Documente Academic
Documente Profesional
Documente Cultură
Models
TL642
TL943
S/N TBK00100 & After
S/N TBL00100 & After
31200292
Revised
May 21, 2012
EFFECTIVITY PAGE
September 29, 2006 - A - Original Issue Of Manual
August 3, 2007 - B - Revised pages 2-6, 2-7, 2-8, 2-9, 4-2, 4-7, 4-8, 8-5, 8-8 & 8-9.
March 31, 2011 - C - Revised pages 2-3 thru 2-9, 2-11 thru 2-21, 3-1 thru 3-25, 4-2 thru 4-9, 5-3, 6-3, 7-3 thru 7-5, 7-7,
7-9 thru 7-11, 8-2, 8-3, 8-7 thru 8-12, 8-14 thru 8-16, 8-25, 8-26, 9-2 thru 9-6, 9-8 thru 9-22, 9-29, 9-30 & 9-33 thru 9-46.
September 22, 2011 - D - Added pages 9-41 thru 9-46.
May 21, 2012 - E - Revised pages 2-11, 8-4, 8-5, 8-6 & 8-8.
31200292
TL642, TL943
EFFECTIVITY PAGE
ii
TL642, TL943
31200292
SECTION CONTENTS
Section
Subject
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Page
1-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
1-2
1-2
1-2
1-3
1-4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2.1
2.2
2.3
2.4
2.5
2.6
Section 3
Boom
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
TL642, TL943
2-2
2-3
2-11
2-14
2-17
2-20
...........................................................
3-1
3-3
3-4
3-4
3-5
3-6
3-14
3-16
3-20
3-20
3-22
3-23
3-24
3-27
3-28
3-31
Section
Subject
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
4.2
4.3
4.4
4.5
Page
4-1
4-2
4-4
4-4
4-10
4-11
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5-2
5-3
5-3
5-9
5-10
5-11
5-11
Section 6
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6.1
6.2
6.3
6.4
6.5
6.6
Section 7
Engine
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
ii
6-2
6-3
6-3
6-3
6-6
6-7
...........................................................
7-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2
7-4
7-4
7-4
7-6
7-7
7-8
7-9
7-10
7-13
7-14
TL642, TL943
Section
Subject
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
Page
8-1
8-2
8-3
8-3
8-4
8-14
8-15
8-18
8-24
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
9.14
9.15
TL642, TL943
9-3
9-5
9-5
9-5
9-11
9-23
9-26
9-27
9-28
9-29
9-30
9-34
9-36
9-38
9-47
iii
Section
iv
Subject
Page
TL642, TL943
Section 1
Safety Practices
Contents
PARAGRAPH
1.1
1.2
1.3
1.4
1.5
1.6
1.7
TL642, TL943
TITLE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5.1
Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.1
Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.2
Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.3
General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.4
Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE
1-2
1-2
1-2
1-2
1-2
1-2
1-3
1-3
1-3
1-3
1-4
1-4
1-1
Safety Practices
1.1
INTRODUCTION
1.4
1.5
SAFETY INFORMATION
1.5.1
1.2
DANGER
WARNING
DISCLAIMER
1.3
CAUTION
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
TL642, TL943
Safety Practices
1.6
SAFETY INSTRUCTIONS
1.6.1
Personal Hazards
1.6.2
Equipment Hazards
1.6.3
General Hazards
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.
TL642, TL943
1-3
Safety Practices
1.6.4
Operational Hazards
1.7
SAFETY DECALS
1-4
TL642, TL943
Section 2
General Information and Specifications
PARAGRAPH
2.1
2.2
2.3
2.4
2.5
2.6
TL642, TL943
TITLE
PAGE
2-2
2-3
2-3
2-7
2-10
2-11
2-11
2-11
2-11
2-12
2-12
2-13
2-14
2-17
2-17
2-18
2-19
2-20
2-1
2.1
* High pressure oil easily punctures skin causing serious injury, gangrene or death.
* If injured, seek emergency medical help. Immediate surgery is required to remove oil.
* Do not use finger or skin to check for leaks.
* Lower load or relieve hydraulic pressure before loosening fittings.
10814B
MAL0500
2-2
TL642, TL943
2.2
TORQUE CHARTS
2.2.1
Torque
(Dry)
Tensile
Clamp Load
Stress Area
Torque
Torque
(Loctite 242TM or 271TM
(Loctite 262TM or VibraTM
OR Vibra-TITE 111 or
TITETM 131)
140)
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
IN-LB
[N.m]
40
48
32
40
32
36
24
32
20
28
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
380
420
580
610
900
940
1120
1285
2020
2320
8
9
16
18
30
31
43
49
96
120
0.9
1.0
1.8
2.0
3.4
3.5
4.8
5.5
10.8
13.5
6
7
12
13
22
23
32
36
75
86
0.7
0.8
1.4
1.5
2.5
2.6
3.5
4
9
10
105
135
12
15
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
3340
3700
4940
5600
6800
7550
9050
10700
11600
12950
14400
16300
21300
23800
29400
32400
38600
42200
42300
47500
53800
59600
64100
73000
78000
87700
FT-LB
17
19
30
35
50
55
75
90
110
120
150
170
260
300
430
470
640
700
800
880
1120
1240
1460
1680
1940
2200
[N.m]
23
26
41
47
68
75
102
122
149
163
203
230
353
407
583
637
868
949
1085
1193
1518
1681
1979
2278
2630
2983
FT-LB
13
14
23
25
35
40
55
65
80
90
110
130
200
220
320
350
480
530
600
660
840
920
1100
1260
1460
1640
[N.m]
18
19
31
34
47
54
75
88
108
122
149
176
271
298
434
475
651
719
813
895
1139
1247
1491
1708
1979
2224
FT-LB
19
21
35
40
55
60
85
100
120
135
165
190
285
330
475
520
675
735
840
925
1175
1300
1525
1750
2025
2300
[N.m]
26
29
48
54
75
82
116
136
163
184
224
258
388
449
646
707
918
1000
1142
1258
1598
1768
2074
2380
2754
3128
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
NOTES:
IN-LB
[N.m]
FT-LB
16
17
28
32
45
50
68
80
98
109
135
153
240
268
386
425
579
633
714
802
1009
1118
1322
1506
1755
1974
[N.m]
22
23
38
43
61
68
92
108
133
148
183
207
325
363
523
576
785
858
968
1087
1368
1516
1792
2042
2379
2676
NO. 5000059
REV. J
MY3141
TL642, TL943
2-3
Torque
(Dry or Loctite 263)
K= 0.20
Torque
Torque
(Loctite 242TM or 271TM (Loctite 262TM or VibraOR Vibra-TITE TM 111 or
TITETM 131)
140)
K=.18
K=0.15
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
40
48
32
40
32
36
24
32
20
28
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
1320
1580
1800
2860
3280
43
60
68
143
164
5
7
8
16
19
129
148
15
17
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
FT-LB
25
25
45
50
70
80
105
120
155
170
210
240
375
420
605
670
860
995
1290
1445
1815
2015
2385
2705
3165
3555
[N.m]
35
35
60
70
95
110
145
165
210
230
285
325
510
570
825
910
1170
1355
1755
1965
2470
2740
3245
3680
4305
4835
FT-LB
20
25
40
45
65
70
95
110
140
155
190
215
340
380
545
600
770
895
1160
1300
1635
1810
2145
2435
2845
3200
[N.m]
25
35
55
60
90
95
130
150
190
210
260
290
460
515
740
815
1045
1215
1580
1770
2225
2460
2915
3310
3870
4350
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
NOTES:
IN-LB
[N.m]
FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665
[N.m
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625
NO. 5000059
REV. J
MY3151
2-4
TL642, TL943
Torque
(Dry) K = .17
Torque
(Loctite 242TM or 271TM
OR Vibra-TITE TM 111 or
140 OR Precoat 85
K=0.16
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
40
48
32
40
32
36
24
32
20
28
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
2860
3280
122
139
14
16
114
131
13
15
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
FT-LB
20
25
35
40
60
65
90
100
130
145
180
205
320
355
515
570
730
845
1095
1225
1545
1710
2025
2300
2690
3020
[N.m]
25
35
50
55
80
90
120
135
175
195
245
280
435
485
700
775
995
1150
1490
1665
2100
2325
2755
3130
3660
4105
FT-LB
20
20
35
40
55
60
85
95
125
135
170
190
300
335
485
535
685
795
1030
1155
1455
1610
1905
2165
2530
2845
[N.m]
25
25
50
55
75
80
115
130
170
185
230
260
410
455
660
730
930
1080
1400
1570
1980
2190
2590
2945
3440
3870
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
Torque
(Loctite 262TM
TM
or Vibra-TITE 131)
K=0.15
IN-LB
[N.m]
FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665
[N.m]
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625
MY3161
TL642, TL943
2-5
Clamp Load
See Note 4
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
2860
3280
143
164
16
19
129
148
15
17
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
FT-LB
25
25
45
50
70
80
105
120
155
170
210
240
375
420
605
670
860
995
1290
1445
1815
2015
2385
2705
3165
3555
[N.m]
35
35
60
70
95
110
145
165
210
230
285
325
510
570
825
910
1170
1355
1755
1965
2470
2740
3245
3680
4305
4835
FT-LB
20
25
40
45
65
70
95
110
140
155
190
215
340
380
545
600
775
895
1160
1300
1635
1810
2145
2435
2845
3200
[N.m]
25
35
55
60
90
95
130
150
190
210
260
290
460
515
740
815
1055
1215
1580
1770
2225
2460
2915
3310
3870
4350
Size
TPI
Bolt Dia
40
48
32
40
32
36
24
32
20
28
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
Torque
(Loctite 242TM or 271TM
OR Vibra-TITE TM 111 or
140 OR Precoat 85
K=0.18
Torque
(Dry)
K = .20
Torque
(Loctite 262TM
TM
or Vibra-TITE 131)
K=0.15
IN-LB
[N.m]
FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665
[N.m]
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625
MY3400
2-6
TL642, TL943
SizePITCH
Tensile
Stress
Area
Sq mm
Clamp
Load
Torque
(Dry or Loctite
263TM)
Torque
(Lub)
KN
[N.m]
[N.m]
Torque
(Loctite
Torque
TM
TM
242 or 271TM
(Loctite 262
OR VibraOR VibraTITETM 131)
TITETM 111 or
140)
[N.m]
[N.m]
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
0.7
8.78
3.82
3.1
2.3
2.8
3.4
0.8
14.20
6.18
6.2
4.6
5.6
6.8
20.10
8.74
11
7.9
9.4
12
28.90
12.6
18
13
16
19
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
16
2
2
115
157
50.0
68.3
140
105
126
154
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
353
153.5
737
553
663
811
27
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
817
355.5
2560
1920
2300
2690
42
4.5
1120
487.0
4090
3070
3680
4290
NO. 5000059
MY3171
TL642, TL943
REV. J
2-7
SizePITCH
Tensile
Stress
Area
Clamp
Load
Torque
(Dry or Loctite
263TM)
K = 0.20
Sq mm
KN
[N.m]
Torque
(Lub OR Loctite
242TM or 271TM OR
Vibra-TITE TM 111 or
140)
K= 0.18
Torque
(Loctite 262TM OR
Vibra-TITE TM 131)
K=0.15
[N.m]
[N.m]
0.5
5.03
3.13
3.5
0.6
6.78
4.22
0.7
8.78
5.47
0.8
14.20
8.85
20.10
12.5
28.90
18.0
25.2
22.7
18.9
1.25
36.60
22.8
36.5
32.8
27.4
10
1.5
58.00
36.1
70
65
55
12
1.75
84.30
52.5
125
115
95
14
16
2
2
115
157
71.6
97.8
200
180
150
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
353
222.0
1065
960
800
27
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
817
509.0
3665
3300
2750
42
4.5
1120
698.0
5865
5275
4395
NO. 5000059
REV. J
2-8
TL642, TL943
Tensile
Stress
Area
SizePITCH
Sq mm
Torque
Torque
(Lub OR Loctite
Torque
(Loctite 262TM
TM
TM
Clamp Load (Dry or Loctite 242 or 271
OR Vibra-TITE TM
See Note 4
263TM)
OR Vibra-TITE TM
131)
K = .17
111 or 140)
K = .15
K = .16
kN
[N.m]
[N.m]
[N.m]
11
0.5
3.5
0.6
5.03
6.78
0.7
8.78
0.8
14.20
20.10
12.5
13
12
28.90
18.0
21
20
19
1.25
36.60
22.8
31
29
27
10
1.5
58.00
36.1
61
58
54
12
1.75
84.30
52.5
105
100
95
14
16
2
2
115
157
71.6
170
160
150
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
353
220.0
900
845
790
27
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
817
509.0
3115
2930
2750
42
4.5
1120
698.0
4985
4690
4395
NO. 5000059
REV. J
TL642, TL943
2-9
Size
ORFS
JIC
Flats Method
13 lb-ft
(18 Nm)
13 lb-ft
(18 Nm)
1.5 to 1.75
23 lb-ft
(31 Nm)
23 lb-ft
(31 Nm)
1 to 1.5
40 lb-ft
(54 Nm)
40 lb-ft
(54 Nm)
1.5 to 1.75
10
60 lb-ft
(81 Nm)
60 lb-ft
(81 Nm)
1.5 to 1.75
12
74 lb-ft
(100 Nm)
85 lb-ft
(115 Nm)
1.0 to 1.5
16
115 lb-ft
(156 Nm)
115 lb-ft
(156 Nm)
0.75 to 1.0
20
170 lb-ft
(230 Nm)
170 lb-ft
(230 Nm)
0.75 to 1.0
24
200 lb-ft
(271 Nm)
200 lb-ft
(271 Nm)
0.75 to 1.0
32
N/A
270 lb-ft
(366 Nm)
0.75 to 1.0
Flats Method:
1. If equipped, lubricate o-ring with hydraulic oil. Hand
tighten the swivel nut until no lateral movement of
the swivel nut can be detected. Average hand torque
is 3 lb-ft (4 Nm).
2. Mark a dot on one of the swivel nut flats and another
dot in line on the hex of the adapter its connecting
to.
3. Use the double wrench method while tightening to
avoid hose twist.
4. After the connection has been properly tightened,
mark a straight line across the connecting parts, not
covering the dots indicating that the connection has
been properly tightened.
2-10
TL642, TL943
2.3
SPECIFICATIONS
2.3.1
Travel Speeds
TL642
TL943
First Gear
Second Gear
Third Gear
Fourth Gear
2.3.2
Note: Machine with no attachment or load, engine at full throttle, hydraulic oil above 130 F (54 C) minimum, engine
at operating temperature.
FUNCTION
TL943
14.0
13.6
Boom Retract
12.3
15.8
Boom Lift
12.6
10.7
Boom Lower
9.2
7.8
3.4
4.6
3.9
4.5
6.3
10.2
8.6
11.8
2.3.3
Cylinder Drift
CYLINDER
Lift/Lower Cylinder
Extend/Retract Cylinder
TL642, TL943
2-11
Electrical System
Battery
Type, Rating
Quantity
Reserve Capacity
Group/Series
Group 31
2.3.5
Note: Engine manufacturer's maximum high idle setting is lockwired and sealed. DO NOT disturb this setting
Description
Engine Make/Model
CAT 3054C
CAT C4.4
Low Idle
1000 rpm
High Idle
Horsepower
Peak Torque
Displacement
Fuel Delivery
Air Cleaner
2-12
Fuel Injection
Dry Type, Replaceable Primary and Safety Elements
TL642, TL943
Tires
Note: Standard wheel lug nut torque is 350-400 lb-ft (475-542 Nm).
Note: Pressure for foam filled tires are for initial fill ONLY.
Size
Tire Type
Minimum Ply/
Star Rating
13.00 x 24
12 Ply
13.00 x 24
12 Ply
13.00 x 24
G2/L-2 Radial
1 Star
13.00 x 24
Pressure
Pneumatic
Pneumatic
Pneumatic
15.50 x 25
12 Ply
15.50 x 25
12 Ply
15.50 x 25
G2/L2 Radial
1 Star
370/75x28
DuraForce
14 Ply
TL642, TL943
Fill Type
Pneumatic
Pneumatic
Pneumatic
Pneumatic
2-13
2.4
a. Fluids
Ambient Temperature Range
Compartment or
System
Min
Max
SAE 0W-20
-40
50
-40
10
SAE 0W-30
-40
86
-40
30
SAE 0W-40
-40
104
-40
40
SAE 5W-30
-22
86
-30
30
SAE 5W-40
-22
122
-30
50
SAE 10W-30
104
-18
40
SAE 10W-40
122
-18
40
SAE 15W-40
15
122
-9.5
50
Cat MTO
-10
104
-23
40
-40
14
-42
-1
Axle Differential*
and Wheel End
SAE 75W-140
-22
113
-30
45
SAE 80W-90
-10
120
-23
49
SAE 85W-140
10
120
-12
59
Cat TDTO-TMS
Cat TDTO-TMS
-4
122
-20
50
SAE 0W-20
-40
104
-40
40
SAE 0W-30
-40
104
-40
40
SAE 5W-30
-22
104
-30
40
SAE 5W-40
-22
104
-30
40
SAE 10W
-4
104
-20
40
SAE 30
50
122
10
50
SAE 10W-30
-4
104
-20
40
SAE 15W-40
122
-15
50
Cat TDTO-TMS
-4
122
-20
50
Cat TDTO
Hydraulic System
C
Max
Transmission
and Transfer
Case
F
Min
Viscosities
Cat TDTO-TMS
Cat Arctic TDTO SYN
Commercial TO-4
NLGI Grade 2
-4
104
-20
40
Cat Multipurpose
NLGI Grade 2
-22
104
-30
40
2-14
TL642, TL943
Viscosities
F
Min
Engine Coolant
Air Conditioning
Max
Min
50/50 Mix
Standard
60/40 Mix
Cold Weather
#2 Diesel
Fuel
C
Max
Standard
Low Sulfur
Refrigerant R-134a
Cold Weather
Tetrafluorethane
Note: Friction Modifier (CAT Brake Oil Additive) required for axle differentials, see Section b, Capacities.
b. Capacities
Engine Crankcase Oil
Capacity w/Filter Change
Fuel Tank
Capacity
Anti-gel Fluid -40 to 0 F(-40 to -20 C)
Cooling System
System Capacity
TL642
Before S/N TBK01167 excluding TBK01162
TL943
Before S/N TBL01599 excluding TBL01551 & TBL01585
Hydraulic System
System Capacity
TL642
Before S/N TBK01167 excluding TBK01162
TL943
Before S/N TBK01167 excluding TBK01162
TL642, TL943
2-15
TL943
Before S/N TBL01599 excluding TBL01551 & TBL01585
Transmission
Capacity with Filter Change
Transfer Case
Capacity
Axles
Differential Housing Capacity
Friction Modifier (differential only)
Wheel End Capacity
2-16
2.5 lb (1134 g)
TL642, TL943
2.5
2.5.1
EVERY
10
Check Fuel
Level
Air Filter
Restriction
Indicator
Check
Transmission
Oil Level
Additional
Checks Section
OMM 8
Check Engine
Oil Level
Check Hydraulic
Oil Level
Check Tire
Condition &
Pressure
Check
Battery
Check Washer
Fluid Level
(if equipped)
Lubrication
Schedule
1st
50
LB/F
T (N
m)
Check Wheel
Lug Nut
Torque
EVERY
50
Drain Fuel/
Water
Separator
Check Engine
Coolant Level
OAL2650
TL642, TL943
2-17
1st
250
Change
Axle Oil
Change Wheel
End Oil
Change
Transmission
Oil & Filter
Change
Transfer Case
Oil
EVERY
250
Change Engine
Oil and Filter*
Check Axle
Oil Level
Check Wheel
End Oil Levels
Air Filter
Vacuator
Valve
Check Boom
Wear Pads
Check Transfer
Case Oil Level
Check
Rear Axle
Stabilization
Lubrication
Schedule
Check
Fan Belt
EVERY
500
LB/F
T (N
m)
Change Fuel
Filters
Check Wheel
Lug Nut
Torque
OAL2660
Note: Engine oil and filter service interval can be extended. See Engine Manual for details.
