Tl1055 Service Manual

Service Manual
Models
TL1055
TL1255
S/N TBM00100 & After
S/N TBN00100 & After
31200293
Revised
May 21, 2012
EFFECTIVITY PAGE
September 29, 2006 - A - Original Issue Of Manual

August 3, 2007 - B - Revised pages 2.7, 2.9, 2.10, 6.3, 7.2, 7.10, 8.5, 8.7 & 9.10
October 1, 2008 - C - Revised page 2.10.
May 28, 2010 - D - Revised page numbering and pages 2-2 thru 2-9, 2-12 thru 2-20, 3-4 thru 3-28, 4-6 thru 4-10, 5-4,
5-5, 5-11, 6-3, 6-6, 7-4 thru 7-12, 8-5 thru 8-9, 8-22, 8-23, 9-4, 9-8 thru 9-12 & 9-15 thru 9-25.
May 16, 2011 - E - Revised 1-3, 2-3 thru 2-9, 2-12, 2-13, 2-15, 2-16, 6-6, 6-7, 6-10, 7-3, 7-5 thru 7-9, 7-11 thru 7-13, 7-16,
8-12, 9-2 thru 9-5, 9-12, 9-15 thru 9-19, 9-28 thru 9-32.
May 12, 2012 - F - Revised pages 2-11, 5-2, 5-9 & 8-7.
31200293 TL1055, TL1255 i

EFFECTIVITY PAGE
ii TL1055, TL1255 31200293

SECTION CONTENTS
Section Subject Page
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4 Fluids and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.5 Service and Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Section 3
Boom ........................................................... 3-1
3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Boom System - Four Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Complete Boom Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.5 Boom Section Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.6 Boom Section Separation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.7 Hose Carrier Assembly Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.8 Quick Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.9 Boom Head - Mounted Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.10 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.11 Boom Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.12 Boom Chain Inspection and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.13 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
TL1055, TL1255 i
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.7 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Section 6
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Transmission Specifications And Maintenance Information. . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5 Torque Convertor Diaphragm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.6 Transmission Cooler Thermal Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Section 7
Engine: CAT C4.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 Engine Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.8 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.10 Engine Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.6 Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.7 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.8 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
ii TL1055, TL1255
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.6 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
9.7 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.8 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.9 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.10 Cab Heater and Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.11 Solenoids, Sensors and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.12 Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.13 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.14 Engine Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
TL1055, TL1255 iii

iv TL1055, TL1255
Section 1
Safety Practices
Contents
PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
TL1055, TL1255 1-1

Safety Practices
1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

This service manual provides general directions for Place Do Not Operate Tags on the ignition key switch and
accomplishing service and repair procedures. Following the steering wheel before attempting to perform any
the procedures in this manual will help assure safety and service or maintenance. Remove key and disconnect
equipment reliability. battery leads.
Read, understand and follow the information in this
manual, and obey all locally approved safety practices, 1.5 SAFETY INFORMATION
procedures, rules, codes, regulations and laws.
To avoid possible death or injury, carefully read,
These instructions cannot cover all details or variations in understand and comply with all safety messages.
the equipment, procedures, or processes described, nor
provide directions for meeting every possible contingency In the event of an accident, know where to obtain medical
during operation, maintenance, or testing. When additional assistance and how to use a first-aid kit and fire
information is desired consult the local Caterpillar dealer. extinguisher/fire suppression system. Keep emergency
telephone numbers (fire department, ambulance, rescue
Many factors contribute to unsafe conditions: carelessness, squad/paramedics, police department, etc.) nearby. If
fatigue, overload, inattentiveness, unfamiliarity, even working alone, check with another person routinely to
drugs and alcohol, among others. For optimal safety, help assure personal safety.
encourage everyone to think, and to act, safely.
Appropriate service methods and proper repair 1.5.1 Safety Alert System and Signal Words
procedures are essential for the safety of the individual
doing the work, for the safety of the operator, and for the
safe, reliable operation of the machine. All references to
the right side, left side, front and rear are given from the
DANGER
operator seat looking in a forward direction.
Supplementary information is available from the DANGER indicates an imminently hazardous situation
manufacturer in the form of Service Bulletins, Service which, if not avoided, will result in death or serious injury.
Campaigns, Service Training Schools, the service
website, other literature, and through updates to the
manual itself. WARNING
1.2 DISCLAIMER
WARNING indicates a potentially hazardous situation
All information in this manual is based on the latest which, if not avoided, could result in death or serious
product information available at the time of publication. injury.
The manufacturer reserves the right to make changes
and improvements to its products, and to discontinue the
manufacture of any product, at its discretion at any time CAUTION
without public notice or obligation.
1.3 OPERATION & MAINTENANCE CAUTION indicates a potentially hazardous situation

MANUAL which, if not avoided, may result in minor or moderate
injury.
The mechanic must not operate the machine until the
Operation & Maintenance Manual has been read and
understood, training has been accomplished and
operation of the machine has been completed under the
supervision of an experienced and qualified operator.
An Operation & Maintenance Manual is supplied with
each machine and must be kept in the manual holder
located in the cab. In the event that the Operation &
Maintenance Manual is missing, consult the local
Caterpillar dealer before proceeding.
1-2 TL1055, TL1255
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 before
PERSONAL SAFETY GEAR: Wear all the protective 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.
TL1055, TL1255 1-3

Safety Practices
1.6.4 Operational Hazards PRESSURE TESTING: When conducting any test, only
use test equipment that is correctly calibrated and in good
ENGINE: Stop the engine before performing any service
condition. Use the correct equipment in the proper
unless specifically instructed otherwise.
manner, and make changes or repairs as indicated by the
VENTILATION: Avoid prolonged engine operation in test procedure to achieve the desired result.
enclosed areas without adequate ventilation.
LEAVING MACHINE: Lower the forks or attachment to
SOFT SURFACES AND SLOPES: NEVER work on a the ground before leaving the machine.
machine that is parked on a soft surface or slope. The
TIRES: Always keep tires inflated to the proper pressure
machine must be on a hard level surface, with the wheels
to help prevent tipover. DO NOT over inflate tires.
blocked before performing any service.
NEVER use mismatched tire types, sizes or ply ratings.
FLUID TEMPERATURE: NEVER work on a machine
Always use matched sets according to machine
when the engine, cooling or hydraulic systems are hot.
specifications.
Hot components and fluids can cause severe burns.
Allow systems to cool before proceeding. MAJOR COMPONENTS: Never alter, remove, or
substitute any items such as counterweights, tires,
FLUID PRESSURE: Before loosening any hydraulic or
batteries or other items that may reduce or affect the
diesel fuel component, hose or tube, turn the engine
overall weight or stability of the machine.
OFF. Wear heavy, protective gloves and eye protection.
NEVER check for leaks using any part of your body; use BATTERY: DO NOT charge a frozen battery.Charging a
a piece of cardboard or wood instead. If injured, seek frozen battery may cause it to explode. Allow the battery
medical attention immediately. Diesel fluid leaking under to thaw before jump starting or connecting a battery
pressure can explode. Hydraulic fluid and diesel fuel charger.
leaking under pressure can penetrate the skin, cause
infection, gangrene and other serious personal injury. 1.7 SAFETY DECALS
Relieve all pressure before disconnecting any
Check that all safety decals are present and readable on
component, part, line or hose. Slowly loosen parts and
the machine. Refer to the Operation & Maintenance
allow release of residual pressure before removing any
Manual supplied with machine for information.
part or component. Before starting the engine or applying
pressure, use components, parts, hoses and pipes that
are in good condition, connected properly and are
tightened to the proper torque. Capture fluid in an
appropriate container and dispose of in accordance with
prevailing environmental regulations.
RADIATOR CAP: The cooling system is under pressure,
and escaping coolant can cause severe burns and eye
injury. To prevent personal injury, NEVER remove the
radiator cap while the cooling system is hot. Wear safety
glasses. Turn the radiator cap to the first stop and allow
pressure to escape before removing the cap completely.
Failure to follow the safety practices could result in death
or serious injury.
FLUID FLAMABILTITY: DO NOT service the fuel or
hydraulic systems near an open flame, sparks or smoking
materials.
NEVER drain or store fluids in an open container. Engine
fuel and hydraulic fluid are flammable and can cause a
fire and/or explosion.
DO NOT mix gasoline or alcohol with diesel fuel. The
mixture can cause an explosion.
1-4 TL1055, TL1255

Section 2
General Information and Specifications
Contents

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.2.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.3 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.4 Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.3.5 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.3.6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.4 Fluids and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.5 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.5.1 10, 1st 50 & 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.5.2 1st 250, 250 & 500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.5.3 1000 & 1500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.6.1 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.6.2 250 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.6.3 1000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
TL1055, TL1255 2-1

2.1 REPLACEMENT PARTS AND

WARRANTY INFORMATION
MAL0350
1
Before ordering parts or initiating service inquiries, make

note of the machine serial number. The machine serial
number plate (1) is located on the left front frame rail
behind the left front tire.
Note: The replacement of any part on this machine with
any other than factory authorized replacement parts can
adversely affect the performance, durability, or safety of
the machine, and will void the warranty. JLG disclaims
liability for any claims or damages, whether regarding
property damage, personal injury or death arising out of
the use of unauthorized replacement parts.
A warranty registration form must be filled out by the local
Caterpillar dealer, signed by the purchaser and returned to
the manufacturer when the machine is sold and/or put
into use.
Registration activates the warranty period and helps to
assure that warranty claims are promptly processed. To
guarantee full warranty service, verify that the service
distributor has returned the business reply card of the
warranty registration form to the manufacturer.
2-2 TL1055, TL1255

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

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
Torque
Tensile Torque Torque (Loctite® 242TM or 271TM
Size TPI Bolt Dia Clamp Load TM
(Loctite® 262TM or Vibra-
Stress Area (Dry) Lubricated OR Vibra-TITE 111 or
TITETM 131)
140)
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
MY3141
TL1055, TL1255 2-3


(Continued)
SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Torque Torque
Torque
Tensile (Loctite® 242TM or 271TM (Loctite® 262TM or Vibra-
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
Stress Area
K= 0.20 OR Vibra-TITE TM 111 or TITETM 131)
140) K=.18 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
NO. 5000059 REV. J
3. * ASSEMBLY USES HARDENED WASHER
MY3151
2-4 TL1055, TL1255


(Continued)
SOCKET HEAD CAP SCREWS

Magni Coating (Ref 4150701)*
Torque
Torque
(Loctite® 242TM or 271TM
Tensile Clamp Load Torque (Loctite® 262TM
Size TPI Bolt Dia
Stress Area See Note 4 (Dry) K = .17 OR Vibra-TITE TM 111 or TM
or Vibra-TITE 131)
140 OR Precoat 85® K=0.15
K=0.16
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
NO. 5000059 REV. J
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.
MY3161
TL1055, TL1255 2-5


(Continued)
SOCKET HEAD CAP SCREWS

Zinc Yellow Chromate Fasteners (Ref 4150707)*
Torque
Torque
Torque (Loctite® 242TM or 271TM
Tensile Clamp Load (Loctite® 262TM
Size TPI Bolt Dia
Stress Area See Note 4
(Dry) OR Vibra-TITE TM 111 or TM
or Vibra-TITE 131)
K = .20 140 OR Precoat 85® K=0.15
K=0.18
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
NO. 5000059 REV. J
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.
MY3400
2-6 TL1055, TL1255

2.2.2 Metric Fastener Torque Chart
CLASS 8.8 METRIC BOLTS

CLASS 8 METRIC NUTS
Torque
Torque (Loctite®
Tensile Torque TM
Clamp Torque (Loctite® 262 242 or 271TM
TM
SizePITCH Stress (Dry or Loctite®
Load (Lub) OR Vibra- OR Vibra-
Area 263TM)
TITETM 131) TITETM 111 or
140)
Sq mm KN [N.m] [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
NO. 5000059 REV. J
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
MY3171 *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.
TL1055, TL1255 2-7


(Continued)
CLASS 10.9 METRIC BOLTS

CLASS 10 METRIC NUTS
CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
Torque
Torque (Lub OR Loctite® Torque
Tensile
Clamp (Dry or Loctite® 242TM or 271TM OR (Loctite® 262TM OR
SizePITCH Stress
Load 263TM) Vibra-TITE TM 111 or Vibra-TITE TM 131)
Area
K = 0.20 140) K=0.15
K= 0.18
Sq mm KN [N.m] [N.m] [N.m]
3 0.5 5.03 3.13

3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25.2 22.7 18.9
8 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 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395
NO. 5000059 REV. J
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
MY3181 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
2-8 TL1055, TL1255


(Continued)
Magni Coating (Ref 4150701)*
CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*
Torque
Torque
Torque (Lub OR Loctite®
Tensile TM TM (Loctite® 262TM
Clamp Load (Dry or Loctite® 242 or 271
SizePITCH Stress OR Vibra-TITE TM
See Note 4 263TM) OR Vibra-TITE TM
Area 131)
K = .17 111 or 140)
K = .15
K = .16
Sq mm kN [N.m] [N.m] [N.m]
3 0.5 5.03
3.5 0.6 6.78
4 0.7 8.78
5 0.8 14.20
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 54
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 220.0 900 845 790
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395
NO. 5000059 REV. J
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
MY3191
TL1055, TL1255 2-9

2.2.3 Hydraulic Hose Torque Chart Flats Method:

1. If equipped, lubricate o-ring with hydraulic oil. Hand
O-Ring Face Seal & JIC Torque Chart tighten the swivel nut until no lateral movement of
the swivel nut can be detected. Average hand torque
Size ORFS JIC Flats Method
is 3 lb-ft (4 Nm).
13 lb-ft 13 lb-ft 2. Mark a dot on one of the swivel nut flats and another
4 1.5 to 1.75
(18 Nm) (18 Nm) dot in line on the hex of the adapter it’s connecting
23 lb-ft 23 lb-ft to.
6 1 to 1.5
(31 Nm) (31 Nm) 3. Use the double wrench method while tightening to
40 lb-ft 40 lb-ft avoid hose twist.
8 1.5 to 1.75
(54 Nm) (54 Nm) 4. After the connection has been properly tightened,
mark a straight line across the connecting parts, not
60 lb-ft 60 lb-ft
10 1.5 to 1.75 covering the dots indicating that the connection has
(81 Nm) (81 Nm)
been properly tightened.
74 lb-ft 85 lb-ft
12 1.0 to 1.5
(100 Nm) (115 Nm)
115 lb-ft 115 lb-ft
16 0.75 to 1.0
(156 Nm) (156 Nm)
170 lb-ft 170 lb-ft
20 0.75 to 1.0
(230 Nm) (230 Nm)
200 lb-ft 200 lb-ft
24 0.75 to 1.0
(271 Nm) (271 Nm)
270 lb-ft
32 N/A 0.75 to 1.0
(366 Nm)
Note: By definition the “Flats Method“ will contain some

variance. Use the “Flats Method” only when accessibility
with a torque wrench is not possible.
Torque Wrench:
1. Identify the appropriate application and refer to the
above chart for the correct torque value.
2. 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).
3. Use the double wrench method while tightening to
avoid hose twist.
4. Torque wrench must be held at the center of the grip.
Apply constant force until it clicks.
5. After the connection has been properly tightened,
mark a straight line across the connecting parts
indicating that the connection has been properly
tightened.
2-10 TL1055, TL1255

2.3 SPECIFICATIONS
2.3.1 Travel Speeds
TL1055 TL1255
First Gear 3.4 mph (5,4 km/h) 3.2 mph (5,1 km/h)
Second Gear 6.1 mph (9,8 km/h) 5.8 mph (9,3 km/h)
Third Gear 13.3 mph (21,4 km/h) 13.0 mph (20,9 km/h)
Fourth Gear 20.0 mph (32,2 km/h) 18.9 mph (30,4km/h)
2.3.2 Hydraulic Cylinder Performance

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

FUNCTION
TL1055 TL1255
Boom Extend (Boom Level) 17.7 17.6
Boom Retract (Boom Level) 15.3 13.9
Boom Lift 13.3 15.7
Boom Lower 11.0 13.9
Attachment Tilt Forward 5.9 6.7
Attachment Tilt Rearward 7.0 7.85
Frame Level - Full Right to Left 7.5 9.8
Frame Level - Full Left to Right 5.0 10.0
Outrigger - Down 4.8 5.0
Outrigger - Up 3.8 4.2
2.3.3 Cylinder Drift
MAXIMUM ROD TRAVEL

CYLINDER
(loaded or unloaded)
Lift/Lower Cylinder 0.125 in (3.2 mm) per hour
Extend/Retract Cylinder 0.125 in (3.2 mm) per hour
Attachment Tilt Cylinder 0.125 in (3.2 mm) per hour
TL1055, TL1255 2-11

2.3.4 Electrical System
Battery
Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free
Quantity 1
Reserve Capacity 1,000 Cold Cranking Amps @ 0° F (-18° C)
Group/Series Group 31
Alternator
TL1055 - Before S/N TBM00366
12V, 85 Amps
TL1255 - Before S/N TBN00206
TL1055 - S/N TBM00366 & After
12V, 100 Amps
TL1255 - S/N TBN00206 & After
2.3.5 Engine Performance Specifications
Description TL1055 TL1255

Engine Make/Model CAT C4.4 Acert CAT C4.4 Acert
Displacement 269 in³ (4,4 liters) 269 in³ (4,4 liters)
Low Idle 1000 rpm 900 rpm
High Idle 2,400 to 2,600 rpm 2,400 to 2,600 rpm
Horsepower 126 HP (94 kW) @ 2400 rpm 141 HP (105 kW) @ 2400 rpm
Peak Torque 364 lb-ft (494 Nm) @ 1400 rpm 394 lb-ft (534 Nm) @ 1400 rpm
Fuel Delivery Electronic Fuel Injection Electronic Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and Dry Type, Replaceable Primary and
Safety Elements Safety Elements
2-12 TL1055, TL1255

2.3.6 Tires
Note: Standard wheel lug nut torque is 350-400 lb-ft (475-542 Nm).
Note: Pressure for foam filled tires are for initial fill ONLY.
a. TL1055
Size Tire Type Minimum Fill Type Pressure

Ply/Star
Rating
Pneumatic 65 psi (4,5 bar)
14.00 x 24 G-2/L-2 Bias Ply Traction 12 Ply
Foam - Approx 720 lb (327 kg) 62 psi (4,3 bar)
14.00 x 24 G-3/L-3 Bias Ply Rock 12 Ply
14.00 x 24 G-2/L-2 Radial 1 Star
14.00 x 24 Solid - 1038 lb (470 kg)
17.50 x 25 E-2/L-2 Radial 1 Star
400/75x28 DuraForce 14 Ply
Foam-Approx 570 lb (259 kg) 73 psi (5,0 bar)
b. TL1255
Size Tire Type Minimum Ply/ Fill Type Pressure

Star Rating
17.50 x 25 E-2/L-2 Radial 1 Star
400/75x28 DuraForce 14 Ply
Foam-Approx 570 lb (259 kg) 73 psi (5,0 bar)
TL1055, TL1255 2-13

2.4 FLUIDS AND LUBRICANT

CAPACITIES
a. Fluids
Ambient Temperature Range

Compartment or
Type and Classification Viscosities °F °C
System
Min Max Min Max
SAE 0W-20 -40 50 -40 10
SAE 0W-30 -40 86 -40 30
Cat DEO Multigrade
SAE 0W-40 -40 104 -40 40
Cat DEO SYN
SAE 5W-30 -22 86 -30 30
Engine Crankcase Cat Arctic DEO SYN
SAE 5W-40 -22 122 -30 50
Cat ECF-1
SAE 10W-30 0 104 -18 40
API CG-4 Multigrade
SAE 10W-40 0 122 -18 40
SAE 15W-40 15 122 -9.5 50
Transmission and Cat MTO -10 104 -23 40

Transfer Case Dextron or Mercron ATF -40 14 -42 -1
Cat Synthetic Gear Oil (GO) SAE 75W-140 -22 113 -30 45
Axle Differentials* Cat Gear Oil (GO) SAE 80W-90 -10 120 -23 49
and Wheel Ends Cat Gear Oil (GO) SAE 85W-140 10 120 -12 59
Cat TDTO-TMS Cat TDTO-TMS -4 122 -20 50
SAE 0W-20 -40 104 -40 40
SAE 0W-30 -40 104 -40 40
SAE 5W-30 -22 104 -30 40
Cat TDTO
SAE 5W-40 -22 104 -30 40
Cat TDTO-TMS
Hydraulic System SAE 10W -4 104 -20 40
Cat Arctic TDTO SYN
SAE 30 50 122 10 50
Commercial TO-4
SAE 10W-30 -4 104 -20 40
SAE 15W-40 5 122 -15 50
Cat TDTO-TMS -4 122 -20 50
Boom Wear Pad
Cat Advanced 3Moly NLGI Grade 2 -4 104 -20 40
Grease
Cylinder and Axle
Cat Multipurpose NLGI Grade 2 -22 104 -30 40
Grease
Cat Extended Life Coolant 50/50 Mix Standard

Engine Coolant
(ELC) 60/40 Mix Cold Weather
2-14 TL1055, TL1255

Ambient Temperature Range

Compartment or
Type and Classification Viscosities °F °C
System
Min Max Min Max
#2 Diesel Standard
Fuel Blend of #1 diesel and #2 Low Sulfur
Cold Weather
diesel fuels (“winterized” #2)
Air Conditioning Refrigerant R-134a Tetrafluorethane
Note: Friction Modifier (CAT Brake Oil Additive) required for axle differentials, see Section b, “Capacities.”
b. Capacities
Engine Crankcase Oil

Capacity with Filter Change
TL1055 Before S/N TBM01316 excluding TBM01298
7 quarts (6,5 liters)
TL1255 Before S/N TBN00799 excluding TBN00785
TL1055 S/N TBM01316 & After including TBM01298
TL1255 S/N TBN00799 & After including TBN00785
Fuel Tank
Capacity 38 gallons (144 liters)
Cooling System
System Capacity
20.5 quarts (19,4 liters)
Overflow Bottle Capacity
Hydraulic System
System Capacity
TL1055 63 gallons (238 liters)
TL1255 65 gallons (246 liters)
Reservoir Capacity
35 gallons (132 liters)
37.5 gallons (142 liters)
Auxiliary Hydraulic Circuit Max Flow 10 gpm (37.9 lpm)
TL1055, TL1255 2-15
Transmission
Capacity with Filter Change 4.23 gallons (16 liters)
Transfer Case
Capacity 1.5 quarts (1,4 liters)
Axles
Differential Housing Capacity
Front Axle 20.9 quarts (19.8 liters)
Rear Axle 16.9 quarts (16 liters)
Friction Modifier (differential only)
Front Axle 32 oz (946 ml)
Rear Axle 26 oz (768 ml)
Wheel End Capacity 2 quarts (1,9 liters)
Air Conditioning System (if equipped)
System Capacity 2.5 lb (1134 g)
2-16 TL1055, TL1255

2.5 SERVICE AND MAINTENANCE

SCHEDULES
2.5.1 10, 1st 50 & 50 Hour
EVERY
10
Check Fuel Air Filter Check Engine Check Hydraulic Check Tire
Level Restriction Oil Level Oil Level Condition &
Indicator Pressure
Check Check Auto-

Transmission Sway Function
Oil Level (if equipped)*
1st
50
LB/F
T (N
m)
Check Wheel
Lug Nut
Torque
EVERY
50
Drain Fuel/ Check Engine Check Check Washer Lubrication

Water Coolant Level Battery Fluid Level Schedule
Separator (if equipped)
MAL0153
Note: Auto-Frame Level Function Check TL1055 Before S/N TBM01168 & TL1255 Before S/N TBN00664.
TL1055, TL1255 2-17
2.5.2 1st 250, 250 & 500 Hour
1st
250
Change Change Wheel Change Change

Axle Oil End Oil Transmission Transfer Case
Oil & Filter Oil
EVERY
250
Change Engine Check Axle Check Wheel Air Filter Check

Oil and Oil Level End Oil Levels Vacuator Fan Belt
Filter* Valve
Check Boom Check Boom Check Transfer Check Lubrication

Extend Chains Wear Pads Case Oil Level Rear Axle Schedule
Stabilization
EVERY
500
LB/F
T (N
m)
Change Fuel Check Wheel

Filters Lug Nut
Torque
MAL0791
Note: Engine oil and filter service interval can be extended. See Engine Manual for details.
2-18 TL1055, TL1255

2.5.3 1000 & 1500 Hour
EVERY
1000
Change Change Change Change Wheel Check

Transmission Transfer Case Axle Oil End Oil Air Intake
Oil & Filter Oil System
Check Boom Lubrication

Retract Chains Schedule
EVERY
1500
Change Change Change

Engine Coolant Hydraulic Hydraulic Tank
Fluid & Filters Breather
OAL2291
TL1055, TL1255 2-19

2.6 LUBRICATION SCHEDULES
2.6.1 50 Hour
EVERY
50
OAL0450
2-20 TL1055, TL1255

2.6.2 250 Hour
EVERY
250
OW1211
TL1055, TL1255 2-21

2.6.3 1000 Hour
EVERY
1000
OY2080
2-22 TL1055, TL1255

Section 3
Boom
Contents

3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Boom System - Four Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Complete Boom Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4.1 Complete Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4.2 Complete Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.5 Boom Section Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.5.1 Second, Third & Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . 3-6
3.5.2 Third & Fourth Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.5.3 Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.5.4 Hose Carrier Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.5 Fourth Boom Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.6 Hose Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.5.7 Third Boom Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.5.8 Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.5.9 Second Boom Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.5.10 Third & Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.5.11 Second, Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . 3-15
3.6 Boom Section Separation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.7 Hose Carrier Assembly Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.7.1 Hose Carrier Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.7.2 Assembling the Hose Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.7.3 Hose Carrier-Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.7.4 Boom Hose Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.8 Quick Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.8.1 Connecting with a Mechanical Quick Coupler Device. . . . . . . . . . . . . . . . 3-21
3.8.2 Connecting with a Hydraulic Quick Coupler Device . . . . . . . . . . . . . . . . . 3-21
3.8.3 Connecting with a Quick Coupler to a Hydraulic Operated Attachment . . 3-21
3.8.4 Quick Coupler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.8.5 Quick Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
TL1055, TL1255 3-1

Boom
3.9 Boom Head - Mounted Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3.9.1 Boom Head-Mounted Winch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.9.2 Boom Head-Mounted Winch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.10 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.10.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.10.2 Wear Pad Installation and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.11 Boom Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.11.1 Retract Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.11.2 Retract Chain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.11.3 Extend Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.11.4 Extend Chain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.12 Boom Chain Inspection and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.12.1 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.12.2 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.12.3 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.12.4 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.13 Forks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-2 TL1055, TL1255

Boom
3.1 BOOM SYSTEM COMPONENT

TERMINOLOGY
The following illustrations identify the components that
are referred to throughout this section.
THIRD
EXTEND
BOOM
CHAINS
SECTION
FOURTH BOOM
SECTION
SECOND BOOM
SECTION FIRST
BOOM
SECTION
AUXILIARY
HYDRAULIC
CONNECTIONS
TILT CYLINDER
QUICK COUPLER
HOSE CARRIER
ASSEMBLY
(INSIDE BOOM)
EXTEND/RETRACT RETRACT
CYLINDER CHAINS
(UNDERSIDE OF BOOM)
HOSE
PIVOT PIN SHEAVE
MY0101
TL1055, TL1255 3-3

Boom
3.2 BOOM SYSTEM - FOUR SECTION 3.3 BOOM ASSEMBLY MAINTENANCE

These instructions provide the complete boom assembly
3.2.1 Boom System Operation removal and installation or the second, third and fourth
The four section boom consists of the first, second, third boom sections removal and installation.
and fourth assemblies with double third and fourth Before beginning, conduct a visual inspection of the
section extend chains, a double third section retract chain machine and work area, and review the task about to be
and a single fourth section retract chain. undertaken. Read, understand and follow these
As the extend/retract cylinder, which is anchored at the instructions.The boom assembly consists of the first,
front of the second boom section, and the rear of the first second and third section booms and supporting
boom section begins to extend, it forces the second boom hardware.
section out of the first boom section.
Note: Before removing the boom or boom section, the
The boom sections are connected by extend and retract carriage or any other attachment must be removed from
chains. These chains are routed around sheaves on the the quick coupler.
second and third boom sections. As the second section is
forced out hydraulically, the third and fourth boom Before beginning, conduct a visual inspection of the
sections are pulled out by the extend chains. machine and work area, and review the task about to be
undertaken. Read, understand and follow these
As hydraulic pressure is applied to the retract port on the instructions.
extend/retract cylinder, the second boom section is pulled
back into the first boom section, and the retract chain During service of the boom, perform the following:
pulls the third and fourth boom sections back into the 1. Check wear pads. (Refer to Section 3.10, “Boom
second boom section. Wear Pads.”)
This mechanical linkage formed by the chains and 2. Check hose sheaves and chain rollers.
supporting hardware, extends and retracts the third and 3. Apply grease at all lubrication points (grease fittings).
fourth boom sections at the same rate. (Refer to Section 2.6, “Lubrication Schedule.”)
The boom section lifts and lowers via action of the lift/ 4. Check for proper operation by operating all boom
lower cylinder. functions through their full ranges of motion several
times.
Depending on your particular circumstance, the following
procedures explain the removal/installation of individual
boom sections or removal/installation of the complete
boom.
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 TL1055, TL1255

Boom
3.4 COMPLETE BOOM REMOVAL/ the park brake, chock the wheels and shut the
INSTALLATION engine OFF.
2. Using suitable slings, balance the boom assembly,
lift and carefully guide the boom into place. Align the
3.4.1 Complete Boom Removal
frame pivot bore with the boom assembly pivot bore.
1. Remove any attachment from the quick coupler
3. Install the boom pivot pin.
assembly. Refer to Section 3.8.1, “Connecting with a
Mechanical Quick Coupler Device.” 4. With the sling still in place, install the compensation
cylinder, pins and bolts.
2. Remove the quick coupler assembly. Refer to
Section 3.8.4, “Quick Coupler Removal.” 5. With the sling still in place, install the rod end of the
left lift/lower cylinder, pin and lock bolt. Repeat for
3. If equipped, remove the Boom Head Mounted
the right side lift/lower cylinder.
Winch. Refer to Section 3.9.1, “Boom Head-
Mounted Winch Removal.” Note: Raising the boom up or down with the sling may
4. Park the machine on a hard, level surface, level the be necessary so the boom, compensation and lift/lower
machine, fully retract the boom, raise the boom, cylinder bores can be aligned for easier pin installation.
place the transmission control lever in Note: Grease the boom pivot bore, compensation
(N) NEUTRAL, engage the park brake and shut the cylinder rod ends, lift/lower cylinder rod end and pins
engine OFF. before installing.
5. Place a Do Not Operate Tag on both the ignition key 6. Uncap and reconnect the previously labeled
switch and the steering wheel, stating that the hydraulic hoses to the extend/retract cylinder.
machine should not be operated.
7. Uncap and connect any remaining hydraulic fittings
6. Open the engine cover. Allow the system fluids to to their appropriate locations.
cool.
8. Recheck the wear pad gaps to ensure they meet the
7. Properly disconnect the battery. minimum gap requirement. Shim if necessary.
8. Support the front of the boom by placing a sling 9. Ensure that the boom chains are properly adjusted.
behind the boom head. Refer to Section 3.6, “Boom Section Separation
9. Label, disconnect and cap all hydraulic hoses for the Adjustment.”
extend/retract and tilt circuits. Cap all fittings and 10. Properly connect the battery.
openings to keep dirt and debris from entering the
hydraulic system. 11. Start the engine and operate all boom functions
several times. Check for leaks, and check the
10. Support the lift/lower cylinder on the left side of the hydraulic fluid level in the reservoir; add fluid if
machine. Remove the lock bolt and rod end pin. required.
Lower the lift/lower cylinder onto the frame rails.
Repeat this step for the right side lift/lower cylinder. 12. Install the quick coupler assembly. Refer to Section
3.8.5, “Quick Coupler Installation.”
11. Support the compensation cylinder. Remove the lock
bolt and rod end pin. Lower the compensation 13. If equipped, install the Boom Head Mounted Winch.
cylinder onto the frame rails. Refer to Section 3.9.2, “Boom Head-Mounted Winch
Installation.”
12. Lower the boom to a level position and place a
suitable support under the boom head. Reposition 14. Clean up all debris, hydraulic fluid, etc., in, on, near
the slings to each end of the boom. and around the machine.
13. Remove the bolt securing the boom pivot pin. Pull 15. Close and secure the engine cover.
out the boom pivot pin. 16. Remove the Do Not Operate Tags from both the
14. Lift the complete boom off machine and set on level ignition key switch and the steering wheel.
ground or supports. 17. Install the previously remove attachment to the quick
coupler assembly. Refer to Section 3.8.1,
3.4.2 Complete Boom Installation “Connecting with a Mechanical Quick Coupler
Device.”
1. Park the machine on a hard, level surface, place the
transmission control lever in (N) NEUTRAL, engage
TL1055, TL1255 3-5

Boom
3.5 BOOM SECTION REMOVAL/ 8. Using a suitable lifting device, secure the tilt cylinder
INSTALLATION barrel with a nylon strap.
9. Remove both retaining clips (4) from each side of
the tilt cylinder mounting pin (5).
3.5.1 Second, Third & Fourth Boom Section
Removal 10. Remove the tilt cylinder mounting pin (5).
1. Remove any attachment from the quick coupler 11. Lower tilt cylinder from the boom head.
assembly. Refer to Section 3.8.1, “Connecting with a 12. Support the front of the boom by placing a sling
Mechanical Quick Coupler Device.” behind the boom head.
2. Remove the quick coupler assembly. Refer to
Section 3.8.4, “Quick Coupler Removal.”
3. If equipped, remove the Boom Head Mounted
Winch. Refer to Section 3.9.1, “Boom Head-
Mounted Winch Removal.”
4. Park the machine on a hard, level surface, level the
machine, fully retract the boom, level the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF. 6 7 8 MY4130
5. Place a Do Not Operate Tag on both the ignition key 13. Loosen the jam nut and lock nut (6) to release
switch and the steering wheel, stating that the tension from the hoses on the hose take-up
machine should not be operated. weldment (7).
6. Open the engine cover. Allow the system fluids to 14. Loosen the hydraulic hoses (8) and electrical cables
cool. if equipped on the hose take-up weldment (7). Plug
3 the hose ends and tube ends to prevent dirt and
debris from entering the hydraulic system.
13 12 11 10 9
4
5
MY3580
2 15. At the top front of the boom, measure and note the
distance from the end of the three extend chain
clevises (9) to the face of the lock nut (10).
16. Loosen and remove the lock nuts (10), adjusting
nuts (11), washers (12) and springs (13) from the
three extend chain clevises (9).
MY3770
7. Label and remove both tilt cylinder hoses (1)

between the tilt cylinder (2) and the hose carrier (3).
Label, cap and plug the hose carrier tube ends and
cylinder ports to prevent dirt and debris from
entering the hydraulic system.
3-6 TL1055, TL1255

Boom
21
19
14
24
9
22
23
23
20
MY3540
MY3440
25. Remove the adjusting nut and lock nut (19), retract
17. Pull the three extend chain clevises (9) off of each chain and clevis (20), spring stop (21) and spring
chain roller (14) and lay each assembly on the third (22). Loosen bolts (23) and adjusting block (24).
and fourth boom sections respectively.
26. Properly disconnect the battery.
Note: It may be necessary to remove the extend chain
rollers to help in the removal of the top wear pads. 30 30
31 31
18. Verify all fittings, tubes and hoses are properly
capped and /or plugged. 27
26
19. Extend the second boom section to access the 28
retract chain adjusting block. 32 29
25 25
MY3420
MY4120
17 18 15 16 27. At the rear of the boom, remove both hose sheave
covers (25).
20. Remove the extend/retract cylinder support (15)
28. Unbolt the hose carrier bracket (26) from the rear of
from the front of the first boom section.
the second boom section and the hose carrier.
21. Support the extend/retract cylinder (16) with a
29. Pull the hose carrier (27) back to gain access to the
suitable sling.
tilt hose (28) and the auxiliary hose (29)
22. Remove the retaining clips (17) from each side of connections.
the extend/retract cylinder rod.
30. Disconnect the tilt hoses, auxiliary hoses and if
23. Remove the extend/retract cylinder rod mounting pin equipped, the electrical connector at the rear of the
(18). hose carrier. Label, plug and cap all hydraulic
24. Lower the front of the extend/retract cylinder to a connections to prevent dirt and debris from entering
secured block on top of the frame. Do Not use the the hydraulic system.
engine hood for support. 31. Push hose carrier (27) as far forward as possible.
Note: Tag each wear pad, spacer, shim and hardware
from each location. Note the location of any grease fitting
(if equipped) on each wear pad.
TL1055, TL1255 3-7

Boom
32. Remove the top rear wear pads, spacers, shims and 3.5.2 Third & Fourth Boom Section
hardware (30) from the rear of the second boom Removal
section. 1 1
33. Remove the left (or right) side rear wear pad, spacer,
2 2
shims and hardware (31) from the rear of the second
boom section.
34. Pull each boom section slightly forward to relieve the
tension in retract chain (32).
35. Remove the snap rings and pin connecting the rear
retract chain (32) from the chain clevis at the rear of
the boom. Allow chain to hang out over the rear of
the boom. 2 2
36. Place a sling around the second boom section. With
a suitable lifting device, slowly pull the second, third
and fourth boom sections approximately 25% out of MY4150
the first boom section.

Note: Tag each wear pad, spacer, shim and hardware
29 29 from each location. Note the location of any grease fitting
28 28 (if equipped) on each wear pad.
1. Remove the top rear wear pads, spacers, shims and
hardware (1) from the rear of the third boom section.
2. Remove the left (or right) side rear wear pad, spacer,
shims and hardware (2) from the rear of the third
boom section.
28 28
3. Verify all disconnected hoses, tubes and fittings are
30 30 capped and/or plugged.
MY4140
37. With the second, third and fourth boom section still
connected to a suitable lifting device, remove all
wear pads, spacers, shims, and hardware (28) from
the front sides of the first boom section.
38. Remove both wear pads, spacers, shims, blocks
and hardware (29) from the front top of the first
boom section.
39. Remove both wear pads, spacers, shims and
hardware (30) from the front bottom of the first boom
section.
MY3590
40. Adjust sling(s) around the second boom section to
help balance the second, third and fourth boom 4. Pull each boom section slightly forward to relieve the
sections. tension on the retract chain (3).
41. Remove the remainder of the second, third and 5. Remove the snap rings and pin connecting the rear
fourth boom sections from the first boom section and retract chain (3) from the chain clevis at the rear of
set on suitable supports. the boom. Allow chain to hang out over the rear of
the boom.
3-8 TL1055, TL1255

Boom
6. Place a sling around the third boom section. With a 3.5.3 Fourth Boom Section Removal
suitable lifting device, slowly pull the third and fourth
1. Place a sling around the fourth boom section and
boom sections approximately 25% out of the second
slowly pull the fourth boom section approximately
boom section.
25% out of the third boom section. Lower the fourth
section boom head onto a suitable support.
5 5
9 9
4 4
8 8
4 4
8 8
6 6
7
MY3450 9 9
7. With the third and fourth boom section still 10
MY3510
connected to a suitable lifting device, remove all
wear pads, spacers, shims, and hardware (4) from 2. With the fourth boom section still connected to a
the front sides of the second boom section. suitable lifting device, remove all wear pads,
spacers, shims, and hardware (8) from the front
8. Remove both wear pads, spacers, shims, blocks
sides of the third boom section.
and hardware (5) from the front top of the second
boom section. 3. Remove top and bottom front wear pads, shims and
blocks (9) from the third boom section.
9. Remove both wear pads, spacers, shims and
hardware (6) from the front bottom of the second 4. Loosen and remove the wear pad support plate (10)
boom section. from the bottom front of the third boom section.
10. Loosen and remove the wear pad support plate (7) 5. Adjust the sling(s) around the fourth boom section
from the bottom front of the second boom section. for stability. Balance the fourth boom section and
slowly pull the fourth boom section out of the third
11. Adjust sling(s) around the third boom section to help
boom section being careful not to damage any
balance the third and fourth boom sections.
surrounding components.
12. Remove the remainder of the third and fourth boom
6. Lower the fourth boom section onto a suitable
sections from the second boom section and set on
support.
suitable supports.
TL1055, TL1255 3-9

Boom
3.5.4 Hose Carrier Removal 1. Place the fourth boom section onto suitable
supports.
11 C
1 2
12
13
13
MY3470
MY3630
1. Remove the guide bracket (11) at the front of the
hose carrier (12). Reuse the existing hardware. 2. Install the previously removed extend chain
2. Loosen and remove the front two mounting bolts assembly and clevis (1) at the top rear of the fourth
(13) holding the hose carrier in place. Tag all boom section. Allow 0.250 in (6,35 mm) (C) between
hardware. the end of the clevis (1) and the face of the lock nut
(2). Torque lock nut to 100 lb-ft (135 Nm).
3. Remove the hose carrier through the front of the
fourth boom section. 5 5
4. When the hose carrier is approximately 25% free of
the fourth boom section, fasten the two hose carriers 4 4
together (using nylon tie-wraps or nylon straps) to
prevent separation.
5. Continue to remove the hose carrier, fastening the
hose carriers together as they are being removed.
6. When the hose carrier is approximately 75% tied
together, pull the assembly free of the boom section.
7. Lower the hose carrier onto a suitable support.
3 3
MY3490
3. Install all wear pads, spacers and shims (3, 4 & 5) at

the rear of the fourth boom section. Snug mounting
bolts. Shim as needed AFTER boom section is
installed. Refer to Section 3.10.2, “Wear Pad
Installation and Lubrication,” for detailed information.
14 MY3610
FRONT OF BOOM
8. Remove the hose carrier guide bracket from the

inside of the fourth boom section (14).
3.5.5 Fourth Boom Section Assembly
3-10 TL1055, TL1255

Boom
3.5.6 Hose Carrier Installation

14
6 MY3610
13 FRONT OF BOOM
MY3480
9. Install the previously removed hose carrier guide
1. Inspect the hose carrier track (6) for any broken or bracket (13). Torque as required.
missing clips. Repair or replace as needed.
10. Install the hose carrier (14) into the front of the fourth
2. Remove the caps from the tubes on the hose carrier. boom section. Remove each nylon tie or nylon strap
10 as the hose carrier is installed.
11
11. Align the hose carrier (14) to the hose carrier guide
bracket (13).
8
7 9
12 12
15
MY3750
MY3470
Note: Connect the tilt cylinder hoses and the auxiliary
hoses to the hose carrier bulkhead before installing the 12. Align the hose carrier mounting bracket and install
hose carrier in the fourth boom section. the previously removed hardware to mounting
bracket at the front of the fourth boom section (15).
3. Install tilt cylinder hose (7) to the bottom left fitting on Torque as required.
the hose carrier tube (8).
4. Install tilt cylinder hose (9) to the top left fitting on the
hose carrier tube (10).
5. Install adaptors (11) to each auxiliary tube at the
front right of the hose carrier.
6. Install auxiliary hoses (12) to each adaptor (11) on
the auxiliary tubes at the front right of the hose
carrier.
7. Orient each auxiliary hose (12) as shown above.
8. Torque each fitting and hose as required.
TL1055, TL1255 3-11

Boom
17 C
5 6
16
MY3480
MY3630
13. Install guide bracket (16) P/N using the previously
removed hardware (17). Torque as required. 4. Install the previously removed extend chain
assemblies and clevises (5) at the top rear of the
3.5.7 Third Boom Section Assembly third boom section. Allow 0.250 in (6,35 mm)
Note: Inspect and lubricate all extend and retract chains between the end of the clevis (5) and the face of the
before re-assembly. Refer to Section 3.12.1, “Boom lock nut (6). Torque lock nut to 100 lb-ft (135 Nm).
Chain Inspection,” for detailed information.
3.5.8 Fourth Boom Section Installation
Note: Using a straight bar approximately 40 in
(1041 mm) long will aid in the installation of the wear Note: Using a straight bar approximately 40 in
pads located on the inside front of each boom section. (1041 mm) long will aid in the installation of the wear
pads located on the inside front of each boom section.
1. Place the third boom section onto suitable supports.
1. Clean and lubricate the bottom of the fourth boom
4 4
section where the wear pads of the third boom
2 2 section contact the fourth boom section.
2. Place the sling, or two slings for better stability,
around the fourth boom section and slowly insert the
fourth boom section into the third boom section
being careful not to damage any surrounding
1 components.
7 7
3 3
MY3500 8 8
2. Install the previously removed chain roller (1) at the
rear of the third boom section. Insert the mounting
pin, retainer plate and hardware. Torque as required.
the rear of the third boom section. Snug mounting
8 8
MY3510
3-12 TL1055, TL1255

Boom
3. Install the wear pad, support plates and spacers (7) 3.5.9 Second Boom Section Assembly
with existing hardware at the inside top front of the
1. Place the second boom section onto suitable
third boom section. Snug mounting bolts. Shim as
supports.
needed AFTER boom section is installed. Refer to
Section 3.10.2, “Wear Pad Installation and
14 14
Lubrication,” for detailed information.
15 15
13
16 16
MY4160
11 11 2. Install the previously removed chain roller (13) at the

rear of the second boom section. Insert the mounting
MY3510
pin, retainer plate and hardware. Torque as required.
12 10 10 12 3. Install the wear pads and spacers (14, 15 & 16) at
the rear of the second boom section. Snug mounting
4. Install the previously removed wear pad support (9)
at the front inside of the third boom section. Use the
previously removed hardened washers and bolts
(10). Torque as required.
5. Install the wear pads, spacers and shims on each 3.5.10 Third & Fourth Boom Section
side and bottom (8 & 11) at the front of the third Installation
boom section. Snug mounting bolts. Shim as
needed AFTER boom section is installed. Refer to Note: Refer to Section 2.2, “Torque Charts,” for
Section 3.10.2, “Wear Pad Installation and standard bolt torque information.
Lubrication,” for detailed information. Note: Refer to Section 2.2.3, “Hydraulic Hose Torque
Note: Longer bolts (12) may be required to fully engage Chart,” for standard hose torque information.
the threaded inserts in the wear pads without allowing Note: Apply Loctite® 242TM to all boom assembly bolts.
bolts to protrude past the chamfer on the wear pads.
Refer to page 6, Wear Pad Installation and Lubrication Note: Using a straight bar approximately 40 in
for detailed information. (1041 mm) long will aid in the installation of the wear
1. Place the sling or using two slings for better stability,
around the third boom section and slowly insert the
third and fourth boom sections into the second boom
section being careful not to damage any surrounding
components.
TL1055, TL1255 3-13

Boom
21
22 17
20
18
18 27
19
28 28
MY3540
29 29
2. Install adjusting block (17) using existing hardware
(18). Torque as required.
MY3450
3. Install chain and clevis (19), spring (20), spring stop 30 30
(21), adjusting nut and lock nut (22).
24
A 8. Install the wear pad support plate (27) with existing
hardware at the inside front of the second boom
section.
23
Note: Longer bolts (30) may be required to fully engage
the threaded inserts in the wear pads without allowing
MY3650 bolts to protrude past the chamfer on the wear pads.
Refer to Section 3.10.2, “Wear Pad Installation and
4. Allow 0.50 in (1,27 mm) (A) between the end of the
Lubrication.”
clevis (23) and the face of the lock nut (24). Torque
lock nut to 100 lb-ft (135 Nm). 9. Install the wear pads, spacers and shims on each
5. Properly connect the battery. side and bottom (26, 28 & 29) at the front of the
second boom section. Snug mounting bolts. Shim as
6. Retract the second boom section pulling both retract needed AFTER boom section is installed. Refer to
chains at the same time. Section 3.10.2, “Wear Pad Installation and
10. Manually retract the boom sections as required to
25 25
connect the retract chains.
26 26
31
MY3450
7. Install the wear pad, support plates and spacers (25)

with existing hardware at the inside top front of the
second boom section. Snug mounting bolts. Shim as
needed AFTER boom section is installed. Refer to
Section 3.10.2, “Wear Pad Installation and MY3590
3-14 TL1055, TL1255

Boom
11. Install the bracket and clevis assembly (31) at the

rear of the fourth boom section. Torque mounting
bolts.
5
3.5.11 Second, Third and Fourth Boom
Section Installation
Note: Using a straight bar approximately 40 in
4
(1041 mm) long will aid in the installation of the wear
1. Place the sling or using two slings for better stability,
around the second boom section and slowly insert
the second, third and fourth boom sections into the
first boom section being careful not to damage any
surrounding components and allowing sufficient
room to install the wear pads at the front of the first
boom section.
MY3590
3 3 4. Connect the rear retract chain (4) to the chain clevis

2 2 with the previously removed pin at the rear of the
third boom section. Secure the pin with the
previously removed snap rings.
5. Pull hose carrier from the rear as far as possible to
access the hydraulic and if equipped, the electrical
connections.
2 6. If equipped, connect the electrical cable (5) to the
2
1
fitting on the hose carrier.
1
MY4140 8
6 7
the front of the first boom section. Snug mounting
3. Re-adjust the sling(s) and push the second, third 9 9
and fourth boom assembly the remainder of the way
into the first boom section.
MY3420
7. Remove any caps and plugs from the tilt and

auxiliary hoses at the rear of the boom assembly.
Connect and tighten the tilt (6) and auxiliary hoses
(7) to their proper fitting locations on the hose
carrier. Torque as required.
8. Install the hose carrier bracket (8) at the rear of the
third boom section and the hose carrier. Torque
mounting bolts as required.
TL1055, TL1255 3-15

Boom
9. Install both hose sheave covers (9).Torque mounting 3.6 BOOM SECTION SEPARATION
bolts as required. ADJUSTMENT
10 11
1. Start the machine and verify the boom is in a
horizontal (level) position.
2. Extend the boom 4-5 ft (1,2-1,5 m), then fully retract
the boom.
3. Shut machine OFF.
MY3440
10. Connect the fourth boom section extend chain (10)

to the clevis at the top front of the third boom section
and adjust to the previously measured setting. Do
Not tighten the lock nut at this time.
D
11. Connect the third boom section extend chains (11) to
the clevises at the top front of the second boom
section and adjust to the previously measured 1
setting. Do Not tighten the lock nut at this time.
1
12. Grease all wear pad at the rear of the boom using
the zerk fittings.
13. Refer to Section 3.6, “Boom Section Separation MY3800
Adjustment,” for proper boom section adjustments.

4. Measure the gap (D) between the flat washer at the
extend chain anchor on the top front of the first boom
section and the second boom section. If the gap is
greater that 0.375 in (9.52 mm), the boom chains will
need to be adjusted.
Adjust the extend chain as follows:
1. Loosen the lock nut (1) on each of the extend
chains.
2. Tighten the adjusting nuts on the first boom section
until the gap (D) between the flat washers and boom
is 0.375 in (9,52 mm) maximum. The gap must be
equal on both chains. Torque the lock nut to 100 lb-ft
(135 Nm).
Note: Verify the exposed threads on both extend chain
clevises are kept equal.
3. Tighten the adjusting nut on the second boom
section until the gap (D) between the washer and
boom is 0.375 in (9,52 mm) maximum. Torque the
lock nut to 100 lb-ft (135 Nm).
3-16 TL1055, TL1255

Boom
2 3
Note: BOTTOM OF BOOM SHOWN

WITH EXTEND/RETRACT CYLINDER
REMOVED FOR CLARITY
MY3820 MY3810
4. After adjusting, check to see that the boom sections 3. Loosen the second to third boom section retract
and access holes (2) are aligned. If they are not, the chain lock nut and adjusting nut (3) as far as
retract chain will need to be adjusted as well. possible.
Adjust the retract chain as follows: 4. Loosen the third to fourth boom section retract chain
1. Fully retract the boom. lock nut and adjusting nut (4) as far as possible.
F
5. Tighten the retract chain adjusting nut (3) until the
proper distance (E) is obtained and proper access
hole alignment (2) is obtained.
6. Torque the lock nut to 100 lb-ft (135 Nm).
7. Recheck the extend chain adjustments and readjust
if necessary.
8. Measure the distance between the third boom
section and fourth boom section (F). The dimension
should be:
TL1055 - 17.5-17.75 in (444,5-451,3 mm)
TL1255 - 18.5-18.75 in (469,9-476,7 mm)
9. Tighten the retract chain adjusting nut (4) until the
proper distance (F) is obtained and proper access
hole alignment (2) is obtained.
10. Torque the lock nuts to 100 lb-ft (135 Nm).
E MY3790
11. Re-adjust the extend chains as needed.
2. Measure the distance between the second boom
section and the third boom section (E). The
dimension should be 0.50-0.75 in (12,7-19,5 mm).
TL1055, TL1255 3-17

Boom
3.7 HOSE CARRIER ASSEMBLY

REMOVAL/INSTALLATION
The hose carrier assembly locates primarily in the fourth 3
boom section. It is fastened at the bottom front of the
fourth boom section and at the rear of the third boom
section.
3.7.1 Hose Carrier Assembly Removal

assembly. Refer to Section 3.8.1, “Connecting with a
MY2710
Mechanical Quick Coupler Device.”
Note: Allow adequate room in front of the machine 2
when removing and installing the hose carrier assembly.
9. Loosen and remove both cap screws and locknuts
2. Park the machine on a hard, level surface, level the (2) from the hose carrier bracket at the front of the
machine, fully retract the boom, level the boom, fourth boom section.
place the transmission control lever in (N) 10. Loosen and remove the guide bracket (3) from the
NEUTRAL, engage the park brake and shut the front of the fourth boom section.
engine OFF.
3. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
4. Open the engine cover. Allow the system fluids to
cool.
4
MY2720
1 11. Loosen and remove the hose carrier bracket (4) at

MY2690 the rear of the third boom section.
6. Loosen and remove both compression springs (1)
from the hose take-up weldment at the bottom of the FRONT
first boom section.
7. Label and disconnect the tilt and auxiliary hydraulic
hoses attached to the hose carrier at the rear of the
boom and at the front of the boom head. Plug and
cap the hose ends to prevent dirt and debris from
entering the hydraulic system.
MY2700
8. If equipped, label and disconnect any electrical
connections at the front and rear of the boom 5
assembly. 12. Install a sling around the hose carrier at the front of
Note: Tag or identify each hose to the corresponding the boom. With a suitable lifting device, slowly pull
fitting it was removed from. the hose carrier loose from the bottom bracket (5)
located approximately halfway in the fourth boom
section.
3-18 TL1055, TL1255

Boom
13. When the hose carrier is pulled approximately 25% 3.7.3 Hose Carrier-Assembly Installation
out of the boom, fasten the two hydraulic carriers
1. Clean and lubricate the side surfaces where the hose
together using plastic tie wraps or nylon straps to
carrier rides.
keep them from separating.
2. Fully collapse the hose carriers and secure together
Note: Do Not wrap the hose carrier since it will not using plastic tie wraps or nylon straps to keep them
prevent the two hydraulic carriers from moving apart from separating.
sideways.
3. Install a sling around the balance point of the hose
14. Continue withdrawing the hose carrier, fastening the carrier. With a suitable lifting device, slowly insert the
two hydraulic carriers together. hose carrier into the front of the fourth boom section.
15. With the two hose assemblies tied together, remove 4. Remove the first plastic tie wrap or nylon strap as
the hose carrier and set on the ground or proper the hose carrier is being inserted into the front of the
supports. fourth boom section.
5. Continue inserting the hose carrier and removing the
3.7.2 Assembling the Hose Carrier plastic tie wraps or nylon straps until the hose carrier
Assembly is fully inserted into the boom.
The following procedure is described with the assumption
that all components have been removed and assembly
proceeding from the beginning.
MY2740
6. Install the guide bracket (1) on the front of the hose

carrier.
MY2730 FRONT
1. Place both sections on a suitable stand or support.

2. Install the wear pad to the bottom of the upper
hydraulic carrier.
3. Install the bulkhead fittings to the each hydraulic
carrier.
MY2700
4. Install the tube assemblies to the bulkhead fittings 2 3
on each hydraulic carrier. 7. Verify that the bottom bracket (2) on the hose carrier
5. Install the cushion clamps to the tube assemblies is in place on the bottom plate (3) of the fourth boom
and secure to each hydraulic carrier. section.
6. Install the hose carrier to each hydraulic carrier and 8. Install the cap screws, washers and nuts to the hose
install each tilt hose and auxiliary hose to the proper carrier bracket at the rear of the third boom section.
fitting or tube connection. 9. Install both cap screws and locknuts to the hose
7. Tie wrap the hydraulic hoses together where they carrier bracket at the front of the fourth boom
extend from each end of the hose carrier. section.
8. Fasten the two hydraulic carriers together using 10. Uncap and reconnect the previously labeled tilt and
plastic tie wraps or nylon straps for stability. auxiliary hydraulic hoses to the proper fittings at the
rear of the hose carrier.
TL1055, TL1255 3-19

Boom
11. Uncap and reconnect the previously labeled tilt and 5. Verify the auxiliary hoses and/or tilt hoses are NOT
auxiliary hydraulic hoses to the proper fittings at the touching the bottom of the second boom section by
front of the fourth boom section. viewing the auxiliary hoses and/or tilt hoses through
12. If equipped, reconnect any electrical connections at the access hole (10) in each side of the second
the front and rear of the boom assembly. boom section.
12
11 MY4470
4
87 6
5
6. Verify that 4 in (101,6 mm) of slack (11) is present
9 5 MY2691
between the hose take-up bracket (5) and the first
13. Install the hose take-up compression spring (4) on hose clamp (12).
each hose take-up bracket (5) at the bottom of the 7. Verify the hose take-up bracket (5) is not bent and is
first boom section. Install the washer (6), adjusting at an 85° angle to the hose.
nut (7) and jam nut (8). Tighten the adjusting nut (7)
Note: Replace both auxiliary hoses and/or tilt hoses if
to compress the hose take-up compression spring to
the hoses are touching the bottom of the second boom
measure 3 in (76,20 mm)(9). Refer to Section 3.7.4,
section AND 4 in (101,6 mm) of slack is present between
“Boom Hose Adjustment,” if required.
the hose take-up bracket and the first hose clamp.
14. Torque the jam nut (8) against the adjusting nut (7)
to 100 ft-lb (135,5 Nm). 8. Refer to Section 3.7.3, “Hose Carrier-Assembly
Installation,” step 13 and 14 for hose take-up bracket
15. Properly connect the battery. adjustment.
16. Remove the Do Not Operate Tags from both the 9. Measure the slack (11) at the lowest point between
ignition key switch and the steering wheel. the hose take-up bracket (5) and the first hose clamp
(12). The 4 in (101,6 mm) measurement is from the
3.7.4 Boom Hose Adjustment bottom of the first boom section to the top of the
1. Park the machine on a hard, level surface, level the hose.
machine, fully extend the boom, lower the boom 10. If necessary, loosen the hose clamp (12), pull the
head to the ground, place the transmission control auxiliary hoses and/or the tilt hoses, tighten the hose
lever in (N) NEUTRAL, engage the park brake and clamp for additional clearance.
shut the engine OFF.
11. Replace the auxiliary hoses and/or the tilt hoses if
2. Place a Do Not Operate Tag on both the ignition key the proper slack, 4 in (101,6 mm)(11) cannot be
switch and the steering wheel, stating that the achieved.
12. Start the machine, raise the boom to level, cycle the
3. Verify any trapped hydraulic pressure in the auxiliary extend/retract cylinder, fully extend the boom.
circuit and the tilt circuit is relieved.
13. Cycle the auxiliary circuit and/or the tilt circuit,
4. Open the engine cover. Allow the system fluids to verifying the auxiliary hoses and the tilt hoses are
cool. NOT touching the bottom of the second boom
section and the proper slack, 4 in (101,6 mm) is
maintained.
14. Retract the boom and shut engine OFF.
15. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
10 MY4480
3-20 TL1055, TL1255

Boom
3.8 QUICK COUPLER ASSEMBLY 4. Unlock the “QC” rocker switch, press and hold down
the switch. Push left on the auxiliary lever to engage
This machine is equipped with a quick coupler assembly the quick coupler locking pin (3). Push the auxiliary
system for easy attachment changes. lever right to disengage the quick coupler locking
pin.
3.8.1 Connecting with a Mechanical Quick 5. Raise boom to eye level and visually check that the
Coupler Device locking pin protrudes through the hole on both sides
1. Retract quick coupler device to provide clearance. of the quick coupler. If the pins do not protrude
Check to be sure lock pin and retainer pin is out. through the hole, place the attachment on the
ground and return to step 2.
6. If attachment is equipped, connect auxiliary
hydraulic hoses. Refer to Section 3.8.2, “Connecting
with a Hydraulic Quick Coupler Device.”
3.8.3 Connecting with a Quick Coupler to a

Hydraulic Operated Attachment
1. Install attachment. Refer to Section 3.8.1,
“Connecting with a Mechanical Quick Coupler
2 Device,” or Section 3.8.2, “Connecting with a
Hydraulic Quick Coupler Device.”
1
2. Lower attachment to ground and set parking brake.
3. Press the decompression valve to relieve auxiliary
hydraulic pressure.
3.8.4 Quick Coupler Removal

1. Remove the lock bolt holding the tilt cylinder rod end
pin to the quick coupler assembly. Remove the Tilt
3 Cylinder pin.
MAL0130
2. Support the quick coupler assembly.Remove the
2. Align attachment pin (1) with recess in capscrew and locknut securing the head pin to the
attachment (2). Raise boom slightly to engage boom head.
attachment pin in recess.
3. Inspect the above pins for nicks or surface corrosion.
3. Engage quick coupler device. Use fine emery cloth to fix minor nicks or corrosion.
4. Shut off engine. Exit cab and insert lock pin (3) and If damaged or if it cannot be repaired the pin must be
secure with retainer pin. replaced.
5. If attachment is equipped, connect auxiliary
3.8.5 Quick Coupler Installation
hydraulic hoses. Refer to Section 3.8.2, “Connecting
with a Hydraulic Quick Coupler Device.” 1. Assemble the quick coupler to the boom head. Line
up the quick coupler between the mounts on the
3.8.2 Connecting with a Hydraulic Quick boom head. The quick coupler should be centered in
Coupler Device the boom head.
1. Retract the quick coupler device to provide 2. Coat the quick coupler head pin with an anti-seize
clearance. Check to be sure lock pin is disengaged. compound. Insert the quick coupler head pin through
the quick coupler and boom head. Secure with the
2. Align attachment pin (1) with recess in
previous capscrew and locknut.
attachment (2). Raise boom slightly to engage
attachment pin in recess. 3. Align the quick coupler with the tilt cylinder rod end
and insert the tilt cylinder pin. Align the tilt cylinder
3. Engage quick coupler device.
pin and screw in the locking bolt. Torque as required.
TL1055, TL1255 3-21

Boom
3.9 BOOM HEAD - MOUNTED WINCH 3.10 BOOM WEAR PADS

The wear pads on this machine are flat rectangular wear
3.9.1 Boom Head-Mounted Winch Removal pads with metal inserts.
3
A total of 42 wear pads are installed on the boom sections
of the TL1055 and the TL1255 machines.
3.10.1 Wear Pad Inspection

6
1 1
4
Ma2070
Inspect all wear pads for wear. If the angle indicators (1)
on the ends of the wear pads are visible, the wear pads
can be reused. If the pads show uneven wear (front to
back), they should be replaced. Replace pads as a set if
MY3710 worn or damaged.
1. Using a suitable lifting device, secure the winch 3.10.2 Wear Pad Installation and Lubrication
assembly (4) with a nylon strap. Note: Inspect all wear pads. Replace as necessary.
2. Disconnect the hydraulic hoses (5).
The following wear pad procedure must be followed to
3. Loosen and remove the mounting bolts, washers insure the proper wear pad installation:
and nuts (6)(not shown).
• The wear pad inserts and mounting bolts MUST be
4. Lower the winch assembly (4) onto a suitable skid or clean from any grease, oil or other contaminates
table. before applying Loctite® 242TM and installing
mounting bolts.
3.9.2 Boom Head-Mounted Winch • Apply Loctite® 242TM to all wear pad mounting bolts.
Installation
4
1. Using a suitable lifting device, secure the winch
assembly (4) with a nylon strap.
2. Raise the winch assembly (4) into position behind
the boom head. 3
2
3. Apply Loctite® 242TM to the previously removed
mounting bolts.
4. Install the mounting bolts, washers and nuts (6)(not
shown). Torque to 200 lb-ft (271Nm).
5. Connect the hydraulic hoses (5).
MAM1390
• A spacer (2) with holes must be used before any

shim (3) is used.
• A shim (3) must be inserted between the spacer (2)
and wear pad support plate, block or boom section
(4).
• The number of shims can vary at each shim point.
• The bottom wear pads must be shimmed equally on
each side.
3-22 TL1055, TL1255

Boom
3.11 BOOM CHAIN REMOVAL/

5
INSTALLATION
3.11.1 Retract Chain Removal

The following section explains the removal of the retract
chains without removing the boom assemblies.
Note: The retract chain on the bottom of the boom must
be removed to gain access to the inner retract chain.
To remove the retract chain from the third to first boom
sections:
1. Park the machine on level ground. Place the
• Maintain a total boom section clearance (5) of transmission control lever in (N) NEUTRAL, engage
0.070 - 0.130 in (1,78 - 3,30 mm) both the horizontal the parking brake switch, level the boom and shut
and vertical directions. the engine OFF.
A 2. Place a Do Not Operate Tag on both the ignition key
B
4. Attach a suitable sling to the extend/retract cylinder.
MY3620 Remove the extend/retract cylinder support.
• The length of the wear pad bolt depends on the 5. Remove the rod end pin and lower the cylinder onto
number of shims, spacers and washers being used. the frame rails. Lowering the extend/retract cylinder
• The thickness of each threaded wear pad insert is will allow access to the chains.
0.312 in (7,92 mm) (A).
4
• The bolt length should be determined by measuring
the distance from the face of the insert to the face of
the boom (B) including any spacer, shim(s) and
washer(s).
• Bolt thread engagement in the wear pad insert MX0510
should be 0.275 ± 0.040 in (6,98 ± 1,0 mm).
1 3
• One or two hardened washers are to be used on 2
each wear pad bolt except where noted otherwise.
DO NOT use more than two hardened washers. 6. Remove tension from the chain by backing off the
jam nut and adjusting nut (1).
• Use only one hardened washer if mounting bolts are
recessed. 7. Remove the four bolts (2) from the chain adjustment
• Wear Pad Bolt Torque: block.
3/8 - 24 Bolt, 32 - 37 lb-ft (43 - 50 Nm) 8. Remove the chain from the clevis (3) at the block.
3/8 - 24 Hollow Bolt, 15 - 17 lb-ft (20 - 23 Nm)
1/2 - 20 Bolt, 76 - 86 lb-ft (103 - 116 Nm) 9. Install a nylon tie wrap through the holes of the
1/2 - 20 Hollow Bolt, 45 - 50 lb-ft (61 - 68 Nm) removed chain, making a loop with a tie wrap and tie
a rope to the loop.
• Torque wear pad bolts after shimming is completed.
• Lubricate the face and pockets of each wear pad 10. At the rear of the boom, pull the chain to the rear to
after being installed. allow slack for removal.
Boom Section Wear Pad Pathway Lubrication: 11. Remove the chain from the clevis and drop it free
from the boom.
• Clean and lightly grease all wear pad pathways with
CAT ADVANCED 3MOLY - NLGI Grade 2 grease. 12. Holding a rope at the front adjustment block,
carefully pull the chain out through the back of the
• Clean and lightly grease the hose carrier guide bar
pathways with CAT ADVANCED 3MOLY - NLGI boom.
Grade 2 grease.
TL1055, TL1255 3-23

Boom
13. Untie the rope and leave it in place for reinstallation 6. Install the chain adjustment block and mounting
of the chain. bolts. Torque the chain adjustment block mounting
To remove the retract chain from the fourth to second bolts to 360-390 lb-ft (475-530 Nm).
boom sections: 7. Install the extend/retract cylinder and cylinder
1. Remove the jam nut (4) from the chain clevis support.
installed in the chain adjustment block. 8. Adjust the retract chains as needed. Refer to Section
2. Back off the adjusting nut fully on the chain clevis. 3.6, “Boom Section Separation Adjustment.”
Do not remove the nut from the clevis. 9. Properly connect the battery.
3. Remove the chain from the clevis, install a nylon tie- 10. Remove the Do Not Operate Tags from both the
wrap through the holes in the chain, making a loop ignition key switch and the steering wheel.
with the tie-wrap and tie a rope to the loop.
4. Move to the back of the boom and pull the chain to 3.11.3 Extend Chain Removal
the rear to allow slack for removal. The following section explains the removal of the extend
5. Remove the chain from the clevis and drop it free chains without removing the boom assemblies.
from the boom. 1. Park the machine on level ground. Place the
6. Holding the rope at the front, carefully pull the chain transmission control lever in (N) NEUTRAL, engage
out through the back of the boom until it’s free. the parking brake switch, level the boom, extend the
boom far enough to access the chain anchor and the
7. Untie the rope and leave it in place for reinstallation
clevis through the top rear access hole, shut the
of the chain.
engine OFF.
3.11.2 Retract Chain Installation 2. Place a Do Not Operate Tag on both the ignition key
Inspect and lubricate chains thoroughly before machine should not be operated.
installation. Articulate the chains to make sure all working
surfaces are thoroughly lubricated. 3. Properly disconnect the battery.
4. Secure the boom sections together to prevent
Note: If the inner retract chain was removed, it must be
uncontrolled boom run out when the extend chains
installed first.
are removed.
1. Fasten a rope to the end of the 3/4 in. chain in order 5. On the chain being removed, loosen and remove the
to pull it back into the boom. jam nut from the rear chain clevis and back off the
2. Attach the chain to the chain clevis at the rear of the adjusting nut on the chain clevis to the end of the
boom. threads. Do not completely remove the nut.
3. Carefully pull the chain into the boom until it can be 6. Remove the chain clevis pin and retaining ring to
fastened to the chain clevis. free the chain.
4. Remove the rope. 7. Install the nylon tie wrap through the holes in the
5. Fasten the chain into the clevis by installing the pin chain, making a loop with the tie wrap and tie a rope
and retaining ring. to the loop.
6. Torque the jam nuts to 100 lb-ft (135 Nm). 8. Pull the slack to the chain clevis at the front of the
boom.
To install the outer retract chain:
9. Remove the clevis pin and the retaining ring from the
1. Fasten a rope to the end of the chain in order to pull chain and chain clevis.
it back into the boom.
10. Install a nylon tie wrap through the chain holes,
2. Attach the chain to the chain clevis at the rear of the forming a loop and tie a rope to the loop.
boom.
11. Carefully pull the chain out of the boom.
3. Carefully pull the chain into the boom until it can be
fastened to the chain clevis. 12. Untie the rope and leave it in place for reinstallation
of the chain.
4. Remove the rope.
5. Fastened the chain into the clevis by installing the
pin and cotter pin.
3-24 TL1055, TL1255

Boom
3.11.4 Extend Chain Installation 3.12 BOOM CHAIN INSPECTION AND

The following section explains the installation of the LUBRICATION
retract chains without removing the boom assemblies.
Inspect and lubricate chains thoroughly before 3.12.1 Boom Chain Inspection
installation.
1. Fasten the previously used rope to the end of the
extend chain. WARNING
2. Carefully pull the chain into the boom to the chain Worn pins, stretched or cracked links or corrosive
clevis anchor. environments can cause chain failure. A chain failure
3. Fasten the chain to clevis with a pin and cotter pin. could result in uncontrolled boom movement, loss of
load or machine instability.
4. At the other end of the chain, connect the chain to
the clevis fastening the chain to the clevis with a pin Under normal operating conditions the extend chains will
and retaining ring. need to be inspected and lubricated every 250 hours of
operation. The retract chains need to be exposed,
5. Install the chain clevis fastening and adjusting inspected and lubricated every 1000 hours of operation.
hardware on both ends. Environmental conditions and dynamic impulse/shock
6. Remove any clamping devises being used to keep loads can drastically affect normal operating conditions
the boom sections from moving. and require more frequent inspection intervals.
7. Properly connect the battery. Environments in which material handling vehicles
operate can vary widely from outdoor moisture to
8. Adjust the extend chains as needed. Refer to temperature to mildly corrosive or highly corrosive
Section 3.6, “Boom Section Separation Adjustment.” industrial atmospheres, in addition to abrasive
9. Remove the Do Not Operate Tags from both the exposures such as sand and grit. Some effects can be
ignition key switch and the steering wheel. as follows:
• Moisture - Corrosive rusting reduces chain
strength by pitting and cracking.
• Temperature - Low temperature reduces chain
strength by embrittlement. Going in and out of
cold storage results in moisture from
condensation.
• Chemical Solutions or Vapors - Corrosive attack
on the chain components and/or the mechanical
connections between the chain components.
Cracking can be (and often is) microscopic.
Going from microscopic cracking to complete
failure can be either abrupt or may require an
extended period of time.
• Abrasives - Accelerated wearing and scoring of
the articulating members of the chain (pins and
plates), with a corresponding reduction in chain
strength. Due to the inaccessibility of the bearing
surfaces (pin surfaces and plate apertures),
wear and scoring are not readily noticeable to
the naked eye.
TL1055, TL1255 3-25

Boom
Following are some examples of dynamic shock loading Edge Wear

which can impose abnormal loads above the endurance
limit of a leaf chain.
• High velocity movement of load, followed by
sudden, abrupt stops. 1 2
• Carrying loads in suspension over irregular
surfaces such as railroad tracks, potholes, and
rough terrain.
MZ1463
• Attempting to “inch” loads which are beyond the
rated capacity of the vehicle. Check the chain for wear on the link plate edges
caused by running back and forth over the sheave.
The above load cycles and environmental conditions
The maximum reduction of material should not
make it impossible to predict chain life. It is therefore
exceed 5%. Measure and compare to a normal link
necessary to conduct frequent inspections until
plate height by measuring a portion of chain that
replacement life can be predicted.
does not run over the sheave. If the measured plate
The boom chain’s normal life expectancy can be height (1) is 5% less than the normal plate height (2),
expressed as a maximum percent of elongation. This is discard and replace the chain.
generally 3%. As the chain flexes back and forth over the
Elongation
sheave, the bearing joints (pins and inside link plates)
gradually incur wear due to articulation. It is important to measure the chain in the section
that moves over the sheaves because it receives the
3.12.2 Inspection Guidelines most frequent articulation. Measuring the chain near
its clevis terminals could give an inaccurate reading.
1. Park the machine on a firm, level surface, raise the The ends of the chains, near the clevis terminal, will
boom to a horizontal (level) position, place the not have flexed as frequently, if at all, as the middle
transmission control lever in (N) NEUTRAL, engage of the chains.
the park brake switch.
It is best to measure in 12 pin increments from pin
2. Fully extend the boom until the extend chain is taut. center to pin center. For example, if the links are one
Shut the engine off. inch from pin center to pin center, the distance
3. The extend chains will be visible for inspection with should be 12 in (305 mm). If the links are 3/4 in
the vehicle in this state. apart, the distance after 12 pins should be 9 in.
4. While doing the chain inspection, check all chain 4

clevis ends for distortion or cracking and sheaves for
3
bearing wear or grooving from the chain.
5. Inspect the retract chains every 1000 hours of
operation.
6. Inspect the chains for the following conditions:
MY1360
If the distance measured (3) is 3% greater than the

normal length (4), discard and replace the chain.
3-26 TL1055, TL1255

Boom
Distorted or Battered Link Plates Cracked Plates

Inspect the chains very carefully, front and back as
85 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:
MZ1466
• Fatigue Cracking -
9
Fatigue cracks (9) are
Distorted or battered link plates (5) on a leaf chain can a result of repeated
cause tight joints and prevent flexing. cyclic loading beyond MZ1467
Turning or Protruding Pins the chain’s endurance

limit.
Highly loaded chain, operating with inadequate
lubrication can generate abnormal frictional forces • Stress Corrosion
between pin and link plates. When chain is allowed Cracking - The
outside link plates 10
to operate in this condition, a pin or series of pins,
can begin to twist out of a chain, resulting in failure. are particularly MZ1468
susceptible to stress
corrosion cracking (10).
• Corrosion Fatigue Cracking - Corrosion
7 fatigue cracks are very similar to fatigue
6
cracks in appearance. Corrosion fatigue is the
8 combined action of an aggressive
MZ1465 environment and cyclic stress.
Other Modes of Failure
Examine the pin head rivets to determine if the
“VEE” flats are still in correct alignment (6). Chain • Ultimate Strength Failure -
with rotated/displaced heads (7) or abnormal pin These types of failures are
protrusion (8) should be replaced immediately. caused by overloads far in 11
DO NOT attempt to repair the chain by welding or excess of the design load. MZ1469
driving the pin(s) back into the chain. Once the press Either fractured plates (11) 12
fit integrity between outside plates and pins has or enlarged holes (12) can
been altered, it cannot be restored. occur. If either of these
MZ1470
failures occurs, the chain
Any wear pattern on the pin heads or the sides of the should be replaced immediately.
link plates indicates misalignment in the system.
This condition damages the chain as well as • Tight Joints
increases frictional loading and should be corrected. - All joints in
the chain
should flex
freely. Tight
joints (13) 13 MZ1471
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.
TL1055, TL1255 3-27

Boom
3.12.3 Expose Chains for Inspection 3.12.4 Chain Lubrication

After inspection and before being returned to service,
c. Extend Chains chains must be lubricated with Cat Multipurpose Grease-
1. Park the machine on a firm, level surface. Place the NLGI Grade 2.
transmission control lever in (N) NEUTRAL, engage The lubricant must penetrate the chain joint to prevent
the park brake switch and raise the boom to a wear. Applying lubricant to the external surfaces will
horizontal (level) position. prevent rust, but the chains should be articulated to
2. Fully extend the boom until both extend chains are make sure the lubricant penetrates to the working
surfaces between the pins and links.
taut. Shut the engine OFF.
The extend chains will be visible for inspection with the To prepare the chain for lubrication, the chain plates
should be brushed with a stiff brush or wire brush to
machine in this state.
clear the space between the plates so that lubricant can
While doing the chain inspection, check all chain clevis penetrate to the working surfaces.
ends for distortion or cracking and sheaves for bearing
Lubricant may be applied with a narrow paint brush or
wear or grooving from the chain. directly poured on, but the chain should be well flooded
If during the inspection, any chain is found to be damaged with lubricant and the boom should be extended and
or stretched, the chain must be replaced. It is retracted to be sure that the lubricant penetrates to the
recommended that when any chain is replaced, that all working surfaces. All surplus lubricant should be wiped
the chains and clevises be replaced at the same time. away from the external surfaces. DO NOT use a solvent
for this wiping operation.
d. Retract Chains Regular application of lubricant is necessary to make
sure that all working surfaces are adequately lubricated.
The three retract chains are only partially visible through In extremely dusty conditions, it may be necessary to
the rear of the boom with all the sections retracted. It is lubricate the chains more often. Refer to Section 2.5,
possible to see a section of the retract chain as the boom “Service and Maintenance Schedules,” and Section 2.6,
is slowly extended. If there is ANY question that one or all “Lubrication Schedules,” for detailed information.
the retract chains are damaged, the chains should be
Lubrication of chains on vehicles working consistently in
removed and inspected. Refer to Section 3.11, “Boom
extreme hot or cold conditions requires special
Chain Removal/Installation” for detailed information. consideration. Contact the Caterpillar dealer for
Replace chains if necessary. guidance.
Note: DO NOT attempt to repair a chain. Replace a
stretched or damaged chain with a new part. Always
replace both the chain and the clevis. It is recommended
that when any chain is replaced, that all chains and
clevis’ be replaced at the same time.
3-28 TL1055, TL1255

Boom
3.13 FORKS
Forks should be cleaned and inspected prior to being
attached to carriage. If the following criteria is not met,
forks must be removed from service immediately.
Daily Inspection
3
6
7
5 4
2
1
9
8
11
10 MH6460
1. Inspect forks (1) for cracks, paying special attention

to heel (2) and mounting tubes (3).
2. Inspect forks for broken or bent tips (4) and twisted
blades (5) and shanks (6).
Yearly Inspection
1. Straightness of the upper face of blade (5) and the
front face of shank (6) should not exceed 0.5 percent
of the length of blade or height of shank.
2. Angle (7) between upper face of blade and front face
of shank should not exceed 93 degrees.
3. Thickness of blade (8) and shank (9) should not be
reduced to 90 percent of original thickness.
Note: Contact the local Caterpillar dealer with the fork
part number to find the manufactured dimensions of the
fork blade.
4. Ensure fork length (10) is adequate for intended
loads.
5. Fork markings should be legible, re-stamp if
required.
6. Compare fork tips (11) when mounted on a carriage.
Maximum difference in height of fork tips is 3 percent
of the length of the blade (10).
TL1055, TL1255 3-29

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

1. Boom will not extend or 1. Broken hydraulic hose(s) or 1. Locate break, replace hose(s)
retract tube(s) and/or connections or tube(s), tighten connections.
leaking.
2. Extend/retract hydraulic system 2. Refer to Section 8.4, “Hydraulic

not operating properly. Circuits.”
3. Faulty extend/retract cylinder. 3. Repair cylinder, Refer to Section

8.8.1, “General Cylinder
Removal Instructions.”
2. Boom shifts to right or left 1. Boom side wear pads 1. Shim wear pads to correct gap.
when extending. improperly shimmed or worn. Replace wear pads as needed.
Refer to Section 3.10, “Boom
Wear Pads.”
3. Excessive boom pivot pin 1. Insufficient lubrication. 1. Lubricate at regular intervals.

noise and/or wear. Refer to Section 2.6,
“Lubrication Schedules.”
Replace worn pins as needed.
2. Worn bearing(s). 2. Replace bearing(s) and

lubricate at regular intervals.
Refer to Section 2.6,
4. Excessive Compensation 1. Insufficient lubrication. 1. Lubricate at regular intervals.

cylinder pivot pin noise and/ Refer to Section 2.6,
or wear. “Lubrication Schedules.”
2. Worn bushing(s). 2. Replace bushing(s) and

3-30 TL1055, TL1255

Boom

5. Drooping chain, or jerky 1. Chain(s) tension not properly 1. Adjust chain(s).
boom extend or retract adjusted.
functions.
2. Chain(s) stretched or binding. 2. Replace chains as needed.
Refer to Section 3.6, “Boom
Section Separation
Adjustment.”
3. Wear pads loose, contaminated, 3. Replace wear pad. Refer to

excessively worn or damaged. Section 3.10, “Boom Wear
Pads.”
4. Contaminated, corroded or 4. Remove contamination and/or

rusted wear pad sliding corrosion from wear pad sliding
surfaces. surfaces and lubricate. If the
surfaces cannot be reconditioned,
replace the boom section(s).
5. Extend/Retract hydraulic 5. Refer to Section 8.4, “Hydraulic

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

section. Refer to Section 3.3,
“Boom Assembly Maintenance.”
6. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s)
and/or connection leaks. or tube(s), tighten connections.
2. Lift/lower hydraulic system not 2. Refer to Section 8.4, “Hydraulic

operating properly. Circuits.”
3. Faulty lift/lower cylinder. 3. Repair cylinder. Refer toSection

8.8.1, “General Cylinder
Removal Instructions.”
4. Seized boom pivot pin bearing. 4. Replace bearing.
7. Excessive Lift/Lower cylinder 1. Insufficient lubrication. 1. Lubricate at regular intervals.

pivot pin noise and/or wear. Refer to Section 2.5, “Service
and Maintenance Schedules.”
Refer to Section 8.8.1, “General
Cylinder Removal Instructions.”
2. Worn self-aligning bushing(s). 2. Replace bushing(s) and

Refer to Section 2.6,
TL1055, TL1255 3-31

Boom

8. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and
correct as needed. Refer to
Section 3.10, “Boom Wear
Pads.”
2. Rapid cycle times with heavy 2. Reduce cycle times.

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

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

abrasive conditions.
9. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8, “Hydraulic
operate. operating properly. System.”
10. Excessive chain wear. 1. Improper chain adjustment. 1. Adjust to correct tension. Refer
to Section 3.6, “Boom Section
Separation Adjustment.”-
Replace chains as needed.
2. Chain sheave(s) not properly 2. Lubricate chain sheave. (Refer

lubricated. to Section 2.5, “Service and
Maintenance Schedules.”
3. Chain sheave(s) not rotating 3. Lubricate chain sheave. Refer

freely. to Section 2.5, “Service and
Maintenance Schedules.”
Repair or replace chain
sheave(s) as needed.
4. Improper chain lubrication. 4. Lubricate at regular intervals.

Refer to Section 2.5, “Service
and Maintenance Schedules.”
Replace chains as needed.
3-32 TL1055, TL1255

Section 4
Cab and Covers
Contents

4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.1 Steering Column and Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.2 Service Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.3 Throttle Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.4 Boom and Tilt Joystick Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.5 Frame Level, Auxiliary and Outrigger Control Joysticks . . . . . . . . . . . . . 4-6
4.3.6 Windshield Wiper Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.7 Heater/Air Conditioning System (if equipped) . . . . . . . . . . . . . . . . . . . . . 4-6
4.4 Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5 Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
TL1055, TL1255 4-1

Cab and Covers
4.1 OPERATOR CAB AND COVERS

COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the machine cab and
covers. The following illustration identifies the
components that are referred to throughout this section.
FRAME LEVEL
INDICATOR
HEATER AND A/C
CONTROLS (OPTIONAL)
STEERING WHEEL
BOOM CONTROL
JOYSTICK
INSTRUMENT
PANEL FRAME LEVEL
CONTROL JOYSTICK
AUXILIARY CONTROL
JOYSTICK
TRANSMISSION
CONTROL LEVER
OUTRIGGER CONTROL
JOYSTICK
IGNITION
SWITCH
FUEL TANK
SERVICE BRAKE
PEDAL
ACCELERATOR MY0930
PEDAL
4-2 TL1055, TL1255

Cab and Covers
4.2 OPERATOR CAB 4. Properly disconnect the battery.

Note: It may be necessary to remove the main dash
panel to gain access to the appropriate hydraulic hoses.
WARNING Refer to Section 9.12.1, “Analog Gauges.”
DO NOT service the machine without following all
safety precautions as outlined in the “Safety 2
Practices” section of this manual.
4.2.1 Cab Safety
WARNING 3
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
4
their specified value.
DO NOT weld, grind, drill, repair or modify the cab in any
way. Any modification or damage to cab structural
components requires cab replacement.
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 Serial Number Decal

1
The cab serial number decal is located on the left side of
the cab, behind the seat. Information specified on the MY0120
serial number plate includes the cab model number, the
cab serial number and other data. Write this information 5. Label, disconnect and cap the four hoses from the
down in a convenient location to use in cab side of the steering valve (1). Cap the fittings on the
correspondence. steering valve. Label, disconnect and plug the load
sense hose at the front of the steering valve. Cap the
4.3 CAB COMPONENTS fitting on the steering valve.
6. Remove the steering wheel (2), disconnect and
4.3.1 Steering Column and Orbitrol Valve remove the travel select lever (3), disconnect the
instrument panel harness connector (4).
a. Orbitrol Valve Removal 7. Remove the steering assembly through the dash
1. Park the machine on a firm, level surface, level the panel opening.
machine, fully retract the boom, lower the boom, 8. Support the steering valve, and remove the four hex-
place the travel select lever in the (N) NEUTRAL head capscrews and four lockwashers.
position, engage the parking brake and turn the
Note: DO NOT disassemble the orbitrol valve. The
engine OFF.
orbitrol valve is not serviceable and must be replaced in
2. Place a Do Not Operate Tag on both the ignition key its entirety, if defective.
cool.
TL1055, TL1255 4-3

Cab and Covers
b. Orbitrol Valve Installation c. Service Brake Pedal Removal

1. Secure the steering valve to the steering column 1. Park the machine on a firm, level surface, level the
with four hex-flange capscrews and four machine, fully retract the boom, lower the boom,
lockwashers. place the travel select lever in the (N) NEUTRAL
2. Install the steering column through the dash panel position, engage the parking brake and turn the
opening. Position steering valve to its original engine OFF.
orientation in the cab. 2. Place a Do Not Operate Tag on both the ignition key
3. Install the travel select lever, connect the instrument switch and steering wheel, stating that the machine
panel harness connector, install the steering wheel should not be operated.
assembly. Torque the steering wheel nut to 29-34 lb-ft 3. Open the engine cover. Allow the system fluids to
(39-46 Nm). cool.
4. Install new o-rings into the steering valve fittings. 4. Properly disconnect the battery.
Lubricate the o-rings with clean hydraulic oil.
5. Uncap and connect the previously labeled load
sense hose to the steering valve.
6. Uncap and connect the remaining previously labeled
four hoses to the steering valve.
Note: If necessary, install the main dash panel. Refer to
Section 9.12.1, “Analog Gauges.”
7. Properly connect the battery.
8. Start the engine and check the operation of steering 3
system. Check for hydraulic fluid leaks. Check the
hydraulic fluid level in the tank and add fluid as 1
required.
9. Close and secure the engine cover.
10. Remove the Do Not Operate Tags from both the 2
c. Steering Test
Conduct a pressure check of the steering hydraulic MY0140
circuits at the main control valve. Refer to Section 8.3.1, 5. Remove the bolt and lockwasher (1) securing the
“Pressure Checks and Adjustments.” service brake pedal pivot pin (2).
4.3.2 Service Brake Pedal 6. Pull the pivot pin from the service brake pedal
bracket (3).
a. Brake Valve Removal 7. Remove the service brake pedal from the cab.
Refer to Section 8.7.3, “Service Brake Valve,” for removal
d. Service Brake Pedal Installation
information.
1. Position the service brake pedal in its mounting
b. Brake Valve Installation location within the cab.
Refer to Section 8.7.3, “Service Brake Valve,” for 2. Secure the brake pedal into position with the pivot pin.
installation information. 3. Be sure the brake pedal has the correct range of motion.
Secure pivot pin with bolt and lockwasher.
4-4 TL1055, TL1255

Cab and Covers
4.3.3 Throttle Pedal 4.3.4 Boom and Tilt Joystick Assembly
a. Throttle Pedal Removal a. Joystick Assembly Removal

1. Park the machine on a firm, level surface, level the 1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom, machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL place the travel select lever in the (N) NEUTRAL
position, engage the parking brake and turn the position, engage the parking brake and turn the
engine OFF. engine OFF.
2. Place a Do Not Operate Tag on both the ignition key 2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine switch and steering wheel, stating that the machine
should not be operated. should not be operated.
3. Properly disconnect the battery. 3. Properly disconnect the battery.
6
7
MY0950
4. Lift the joystick’s rubber sleeve, remove the bolts

securing the boom joystick to the cab (7).
5. Lift the joystick from its mounting position.
6. Label, disconnect and cap the hydraulic hoses
attached to the boom joystick.
7. Disconnect the tilt function electronic connector.
MY0940 8. Remove the joystick assembly.
4. Disconnect the electrical harness connector (4).
5. Remove the bolts (5) securing the throttle pedal to
the throttle pedal bracket (6).
6. Remove the throttle pedal assembly from the cab.
b. Throttle Pedal Installation

1. Position the throttle pedal in its mounting location
within the cab.
2. Secure the throttle pedal into position with the pivot
pin.
3. Install the throttle pedal ball joint to the throttle pedal.
5. Verify proper throttle pedal operation.
TL1055, TL1255 4-5

Cab and Covers
b. Joystick Assembly Installation 4. Remove the screws (8) securing the dash panel (9)
to the cab. Remove the dash panel.
1. Uncap and connect the previously labeled hydraulic
hoses to their appropriate locations. 5. Remove any hardware securing the joystick to the
cab.
2. Connect the tilt function electronic connector.
6. Label, disconnect and cap the hydraulic hoses
3. Install the bolts securing the joystick to the cab.
attached to the joystick.
7. Remove the joystick from the cab.
5. Test the joystick functions:
a. Move the joystick handle rearward, activating the b. Joystick Installation
boom lift function. The boom should RISE. 1. Uncap and connect the previously labeled hydraulic
b. Move the joystick handle forward, activating the hoses to their appropriate locations.
boom lower function. The boom should LOWER.
2. Install the bolts securing the joystick to the cab.
c. Move the joystick handle to the right, activating
the boom extend function. The boom should 3. Install the dash panel to its original position with the
EXTEND. previously used hardware.
d. Move the joystick handle to the left, activating the 4. Properly connect the battery.
boom retract function. The boom should 5. Test the complete range of the joystick functions.
RETRACT.
e. Depress the left side of the switch to activate the
tilt up function. The attachment should TILT UP. 7. Remove the Do Not Operate Tags from both the
f. Depress the right side of the switch to activate ignition key switch and the steering wheel.
the tilt down function. The attachment should
TILT DOWN. 4.3.6 Windshield Wiper Assembly
6. Close and secure the engine cover. Refer to Section 9.9, “Window Wiper/Washer Windshield
7. Remove the Do Not Operate Tags from both the Wiper Motor,” for removal and installation information.
4.3.7 Heater/Air Conditioning System
4.3.5 Frame Level, Auxiliary and Outrigger (if equipped)
Control Joysticks Note: If machine is equipped with air conditioning,
DO NOT loosen or disconnect any air conditioning hoses
a. Joystick Removal until the air conditioning system has been properly
1. Park the machine on a firm, level surface, level the drained by the local Caterpillar dealer or certified air
machine, fully retract the boom, lower the boom, conditioning service center.
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake and turn the a. Heater Assembly Removal
engine OFF. 1. Park the machine on a firm, level surface, level the
2. Place a Do Not Operate Tag on both the ignition key machine, fully retract the boom, lower the boom,
switch and steering wheel, stating that the machine place the travel select lever in the (N) NEUTRAL
should not be operated. position, engage the park brake and shut the engine
OFF.
9
cool.
5. Place a suitable container beneath the radiator.
Slowly turn the radiator cap to the first stop, allow
8 any pressure to escape. Remove the radiator cap.
MY0960
4-6 TL1055, TL1255

Cab and Covers
6. Place a funnel at the base of the radiator to channel

the drained coolant into the container. Loosen the 14
HEATER WITH AIR
drain petcock and allow the coolant to drain. CONDITIONING SHOWN
7. Transfer the coolant to a container with a cover, and
label as “Used Antifreeze.” Dispose of the used
coolant at an approved recycling facility.
8. Tighten the radiator drain petcock. 15
9. Remove the bolts that secure the seat to the cab.

Remove the seat.
MY4390
16
16 14 13
13. Loose the hose clamps securing the heater hoses

(13).
14. Label and remove both heater hoses.
15. Label and disconnect any electrical connections
(14).
16. Label and disconnect both air conditioning hoses
(15).
11 17. Remove the bolts (16) securing the heater assembly
10
to the cab. Remove the heater assembly.
MY0190
b. Heater Assembly Installation
Note: If machine is equipped with air conditioning,
10. Remove the bolts securing the front plate (10) to the
the air conditioning system must be charged by the local
seat riser weldment (11).
Caterpillar dealer or certified air conditioning service
11. Remove the bolts securing the seat riser weldment center.
to the cab. Remove the riser weldment.
1. Position the heater assembly to its original orientation
in the cab. Secure with the previous hardware.
2. Connect the previously labeled electrical
connections.
3. Connect the previously labeled heater hoses to their
appropriate locations.
4. Connect the previously labeled air conditioning
hoses to their appropriate locations.
5. Install the seat riser weldment.
6. Install the front plate to the seat riser weldment.
7. Install the cab seat.
8. Fill the cooling system completely with coolant,
12
allowing time for the coolant to fill the engine block.
MAL0420
The cooling system capacity is listed in Section 2.4,
“Fluids and Lubricant Capacities.”
12. Loosen the hose and disconnect the heater air duct
hoses (12).
TL1055, TL1255 4-7

Cab and Covers
Note: When the engine is initially started, run it briefly at 5. Place a funnel at the base of the radiator to channel
low idle and check the machine for any visual sign of the drained coolant into the container. Loosen the
fluid leakage. STOP the engine immediately if any drain petcock and allow the coolant to drain.
leakage is noted, and make any necessary repairs 6. Transfer the coolant to a container with a cover, and
before continuing. label as “Used Antifreeze.” Dispose of the used
10. Wait for the engine to cool and check the coolant coolant at an approved recycling facility.
level. Add coolant as required to bring the coolant to 7. Tighten the radiator drain petcock.
the proper level.
8. Disconnect the cab heater hoses. Refer to Section
11. Remove the Do Not Operate Tags from both the 4.3.7, “Heater/Air Conditioning System (if
ignition key switch and the steering wheel. equipped).”
9. Remove the necessary dash panels to gain access
4.4 CAB REMOVAL to the electrical wiring connections. Label and
disconnect the harnesses. Push the harness
connectors through the opening in the cab.
WARNING 10. Remove the boom joystick from is mounting
The protection offered by this ROPS/FOPS will be position. Refer to Section 4.3.4, “Boom and Tilt
impaired if subjected to any modification or structural Joystick Assembly.” Label, disconnect and cap all
damage, at which time replacement is necessary. hydraulic hoses attached to the boom joystick. Cap
ROPS/FOPS must be properly installed using all fittings and openings to keep dirt and debris from
fasteners of correct size and grade, and torqued to entering the hydraulic system.
their specified value. 11. Remove the frame level and attachment tilt and
auxiliary control joystick. Refer to Section 4.3.5,
Note: To help ensure safety and optimum performance,
“Frame Level, Auxiliary and Outrigger Control
replace the cab if it is damaged. Refer to the appropriate
Joysticks.” Label, disconnect and cap all hydraulic
parts manual for ordering information.
hoses attached to the joystick. Cap all fittings and
Inspect the cab, its welds and mounts. If modification, openings to keep dirt and debris from entering the
damage, a cracked weld and/or fatigued metal is hydraulic system.
discovered, replace the cab. Contact the local Caterpillar 12. Label, disconnect and cap all hydraulic hoses
dealer with any questions about the suitability or attached to the steering orbitrol valve. Cap all fittings
condition of a cab. and openings to keep dirt and debris from entering
Note: Remove and label cab components as needed the hydraulic system.
before removing the cab from the machine. Label, 13. Label, disconnect and cap all hydraulic hoses
disconnect and cap hydraulic hoses. Transfer cab parts attached to the steering orbitrol valve. Cap all fittings
to the replacement cab after the replacement cab is and openings to keep dirt and debris from entering
securely mounted on the machine. the hydraulic system.
1. Park the machine on a firm, level surface. Allow 14. Label, disconnect and cap all hydraulic hoses
sufficient overhead and side clearance for cab attached to the service brake valve. Cap all fittings
removal. Level the machine, fully retract the boom, and openings to keep dirt and debris from entering
lower the boom, place the travel select lever in the the hydraulic system.
(N) NEUTRAL position, engage the park brake and 15. Push all the hydraulic hoses through the opening in
shut the engine OFF. the cab.
2. Block all four wheels to help prevent the machine 16. Disconnect the throttle cable from the throttle
from moving. Assure that there is sufficient overhead assembly. Refer to Section 4.3.3, “Throttle Pedal.”
and side clearance for cab removal.
17. Disconnect the engine air filter and hydraulic oil
3. Open the engine cover. Allow the system fluids to reservoir breather from their brackets at the top of
cool. the cab. Move the air filter and breather clear from
4. Properly disconnect the battery. the cab so they do not become damaged during cab
removal.
4-8 TL1055, TL1255

Cab and Covers
18. Remove the fuel tank from the cab. Refer to Section 23. Remove the mirrors and all other cab components
7.6.2, “Fuel Tank.” as needed, if not previously removed.
13 14 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
15
no personnel enter the cab while it is being removed
MY0610 from the machine.
27. Inspect the condition of the fittings, clamps,
19. Open Cab: Route a sling with a minimum lifting hydraulic hoses, etc. Replace parts as indicated by
capacity of 1000 lb (453 kg) under the inner four their condition.
braces (13) and behind the center cross support
above the wind shield or install two lifting eye bolts 28. Inspect and replace other machine parts that are
(14) in the threaded holes on the roof of the cab exposed with the cab removed. Repair or replace as
above the B pillars (15). required.
20. Enclosed Cab: Install two lifting eye bolts (14) in the
4.5 CAB INSTALLATION
threaded holes on the roof of the cab above the B
pillars (15).
1. Block all four wheels to help prevent the machine
from moving. Assure that there is sufficient overhead
and side clearance for cab installation.
13 14
16 16
15
MY0610
2. Open Cab: Route a sling with a minimum lifting

MY4170 capacity of 1000 lb (453 kg) under the inner four
braces (13) and behind the center cross support
17 17 above the wind shield or install two lifting eye bolts
(14) in the threaded holes on the roof of the cab
21. Remove the two cab side-mount bolts in the cab
above the B pillars (15).
(16).
3. Enclosed Cab: Install two lifting eye bolts (14) in the
22. Remove the four cab-to-frame bolts, flat washers and
threaded holes on the roof of the cab above the B
nuts (17).
pillars (15).
TL1055, TL1255 4-9

Cab and Covers
4. Use a hoist or overhead crane and sling attached to 14. Fill the cooling system completely with coolant,
the cab. Carefully begin to align the cab with the allowing time for the coolant to fill the engine block.
mounting holes in the frame. Stop and check that The cooling system capacity is listed in Section 2.4,
wiring, hydraulic hoses, cables, etc., will not be “Fluids and Lubricant Capacities.”
pinched or damaged as the cab is positioned. 15. Properly connect the battery.
Readjust the position of the sling as needed to help
balance the cab during installation. 16. Start the engine and check the operation of all controls.
Check for hydraulic fluid leaks. Check the hydraulic
fluid level in the tank and add fluid as required.
Note: When the engine is initially started, run it briefly at
low idle and check the machine for any visual sign of
fluid leakage. STOP the engine immediately if any
leakage is noted, and make any necessary repairs
before continuing.
16 16
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.
20. Unblock the wheels.
MY4170
17 17
5. Install the four cab-to-frame mount bolts, washers and
nuts (17). Torque to 280-305 lb-ft (379-414 Nm).
6. Install the two cab side mount bolts washers and
nuts (16). Torque to 680-720 lb-ft (922-976 Nm).
7. Install the engine air filter and hydraulic oil reservoir
breather to their brackets at the top of the cab.
8. Install the throttle cable to the throttle pedal
assembly. Refer to Section 4.3.3, “Throttle Pedal.”
9. Pull all the hydraulic hoses and electrical wires
through the cab.
10. Uncap and reconnect the previously labeled
hydraulic hoses to their appropriate locations.
11. Reconnect the previously labeled electrical
connections to their appropriate locations.
12. For machines equipped with the heater option,
reconnect the heater hoses to the cab heater. Refer
to Section 4.3.7, “Heater/Air Conditioning System (if
equipped).”
13. Install the fuel tank to the cab. Refer to Section
7.6.2, “Fuel Tank.”
4-10 TL1055, TL1255

Section 5
Axles, Drive Shafts, Wheels and Tires
Contents

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . 5-2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.3 Axle Internal Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.4 Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.5 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.6 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.7 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . 5-6
5.4 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.5.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5-10
5.5.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . 5-11
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.7 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.7.1 Manually Releasing the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.7.2 Manually Resetting the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
TL1055, TL1255 5-1

5.1 AXLE, DRIVE SHAFT AND WHEEL

locations of the major assemblies of the axles, drive shafts,
wheels and tires. The following illustration identifies the
components that are referred to throughout this section.
REAR STEERING
CYLINDER
REAR AXLE
ASSEMBLY
CARRIER
BEARING
TRANSMISSION
TRANSFER CASE
REAR DRIVE SHAFT
FRONT STEERING
CYLINDER REAR AXLE
WHEEL HUBS (2)
FRONT DRIVE SHAFT
FRONT AXLE
ASSEMBLY
FRONT AXLE
WHEEL HUBS
(2)
MAL2070
5-2 TL1055, TL1255

5.2 GENERAL INFORMATION 5.3.3 Axle Internal Service

Detailed axle service instructions (covering the axle,
differential, brakes and wheel-end safety, repair,
WARNING disassembly, reassembly, adjustment and
troubleshooting information) are provided in the Axle
Repair Manual (P/N 31200240).
safety precautions as outlined in Section 1, “Safety
Practices,” of this manual.
5.3.4 Axle Maintenance
Note: To help ensure optimum performance, the drive CLEANING: Clean parts with machined or ground
shaft assemblies are specially balanced as a unit at the surfaces (such as gears, bearings and shafts) with
factory. When servicing any flange yoke, slip yoke or emulsion cleaners or petroleum-based cleaners. DO
drive shaft tube, order a complete assembly if NOT steam clean internal components and the interior of
components are bent or damaged. Refer to the the planetary hub and axle housing. Water can cause
appropriate parts manual for ordering information. corrosion of critical parts. Rust contamination in the
Before performing any inspection, maintenance or lubricant can cause gear and bearing failure. Remove old
service operation, thoroughly clean the unit. The axles gasket material from all surfaces.
and drive shafts should be checked and repaired only by DRYING: Use clean, lintless towels to dry components
experienced service technicians who are aware of all after cleaning. DO NOT dry bearings by spinning them
safety instructions and particular component features. with compressed air; this can damage mating surfaces
Use suitable products to thoroughly clean all due to lack of lubrication. After drying, lightly coat
disassembled mechanical parts to help prevent personal components with oil or a rust-preventive chemical to help
injury to the worker and prevent damage to the parts. protect them from corrosion. If storing components for a
Carefully inspect the integrity of all moving parts prolonged period, wrap them in wax paper.
(bearings, yokes, tubes, gears, shafts, etc.) and fasteners PERIODIC OPERATION REQUIREMENT: Every two
(nuts, bolts, washers, etc.) as they are subject to major weeks, drive the machine far enough to cause the drive-
stress and wear. Always replace elastic locknuts and any train components to make several complete revolutions.
damaged, worn, cracked, seized or otherwise improper This will help ensure that internal components receive
parts that could affect the safe and proper functioning of lubrication to minimize deterioration caused by
the machine, axles and drive shafts. environmental factors such as high humidity.
SUBMERSION: If the machine has been exposed to
5.3 AXLE ASSEMBLIES water deep enough to cover the hubs, disassemble the
wheel ends and inspect for water damage and
5.3.1 Axle Serial Number Plate contamination. If the carrier housing was submerged in
water, especially if the water level was above the vent
The front and rear axle serial number plate is located on tube (breather), drain the axle and inspect internal parts
a mounting pad on the front side of the center section of for water damage and contamination. Before assembling
each axle. Information on the serial number plate is and refilling the unit with the specified lubricant(s), clean,
required in correspondence regarding the axle. examine and replace damaged parts as necessary.
Supply information from the axle serial number plate
when communicating about an axle assembly or axle Note: Use a suitable puller for bearing removal. Clean,
components. inspect and lubricate all bearings just prior to
reassembly. If replacement of a damaged bearing cup or
5.3.2 Axle Specifications cone is necessary, replace the cup and cone as a set.
General axle specifications are found in Section 2,

“General Information and Specifications.”
TL1055, TL1255 5-3

5.3.5 Axle Removal frame and lower the machine onto the supports.
Ensure that the machine will remain in place during
The front and rear axle assemblies differ in that the front
axle removal.
axle assembly is equipped with a parking brake
mechanism and a limited-slip feature; the rear axle has 10. Support the axle that is being removed with a suitable
neither. The following steps outline a typical axle removal jack, hoist or overhead crane and sling. DO NOT
procedure, suitable for either the front or the rear axle raise the axle or the machine.
assembly. 11. Remove both wheel and tire assemblies from the
Cleanliness is extremely important. Before attempting to axle that is being removed. (Refer to Section 5.5.1,
remove the axle, thoroughly clean the machine. Avoid “Removing Wheel and Tire Assembly from
spraying water or cleaning solution on electrical Machine.”)
components. If using a steam cleaner, seal all openings Note: The wheel and tire assemblies must be re-installed
before steam cleaning. later with the directional tread pattern “arrows” facing in
Note: Clear the work area of all debris, unnecessary the direction of forward travel.
personnel, etc. Allow sufficient space to raise the 12. Remove the drive shaft assembly. Refer to Section
machine and to remove the axle. 5.4.3, “Drive Shaft Removal.”
1. Park the machine on a firm, level surface, level the 13. On the front axle remove the capscrew and locknuts
machine, fully retract the boom, lower the boom, securing the lower position cylinder-mount pin to the
place the travel select lever in the (N) NEUTRAL front cylinder. Tap the cylinder mount pin out, and
position, engage the parking brake, straighten all move the cylinder to prevent it from interfering with
wheels and shut the engine OFF. axle removal.
2. Place a Do Not Operate Tag on both the ignition key 14. Remove the bolts and locknuts securing the axle to
switch and steering wheel, stating that the machine the frame.
should not be operated.
15. Remove the axles from the machine using the jack,
3. Open the engine cover. Allow the system fluids to hoist or overhead crane and sling supporting the
cool. axle. DO NOT raise or otherwise disturb the
4. Properly disconnect the battery. machine while removing the axle. Balance the axle
and prevent it from tipping, turning or falling while
5. Remove the optional fender assembly.
removing it from beneath the machine. Place the
axle on a suitable support or holding stand.
5.3.6 Axle Installation

1. Before proceeding, ensure that the machine will
MY4180
remain in place during axle installation. Block the
2 1 1 2 front and rear of both tires on the axle that is already
6. If the axle will be disassembled after removal, place installed on the machine.
a suitable receptacle under the axle (1) and wheel 2. If applicable, raise the machine using a suitable jack
hubs drain plugs (2). Remove the drain plugs and or hoist. Place suitable supports beneath the frame
allow the axle oil to drain into the receptacle. and lower the machine onto the supports, allowing
Transfer the used axle oil into a suitable covered enough room for axle installation. Ensure that the
container, and label the container as “Used Oil.” machine will remain in place during axle installation.
Dispose of used oil at an approved recycling facility.
7. Label, disconnect and cap the steering and brake
lines at the axle. Wipe up any spilled oil.
8. 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.
9. Raise the machine using a suitable jack or hoist.
Place suitable supports under both sides of the
5-4 TL1055, TL1255

3. Using a suitable jack, hoist or overhead crane and 11. Rotate wheel hubs 90 degrees so the drain plug (2)
sling, remove the axle from its support or holding becomes the fill plug (3). Refer to Section 2.4,
stand. Balance the axle and prevent it from tipping, “Fluids and Lubricant Capacities,” for proper oil and
turning or falling while positioning it beneath the capacities.
machine. DO NOT raise or otherwise disturb the 12. Install the wheel and tire assemblies. Refer to
machine while installing the axle. Keep the axle Section 5.5.2, “Installing Wheel and Tire Assembly
supported and balanced on the jack, hoist or onto Machine.”
overhead crane and sling throughout the installation
procedure. 13. Carefully remove the jack, hoist or overhead crane
and sling supporting the axle.
4. Position the axle under the frame, and align the axle
housings with the holes in the frame. 14. Carefully raise the machine using a suitable jack or
hoist. Remove the supports from beneath the frame
5. Install the four axle bolts and nuts. Tighten and and lower the machine to the ground.
torque to 530-565 lb-ft (718-766 Nm).
15. Remove the blocks from the front and rear of both
6. Move the cylinder into position on the axle cylinder tires on the other axle.
anchor. Insert a cylinder-mount pin through the
cylinder and cylinder anchor. Secure the cylinder- Note: ALWAYS use new o-rings when servicing the
mount pin with one capscrew and a new locknut. machine.
7. Apply multi-purpose grease through the self-tapping 16. Install new o-rings into the fittings. Lubricate the
lube fitting to lubricate the self-align bearing and the o-rings with clean hydraulic oil.
cylinder-mount pin. 17. Uncap and connect the steering and brake lines at
8. Install the drive shaft assemblies. (Refer to Section their axle fittings.
5.4.5, “Drive Shaft Installation.”) 18. Check the hydraulic reservoir oil level.
9. If reinstalling an axle previously removed from the 19. Start the engine. Turn the steering wheel several
machine, position the driveshaft yoke on the axle times lock to lock, operate the frame tilt function
according to the alignment marks made earlier. If several times in both directions and check the
installing a new axle, note the position of the function of the brakes. Check for hydraulic leaks,
driveshaft yoke at the transmission. Align the and tighten or repair as necessary.
driveshaft yoke on the axle in the same plane as the
yoke on the transmission. 20. Install the optional fender assembly.
Note: The service brake and parking brake circuits will
MY4180 need to bled after axle installation. Refer to Section
2 1 1 2 8.7.4, “Service Brake Bleeding.”
10. Tighten the axle oil drain plug, loosen and remove
the axle oil fill plug (1). (Refer to Section 2.4, “Fluids
and Lubricant Capacities,” for proper oil and
capacities.
LEVEL
MT0220
TL1055, TL1255 5-5

5.3.7 Axle Assembly and Drive Shaft Troubleshooting

1. Excessive axle noise while 1. Oil level too low. 1. Fill oil to correct level. Refer to
driving. Section 2.4, “Fluids and
Lubricant Capacities.”
2. Axle and/or wheel end housings 2. Drain axle and/or wheel end
filled with incorrect oil or oil level housings and fill to correct level
low. with hydraulic oil. Refer to
Section 2.4, “Fluids and
3. Incorrect alignment of ring and 3. Correct alignment by adding or

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

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

housings and fill to correct level
with hydraulic oil. Refer to
8. Axle housing damaged. 8. Replace damaged parts.
2. Intermittent noise when 1. Universal joint(s) worn or 1. Repair or replace universal

traveling. damaged. joints as needed.
2. Differential ring and/or pinion 2. Determine cause and repair as

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

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

unbalanced. needed.
5-6 TL1055, TL1255


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

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

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

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

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

housing(s) damaged.
5. Oil leaking from wheel end 1. Oil level plugs loose and/or 1. Replace o-rings as needed and
housing (planet carrier). o-rings damaged or missing. tighten plugs to 130 Nm
(96 lb-ft).
2. O-ring between hub and 2. Replace o-ring.

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

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

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

cylinder.
2. Steering cylinder o-rings and/or 2. Replace o-rings and seals.
seals worn or damaged.
3. Piston rod seal worn or 3. Replace piston rod seal.

damaged.
4. Cylinder tube damaged. 4. Replace cylinder tube.
TL1055, TL1255 5-7


7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level with
hydraulic oil. Refer to Section
2.4, “Fluids and Lubricant
Capacities.”
2. Axle and/or wheel end housings 2. Drain axle and fill to correct
filled with incorrect oil or oil level with hydraulic oil. Refer to
contaminated or oil level low. Section 2.4, “Fluids and
3. Dragging park brake. 3. Adjust park brake cable as

needed.
8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to Section 8.4, “Hydraulic
2. Excessive joint housing swivel 2. Correct bearing preload by

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

bearings. needed.
9. Slow steering response. 1. Steering (hydraulic) system not 1. Refer to Section 8.4, “Hydraulic
2. Steering cylinder leaking 2. Repair or replace steering

internally. cylinder as needed.
10. Excessive noise when brakes 1. Brake discs worn. 1. Check brake discs for wear.
are engaged. Refer to Section 5.6, “Brakes.”
2. Brake discs damaged. 2. Replace brake discs.
11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to Section 8.4, “Hydraulic
2. Brake piston o-rings and seals 2. Replace o-rings and seals.

damaged (leaking).
12. Brakes will not hold the 1. Brake discs worn. 1. Check brake discs for wear.
machine or braking power Refer to Section 2.4, “Fluids and
reduced. Lubricant Capacities.”
2. Brake (hydraulic) system not 2. Refer to Section 8.4, “Hydraulic

3. Brake piston o-rings and seals 3. Replace o-rings and seals.

damaged (leaking).
5-8 TL1055, TL1255

5.4 DRIVE SHAFTS

TO AXLE
5.4.1 Drive Shaft Inspection and Service

Whenever servicing the machine, conduct a visual
inspection of the drive shafts and cross and bearing
assemblies (universal joints, or U-joints). A few moments
spent doing this can help prevent further problems and TO
TRANSMISSION
1 2
down time later.
Inspect areas where the drive shaft flange yokes and slip
yokes mount to the drive shafts. Attempt to turn each
3
drive shaft in both directions. Look for excessive MT0350
4
looseness, missing parts, cracks or other damage. Worn
or damaged drive shafts and cross and bearing 7. Remove the four bolts (1) and two straps (2)
assemblies may cause an excessive amount of vibration securing the bearing cross to the transmission
or noise. output shaft flange. Discard bolts.
Note: Any bolt removed from the drive shaft assembly 8. Remove the four bolts (3) and two straps (4)
MUST be replaced. Do Not re-torque. securing the bearing crosses to the axle. Discard
bolts.
5.4.2 Drive Shaft Maintenance 9. Remove the front drive shaft assembly.
Refer to Section 2.4, “Fluids and Lubricant Capacities,” 10. Repeat the above procedure on the rear drive shaft.
for information regarding the lubrication of the grease
fittings on the drive shafts. 5.4.4 Drive Shaft Cleaning and Drying
1. Disassemble and clean all parts using an approved
5.4.3 Drive Shaft Removal cleaning fluid. Allow to dry.
1. Park the machine on a firm, level surface, level the 2. Remove and burrs or rough spots from all machined
machine, fully retract the boom, lower the boom, surfaces. Re-clean and dry as required.
place the transmission control lever in (N) NEUTRAL,
5.4.5 Drive Shaft Installation
engage the park brake and shut the engine OFF.
1. Raise the drive shaft assembly into position. The
slip-yoke end of the drive shaft mounts toward the
switch and steering wheel, stating that the machine
axle. If reinstalling a drive shaft previously removed,
align the flange yokes according to the alignment
3. Open the engine cover. Allow the system fluids to marks made during removal.
cool.
Note: The yokes at both ends of the drive shaft must be
4. Properly disconnect the battery. in the same plane to help prevent excessive vibration.
5. Block the wheels.
2. Apply Loctite® 243TM to all mounting bolts.
6. The drive shaft assembly is a balanced assembly.
3. Install the two straps (2) and four new bolts (1)
Mark the yoke and axle, transmission and the shaft
securing the bearing crosses to the transmission.
and slip yoke so that these components can be
Torque bolts to 55-60 lb-ft (75-81 Nm).
returned to their original positions when reinstalled.
Yokes at both ends of the drive shaft must be in the 4. Install the two straps (4) and four new bolts (3)
same plane to help prevent excessive vibration. 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.
8. Unblock the wheels.
TL1055, TL1255 5-9
5.5 WHEELS AND TIRES 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
MY4190
that replacement tires have the following characteristics:
• Equal or greater ply/load rating and size of original. The wheel and tire assemblies must be installed with the
directional tread pattern “arrows” (5) facing in the direc-
• Tire tread contact width equal or greater than tion of forward travel.
original.
• Wheel diameter, width and offset dimensions equal
5.5.1 Removing Wheel and Tire Assembly
to the original. from Machine
• Approved for the application by the tire manufacturer 1. Park the machine on a firm, level surface, fully
(including inflation pressure and maximum tire load). retract the boom, lower the boom, place the
transmission control lever in (N) NEUTRAL, engage
The rims installed have been designed for stability the park brake and shut the engine OFF.
requirements which consist of track width, tire pressure
and load capacity. Size changes such as rim width, 2. Place an Do Not Operate Tag on both the ignition
center piece location, larger or smaller diameter, etc., key switch and steering wheel, stating that the
without written factory recommendations, may result in machine should not be operated.
unsafe condition regarding stability. 3. Loosen but DO NOT remove the lug nuts on the
Foam filled tires have a positive effect on the weight, wheel and tire assembly to be removed.
stability and handling characteristics of the machine, 4. Place a suitable jack under the axle pad closest to
especially under load. The use of hydrofill as a tire-fill the wheel being removed. Raise the machine and
substance is not recommended because of possible position a suitable support beneath the axle. Allow
environmental impact. sufficient room to lower the machine onto the
Large-bore valve stems are used to help expedite tire support and to remove the wheel and tire assembly.
inflation and deflation. An inner tube may be used if a tire 5. Lower the machine onto the support.
does not provide an airtight seal. Check tire inflation 6. Remove lug nuts and lug washers in an alternating
pressures when the tires are cold. When mounting a tire pattern.
on the wheel, the tire must be mounted on the wheel
respective of the directional tread pattern of the tire; this 7. Remove the wheel and tire assembly from the
produces a left or right tire and wheel assembly. machine.
5-10 TL1055, TL1255

5.5.2 Installing Wheel and Tire Assembly 6. Remove the Do Not Operate Tags from both the
onto Machine ignition key switch and the steering wheel.
Note: The wheel and tire assemblies must be installed
with the directional tread pattern “arrows” facing in the 5.6 BRAKES
direction of forward travel.
Check the brake disks for wear every 1,000 hours of
operation or yearly.
Tread “arrows” must point For more information on brake disk inspection, refer to
forward the Axle Repair Manual (P/N 31200240).
5.7 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
own power, before using the emergency towing
procedures outlined below.
Note: Block the wheels of the machine BEFORE
attempting to release the park brake. Once the park
brake is released the machine’s park brake AND service
brakes are inoperable.
Install tires onto wheels
to rotate in proper direc- 5.7.1 Manually Releasing the Park Brake
tion
5 5
MAH0460
1. Position wheel onto studs on wheel end of axle.

2. Install wheel lug washers.
3. Start all nuts by hand to prevent cross threading. DO
NOT use a lubricant on threads or nuts. 5 5
MZ1020
1 8
1. Loosen the nuts of the screws (5) for the manual

6 3 release of the braking units. Draw the nuts back
approximately 6 mm.
2. Tighten the screws until they are gently seated on
the driving plate
9 10
3. Carefully tighten each release screw a 1/4 turn at a
time in sequence until all have been turned on full
turn 360°.
4 5 4. Repeat steps 1 thru 3 for the other side of the
differential.
7 2 MY4200 Note: After the machine has been towed to a secure

location, reactivate the parking brake. Carefully follow
4. Tighten lug nuts in an alternating pattern as the procedures from start to finish. Contact the local
indicated in figure. Torque to 350-400 lb-ft Caterpillar dealer if you are unsure about any part of the
(475-542 Nm). procedure, or for specific instructions concerning your
5. Remove machine from supports. particular situation.
TL1055, TL1255 5-11

5.7.2 Manually Resetting the Park Brake

Note: Block the wheels of the machine BEFORE
attempting to reset the machine’s park brake. Once the
park brake is released the machine’s park brake AND
service brakes are inoperable.
5 5
5 5
MZ1020
1. Loosen each release screw (5), only 1/4 turn at a

time, in sequence, until each screw has lost contact
with the guide pin.
2. Remove the screws along with the nuts and seals.
Replace the seals, lubricate the screws with a
silicone-based grease and re-install the screws
along with the nuts.
3. Adjust the nut of the screw heads in relation to the
arm by 1.18 in (30 mm).
4. Repeat steps 1 thru 3 for the other side of the
differential.
5. After repairs to the machine have been made, start
the machine and check the park brake and service
brakes for proper function. Refer to Section 8.7.4,
“Service Brake Bleeding,” Section 8.7.5, “Service
Brake Test,” and Section 8.7.6, “Park Brake Test.”
5-12 TL1055, TL1255

Section 6
Transmission
Contents

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Transmission Specifications And Maintenance Information . . . . . . . . . . . . . . . 6-3
6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.3 Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.4 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.5 Torque Convertor Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.5.1 Torque Convertor Diaphragm Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.5.2 Torque Convertor Diaphragm Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.6 Transmission Cooler Thermal Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.6.1 Thermal Bypass Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.6.2 Thermal Bypass Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
TL1055, TL1255 6-1

Transmission
6.1 TRANSMISSION ASSEMBLY

locations of the major assemblies of the transmission.
The following illustration identifies the components that
are referred to throughout this section.
TRANSMISSION
FILTER
TORQUE CONVERTER
OIL DRAIN PLUG
OIL FILLER PLUG
TRANSFER CASE
BREATHER
OIL FILL TUBE AND

DIPSTICK
SHIFT SOLENOIDS
SHIFT SOLENOIDS
OIL DRAIN PLUG

MY0970
6-2 TL1055, TL1255

Transmission
6.4.1 Transmission Removal

WARNING
DO NOT service the machine without following all WARNING
safety precautions as outlined in Section 1, “Safety NEVER lift a transmission alone; enlist the help of at
Practices,” of this manual. least one assistant or use a suitable hoist or overhead
crane and sling with a minimum lifting capacity of
6.2 TRANSMISSION SERIAL NUMBER 1000 lb (454 kg).
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.
3. Open the engine cover. Allow the system fluids to cool.
MY0990 4. Remove engine cover to allow easier access to the
1
transmission.
The transmission serial number plate (1) is located on the
5. Drain the hydraulic oil reservoir. Refer to Section
front of the transmission case behind the oil dipstick.
8.5.1, “Hydraulic Oil Reservoir Draining.”
Information on the serial number plate is required in
correspondence regarding the transmission. 6. Properly disconnect the battery.
7. Thoroughly clean the transmission and surrounding
6.3 TRANSMISSION SPECIFICATIONS area, including all hoses and fittings, before
AND MAINTENANCE INFORMATION proceeding.
For transmission, oil specifications and maintenance

information, refer to Section 2, “General Information and
Specifications.”
Detailed transmission service instructions are provided in
the following publications:
• Service Manual (P/N 31200241)
• Parts Manual (P/N 31200257)
6.4 TRANSMISSION REPLACEMENT

Note: Contact the local Caterpillar dealer if internal
transmission repair is required during the warranty 2 3
period. MY0980
Cleanliness is of extreme importance. Before attempting 8. Place a suitable receptacle under the transmission
to remove the transmission, thoroughly clean the exterior drain plug (2). Remove the transmission drain plug,
of the transmission to help prevent dirt from entering and allow the transmission oil to drain into the
during the replacement process. Avoid spraying water or receptacle. Repeat drain procedure with the drop
cleaning solution onto or near the transmission shift box (3).
solenoids and other electrical components. 9. Transfer the used transmission oil into a suitable,
covered container, and label the container as “Used
Oil.” Dispose of used oil at an approved recycling
TL1055, TL1255 6-3

Transmission
facility. Clean and reinstall the transmission drain

plug.
10. Remove the transmission-to-axle drive shafts. Refer 4
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,
“Implement Pump Replacement.”
13. Label and disconnect the transmission temperature
switch connector and shift solenoid wiring harness
connectors. MY0990
14. Label, disconnect and cap the transmission oil
cooler inlet and outlet hoses at the transmission. 27. Remove the transmission oil filter (3) and dispose of
properly. Clean the filter mounting surface. Cover or
15. Remove the access plug from side of the engine bell cap the oil filter mount.
housing. This will allow access to remove the four
bolts holding the torque convertor diaphragm to the 28. If transmission oil is suspect to contamination or
engine flywheel. torque converter is damaged, remove the converter
and flex plate from the transmission.
16. Turn the engine over slowly by hand and align each
of the four torque convertor diaphragm bolts to be 29. Remove the bolt and washers holding the converter
accessed. Remove them one at a time. to the flex plate.
17. Wipe up any spilled hydraulic and transmission oil. 6.4.2 Transmission Inspection and Internal
18. Connect a lifting strap or chain to the lifting eye at Repair
the top of the transmission, and to a suitable hoist or
If replacing the entire transmission, transfer the
overhead crane. Operate the hoist or crane to
transmission temperature switch to the replacement
remove slack from the chain, but DO NOT raise the
transmission. The gear shift solenoids are included with a
transmission at this time.
new transmission.
19. Place blocks under rear of engine for support
BEFORE transmission mounts are removed. 6.4.3 Transmission Installation
20. Place blocks under the transmission to help support
it during removal.
21. Remove both rear transmission mount bolts and
WARNING
lockwashers securing the transmission mount to the NEVER lift a transmission alone; enlist the help of at
frame. least one assistant or use a suitable hoist or overhead
22. Remove the bolts and washers holding the crane and sling.
transmission to the engine. 1. Install both rear transmission mounts on the
23. Remove the capscrews and lockwashers securing transmission. Torque capscrews to 125-140 lb-ft
each rear transmission mount to the transmission. (170-190 Nm).
24. Carefully remove the transmission from the 2. Install two guide studs near the top of the bell
machine. Avoid causing damage to the transmission housing holes.
or surrounding parts. 3. Use a hoist or overhead crane and sling attached to
25. Lift the transmission clear of the machine, and lower the lifting eye at the top of the transmission. Raise
it onto suitable supports or secure it to a stand built and position the transmission within the chassis.
especially for transmission or engine service. Secure 4. Align the torque converter, align the transmission
the transmission so that it will not move or fall. bolt holes with the two studs in the bell housing.
26. Remove any external transmission components as Install the eight bolts and washers and torque to
required, including the transmission temperature 53 lb-ft (72 Nm). Remove the two alignment studs
switch, and inlet and outlet cooler hose fittings. and install and torque the last two transmission
Cover all transmission openings. mounting bolts.
6-4 TL1055, TL1255

Transmission
5. Install the two rear transmission mounting bolts on 6.4.4 After Transmission Service or
the frame with two capscrews and two lockwashers. Replacement
Apply Loctite® 242TM to the transmission mount bolts
In general:
and torque to 125-140 lb-ft (169-190 Nm)
1. Check the transmission oil level and add oil as
required.
of the four torque convertor diaphragm bolts through
the access plug in the bell housing. Install them one 2. Disconnect and clean all transmission cooler hoses.
at a time. DO NOT fully tighten until all of the When possible, remove transmission lines from the
capscrews and locknuts are in place. Torque to machine for cleaning.
26-39 lb-ft (35-59 Nm). Replace access plug. 3. Drain and flush the entire transmission cooling
7. Remove the hoist or overhead crane and sling. system.
8. Connect the transmission temperature switch 4. Thoroughly clean transmission filter screens and
connector and shift solenoid wiring harness cases, and replace transmission filter elements.
connectors.
9. Secure the wiring harness to the transmission
housing.
10. Connect the transmission oil cooler inlet and outlet
hoses at the transmission.
11. Install the hydraulic pump. Refer to Section 8.6.1,
“Implement Pump Replacement.”
5
12. Install the transmission-to-axle drive shafts. Refer to
Section 5.4.5, “Drive Shaft Installation.” MY0990
13. Install the air cleaner and tubing.
5. Reassemble all components and fill the transmission
14. Clean the transmission oil filter mounting surface.
with clean, fresh hydraulic oil through the dipstick
15. Apply a thin film of clean hydraulic oil to the new tube opening (5). Check the level by taking
transmission filter gasket. Install the new filter and intermittent dipstick readings as outlined in the
torque to 20-25 lb-ft (27-34 Nm). appropriate Operation & Maintenance Manual. DO
16. Transmission oil may be added through the dipstick NOT overfill. Reinstall the dipstick when finished.
tube. Remove the dipstick and add hydraulic oil. 6. Run the engine for two minutes at idle to help prime the
Check the oil level by taking intermittent dipstick torque converter and the transmission oil lines.
readings as outlined in the appropriate Operation &
7. Recheck the level of the fluid in the transmission
Maintenance Manual. DO NOT overfill. Reinstall the
with the engine running at idle.
dipstick when finished.
8. Add hydraulic oil as necessary to bring the fluid level
up until it reaches the FULL mark on the dipstick.
18. Install the engine cover. Recheck the oil level when it reaches operating
19. Close and secure the engine cover. temperature 180-200° F (83-94° C).
20. Remove the Do Not Operate Tags from both the 9. Recheck all drain plugs, lines, connections, etc., for
ignition key switch and the steering wheel. leaks, and tighten where necessary.
TL1055, TL1255 6-5

Transmission
6.5 TORQUE CONVERTOR DIAPHRAGM 6.6 TRANSMISSION COOLER THERMAL

BYPASS VALVE
6.5.1 Torque Convertor Diaphragm
Removal 6.6.1 Thermal Bypass Valve Removal
1. Park the machine on a firm, level surface, level the 1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom, machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL place the travel select lever in the (N) NEUTRAL
position, engage the parking brake, and shut the position, engage the parking brake, and shut the
engine OFF. engine OFF.
Note: In order to remove the engine drive plates, the 2. Place a Do Not Operate Tag on both the ignition key
engine and transmission must be separated. switch and steering wheel, stating that the machine
2. Refer to Section 6.4.1, “Transmission Removal,” or
Section 7.9.1, “Engine Removal.” 3. Open the engine cover. Allow the system fluids to
cool.
7 8
4. Properly disconnect and remove the battery.
6
3. Remove the four bolts holding the diaphragms to the

flywheel.
1
4. With the drive plates and torque converter removed,
loosen and remove the four bolts (6) and eight lock MY0980
2
washers holding the two diaphragms (7) to the
torque converter (8). 5. Place a suitable container under the transmission
5. Replace both diaphragms if damaged. drain plug (1). Remove the transmission drain plug,
and allow the transmission oil to drain into the
6.5.2 Torque Convertor Diaphragm receptacle. Repeat drain procedure with the drop
Installation box (2).
1. Install the two new diaphragms on the torque 6. Transfer the used transmission oil into a suitable,
converter and install the four bolts with lock washers. covered container, and label the container as “Used
Oil.” Dispose of used oil at an approved recycling
2. Mount the diaphragm/converter assembly to the facility. Clean and reinstall the transmission and drop
transmission. box drain plugs.
3. Refer to Section 6.4.3, “Transmission Installation,” or
Section 7.9.2, “Engine Installation,” for the
remainder of the installation.
6-6 TL1055, TL1255

Transmission
6.6.2 Thermal Bypass Valve Installation

1. Place the new thermal bypass valve (5) in the
6 5 engine compartment and secure using the
previously used bolts (6).
4
oil cooler hoses (4) to the thermal bypass valve.
3. Uncap and connect the previously labeled
transmission oil cooler hoses to the transmission oil
cooler.
4. Clean the transmission oil filter mounting surface.
3 5. Apply a thin film of clean hydraulic oil to the new
transmission filter gasket. Install the new filter and
torque to 20-25 lb-ft (27-34 Nm).
6. Transmission oil may be added through the dipstick
tube. Remove the dipstick and add transmission oil.
Check the oil level by taking intermittent dipstick
readings as outlined in the appropriate Operation &
Maintenance Manual. DO NOT overfill. Reinstall the
dipstick when finished.
7. Remove drop box fill/level plug and fill with
transmission fluid. Reinstall plug.
MAL1410
NOTE: ITEMS REMOVED FROM ILLUSTRATION FOR CLARITY 8. Install and properly connect the battery.
9. Run the engine for two minutes at idle.
7. Remove the transmission oil filter (3) and dispose of
properly. Clean the filter mounting surface. Cover or 10. Recheck the level of the fluid in the transmission
cap the oil filter mount. with the engine running at idle.
8. Place a suitable container beneath the transmission 11. Add transmission oil as necessary to bring the fluid
cooler fittings on the hydraulic cooler. Transfer any level up until it reaches the FULL mark on the
transmission oil into a properly labeled container. dipstick. Recheck the oil level when it reaches
Dispose of properly. operating temperature 180-200° F (83-94° C).
9. Label, disconnect and cap both transmission cooler 12. Recheck all drain plugs, lines, connections, etc., for
hoses at the radiator. Cap all fittings and openings to leaks and tighten where necessary.
prevent dirt and debris from entering. 13. Close and secure the engine cover.
10. Label, disconnect and cap the hoses (4) at the 14. Remove the Do Not Operate Tags from both the
thermal bypass valve (5). Cap all fittings and ignition key switch and the steering wheel.
openings to prevent dirt and debris from entering.
11. Loosen and remove the two bolts (6) securing the
thermal bypass valve.
12. Remove the thermal bypass valve.
TL1055, TL1255 6-7

Transmission
6.7 TROUBLESHOOTING
This section provides an easy reference guide covering The transmission should be checked, serviced and
the most common problems that may occur during repaired only by experienced service technicians who
operation of the transmission. are aware of all safety instructions and particular
component features
Note: Contact the local Caterpillar dealer if internal
transmission repair is required during the warranty
period.

1. Transmission will not engage 1. Oil level too high or low. 1. Fill transmission to correct level
or will not shift properly. with hydraulic oil. Refer to
2. Transmission control lever not 2. Refer to Section 9.5, “Electrical

functioning properly and/or a System Schematics.”
fault in the wiring
harness.Transmission control
lever not functioning properly
and/or a fault in the wiring
harness.
3. Transmission valve body 3. Refer to Section 9.5, “Electrical

solenoids not functioning System Schematics.”
properly.
4. Pilot-operated shift valves not 4. Clean the valve spool and

operating properly. housing. Replace return spring
as needed.
5. Pump output pressure low. 5. Refer to Section Note:, “Contact

the local Caterpillar dealer if
internal transmission repair is
required during the warranty
period.,” Problem 2. “Low or no
pump flow or pressure.”
6. Clutch piston o-rings damaged. 6. Replace o-rings.
7. Clutch discs worn or damaged. 7. Replace clutch discs.
8. Coupling shafts or gear teeth 8. Replace couplings.

damaged.
6-8 TL1055, TL1255

Transmission

2. Low or no pump flow or 1. Low oil level. 1. Fill transmission to correct level
pressure. with hydraulic oil. Refer to
2. Transmission filled with 2. Drain transmission and fill to

incorrect oil, or oil correct level with hydraulic oil.
contaminated. Refer to Section 2.4, “Fluids and
3. Pump suction pipe screen 3. Clean, repair and/or replace

clogged. suction pipe.
4. Central shaft damaged. 4. Replace central shaft.
5. Pump worn or damaged. 5. Repair or replace pump

assembly.
3. Low clutch pressure. 1. Incorrect oil level. 1. Fill transmission to correct level
with hydraulic oil. Refer to
2. Main pressure valve stuck open. 2. Clean the valve spool and
housing.
3. Broken or worn coupling shaft or 3. Replace coupling and/or o-rings.

piston o-rings.
4. Pressure reducing valve stuck 4. Clean the valve spool and

open. housing.
4. Lack of power. 1. Park or service brake dragging. 1. Refer to Section 8.4, “Hydraulic
Circuits.”
2. Low engine rpm causes 2. Adjust the engine rpm to

converter stall. specifications. Refer to Engine
Service Manual.
3. Pump output pressure is low. 3. Refer to Section Note:, “Contact

period.,” Problem 2. “Low or no
pump flow or pressure.”
4. Clutch discs worn or damaged. 4. Replace clutch discs.
5. Transmission overheating. 5. Refer to Section Note:, “Contact

period.,” Problem 5.
“Transmission overheating (oil
above 248° F (120° C)).”
TL1055, TL1255 6-9

Transmission

5. Transmission overheating 1. Low oil level. 1. Fill transmission to correct level
(oil above 248° F (120° C)). with hydraulic oil. Refer to
2. Clogged radiator. 2. Remove debris from the

radiator.

incorrect oil, or oil correct level with hydraulic oil.
contaminated. Refer to Section 2.4, “Fluids and
4. Excessive “roading.” 4. Stop and idle the engine.
5. Restriction in oil cooler hoses. 5. Replace cooler hoses.
6. Pump worn or damaged. 6. Repair or replace pump

assembly.
7. Engine thermostat stuck. 7. Replace engine thermostat.

Refer to Section 7.4.2,
“Thermostat Replacement.”
8. Thermal by-pass valve 8. Replace thermal by-pass valve.

damaged or flow restricted. Refer to Section 6.6,
“Transmission Cooler Thermal
Bypass Valve.”
6. Grinding or “clunking” noise 1. Oil level too low. 1. Fill oil to correct level. Refer to
from transmission. Section 2.4, “Fluids and
2. Repair or replace parts as
needed.

incorrect oil. correct level with hydraulic oil.
Refer to Section 2.4, “Fluids and
3. Incorrect clutch engagement. 4. Refer to Section 9.11.2,

“Transmission Solenoid Valves.”
4. Internal damage. 5. Repair or replace parts as

needed.
5. Broken diaphragm (torque 6. Replace diaphragm (torque

convertor). convertor). Refer to Section
6.4.1, “Transmission Removal.”
6. Loose diaphragm (torque 7. Tighten capscrews.

convertor) mounting capscrews.
6-10 TL1055, TL1255

Transmission

7. Oil leaking from transmission. 1. Oil leaking from vent (high oil 1. Remove drain plug and drain oil
level). as needed, until oil is at correct
level. Refer to Section 2.4,
“Fluids and Lubricant
Capacities.” Replace o-rings as
needed and tighten plugs to
96 lb-ft (130 Nm).
2. Drain plug loose and/or o-rings 2. Replace o-rings as needed and

damaged or missing. tighten plug to 26 lb-ft (35 Nm).
3. Hose fittings loose. 3. Tighten fittings.
4. Oil leaking at valve bodies 4. Replace gaskets and/or tighten

(possible valve body gaskets capscrews to 7 lb-ft (9,5 Nm).
damaged or missing and/or
mounting capscrews not tight).
5. Housing capscrews loose. 5. Tighten capscrews to 34 lb-ft

(46 Nm).
6. Oil leaking at pump (possible 6. Replace o-rings and/or tighten

pump-to-housing o-rings capscrews to 85 lb-ft (115 Nm).
missing or damaged, and/or
pump mounting capscrews not
tight).
7. Oil leaking at converter bell 7. Replace converter and/or input

(possible converter leak and/or shaft seal.
input shaft seal damage).
8. Oil leaking at output shaft 8. Replace output shaft seal.

(output shaft seal damaged).
9. Oil escaping from breather at 9. Transmission may be under full.

shut down. Ensure transmission is at
operating temperature, 185° F
(85° C) and fill to upper mark on
transmission dip stick.
10. Housing damaged. 10. Replace housing as needed.
TL1055, TL1255 6-11

Transmission
6-12 TL1055, TL1255

Section 7
Engine: CAT C4.4
Contents

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 Engine Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . 7-4
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4.3 Radiator/Transmission Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4.4 Radiator/Transmission/Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . 7-7
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.6.2 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.6.3 After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.7.1 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.7.2 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.7.3 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.7.4 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.8.1 Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.8.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.8.3 Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.8.4 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.9.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.9.2 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.10 Engine Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
TL1055, TL1255 7-1

Engine: CAT C4.4
7.1 INTRODUCTION
7.1.1 Disclaimer and Scope

These instructions are written for worldwide use. In
territories where legal requirements govern engine smoke
emission, noise, safety factors, etc., apply all instructions,
data and dimensions provided herein in such a way that
after maintenance, service and repair of the engine,
engine operation does not violate local regulations.
Note: These instructions cover only the routine
maintenance, removal, installation and troubleshooting
of the engine. Refer to the local Caterpillar dealer and
the applicable Engine Service Manual for assistance
with comprehensive engine diagnosis, repair and
component replacement. A gradual running-in (break-in)
of a new engine is not necessary. Full load can be
applied to a new engine as soon as the engine is put into
service and the coolant temperature is at least 140° F
(60° C). Extended light-load operation during the early
life of the engine is not recommended. DO NOT run the
engine at high, no-load speeds. DO NOT apply an
overload to the engine.
7-2 TL1055, TL1255

Engine: CAT C4.4
7.1.2 Component Terminology

locations of the engine components. The following
illustration identifies the components that are referred to
throughout this section.
TL1055 - BEFORE S/N TBM01316 EXCLUDING TBM01298

TL1255 - BEFORE S/N TBN00799 EXCLUDING TBN00785
THERMOSTAT ENGINE CONTROL

MODULE (ECM)
FUEL FILTER
FUEL INJECTOR
PUMP ALTERNATOR
WATER PUMP
TURBOCHARGER
MAL0261
OIL FILTER STARTER
TL1055 - S/N TBM01316 & AFTER INCLUDING TBM01298

TL1255 - S/N TBN00799 & AFTER INCLUDING TBN00785
THERMOSTAT ENGINE CONTROL

MODULE (ECM)
FUEL FILTER
ALTERNATOR
FUEL INJECTOR
PUMP
TURBOCHARGER
WATER PUMP
MAL1390
OIL FILTER STARTER FUEL FILTER

(PRIMARY)
TL1055, TL1255 7-3

Engine: CAT C4.4
7.2 ENGINE SERIAL NUMBER • If the engine has overheated, performance may
suffer, indicating other damage including a leak-
The CAT C4.4 serial number is stamped on top of the ing cylinder head gasket, cracked cylinder head
engine. Information contained in the serial number is or block, and/or other internal engine damage.
required in correspondence with the engine
manufacturer. a. Thermostat Removal
7.3 ENGINE SPECIFICATIONS AND machine, fully retract the boom, lower the boom,
MAINTENANCE INFORMATION place the travel select lever in the (N) NEUTRAL
position, engage the parking brake, and shut the
For engine, coolant and oil specifications, and engine OFF.
maintenance information, refer to Section 2, “General
Information and Specifications.”
Detailed engine service instructions are provided in the should not be operated.
following publications:
• Operation and Maintenance Manual cool.
(P/N SEBU8180)
• Specifications (P/N RENR9961) 5. Slowly turn the radiator cap to the first stop and allow
• System Operation Testing and Adjusting any pressure to escape. Remove the radiator cap.
(P/N RENR7568) 6. Place a funnel at the base of the radiator to channel
• Disassembly and Assembly (P/N KENR6216) the drained coolant into the container. Loosen the
drain plug and slowly remove to allow the coolant to
• Troubleshooting (P/N KENR9969)
drain. Transfer the coolant into a properly labeled
• Schematic (P/N RENR9964) container. Dispose of properly if coolant needs to be
• Parts Manual (P/N SEBP4124) replaced. Replace the radiator drain plug.
• Service Manual (P/N KENR6217) 7. Loosen and remove the top radiator hose from the
thermostat housing.
1 TYPICAL THERMOSTAT
7.4 ENGINE COOLING SYSTEM
7.4.1 Radiator Pressure Cap

For a 210° F (99° C) system, use a 13 psi (90 kPa)
radiator cap. An incorrect or malfunctioning cap can
result in the loss of coolant and a hot-running engine.
7.4.2 Thermostat Replacement

Before considering thermostat replacement, check the
coolant level, fan belt tension and instrument cluster
temperature indicator.
MY4260
• If the engine seems to take a long time to warm
up, the thermostat may be stuck in the open 8. Remove the two capscrews securing the thermostat
position and requires replacement. housing (1) to the engine.
• If the engine runs hot, check the temperature of 9. Remove the thermostat housing, old gasket and
the upper radiator hose. thermostat. Clean all gasket surfaces. DO NOT let
• If the hose is not hot, the thermostat may be any debris into the thermostat opening.
stuck in the closed position. Note: ALWAYS use the correct thermostat and install a
new gasket. NEVER operate the engine without a
thermostat, or engine damage will result.
7-4 TL1055, TL1255

Engine: CAT C4.4
b. Thermostat Installation 6. Place a suitable container beneath the radiator

drain.
1. Install the engine thermostat, thermostat gasket and
6 3
thermostat housing. Secure with the two capscrews. 3
7
2. Connect the Engine Water Temperature sender.
3. Properly connect the battery. 5
4
4. Open the radiator cap, and fill the radiator 7
completely with a coolant. Replace and tighten the
radiator cap.
2
5. Add coolant to the overflow bottle until the bottle is
1/4 to 1/2 full. This overfilling will compensate for any
air trapped in the cooling system. 7
6. Run the engine to operating temperature. Visually 5

check for leaks with the engine running. Check the 4
coolant level in the overflow bottle and fill, or drain,
as necessary.
1
7.4.3 Radiator/Transmission Cooler
Replacement
MY4220
TL1055 - Before S/N TBM01346 excluding TBM01298
TL1255 - Before S/N TBN00799 excluding TBN00785 7. Place a funnel at the base of the radiator to channel
the drained coolant into a container. Loosen the
Before considering radiator or transmission cooler
drain cock (1) to allow the coolant to drain. Transfer
replacement for other than obvious damage, conduct a
the coolant into a properly labeled container.
cooling system pressure test check the coolant specific
Dispose of properly if coolant needs to be replaced.
gravity, coolant level, fan belt tension and dash panel
Tighten the radiator drain cock.
temperature indicator.
8. Label, disconnect and cap the hose attached to the
• If the engine runs hot, check the temperature of
coolant recovery tank (2). Remove the coolant
the upper radiator hose.
recovery tank.
• If the hose is not hot, the thermostat may be
9. Loosen the clamps on both hoses attached to the
stuck in the closed position.
charge air cooler (3). Work the hoses and tubes off
• If the engine has overheated, performance may the charge air cooler. Position the hoses and tubes
suffer, indicating other damage including a leaking out of the way to allow radiator removal, or remove
cylinder head gasket, cracked cylinder head or the hoses and tubes from the engine. Plug and/or
block, and/or other internal engine damage. cap the openings on the charge air cooler and tubes
to prevent dirt and debris from entering system.
a. Radiator/Transmission Cooler Removal
10. Loosen the clamps on both hoses attached to the
1. Park the machine on a firm, level surface, level the radiator (4). Work the hoses off the radiator. Position
machine, fully retract the boom, lower the boom, the hoses out of the way to allow radiator removal, or
place the travel select lever in the (N) NEUTRAL remove the hoses from the engine. Inspect the
position, engage the parking brake, and shut the hoses, and replace if necessary. Plug and/or cap the
engine OFF. openings on the radiator and hoses to prevent dirt
2. Place a Do Not Operate Tag on both the ignition key and debris from entering system.
switch and steering wheel, stating that the machine 11. Place a suitable container beneath the transmission
should not be operated. cooler fittings.Transfer any transmission oil into a
3. Open the engine cover. Allow the system fluids to properly labeled container. Dispose of properly.
cool. 12. Label, disconnect and cap both transmission cooler
4. Properly disconnect the battery. hoses at the radiator (5). Cap all fittings and
openings to prevent dirt and debris from entering the
5. Slowly turn the radiator cap to the first stop and allow transmission.
any pressure to escape. Remove the radiator cap.
TL1055, TL1255 7-5

Engine: CAT C4.4
13. Remove the fan guard (not shown). 26. Carefully lift the radiator/transmission cooler out of
14. Loosen and remove the six bolts from the radiator the engine compartment.
fan shroud (6). Pull the fan shroud back and over the Note: If more clearance is needed to remove the
fan assembly. radiator, the engine fan may be removed for easier
15. Loosen and remove the three radiator mounting access.
bolts (7).
b. Radiator/Transmission Cooler Installation
10 10
1. Install the hydraulic oil cooler (9) to the bottom of the
16 radiator/transmission cooler using the previously
15 removed hardware (14).
15 2. Place the radiator/transmission cooler and hydraulic
12 oil cooler in the engine compartment and secure
using the previously used hardware (13).
11 3. Install the charge air cooler (16) to the top of the
9 radiator/transmission cooler and the top of the
hydraulic oil cooler using the previously used
hardware (10 & 12).
4. If removed, install the engine fan.
6 3
8 3
7
5
4
13 13 7
14 8 MY4210
16. Place a suitable container beneath the hydraulic oil 2

cooler fittings.Transfer any transmission oil into a
properly labeled container. Dispose of properly. 7
17. Label, disconnect and cap hydraulic oil cooler hoses
(8) at the hydraulic oil cooler (9). Cap all fittings and 5
4
openings to prevent dirt and debris from entering the
hydraulic system.
18. Loosen and remove the two nuts and washers from
the top of the radiator (10).
19. Loosen and remove the nut and washer from the
MY4220
side of the charge air cooler (11).
20. Loosen and remove the three nuts and washers 5. Install the radiator fan shroud (6) using the
from the bottom of the charge air cooler (12). previously removed hardware.
21. Loosen and remove the nuts and washers from two 6. Install the baffles (15) using the previously removed
isolator mounts at the bottom of the radiator (13). hardware (7).
22. Loosen and remove the three bolts from the bottom Note: Verify proper clearance between the fan and the
of the hydraulic oil cooler (14). fan shroud (6).
23. Remove both baffles (15). 7. Install the previously removed fan shroud (not
24. Carefully lift the charge air cooler (16) out of the shown).
engine compartment. 8. Uncap and connect the previously labeled hydraulic
25. Carefully lift the hydraulic oil cooler (9) out of the oil cooler hoses (8) to the hydraulic oil cooler.
engine compartment.
7-6 TL1055, TL1255

Engine: CAT C4.4
9. Uncap and connect the previously labeled 2. Place a Do Not Operate Tag on both the ignition key
transmission oil cooler hoses (5) to the transmission switch and steering wheel, stating that the machine
cooler. should not be operated.
10. Uncap and connect the top and bottom radiator 3. Open the engine cover. Allow the system fluids to
hoses (4) to the radiator. cool.
11. Connect the previously removed charge air cooler 4. Remove the engine cover for radiator access.
hoses/tubes (3) to the charge air cooler. 5. Properly disconnect the battery.
12. Install the coolant recovery tank (2). Uncap and 6. Slowly turn the radiator cap to the first stop and allow
connect the previously removed hose. any pressure to escape. Remove the radiator cap.
13. Open the radiator cap and fill the radiator completely 7. Place a suitable container beneath the radiator
with coolant. Replace and tighten the radiator cap. drain.
Refer to Section 2.4, “Fluids and Lubricant 2
Capacities,” for proper capacities.
15. Run the engine to operating temperature. Visually
check for leaks with the engine running. Check the
as necessary.
7.4.4 Radiator/Transmission/Cooler
Replacement
TL1055 - S/N TBM01346 & After including TBM01298
TL1255 - S/N TBN00799 & After including TBN00785
Before considering radiator/transmission/cooler
replacement for other than obvious damage, conduct a 1 3 2 MY5890
cooling system pressure test check the coolant specific

gravity, coolant level, fan belt tension and dash panel 8. Place a funnel at the base of the radiator to channel
temperature indicator. the drained coolant into a container. Loosen the
drain cock (1) to allow the coolant to drain. Transfer
• If the engine runs hot, check the temperature of
the coolant into a properly labeled container.
the upper radiator hose.
Dispose of properly if coolant needs to be replaced.
• If the hose is not hot, the thermostat may be Tighten the radiator drain cock.
stuck in the closed position.
9. Loosen the clamps (2) on both hoses attached to the
• If the engine has overheated, performance may charge air cooler (3). Work the hoses and tubes off
suffer, indicating other damage including a leaking the charge air cooler. Position the hoses and tubes
cylinder head gasket, cracked cylinder head or out of the way to allow radiator removal, or remove
block, and/or other internal engine damage. the hoses and tubes from the engine. Plug and/or
cap the openings on the charge air cooler and tubes
a. Radiator/Transmission/Cooler Removal to prevent dirt and debris from entering system.
engine OFF.
TL1055, TL1255 7-7

Engine: CAT C4.4
5 9 7
4 8
6
11
6
10
MY5890
MY5880 12 12
4 8
16. Loosen and remove the nut and washer from the
10. Loosen the clamps on both hoses (4) attached to the
isolator mount at the top of the radiator (11).
radiator (5). Work the hoses off the radiator. Position
the hoses out of the way to allow radiator removal, or 17. Through the access holes under the engine pod,
remove the hoses from the engine. Inspect the loosen and remove the nuts and washers from two
hoses, and replace if necessary. Plug and/or cap the isolator mounts at the bottom of the radiator (12).
openings on the radiator and hoses to prevent dirt (Not Shown)
and debris from entering system. 18. Carefully lift the radiator/transmission/cooler
11. Place a suitable container beneath the transmission assembly out of the engine compartment.
cooler fittings.Transfer any transmission oil into a 19. Disassemble each section as required.
properly labeled container. Dispose of properly.
Note: If more clearance is needed to remove the
12. Label, disconnect and cap both transmission oil radiator, the engine fan may be removed for easier
cooler hoses (6) at the transmission oil cooler (7). access.
Cap all fittings and openings to prevent dirt and
debris from entering the transmission. b. Radiator/Transmission/Cooler Installation
13. Place a suitable container beneath the hydraulic oil
1. Place the radiator/transmission/cooler in the engine
cooler fittings.Transfer any transmission oil into a
compartment and secure using the previously used
properly labeled container. Dispose of properly.
hardware (11&12).
14. Label, disconnect and cap both hydraulic oil cooler
2. If removed, install the engine fan.
hoses (8) at the hydraulic oil cooler (9). Cap all
fittings and openings to prevent dirt and debris from Note: Verify proper clearance between the fan and the
entering the hydraulic system. fan shroud.
15. Remove the fan guard (10).
7-8 TL1055, TL1255

Engine: CAT C4.4
7.6 FUEL SYSTEM

5 9 7
4 8
6 7.6.1 Diesel Fuel
Fuel represents a major portion of machine operating
costs and therefore must be used efficiently. ALWAYS
use a premium brand of high-quality, clean diesel fuel.
Low cost, inferior fuel can lead to poor performance and
expensive engine repair.
Note: Due to the precise tolerances of diesel injection
systems, keep the fuel clean, and free of dirt and water.
Dirt and water in the fuel system can cause severe
damage to both the injection pump and the injection
6 nozzles. Use ASTM #2 diesel fuel with a minimum Cetane
10 rating of 40. #2 diesel fuel gives the best economy and
performance under most operating conditions. Fuels
with Cetane numbers higher than 40 may be needed in
high altitudes or extremely low ambient temperatures to
MY5880
help prevent misfiring and excessive smoking.
4 8 Inform the owner/operator of the machine to use #2
3. Install the previously removed fan guard (10). diesel fuel, unless ambient temperatures are below 32° F
(0° C). When temperatures are below 32° F (0° C), a
4. Uncap and connect the previously labeled hydraulic blend of #1 diesel and #2 diesel fuels (known as
oil cooler hoses (8) to the hydraulic oil cooler (9). “winterized” #2 diesel) may be used.
5. Uncap and connect the previously labeled
Note: #1 diesel fuel may be used, however, fuel
transmission oil cooler hoses (6) to the transmission
economy will be reduced.
oil cooler (7).
6. Uncap and connect the top and bottom radiator Use a low-sulfur content fuel with a cloud point (the
hoses (4) to the radiator (5). temperature at which wax crystals form in diesel fuel) at
least 10° below the lowest expected fuel temperature.
7. Connect the previously removed charge air cooler The viscosity of the fuel must be kept above
hoses/tubes (2) to the charge air cooler (3). 1.3 centistrokes to provide adequate fuel system
8. Open the radiator cap and fill the radiator completely lubrication.
with coolant. Replace and tighten the radiator cap.
Refer to Section 2.4, “Fluids and Lubricant 7.6.2 Fuel Tank
Capacities,” for proper capacities.
Note: The fuel tank is a one piece unit. It is located on the
9. Properly connect the battery. rear of the cab. If it is determined that the fuel tank must be
10. If removed, install the engine cover. removed, the fuel must be drained before tank removal.
Always dispose of fuel properly.
11. Run the engine to operating temperature. Visually
check for leaks with the engine running. Check the a. Fuel Tank Removal
as necessary.
12. Close and secure the engine cover. place the travel select lever in the (N) NEUTRAL
13. Remove the Do Not Operate Tags from both the position, engage the parking brake, and shut the
ignition key switch and the steering wheel. engine OFF.
7.5 ENGINE ELECTRICAL SYSTEM switch and steering wheel, stating that the machine
The engine electrical system, including the starter,
alternator and primary wiring, is described in Section 9.5,
cool.
“Electrical System Schematics.”
TL1055, TL1255 7-9

Engine: CAT C4.4
4. Properly disconnect the battery. Note: If a leak is suspected in the fuel tank, contact the
local Caterpillar dealer.
Note: If replacing the tank, remove all internal and
external components from the old tank, and retain for To clean the fuel tank:
use on the replacement tank. 1. Have a dry chemical (Class B) fire extinguisher near
Note: Have a dry chemical (Class B) fire extinguisher the work area.
near the work area. 2. Remove the fuel or oil tank drain plug, and safely
drain any fuel into a suitable container. Dispose of
13
fuel properly.
12
3. Clean the fuel tank with a high-pressure washer, or
flush the tank with hot water for five minutes and
drain the water. Dispose of contaminated water
properly.
4. Add a diesel fuel emulsifying agent to the tank. Refer
to the manufacturer’s instructions for the correct
emulsifying agent-to-water mixture ratio. Refill the
tank with water, and agitate the mixture for 10
minutes. Drain the tank completely. Dispose of
contaminated water properly.
8 5. Refill the fuel tank with water until it overflows.
10 Completely flush the tank with water. Empty the fuel
tank, and allow it to dry completely.
11
9 d. Assembly
MY4230
The fuel level indicator can be removed and reused on the
5. Remove fuel tank drain plug (8), and drain fuel into new replacement tank. Dispose of the old tank according
an approved, clean and suitable container. Dispose to local regulations concerning hazardous materials
of fuel properly if contaminated. disposal regulations.
6. Label, disconnect and cap the supply fuel line (9)
from the bottom of the fuel tank. e. Inspection
7. Label, disconnect and cap the return fuel line (10) Note: If a leak is suspected in the fuel tank, contact the
from the bottom of the fuel tank. local Caterpillar dealer.
8. Disconnect the fuel gauge harness (11). 1. Inspect the fuel tank thoroughly for any cracks,
9. Remove screws securing fuel sender (12) to the slices, leaks or other damage.
tank. Remove fuel sender from tank. 2. With the fuel tank removed from the machine, plug
10. Remove the bolts on the fuel tank hold down bar all openings except one elbow fitting. Install the
(13). elbow fitting, and apply approximately 1-1.5 psi
(7-10 kPa) of air pressure through the elbow. Check
11. Lift the empty fuel tank from the rear of the cab. the reservoir for leaks by applying a soap solution to
the exterior and look for bubbles to appear at the
b. Disassembly cracked or damaged area.
The fuel tank is a one-piece unit and cannot be
disassembled. The fuel level indicator can be removed and f. Fuel Tank Installation
reused on the new replacement tank. Dispose of the old 1. Set fuel tank in its original orientation at the rear of
tank according to local regulations concerning hazardous the cab.
materials disposal.
2. Install the fuel tank hold down bar.
c. Cleaning and Drying 3. Install the fuel sender with new gasket into the fuel
tank and secure with screws. DO NOT overtighten.
If contaminated fuel or foreign material is in the tank, the
tank can usually be cleaned.
7-10 TL1055, TL1255

Engine: CAT C4.4
4. Connect the previously labeled fuel hoses to their

appropriate locations. Secure with clamps. 9
5. Connect the fuel gauge harness.
6. Fill the fuel tank according to specifications.Refer to
8
Section 2.4, “Fluids and Lubricant Capacities.” 7
7. Check fuel tank for leaks.
10. Remove the Do Not Operate Tags from both the 10
5
7.6.3 After Fuel System Service

1. Drain and flush the fuel tank if it was contaminated. 3
2. Vent air from the fuel system in accordance with the 4
instructions found in the appropriate Operation & 1
Maintenance Manual. 3 6
MY4240
3. Fill the fuel tank with fresh, clean diesel fuel as required. 2
5. Remove the muffler heat shield (1)

7.7 ENGINE EXHAUST SYSTEM
6. Remove the exhaust heat shield (2).
7. Loosen and remove both clamps (3) securing the
7.7.1 Exhaust System Removal
muffler (4) to the frame mounted brackets. Remove
TL1055 - Before S/N TBM01346 excluding TBM01298 the muffler.
TL1255 - Before S/N TBN00799 excluding TBN00785 8. Loosen and remove the clamp (5) securing the
1. Park the machine on a firm, level surface, level the exhaust pipe (6) to the frame at the bottom rear
machine, fully retract the boom, lower the boom, corner of the engine pod. Remove the exhaust pipe.
Note: Removal of the turbo charger heat shields may be
required to access exhaust pipe bolts.
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key 9. Disconnect and remove the three bolts (7) securing
switch and steering wheel, stating that the machine the exhaust pipe/flex pipe (8) to the turbo charger.
should not be operated. Remove the exhaust pipe/flex pipe from under
machine.
3. Open the engine cover. Allow the system fluids and
the exhaust system to cool. 7.7.2 Exhaust System Installation
Note: Keep all clamps loosened until entire exhaust
system is in place.
1. Install the exhaust pipe/flex pipe (8) with a new seal
(9) to the turbo charger.
2. Install the exhaust pipe/flex pipe clamp (5) at the
bottom rear corner of the engine pod.
3. Install the exhaust pipe (6) to the exhaust/flex pipe
(8).
4. Install the muffler (4) to the exhaust pipe (6).
5. Install the tail pipe (10) to the muffler (4).
6. Install the clamps (3) securing the tail pipe/muffler/
exhaust pipe to the frame mounted brackets.
TL1055, TL1255 7-11

Engine: CAT C4.4
7. Adjust the muffler, exhaust and tail pipes for proper 9. Loosen and remove the clamp (5) securing the
clearance then tighten all clamps. exhaust pipe (6) to the frame at the bottom rear
8. Install the exhaust heat shield (2). corner of the engine pod. Remove the exhaust pipe.
9. Install the muffler heat shield (1). Note: Removal of the turbo charger heat shields may be
required to access exhaust pipe bolts.
11. Start engine and check for exhaust leaks at all 10. Disconnect and remove the three bolts (7) securing
exhaust connections. Adjust as needed. the exhaust pipe (8) to the turbo charger. Remove
the exhaust pipe from the machine.
13. Remove the Do Not Operate Tags from both the 7.7.4 Exhaust System Installation
Note: Keep all clamps loosened until entire exhaust
system is in place.
7.7.3 Exhaust System Removal
1. Install the exhaust pipe (8) with a new seal (9) to the
turbo charger.
2. Install the exhaust pipe clamp (5) at the bottom rear
corner of the engine pod.
place the travel select lever in the (N) NEUTRAL 3. Install the exhaust pipe (6) to the exhaust pipe (8).
position, engage the parking brake, and shut the 4. Install the muffler (3) to the exhaust pipe (6).
engine OFF.
5. Install the tail pipe (10) to the muffler (4).
6. Install the clamps (2) securing the tail pipe (4),
muffler (3) and exhaust pipe (6) to the frame
mounted brackets.
3. Open the engine cover. Allow the system fluids and
7. Adjust the muffler, exhaust and tail pipes for proper
the exhaust system to cool.
clearance then tighten all clamps.
8. Install the exhaust heat shield (1).
7
10. Start engine and check for exhaust leaks at all
exhaust connections. Adjust as needed.
8 9 11. Close and secure the engine cover.
4 12. Remove the Do Not Operate Tags from both the
7.8 AIR CLEANER ASSEMBLY

2
3 1 WARNING
2
NEVER run the engine with only the inner safety
5 element installed.
6MY5900
Note: Refer to the appropriate Operation &
5. Remove the exhaust heat shield (1). Maintenance Manual for your machine for the correct
element change procedure.
6. Loosen and remove both clamps (2) securing the
muffler (3) to the frame mounted brackets. 7.8.1 Air Cleaner Assembly Removal
7. Remove the tail pipe (4) from the muffler.
TL1055 - Before S/N TBM01346 excluding TBM01298
8. Remove the muffler (3). TL1255 - Before S/N TBN00799 excluding TBN00785
7-12 TL1055, TL1255

Engine: CAT C4.4
1. Park the machine on a firm, level surface, level the 6. Remove the Do Not Operate Tags from both the
machine, fully retract the boom, lower the boom, ignition key switch and the steering wheel.
position, engage the parking brake, and shut the 7.8.3 Air Cleaner Assembly Removal
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key TL1255 - S/N TBN00799 & After including TBN00785
3. Open the engine cover. Allow the system fluids to place the travel select lever in the (N) NEUTRAL
cool. position, engage the parking brake, and shut the
4. Properly disconnect the battery. engine OFF.
13 switch and steering wheel, stating that the machine
cool.
14 4. Properly disconnect the battery.
15 16
11 17
12
18
MY4250
MY5070
5. Remove the clamp (11) securing the air intake elbow
(12) to the air cleaner assembly (13). Pull the air 5. Loosen the clamp (15) securing the air intake elbow
intake elbow off the air cleaner. (16) engine.
6. Remove the capscrews and nuts securing the air 6. Loosen the capscrews securing the air cleaner
cleaner mounting bracket (14) to the air cleaner mounting bracket (17) to the engine fire wall.
mounting plate. Remove the air cleaner assembly. 7. Remove the air cleaner assembly (17 & 18).
7.8.2 Air Cleaner Assembly Installation 8. Remove the air cleaner mounting bracket (17) from
the air cleaner (18).
Note: Apply Loctite® 242TMto the capscrew threads
before installation. 7.8.4 Air Cleaner Assembly Installation
1. Install the air cleaner assembly (13) to the cab Note: Apply Loctite® 242™to the capscrew threads
mounting plate with the previously removed before installation.
hardware (14).
1. Install the air cleaner (18) to the air cleaner mounting
2. Place the loosened clamp (11) over the air outlet
bracket (17).
elbow (12) and install elbow on the air cleaner
assembly. 2. Install the air cleaner assembly (17 & 18) to the
engine fire wall.
3. Adjust and tighten the clamp.
3. Tighten the previously loosened capscrews.
4. Install the air intake elbow (16) onto the engine.
5. Adjust and tighten the clamp (15).
TL1055, TL1255 7-13
Engine: CAT C4.4
6. Properly connect the battery. 11. Remove the Power Distribution bracket.
7. Close and secure the engine cover. 12. Disconnect and cap the fuel inlet line at the fuel filter
8. Remove the Do Not Operate Tags from both the head.
ignition key switch and the steering wheel. 13. Disconnect and cap the fuel return line from the fuel
filter head.
7.9 ENGINE REPLACEMENT 14. Remove the exhaust pipe from the exhaust
manifold. Refer to Section 7.7.1, “Exhaust System
7.9.1 Engine Removal Removal.”
Note: The radiator and oil cooler must be removed from 15. Loosen the clamps on the sleeve reducer at the
the machine before engine removal. Refer to Section engine and on the air suction pipe.
7.4, “Engine Cooling System.” Several additional 16. Remove the air cleaner tube assembly.
components must be removed before engine removal. 17. Remove the access plug from bottom of the engine
They will be addressed in the following procedures. bell housing. This will allow access to remove the
1. Park the machine on a firm, level surface, level the bolts holding the torque convertor diaphragm to the
machine, fully retract the boom, lower the boom, engine flywheel.
place the travel select lever in the (N) NEUTRAL 18. Turn the engine over slowly by hand and align each
position, engage the parking brake, and shut the of the four torque convertor diaphragm bolts to be
engine OFF. accessed. Remove them one at a time.
1
cool.
4. Properly disconnect and remove the battery.
Properly disconnect and remove the second battery
if equipped
5. Remove the engine cover. Mark the position of the
cover to help with cover adjustment when being
reinstalled.
6. Remove the oil pan cover underneath the engine
compartment.
1
7. Drain and remove the radiator assembly. Refer to
Section 7.4.3, “Radiator/Transmission Cooler
Replacement.” MY4270
8. Remove the heater hoses attached to the engine (if 19. Secure the engine with a lifting strap or chain from
equipped). the appropriate lifting points (1). Use a suitable hoist
Note: The engine harness is routed and attached to the or overhead crane.
engine using hold-down clamps and plastic wire ties at 20. Place a support or jack under the transmission to
various places on the engine. Before removing engine, hold the transmission in place while engine is being
ensure that the harness has been completely separated removed.
(disconnected) from the engine. Move the harness clear 21. Remove the bolts and washer securing the engine
of the engine, and with the help of an observer, ensure mounts.
that the engine clears the harness during removal.
22. Remove the ten bolts holding the transmission to the
9. Label and disconnect all electrical wire connections engine. Slightly lift and pull the engine out of the
on the engine. machine. Have an assistant ensure that the engine
10. Label and disconnect all electrical wire connections clears all frame components during removal.
on the Power Distribution bracket. 23. Place engine on a flat, level surface.
7-14 TL1055, TL1255

Engine: CAT C4.4
7.9.2 Engine Installation 18. Install and properly connect the battery. Install and
properly connect the second battery if equipped.
1. Attach a lifting chain to the front and rear engine lift
brackets, and lift engine clear of the ground. 19. Check that all hydraulic system, electrical system,
cooling system, fuel system and exhaust system
Note: Apply Loctite® 242TM to the engine mount bracket connections are correct and connected tightly.
capscrew threads before installation.
20. From within the cab, lightly depress the throttle pedal
2. Install two guide studs in the bell housing holes. to full-throttle position.
3. Lift the engine and slowly push and lower into the Note: Have an assistant stand by with a Class B fire
engine bay. Have an assistant ensure that the extinguisher.
engine clears the frame, hose and harness
components during engine installation. Position 21. Start the engine and run to normal operating
engine brackets over the front frame mounts. temperature then shut off the engine. While the
engine is cooling, check for leaks.
4. Push the engine towards the transmission aligning
the guide studs and the torque convertor shaft with 22. Allow the engine to cool. Check the radiator coolant
the corresponding holes. level, and top off with a mixture of ethylene glycol
and water. Add the coolant solution at a maximum
5. Push the engine against the transmission and install
rate of 1.3 gallons per minute (5 liters per minute).
eight of the ten bolts and washers. Remove both
Replace the radiator cap.
guide studs and replace with the remaining two bolts
and washers. Torque bolts to 53-58 lb-ft (72-79 Nm). 23. Check for leaks from the engine, main hydraulic
pump and lines, transmission, hydraulic reservoir
6. Remove the support from under the transmission
and fuel tank. Check the levels of all fluids and
and lower the engine the remainder of the way onto
lubricants. Fill as required.
the frame. Align the motor mount holes and install
the bolts. Apply Loctite® 242TM to the motor mount Note: During the full throttle check:
bolts and torque to 125-140 lb-ft (169-190 Nm). • DO NOT operate any hydraulic function.
• DO NOT steer or apply any pressure to the steering
of the four torque convertor diaphragm bolts through wheel.
the access plug in the bell housing. Install them one
at a time. DO NOT fully tighten until all of the • Keep the transmission in (N) NEUTRAL.
capscrews and locknuts are in place. Torque to 24. Obtain and connect an appropriate engine analyzer
26-39 lb-ft (35-59 Nm). Replace access plug. or tachometer. Check the engine rpm at full throttle.
8. Install the exhaust pipe. Refer to Section 7.7.2, 25. Purge the hydraulic system of air by operating all
“Exhaust System Installation.” boom functions through their entire range of motion
9. Install the complete air cleaner assembly. Refer to several times. Check the hydraulic oil level.
Section 7.8.2, “Air Cleaner Assembly Installation.” 26. Check for proper operation of all components.
10. Connect the fuel inlet line to the fuel filter head. 27. Turn the engine OFF.
11. Connect the fuel return line to the fuel filter head. 28. Install the oil pan cover underneath the engine
12. Install the Power Distribution bracket. compartment.
13. Connect all the previously labeled electrical wire 29. Close and secure the engine cover.
connections on the Power Distribution bracket. 30. Remove the Do Not Operate Tags from both the
14. Connect all the previously labeled electrical wire ignition key switch and the steering wheel.
connections on the engine.
15. Install both heater hoses to the engine and tighten
clamps (if equipped).
16. Install the complete radiator assembly. Refer to
Section 7.4.3, “Radiator/Transmission Cooler
Replacement.”
17. Install the engine cover and adjust.
TL1055, TL1255 7-15

Engine: CAT C4.4
7.10 ENGINE INDICATOR LAMPS
Warning Shutdown Lamp State Lamp Indication Engine State

Lamp Lamp
ON ON Bulb Check When the ignition is turned on, the Key on but engine has yet
EMS shall illuminate each bulb for to be cranked
2 seconds and extinguish them
afterwards
OFF OFF No Faults Present With both lamps off while engine is Engine is running with no
running then are no currently active detected faults
warnings, diagnostics or events
ON OFF Active Diagnostic Should the warning lamp illuminate Engine is running
during engine running, this normally but has one or
indicates that an Active diagnostic more faults with engine
(Electrical fault) is present management system
ON FLASH Derate Should the warning lamp illuminate Engine is running but has
(Invoked by Active and the shutdown lamp flash one or more active
Diagnostic) during engine running, this diagnostic events that
indicates that an active diagnostic have initiated engine
is present. The diagnostic is derate
sufficiently serious to invoke
engine derate
FLASH OFF Warning Should the warning lamp flash Engine is running
(Warning only) during engine running, this normally but has one or
indicates that one or more of the more monitored engine
engine protection strategy warning parameters outside of the
values have been exceeded, but acceptable range
not to a level that will invoke
Derate.
FLASH FLASH Derate Should both the Warning Lamp Engine is running but one
(Warning and and Shutdown Lamp flash during or more of the monitored
Derate) engine running, this indicates that engine parameters has
one, or more of the engine gone beyond that of
protection strategy values have warning only and has now
been exceeded beyond the level exceeded those set for
required to invoke engine derate engine derate
7-16 TL1055, TL1255

Engine: CAT C4.4
7.11 TROUBLESHOOTING
Trouble Possible Causes (see key, below)

Low Cranking Power 1, 2, 3, 4
Will Not Start 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
Excessive Fuel Consumption 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
Low Oil Pressure 4, 36, 37, 38, 39, 40, 42, 43, 44, 58
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
High Oil Pressure 4, 38, 41
Overheating 11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57
Excessive Crankcase Pressure 25, 31, 33, 34, 45, 55, 60
Poor Compression 11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
Starts and Stops 10, 11, 12
Key to Possible Causes
TL1055, TL1255 7-17

Engine: CAT C4.4
Trouble Possible Causes (see key, below)

1. Battery charge low 21. Blocked fuel tank vent 43. Faulty suction pipe
2. Bad electrical connection 22. Incorrect grade of fuel 44. Restricted oil filter
3. Faulty starter motor 23. Sticking throttle or 45. Piston seizure/pick up
4. Incorrect grade of restricted movement 46. Incorrect piston height
lubricating oil 24. Exhaust pipe restriction 47. Damaged fan
5. Low cranking speed 25. Leaking cylinder head gasket 48. Faulty engine mounting
6. Fuel tank empty 26. Overheating 49. Incorrectly aligned flywheel
7. Faulty stop control operation 27. Cold running housing or incorrectly aligned
8. Fuel inlet restricted 28. Incorrect tappet adjustment flywheel
9. Faulty fuel lift pump 29. Sticking valves 50. Faulty thermostat
10. Clogged fuel filter 30. Incorrect high pressure pipes 51. Restriction in water jacket
11. Restricted air cleaner 31. Worn cylinder bores 52. Loose fan belt
12. Air in fuel system 32. Pitted valves and seats 53. Restricted radiator
13. Faulty fuel injection pump 33. Broken, worn or sticking 54. Faulty water pump
14. Faulty fuel injectors or piston ring(s) 55. Restricted breather pipe
incorrect type 34. Worn valve stems and guides 56. Damaged valve stem oil
15. Incorrect use of cold start 35. Restricted air cleaner deflectors (if fitted)
equipment 36. Worn or damaged bearings 57. Coolant level too low
16. Faulty cold start equipment 37. Insufficient oil in sump 58. Blocked sump strainer
17. Broken fuel injection 38. Inaccurate gauge 59. Broken valve spring
pump drive 39. Oil pump worn 60. Exhauster or vacuum pipe leak
18. Incorrect fuel pump timing 40. Pressure relief valve sticking open 61. Turbo impeller damaged or dirty
19. Incorrect valve timing 41. Pressure relief valve sticking 62. Turbo lubricating oil seal leak
20. Poor compression closed 63. Induction system leaks
42. Broken relief valve spring
7-18 TL1055, TL1255

Section 8
Hydraulic System
Contents

8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4.1 Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4.2 Tilt Circuit Port Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4.3 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.5 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.5.1 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.5.2 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.5.3 Hydraulic Oil Reservoir Removal/Installation . . . . . . . . . . . . . . . . . . . . . . 8-12
8.6 Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.6.1 Implement Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.7 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.7.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.7.2 Main Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.7.3 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8.7.4 Service Brake Bleeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.7.5 Service Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.7.6 Park Brake Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.7.7 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.7.8 Steer Select Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.8 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.8.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.8.2 Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.8.3 Cylinder Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
8.8.4 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
8.8.5 Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
TL1055, TL1255 8-1

Hydraulic System
8.1 HYDRAULIC COMPONENT

TERMINOLOGY
To understand the safety, operation and service
the operator/mechanic be familiar with the name and
location of the hydraulic components of the machine. The
following illustration identifies the components that are
referred to throughout this section.
EXTEND/RETRACT HYDRAULIC LIFT/LOWER COMPENSATION

CYLINDER FLUID RESERVOIR CYLINDER(S) CYLINDER
TILT CYLINDER
MAL0380
MAIN CONTROL STEERING STABILIZER

OUTRIGGER FRAME LEVEL STEERING
VALVE CYLINDER(S) CYLINDER
CYLINDER(S) CYLINDER CYLINDER(S)
8-2 TL1055, TL1255

Hydraulic System
8.2 SAFETY INFORMATION Some hydraulic functions are actuated by interfacing with
electrical system components (switches, solenoids and
sensors). When the hydraulic system is not functioning
WARNING properly, check the electrical aspect of the malfunctioning
circuit also. Refer to Section 9.5, “Electrical System
DO NOT service the machine without following all Schematics,” in this manual.
Practices,” of this manual. 8.3 HYDRAULIC PRESSURE DIAGNOSIS
Petroleum-based hydraulic fluids are used in this
machine. The temperature of hydraulic fluid increases 8.3.1 Pressure Checks and Adjustments
during the operation of various hydraulic functions. A When diagnosing trouble in the hydraulic system, use the
heated petroleum-based hydraulic fluid presents a fire hydraulic testing information in Section 8.4.1, “Hydraulic
hazard, especially when an ignition source is present. Pressures.”
Hydraulic fluid has a flash point that ranges from
300-600° F (150-318° C) and an auto-ignition temperature In general, follow the steps below whenever conducting
of 500-750° F (262-402° C). pressure checks and performing adjustments:
Accordingly, periodically inspect all hydraulic system 1. Park the machine on a firm, level surface. Engage
components, hoses, tubes, lines, fittings, etc. Carefully the park brake, place the travel select lever in (N)
examine any deterioration and determine whether any NEUTRAL, level the boom and turn the engine OFF.
further use of the component would constitute a hazard. 2. Locate the proper test port. Install a pressure gauge
If in doubt, replace the component. capable of measuring at least 10% more pressure
Operate the hydraulic controls after the engine has than that which the circuit being checked operates
stopped to relieve trapped pressure. under.
3. Start the engine. Operate machine functions several
Note: Residual pressure may remain in hydraulic
times to allow hydraulic oil to reach operating
cylinders, hoses, valve bodies, components, etc. If the
temperature. The hydraulic oil temperature should
hydraulic lines going to or coming from a component are
be a minimum of 130°F (54° C). If a temperature
taut, slowly and cautiously relieve (“bleed off”) pressure.
gauge or thermometer is unavailable, the hydraulic
Whenever you disconnect a hydraulic line, coupler, fitting oil reservoir should be warm to the touch.
or other component, slowly and cautiously loosen the part 4. Refer to Section 8.4.1, “Hydraulic Pressures,” for
involved. A hissing sound or slow seepage of hydraulic testing procedures.
fluid may occur in most cases. After the hissing sound
has ceased, continue removing the part. Any escaping oil 5. Fully depress the accelerator pedal if required. Place
should be directed into an appropriate container. Cap or and hold the joystick in the position needed to
otherwise block off the part to prevent further fluid seepage. operate the particular machine function being
checked. Continue holding the joystick in position
Hydraulic system maintenance will, at times, require that until pressure readings are taken.
the engine be operated. Always follow safety precautions.
6. Check the pressure gauge reading. It should read as
A major cause of hydraulic component failure is specified in the Pressure Readings column of the
contamination. Keeping the hydraulic fluid as clean as charts found in Section 8.4.1, “Hydraulic Pressures.”
possible will help avoid downtime and repairs. Sand, grit If the reading is not as specified, turn the engine
and other contaminants can damage the finely machined OFF and check other components in the system.
surfaces within hydraulic components. If operating in an Verify that all related hydraulic components and
exceptionally dirty environment, change filters and electrical switches, sensors, solenoids, etc. are
inspect the fluid more often. When servicing the system, operating correctly.
cap or plug hydraulic fittings, hoses and tube assemblies.
Plug all cylinder ports, valves and the hydraulic reservoir, 7. Adjust the relief valve by turning the adjustment
and pump openings until installation occurs. Protect screw. Turning clockwise will increase the pressure;
threads from contamination and damage. turning the screw counterclockwise will decrease the
pressure.
TL1055, TL1255 8-3

Hydraulic System
8. Start the engine and check the pressure again. Turn 2. Start the machine and loosen the jam nut on the
the engine OFF. If there is pressure reading in the relief. Turn the relief clockwise to increase pressure
gauge, bleed it off then disconnect or remove the or counter-clockwise to decrease pressure. Set to
pressure gauge from the machine. the correct pressure.
3. Tighten the jam nut and recheck the pressure at full
8.4 HYDRAULIC CIRCUITS throttle. If the reading is within specification, shut the
machine off, install the safety cap and remove the
This section covers the hydraulic circuits and includes gauge from the test port.
listings for all hydraulic function pressures, where and
how to check those pressures and a hydraulic schematic. 4. If the proper pressure cannot be set, use the
accompanying hydraulic schematic and/or the
Electrical and hydraulic functions are often related. Verify electrical schematic to help troubleshoot and correct
that the electrical components of the circuit are the problem.
functioning properly whenever troubleshooting the
hydraulic circuit. 8.4.2 Tilt Circuit Port Relief Adjustment
Always check the following before beginning to
The following procedure is specific to the tilt circuit only
troubleshoot a circuit that is not functioning correctly.
and should be performed and verified if the main and/or
1. Check the hydraulic oil level in the reservoir. Oil level load sense circuits pressures are in question.
should be to the middle of the sight glass with all
cylinders retracted.
assembly. Refer to Section 3.8, “Quick Coupler
2. Check hoses, tubes, fittings and other hydraulic Assembly.”
components for leaks, bends, kinks, interference, etc.
2. Raise the boom for access to the compensation
3. Check for air in the hydraulic system. Erratic machine cylinder.
performance and/or spongy cylinder operation are
signs of air in the hydraulic system.
If air in the hydraulic system is suspected, you will 1
hear air leakage when hydraulic fittings are loosened
and see air bubbles in the hydraulic fluid.
2
Loose fittings, faulty o-rings or seals, trapped oil,
leaks, system opened for service, etc., can cause air
in the system. Determine what is causing air to enter
the system and correct it. Bleed air from the system.
8.4.1 Hydraulic Pressures MY4500
a. Checking Pressure 3. Slowly loosen and remove the retract (1) hose from
the compensation cylinder.
1. Start the machine and warm the hydraulic system to
operating temperature. 4. Install a tee fitting to the retract (1) port of the
compensation cylinder. Reconnect the previously
2. Shut off the machine and install a digital or a
removed retract (1) hose to the tee fitting.
5000 psi (345 bar) gauge to the appropriate test port
on the hydraulic manifold. 5. Slowly loosen and remove the extend (2) hose from
3. Start the machine, run the engine at high idle and
bottom the appropriate hydraulic function. Refer to 6. Install a tee fitting to the extend (2) port of the
Section 8.4.1, “Hydraulic Pressures,” for the correct compensation cylinder. Reconnect the previously
pressure rating. removed extend (2) hose to the tee fitting and cap
the open port.
b. Adjusting Hydraulic Pressure 7. Install a digital or a 5000 psi (345 bar) gauge to the
1. Shut the machine off. Remove the cap on the relief retract (1) port tee fitting on the compensation
(if necessary). cylinder.
8. Start the machine and warm the hydraulic system to
operating temperature.
8-4 TL1055, TL1255

Hydraulic System
9. Tilt the forks down to allow the tilt cylinder to fully

retract. B
B
10. Monitor the gauge and slowly raise the boom. The
gauge should read 4100 psi (282 bar).
11. If pressure is correct, proceed to step 14.
A
A
HUSCO REXROTH
MY4490
FRONT OF MACHINE
21. If the pressure requires adjustment and if the

machine is equipped with a Rexroth main control
HUSCO REXROTH valve, adjust the relief on the (B) port and repeat
MY4490
FRONT OF MACHINE steps 17 and 18.
If the machine is equipped with a Husco main control
12. If the pressure requires adjustment and if the valve, the relief on the (B) port is non-adjustable and
machine is equipped with a Rexroth main control must be replaced. Replace and repeat steps 17 and
valve, adjust the relief on the (A) port and repeat 18.
steps 9 and 10.
22. Verify pressure is correct.
If the machine is equipped with a Husco main control
valve, the relief on the (A) port is non-adjustable and 23. Shut engine OFF.
must be replaced. Replace and repeat steps 9 and 24. Slowly remove the gauge, line and tee fitting from
10. the compensation cylinder (1 & 2). Reinstall each
13. Verify pressure is correct. hose and torque as required.
14. Shut engine OFF. 25. Install any previously removed attachment.
15. Remove the digital or the 5000 psi (345 bar) gauge
from the retract (1) port tee fitting on the
compensation cylinder and cap the open port.
16. Remove the cap and install a digital or a 5000 psi
(345 bar) gauge to the extend (2) port tee fitting on
17. Start the machine and if needed, warm the hydraulic
system to operating temperature.
18. Tilt the forks up to allow the tilt cylinder to fully
extend.
19. Monitor the gauge and slowly lower the boom. The
gauge should read 4100 psi (282 bar).
20. If pressure is correct, proceed to step 23.
TL1055, TL1255 8-5

Hydraulic System
c. Pressure Specifications
Hydraulic Circuit Test Port Function Used to Adjustment Pressure Range

Test Location
Main P1 (A) Bottom Tilt Down 1 3600-3650 psi
(248-252 Bar)
Pilot JS1 (B) No Function 2 500-550 psi
(34-38 Bar)
Standby P1 (A) No Function 3 750-775 psi
(52-53 Bar)
Service Brake BV1 (C) Bottom Steering, 4 1000-1100 psi
Supply Any Mode (69-76 Bar)
Steering GLS (D) Bottom Steering, 5 2400-2500 psi
Any Mode (165-172 Bar)
Lift LS2 (E) Bottom Lift Down 6 3500-3525 psi
(241-243 Bar)
Boom Retract LS2 (E) Bottom Boom 7 3050-3075 psi
Retract (210-212 Bar)
E E
HYDRAULIC HYDRAULIC
MANIFOLD
3 3
MANIFOLD
1 1
4 4
2 2
D C MY1141 MY1831
B D C B
TL1055 - Before S/N TBM00511, including S/N TBM00517 TL1055 - S/N TBM00511 to TBM00894, excluding S/N TBM00517
TL1255 - Before S/N TBN00268 TL1255 - S/N TBN00268 to TBN00435
MAIN CONTROL VALVE
MY1300
7 6 5
8-6 TL1055, TL1255

Hydraulic System
d. Pressure Specifications
TL1055 - S/N TBM00895 & After
TL1255 - S/N TBN00436 & After
Note: 1. All pressures must be checked in numerical order.
Note: 2. Connect gauge to P1 port, adjust Standby Pressure down to 300 psi (step 2). Adjust Main Compensator
Pressure to 3800 psi (step 3). Adjustment may require incrementally increasing Load Sense Relief Valve (adjustment
location 6) and Main Pump Compensator until a setting of 3800 psi can be observed on the gauge. Connect additional
gauge to GLS (A) port, bottom lift down, adjust Load Sense relief to the setting noted below.
Function Used to Adjustment

Hydraulic Circuit Test Port Pressure Range
Test Location
Bottom Lift Down 3250-3350 psi
1 Load Sense Relief GLS (A) 6
(See Note 2) (224-231 Bar)
High Idle - 500-515 psi
2 Standby P1 (B) 1
No Function (34-35 Bar)
High Idle - 3575-3675 psi
3 Main P1 (B) 2
Bottom Lift Down (246-253 Bar)
High Idle - Bottom 500-550 psi
4 Pilot JS1 (C) 4
Steering, Any Mode (34-38 Bar)
5 Service Brake BV1 (D) 5
Steering, Any Mode (72-79 Bar)
Priority Load High Idle - Bottom 2375-2475 psi
6 GLS (A) 3
Sense Steering, Any Mode (164-171 Bar)
7 Boom Extend GLS (A) No Adjustment
Boom Extend (224-231 Bar)
8 Boom Retract GLS (A) No Adjustment
Boom Retract (224-231 Bar)
9 Boom Lift GLS (A) No Adjustment
Lift Up (224-231 Bar)
10 Auxiliary Hydraulic GLS (A) No Adjustment
Auxiliary Function (200-214 Bar)
6
5 4
1
3
2
B
HYDRAULIC
MANIFOLD
MAL2150
MY4361
A D C MAIN CONTROL VALVE
TL1055, TL1255 8-7

8-8
8.4.3
STEER SELECT
VALVE
P T
SERVICE
BRAKE VALVE
B1 B2
MAN0040
A1 A2
CYLINDER
CYLINDER
REAR
REAR STEERING
SERVICE
FRONT STEERING
BRAKES
P T
SL SR
OUTLET
RSB
Hydraulic System
INLET
BV
Hydraulic Schematic
OUTLET
FSB
LOAD
SENSE
STEERING ORBITROL
BLS FRONT
SERVICE
BRAKES
PR T ST PARK
BRAKES
TANK
BT
PR
JS
TO MAIN
CONTROL
VALVE
LS
(SEE SHEET 2)
SLS
P BV BV1 JS JS1 PB T
T2
BLS
HYDRAULIC OIL
COOLER
70 PSI
1100 PSI
PLS
500 PSI SLS
25 PSI
GLS RETURN
FILTER .030
B 8 = 75
GP T
.030
3.66 CID
LS
3625PSI
261PSI
STABILIZER
LS2 CYLINDER
W/O LOCK
S L,L1
10 MICRON
BREATHER
TL1055, TL1255
TL1055, TL1255
LEFT OUTRIGGER RIGHT OUTRIGGER
LIFT CYLINDER LIFT CYLINDER CROWD CYLINDER CYLINDER CYLINDER SWAY CYLINDER TILT CYLINDER
.040 .050
5000 5000 5000

PSI PSI 5000 5000 PSI
PSI PSI
COMPENSATING
SWAY CYLINDER
AUX
TL1255 Before S/N TBN00436
TL1055 Before S/N TBM00895
T COMBINATION VALVE
P P
LEFT AND RIGHT

JOYSTICK OUTRIGGER JOYSTICK
T T SV1
1 2 1 2
P
8.4.3Hydraulic Schematic (Continued)
P
SV2 SV3
T
RTT 1 2 3 4 1 2 1 2
LOD LOU ROD ROU
LUP CIN LDN COUT 2 SV4 SV5
1
L R
PR
P
"QD'S"
THIS
LOC'N
JS ON STD.
MACHINE
SEE
LS SHT. 3
SLS
T
T2
DECOMPRESSION
VALVE
P PR b1 a1 B1 A1 b2 a2 B2 A2 b3 a3 B3 A3 b4 a4 B4 A4 b5 a5 B5 A5 b6 a6 B6 A6 B7 A7
X
3500 PSI 2850 PSI (-0/+25)
PRLS
T2
P2
4100 PSI
4100 PSI
4100 PSI
3000 PSI
3000 PSI
4100 PSI
4100 PSI
4100 PSI
2600 PSI
LS LSb
LIFT CROWD OUTRIGGER OUTRIGGER SWAY AUX TILT
MAL0050
Hydraulic System
8-9
8-10
LEFT OUTRIGGER RIGHT OUTRIGGER
LIFT CYLINDER LIFT CYLINDER CROWD CYLINDER CYLINDER CYLINDER SWAY CYLINDER TILT CYLINDER
.040 .050
5000 5000 5000

PSI PSI 5000 5000 PSI
PSI PSI
COMPENSATING
SWAY CYLINDER
AUX
T
Hydraulic System
P
TL1255 S/N TBN00436 & After
TL1055 S/N TBM00895 & After
LEFT AND RIGHT

JOYSTICK OUTRIGGER JOYSTICK
T
1 2 1 2
P
P
T
RTT 1 2 3 4 1 2 1 2
LOD LOU ROD ROU
LUP CIN LDN COUT
TO PUMP
(SEE SHEET 1)
PR
P
"QD'S"
JS
LS
SLS
T
T2
DECOMPRESSION
VALVE
PILOT
SUMP
LS PR HPCO PPA A B PPA A B PPA A B PPA A B PPA A B PPA A B A B
4100psi 3000psi 3000psi 4100psi
2600psi 3300psi 3300psi 3300psi 4100psi 4100psi
SLS
3400psi
GAGE
INLET
GAGE
PRIORITY FLOW INLET LIFT CROWD LEFT O/R RIGHT O/R SWAY AUX TILT OUTLET
MAL0710-C
TL1055, TL1255
Hydraulic System
OPTIONAL REMOTE
HYDRAULIC QUICK ATTACH
QA CYLINDER
C2 C3
AUXILIARY
HYD. PORTS
C1 C4
P1 P2
LEFT RIGHT,
DWN UP,
QA EXTD. QA RET.
AUXILIARY HYD.
MAL0060 PORTS @ BOOM NOSE
TL1055, TL1255 8-11

Hydraulic System
8.5 HYDRAULIC RESERVOIR 3. Fill the reservoir with hydraulic oil. Refer to Section
2.4, “Fluids and Lubricant Capacities.”
TL1055 - BEFORE S/N TBM00776
TL1255 - BEFORE S/N TBN00388 4. Properly connect the battery.
1
A
REV A
REV
9156-3220
9156-3220
8.5.3 Hydraulic Oil Reservoir Removal/

Installation
If it is determined that the hydraulic oil reservoir must be
TL1055 - S/N TBM00776 & AFTER removed, the hydraulic oil must be drained before the
TL1255 - S/N TBN00388 & AFTER
reservoir is removed. Always dispose of hydraulic oil
1 properly.
a. Reservoir Removal
MY6010
engine OFF.
The hydraulic reservoir (1) is located on the frame 2. Place a Do Not Operate Tag on both the ignition key
between the engine compartment and the cab. switch and the steering wheel, stating that the
8.5.1 Hydraulic Oil Reservoir Draining
1. Park the machine on a firm, level surface, level the cool.
machine, fully retract the boom, lower the boom, 4. Properly disconnect the battery.
(N) NEUTRAL, engage the park brake and shut the 5. Drain the hydraulic oil reservoir. Refer to Section
engine OFF. 8.5.1, “Hydraulic Oil Reservoir Draining.”
2. Place a Do Not Operate Tag on both the ignition key 6. Label, disconnect and cap all hydraulic hoses
switch and the steering wheel, stating that the attached to the hydraulic oil reservoir. Cap all fittings
machine should not be operated. and openings to keep dirt and debris from entering
the hydraulic system.
cool. 7. Remove the bolts securing the hydraulic oil reservoir
to the frame.
8. Remove the hydraulic oil reservoir.
5. Open the filler cap on the hydraulic oil reservoir.
Remove the drain plug on the side of the hydraulic b. Disassembly
oil reservoir.
The hydraulic oil reservoir is a one-piece unit and cannot
6. Transfer the used hydraulic oil into a suitable
be disassembled. The hydraulic oil level sight- glass and
covered container, and label as "Used Oil". Dispose
hydraulic oil filler cap can be removed and reused on the
of used oil at an approved recycling facility. Clean
new replacement reservoir. Dispose of the old reservoir
and reinstall the drain plug.
according to local regulations concerning hazardous
7. Wipe up any hydraulic fluid spillage in, on, near and materials disposal.
around the machine and the work area.
c. Cleaning and Drying
8.5.2 Hydraulic Oil Reservoir Filling
If contaminated hydraulic oil or foreign material is in the
1. Be sure the reservoir is clean and free of all debris. tank, the tank can usually be cleaned.
2. Install a new hydraulic oil filter.
8-12 TL1055, TL1255

Hydraulic System
Note: If a leak is suspected in the hydraulic oil reservoir, 8.6 IMPLEMENT PUMP
contact your local Caterpillar dealer.
For internal service instructions contact your local
To clean the hydraulic oil reservoir:
Caterpillar dealer.
1. Have a dry chemical (Class B) fire extinguisher near
the work area. 8.6.1 Implement Pump Replacement
2. Remove the hydraulic oil reservoir drain plug, and
safely drain any hydraulic oil into a suitable a. Pump Removal
container. Dispose of hydraulic oil properly. 1. Park the machine on a firm, level surface, level the
3. Clean the hydraulic oil reservoir with a high-pressure machine, fully retract the boom, lower the boom,
washer, or flush the tank with hot water for five place the transmission control lever in (N) NEUTRAL,
minutes and drain the water. Dispose of engage the park brake and shut the engine OFF.
contaminated water properly. 2. Place a Do Not Operate Tag on both the ignition key
d. Inspection machine should not be operated.
1. Inspect the hydraulic oil reservoir thoroughly for any 3. Open the engine cover. Allow the system fluids to
cracks, slices, leaks or other damage. cool.
2. With the hydraulic oil reservoir removed from the 4. Properly disconnect the battery.
machine, plug all openings except one elbow fitting.
5. Drain the hydraulic reservoir. Refer to Section 8.5.1,
Install the elbow fitting, and apply approximately
“Hydraulic Oil Reservoir Draining.”
1-1.5 psi (7-10 kPa) of air pressure through the
elbow. Check the reservoir for leaks by applying a 6. Thoroughly clean the pump and surrounding area,
soap solution to the exterior and look for bubbles to including all hoses and fittings before proceeding.
appear at the cracked or damaged area. Note: Cap all hoses as you remove them to prevent
e. Reservoir Installation unnecessary fluid spillage.
1. Place the hydraulic oil reservoir into its original 7. Label, disconnect and cap the hydraulic hoses
orientation. attached to the pump.
2. Secure the hydraulic oil reservoir to the frame with
the previous mounting hardware.
hoses to their appropriate locations.
2
4. Install the hydraulic fluid level sight-glass using
special designed and drilled capscrews and gaskets. 2
5. Install hydraulic filter bracket and hydraulic filter.
6. Fill the hydraulic oil reservoir according to
specifications. Refer to Section 2.4, “Fluids and
7. Check the hydraulic oil reservoir for leaks.
MAL0720
8. Remove the four bolts and lockwashers (2) securing

the pump to the transmission (top bolts shown only).
Remove the o-ring located between the transmission
and the pump. Wipe up any hydraulic oil spillage.
TL1055, TL1255 8-13

Hydraulic System
Note: DO NOT disassemble the operating pump. The 8.7 CONTROL VALVES
pump is pre-set from the manufacturer. Any adjustments
or repairs performed by anyone other than your local
Caterpillar dealer could void the warranty. 8.7.1 Main Control Valve
The main control valve is mounted at the top of the
b. Pump Installation chassis in front of the mast supports.
1. Place the pump and a new, oiled o-ring into position The main control valve assembly consists of individual
on the transmission. Align the pump shaft with the working sections with their own valve assemblies, each
internal transmission gear, so that the machined providing a specific hydraulic function.
teeth mesh together.
a. Main Control Valve Removal
2. Align the bolt holes with the pump mount holes.
3. Apply Loctite® 242TM to the previously removed bolts. 1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, raise the boom, place
4. Secure the pump to the transmission with the four the transmission control lever in (N) NEUTRAL,
bolts and washers. Torque as required. engage the park brake and shut the engine OFF.
5. Uncap and connect the previously labeled hydraulic 2. Place a Do Not Operate Tag on both the ignition key
hoses to their appropriate locations. switch and the steering wheel, stating that the
6. Fill the hydraulic reservoir. