG GXL

YEL J2A2 CAN 2H
WHT XAE HORN 16AWG GXL

A
WHT XAC AC HS 18AWG GXL

YEL 2-4 RFRM IGN 6AWG SGT
WHT XAL KEY ON 18AWG GXL

GRN J2D2 CAN 2L
WHT XAG IGN SIG 18AWG GXL

ET2 B
WHT XAD WORK LTS 16AWG GXL

WHT XAD WORK LTS 16AWG GXL
WHT 14 AUX EL PWR 14AWG GXL
C
YEL CAN 1H-1 CAN 1H 18AWG GXL

GRN CAN 1L-1 CAN 1L 18AWG GXL
A
B
C
A
B
C
S873

CONNECTS
X868
MS330-3
MS330-2
WHT J2L4 ENG ST 14AWG
1
TO ENGINE WHT J2J4 DRIVE NEUT
2
WHT J1C3 AUX STEER S1008
3
/ TRANS WHT J1F3 VEH SP SIG
4
WHT J2H3 VEH SP GND
5
HARNESS WHT J2K4 ANTI-ST1
6
ET3 WHT J2D3 ANTI-ST2
7
WHT 11 START LS 18AWG GXL
8
G WHT 10 START HS 18AWG GXL G
9
WHT J1F1 INTER TEMP
10
Electrical System
WHT 355 AC COMP 18AWG GXL

11
12

X866
RED 1-3 ECM B+ 10AWG GXL
1
2
ET4 YEL 2-6 ECM IGN 12AWG GXL
3
WHT 12 START OUT 10AWG GXL
4
SN869
WHT J2J3 FUEL GR
2
WHT J1E1 FUEL SIG FRONT FRAME MODULE
1
CO285-J1 CO285-J2
FUEL SENSOR
WHT J1A1 OUT LT PR YEL CAN 1H-2 CAN 1H
A1 AI TYPE 1 CAN1H A1
YEL J2A2 CAN 2H
A2 499 RES AI 3 CAN2H A2
BLK 0-5-3 GND 18AWG GXL WHT J1A3 TRANS SOL6
2 A3 DO TYPE 2 (PWM) LS CUR S 1 A3
WHT J1B1 HYD OIL TEMP 1 WHT J1A4 F LVL LT
1 A4 DO TYPE 2 LS CUR S 1 A4
WHT J1B1 HYD OIL TEMP 1
SN1282 B1 AI TYPE 1 CAN1L B1
TEMP SENSOR
WHT J1B2 HYD OILT JUMP WHT J2B2 CAN2 TERM
B2 499 RES AI 2 CAN2L B2
WHT XAL KEY ON 18AWG GXL
YEL 2-6 ECM IGN 12AWG GXL
BLK 0-7-4 GND 16AWG GXL
YEL 2-5 FR IGN 14AWG GXL
WHT XAG IGN SIG 18AWG GXL
RED 1 CAB B+ 12AWG GXL
WHT 19 AC FANS 12AWG GXL
WHT XA-1 AC HS 18AWG GXL
WHT 12 START OUT 10AWG GXL
WHT 11 START LS 18AWG GXL
WHT 10 START HS 18AWG GXL
F WHT J1B3 F LVL RT F

B3 DO TYPE 2 LS CUR S 1 B3 SN1699
WHT J1B4 OUT LT UP WHT J2B4 PARK BR2 WHT J2F1 5V REF
B4 DO TYPE 2 (PWM) LS CUR S 1 B4 A PWR
WHT J1C1 TR TP SN WHT J2G3 AGND
C1 AI TYPE 1 CAN1S GROUND C1 B GND
9
4
5
8
7
6
3
2
1
HV299
19
18
17
16
14
13
11
10
15
12
WHT J1A4 F LVL LT WHT J1C2 TR TP JUMP WHT J1A1 OUT LT PR

FC329-J7
1 C2 499 RES AI 1 CAN2S GROUND C2 C SIG
LEFT PR
BLK 0-6-6 GND 18AWG GXL WHT J1C3 AUX STEER
2 C3 DO TYPE 2 LS CUR S 1 C3
WHT J1C4 OUT LT DN
C4 DO TYPE 2 LS CUR S 1 C4
FRM LVL LT
SN1700
WHT J1D1 OUT RT PR GRN CAN 1L-2 CAN 1L WHT J2F2 5V REF
D1 AI TYPE 1 CAN1L D1 A PWR
F8
F7
GRN J2D2 CAN 2L WHT J2K3 AGND

HV300 D2 499 RES AI 4 CAN2L D2 B GND
F9
F12
WHT J1B3 F LVL RT WHT J1D3 OUT RT UP WHT J2D3 ANTI-ST2 WHT J1D1 OUT RT PR
1 D3 DO TYPE 2 LS CUR S 1 D3 C SIG
RIGHT PR
BLK 0-6-5 GND 18AWG GXL WHT J1D4 TRANS SOL4
2 D4 DO TYPE 2 (PWM) LS CUR S 1 D4
WHT J1E1 FUEL SIG
E1 AI TYPE 1 CAN1T E1
FRM LVL RT
WHT J2B2 CAN2 TERM
E2 499 RES AI 5 CAN2T E2
K6
WHT J1E3 FUEL JUMP

HV303 E3 270 RES AI 5 LS CUR S 1 E3
K5
WHT J1B4 OUT LT UP WHT J1E4 TRANS SOL3 WHT J2E4 BLOCK
1 E4 DO TYPE 2 (PWM) DO TYPE 1 (PWM) E4
BLK 0-6-4 GND 18AWG GXL WHT J1F1 INTER TEMP WHT J2F1 5V REF
F10
2 F1 AI TYPE 1A +5V AREF F1

F6
WHT J1F2 BR PD PR WHT J2F2 5V REF

F2 AI TYPE 1A +5V AREF F2
OUT LT UP
K7
WHT J1F3 VEH SP SIG WHT J2F3 OUT FR LVL SP2

F3 FI TYPE 1 LS CUR S 1 F3
WHT J1F4 OUT RT DN WHT J2F4 OUT FR LVL SP1
HV301 F4 DO TYPE 2 DO TYPE 1 (PWM) F4
WHT J1C4 OUT LT DN
1 G1 FI TYPE 1 RS232 RX G1
K4
2 G2 FI TYPE 1 RS 232 TX G2
F11
WHT J2G3 AGND

G3 DO TYPE 2A (PWM) AGND G3
OUT LT DN
E WHT J2G4 TRANS SOL2
E
HV302 G4 DO TYPE 2A (PWM) DO TYPE 1 (PWM) G4
WHT J1D3 OUT RT UP
1 H1 FI TYPE 1 DI TYPE 1 H1
BLK 0-6-2 GND 18AWG GXL WHT J1C2 TR TP JUMP YEL 2 IGN 6AWG SGT
K3
F5
2 H2 +5V ANLG REF DI TYPE 1 H2 1

WHT J2H3 VEH SP GND
H3 DO TYPE 2A (12V) AGND H3 FC329-J6
OUT RT UP
WHT J2H4 TRANS SOL1
H4 DO TYPE 2A DO TYPE 1 (PWM) H4
HV289 DI TYPE 1 J1
WHT J1F4 OUT RT DN YEL 2-4 RFRM IGN 6AWG SGT
K2
F3
1 DI TYPE 1 J2 1
FRAME LEVEL / OUTRIGGER

CO285-J3
BLK 0-6-1 GND 18AWG GXL WHT J3A1 CRAB STR WHT J2J3 FUEL GR
PDM
2 A1 DO TYPE 2 AGND J3 FC329-J5

WHT J2J4 DRIVE NEUT
A2 +5V AREF DO TYPE 1 (PWM) J4
OUT RT DN
HV312 A3 AGND ANALYZER SUPPLY K1
WHT J2F4 OUT FR LVL SP1 YEL J41 FRFM IGN 6AWG SGT
F4
K1
1 A4 DI TYPE 1A ANALYZER GND K2 1

WHT J2F3 OUT FR LVL SP2 WHT J2K3 AGND
2 B1 DO TYPE 2 AGND K3 FC329-J4
WHT J1B2 HYD OILT JUMP WHT J2K4 ANTI-ST1
B2 +5V AREF DO TYPE 1 (PWM) K4
WHT J3B3 AGND BLK 0-3-1 GND 14AWG RED 1-48 B+ 2/0AWG EPDM
B3 AGND MASTER GND L1 1
WHT J2L2 5V REF 18AWG
OUT FR LVL SP
B4 DI TYPE 1A +5V AREF L2 FC329-J1
31211036
WHT J3C1 TRANS SOL5 WHT J2L3 RT TN 14AWG RED 1-24 ALT 2AWG EPDM
F1
C1 DO TYPE 2 DO TYPE 3 L3 1
WHT J2L4 ENG ST 14AWG RED 1-24 ALT 2AWG EPDM
C2 +5V AREF DO TYPE 3 L4 FC329-J2
BLK 0-3-2 GND 14AWG RED 1-21 GLOW PL 2AWG EPDM
F2
HV295 C3 AGND MASTER GND M1 1

WHT J3A1 CRAB STR BLK 0-3-3 GND 14AWG RED 1-21 GLOW PL 2AWG EPDM
1 C4 DI TYPE 1A MASTER GND M2 FC329-J3
BLK 0-5-2 GND 18AWG GXL WHT J3D1 PARK BK
2 D1 DO TYPE 1 (PWM) DO TYPE 3 M3
D2 +5V AREF DO TYPE 3 M4
CRAB STR
D D
D3 +5V AREF
CO285-J4
HV294 D4 DI TYPE 1A
WHT J3F1 ALL WH STR WHT J3E1 PARK BR2 YEL J41 FRFM IGN 6AWG SGT
1 E1 DO TYPE 1 (PWM) MASTER POWER FOR OUTPUTS 1
BLK 0-5-1 GND 18AWG GXL WHT J3E2 HI TR TP SW RED 1-21 GLOW PL 2AWG EPDM
2 E2 DI TYPE 4 Sheet_10 PERKINS LRC-[5,A]
WHT J1E3 FUEL JUMP RED 1-21 GLOW PL 2AWG EPDM
STEERING
E3 +5V AREF Sheet_8 CAT 4_4 ENG-[4,B]
ALL WHL STR

E4 AI TYPE 2
WHT J3F1 ALL WH STR RED 1-24 ALT 2AWG EPDM
F1 DO TYPE 2 Sheet_10 PERKINS LRC-[8,G]
RED 1-24 ALT 2AWG EPDM
HV311 F2 DI TYPE 4 Sheet_8 CAT 4_4 ENG-[1,H]
WHT J3D1 PARK BK
1 F3 DI TYPE 1
WHT J2B4 PARK BR2 S297
2 F4 AI TYPE 2
WHT J3G1 HI BEAM 14AWG
G1 DO TYPE 3
PARK BR
WHT J3G2 MK LT 14AWG
HV489 G2 DO TYPE 3
WHT J3E1 PARK BR2 WHT J3G3 LO BEAM 14AWG
1 G3 DO TYPE 3
2 G4 DI TYPE 1
WHT J3H1 MK LT 14AWG
H1 DO TYPE 3
PARK BR2
BRAKE
WHT J3H2 HI BEAM 14AWG RED 1-45 B+ 3/0AWG EPDM
HV490 H2 DO TYPE 3 1 BT317+
WHT J2E4 BLOCK WHT J3H3 LT TN 14AWG
1 H3 DO TYPE 3 X1278
BLK 0-7-3 GND 18AWG GXL WHT J3H4 LO BEAM 14AWG
2 H4 DO TYPE 3
BLOCKING
BT317+ BT335+
RED 1-48 B+ 2/0AWG EPDM RED 1-45 B+ 3/0AWG EPDM
1 1
C C
WHT J1F2 BR PD PR
SIG C BT317- BT335-
BATTERY
WHT J3B3 AGND BLK 0-44 GND 3/0AWG EPDM BLK 0-43 GND 3/0AWG EPDM
GND B 1 1
2ND BATTERY
WHT J2L2 5V REF 18AWG

PWR A
BR PD PR
BLK 0-43 GND 3/0AWG EPDM
SN1759 1 BT317-
X1277
MS334-1
1
S542
S541
S543
MS334-2
1
BATT DIS
X1268 S1267
BLK 0-7 GND 12AWG GXL WHT 19-2 AC FANS 14AWG GXL
1
BLK 0-6 GND 12AWG GXL BLK 0-4-3 GND 14AWG GXL
1 2
TO AC WHT 19-1 AC FANS 14AWG GXL BLK 0-46 GND 2/0AWG EPDM
X539 3 X534
4 1
BLK 0 GND 8AWG GXL HARNESS WHT 355 AC COMP 18AWG GXL
1 5
B WHT XA-2 AC HS 18AWG GXL B
X540 6 X535
BLK 0-5 GND 14AWG GXL OPT AC BLK 0-3 GND 10AWG GXL
1
BLK 0-4 GND 12AWG GXL
1
FRONT FRAME
GNDS
S327 BLK 0-2 GND 6AWG SGT GND
X296 X536
1
FUSE VALUE BUSSBAR
AH326-G RELAY VALUE X537
BLK 0-7-1 GND 16AWG GXL F1 200A REAR BLK 0 GND 8AWG GXL
1 1
K1 70A BLK 0-55 GND 6AWG SGT
AH326 1
WHT XAE HORN 16AWG GXL
HORN
1 F2 150A FRAME X1028 X1033
K2 70A BLK 0-55 GND 6AWG SGT
1
F3 80A GND BLK 0-76 GND 6AWG SGT
X305
WHT J3G1 HI BEAM 14AWG K3 70A
1
WHT J3G2 MK LT 14AWG F4 80A
2
TO HEADLIGHT WHT J3G3 LO BEAM 14AWG K4 70A CAB
3
WHT J3H2 HI BEAM 14AWG F5 80A BLK 0-76 GND 6AWG SGT
4 1
HARNESS WHT J3H1 MK LT 14AWG K5 30A FRAME
5 X2136
WHT J3H4 LO BEAM 14AWG F6 25A
6
OPT HL WHT J3H3 LT TN 14AWG K6 30A GND
7
WHT J2L3 RT TN 14AWG F7 15A
8
BLK 0-4-1 GND 14AWG K7 30A
A 9
BLK 0-4-2 GND 14AWG F8 30A A
10
11
12
F9 25A
F10 30A
ALL WIRES ARE 20 AWG TXL UNLESS OTHERWISE NOTED. F11 30A
F12 30A
1 2 3 4 5 6 7 8
MAG0540F
TL642D, TL943D, TL1055D, TL1255D

f.
1 2 3 4 5 6 7 8
C
MS360-1 B
Rear Frame
YEL CAN 1H-5 CAN 1H YEL CAN 1H-7 CAN 1H 18AWG GXL
A A
GRN CAN 1L-5 CAN 1L
B MS360-2
C C
B X336
YEL CAN 1H-4 CAN 1H 18AWG GXL YEL CAN 1H-4 CAN 1H 18AWG GXL
H A 1 H
MS360-3 2
WHT 15 WORK LT 16AWG GXL
3
YEL 2-5-1 BM ANG IGN 18AWG GXL
4
5
B+ RED YEL 2-5-1 BM ANG IGN 18AWG GXL RH1
2 6
SIG WHT WHT J1A1 BM ANG SG
3 7
GND BLK WHT J2K3 BM ANG GND
1 8
BOOM ANG
SN341 9
10
11
FRONT HARNESS
X337
1 12
2
CONNECTIONS
X338
YEL 2-7 RFRM IGN 6AWG SGT
1 3
BLK 0-0 GND 6AWG SGT RH2
2 4
3 5
WHT J1F4 AUX QU CONN
4 6
TL642D, TL943D, TL1055D, TL1255D

WHT J1E4 AUX F1/2
5
BOOM 6
7 HV343
CABLE WHT J2H4 TELE IN
8 1
G WHT J2A3 TELE RTN
2 G
OPT BC
TELE IN
X605
WHT 16 AUX EL PWR 14AWG GXL REAR FRAME MODULE
1
BLK 0-8-4 GND 12AWG GXL CO328-J1 CO328-J2
2 HV342
WHT J1A1 BM ANG SG YEL CAN 1H-5 CAN 1H WHT J2G4 TELE OUT
A1 AI TYPE 1 CAN1H A1 1
WHT J2B3 TELE RTN
A2 499 RES AI 3 CAN2H A2 2
WHT J2A3 TELE RTN
A3 DO TYPE 2 (PWM) LS CUR S 1 A3
TELE OUT
WHT J1A4 BM RIDE WHT J2A4 AUX A2

X885 A4 DO TYPE 2 LS CUR S 1 A4
BOOM WORK WHT 15 WORK LT 16AWG GXL WHT CAN TERM CAN TERM
1 B1 AI TYPE 1 CAN1L B1 HV346
BLK 0-8-3 GRD 16AWG GXL WHT J2F4 LIFT UP1
2 B2 499 RES AI 2 CAN2L B2 1
LIGHTS WHT J1B3 BM TANK WHT J2B3 TELE RTN WHT J2F3 LIFT UP2
3 B3 DO TYPE 2 LS CUR S 1 B3 2
WHT J1B4 RCONT11 WHT J2B4 AUX B2
4 B4 DO TYPE 2 (PWM) LS CUR S 1 B4
LIFT UP
OPT BWL AI TYPE 1 CAN1S GROUND

C1 C1
C2 499 RES AI 1 CAN2S GROUND C2 HV347
WHT J2C3 FRK RET WHT J2E4 LIFT DN1
C3 DO TYPE 2 LS CUR S 1 C3 1
WHT J2C4 RCONT12 WHT J2E3 LIFT DN2
C4 DO TYPE 2 LS CUR S 1 C4 2
GRN CAN 1L-5 CAN 1L
D1 AI TYPE 1 CAN1L D1
LIFT DN
D2 499 RES AI 4 CAN2L D2

WHT J2D3 FRK RET
D3 DO TYPE 2 LS CUR S 1 D3 HV348
MCV
WHT J1D4 RCONT21 WHT J2D4 RCONT22 WHT J3D1 AUX A1

D4 DO TYPE 2 (PWM) LS CUR S 1 D4 1
WHT CAN TERM CAN TERM WHT J2A4 AUX A2
E1 AI TYPE 1 CAN1T E1 2
F 499 RES AI 5 CAN2T
F
E2 E2
AUX A
WHT J2E3 LIFT DN2

E3 270 RES AI 5 LS CUR S 1 E3
WHT J1E4 AUX F1/2 WHT J2E4 LIFT DN1
E4 DO TYPE 2 (PWM) DO TYPE 1 (PWM) E4 HV349
WHT J3E1 AUX B1
F1 AI TYPE 1A +5V AREF F1 1
WHT J2B4 AUX B2
F2 AI TYPE 1A +5V AREF F2 2
WHT J2F3 LIFT UP2
F3 FI TYPE 1 LS CUR S 1 F3
AUX B
WHT J1F4 AUX QU CONN WHT J2F4 LIFT UP1

F4 DO TYPE 2 DO TYPE 1 (PWM) F4
G1 FI TYPE 1 RS232 RX G1 HV344
WHT J2K4 FRK UP
G2 FI TYPE 1 RS 232 TX G2 1
WHT J2C3 FRK RET
G3 DO TYPE 2A (PWM) AGND G3 2
WHT J2G4 TELE OUT
G4 DO TYPE 2A (PWM) DO TYPE 1 (PWM) G4
FORK UP
H1 FI TYPE 1 DI TYPE 1 H1
HV350 H2 +5V ANLG REF DI TYPE 1 H2 HV345
WHT J1B4 RCONT11 WHT J2J4 FRK DN
1 H3 DO TYPE 2A (12V) AGND H3 1
WHT J2C4 RCONT12 WHT J2H4 TELE IN WHT J2D3 FRK RET
2 H4 DO TYPE 2A DO TYPE 1 (PWM) H4 2
DI TYPE 1 J1
RATE CNT 1
FORK DN
CO328-J3 DI TYPE 1 J2
HV351 A1 DO TYPE 2 AGND J3
RAS
WHT J1D4 RCONT21 WHT J2J4 FRK DN
1 A2 +5V AREF DO TYPE 1 (PWM) J4
WHT J2D4 RCONT22
2 A3 AGND ANALYZER SUPPLY K1
A4 DI TYPE 1A ANALYZER GND K2
RATE CNT 2
E E
WHT J2K3 BM ANG GND
B1 DO TYPE 2 AGND K3
WHT J2K4 FRK UP
B2 +5V AREF DO TYPE 1 (PWM) K4
BLK 0-1 GND 14AWG
B3 AGND MASTER GND L1
B4 DI TYPE 1A +5V AREF L2
GRN CAN 1L-7 CAN 1L 18AWG GXL WHT J2L3 RT TN 14AWG
4 C1 DO TYPE 2 DO TYPE 3 L3
YEL CAN 1H-7 CAN 1H 18AWG GXL WHT J2L4 REV AL 16AWG
3 C2 +5V AREF DO TYPE 3 L4
REVERSE SENSOR BLK 0-8-2 GND GXL BLK 0-2 GND 14AWG
2 C3 AGND MASTER GND M1
WHT J2L4-1 REV SEN GXL BLK 0-3 GND 14AWG
1 C4 DI TYPE 1A MASTER GND M2
OPT RS WHT J3D1 AUX A1
X764 D1 DO TYPE 1 (PWM) DO TYPE 3 M3
S544
D2 +5V AREF DO TYPE 3 M4
D3 +5V AREF
CO328-J4
D4 DI TYPE 1A
WHT J3E1 AUX B1 YEL 2-7 RFRM IGN 6AWG SGT
E1 DO TYPE 1 (PWM) MASTER POWER FOR OUTPUTS 1
E2 DI TYPE 4
WHT J2L4-2 REV AL 16AWG GXL
31211036
1 E3 +5V AREF
BLK 0-8-1 GND 16AWG GXL S765
2 E4 AI TYPE 2
AH355 F1 DO TYPE 2
F2 DI TYPE 4
REVERSE ALARM
F3 DI TYPE 1
F4 AI TYPE 2
D WHT J3G1 BR LT 14AWG D
G1 DO TYPE 3
WHT J3G2 MK LT 14AWG
G2 DO TYPE 3
WHT J3G3 RV LT 14AWG
G3 DO TYPE 3
G4 DI TYPE 1
WHT J3H1 MK LT 14AWG
H1 DO TYPE 3
WHT J3H2 BR LT 14AWG
H2 DO TYPE 3
WHT J3H3 LT TN 14AWG
H3 DO TYPE 3
WHT J3H4 RV LT 14AWG
H4 DO TYPE 3
C C
X339
1
TO BOOM WHT J1A4 BM RIDE
2
WHT J1B3 BM TANK
3
RIDE HARNESS BLK 0-9-3 GND 16AWG GXL
4
5
OPT BR
BLK 0-8 GND 10AWG GXL

TAIL S496 X547
BLK 0-9 GND 10AWG GXL GND
LB510 1
1
B BACK B
2
WHT J3G3-2 RV LT 14AWG GXL
3
WHT J3G2-5 MK LT 14AWG GXL S359
4
TURN WHT J3G1-2 BR LT 14AWG GXL
5
WHT J3H3-2 LT TN 14AWG GXL
LEFT TAIL
6
7
STOP
X512 X354
WHT J3G1-2 BR LT 14AWG GXL WHT J3G1 BR LT 14AWG
1 1
FOG WHT J3G2-5 MK LT 14AWG GXL WHT J3G2 MK LT 14AWG
2 2
WHT J3G3-2 RV LT 14AWG GXL WHT J3G3 RV LT 14AWG
3 3
WHT J3H2-2 BR LT 14AWG GXL WHT J3H2 BR LT 14AWG
4 4
WHT J3H1-2 MK LT 14AWG GXL WHT J3H1 MK LT 14AWG ALL WIRES ARE 20 AWG TXL UNLESS OTHERWISE NOTED.
5 5
WHT J3H4-2 RV LT 14AWG GXL WHT J3H4 RV LT 14AWG
6 6
WHT J3H3-2 LT TN 14AWG GXL WHT J3H3 LT TN 14AWG
7 7
TAIL WHT J3L3-2 RT TN 14AWG GXL WHT J2L3 RT TN 14AWG
8 8
BLK 0-9-4 GND 14AWG GXL BLK 0-9-2 GND 14AWG GXL
LB511 9 9
BLK 0-9-5 GND 14AWG GXL BLK 0-9-5 GND 14AWG GXL BLK 0-9-1 GND 14AWG GXL
1 10 10
BACK WHT J3L3-2 RT TN 14AWG GXL
2 11 11
WHT J3H2-2 BR LT 14AWG GXL
3 12 12
WHT J3H1-2 MK LT 14AWG GXL
A 4
TURN WHT J3H4-2 RV LT 14AWG GXL A
5
6
RIGHT TAIL
7
STOP
TAILLIGHTS
FOG
1 2 3 4 5 6 7 8
MAG0860F
Electrical System
9-33
9-34
1 2 3 4 5 6 7 8
2 x 6 BUSS BAR
DOC TEMP SCR TEMP

DEF HEATER 1 HEATER 2 HEATER 3
1
2
3
10
11
12
4
5
6
7
8
9
INJECTOR SUCTION DELIVERY RETURN
MS633
1
2
1
2
1
2
1
2
1
2
1
2
X679
X678
X677
X676
H H
SN672
SN673
WHT 153 H1LS
WHT 147 H2LS
WHT 146 H1HS
YEL CAN CH-1 CAN C HI

GRN CAN CL-1 CAN C LO
WHT 145 H2HS 16AWG
WHT 148 H3LS TEFLON
WHT 150 DINJLS TEFLON

WHT 151 DINJHS TEFLON
WHT 136-2 0 V TEFLON

WHT 136-3 0 V TEFLON
WHT 144-2 VLVHS TEFLON
YEL CAN CH-4 CAN C HI TEFLON

GRN CAN CL-4 CAN C LO TEFLON
WHT 152 SCR TSIG TEFLON
WHT 149 DOC TSIG TEFLON

6
5
WHT 258-1 NOX GR TEFLON
4
3
2
Electrical System
WHT 121 NOX ON TEFLON

1
G X666 G
TAILPIPE NOX
SENSOR
S1751
X675
WHT 144-1 VLVHS TEFLON
C 1
S694
MS1236-1 B 2
YEL CAN CH-7 CAN C HI YEL CAN CH-8 CAN C HI WHT 154 VLVLS TEFLON
A A 3
VALVE

B MS1236-2
C C
COOLANT
DIVERTER
B
120 OHM
A
6 MS1236-3
5
WHT 258-2 NOX GR TEFLON
4
3 C
S705
GRN CAN AL-7 CAN A LO
2 MS1233-1 B
WHT 123 NOX ON TEFLON YEL CAN AH-11 CAN A HI YEL CAN AH-7 CAN A HI
1 A A
TURBO NOX
SENSOR
GRN CAN AL-11 CAN A LO
X667 B MS1233-2
C C
B
120 OHM
A
F MS1233-3
F

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31211036_A_TL1055D, TL1255D_CAT_Service

DATE REVISION DESCRIPTION

TL642D, TL943D, TL1055D, TL1255D 31211036 i

ii 31211036 TL642D, TL943D, TL1055D, TL1255D

TL642D, TL943D, TL1055D, TL1255D 31211036 iii

iv 31211036 TL642D, TL943D, TL1055D, TL1255D

TL642D, TL943D, TL1055D, TL1255D 31211036 v

vi 31211036 TL642D, TL943D, TL1055D, TL1255D

PARAGRAPH TITLE PAGE

TL642D, TL943D, TL1055D, TL1255D 31211036 1-1

1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

1.2 DISCLAIMER WARNING

1-2 31211036 TL642D, TL943D, TL1055D, TL1255D

1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards

TL642D, TL943D, TL1055D, TL1255D 31211036 1-3

1-4 31211036 TL642D, TL943D, TL1055D, TL1255D

PARAGRAPH TITLE PAGE

TL642D, TL943D, TL1055D, TL1255D 31211036 2-1

2.8 Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . 2-35

2-2 31211036 TL642D, TL943D, TL1055D, TL1255D

2.1 REPLACEMENT PARTS AND WARRANTY

Before ordering parts or initiating service inquiries, make

TL642D, TL943D, TL1055D, TL1255D 31211036 2-3

2.2.1 Travel Speed

AVERAGE MAXIMUM SPEED - FORWARD AVERAGE MAXIMUM SPEED - REVERSE

2.2.2 Hydraulic Cylinder Performance

APPROXIMATE TIMES (seconds)

2.2.3 Cylinder Drift

Maximum Rod Travel

2-4 31211036 TL642D, TL943D, TL1055D, TL1255D

2.2.4 Steering Angle Specifications

Model Angle (in Degree)

2.2.5 Electrical System

Description Standard Dual/Arctic

TL642D, TL943D, TL1055D, TL1255D 31211036 2-5

2.2.6 Engine Performance Specifications

2-6 31211036 TL642D, TL943D, TL1055D, TL1255D

TL642D, TL943D, TL1055D, TL1255D 31211036 2-7

2-8 31211036 TL642D, TL943D, TL1055D, TL1255D

2.3 FLUID AND LUBRICANT CAPACITIES

2-10 31211036 TL642D, TL943D, TL1055D, TL1255D

Engine Crankcase Oil

TL642D, TL943D, TL1055D, TL1255D 31211036 2-11

Engine Crankcase Oil

2-12 31211036 TL642D, TL943D, TL1055D, TL1255D

Engine Crankcase Oil

TL642D, TL943D, TL1055D, TL1255D 31211036 2-13

2.4 SERVICE AND MAINTENANCE

2.4.1 Every 10 Hours

OC0880 OC0890 OC0950 OC0910 OC0920

OC0930 OC0940 OC0900

Check Check DEF Level Check Brake

2.4.2 First 50 Hours

Check Wheel Lug Check Boom

2-14 31211036 TL642D, TL943D, TL1055D, TL1255D

2.4.3 Every 50 Hours

OC1010 OC0960 OC0970 OC1020 OC1030

2.4.4 First 250 Hours

Change Axle Oil Change Wheel

2.4.5 Every 250 Hours

OC1010 OC1090 OC1080 OC1160 OC1130

Check Transfer Check Axle Oil

TL642D, TL943D, TL1055D, TL1255D 31211036 2-15

2.4.6 First 500 Hours