2-18
TL642, TL943
EVERY
1000
Change
Transmission
Oil & Filter
Change
Transfer Case
Oil
Check Boom
Chains
Lubrication
Schedule
Change
Axle Oil
Change Wheel
End Oil
Check
Air Intake
System
EVERY
1500
Change
Engine Coolant
Change
Hydraulic
Fluid & Filters
Change
Hydraulic Tank
Breather
OAL2670
TL642, TL943
2-19
2.6
LUBRICATION SCHEDULES
a. 50 Hour
EVERY
50
2
B
B
2
2
B
B
2
2
B
B
2
B 2
B
2
B
2
2
2
2
2
IF EQUIPPED
OAL0321
2-20
TL642, TL943
EVERY
250
2
B
2
B
B
2
B
2
B
2
B
2
B
2
IF EQUIPPED
OAL0912
TL642, TL943
2-21
EVERY
1000
IF EQUIPPED
OAL2680
2-22
TL642, TL943
Section 3
Boom
Contents
PARAGRAPH
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
TL642, TL943
TITLE
PAGE
3-3
3-4
3-4
3-4
3-5
3-5
3-5
3-6
3-6
3-7
3-8
3-9
3-10
3-12
3-14
3-14
3-15
3-16
3-16
3-18
3-20
3-20
3-20
3-20
3-21
3-21
3-22
3-22
3-22
3-22
3-23
3-23
3-23
3-1
Boom
3.12
3.13
3.14
3.15
3-2
3-24
3-24
3-24
3-26
3-27
3-28
3-31
TL642, TL943
Boom
3.1
SECOND BOOM
SECTION
EXTEND CHAIN
(INSIDE BOOM)
FIRST BOOM
SECTION
THIRD BOOM
SECTION
PUSH BEAM
ASSEMBLY
RETRACT CHAIN
(INSIDE BOOM)
EXTEND/RETRACT
CYLINDER
(INSIDE BOOM)
STRONG BACK
HOSE SHEAVE
(INSIDE BOOM)
MY0112
PIVOT PIN
TL642, TL943
3-3
Boom
3.2
3.2.1
3.3
The boom section lifts and lowers via action of the lift/
lower cylinder.
WARNING
NEVER weld or drill the boom unless approved in
writing by the manufacturer. The structural integrity of
the boom will be impaired if subjected to any repair
involving welding or drilling.
3-4
TL642, TL943
Boom
3.4
3.4.1
14. Lift the boom assembly from the machine and lower
onto suitable supports.
3.4.2
MY1520
13. Clean up all debris, hydraulic fluid, etc., in, on, near
and around the machine.
14. Close and secure the engine cover.
3-5
Boom
15. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
16. Install the previously removed attachment to the
quick coupler assembly. Refer to Section 3.9, Quick
Coupler Assembly.
3.5
3.5.1
11
9
10
MY3860
10. Loosen and remove the four bolts (8) securing the
retract chain anchor plate (9).
3
2
MY3850
3-6
12. Disconnect both tilt tubes (10) and (if equipped) both
auxiliary tubes from the fittings on the hose retainer
brackets (11) at the bottom front inside the boom.
Plug the tube ends to prevent dirt and debris from
entering the hydraulic system.
13. Disconnect both tilt hoses (not shown) and (if
equipped) both auxiliary hoses from the hose
retainer brackets at the bottom front inside the
boom. Plug the hose ends to prevent dirt and debris
from entering the hydraulic system.
14. Loosen and remove the hose retainer brackets (11)
and (if equipped) both auxiliary take-up brackets.
TL642, TL943
Boom
15. Between the bottom front of the first and second
boom sections, feed a rope or wire to both tilt hoses
(not shown) and (if equipped) both auxiliary hoses
and secure to the second or third boom section.
16. Place a suitable sling around the second boom
section. Slowly pull the second and third boom
sections approximately 25% out of the first boom
section. Lower the second and third boom sections
onto a suitable support.
12
12
13
13
12
12
MY3840
4
5
3.5.2
MY4070
8
1
MY4110
MY3880
TL642, TL943
3-7
Boom
6. Loosen and remove the tilt hose and auxiliary hose
retainers (7 & 8) from the front of the third boom
section.
10
10
3.5.3
CAUTION
The complete push beam assembly weighs over
1,200 lb (545 kg).
9
9
MY3890
11
17
16
15
3. Lift the push beam (14) to unload the clevis pin (17)
and remove the pin securing the clevis to the third
boom section.
11
MY3870
3-8
14
MY4060
12
11
13
TL642, TL943
Boom
3.5.4
14
19
18
20
MY3930
NOTICE
Guide the push beam/extend/retract cylinder
assembly over the top of the retract chain anchor at
the rear of the third boom section being careful not to
damage any components.
10. Place a sling around the push beam assembly. Lift
and slowly pull the push beam assembly
approximately half way out of the third boom section.
Lower the push beam onto a suitable support.
NOTICE
Guide the push beam/extend/retract cylinder
assembly over the top of the retract chain anchor at
the rear of the third boom section being careful not to
damage any components.
5
7
8
4
MY3930
TL642, TL943
3-9
Boom
MY4060
11
15
15
14
14
MY3890
12
MY3940
11. Install the tilt cylinder hoses and (if equipped) the
auxiliary hoses through the front of the third boom
section.
Note: Verify the tilt cylinder hoses and (if equipped) the
auxiliary hoses are routed UNDER the hose guide (12)
at the rear of the third boom section at the retract chain
clevis bracket.
12. Snug the Temporary Extend Chain Bracket (9).
3.5.5
13
MY3900
3-10
Boom
4. Lower the third boom section onto a suitable
support, relocate one sling and insert the third boom
section assembly approximately 75% into the
second boom section.
3
4
5
1
4
MY3870
8
6
MY3960
10
9
9
MY3970
19. Feed the tilt cylinder hoses and (if equipped) the
auxiliary hoses over and around the hose sheaves.
TL642, TL943
3-11
Boom
11
12
11
17
12
16
15
15
MY3880
MY3880
20. Align the push beam bores with the second boom
section bores and install the previously removed
pins (11).
Note: Verify the cross holes in push beam pins align
with holes in each pin bore on the second boom section.
21. Install the previously removed tilt cylinder hose
guide (12) and if equipped, the auxiliary hose guide
at the rear of the third boom section using the
existing hardware. Torque as required.
14
16
14
3.5.6
13
13
MY3910
3-12
TL642, TL943
Boom
4. Remove any rope or wire securing the retract chain
and tilt hoses and (if equipped) auxiliary hoses as
the second and third boom sections are installed into
the first boom section.
10
8
11
4
MY3990
5
2
MY3840
13. Connect both tilt hoses (10) and (if equipped) both
auxiliary hoses to the fittings on the hose retainer
bracket. Torque as required.
14. Connect both tilt tubes (11) and (if equipped) both
auxiliary tubes to the fittings on the hose retainer
bracket. Torque as required.
13
12
12
MY3980
MY3890
3-13
Boom
30. Start the engine and operate all boom functions
several times. Check for leaks, and check the
hydraulic fluid level in the reservoir; add fluid if
required.
18
16
31. Clean up all debris, hydraulic fluid, etc., in, on, near
and around the machine.
17
19
20
20
3.6
EXTEND/RETRACT CHAIN
REMOVAL/INSTALLATION
3.6.1
3-14
MY0580
TL642, TL943
Boom
7. Remove the extend/retract cylinder mounting pin (5)
from the strong back.
8. Remove the extend chain locknut and jamnut (6)
from the strong back.
11. Remove the push beam mounting pins from the rear
of the second boom section.
MY1540
12. Place the chain clevis rod to one side of the push
beam.
13. Lift the push beam to gain access to the chain clevis
at the rear of the third boom section.
14. Reaching inside the rear of the boom at the chain
anchor bracket, remove the cotter pin and pin from
the retract chain clevis. Remove the cotter pin and
pin from the extend chain.
15. Connect wire or rope (approximately 30 ft (9,1 m) to
the end of the extend chain.
16. Lower the push beam. Center the chain clevis rod on
the push beam to aid in removal.
17. Pull the push beam/extend chain from the rear of the
boom. Disconnect the wire or rope from the extend
chain.
18. Pull the retract chain from the rear of the boom.
3.6.2
3-15
Boom
3.7
5
4
CAUTION
The complete push beam - extend/retract cylinder
assembly weighs over 1,200 lb (545 kg).
The following section explains the removal of the push
beam - extend/retract cylinder without removing or
disassembling the boom assembly.
3.7.1
MY3860
6
7
MY3850
3-16
TL642, TL943
Boom
16
15
11
11
14
10
10
13
12
9
MY3930
15. Loosen and remove the four bolts (12), guide bar
(13) and chain retainer (14) from the front of the
push beam.
MAL1290
10. Loosen and remove the tilt cylinder hose guide (10)
and if equipped, the auxiliary hose guide from the
rear of the third second section.
Note: The hose guide mounting bolts also hold the push
pin beams in place.
19
20
20
18
20
11. Remove the left and right push beam pins (11).
12. Start the machine and SLOWLY extend the extend/
retract cylinder 1 - 2 ft (305 - 609 mm) or until the
push beam assembly can be accessed through the
front of the third boom section.
Note: Only the push beam - extend/retract cylinder
assembly should move during this procedure.
NOTICE
The extend chain rod will move toward the front of
boom. Do Not allow the rod to come into contact with
the chain and/or chain roller.
13. Shut machine OFF.
14. Properly disconnect the battery.
TL642, TL943
17
17
MAL1290
3-17
Boom
20. Place a sling around the push beam - extend/retract
cylinder assembly. Lift and slowly pull the push
beam - extend/retract cylinder assembly
approximately half way out of the boom assembly.
Lower the push beam onto a suitable support.
1
2
2
NOTICE
3
2
MAL1290
3.7.2
NOTICE
Guide the push beam - extend/retract cylinder
assembly over the top of the retract chain anchor at
the rear of the third boom section being careful not to
damage any components.
4. Remove the plugs and caps from the extend/retract
cylinder hydraulic tubes. Install both extend/retract
cylinder hydraulic tubes.
3-18
8
7
9
MY3930
TL642, TL943
Boom
15. Install the belleville washers (13) to the extend chain
anchor (14) as previously removed at the rear of the
first boom section.
10
10
12
12
16
17
11
11
18
MY3860
17. Remove the rope or wire from the retract chain (16).
MAL1290
14. Install the tilt cylinder hose guide (12) and the
auxiliary hose guide from the rear of the third second
section.
20
14
15
13
19
MAL1310
MY3850
22. Connect both tilt hoses (20) and both auxiliary hoses
(not shown) to the hose retainer brackets (19) at the
bottom front inside the boom.
23. Properly connect the battery.
3-19
Boom
24. Adjust the chain as needed. Refer to Section 3.8,
Boom Section Separation Adjustment.
25. Install the cover on the rear of the boom.
26. Close and secure the engine cover.
3.8
MY0880
3.9
3.9.1
1. Remove the lock bolt holding the tilt cylinder rod end
pin to the quick coupler assembly. Remove the Tilt
Cylinder pin.
2. Support the quick coupler assembly. Remove the
capscrew and locknut securing the head pin to the
boom head.
3. Inspect the above pins for nicks or surface corrosion.
Use fine emery cloth to fix minor nicks or corrosion.
If damaged or if it cannot be repaired the pin must be
replaced.
3.9.2
TL642, TL943
Boom
2. Coat the quick coupler head pin with an anti-seize
compound. Insert the quick coupler head pin through
the quick coupler and boom head. Secure with the
previous capscrew and locknut.
3.9.4
3. Align the quick coupler with the tilt cylinder rod end
and insert the tilt cylinder pin. Align the tilt cylinder
pin and screw in the locking bolt. Torque as required.
3.9.3
5
6
MAL1160
11
4
9
3
MAL0131
TL642, TL943
8
10
MAL1340
MAL1170
4. TL642 - All
TL943 - S/N TBL01599 & After including TBL01551
& TBL01585
Press and hold the quick coupler switch (8). At the
same time push the auxiliary hydraulic joystick (9) up
to engage the lock pin or push the auxiliary hydraulic
joystick down to disengage the lock pin.
TL943 - S/N TBL01599 & After including TBL01551
& TBL01585
Press and hold the quick coupler switch (10). At the
same time push the roller switch (11) down to
engage the lock pin or push the roller switch up to
disengage the lock pin.
3-21
Boom
5. Raise boom to eye level and visually check that the
locking pin protrudes through the hole on both sides
of the quick coupler. If the pins do not protrude
through the hole, place the attachment on the
ground and return to step 2.
3.10
3.10.1
3.9.5
MAL0880
3.10.2
MAL1280
10
MAL1180
TL642, TL943
Boom
3.11
3.11.1
MY3620
Ma2070
Inspect all wear pads for wear. If the angle indicators (1)
on the end of the wear pads are visible, the wear pads
can be reused. If the wear pads show uneven wear (front
to back), they should be replaced. Replace wear pads as
a set if worn or damaged.
3.11.2
2
1
MAM1390
TL642, TL943
3-23
Boom
3.12
3.12.1
WARNING
Worn pins, stretched or cracked links or corrosive
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
need to be inspected every 250 hours of operation. The
retract chains need to be exposed and inspected every
1000 hours of operation. 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 atmospheres, in addition to abrasive
exposures such as sand and grit. Some effects can be
as follows:
3.12.2
Inspection Guidelines
3-24
TL642, TL943
Boom
Distorted or Battered Link Plates
Edge Wear
Check the chain for wear on the link plate edges
caused by running back and forth over the sheave.
The maximum reduction of material should not
exceed 5%. Measure and compare to a normal link
plate height by measuring a portion of chain that
does not run over the sheave. If the measured plate
height (1) is 5% less than the normal plate height (2),
discard and replace the chain.
85
MZ1466
Elongation
It is important to measure the chain in the section
that moves over the sheaves because it receives the
most frequent articulation. Measuring the chain near
its clevis terminals could give an inaccurate reading.
The ends of the chains, near the clevis terminal, will
not have flexed as frequently, if at all, as the middle
of the chains.
It is best to measure in 12 pin increments from pin
center to pin center. For example, if the links are one
inch from pin center to pin center, the distance
should be 12 in (305 mm). If the links are 3/4 in
apart, the distance after 12 pins should be 9 in.
If the distance measured (3) is 3% greater than the
normal length (4), discard and replace the chain.
4
3
8
MZ1465
MY1360
TL642, TL943
3-25
Boom
3.12.3
Cracked Plates
Inspect the chains very carefully, front and back as
well 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:
Fatigue Cracking Fatigue cracks (9) are
a result of repeated
cyclic loading beyond
the chains endurance
limit.
Stress Corrosion
Cracking - The
10
outside link plates
are particularly
susceptible to stress
corrosion cracking (10).
9
MZ1467
MZ1468
Chain Lubrication
MZ1469
MZ1470
Tight Joints
- All joints in
the chain
should flex
freely. Tight
3
MZ1471
joints (3)
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.
3-26
TL642, TL943
Boom
3.13
FORKS
6
1
9
8
11
10
MH6460
TL642, TL943
3-27
Boom
3.14
TROUBLESHOOTING
Problem
1. Boom will not extend or
retract
Cause
Remedy
1. Insufficient lubrication.
2. Worn bearing(s).
1. Insufficient lubrication.
2. Worn bushing(s).
4. Excessive Compensation
cylinder pivot pin noise and/
or wear.
3-28
TL642, TL943
Boom
Problem
5. Drooping chain, or jerky
boom extend or retract
functions.
TL642, TL943
Cause
Remedy
1. Adjust chain(s).
4. Contaminated, corroded or
rusted wear pad sliding
surfaces.
5. Extend/Retract hydraulic
system not operating properly.
4. Replace bearing.
1. Insufficient lubrication.
3-29
Boom
Problem
8. Rapid boom pad wear.
3-30
Cause
Remedy
3. Contaminated, corroded or
rusted wear pad sliding
surfaces.
TL642, TL943
Boom
3.15
Note: The drawings below are only suggested and can be subject to individual interpretation.
Temporary Extend Chain Bracket
5.00
3.125
0.1875
0.250
0.50
0.875
2.0
SEE NOTE A
1.3125
1/4
6.875
7.00
1.50
3/16
2.1875
4.0
1.50
3.125
0.1875
2.0
3/16
1.0
0.50
3/16
0.875
2.0
1.50
0.50
2.50
3.0
0.50
3.0
TL642, TL943
MY4100
3-31
Boom
3-32
TL642, TL943
Section 4
Cab and Covers
Contents
PARAGRAPH
4.1
4.2
4.3
4.4
4.5
TL642, TL943
TITLE
PAGE
4-2
4-2
4-3
4-4
4-4
4-4
4-4
4-4
4-5
4-6
4-7
4-8
4-8
4-9
4-10
4-11
4-1
4.1
4.1.1
General Overview
FRAME LEVEL
INDICATOR
STEERING WHEEL
BOOM CONTROL
JOYSTICK
INSTRUMENT PANEL
FRAME LEVEL AND
ATTACHMENT TILT
CONTROLLER
TRANSMISSION
CONTROL LEVER
OUTRIGGER CONTROLS
(IF EQUIPPED)
HEATER AND A/C
CONTROLS
(IF EQUIPPED)
AUXILIARY
HYDRAULICS
CONTROLLER
IGNITION
SWITCH
SERVICE BRAKE
PEDAL
MAL0200
ACCELERATOR
PEDAL
4-2
TL642, TL943
General Overview
ACCESSORY
CONTROL
LEVER
FRAME LEVEL
INDICATOR
STEERING WHEEL
FRAME LEVEL
JOYSTICK
INSTRUMENT PANEL
TRANSMISSION
CONTROL LEVER
OUTRIGGER CONTROLS
(IF EQUIPPED)
IGNITION
SWITCH
SERVICE BRAKE
PEDAL
ACCELERATOR
PEDAL
TL642, TL943
MAL1190
4-3
WARNING
DO NOT service the machine without following all
safety precautions as outlined in the Safety
Practices section of this manual.
4.2
4.2.1
OPERATOR CAB
Cab Safety
WARNING
WARNING
DO NOT weld, grind, drill, repair or modify the cab in
any way. Any modification or damage to cab structural
components requires cab replacement. Refer to the
Operation & Maintenance Manual.
To help ensure optimum safety, protection and
performance, replace the cab if it is damaged. Refer to
the appropriate parts manual for ordering information.
4.2.2
4.3.1
CAB COMPONENTS
Steering Column and Orbitrol Valve
4-4
4.3
MY0120
3
1
4.3.2
2
MY0141
4-5
Throttle Pedal
c. Throttle Adjustment
6
MAL0990
10
9
8
MAL1000
4-6
TL642, TL943
4.3.4
Boom Joystick
a. Joystick Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake and turn the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
should not be operated.
(If Equipped)
14
12
13
(If Equipped)
MAL0940
11
11
MAL0940
TL642, TL943
4-7
a. Joystick Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake and turn the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
should not be operated.
b. Joystick Installation
15
16
MAL0211
4.3.6
4-8
TL642, TL943
10. Remove the bolts securing the front plate (1) to the
seat riser weldment (2).
MY4390
12. Loosen the hose and disconnect the heater air duct
hoses (3).
2
1
MY0190
TL642, TL943
4-9
10. Wait for the engine to cool and check the coolant
level. Add coolant as required to bring the coolant to
the proper level.
4.4
CAB REMOVAL
WARNING
The protection offered by this ROPS/FOPS will be
impaired if subjected to any modification or structural
damage, at which time replacement is necessary.
ROPS/FOPS must be properly installed using
fasteners of correct size and grade, and torqued to
their specified value.
Note: To help ensure safety and optimum performance,
replace the cab if it is damaged. Refer to the appropriate
parts manual for ordering information.
Inspect the cab, its welds and mounts. If modification,
damage, a cracked weld and/or fatigued metal is
discovered, replace the cab. Contact the local Caterpillar
dealer with any questions about the suitability or
condition of a cab.
Note: Remove and label cab components as needed
before removing the cab from the machine. Label,
disconnect and cap hydraulic hoses. Transfer cab parts
to the replacement cab after the replacement cab is
securely mounted on the machine.
1. Park the machine on a firm, level surface. Allow
sufficient overhead and side clearance for cab
removal. Level the machine, fully retract the boom,
lower the boom, place the travel select lever in the
(N) NEUTRAL position, engage the park brake and
shut the engine OFF.
2. Block all four wheels to help prevent the machine
from moving. Assure that there is sufficient overhead
and side clearance for cab removal.
3. Open the engine cover. Allow the system fluids to
cool.
4-10
24. Carefully begin to lift the cab. Stop and check that all
wiring, hydraulic hoses and fasteners are
disconnected or removed.
25. When all wiring, hydraulic hoses and fasteners are
disconnected or removed, carefully and slowly lift
the cab and remove it from the frame. Readjust the
position of the sling as needed to help balance the
cab during removal.
26. When the cab is completely clear of the machine,
carefully lower it to the ground. Block up or support
the cab so that it does not move or fall. Assure that
no personnel enter the cab while it is being removed
from the machine.
MY0610
20. Enclosed Cab: Install two lifting eye bolts (14) in the
threaded holes on the roof of the cab above the B
pillars (3).
4.5
CAB INSTALLATION
3
MY0610
MY4170
21. Remove the two cab side-mount bolts in the cab (4).
22. Remove the four cab-to-frame bolts, flat washers and
nuts (5).
4-11
17. Wait for the engine to cool and check the coolant
level. Add coolant to the overflow bottle as required
to bring the coolant to the proper level.
18. Install the mirrors and all other cab components as
needed, if removed.
19. Close and secure the engine cover.
20. Unblock the wheels.
21. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
MY4170
4-12
TL642, TL943
Section 5
Axles, Drive Shafts, Wheels and Tires
Contents
PARAGRAPH
5.1
5.2
5.3
5.4
5.5
5.6
5.7
TL642, TL943
TITLE
PAGE
5-2
5-3
5-3
5-3
5-3
5-3
5-3
5-4
5-4
5-6
5-9
5-9
5-9
5-9
5-9
5-9
5-10
5-10
5-11
5-11
5-11
5-11
5-12
5-1
5.1
REAR STEERING
CYLINDER
TRANSMISSION
DROP BOX
REAR AXLE
ASSEMBLY
FRONT STEERING
CYLINDER
FRONT AXLE
ASSEMBLY
FRONT AXLE WHEEL
HUBS
5-2
MY0570
TL642, TL943
5.2
GENERAL INFORMATION
WARNING
DO NOT service the machine without following all
safety precautions as outlined in Section 1, Safety
Practices, of this manual.
Note: To help ensure optimum performance, the drive
shaft assemblies are specially balanced as a unit at the
factory. When servicing any flange yoke, slip yoke or
drive shaft tube, order a complete assembly if
components are bent or damaged. Refer to the
appropriate parts manual for ordering information.
Before performing any inspection, maintenance or
service operation, thoroughly clean the unit. The axles
and drive shafts should be checked and repaired only by
experienced service technicians who are aware of all
safety instructions and particular component features.
Use suitable products to thoroughly clean all
disassembled mechanical parts to help prevent personal
injury to the worker and prevent damage to the parts.
Carefully inspect the integrity of all moving parts
(bearings, yokes, tubes, gears, shafts, etc.) and fasteners
(nuts, bolts, washers, etc.) as they are subject to major
stress and wear. Always replace any damaged, worn,
cracked, seized or otherwise improper parts that could
affect the safe and proper functioning of the machine,
axles and drive shafts.
5.3
5.3.1
AXLE ASSEMBLIES
Axle Serial Number Plate
5.3.2
Axle Specifications
TL642, TL943
5.3.3
5.3.4
Axle Maintenance
5-3
Axle Removal
The front and rear axle assemblies differ in that the front
axle assembly is equipped with a parking brake
mechanism and a limited-slip feature; the rear axle has
neither. The following steps outline a typical axle removal
procedure, suitable for either the front or the rear axle
assembly.
Cleanliness is extremely important. Before attempting to
remove the axle, thoroughly clean the machine. Avoid
spraying water or cleaning solution on electrical
components. If using a steam cleaner, seal all openings
before steam cleaning.
Note: Clear the work area of all debris, unnecessary
personnel, etc. Allow sufficient space to raise the
machine and to remove the axle.
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake, straighten all
wheels and shut the engine OFF.
15. Remove the axles from the machine using the jack,
hoist or overhead crane and sling supporting the
axle. DO NOT raise or otherwise disturb the
machine while removing the axle. Balance the axle
and prevent it from tipping, turning or falling while
removing it from beneath the machine. Place the
axle on a suitable support or holding stand.
5. Block the front and rear of both tires on the axle that
is not being removed. Ensure that the machine will
remain in place during axle removal before
proceeding.
6. Raise the machine using a suitable jack or hoist.
Place suitable supports under both sides of the
frame and lower the machine onto the supports.
Ensure that the machine will remain in place during
axle removal.
7. Remove both wheel and tire assemblies from the
axle that is being removed. (Refer to Section 5.5.1,
Removing Wheel and Tire Assembly from
Machine.)
5.3.6
Axle Installation
MY4180
5-4
TL642, TL943
MT0220
MY0230
4
1
10. Tighten the axle oil drain plugs (1), loosen and
remove the axle oil fill plug (3) and sight plugs (4).
(Refer to Section 2.4, Fluids and Lubricant
Capacities, for proper oil and capacities.
TL642, TL943
5-5
Problem
1. Excessive axle noise while
driving.
5-6
Cause
Remedy
TL642, TL943
Problem
4. Oil leaking from axle
(differential housing and/or
axle housings).
TL642, TL943
Cause
Remedy
2. Tighten fittings.
2. Replace o-ring.
1. Tighten fittings.
5-7
Problem
7. Axle overheating.
5-8
Cause
Remedy
TL642, TL943
5.4
DRIVE SHAFTS
To Transmission
5.4.1
5.4.2
5.4.3
To Axle
3
MT0350
5.4.4
5.4.5
3. Install the two straps (2) and four new bolts (1)
securing the bearing crosses to the transmission.
Torque bolts to 55-60 lb-ft (75-81 Nm).
4. Install the two straps (2) and four new bolts (1)
securing the bearing crosses to the axle. Torque
bolts to 55-60 lb-ft (75-81 Nm).
5. Repeat the above procedure on the rear drive shaft.
6. Properly connect the battery.
7. Close and secure the engine cover.
8. Unblock the wheels.
9. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
TL642, TL943
5-9
5.5
WARNING
Mismatched tire sizes, ply ratings or mixing of tire
types (radial tires with bias-ply tires) may compromise
machine stability and may cause machine to tip over.
It is recommended that a replacement tire to be the same
size, ply and brand as originally installed. Refer to the
appropriate parts manual for ordering information. If not
using an approved replacement tire, it is recommended
that replacement tires have the following characteristics:
Equal or greater ply/load rating and size of original.
Tire tread contact width equal or greater than
original.
Wheel diameter, width and offset dimensions equal
to the original.
Approved for the application by the tire manufacturer
(including inflation pressure and maximum tire load).
The rims installed have been designed for stability
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 factory recommendations, may result in
unsafe condition regarding stability.
Foam filled tires have a positive effect on the weight,
stability and handling characteristics of the machine,
especially under load. The use of hydrofill as a tire-fill
substance is not recommended because of possible
environmental impact.
Large-bore valve stems are used to help expedite tire
inflation and deflation. An inner tube may be used if a tire
does not provide an airtight seal. Check tire inflation
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
produces a left or right tire and wheel assembly.
5-10
MY4190
5.5.1
TL642, TL943
5.6
BRAKES
5.7
5.7.1
MAH0460
MZ1020
10
MY4200
MZ1020
5-12
TL642, TL943
Section 6
Transmission
Contents
PARAGRAPH
6.1
6.2
6.3
6.4
6.5
6.6
TL642, TL943
TITLE
PAGE
6-2
6-3
6-3
6-3
6-3
6-4
6-4
6-5
6-6
6-6
6-6
6-7
6-7
6-1
Transmission
6.1
TRANSMISSION ASSEMBLY
COMPONENT TERMINOLOGY
Transmission Filter
SHIFT SOLENOIDS
SHIFT SOLENOIDS
OAL0010
6-2
TL642, TL943
Transmission
6.4.1
Transmission Removal
WARNING
WARNING
6.2
1
MY5550
6.3
TRANSMISSION SPECIFICATIONS
AND MAINTENANCE INFORMATION
6.4
TRANSMISSION REPLACEMENT
OAL0030
6-3
Transmission
10. Remove the transmission-to-axle drive shafts. Refer
to Section 5.4.3, Drive Shaft Removal.
11. Remove air cleaner unit and intake tubes.
12. Remove the hydraulic pump. Refer to Section 8.6.1,
Pump Replacement.
13. Label and disconnect the transmission temperature
switch connector and shift solenoid wiring harness
connectors.
14. Label, disconnect and cap the transmission oil
cooler inlet and outlet hoses at the transmission. The
transmission oil cooler outlet hose, routed to the
lower radiator fitting, is located on the top of the
transmission. The transmission oil cooler inlet hose,
routed to the upper radiator fitting, is located on top
of the transmission.
15. Remove the access plug from side of the engine bell
housing. This will allow access to remove the eight
bolts holding the flex plate to the engine flywheel.
16. Turn the engine over slowly by hand and align each
of the eight flex plate bolts to be accessed. Remove
them one at a time.
17. Wipe up any spilled hydraulic and transmission oil.
18. Connect a lifting strap or chain to the lifting eye at
the top of the transmission, and to a suitable hoist or
overhead crane. Operate the hoist or crane to
remove slack from the chain, but DO NOT raise the
transmission at this time.
19. Place blocks under rear of engine for support
BEFORE transmission mounts are removed.
20. Place blocks under the transmission to help support
it during removal.
21. Remove both rear transmission mount bolts and
lockwashers securing the transmission mount to the
frame.
22. Remove the bolts and washers holding the
transmission to the engine.
23. Remove the capscrews and lockwashers securing
each rear transmission mount to the transmission.
24. Remove the transmission mounts from the machine.
25. Inspect the rubber mounts. Replace the mounts if
damaged.
6.4.2
6.4.3
Transmission Installation
WARNING
NEVER lift a transmission alone; enlist the help of at
least one assistant or use a suitable hoist or overhead
crane and sling with a minimum lifting capacity of
1000 lb (454 kg).
1. Install both rear transmission mounts on the
transmission. Torque capscrews to 66 lb-ft (89 Nm).
2. Install two guide studs near the top of the bell
housing holes.
3. Use a hoist or overhead crane and sling attached to
the lifting eye at the top of the transmission. Raise
and position the transmission within the chassis.
4. 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). Remove the two alignment studs
and install and torque the last two transmission
mounting bolts.
6-4
TL642, TL943
Transmission
7. Remove the hoist or overhead crane and sling.
6.4.4
In general:
6. Run the engine for two minutes at idle to help prime the
torque converter and the transmission oil lines.
7. Recheck the level of the fluid in the transmission
with the engine running at idle.
8. Add hydraulic oil as necessary to bring the fluid level
up until it reaches the FULL mark on the dipstick.
Recheck the oil level when it reaches operating
temperature 180-200 F (83-94 C).
5
MY0990
TL642, TL943
6-5
Transmission
6.5
6.5.1
6.5.2
6-6
TL642, TL943
Transmission
6.6
TROUBLESHOOTING
6.6.1
Transmission Troubleshooting
Problem
1. Transmission will not engage
or will not shift properly.
TL642, TL943
Cause
Remedy
6. Replace o-rings.
8. Replace couplings.
6-7
Transmission
Problem
2. Low or no pump flow or
pressure.
4. Lack of power.
6-8
Cause
Remedy
5. Transmission overheating.
TL642, TL943
Transmission
Problem
5. Transmission overheating
(oil above 248 F (120 C)).
TL642, TL943
Cause
Remedy
2. Clogged radiator.
4. Excessive roading.
4. Internal damage.
6. Tighten capscrews.
6-9
Transmission
Problem
7. Oil leaking from transmission.
6-10
Cause
Remedy
3. Tighten fittings.
5. Tighten capscrews to 46 Nm
(34 lb-ft).
9. Housing damaged.
TL642, TL943
Section 7
Engine
Contents
PARAGRAPH
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
TL642, TL943
TITLE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1
Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.2
Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.1
Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.2
Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.3
Radiator/Oil Cooler and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.1
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.2
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.3
After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.1
Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.2
Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8.1
Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8.2
Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8.3
Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8.4
Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.9.1
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.9.2
Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Drive Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.10.1
Drive Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.10.2
Drive Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE
7-2
7-2
7-3
7-4
7-4
7-4
7-4
7-4
7-5
7-6
7-7
7-7
7-7
7-8
7-8
7-8
7-9
7-9
7-9
7-9
7-10
7-10
7-10
7-10
7-11
7-13
7-13
7-13
7-14
7-1
Engine
7.1
7.1.1
INTRODUCTION
Disclaimer and Scope
7-2
TL642, TL943
Engine
7.1.2
Component Terminology
THERMOSTAT
ALTERNATOR
TURBOCHARGER
OIL FILTER
STARTER
FUEL INJECTOR
PUMP
4.4C
TL642 - S/N TBK01167 & AFTER INCLUDING TBK01162
TL943 - S/N TBL01599 & AFTER INCLUDING TBL01551 & TBL01585
ALTERNATOR
THERMOSTAT
FUEL FILTER
TURBOCHARGER
MAL0970
OIL FILTER
TL642, TL943
FUEL INJECTOR
PUMP
STARTER
7-3
Engine
7.2
7.3
SPECIFICATIONS AND
MAINTENANCE INFORMATION
7.4
7.4.1
7.4.2
Thermostat Replacement
7-4
TL642, TL943
Engine
7.4.3
MAL1030
3054C
4.4C
MAL1010
TL642, TL943
7-5
Engine
a. Radiator/Oil Cooler Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake, and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
should not be operated.
5. Slowly turn the radiator cap to the first stop and allow
any pressure to escape. Remove the radiator cap.
6. Place a suitable container beneath the radiator
drain.
7. Place a funnel at the base of the radiator to channel
the drained coolant into a container. Loosen the
drain cock and slowly remove to allow the coolant to
drain. Transfer the coolant into a properly labeled
container. Dispose of properly if coolant needs to be
replaced. Tighten the radiator drain cock.
8. Loosen the radiator clamp on the top radiator hose.
Work the hose off the radiator. Position the hose out
of the way to allow radiator removal, or remove the
hose from the engine. Inspect the hose, and replace
if necessary.
9. Loosen the clamp on the radiator return (lower)
hose. Work the hose off the radiator. Position the
hose out of the way to allow radiator removal, or
remove the hose from the engine. Inspect the hose,
and replace if necessary.
10. Label, disconnect and cap the hoses on the oil
cooler.
11. Remove the radiator fan shroud.
12. Remove the radiator bracket.
13. Remove the nuts and washers from the radiator
mounts.
7.5
7-6
TL642, TL943
Engine
7.6
7.6.1
FUEL SYSTEM
7.6.2
Diesel Fuel
Fuel Tank
MAL1200
TL642, TL943
Engine
1. Have a dry chemical (Class B) fire extinguisher near
the work area.
7.6.3
7.7
7.7.1
f.
3. Install the fuel sender with new gasket into the fuel
tank and secure with screws. DO NOT overtighten.
4. Connect the previously labeled fuel hoses to their
appropriate locations. Secure with clamps.
5. Connect the fuel gauge harness.
TL642, TL943
Engine
10. Loosen and remove the bolts at the front and rear of
the muffler, remove the muffler.
11. Remove the exhaust heat shield (if equipped).
7.7.2
7.8.1
7.8
CAUTION
NEVER run the engine with only the inner safety
element installed.
Note: Refer to the appropriate Operation &
Maintenance Manual for your machine for the correct
element change procedure.
TL642 - Before S/N TBK01167 excluding TBK01162
TL943 - Before S/N TBL01599 excluding TBL01551 &
TBL01585
MAL1020
7.8.2
TL642, TL943
7-9
Engine
TL642 - Before S/N TBK01167 excluding TBK01162
TL943 - Before S/N TBL01599 excluding TBL01551 &
TBL01585
7.8.3
7.9
ENGINE REPLACEMENT
7.9.1
Engine Removal
MAL1050
7.8.4
10. Disconnect and cap the fuel inlet line at the fuel filter
head.
11. Disconnect and cap the fuel return line from the fuel
filter head.
TL642, TL943
Engine
12. Mark the location of the throttle cable at the throttle
cable mount. Loosen jam nuts and remove.
7.9.2
1
MY1610
Engine Installation
MY1590
TL642, TL943
7-11
Engine
11. Connect the throttle cable at the engine throttle
lever.
12. Connect the fuel inlet line to the fuel filter head.
13. Connect the fuel return line to the fuel filter head.
14. Connect all the labeled wire harness connections on
the engine.
15. Install both heater hoses to the engine and tighten
clamps (if equipped).
TL642, TL943
Engine
7.10
7.10.1
RING
MZ0580
7.10.2
TL642, TL943
7-13
Engine
7.11
TROUBLESHOOTING
Trouble
1, 2, 3, 4
5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
Difficult Starting
5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61, 63
Lack of Power
8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 61, 63
Misfiring
8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32
11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63
Black Exhaust
11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 61, 63
Blue/White Exhaust
4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56, 62
Knocking
9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59
Erratic Running
7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59
Vibration
13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 49
4, 38, 41
Overheating
11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57
Poor Compression
11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
10, 11, 12
Key to Possible Causes
7-14
TL642, TL943
Engine
Trouble
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
TL642, TL943
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
7-15
Section 8
Hydraulic System
Contents
PARAGRAPH
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
TL642, TL943
TITLE
PAGE
8-1
Hydraulic System
8.1
HYDRAULIC COMPONENT
TERMINOLOGY
EXTEND/RETRACT
CYLINDER
(inside boom)
HYDRAULIC FLUID
RESERVOIR
COMPENSATION
CYLINDER
LIFT/LOWER
CYLINDER
TILT CYLINDER
PRIORITY
VALVE
FO
AM
2
F I L L ED
WI T H 5 4
LB
FO
AM
BS
FI L L E
2 L
D WI T H 5 4
MAL0340
FRAME LEVEL
CYLINDER
(behind tire)
8-2
OUTRIGGER
MAIN CONTROL
VALVE
(if equipped)
MAIN CONTROL
VALVE
TL642, TL943
Hydraulic System
8.2
SAFETY INFORMATION
WARNING
DO NOT service the machine without following all
safety precautions as outlined in Section 1, Safety
Practices, of this manual.
Petroleum-based hydraulic fluids are used in this
machine. The temperature of hydraulic fluid increases
during the operation of various hydraulic functions. A
heated petroleum-based hydraulic fluid presents a fire
hazard, especially when an ignition source is present.
Hydraulic fluid has a flash point that ranges from
300-600 F (150-318 C) and an auto-ignition temperature
of 500-750 F (262-402 C).
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.
Operate the hydraulic controls after the engine has
stopped to relieve trapped pressure.
Note: Residual pressure may remain in hydraulic
cylinders, hoses, valve bodies, components, etc. If the
hydraulic lines going to or coming from a component are
taut, slowly and cautiously relieve (bleed off) pressure.
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. Sand, grit
and other contaminants can damage the finely machined
surfaces within hydraulic components. If operating in an
exceptionally dirty environment, change filters and
inspect the fluid more often. 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.
TL642, TL943
8.3
8.3.1
8-3
Hydraulic System
8. 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.
8.4
HYDRAULIC CIRCUITS
8.4.2
8.4.1
Hydraulic Pressures
a. Checking Pressures
1. Start the machine and warm the hydraulic system to
operating temperature.
2. Shut off the machine and install a digital or a
5000 psi (345 bar) gauge to the appropriate test port
on the priority valve.
3. Start the machine, run the engine and follow the
procedures in Section 8.4.2, c. Pressure
Specifications - TL642, Section d, Pressure
Specifications - TL943 Before S/N TBL01599
excluding TBL01551 & TBL01585, or Section e,
Pressure Specifications - TL943 S/N TBL01599 &
After including TBL01551 & TBL01585.
8-4
MY4500
Hydraulic System
7. Install a digital or a 5000 psi (345 bar) gauge to the
retract (1) port tee fitting on the compensation
cylinder.
8. Start the machine and warm the hydraulic system to
operating temperature.
9. Tilt the forks down to allow the tilt cylinder to fully
retract.
10. Monitor the gauge and slowly raise the boom. The
gauge should read:
TL642: 4150 - 4450 psi (286,5 - 306,5 bar)
TL943: 3911 - 4211 psi (270 - 290 bar)
11. If pressure is correct, proceed to step 14.
19. Monitor the gauge and slowly lower the boom. The
gauge should read:
TL642: 4150 - 4450 psi (286,5 - 306,5 bar)
TL943: 3911 - 4211 psi (270 - 290 bar)
20. If pressure is correct, proceed to step 23.
21. The relief on the (B) port is non-adjustable and must
be replaced. Replace and repeat steps 17 and 18.
22. Verify pressure is correct.
23. Shut engine OFF.
24. Slowly remove the gauge, line and tee fitting from
the compensation cylinder (1 & 2). Reinstall each
hose and torque as required.
25. Install any previously removed attachment.
TL642
TL943
BEFORE S/N TBL01599
A
MAL2130
TL642, TL943
8-5
Hydraulic System
c. Pressure Specifications - TL642
Note: All pressures must be checked in numerical order.
Hydraulic
Circuit
Test
Port
Adjustment
Location
Pressure Range
Pilot Pressure
BV
(A)
Relief Valve
Cartridge
CF1
(C)
2550 - 2650psi
(176 - 183 Bar)
Main Relief
Valve
EF1
(D)
Boom Extend
EF1
(D)
N/A
Boom Lift
EF1
(D)
N/A
Auxiliary
EF1
(D)
N/A
HYDRAULIC
MANIFOLD
A
C
B
2
MAL0900
MAL0110
8-6
TL642, TL943
Hydraulic System
d. Pressure Specifications - TL943 Before S/N TBL01599 excluding TBL01551 & TBL01585
Hydraulic
Circuit
Test Port
Procedure
Adjustment
Location
Pressure Range
TP (A)
500 50 psi
(34,5 3,4 Bar)
Primary (B)
Service Brake
P1 (C)
1100 10 psi
(75,8 0,7 Bar)
Boom Lift
Extend/Retract
Frame Level
Fork Tilt
Secondary (D)
3800 50 psi
(262,0 13,4 Bar)
Park Brake
Pilot
Steering
HYDRAULIC
MANIFOLD
8
A
D
7
MAL0910
MAL0120
TL642, TL943
8-7
Hydraulic System
e. Pressure Specifications - TL943 S/N TBL01599 & After including TBL01551 & TBL01585
Note: 1. All pressures must be checked in numerical order.
Note: 2. Connect gauge to P1 port, adjust Standby Pressure to 250 psi (step 2). Adjust Main Compensator Pressure
to 3950 psi (step 3). Adjustment may require incrementally increasing Load Sense Relief Valve (adjustment
location 6) and Main Pump Compensator until a setting of 3950 psi can be observed on the gauge. Connect additional
gauge to GLS (A) port, bottom boom lift, adjust Load Sense Relief to the setting noted below.
Hydraulic
Circuit
Test Port
Adjustment
Location
Pressure Range
Load Sense
Relief
GLS/PLS
(A)
Standby
P1
(B)
Main
P1
(B)
Pilot
JS1
(C)
Service Brake
BV1
(D)
Priority Load
Sense
GLS/PLS
(A)
Boom Extend
GLS/PLS
(A)
No
Adjustment
Boom Retract
GLS/PLS
(A)
No
Adjustment
Boom Lift
GLS/PLS
(A)
No
Adjustment
10
Auxiliary
GLS/PLS
(A)
No
Adjustment
5
4
3
HYDRAULIC
MANIFOLD
1
2
A
MY4361
8-8
MAL0920
TL642, TL943
PARK
BRAKE
SERVICE
BRAKE
EF1
STEERING ORBITROL
P1
COM
EF
LP
DRAIN LINES
PILOT LINES
OR
CF1
LS
450 PSI
RV
2600 PSI
LS
IMPLEMENT PUMP
1.97 CU.IN./REV
.120
CF
BV
PR
JS
TP
CV
550 PSI
.
PB
PRIORITY/BRAKE
VALVE
SV
.
RV2
SERVICE BRAKE
VALVE
A2
B2
B1
A1
25 PSI
P T
B 8=75
TE
(TEST PORT)
10 MICRON
BREATHER
RETURN
FILTER
HYDRAULIC
OIL COOLER
OUTLET
INLET
OUTLET
4000
PSI
LIFT CYLINDER
RED
STEER SELECT
VALVE
LIFT
5000
PSI
CROWD
3800
PSI
CROWD CYLINDER
MAIN
CONTROL VALVE
(W/O POWER BEYOND)
JOYSTICK
PURPLE
LEGEND
.
M
TL642, TL943
YELLOW
SWAY
3000
PSI
AUX.
AUX. HYD.
PORTS
.050
3000
PSI
.040
SWAY CYLINDER
P1 P2
C1 C4
"QD'S"
THIS
LOC'N
ON STD.
MACHINE
RIGHT,
UP,
QA RET.
C2 C3
AUXILIARY HYD.
PORTS @ BOOM NOSE
LEFT
DWN
QA EXTD.
AUXILIARY
HYD. PORTS
QA CYLINDER
4300
PSI
OPTIONAL REMOTE
HYDRAULIC QUICK ATTACH
4300
PSI
TILT
COMPENSATING
CYLINDER
5000
PSI
TILT CYLINDER
8.4.3
GREEN
Hydraulic System
MAL0020J
8-9
SEE
SHT #1
4000
PSI
HOIST
TILT
4300
PSI
4300
PSI
OUTRIGGER OPTION
JS PORT
ON PRIORITY/BRAKE VALVE
SEE SHT #1
MAIN
CONTROL VALVE
WITH POWER BEYOND
(SEE STD VALVE SHT #1
FOR REMAINING CONNECTIONS)
CROWD
3800
PSI
SWAY
AUX
3000
PSI
YELLOW
JOYSTICK
SEE SHT #1
3000
PSI
GREEN
8-10
RED
PB
RETURN
FILTER
B8=75
10 MICRON
BREATHER
HYDRAULIC
OIL COOLER
LOD
LOU
2
LOU
1
ROD
2
ROU
OUTRIGGER
VALVE
PUMP
LOD
5000
PSI
5000
PSI
ROU
ROD
RIGHT OUTRIGGER
CYLINDER
TANK
8.4.3
BLUE
LEFT OUTRIGGER
CYLINDER
Hydraulic System
Hydraulic Schematic - TL642 (Continued)
TL642, TL943
25 PSI
MAL0030J
STEERING ORBITROL
REAR SEC
3.19 CU IN/REV
@@2750 RPM
LOAD SENSING
SIGNAL PORT
PRIMARY
GAUGE
PORT
.030
LP
2450
PSI
P P
SECONDARY
GAUGE PORT
SECONDARY
PORT
LS
PUMP
PRIMARY
PORT
P1
500
PSI
SV
VALVE BLOCK
RV
PR
FRONT SEC
.75 CU IN/ REV
@@2750 RPM
1100
PSI
BV
CV
PB
FRONT STEERING
CYLINDER
TP
JS
TANK
A1
100
MESH
OUTLET
LOAD
SENSE
OUTLET
INLET
A2
STEER SELECT
VALVE
SERVICE
BRAKE VALVE
25 PSI
B2
RETURN
FILTER
B8=75
HYDRAULIC
OIL
COOLER
PARK
BRAKES
FRONT
SERVICE
BRAKES
10 MICRON
BREATHER
REAR STEERING
CYLINDER
REAR
SERVICE
BRAKES
YELLOW
PT
1
3
JOYSTICK
GREEN
TL642, TL943
RED
PUMP
3800
PSI
CROWD
4100
PSI
4100
PSI
5000
PSI
CROWD CYLINDER
LIFT
5000
PSI
LIFT CYLINDER
4100
PSI
4100
PSI
TILT
COMPENSATING
CYLINDER
5000
PSI
TILT CYLINDER
SWAY
.050
SWAY CYLINDER
.040
AUX
RIGHT,
UP,
QA RET.
TANK
AUXILIARY
HYDRAULICS
PORTS
LEFT
DWN
QA EXTD.
8.4.4
BLUE
B1
Hydraulic System
Hydraulic Schematic - TL943 Before S/N TBL01599 excluding TBL01551 & TBL01585
MAL0020
8-11
PRIMARY
GAUGE
PORT
LOAD SENSING
SIGNAL PORT
PUMP
3800
PSI
.030
2450
PSI
P P
SECONDARY
GAUGE PORT
CROWD
4100
PSI
P1
1100
PSI
BV
RV
PR
500
PSI
SV
VALVE BLOCK
SECONDARY
PORT
4100
PSI
PUMP
PRIMARY
PORT
LIFT
TP
JS
4100
PSI
4100
PSI
SWAY
OUTRIGGER OPTION
CV
PB
TILT
AUX
YELLOW
8-12
3
100
MESH
SEE SHT #1
JOYSTICK
POWER
BEYOND
TANK
GREEN
MAL0030
RED
RETURN
FILTER
B8=75
10 MICRON
BREATHER
PUMP
LOD
1
2
LOU
1
ROD
ROU
LOU
LOD
5000
PSI
5000
PSI
ROU
ROD
RIGHT OUTRIGGER
CYLINDER
TANK
TO HYDRAULIC
OIL COOLER
SHT1
C2 C3
P1 P2
C1 C4
RIGHT,
UP,
QA RET.
AUXILIARY HYD.
PORTS @ BOOM NOSE
LEFT
DWN
QA EXTD.
AUXILIARY
HYD. PORTS
QA CYLINDER
OPTIONAL REMOTE
HYDRAULIC QUICK ATTACH
8.4.4
BLUE
LEFT OUTRIGGER
CYLINDER
Hydraulic System
Hydraulic Schematic - TL943 Before S/N TBL01599 excluding TBL01551 & TBL01585
(Continued)
TL642, TL943
25 PSI
Hydraulic System
8.4.5
Hydraulic Schematic - TL943 S/N TBL01599 & After including TBL01551 & TBL01585
MAL1080E
TL642, TL943
8-13
Hydraulic System
8.5
HYDRAULIC RESERVOIR
8.5.3
8.5.1
8.5.2
8-14
TL642, TL943
Hydraulic System
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.
8.6
8.6.1
Pump Replacement
TL642 - All
TL943 - Before S/N TBL01599 excluding TBL01551 &
TBL01585
a. Pump Removal
d. Inspection
Note: If a leak is suspected in the fuel or hydraulic oil tank,
contact your local Service Department.
1. Inspect the hydraulic oil reservoir thoroughly for any
cracks, slices, leaks or other damage.
2. With the hydraulic oil reservoir removed from the
machine, plug all openings except one elbow fitting.
Install the elbow fitting, and apply approximately
1-1.5 psi (7-10 kPa) of air pressure through the
elbow. Check the reservoir for leaks by applying a
soap solution to the exterior and look for bubbles to
appear at the cracked or damaged area.
e. Reservoir Installation
TL642, TL943
8-15
Hydraulic System
b. Pump Installation
1. Place the pump and a new, oiled o-ring into position
on the transmission. Align the pump shaft with the
internal transmission gear, so that the machined
teeth mesh together.
MAL1320
a. Pump Removal
TL642, TL943
Hydraulic System
c. Pump Priming
MAL1350
d. Pump Test
Refer to Section 8.3.1, Pressure Checks and
Adjustments.
MAL1320
TL642, TL943
8-17
Hydraulic System
8.7
8.7.1
CONTROL VALVES
MAL0090
3
TL943
MAL0100
MAL0080
8-18
TL642, TL943
Hydraulic System
Disassemble each Valve Section
1. Carefully separate the load sense outlet section from the
lift/lower section.
2. Remove the o-rings from between the two sections.
3. Carefully separate each remaining sections, being
careful not to lose the load sense shuttle ball.
4. Remove both end caps from each end of the valve
sections then remove each control spool.
5. Remove any check valves, compensator valves,
anti-cavitation valves or shock valves from individual
valve section if equipped.
6. Keep all parts being removed from individual valve
sections tagged and kept together.
c. Main Control Valve Parts Cleaning
TL642, TL943
8-19
Hydraulic System
b. Service Brake Valve Installation
8.7.2
MAL1070
8-20
TL642, TL943
Hydraulic System
8.7.3
8.7.4
Brake Test
MY0150
TL642, TL943
8-21
Hydraulic System
8.7.5
4
MY0350
8-22
TL642, TL943
Hydraulic System
5. Start the engine and run at approximately 1/3-1/2
throttle for about one minute without moving the
machine or operating any hydraulic functions.
6. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as
needed.
7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
8. Close and secure the engine cover.
9. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
d. Steering Test
Refer to Section 8.4.1, Hydraulic Pressures.
1. Conduct a pressure check of the steering hydraulic
circuit.
2. Check each steering mode for proper function.
8.7.6
OAL0070
TL642, TL943
8-23
Hydraulic System
8.8
8.8.1
HYDRAULIC CYLINDERS
General Cylinder Removal
Instructions
MZ0400
WARNING
Significant pressure may be trapped inside the cylinder.
Exercise caution when removing a counterbalance valve
or a pilot-operated check valve from a cylinder.
Note: Avoid using excessive force when clamping the
cylinder in a vise. Apply only enough force to hold the
cylinder securely. Excessive force can damage the
cylinder tube.
3. If applicable, remove the counterbalance valve from
the side of the cylinder barrel.
Note: DO NOT tamper with or attempt to adjust the
counterbalance valve cartridge. If adjustment or
replacement is necessary, replace the counterbalance
valve with a new part.
4. Extend the rod as required to allow access to the
base of the cylinder.
Note: Protect the finish of the rod at all times. Damage
to the surface of the rod can cause seal failure.
5. Using a pin spanner wrench, unscrew the head
gland from the tube. A considerable amount of force
will be needed to remove the head gland. Carefully
slide the head gland down along the rod toward the
rod eye, away from the cylinder barrel.
8-24
TL642, TL943
Hydraulic System
Note: When sliding the rod and piston assembly out of
the barrel, prevent the threaded end of the barrel from
damaging the piston. Keep the rod centered within the
barrel to help prevent binding.
6. Carefully pull the rod assembly along with the head
gland out of the cylinder barrel.
7. Fasten the rod eye in a soft-jawed vise, and place a
padded support under and near the threaded end of
the rod to prevent any damage to the rod.
8. Remove the set screw from the piston head.
Note: It may be necessary to apply heat to break the
bond of the sealant between the piston and the rod
before the piston can be removed.
Some cylinder parts are sealed with a special organic
sealant and locking compound. Before attempting to
disassemble these parts, remove any accessible seals
from the area of the bonded parts. Wipe off any hydraulic
oil, then heat the part(s) uniformly to break the bond. A
temperature of 300-400 F (149-204 C) will destroy the
bond. Avoid overheating, or the parts may become
distorted or damaged. Apply sufficient torque for removal
while the parts are still hot. The sealant often leaves a
white, powdery residue on threads and other parts, which
must be removed by brushing with a soft brass wire brush
prior to reassembly.
9. Remove the piston head from the rod and carefully
slide the head gland off the end of the rod.
10. Remove all seals, back-up rings and o-rings from the
piston head and all seals, back-up rings and o-rings
from the head gland.
Note: The head gland bearing will need to be inspected
to determine if replacement is necessary.
DO NOT attempt to salvage cylinder seals, sealing rings
or o-rings. ALWAYS use a new, complete seal kit when
rebuilding hydraulic components. Consult the parts
catalog for ordering information.
b. Cylinder Cleaning Instructions
1. Discard all seals, back-up rings and o-rings. Replace
with new items from seal kit to ensure proper
cylinder function.
2. Clean all metal parts with an approved cleaning
solvent such as trichlorethylene. Carefully clean
cavities, grooves, threads, etc.
Note: If a white powdery residue is present on threads
or parts, it can be removed by using a soft brass wire
brush. Wipe clean with Loctite Cleaner prior to
reassembly.
TL642, TL943
c. Cylinder Inspection
1. Inspect internal surfaces and all parts for wear,
damage, etc. If the inner surface of the cylinder
barrel does not display a smooth finish, or is scored
or damaged in any way, replace the barrel.
2. Remove light scratches on the piston, head gland,
rod or inner surface of the cylinder barrel with a 400600 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.
d. General Cylinder Assembly Instructions
1. Use the proper tools for specific installation tasks.
Clean tools are required for installation.
2. Install new seals, back-up rings and o-rings on the
piston and new seals, back-up rings, o-rings and
bearing on the head gland.
Note: The extend/retract cylinder has a spacer that
MUST be installed over the rod AFTER the head gland
and BEFORE the piston head.
3. Fasten the rod eye in a soft-jawed vise, and place a
padded support under and near the threaded end of
the rod to prevent any damage to the rod.
Note: Protect the finish on the cylinder rod at all times.
Damage to the surface of the rod can cause seal failure.
4. Lubricate and slide the head gland over the cylinder
rod. Install the piston head on to the end of the
cylinder rod. Loctite 243TM and install the set screw
in the piston head. Refer to Section 8.8.4, Cylinder
Torque Specifications - TL642 or Section 8.8.5,
Cylinder Torque Specifications - TL943 for torque
specifications for the piston head and the set screw.
Note: Avoid using excess force when clamping the
cylinder barrel in a vise. Apply only enough force to hold
the cylinder barrel securely. Excessive force can
damage the cylinder barrel.
5. Place the cylinder barrel in a soft-jawed vise or other
acceptable holding devise.
Note: When sliding the rod and piston assembly into the
cylinder barrel, prevent the threaded end of the cylinder
barrel from damaging the piston head. Keep the cylinder
rod centered within the barrel to prevent binding.
6. Carefully insert the cylinder rod assembly into the
cylinder barrel.
8-25
Hydraulic System
7. Screw the head gland into the cylinder barrel and
tighten with a spanner wrench. Refer to Section
8.8.4, Cylinder Torque Specifications - TL642 or
Section 8.8.5, Cylinder Torque Specifications TL943 for torque specifications for the head gland.
8. If applicable, install new counter balance valve into
block on the cylinder barrel.
8.8.3
Steering Cylinders
8.8.2
Attach a 5000 psi (345 bar) gauge to the test port on the
P1 port on the priority valve to check the system
pressure.
Note: If a hydraulic cylinder pressure is greater than the
main control valve pressure, increase the main control
valve pressure by adjusting the main relief. Generally,
one half turn clockwise will be adequate to check an
individual circuit. Activate the circuit and if pressure is
obtained turn the main relief counter clockwise one half
turn. Re-check the main relief setting and adjust if
necessary.
8-26
TL642, TL943
Hydraulic System
8.8.4
a. Lift/Lower Cylinder
Head
Nut
100 lb-ft
(135 Nm)
100 lb-ft
(135 Nm)
100 lb-ft
(135 Nm)
Bolt Plate
Valve
Valve Screw
Set Screw
2025-2075 lb-ft
(2745-2813 Nm)
44 lb-ft
(60 Nm)
10-12 lb-ft
(14-16 Nm)
1600-2000 lb-ft
(2169-2712 Nm)
44 lb-ft
(60 Nm)
10-12 lb-ft
(14-16 Nm)
44 lb-ft
(60 Nm)
10-12 lb-ft
(14-16 Nm)
(See Note)
Note: The capscrews for the bolt plate need to be torqued in sequence in an alternating pattern starting at 35 lb-ft to
75 lb-ft to the final 95 lb-ft. Check the final torque in a circular pattern a minimum of two times.
b. Extend/Retract Cylinder
Head
Nut
Valve
Set Screw
600-650 lb-ft
(813-881 Nm)
40-45 lb-ft
(54-61 Nm)
1020-1250 lb-ft
(1383-1695 Nm)
40-45 lb-ft
(54-61 Nm)
Head
Nut
Valve
Set Screw
1250-1300 lb-ft
(1694-1762 Nm)
40-45 lb-ft
(54-61 Nm)
1125-1375 lb-ft
(1525-1864 Nm)
40-45 lb-ft
(54-61 Nm)
c. Tilt Cylinder
d. Compensation Cylinder
Head
Nut
Set Screw
f.
Head
Nut
Set Screw
TL642, TL943
Head
Nut
Set Screw
N/A
8-27
Hydraulic System
8.8.5
a. Lift/Lower Cylinder
Capscrew/Nut
Valve
Set Screw
(See Note)
N/A
Note: The capscrews for the piston need to be torqued in sequence in an alternating pattern starting at 150 lb-ft to
300 lb-ft to the final 460 lb-ft. Check the final torque in a circular pattern a minimum of two times.
b. Extend/Retract Cylinder
Head
Nut
Valve
Set Screw
300-400 lb-ft
(407-542 Nm)
745-825 lb-ft
(1010-1118 Nm)
105-115 lb-ft
(142-115 Nm)
c. Tilt Cylinder
Head
Nut
Valve
Valve Plug
Set Screw
550-600 lb-ft
(745-813 Nm)
2025-2075 lb-ft
(2745-2813 Nm)
10-15 lb-ft
(14-20 Nm)
N/A
2025-2075 lb-ft
(2745-2813 Nm)
10-15 lb-ft
(14-20 Nm)
d. Compensation Cylinder
Head
Nut
Set Screw
Head
Nut
Set Screw
N/A
8-28
TL642, TL943
Hydraulic System
f.
TL642, TL943
Head
Nut
Set Screw
N/A
8-29
Hydraulic System
8-30
TL642, TL943
Section 9
Electrical System
Contents
PARAGRAPH
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
TL642, TL943
TITLE
PAGE
9-1
Electrical System
9.13
9.14
9.15
9-2
TL642, TL943
Electrical System
9.1
ELECTRICAL COMPONENT
TERMINOLOGY
9.1.1
General Overview
POWER CONTROL
BOARD
(under dash panel)
IGNITION & DASH
SWITCHES
HEATER/AC CONTROLS
(if equipped)
MAL0440
STARTER
RELAYS
ALTERNATOR
TRANSMISSION
TEMPERATURE
SWITCH
MAL0450
OIL PRESSURE
SWITCH
TL642, TL943
OIL PRESSURE
SENDER
9-3
Electrical System
9.1.2
General Overview
HEATER/AC CONTROLS
(if equipped)
POWER CONTROL
BOARD & UGM
(under dash panel)
MAL1090
ALTERNATOR
STARTER
RELAYS
TRANSMISSION
TEMPERATURE
SWITCH
COOLANT TEMPERATURE SENDER
MAL1140
9-4
TL642, TL943
Electrical System
9.2
SPECIFICATIONS
9.4.2
9.3
Engine Compartment
SAFETY INFORMATION
WARNING
DO NOT service the machine without following all
safety precautions as outlined in Section 1, Safety
Practices, of this manual.
4
MAL0460
9.4
9.4.1
The starter relay (2), glow plug relay (3), fuel pump relay
(4), 50 amp fuse (5) are located on the frame directly
above the engine.
Cab
6
9
MAL1150
TL642, TL943
MY4550
The starter relay (6) and VEC control module (7) 100 amp
relay(8), 60 amp fuse (9) are located on the power
distribution unit bracket in the engine compartment.
9-5
Electrical System
9.4.3
X1
F1 F2 F3
X5
X6
X7
X8
X9
X10
X2
X3
F4 F5 F6 F7
R1
F8
R2
X4
F9
F10
R3
R4
X11
X12 X13
X14 X15
X16
R6
R7
R8
R9
9-6
No.
Function
Amp Rating
F1
OPTIONAL POWER
30
F2
HORN
10
F3
KEY
15
F4
SPARE BATTERY
25
F5
STEER
10
F6
GAUGES
10
F7
RELAYS
10
F8
LIGHTS
25
F9
W/W
25
F10
FAN/HEATER
25
F11
OPTION3
15
F12
OPTION2
15
F13
OPTION1
10
R1
ACC
R2
LIGHTS
R3
W/W
TL642, TL943
Electrical System
FUNCTION
R4
FAN/HEATER
R5
OPT
R6
AUX ELEC2
R7
AUX ELEC1
R8
WARN LT CK
R9
REV ALARM
X1
SPARE BAT
X2
SL SWA
X3
WL SWA
X4
W/W SW
X5
GND 3
X6
GND 2
X7
GND 1
X8
OPT 3
X9
OPT 2
X10
OPT 1
X11
FAN SW
X12
HEATER SW
X13
WL 2
X14
SL SWB
X15
WL SWB
X16
SPARE COIL
X17
GND 85
X18
SW1-87A
X19
SW2-86
X20
SW2-87A
X21
SW1-86
TL642, TL943
Amp Rating
9-7
Electrical System
9.4.4
XXXXXXX
XXXXXX
F8
F3
25
10
POWER DISTRIBUTION
F15
F4
20
10
F16
F14
F13
F1
20
20
20
15
F9
F7
25
15
F10
10
F11
F2
10
F12
F5
15
15
F6
10
MAL1100
FUSE/BREAKER LEGEND
9-8
No.
Function
Amp Rating
F1
15
F2
ALTERNATOR EXCITE
F3
10
F4
10
F5
15
F6
10
F7
HORN PWR
15
F8
25
F9
25
F10
10
F11
10
F12
15
F13
OPTION PWR 3
20
F14
OPTION PWR 4
20
F15
OPTION PWR 1
20
F16
OPTION PWR 2
20
TL642, TL943
Electrical System
9.4.5
b. Disassembly
MAL1110
a. UGM Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Remove the hardware securing the right hand side
panel to the dash.
6. Disconnect the electrical harnesses attached to the
UGM.
7. Remove the bolts securing the UGM to the cab and
remove the UGM.
TL642, TL943
9-9
Electrical System
9.4.6
UGM Connections
J1 (Black)
J2 (Grey)
XXXXXXXX
XXXXXXXX
MAL1120
Connector
J1
(Black)
J2
(Grey)
9-10
Pin
Tag Name
Description
Type
KEY IGN
Ignition
Power
Input
Power
Input
TRIG
Digital
Input
DCLUTCH IN
Digital
Input
D12
Digital
Input
ROLLER SEL
Roller/Joystick Select
Digital
Input
TILT UP
Tilt Up Valve
Digital
Output
TILT DOWN
Digital
Output
AUX A
Digital
Output
10
AUX B
Digital
Output
11
DCLUTCH
Digital
Output
12
GND FAULT
Digital
Output
5 EXC TILT
Power
Output
TILT SIG A
Analog
Input
TILT GRD
Analog Ground
Power
Output
5 EXC AUX
Power
Output
AUX SIG A
Analog
Input
AUX GND
Analog Ground
Power
Output
TILT SIG B
Analog
Input
AUX SIG B
Analog
Input
CAN L/904
CANBUS High
Serial
I/O
10
CAN L/905
CANBUS Low
Serial
I/O
11
TX
RS-232 Transmit
Serial
Output
12
RX
RS-232 Receive
Serial
Input
TL642, TL943
INST GND
DEUTSCH
P/N DT04-8P
LOCKING WEDGE
W8P
TO TRANSMISSION
SHIFTER
HORN
LIGHT
GAG PWR
HORN
CARLING SWITCH
P/N V2D1S00B-AZC00-000
CLT TMP
INST GND
FUL GAG
HORN
OIL
KEY PWR
KEY STRT
OIL GAG
BAT
IGN
STRT
ACC
FUEL
IGNITION SWITCH
TEMP
4 IN 1 GAGE
BEEDE
GND
B+
12 UDC
PARK
BRAKE
LIGHT
4
5
6
2
3
STEER
LIGHT
8
1
7
4
5
6
8
1
2
3
STEER SELECT
CARLING SWITCH
P/N VJD1S00B-AZC00-000
INST GND
GAG PWR
DASH PANEL
INST GND
PARK BRAKE
CARLING SWITCH
P/N VDD1B6AB-ARC00-000
PB LT GND
BR SW PWR
STR CRB
STR PWR
STR AW
GAG PWR
PS IGN
GP SW
INST GND
GAG PWR
HRN PWR
KEY PWR
STR PWR
D10
(NOT REQUIRED)
J
K
L
87
86
87
INST GND
REV
ALARM
(25A)
FAN/HTR
FAN/HTR
85
30
87a
85
30
87a
D6
86
D1
MOTOROLA
MR 752
OR EQUIV
FAN
SW
SL
SWB
HTR
SW
KEY ACC
10 OHM
30W
R1
WL
SWB
SHFT PWR 2
WL2
SHIFT STRT
GP SIG
A
B
C
D
E
SHIFT-B
TR LT
BRK SW
KEY STRT
PRE-HEAT
CARLING SWITCH
P/N V2D1B60B-AEC3V-100
WARN
LT CK
W/W_SW
W/W
85
30
87a
(25A)
W/W
86
87
85
30
87a
D7
86
87
D2
(25A)
LIGHTS
HMTR GND
87
LIGHTS
85
30
87a
WL_SWA
(10A)
RELAYS
86
(10A)
GAGES
86
87
SW2-86
HR MTR
(10A)
STEER
ACC
85
30
AUX
ELEC2
87a
85
30
87a
D9
86
87
D4
SW1-87a
TRANS
TEMP
WARN
LIGHT
12V
SL_SWA
SW2-87a
AUX
ELEC1
85
30
87a
D8
86
87
D3
SWI-86
GND
HOUR METER
DATCON
P/N 56458-10
PS IGN
TR LT
HRN PWR
1
2
3
4
5
6
7
8
SHFT PWR 1
TRANS-A
SHIFT-B
SHIFT STRT
TRANS-C
TRANS-E
TRANS-D
SHFT PWR 2
(25A)
SPARE
BAT
86
87
D5
GND 85
SPARE_BAT
(15A)
KEY
OPT
85
30
87a
SPARE_COIL
(10A)
HORN
(10A)
OPT-1
(15A)
OPT-2
(15A)
OPT-3
(30A)
OPT_PWR
OPT-1
TL642, TL943
OPT-2
GND-2
BATT
BAT-1
BAT-2
GND-1
AA
GND
W
X
STOP LT
WORK LT
S
T
U
V
ALT EXC
TRANS-B
TR LT SW
BRK SOL
REV AL
BACK LT
O
P
Q
R
SP-3
SP-2
SP-1
BACK LT
GND-1
GP SIG
GP SW
TR LT SW
BRK SOL
CLT TMP
OIL GAG
PS IGN
STOP LT
GND-2
WORK LT
REV AL
TRANS-E
TRANS-D
TRANS-C
TRANS-A
TRANS-B
STR CRB
STR AW
SP-3
ALT EXC
SP-2
SP-1
BAT-2
ST RLY
FUL GAG
HORN
HR MTR
BAT-1
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
TO ENGINE
HARNESS
CAB FIREWALL
TO ENGINE
HARNESS
9.5.1
OPT-3
ST RLY
SHFT PWR 1
BRK SW
9.5
GAG PWR
Electrical System
a. Cab Schematic
MY1370
9-11
SEALED ENDS
KEY ACC
PS IGN
BR SW PWR
Electrical System
DIODE
REV AL
TRANS-E
TRANS-D
TRANS-C
TRANS-A
TRANS-B
STR CRB
STR AW
SP-3
ALT EXC
SP-2
SP-1
BAT-2
ST RLY
FUL GAG
HORN
HR MTR
BAT-1
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
STR CRB
STR CRB
GND-7
4W
STR AW
STR AW
GND-8
GND-8
TO CAB
INSTRUMENT
PANEL HARNESS
ST RLY PWR
CAB FIREWALL
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
STEER
SELECT
VALVE
2W
GND-7
DIODE
TO CAB
INSTRUMENT
PANEL HARNESS
b. Engine Schematic
30
86
87
85
ST RLY
GND-6
GP SIG
GP SW
TR LT SW
BRK SOL
CLT TMP
OIL GAG
PS IGN
STOP LT
GND-2
WORK LT
GND-6
STARTER
RELAY
STRT SOL
STARTER
MOTOR
BAT-2
BAT-1
GP PWR
ALT BAT 1
ALT BAT 2
BACK LT
GND-1
GROUND
HORN
HORN
BATTERY
12VDC
GROUND
(AT ENGINE
POD)
ALT EXC
TRANS-A
TRANS-B
TRANS-C
TRANS-D
TRANS-E
BRK SOL
TR LT SW
GND-9
GND-10
GND-11
GND-12
GND-13
D+
ALT BAT 2
ALT BAT 1
BATT
DIODE
GND-7
GND-8
GND-2
GND-13
GND-12
GND-11
GROUND
(AT
STARTER
MOTOR)
GND-6
BRK SOL
BRK SOL
GND-5
STOP LT
WORK LT
BACK LT
GND-14
BACK-UP
ALARM
GND-5
GND-4
FUSE, 50 AMP
SLOW BLOW
SEALED
ENDS
FUL GAG
GND-15
REV AL
FUEL
LEVEL
SENDER
GND-3
GND-3
GND-3
FUL GAG
WORK
LIGHT
OPTION
ALTERNATOR
GND-10
GND-9
GND-1
TO TRANSMISSION
HARNESS
1
2
3
4
5
6
7
8
9
10
11
12
GP PWR
FP PWR
SP-1
SP-2
SP-3
GLOW PLUGS
GP RLY
GP SIG
GND-6
86
30
85
87
GLOW PLG
GLOW PLUG
RELAY
OIL
PRESSURE
SENDER
9-12
WATER
TEMP.
SENDER
OIL
PRESSURE SWITCH
5 PSI
COLD START
ADVANCE
SOLENOID
FUEL PUMP
GND-14
1
2
GND-6
PS IGN
FUEL PUMP
FP RLY
85
86
87
30
87A
FP PWR
FP RLY
FUEL
SOLENOID
A
B
1
2
PS IGN
GND-14
PS IGN
PS IGN
HR MTR
PS IGN
GP SW
MY1380
A
B
C
CLT TMP
OIL GAG
GND-6
FUSE
7.5 AMP
FUEL PUMP
RELAY
FUEL PUMP
TL642, TL943
Electrical System
c. Transmission Schematic
TRANSMISSION
TEMPERATURE SWITCH
TRANSMISSION
TR LT SW
GND-13
ZF TRANSMISSION
250F
(RISING)
TRANS-A
GND-9
Y1
A
B
Y2
A
B
TRANS-B
GND-9
Y3
A
B
TRANS-C
GND-10
Y4
A
B
TRANS-D
GND-11
Y5
A
B
TRANS-E
GND-11
Y6
A
B
BRK SOL
GND-12
TRANS-A
TRANS-B
TRANS-C
TRANS-D
TRANS-E
BRK SOL
TR LT SW
GND-9
GND-10
GND-11
GND-12
GND-13
1
2
3
4
5
6
7
8
9
10
11
12
TO ENGINE
HARNESS
ZF/HOBBS SHIFTER
1
2
3
4
F
N
R
1
2
3
4
SHFT PWR 1
TRANS-A
SHIFT-B
SHIFT STRT
TRANS-C
TRANS-E
TRANS-D
SHFT PWR 2
1
2
3
4
5
6
7
8
SHFT PWR 1
TRANS-A
SHIFT-B
SHIFT STRT
TRANS-C
TRANS-E
TRANS-D
SHFT PWR 2
TRANS-A
TRANS-C
TRANS-E
TRANS-D
SHFT PWR 1
SHIFT STRT
SHIFT-B
SHFT PWR 2
1
2
3
4
5
6
7
8
F
N
R
CAB INSTRUMENT
PANEL HARNESS
TL642, TL943
MY1400
9-13
Electrical System
d. Auxiliary Schematic
DASH PANEL
PARK
BRAKE
LIGHT
HOUR METER
DATCON
P/N 56458-10
FUEL
OIL
12 UDC
PARK BRAKE
CARLING SWITCH
P/N VDD1B6ABARC00-000
B+
GND
TEMP
GND
12V
4 IN 1 GAGE
BEEDE
STEER
LIGHT
HORN
LIGHT
STEER SELECT
CARLING SWITCH
P/N VJD1S00BAZC00-000
HORN
CARLING SWITCH
P/N V2D1S00BAZC00-000
8
MAST
SW1-87a
SIDESHIFT
7
4
1
2
GND 85
SW1-86
SW1-87a
SW1-86
SWING
SW2-87a
EXTRA
7
4
1
2
GND 85
SW2-86
SW2-87a
SW2-86
MAST
SWING
TRANS
TEMP
WARN
LIGHT
SW1-87a
SW1-86
SW2-87a
SW2-86
MAST
SIDESHIFT
GND 85
SWING
EXTRA
PLUG
SWI-86
SW2-87a
SW1-87a
SW2-86
A
B
C
D
E
F
BLACK
RED
WHITE
GREEN
ORANGE
PLUG
SPARE_COIL
GND 85
S
T
D1
85
30
REV
ALARM
86
87
87
87a
85
30
86
87a
86
85
30
WARN
LT CK
(15A)
OPT-3
A
B
C
D
E
F
(15A)
OPT-2
87
87a
85
30
86
AUX
ELEC2
AUX
ELEC1
87a
85
30
OPT
BLACK
RED
WHITE
GREEN
ORANGE
PLUG
87
87a
(10A)
OPT-1
D5
OPT-2
87
D4
D3
OPT-3
D2
OPT-1
10 OHM
30W
R1
86
BLACK
RED
WHITE
GREEN
ORANGE
PLUG
O
P
Q
R
A
B
C
D
E
G
GND1 GND2 GND3
SL
SWB
WL2
WL
SWB
D6
HTR
SW
FAN
SW
86
D8
D7
87
87
87a
85
30
86
87
87a
85
30
86
W/W
FAN/HTR
U
V
D9
87
87a
85
30
86
87a
85
30
ACC
LIGHTS
"A" OPEN
GROUND (YELLOW)
H
W
X
D10
MOTOROLA
MR 752
OR EQUIV
(25A)
FAN/HTR
(25A)
W/W
(25A)
LIGHTS
(10A)
RELAYS
(10A)
GAGES
(10A)
STEER
(25A)
SPARE
BAT
(15A)
KEY
(10A)
HORN
(30A)
OPT_PWR
GND
AA
BAT
WL_SWA
W/W_SW
SL_SWA
SPARE_BAT
9-14
M
N
J
K
L
MY1420
TL642, TL943
Electrical System
e. Quick Coupler Schematic
STEER
LIGHT
HORN
LIGHT
STEER SELECT
CARLING SWITCH
P/N VJD1S00BAZC00-000
HORN
CARLING SWITCH
P/N V2D1S00BAZC00-000
8
4
5
QUICK COUPLER
CARLING SWITCH
P/N VLD1CW6B-AP4-000
QC PWR
PWR
QC PWR
GND
QC GND
GND
QC GND
TRANS
TEMP
WARN
LIGHT
PLUG
QC PWR
QC PWR
QC GND
QC GND
PLUG
SW1-87a
SW2-86
SPARE_COIL
GND 85
S
T
D1
85
30
REV
ALARM
86
87
87
87a
85
30
86
87a
86
85
30
WARN
LT CK
(15A)
OPT-3
A
B
C
D
E
F
(15A)
OPT-2
87
87a
85
30
86
AUX
ELEC2
AUX
ELEC1
87a
85
30
OPT
BLACK
RED
WHITE
GREEN
ORANGE
PLUG
87
87a
(10A)
OPT-1
D5
OPT-2
87
86
D4
D3
OPT-3
D2
OPT-1
10 OHM
30W
R1
BLACK
RED
WHITE
GREEN
ORANGE
PLUG
SW2-87a
O
P
Q
R
A
B
C
D
E
BLACK
RED
WHITE
GREEN
ORANGE
PLUG
PWR
GND
SWI-86
A
B
C
D
E
F
G
GND1 GND2 GND3
SL
SWB
WL
SWB
D6
HTR
SW
FAN
SW
86
D8
D7
87
87
87a
85
30
86
87
87a
85
30
86
W/W
FAN/HTR
U
V
D9
87
87a
85
30
86
87a
85
30
QC PWR
QC GND
WL2
ACC
LIGHTS
1
2
H
W
X
I
J
K
L
M
D10
N
MOTOROLA
MR 752
OR EQUIV
(25A)
FAN/HTR
(25A)
W/W
(25A)
LIGHTS
(10A)
RELAYS
(10A)
GAGES
(10A)
STEER
(25A)
SPARE
BAT
(15A)
KEY
(10A)
HORN
(30A)
OPT_PWR
GND
AA
BAT
WL_SWA
W/W_SW
SL_SWA
SPARE_BAT
Q.C. DIVERTOR
VALVE
MY1430
TL642, TL943
9-15
STOP LT
STOP SW
STOPLT SW
STOP LT
LIGHT-1
GND L
LIGHT-1
J
K
L
D10
HTR
SW
WL2
SL
SWB
10 OHM
30W
R1
A
B
C
D
E
86
86
85
30
FUEL
(25A)
FAN/HTR
FAN/HTR
87a
87
D6
REV
ALARM
85
30
87a
87
D1
MOTOROLA
MR 752
OR EQUIV
FAN
SW
WL
SWB
HORN
CARLING SWITCH
P/N V2D1S00BAZC00-000
HORN
LIGHT
TEMP
4 IN 1 GAGE
BEEDE
GND
B+
12 UDC
4
5
WARN
LT CK
LIGHT SW
85
30
W/W_SW
(25A)
LIGHTS
DOME LT
SL_SWA
ACC
85
30
87a
(10A)
STEER
86
(25A)
SPARE
BAT
SPARE_BAT
(15A)
KEY
OPT
85
30
87a
(10A)
HORN
SPARE_COIL
STOP SW
WORK LT
WL_SWA
(10A)
RELAYS
LIGHTS
87a
87
86
87
W/W
87a
87
86
87
87a
87
86
D9
86
GND 85
D5
AUX
ELEC2
SW1-87a
GND L1
IND LT
D4
85
30
SW2-86
(10A)
GAGES
SW2-87a
LIGHT-2
D8
85
30
7
4
WORK LIGHT
CARLING SWITCH
P/N V1D1S00BAZC00-000
AUX
ELEC1
87a
WORK LT
D7
86
87
D3
SWI-86
LIGHT SW
8
1
STEER SELECT
CARLING SWITCH
P/N VJD1S00BAZC00-000
85
30
85
30
87a
(25A)
W/W
86
87
D2
STEER
LIGHT
PARK BRAKE
CARLING SWITCH
P/N VDD1B6ABARC00-000
(10A)
OPT-1
GND
(15A)
OPT-2
TRANS
TEMP
WARN
LIGHT
12V
(15A)
OPT-3
(30A)
OPT_PWR
OPT-1
OPT-2
OIL
OPT-3
HOUR METER
DATCON
P/N 56458-10
BAT
AA
GND
W
X
U
V
O
P
Q
R
S
T
FRONT
WORK
LIGHT
(ON CAB)
GND L
GND L1
GND L1
IND LT
LIGHT-2
IND LT
WORK
LIGHT
INDICATOR
GND L
GND L
GND L
PARK
BRAKE
LIGHT
DOME LT
DOME
LIGHT
SWITCH
REV AL
DOME
LIGHT
GND DL
GND-1
BACK LT
WORK LT
GND-2
STOP LT
PS IGN
OIL GAG
CLT TMP
BRK SOL
TR LT SW
BAT-1
HR MTR
HORN
FUL GAG
ST RLY
BAT-2
SP-1
SP-2
ALT EXC
SP-3
STR AW
STR CRB
TRANS-B
TRANS-A
TRANS-C
TRANS-D
TRANS-E
DASH PANEL
GND L
GND L
GND DL
18
10
11
12
13
14
15
16
17
18
10
11
12
13
14
15
16
17
REV AL
BAT-1
HR MTR
HORN
FUL GAG
ST RLY
BAT-2
SP-1
SP-2
ALT EXC
SP-3
STR AW
STR CRB
TRANS-B
TRANS-A
TRANS-C
TRANS-D
TRANS-E
GND-1
BACK LT
WORK LT
GND-2
STOP LT
PS IGN
OIL GAG
CLT TMP
BRK SOL
TR LT SW
CAB FIREWALL
9-16
BACK LT
STOP LT
WORK LT
MIRROR-LT
GND
GND
FRONT
WORK
LIGHT
BACK-UP
LIGHT
(GREEN)
STOP LT
STOP
LIGHT
(RED)
TAIL LT
BACK LT
TAIL
LIGHT
(BLACK)
GND 2
GND 1
REV AL
GND-5
BACK-UP
ALARM
GROUND
(AT
STARTER
MOTOR)
f.
MIRROR-LT
FRONT
WORK
LIGHT
(ON CAB)
Electrical System
MY1440
TL642, TL943
LIGHT SW
WORK LT
GND L
J
K
L
D10
HTR
SW
WL2
SL
SWB
10 OHM
30W
R1
A
B
C
D
E
BEACON SW
86
85
30
(25A)
FAN/HTR
FAN/HTR
87a
87
D6
REV
ALARM
85
30
87a
MOTOROLA
MR 752
OR EQUIV
FAN
SW
WL
SWB
86
87
D1
86
WARN
LT CK
TEMP
(25A)
LIGHTS
W/W
87a
87
D7
GND
B+
12 UDC
4 IN 1 GAGE
BEEDE
85
30
85
30
87a
(25A)
W/W
86
87
D2
W/W_SW
7
4
HORN
CARLING SWITCH
P/N V2D1S00BAZC00-000
HORN
LIGHT
OIL
86
85
30
4
5
6
2
3
SL_SWA
(10A)
STEER
ACC
85
30
87a
(25A)
SPARE
BAT
OPT
SPARE_BAT
GND L1
IND LT
7
4
(10A)
HORN
(10A)
OPT-1
(15A)
OPT-2
(15A)
OPT-3
(30A)
OPT_PWR
BEACON LIGHT
CARLING SWITCH
P/N V1D1S00BAZC00-000
BEACON
LIGHT
INDICATOR
BEACON-1
SPARE_COIL
(15A)
KEY
87a
85
30
BEACON SW
WL_SWA
(10A)
GAGES
86
87
D9
86
87
87a
87
86
D5
AUX
ELEC2
GND 85
D4
85
30
SW2-86
8
1
LIGHTS
87a
87
D8
SW1-87a
STEER
LIGHT
PARK BRAKE
CARLING SWITCH
P/N VDD1B6ABARC00-000
STEER SELECT
CARLING SWITCH
P/N VJD1S00BAZC00-000
SW2-87a
AUX
ELEC1
85
30
87a
(10A)
RELAYS
86
87
D3
SWI-86
FUEL
PARK
BRAKE
LIGHT
OPT-1
DASH PANEL
OPT-2
TL642, TL943
OPT-3
BEACON
LIGHT
(ON CAB)
GND
BAT
AA
GND
W
X
U
V
S
T
O
P
Q
R
TRANS
TEMP
WARN
LIGHT
12V
HOUR METER
DATCON
P/N 56458-10
GND L
Electrical System
MAL0390
9-17
BEACON-1
TL642, TL943
2
KEY/IGN
(SHIELD/020)
(CAN L/905,GREEN)
(CAN H/904, YELLOW)
12
(D BLU, 18 GA GXL)
1
FUL LVL
5
21 20
6 7 8
(ORG, 18 GA GXL)
(WHT, 18 GA GXL)
PLUGGED
7 11
17
HORN
16
ENG STOP
(RED, 18 GA GXL)
ENG WARN
(RED, 18 GA GXL)
10 8 9
WAIT TO START
STR CRB
STR CRB
STEER/SWAY PWR
STR AW
(RED, 18 GA GXL)
6 22 13
3 4 5
5 4
(BLK, 18 GA GXL)
3 2
(RED, 18 GA GXL)
(ORG, 18 GA GXL)
(D BLU, 18 GA GXL)
DASH GND
STONERIDGE
GAUGE
3 31 30 29
C
B
A
(SHIELD/020)
(CAN L/905,GREEN)
(CAN H/904, YELLOW)
(SHIELD/020)
C
B
A
C
B
A
ENG WARN LT
WAIT TO START LT
PLUGGED
ENG WARN LT
WAIT TO START LT
KEY START
KEY IGN
KEY ACC
SHIELD
CAN L
CAN H
(SHIELD/020)
(CAN L/905)
(CAN H/904)
SHIELDED
CABLE
FUL LVL
DASH GND
GAGE PWR
ENG STOP LT
TRANS TMP SW
GAGE PWR
ENG STOP LT
TRANS TMP SW
HORN PWR
HORN
HORN PWR
HORN
GND FAULT
PK BRK SOL
PK BRK SOL
9-18
MY5830
STR AW
23
14
15 25 26 27 18 19 24
PARK BRAKE
STEER MODE
ST RLY
SHIFT PWR 1
STEER/SWAY PWR
TRAN/BRK PWR
DCLUTCH IN
TRAN/BRK PWR
ST RLY
SHIFT PWR 1
TILT UP
TILT DN
DCLUTCH
AUX A
AUX B
ACC MOD GND
DASH GND
C
B
A
C
B
A
(SHIELD/020)
(CAN H/904, YELLOW)
(CAN L/905,GREEN)
N4
C
B
A
N3
DCLUTCH IN
KEY IGN
TILT UP
TILT DN
DCLUTCH
AUX A
AUX B
ACC MOD GND
PK BRK SOL
GND FAULT
CAN TERMINATOR
120 OHM
Y2,Y6
N2
Y2,Y3,Y6
R3
N1
Y2,Y3,Y5,Y6
R2
R4
Y1,Y6
Y1,Y3,Y6
Y2,Y3,Y4,Y6
F4
F3
Y1,Y3,Y5,Y6
R1
Y1,Y3,Y4,Y6
F2
F1
E4, E3
R3
E4, E2
NO SOLENOIDS INGAUGED
R2
TRANSMISSION LEGEND ZF
E4, E1
GEAR
E6, E3
E5, E3
F4
E5, E2
F2
F3
E5, E1
F1
R1
GEAR
SW3
SW1
F
SW4
SW2
1 2 3 4 5 6 7 8 9 10 11 12
SEE SHEET 3
HOBBS
TRANSMISSION SHIFTER
TRANS SOL Y1
TRANS SOL
TRANS SOL Y3
TRANS SOL Y6
SHIFT PWR 2
REVERSE SOL
PLUGGED
TRANS SOL Y5
KEY START
SHIFT PWR 1
PLUGGED
PLUGGED
26 27
SW3
SW1
1 3 5 4 8 7 2 9
1 2 3 4 5 6 7 8
HOBBS
N
F
TRANSMISSION SHIFTER
11 10 20 21 22
12 TURNS
PER FOOT
TWIST
87
87a
30
85
86
REVERSE
RELAY
30 31 14 15 13 29 12 17 18 19
A B C D E F
SW4
SW2
WILLIAMS
(SUSPENDED)
PLUGGED
TRAN/BRK PWR
REVERSE
REVERSE SOL
SHIFTER GND
25
23 16 28
85
86
87
87a
30
WARN LIGHT
TEST RELAY
PLUGGED
SHIFTER GND
TRANS TMP SW
KEY START
SHIFTER GND
THROTTLE
THR SGN/915
THR RTN/914
THR SUP/911
IVS
ON-IDLE
IVR
CAB
PLUGGED
PLUGGED
TRANS SOL Y1
TRANS SOL Y3
TRANS SOL Y5
TRANS SOL
SHIFT PWR 1
KEY START
REVERSE SOL
SHIFT PWR 2
TRANSMISSION LEGEND
TURNER
TRANS SOL Y1
TRANS SOL Y3
TRANS SOL Y5
TRANS SOL
SHIFT PWR 1
KEY START
REVERSE SOL
SHIFT PWR 2
TRANS SOL Y6
ON-IDLE
IVR
THR SGN/915
THR RTN/914
THR SUP/911
IVS
SHIFTER GND
SP ACCY PWR
SP CAB GND 1
SP CAB GND 2
TRAN/BRK PWR
REVERSE
SP-1
SP-2
SP-3
PLUGGED
TRANS TMP SW
SP BAT PWR
SP BAT PWR
24
AC CLUTCH
SP-1
SP-2
SP-3
SP BAT PWR
SP ACCY PWR
SP CAB GND 1
SP CAB GND 2
AC CLUTCH
SEE
SHEET 2
a. Cab Schematic
9.5.2
AND ALTERNATOR
STEER/SWAY PWR
R. AXLE STAB/TILT
10A
10A
15A
F11
F10
HORN PWR
ALTERNATOR EXCITE
OPTION POWER 2
OPTION POWER 1
OPTION POWER 4
F12
10A
15A
25A
25A
F6
F7
15A
F5
F8
10A
F4
F9
10A
F3
20A
15A
20A
5A
FUSE
F1
FUSE
F2
20A
FUSE
OPTION POWER 3
POWER DISTRIBUTION
FUSE/BREAKER LEGEND
20A
FUSE
ACCY-2
IGNITION-1
87a
30
BLACK-6
IGNITION-2
BAT GND
ACCY-1
BLACK-1
H G F E D C B A
87a
30
NEGATIVE CABLE
TO ENG BLOCK
87
87
CB4
NEGATIVE CABLE
FLAG TO
CHASSIS FRAME
85
85
CB3
12 VDC
BATTERY
F8
25
TILT-ON
JOYSTICK
VALVE
FUEL
SNDR
ALL WHEEL
STEER
MODE
VALVE
CRAB
PROPORTIONAL
HYDRALIC AUX.
VALVE
87
87
86
86
20
BAT POS
GRAY-5
F7
BAT GND
F3
10
86
86
85
F1 15
F6 10
F5 15
F2
1
2
1
2
B
A
2
1
2
1
2
1
2
1
STR/FUL GND
FUL LVL
STR CRB
STR/FUL GND
STR AW
STR/FUL GND
VLV GND
TILT UP
VLV GND
TILT DN
VLV GND
AUX A
VLV GND
AUX B
A
B
C
D
E
F
G
H
A
B
C
D
E
F
G
H
GRN
RED
BLK
(-)
REVERSE
STOP LT
WORK LT
LT GND
SP CAB GND 1
SP CAB GND 2
SP GND 1
AC CLUTCH GND
AUX ELEC GND
LT GND
STR/FUL GND
ACC MOD GND
DASH GND
ALT EXC
SP ACCY PWR
AUX RLYS PWR
OPT GND 1
KEY ACC
TRAN/BRK PWR
OPT GND 2
POWER DIST
VEC
GRAY-2
H G F E D C B A
85
87a
30
F4
20
10
87a
30
F9
25
SHIFTER GND
OPT PWR 2
KEY IGN
SP BAT PWR
ECU IGN/012
OPT PWR 1
GAGE PWR
ECU BAT/022
CB1
20
15
F10
10
F12
15
GREEN-4
BLUE-3
BAT POS
CB2
20
F11
10
ENG GND
OPT PWR 3
HORN PWR
STEER/SWAY PWR
OPT PWR 4
STAB/TILT PWR
KEY BAT PWR
ECU GND/050
POSITIVE CABLE
TO STARTER
85
86
A
30
87
VLV GND
ACC MOD GND
GROUND FAULT
RLY
CABLE
CABLE
20 7 8
1
WAIT TO START LT
ENG WARN LT
ENG STOP LT
ECU IGN/012
ECU BAT/022
A B C D
REVERSE
LT GND
13 5
CHASSIS HARNESS
HD34-24-29PE
19 21 22 25 26 3 28
10 11 12
14 15 16 4
CAN H/904
CAN L/905
SHIELD /020
ENG GND
A B
HORN
GND FAULT
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
THR SUP/911
THR SGN/915
THR RTN/914
TAIL
23 24
PLUGGED
PLUGGED
STOP
ALT EXC
BU
12 TURNS
PER FOOT
TWIST
17 27
29
18 23 24
TO OPTIONS HARNESS
HD34-24-19SE
CHASSIS HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
KEY ACC
AUX RLYS PWR
STOP LT
WORK LT
EXTRA
SWING
QC PWR 1
OPT PWR 1
QC PWR 2
OPT PWR 2
QC GND 5
OPT PWR 3
QC GND 7
OPT PWR 4
AUX ELEC GND
OPT GND 1
SIDESHIFT
OPT GND 2
MAST
NEGATIVE CABLE
TO CAB FIREWALL
A/C
COMPRESSOR
(OPT)
PK BRK SOL
85
A
30
87
SHIFT PWR 2
86
STR/FUL GND
DCLUTCH
AC CLUTCH
SP-3
SP-2
SP-1
SP BAT PWR
SP ACCY PWR
SP GND 1
AC CLUTCH GND
TO CAB ASSEMBLY
PLUGGED
HORN
IVS
ON-IDLE
IVR
A B C D E F
A B C D E F
BLK
RED
YEL
BLU
ORG
PLUGGED
TRANSMISSION DECLUTCH
RELAY
QC PWR 1
QC PWR 2
AUX ELEC GND
QC GND 5
QC GND 7
PLUGGED
REVERSE
ALARM
PK BRK SOL
TRANS SOL Y1
REVERSE SOL
TRANS SOL Y3
TRANS SOL
TRANS SOL Y5
ECU GND/050
TRANS SOL Y6
TRANS SOL Y1
REVERSE SOL
TRANS SOL Y3
TRANS SOL
TRANS SOL Y5
TRANS SOL Y6
KEY START
SHIFT PWR 1
SHIFT PWR 2
REVERSE
TRAN/BRK PWR
SHIFTER GND
THR SUP/911
THR SGN/915
THR RTN/914
SP BAT PWR
SP ACCY PWR
SP CAB GND 1
SP CAB GND 2
SP-1
SP-2
SP-3
TRANS TMP SW
AC CLUTCH
STAB/TILT PWR
TILT UP
TILT DN
SP BAT PWR
IVS
ON-IDLE
IVR
TRANS TMP SW
PLUGGED
1
2
QC DIVERTOR
VALVE
RT TM
(OPT)
AUXILIARY
ELECTRIC
A S LT
A B C D E F
PLUGGED
TL642, TL943
BLK
RED
YEL
BLU
ORG
MY5860D
PLUGGED
MAST
SIDESHIFT
AUX ELEC GND
SWING
EXTRA
(OPT)
TAIL LIGHT
Electrical System
b. Chassis Schematic
9-19
DIAGNOSTIC
CONNECTOR (9 PIN)
ELECTRONIC
WASTEGATE
ACTUATOR
1
2
P920 BR
1
2
PUMP/CAM SPEED
SENSOR
FUEL PUMP
SOLENOID
996 GN
E965 BU
1
2
CRANKSHAFT SPEED/
TIMING SENSOR
C211 BK
M795 WH
101 RD
229 BK
944 OR
945 BR
Y793 YL
Y792 PK
1
2
A
B
C
D
E
F
G
H
J
Y950 YL
Y951 PU
C967 BU
L731 BR
1
2
INTAKE MANIFOLD
TEMP SENSOR
18
45
21
20
23
24
19 WASTEGATE RETURN
17 WASTEGATE PWM SIGNAL
42 IMT SIGNAL
37 TEMPERATURE SENSOR RETURN
1
2
COOLANT TEMP
SENSOR
955 BU
R997 OR
Y948 BR
Y946 BU
1
FUEL MANIFOLD
2
PRESSURE SENSOR
3
OIL PRESSURE
SENSOR
35
57
L730 OR
Y947 BR
994 GY
EXTERNAL
X926 GY
X920 BR
X927 YL
X921 PK
1
2
3
3
4
1
2
X928 GN
X922 WH
T997 OR
T993 BR
X731 BU
INTERNAL
(ROCKER
COVER)
T957 BK
T951 BK
T958 BK
T952 BK
3
4
1
INTAKE MANIFOLD
2
PRESSURE SENSOR
3
INJECTOR CYLINDER 1
INJECTOR CYLINDER 2
T959 BK
T953 BK
N3
E4, E3
E4, E2
NO SOLENOIDS INGAUGED
R3
R2
E6, E3
F4
E4, E1
E5, E3
F3
R1
E5, E2
E5, E1
F1
F2
GEAR
TRANSMISSION LEGEND
TURNER
N2
N4
N1
Y2,Y3,Y6
R3
Y2,Y6
Y2,Y3,Y5,Y6
R4
Y1,Y6
Y2,Y3,Y4,Y6
F4
R2
Y1,Y3,Y6
R1
Y1,Y3,Y5,Y6
F3
Y1,Y3,Y4,Y6
F2
F1
Y1
Y2
Y3
Y4
Y5
Y6
E1
E2
E3
E4
E5
E6
TRANS SOL Y1
ENG GND
TRANS TMP SW
TRANS SOL E6
ENG GND
TRANS SOL E5
ENG GND
TRANS SOL E4
ENG GND
TRANS SOL E3
ENG GND
TRANS SOL E2
ENG GND
TRANS SOL E1
ENG GND
TRANS TMP SW
ENG GND
TRANS SOL Y5
ENG GND
TRANS SOL Y4
ENG GND
TRANS SOL Y3
ENG GND
TRANS SOL Y2
ENG GND
120 OHM
CAN TERMINATOR
1
2
3
4
5
6
7
8
9
10
11
12
A
B
C
(CAN H/904)
(CAN L/905)
(SHIELD/020)
SHIELDED
CABLE
ECU GND/050
INJECTOR CYLINDER 4
6A/400V
INJECTOR CYLINDER 3
ENG WARN LT
ENT STOP LT
CAN H/904
CAN L/905
SHIELD/020
GEAR
THR SUP/911
THR SGN/915
RTN
64 PIN
ENGINE ECM
IVS
34
58
ON-IDLE
X929 BU
X923 OR
WAIT TO START LT
1
2
45
T960 BK
T954 BK
HD36-24-29SE
POWER UNIT HARNESS
ALT EXC A
D+
B+
ALTERNATOR
PLUGGED
TRANS SOL Y6
PLUGGED
ALT PWR
F5
50
RELAY
PARK
BRAKE
VALVE
85
30
87
STARTER
RELAY
86
STARTER
AMBIENT TEMPERATURE
SENSOR
(4 AWG, RED)
ST RLY
ENG GND
TO CHASSIS ASSEMBLY
PK BRK SOL
ENG GND
POWER UNIT
ST RLY PWR
STRT SOL
ST RLY PWR
STRT SOL
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
ECU IGN/012
ECU BAT/022
ECU GND/050
ENG GND
PLUGGED
PK BRK SOL
ENG WARN LT
ENG STOP LT
ALT EXC
THR SUP/911
THR SGN/915
THR RTN/914
ST RLY
CAN H/904
CAN L/905
SHIELD/020
TRANS TMP SW
IVS
TRANS SOL Y1
WAIT TO START
REVERSE SOL
TRANS SOL Y3
ON-IDLE
PLUGGED
TRANS SOL
TRANS SOL Y5
35
NEGATIVE CABLE
TO BATTERY
(3/0 AWG, BLACK)
TRANSMISSION LEGEND
ECU IGN/012
40
ECU BAT/022
A B
7
8
15
16
A B
41
A B
1
2
3
9
10
A B
59
60
250 F
A B
54
33
ZF TRANSMISSION
A B
20
21
22
A B
63
A B
A B
A B
30
57
87
42
56
A B
A B
A B
85
POSITIVE CABLE
TO BATTERY
86
TO GLOW PLUGS
9-20
1
Electrical System
c. Engine Schematic
TURNER TRANSMISSION
250 F
MY5870D
TL642, TL943
J1 (BLACK)
1 2
J2 (GREY)
8
9
OUTPUT
OUTPUT
DIGITAL
DIGITAL
AUX A
TILT DN
12
OUTPUT
DIGITAL
GND FAULT
12
2 3 4 5 6 7 8 9 10 11 12
5 EXC TILT
TILT SIG A
TILT GND
5 EXC AUX
AUX SIG A
AUX GND
TILT SIG B
AUX SIG B
CAN H/904
CAN L/905
TX
RX
J1 (BLACK)
ACCY. MODULE
JLG ANALYZER
3 4
11
11
KEY IGN
ACC MOD GND
TRIG
DCLUTCH IN
DI2
ROLLER SEL
TILT UP
TILT DN
AUX A
AUX B
DCLUTCH
GND FAULT
10
OUTPUT
OUTPUT
DIGITAL
DIGITAL
AUX B
DCLUTCH
10
OUTPUT
DIGITAL
TILT UP VALUE
TILT UP
INPUT
INPUT
4
5
INPUT
DIGITAL
DIGITAL
DIGITAL
DI2
DCLUTCH IN
1
2
INPUT
INPUT
INPUT
DIGITAL
ROLLER SEL
TYPE
POWER
TRIG
DESCRIPTION
POWER
IGNITION
KEY IGN
TAGNAME
TL642, TL943
CONNECTOR PIN
PLUGGED
PLUGGED
GND FAULT
PLUGGED
RX
TX
CAN L/905
CAN H/904
AUX SIG B
TILT SIG B
AUX GND
AUX SIG A
5 EXC AUX
TILT GND
TILT SIG A
5 EXC TILT
+5 ANALOG EXCITATION VOLTAGE
7
8
9
10
11
12
5
6
2
3
4
AUX SIG B
KEY IGN
ROLLER SEL
5 EXC AUX
AUX SIG A
AUX GND
CAN SHIELD
CAN L/905
CAN H/904
DCLUTCH IN
KEY IGN
TILT UP
TILT DN
DCLUTCH
AUX A
AUX B
ACC MOD GND
PK BRK SOL
PLUGGED
GND FAULT
PLUGGED
RS-232 RECEIVE
RS-232 TRANSMIT
CANBUS LOW
CANBUS HIGH
ANALOG GROUND
4
5
6
1
3
2
ANALOG GROUND
POWER
INPUT
OUTPUT
I/O
I/O
INPUT
INPUT
OUTPUT
INPUT
OUTPUT
OUTPUT
INPUT
OUTPUT
SEE SHEET 1
SERIAL
SERIAL
SERIAL
SERIAL
ANALOG
ANALOG
POWER
ANALOG
POWER
POWER
ANALOG
KEY IGN
7
8
6
3
2
4
1
TRIG
TILT SIG A
TILT GND
TILT SIG B
5 EXC TILT
PLUGGED
PLUGGED
7
8
9
10
11
12
5
6
2
3
4
DCLUTCH IN
IGN
TILT UP
TILT DN
DCLUTCH
AUX A
AUX B
ACC MOD GND
PK BRK SOL
PLUGGED
PLUGGED
PLUGGED
SEE SHEET 1
Electrical System
1 2 3 4 5 6 7 8 9 10 11 12
J2 (GREY)
MY5850D
9-21
ROOF WIPER
MOTOR
AUX
ELECTRIC
OPTION
1 2 3 4 5 6 7 8 9 10 11 12
19
17
PLUGGED
15
87
86
LIGHTS
87a
30
85
OPTION (15A)
87a
30
BCN/FAN
OPTION (25A)
BLACK-1
H G F E D C B A
AUX ELEC1
F6 20
F8 10
F7 10
F5 20
F1 20
AUX ELEC2
GRAY-2
H G F E D C B A
HEATER/BLOWER
86
WIPER
85
85
85
85
85
87
87
87
86
86
87a
30
87a
30
87a
30
16 18 7 9 11 13
TO CHASSIS ASSEMBLY
OPTIONS HARNESS
HD36-24-19PE
10 12 14
F1
F2
F3
F4
F5
F6
F7
F8
A
B
C
D
E
F
G
H
A
B
C
D
E
F
G
H
20A
5A
15A
25A
20A
20A
10A
10A
85
QUICK CONNECT
86
WIPER PWR
5A ROOF WIPER PWR
15A OPTION PWR 2
25A OPTION PWR
HEATER/BLOWER PWR
LIGHT PWR
BEACON PWR
DASH FAN PWR
OPTIONS
FUSE LEGEND
CAB LT GND
DOME/BCN GND
AUX ELEC PWR
SW1 87A
SW2 86
SW2 87A
SW1 86
HEATER GND
WIPER PWR
HEATER PWR
KEY ACC
BCN PWR
D FAN PWR
DOME LT
CAB LT PWR
S/W LT PWR
30
87
2 1
4
86
85
30
87
A/C
RELAY
SEE SHEET 1
RLY 87
25A OPT GND
D FAN PWR
HEATER PWR
WIPER PWR
HEATER GND
D FAN GND
PLUGGED
AC SW
M 17A
A/C SWITCH
WORK LT
AC SW
PRESSURE SWITCH
PRS SW
A B C D
A B
BLOWER
MOTOR
DASH
FAN
CAB LT GND
DOME/BCN GND
WORK LT
CAB LT GND
DOME/BCN GND
DOME LT
CAB LT PWR
S/W LT PWR
DOME LT
CAB LT PWR
S/W LT PWR
STOP LT
BCN PWR
STOP LT
BCN PWR
CONDENSER FANS
(ON ROOF)
THERMOSTATIC
SWITCH A/C
AC CLUTCH
A
B
ENCLOSED CAB
OPTION
D FAN PWR
HEATER PWR
WIPER PWR
HEATER GND
D FAN GND
PLUGGED
WORKLIGHT/
BEACON
OPTION
(BLACK)
OPTIONS VEC
85
SWING
EXTRA
86
SIDESHIFT
87
87
87
F4
25
87a
30
85
AUX ELECTRICS
MAST
86
87a
30
F3
15
OPTION 2 B
15 A
A
SWING
EXTRA
SW2 87A
SW2 86
MAST
SW1 87A
SIDESHIFT
SW1 86
AUX SW GND
PLUGGED
PLUGGED
PLUGGED
SWING
EXTRA
SW2 87A
SW2 86
MAST
SW1 87A
SIDESHIFT
SW1 86
AUX SW GND
PLUGGED
PLUGGED
PLUGGED
F2
25A OPT
15A OPT 2
OPT PWR 1
AUX SW GND
5A ROOF WIPER PWR
OPT PWR 2
OPT PWR 3
OPT PWR 4
87
OPT PWR 1
(RED)
86
86
OPTION
25 A
D FAN PWR
D FAN GND
87a
30
25A OPT
25A OPT GND
A
B
25A OPT
25A OPT GND
HEATER HI
HEATER MED
HEATER LOW
HEATER GND
GREEN-4
BLUE-3
OPT PWR 2
OPT PWR 3
OPT PWR 4
PLUGGED
QC GND
25A OPT GND
15A OPT 2 GND
5A ROOF WIPER GND
OPT GND 1
OPT GND 2
D FAN GND
OPT GND 1
OPT GND 2
QC PWR 1
QC PWR 2
QC GND 5
QC GND 7
A B C D E F
(RED/WHITE)
1 2 3 4 5 6 7 8 9 10
HEATER
VALVE
BEACON
H
B
BLOWER
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
HEATER GND
HTR CNTRL B
EMPTY
HEATER PWR
24 KOHM,1W
7 5
HEATER PWR
WIPER MOTOR
WIPER
H
LW
RESISTOR LOCATED
APPROX 10" BEHIND
HEATER TEMP SWITCH
CONNECTION IN
ENCLOSED CAB
OPTIONS HARNESS
WORKLIGHTS
WIPER LO
WIPER HI
WIPER PARK
EMPTY
EMPTY
4 6 2
FAN SW C
WIPER HI
WIPER LO
9-22
1 3
WIPER PWR
HTR TEMP
A
8K OHM
WINDSHIELD
WASHER
MOTOR
STOP LT
S/W LT PWR
CAB LTS
CAB LT GND
CAB LTS
CAB LT GND
BCN LT
DOME/BCN GND
DOME LT
DOME/BCN GND
A B
WIPER PARK
WASHER
MY5840D
A B
WASHER
HEATER GND
HTR CNTRL A
HEATER PWR
OPTIONS
RIGHT
CAB LIGHTS
LEFT
BEACON
DOME
LIGHT
STOPLIGHT
SWITCH
Electrical System
e. Options
A B
TL642, TL943
Electrical System
9.6
CIRCUIT BREAKDOWNS
9.6.1
ST RLY PWR
ENGINE HARNESS
30
86
87
85
STARTER
RELAY
STARTER
MOTOR
STRT SOL
BAT-2
BAT-1
SNSR
ALT BAT
GROUND
(AT ENGINE
POD)
GROUND
BATTERY
12VDC
SNSR
SNSR
#1
BAT-2
TO PCB
DEUTSCH P/N HD-34-24-18-SN
BAT-1
BATT
ALTERNATOR
#2
ALT BAT
AA
PCB
DEUTSCH P/N HD-36-24-18-PN
BATT
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
D9
D5
87
86
D8
87
87a
86
85
30
ACC
D7
87
87a
86
85
30
87
87a
LIGHTS
OPT
D6
85
30
86
87
87a
W/W
85
30
86
87a
85
30
FAN/HTR
SPARE
BAT
(10A)
HORN
(30A)
OPT_PWR
(15A)
KEY
(25A)
SPARE
BAT
(25A)
LIGHTS
(25A)
W/W
(25A)
FAN/HTR
K
L
TO DASH PANEL
IGNITION SWITCH
POLLACK P/N 31-610
HORN
CARLING SWITCH
P/N V2D1S00BAZC00-000
8
BAT
DASH PANEL
ACC
1
STRT
2
3
IGN
4
5
6
HORN PWR
KEY PWR
MY0810
TL642, TL943
9-23
Electrical System
9.6.2
Start Circuit
ENGINE HARNESS
ST RLY
PS IGN
FUL SOL
ST RLY PWR
HR MTR
PS IGN
GP SW
FUEL PUMP
PS IGN
FUEL PUMP
FP RLY
FP PWR
FP RLY
86
87
85
1
2
85
86
87
30
87A
A
B
1
2
FUEL
SOLENOID
FUEL PUMP
RELAY
FUSE
7.5 AMP
GP SW
COLD START
ADVANCE
SOLENOID
30
STARTER
RELAY
A
B
C
PS IGN
PS IGN
PS IGN
HR MTR
FUEL PUMP
OIL
PRESSURE SWITCH
5 PSI
FUSE, 50 AMP
SLOW BLOW
GLOW PLUGS
STARTER
MOTOR
STRT SOL
GP PWR
BAT-2
BAT-1
SNSR
ALT BAT
GROUND
GP RLY
GP PWR
FP PWR
GP SIG
86
85
30
GROUND
(AT ENGINE
POD)
GLOW PLG
87
BATTERY
12VDC
GLOW PLUG
RELAY
SNSR
SNSR
ALT EXEC
#1
BAT-1
HR MTR
ST RLY
BAT-2
ALT EXEC
PS IGN
ALTERNATOR
#2
ALT BAT
BATT
ALT EXEC
PS IGN
HR MTR
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AA
ST RLY
GP SW
GP SIG
BATT
ST RLY
PCB
HR MTR
D2
Q
TR LT SW
87
86
F-N-R AND
GEAR SELECTOR
TO
TRANSMISSION
TEMPERATURE
SWITCH
87a
85
30
WARN
LT CK
DEUTSCH
P/N DT06-8S
LOCKING WEDGE
W8S
87
(15A)
KEY
86
1 2 3 4 5 6 7 8
DEUTSCH
P/N DT04-8P
LOCKING WEDGE
W8P
SHIFT STRT
DASH PANEL
87a
85
30
ACC
KEY PWR
D9
10 OHM
30W
R1
KEY ACC
HOUR METER
DATCON
P/N 56458-10
KEY STRT
KEY ACC
12V
ST RLY
GND
HR MTR
TR LT
PARK BRAKE
CARLING SWITCH
P/N VDD1B6ABARC00-000
8
IGNITION SWITCH
POLLACK P/N 31-610
BAT
ACC
KEY PWR
TRANS
TEMP
WARN
LIGHT
STRT
PS IGN
BR SW PWR
IGN
BR SW PWR
MY1630
9-24
TL642, TL943
Electrical System
9.6.3
Charging Circuit
ENGINE HARNESS
STRT SOL
STARTER
MOTOR
SNSR
ALT BAT
GROUND
(AT ENGINE
POD)
GROUND
BATTERY
12VDC
SNSR
ALT EXC
SNSR
ALT EXC
#1
ALT EXC
BATT
TO PCB
DEUTSCH P/N HD-34-24-18-SN
#2
ALTERNATOR
ALT BAT
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
PCB
DEUTSCH P/N HD-36-24-18-PN
D9
O
10 OHM
30W
R1
87
86
87a
85
30
(10A)
GAGES
ACC
J
TO DASH PANEL
DASH PANEL
GAG PWR
FUEL
OIL
12 UDC
1
B+
GND
TEMP
4 IN 1 GAGE
BEEDE
MY0800
TL642, TL943
9-25
Electrical System
9.7
9.7.1
9-26
MAL0470
TL642, TL943
Electrical System
9.8
CHARGING CIRCUIT
MY0370
9.8.1
Alternator
a. Alternator Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake and turn the
engine OFF.
9-27
Electrical System
9.9
WINDOW WIPER/WASHER
WINDSHIELD WIPER MOTOR
b. Disassembly
DO NOT disassemble the motor. The motor is not
serviceable. Replace motor if found to be defective.
a. Removal
Note: It may be necessary to remove several hydraulic
hoses from behind the dash in order to remove and
install the wiper motor housing. (Refer to Section 4.3.1,
Steering Column and Orbitrol Valve.)
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
MY0440
9-28
TL642, TL943
Electrical System
9.9.1
9.10
9.10.1
b. Disassembly
DO NOT disassemble the pump. The pump is not
serviceable. Replace pump if found to be defective.
TL642, TL943
9-29
Electrical System
5. Remove the four screws (5) from the cab heater and
fan control panel.
6. Pull the control panel out from the dash panel and
disconnect the variable speed fan control cab
harness connector and disconnect the temperature
cable.
9.11
9.11.1
5
MAL0960
b. Disassembly
DO NOT disassemble the cab heater and fan controls.
The controls are not serviceable. Replace controls if
found to be defective.
9-30
TL642, TL943
Electrical System
c. Priority Valve Solenoid Installation
9.11.2
7
8
8
MAL1220
OAL0030
b. Disassembly
DO NOT disassemble the solenoid. The solenoid is not
serviceable. Replace solenoid if found to be defective.
TL642, TL943
9-31
Electrical System
9.11.3
9.11.4
9-32
TL642, TL943
Electrical System
4. Start the engine, allow it to reach operating
temperature and observe the operator instrument
cluster for warning indication. If the sensor is not
defective, the problem could be elsewhere; possibly
in a shorted wire, improper-running engine, improper
or low coolant, obstructed or faulty radiator, coolant
pump, loose fan belt, defective instrument display,
etc.
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
9.11.5
9.11.6
2
MAL0490
TL642, TL943
9-33
Electrical System
9.12
9.12.1
MAL1240
MY5560
9-34
TL642, TL943
Electrical System
a. Gauge Removal
9.12.2
5
MAP0300
XXXXXX.X
XXXX
XXXXXX.X
XX.X V
RPM
XXXX
XX.X V
RPM
b. Disassembly
XXX.XX
XXXX
9
10
MAP0640
TL642, TL943
9-35
Electrical System
9.13
DASH SWITCHES
9.13.1
9.13.2
a. Switch Removal
ACC
T
BA
BAT
ST
IG
AC
C
Dash Switches
b. Disassembly
DO NOT disassemble the dash switch. Replace a
defective switch with a new part.
IG
MY0830
9-36
TL642, TL943
Electrical System
c. Inspection and Replacement
b. Disassembly
d. Switch Installation
1. Connect the switch to the cab harness connector.
d. Switch Installation
9.13.3
TILT SPEED
CONTROL
MAL1250
TL642, TL943
MAL1260
9-37
Electrical System
6. Disconnect the harness connector to the switch (8)
and remove the switch.
1. Cable Connector.
2. Analyzer Display Screen.
3. Escape Key: To return home or access previous
menu.
b. Disassembly
DO NOT disassemble the Rheostat switch. Replace a
defective switch with a new part.
9.14.1
d. Switch Installation
1. Connect the switch to the cab harness connector.
2. Position the switch its original orientation. Secure
with the previously used hardware.
3. Install the switch panel with the previously removed
hardware.
Analyzer Usage
9.14
7
MAL1110
2
3
MAM1410
9-38
TL642, TL943
The Access Level Menu controls security for Control Module settings. Access Level 2 is the default and allows view access to all menus, except
Calibration. Access Level 1 (33271) provides view, edit and calibration authorization.
Note: The layout shows all possible analyzer screens. Please note, some screens may not be available depending upon machine configuration.
Electrical System
9.14.2
Analyzer Software Version A
MAL0890A
TL642, TL943
9-39
Electrical System
9.14.3
Personality Settings
MENU
MIN
MAX
DEFAULT
0.0
5.0
0.1
0.0
5.0
0.3
0.0
5.0
0.1
0.0
5.0
0.3
100
1000
300
500
1700
1100
100
1000
300
500
1700
1100
0.0
5.0
0.1
0.0
5.0
0.3
0.0
5.0
0.1
0.0
5.0
0.3
100
1000
300
500
1700
1100
100
1000
300
500
1700
1100
Fork Tilt:
AUX FUNCTION:
9-40
TL642, TL943
Electrical System
9.14.4
SUB-MENU
Cal. Fork Tilt?
Yes: Enter, No:ESC
Calibrations:
Fork Tilt
Calibrations:
Aux Hydraulic
TL642, TL943
COMMENT
The technician will press the ENTER key to initiate calibration, or the
ESC key to leave menu.
The technician will knurl the fork tilt roller to the +AR position and
press the ENTER key to confirm.
The the technician will release the fork tilt roller and press the ENTER
key to confirm.
The technician will knurl the fork tilt roller to the - AR position and
press the ENTER key to confirm.
Calibrations:
Complete
The control system will display this message to advise that the
procedure was successful. The technician will press the ESC key to
leave this menu.
Calibrations:
Failed
The control system will display this message to advise that the
procedure was unsuccessful. The technician will press the ESC key to
leave this menu.
The technician will press the ENTER key to initiate calibration, or the
ESC key to leave menu.
The technician will knurl the auxiliary hydraulic roller to the +AR
position and press the ENTER key to confirm.
The the technician will release the auxiliary hydraulic roller and press
the ENTER key to confirm.
Calibrations:
Complete
The control system will display this message to advise that the
procedure was successful. The technician will press the ESC key to
leave this menu.
Calibrations:
Failed
The control system will display this message to advise that the
procedure was unsuccessful. The technician will press the ESC key to
leave this menu.
9-41
Electrical System
9.14.5
DTC
Event
211
Power Cycle
Comment
No motion restrictions
Latched
No
No
2123
No
2126
2356
No
No
9-42
TL642, TL943
Electrical System
DTC
Event
2357
Comment
Auxiliary Hydraulic A & B prevented
Latched
Yes
2358
Yes
2397
2398
2399
33191
Yes
Yes
TL642, TL943
9-43
Electrical System
DTC
Event
33192
Comment
Fork Tilt Up & Down, Auxiliary Hydraulics
functionality prevented
Latched
Yes
Yes
Yes
Yes
Yes
Yes
9-44
TL642, TL943
Electrical System
DTC
Event
33198
Comment
The actual current is greater than 200mA, PWM is
95%, and the digital output drivers diagnostic
feedback is low
Latched
Yes
Yes
The auxiliary hydraulic B digital output was opencircuit. This fault may be caused by improper
wiring or a control module issue.
Active when Machine Setups AUX HYDRAULIC is
set to ENABLED
33200
Yes
Fork Tilt Up & Down, Auxiliary Hydraulics & DeClutch functionality prevented
No
Fork Tilt Up & Down, Auxiliary Hydraulics & DeClutch functionality prevented
Yes
Fork Tilt Up & Down, Auxiliary Hydraulics & DeClutch functionality prevented
Yes
TL642, TL943
9-45
Electrical System
DTC
Event
Comment
Latched
998
Fork Tilt Up & Down, Auxiliary Hydraulics & DeClutch functionality prevented
Yes
No
23100
259
Fork Tilt Up & Down, Auxiliary Hydraulics & DeClutch functionality prevented
Yes
9-46
TL642, TL943
Electrical System
9.15
CDL
Code
Description
CatET J1939
Code
3rd Party
Device J1939
Code
Flash
Code
N/A
N/A
N/A
551
0001-02
J651-2
651-2
111
0001-05
J651-5
651-5
111
0001-06
J651-6
651-6
111
0001-07
J651-7
651-7
111
0002-02
J652-2
652-2
112
0002-05
J652-5
652-5
112
0002-06
J652-6
652-6
112
0002-07
J652-7
652-7
112
0003-02
J653-2
653-2
113
0003-05
J653-5
653-5
113
0003-06
J653-6
653-6
113
0003-07
J653-7
653-7
113
0004-02
J654-2
654-2
114
0004-05
J654-5
654-5
114
0004-06
J654-6
654-6
114
0004-07
J654-7
654-7
114
0005-02
J655-2
655-2
115
0005-05
J655-5
655-5
115
0005-06
J655-6
655-6
115
0005-07
J655-7
655-7
115
0006-02
J656-2
656-2
116
0006-05
J656-5
656-5
116
TL642, TL943
9-47
Electrical System
CDL
Code
Description
CatET J1939
Code
3rd Party
Device J1939
Code
Flash
Code
0006-06
J656-6
656-6
116
0006-07
J656-7
656-7
116
0041-03
J678-03
678-03
517
0041-04
J678-04
678-04
517
0091-02
J91-02
91-02
154
0091-03
J91-03
91-03
154
0091-04
J91-04
91-04
154
0091-08
J91-08
91-08
154
0100-03
J100-03
100-03
157
0100-04
J100-04
100-04
157
0100-10
J100-10
100-10
157
0110-03
J110-03
110-03
168
0110-04
J110-04
110-04
168
0168-00
J168-00
168-00
422
0168-01
J168-01
168-01
422
0168-02
J168-02
168-02
422
0172-03
J105-03
105-03
133
0172-04
J105-04
105-04
133
0190-08
J190-08
190-08
141
0247-09
514
0247-12
514
0253-02
J631-02
631-02
415
0261-11
J637-11
637-11
143
9-48
TL642, TL943
Electrical System
CDL
Code
Description
CatET J1939
Code
3rd Party
Device J1939
Code
Flash
Code
0262-03
J1079-03
1079-03
516
0262-04
J1079-04
1079-04
516
0268-02
J630-02
630-02
527
0342-08
J723-08
723-08
142
0526-05
J1188-05
1188-05
177
0526-06
J1188-06
1188-06
177
0526-07
J1188-07
1188-07
177
0774-02
J29-02
29-02
155
0774-03
J29-03
29-03
155
0774-04
J29-04
29-04
155
0774-08
J29-08
29-08
155
1639-09
J1196-09
1196-09
426
1743-02
J2882-02
2882-02
144
1779-05
J1347-05
1347-05
162
1779-06
J1347-06
1347-06
162
1785-03
J102-03
102-03
197
1785-04
J102-04
102-04
197
1785-10
J102-10
102-10
197
1797-03
J157-03
157-03
159
1797-04
J157-04
157-04
159
1834-02
J158-02
158-02
439
TL642, TL943
9-49
Electrical System
CDL
Code
Description
CatET J1939
Code
3rd Party
Device J1939
Code
Flash
Code
2246-06
J676-06
676-06
199
Event
Code
Description
CatET J1939
Code
3rd Party
Device J1939
Code
Flash
Code
E172-1
J107-15
107-15
151
E194-1
J173-15
173-15
185
E232-1
J97-15
97-15
E360-1
J100-17
100-17
157
E360-3
J100-01
100-01
157
E361-1
J110-15
110-15
168
E361-2
J110-16
110-16
168
E361-3
J110-00
110-00
168
E362-1
Engine Overspeed
J190-15
190-15
141
E396-1
J157-00
157-00
159
E398-1
J157-01
157-01
159
E539-1
J105-15
105-15
133
E539-2
J105-16
105-16
133
E2143-3
J111-01
111-01
169
9-50
TL642, TL943
31200292