PDF Service Manual Cat TL642C TL943C - 3 MB
This is the complete service manual for the Cat TL642C and TL943C telehandlers.
It provides comprehensive instructions for maintenance, troubleshooting, and major repairs.
Technicians will find detailed information on the engine, hydraulics, transmission, and electrical systems.
This manual is the official factory guide for keeping your Cat telehandlers performing at their best.
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--- Page 1 ---
Service Manual
Models
TL642C
TL943C
S/N THG00150 & After
S/N THL00150 & After
S/N THH00150 & After
S/N SXH00150 & After
31200794
Revised
October 14, 2014
--- Page 3 ---
Safety Practices
1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards
SOLVENTS: Only use approved solvents that are known
Following are general safety statements to consider before
to be safe for use.
performing maintenance procedures on the telehandler.
Additional statements related to specific tasks and HOUSEKEEPING: Keep the work area and operator cab
procedures are located throughout this manual and are clean, and remove all hazards (debris, oil, tools, etc.).
listed prior to any work instructions to provide safety FIRST AID: Immediately clean, dress and report all injuries
information before the potential of a hazard occurs. (cuts, abrasions, burns, etc.), no matter how minor the
For all safety messages, carefully read, understand and injury may seem. Know the location of a First Aid Kit, and
follow the instructions before proceeding. know how to use it.
CLEANLINESS: Wear eye protection, and clean all
1.6.1 Personal Hazards components with a high-pressure or steam cleaner
PERSONAL SAFETY GEAR: Wear all the protective before attempting service.
clothing and personal safety gear necessary to perform When removing hydraulic components, plug hose ends
the job safely. This might include heavy gloves, safety and connections to prevent excess leakage and
glasses or goggles, filter mask or respirator, safety shoes contamination. Place a suitable catch basin beneath the
or a hard hat. machine to capture fluid run-off.
LIFTING: NEVER lift a heavy object without the help of at It is good practice to avoid pressure-washing electrical/
least one assistant or a suitable sling and hoist. electronic components. In the event pressure-washing
the machine is needed, ensure the machine is shut down
1.6.2 Equipment Hazards before pressure-washing. Should pressure-washing be
utilized to wash areas containing electrical/electronic
LIFTING OF EQUIPMENT: Before using any lifting
components, it is recommended a maximum pressure of
equipment (chains, slings, brackets, hooks, etc.), verify
750 psi (52 bar) at a minimum distance of 12 in (30,5 cm)
that it is of the proper capacity, in good working order, and
away from these components. If electrical/electronic
is properly attached.
components are sprayed, spraying must not be direct and
NEVER stand or otherwise become positioned under a for brief time periods to avoid heavy saturation,
suspended load or under raised equipment. The load or
Check and obey all Federal, State and/or Local
equipment could fall or tip.
regulations regarding waste storage, disposal and
DO NOT use a hoist, jack or jack stands only to support recycling.
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load.
HAND TOOLS: Always use the proper tool for the job;
keep tools clean and in good working order, and use
special service tools only as recommended.
TL642C, TL943C 1-3
--- Page 4 ---
General Information and Specifications
2.3.2 Metric Fastener Torque Chart
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*
CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque
Torque TM or 271TM
Tensile Stress Clamp Load Torque TM TM (Loctite® 242
Size Pitch Torque (Lube) (Loctite® 262 or 271
Area See Note 4 (Dry or Loctite® 263TM) or Vibra-TITE TM
111
or Vibra-TITETM 131)
or 141)
Sq mm KN [N.m] [N.m] [N.m]
3 0.5 5.03 2.19 1.3 1.0 1.2 1.4
3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.
TL642C, TL943C 2-9
--- Page 5 ---
General Information and Specifications
Ambient Temperature Range
Compartment or
Type and Classification Viscosities °F °C
System
Min Max Min Max
Boom Wear Pad
CAT Advanced 3Moly NLGI Grade 2 -4 104 -20 40
Grease
Cylinder and Axle
CAT Multipurpose NLGI Grade 2 -22 104 -30 40
Grease
Boom Chain
Schaffer 200S Silver Streak
Lubricant
Cat DEAC 50/50 Mix Standard
Engine Coolant
(Glycol and Water) 60/40 Mix Cold Weather
#2 Diesel Standard
Ultra Low Sulfur
Fuel Blend of #1 diesel and #2 (S < 15 mg/kg) Cold Weather
diesel fuels (“winterized” #2)
Air Conditioning Refrigerant R-134a Tetrafluorethane
Note: Friction Modifier (CAT Brake Oil Additive P/N 197-0017) required for axle differentials, see Section b,
“Capacities.”
TL642C, TL943C 2-19
--- Page 6 ---
General Information and Specifications
c. 1000 Hour
EVERY
1000
B B
IF EQUIPPED
OAL2680
TL642C, TL943C 2-29
--- Page 7 ---
Boom
3.5.4 Push Beam - Extend/Retract Cylinder
Installation and Third Boom Section
Assembly
14
Note: Inspect the wear pad surfaces of the second and
third boom sections. Verify all areas are clean and free of
19 any weld spatter, paint, etc., before beginning the re-
assembly procedure.
18 Note: Inspect and lubricate all extend and retract chains
before re-assembly. Refer to Section 3.12, “Boom
Extend and Retract Chains,” for detailed information.
1. Place the third boom section onto suitable supports.
20 MY3930 2. Clean and lubricate the bottom and sides of the third
boom section where the push beam guide bar
7. Remove the guide bar (18) and chain retainer (19).
travels.
Remove the push beam wear pad (20).
3. Place a sling or using two slings for better stability,
8. Lower the push beam assembly and remove the pry
lift and slowly push the push beam assembly
bars.
approximately half way into the third boom section.
9. Push/pull the push beam assembly along with the Lower the push beam onto a suitable support.
extend chain, to the front of the third boom section. 4. Relocate the sling and slowly insert the push beam
assembly into the front of the third boom section.
NOTICE
Guide the push beam/extend/retract cylinder
NOTICE
assembly over the top of the retract chain anchor at
Guide the push beam/extend/retract cylinder
the rear of the third boom section being careful not to
assembly over the top of the retract chain anchor at
damage any components.
the rear of the third boom section being careful not to
10. Place a sling around the push beam assembly. Lift damage any components.
and slowly pull the push beam assembly
approximately half way out of the third boom section.
Lower the push beam onto a suitable support.
6
11. Relocate the sling or using two slings for better
stability, balance the push beam assembly and
slowly pull the push beam assembly out of the third 5
boom section. Lower the push beam assembly onto
suitable supports. 7
12. Remove all remaining brackets, clevises, hoses,
wear pads, shims, backing plates and hardware from
the second and third boom sections. Label all parts 8
and hardware being removed from each section.
4
MY3930
Note: Inspect all chains, hoses and sheaves for wear
and/or damage and replace as needed. 5. Install the push beam wear pad (4) to the previously
removed chain retainer (5) using two bolts and two
washers. Torque as required.
6. Lift the push beam assembly (6) with pry bars using
the access holes on each side of the third boom
section and install the guide bar (7) and chain
retainer (5) using the previously removed hardware
(8). Torque to 25-30 lb-ft (34-41 Nm).
TL642C, TL943C 3-9
--- Page 8 ---
Boom
15. Install the belleville washers (13) to the extend chain
anchor (14) as previously removed at the rear of the
first boom section.
16. Install the adjustment and lock nut, (15) to the
10 10 extend chain anchor (14) at the rear of the first boom
section.
12 12
TL642C
16
11 11 TL943C
18 17
MAL2640
MAL1290
17. Remove the rope or wire from the retract chain (16).
13. Install both push beam pins (10) being careful to 18. Install the belleville washers (17) to the retract chain
align the pin mounting bolt holes. clevis (16) as previously removed at the bottom front
Note: Disconnecting one or both extend/retract of the first boom section.
hydraulic tubes (11) may be required to gain access to 19. Install the adjustment and lock nut (18) to the retract
the hose guide mounting bolts. After installing both hose chain clevis (16) at the bottom front of the first boom
guides, re-connect one or both extend/retract hydraulic section.
tubes BEFORE preceding.
Note: Note the position of the belleville washer for
14. Install the tilt cylinder hose guide (12) and the reassembly.
auxiliary hose guide from the rear of the third second
section.
14 TL642C
20
13
15
TL943C
19
MAL1310
20. Install both hose retainer brackets (19).
21. Remove the plugs and caps from the tilt hoses and
auxiliary hoses.
22. Connect both tilt hoses (20) and both auxiliary hoses
MAL2650
(not shown) to the hose retainer brackets (19) at the
Note: Note the position of the belleville washers for bottom front inside the boom.
reassembly. 23. Properly connect the battery.
TL642C, TL943C 3-19
--- Page 9 ---
Boom
Cracked Plates 3.12.4 Chain Lubrication
Inspect the chains very carefully, front and back as After inspection and before being returned to service,
well as side to side, for any evidence of cracked chains must be lubricated. Refer to Section 2.5, “Fluids
plates. If any one crack is discovered, the chain and Lubricant Capacities,” for proper lubricant.
should be replaced in its entirety.
The lubricant must penetrate the chain joint to prevent
It is important, however to determine the cause of wear. Applying lubricant to the external surfaces will
the crack before installing a new chain so the prevent rust, but the chains should be articulated to
condition does not repeat itself. make sure the lubricant penetrates to the working
surfaces between the pins and links.
The types of cracks are:
To prepare the chain for lubrication, the chain plates
• Fatigue Cracking - should be brushed with a stiff brush or wire brush to
9
Fatigue cracks (9) are a clear the space between the plates so that lubricant can
result of repeated penetrate to the working surfaces.
cyclic loading beyond MZ1467
the chain’s endurance Lubricant may be applied with a narrow paint brush or
limit. directly poured on, but the chain should be well flooded
with lubricant and the boom should be extended and
• Stress Corrosion retracted to be sure that the lubricant penetrates to the
Cracking - The working surfaces. All surplus lubricant should be wiped
outside link plates 10
away from the external surfaces. DO NOT use a solvent
are particularly MZ1468
for this wiping operation.
susceptible to stress
corrosion cracking (10). Regular application of lubricant is necessary to make
sure that all working surfaces are adequately lubricated.
• Corrosion Fatigue Cracking - Corrosion In extremely dusty conditions, it may be necessary to
fatigue cracks are very similar to fatigue lubricate the chains more often. Refer to Section 2.6,
cracks in appearance. Corrosion fatigue is the “Service and Maintenance Schedules,” and Section 2.7,
combined action of an aggressive “Lubrication Schedules,” for detailed information.
environment and cyclic stress.
Lubrication of chains on machines working consistently
Other Modes of Failure in extreme hot or cold conditions requires special
• Ultimate Strength Failure - consideration. Contact the local Caterpillar dealer for
These types of failures are guidance.
caused by overloads far in 1
excess of the design load. MZ1469
Either fractured plates (1) or 2
enlarged holes (2) can
occur. If either of these
MZ1470
failures occurs, the chain
should be replaced immediately.
• 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.
TL642C, TL943C 3-29
--- Page 10 ---
Cab and Covers
4.2 OPERATOR CAB 2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to
WARNING cool.
DO NOT service the machine without following all 4. Properly disconnect the battery.
safety precautions as outlined in the “Safety Note: It may be necessary to remove the main dash
Practices” section of this manual. panel to gain access to the appropriate hydraulic hoses.
Refer to Section 9.13, “Gauges and Display Monitor.”
4.2.1 Cab Safety 2
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.
WARNING 3
4
DO NOT weld, grind, drill, repair or modify the cab in
any way. Any modification or damage to cab structural
components requires cab replacement. Refer to the
Operation & Maintenance Manual. 4
To help ensure optimum safety, protection and
performance, replace the cab if it is damaged. Refer to
1
the appropriate parts manual for ordering information. MAL1430
4.2.2 Serial Number Decal 5. Label, disconnect and cap the four hoses from the
side of the steering valve (1). Cap the fittings on the
The cab serial number decal is located on the left side of steering valve. Label, disconnect and plug the load
the cab, behind the seat. Information specified on the sense hose at the front of the steering valve. Cap the
serial number plate includes the cab model number, the fitting on the steering valve.
cab serial number and other data. Write this information
6. Remove the steering wheel (2), disconnect and
down in a convenient location to use in cab
remove the travel select lever (3), disconnect the
correspondence.
instrument panel harness connector.
7. Remove the steering assembly through the dash
panel opening.
4.3 CAB COMPONENTS
8. Support the steering valve, and remove the four hex-
head capscrews and four lockwashers (4).
4.3.1 Steering Column and Orbitrol Valve
Note: DO NOT disassemble the orbitrol valve. The
a. Orbitrol Valve Removal orbitrol valve is not serviceable and must be replaced in
its entirety, if defective.
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 the (N)
NEUTRAL position, engage the parking brake and
turn the engine OFF.
TL642C, TL943C 4-3
--- Page 11 ---
Section 5
Axles, Drive Shafts, Wheels and Tires
Contents
PARAGRAPH TITLE PAGE
5.1 Axles, Drive Shafts, Wheels and Tires Component Terminology . . . . . . . . . . . 5-2
5.2 Axle Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Axle Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Axle Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.1 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.2 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4.3 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . 5-6
5.5 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.6 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.6.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5-10
5.6.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . 5-10
5.7 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.8 Towing a Disabled machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.8.1 Manually Releasing the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.8.2 Manually Resetting the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
TL642C, TL943C 5-1
--- Page 13 ---
Axles, Drive Shafts, Wheels and Tires
4. Tighten lug nuts in an alternating pattern as 3. Carefully tighten each release screw a 1/4 turn at a
indicated in figure. Torque to 350-400 lb-ft time in sequence until all have been turned on full
(475-542 Nm). turn 360°.
5. Remove machine from supports. 4. Repeat steps 1 thru 3 for the other side of the
6. Remove the Do Not Operate Tags from both the differential.
ignition key switch and the steering wheel. Note: After the machine has been towed to a secure
location, reactivate the parking brake. Carefully follow
the procedures from start to finish. Consult your local
service distributor or service department if you are
5.7 BRAKES
unsure about any part of the procedure, or for specific
Check the brake disks for wear every 1,000 hours of instructions concerning your particular situation.
operation or yearly.
5.8.2 Manually Resetting the Park Brake
For more information on brake disk inspection, refer to
the appropriate axle repair manual; Note: Block the wheels of the machine BEFORE
attempting to reset the machine’s park brake. Once the
TL642C
park brake is released the machine’s park brake AND
• Service Manual - P/N 31200162 service brakes are inoperable.
TL943C 5 5
• Service Manual - P/N 31200239
5.8 TOWING A DISABLED MACHINE
Towing a disabled machine should only be attempted as
a last resort, after exhausting all other options. Make
every effort to repair the machine, and move it under its 5
own power, before using the emergency towing 5 MZ1020