Caterpillar TL642 TL642C TL943 TL943C TL1055 TL1055C TL1255 TL1255C Telehandler Workshop Repair Service Manual PDF - MCATTL642TL1255.zip

A full factory-style service and repair guide, complete with electrical wiring schematics, covering the Caterpillar TL642, TL642C, TL943, TL943C, TL1055, TL1055C, TL1255, and TL1255C machines. It contains every technical detail needed to service, troubleshoot, fix, and rebuild these units just as trained technicians would.

The workshop service and repair guide for the Caterpillar TL642, TL642C, TL943, TL943C, TL1055, TL1055C, TL1255, and TL1255C includes:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

31200162 - JLG Drive Axle Supplemental Repair Manual (Models 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013, 4017, G6-42A, 642, TF6-42, TL642, & TL642C).pdf

31200239 - JLG Drive Axle Supplemental Repair Manual (Models G9-43A, G10-43A, 943, 1043, 1055, 1255, TL943, TL943C, TL1055C, TL1255C).pdf

31200247 - Operation & Maintenance Manual (Model TL642).pdf

31200248 - Operation & Maintenance Manual (Model TL943).pdf

31200249 - Operation & Maintenance Manual (Models TL1055, TL1255).pdf

31200255 - Parts Manual (Model TL642).pdf

31200256 - Parts Manual (Model TL943).pdf

31200257 - Parts Manual (Models TL1055, TL1255).pdf

31200261 (SEBU9288) - Operation & Safety Manual (Telehandler Personnel Work Platform).pdf

31200292 - Service Manual (Models TL642, TL943).pdf

31200293 - Service Manual (Models TL1055, TL1255).pdf

31200328 - Manual del operador y de mantenimiento (Modelo TL642).pdf

31200329 - Manual de Operação e Manutenção (Modelo TL642).pdf

31200330 - Manuel d’utilisation et de maintenance (Modèle TL943).pdf

31200331 - Manual del operador y de mantenimiento (Modelo TL943).pdf

31200334 - Manual del operador y de mantenimiento (Modelos TL1055, TL1255).pdf

31200335 - Manual de Operação e Manutenção (Modelos TL1055, TL1255).pdf

31200337 (SSBU9288) - Manual de Operação e Segurança (Plataforma de Trabalho de Pessoal do Manipulador Telescópico).pdf

31200338 (SPBU9288) - Manual de Operação e Segurança (Plataforma de Trabalho de Pessoal do Manipulador Telescópico).pdf

31200701 - Operation & Maintenance Manual (Model TL943).pdf

31200708 - Manual del operador y de mantenimiento (Modelo TL943).pdf

31200723 - Parts Manual (Models TL642C, TL943C).pdf

31200724 - Parts Manual (Models TL1055C, TL1255C).pdf

31200747 (SEBU9289) - Operation & Maintenance Manual (Models TL642C, TL943C).pdf

31200748 (SEBU9290) - Operation & Maintenance Manual (Models TL1055C, TL1255C).pdf

31200793 - Service Manual (Models TL1055C, TL1255C).pdf

31200794 - Service Manual (Models TL642C, TL943C).pdf

31200817 (SSBU9290) - Manual del operador y de mantenimiento (Modelos TL1055C, TL1255C).pdf

31200818 (SPBU9290) - Manual de Operação e Manutenção (Modelos TL1055C, TL1255C).pdf

31200820 (SSBU9289) - Manual del operador y de mantenimiento (Modelos TL642C, TL943C).pdf

31200821 (SPBU9289) - Manual de Operação e Manutenção (Modelos TL642C, TL943C).pdf

31200827 - Electrical Schematic (Models TL1055C, TL1255C).pdf

31200828 - Electrical Schematic (Models TL1055C, TL1255C).pdf

31200829 - Electrical Schematic (Models TL642C & TL943C).pdf

31200830 - Electrical Schematic (Models TL642C & TL943C).pdf

31211035 (SEBU9293) - Operation & Maintenance Manual (Models TL642D, TL943D, TL1055D, TL1255D).pdf

31211037 (SFBU9293) - Manuel d'utilisation et de maintenance (Modèles TL943D, TL1055D. TL1255D).pdf

31211065 (SSBU9293) - Manual del operador y de mantenimiento (Modelos TL642D, TL943D, TL1055D, TL1255D).pdf

31211066 (SDBU9293) - Manual de Operação e Manutenção (Modelos TL642D, TL943D, TL1055D, TL1255D).pdf

TABLE OF CONTENTS

31200162 - JLG Drive Axle Supplemental Repair Manual (Models 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013, 4017, G6-42A, 642, TF6-42, TL642, & TL642C)....1

31200162_C_Dana_Axle_ASM-0025E_212....1

CONTENTS....5

INTRODUCTION....9

SPECIFICATIONS....11

SAFETY PRECAUTIONS....19

CHECKING WEAR AND REPLACING THE BRAKING DISCS....21

COMPLETE STEERING CASE....27

DOUBLE U-JOINT....31

PLANETARY REDUCTION GEAR....37

STEERING CYLINDER....49

DIFFERENTIAL UNIT....63

BEVEL PINION....69

MANUAL EMERGENCY RELASE....85

MECHANICAL PARKING BRAKE....89

EXTERNAL HYDRAULIC NEGATIVE BRAKE....95

EXTERNAL HYDRAULIC NEGATIVE BRAKE WITH QUICK RELEASE....99

INCOMING DRUM BRAKE....105

4" INCOMING BRAKE (2 AND 3 FUNCTION VERSIONS)....113

NORMAL DIFFERENTIAL UNIT....127

LIMITED SLIP DIFFERENTIAL UNIT (25% AND 45%)....135

HYDRAULIC DIFFERENTIAL LOCK....145

HYDRAULIC NEGATIVE BRAKE....153

INCORPORATED REDUCTION GEAR AND PINION 602....163

31200239 - JLG Drive Axle Supplemental Repair Manual (Models G9-43A, G10-43A, 943, 1043, 1055, 1255, TL943, TL943C, TL1055C, TL1255C)....181

31200239_E_Dana Axle_ASM-0029E....181

CONTENTS....185

INTRODUCTION....187

SPECIFICATIONS....188

DEFINITION OF VIEWPOINTS....188

DATA PLATE....188

CONVERSION TABLES....189

TORQUE SPECIFICATIONS....190

COARSE PITCH....190

FINE PITCH....190

WHEEL NUT TIGHTENING TORQUES....191

MAINTENANCE....192

MAINTENANCE POINTS....192

MAINTENANCE INTERVALS....193

ADJUSTMENT AND CHECKS....193

LUBRICANT & SEALANT SPECIFICATIONS....194

SAFETY PRECAUTIONS....195

PLANETARY REDUCTION GEAR....197

EXPLODED VIEW....197

DISASSEMBLY....198

ASSEMBLY....202

SPECIAL TOOLS....206

T1....206

T2....206

T3....207

T4....208

T5....209

T6....210

COMPLETE STEERING CASE....211

EXPLODED VIEW....211

DISASSEMBLY....212

ASSEMBLY....213

STEERING CYLINDER....215

EXPLODED VIEW....215

DISASSEMBLY....216

ASSEMBLY....219

SPECIAL TOOLS....225

T1....225

T2....225

U-JOINT....227

EXPLODED VIEW....227

DISASSEMBLY....228

ASSEMBLY....229

SPECIAL TOOLS....230

T1....230

T2....230

BRAKE WEAR CHECK PROCEDURE....231

OLD VERSION....231

NEW VERSION....232

SPECIAL TOOLS....233

T1....233

SERVICE BRAKE AND NEGATIVE PARKING BRAKE....235

EXPLODED VIEW....235

DISASSEMBLY....236

ASSEMBLY....239

RELEASE....245

ADJUST....245

DIFFERENTIAL UNIT....247

EXPLODED VIEW....247

DISASSEMBLY....248

ASSEMBLY....252

SPECIAL TOOLS....257

T1....257

BEVEL PINION....259

EXPLODED VIEW....259

DISASSEMBLY....260

ASSEMBLY....263

SPECIAL TOOLS....268

T1....268

T2....269

T3....269

T4....270

T5....271

LIMITED SLIP DIFFERENTIAL UNIT 45%....273

EXPLODED VIEW....273

DISASSEMBLY....274

ASSEMBLY....276

SWINGING SUPPORT....277

EXPLODED VIEW....277

DISASSEMBLY....278

ASSEMBLY....279

31200247 - Operation & Maintenance Manual (Model TL642)....285

31200247_F_TL642_CAT_OMM....285

Revision Log....287

Read This First....288

Table of Contents....291

Section 1 - General Safety Practices....295

1.1 Hazard Classification System....295

Safety Alert System and Safety Signal Words....295

1.2 General Precautions....295

1.3 Operation Safety....296

Electrical Hazards....296

Tip Over Hazard....297

Travel Hazard....300

Load Falling Hazard....301

Lifting Personnel....302

Driving Hazards on Slopes....303

Pinch Points and Crush Hazards....304

Fall Hazard....306

Chemical Hazards....307

Section 2 - Pre-Operation and Inspection....309

2.1 Pre-Operation Check and Inspection....309

2.2 Safety Decals....311

2.3 Walk-Around Inspection....316

2.4 Warm-Up and Operational Checks....318

Warm-Up Check....318

Operational Check....318

2.5 Operator Cab....319

2.6 Windows....320

Cab Door Window (if equipped)....320

Section 3 - Controls and Indicators....321

3.1 General....321

3.2 Controls....322

Dash Controls and Indicators....324

Ignition....326

Park Brake....327

Parking Procedure....327

Transmission Control Lever....328

Boom Joystick....330

Frame Level Joystick....331

Outrigger Joysticks (if equipped)....332

Auxiliary Hydraulic Joystick....333

Right Hand Panel (S/N TBK01167 & After including TBK01162)....334

Heater and Air Conditioning Controls (Before S/N TBK01167 excluding TBK01162, if equipped)....335

Accessory Control Lever (if equipped)....336

3.3 Steer Modes....337

Steer Mode Change....337

3.4 Operator Seat....338

Adjustments....338

Seat Belt....339

3.5 Boom Angle and Extension Indicators....340

Section 4 - Operation....341

4.1 Engine....341

Starting the Engine....341

Extreme Cold Weather Starting (if equipped)....342

Battery Boosted Starting....343

Normal Engine Operation....344

Shut-Down Procedure....344

4.2 Operating with a Non-Suspended Load....345

Lift Load Safely....345

Picking Up a Load....345

Transporting a Load....346

Leveling Procedure....346

Placing a Load....347

Disengaging a Load....347

4.3 Operating with a Suspended Load....348

Lift Load Safely....348

Picking Up a Suspended Load....348

Transporting a Suspended Load....349

Leveling Procedure....349

Placing a Suspended Load....350

Disengaging a Suspended Load....350

4.4 Loading and Securing for Transport....351

Tiedown....351

Lifting....352

Section 5 - Attachments....353

5.1 Approved Attachments....353

5.2 Unapproved Attachments....353

5.3 JLG Supplied Attachments....354

5.4 Telehandler/Attachment/Fork Capacity....356

5.5 Use of the Load Chart....357

Capacity Indicator Locations....357

Sample Load Chart....358

Example....360

5.6 Attachment Installation....361

Mechanical Quick Coupler....362

Hydraulic Quick Coupler....363

5.7 Hydraulic Operated Attachment....365

5.8 Adjusting/Moving Forks....366

5.9 Attachment Operation....368

Carriage w/Forks....369

Side Shift Carriage....370

Rotate/Side Tilt Carriage....372

Swing Carriage....374

Bucket....376

Multi-Purpose Bucket....378

Fork Mounted Hook....380

Coupler Mounted Hook....382

Truss Boom....383

Personnel Work Platform - Fork Mounted....384

Boom Head-Mounted Winch....386

Section 6 - Emergency Procedures....387

6.1 Towing a Disabled Product....387

Moving Short Distances....387

Moving Longer Distances....387

6.2 Emergency Lowering of Boom....388

6.3 Emergency Exit from Enclosed Cab....388

Section 7 - Lubrication and Maintenance....389

7.1 Introduction....389

Clothing and Safety Gear....389

7.2 General Maintenance Instructions....390

7.3 Service and Maintenance Schedule....391

10, 1st 50 & 50 Hour Maintenance Schedule....391

1st 250, 250 & 500 Hour Maintenance Schedule....392

1000 & 1500 Hour Maintenance Schedule....393

7.4 Lubrication Schedules....394

50 Hour Lubrication Schedule....394

250 Hour Lubrication Schedule....395

1000 Hour Lubrication Schedule....396

7.5 Operator Maintenance Instructions....398

Fuel System....398

Air Intake System....400

Engine Oil....402

Hydraulic Oil....403

Tires....404

Transmission Oil....407

Engine Cooling System....408

Battery....410

Windshield Washer System (if equipped)....411

Section 8 - Additional Checks....413

Section 9 - Specifications....415

9.1 Product Specifications....415

Fluids....415

Capacities....417

Tires....418

Performance....419

Dimensions....420

Index....423

Inspection, Maintenance and Repair Log....427

31200248 - Operation & Maintenance Manual (Model TL943)....433

31200248_G_TL943_CAT_OMM....433

Revision Log....435

Read This First....436

Table of Contents....439

Section 1 - General Safety Practices....443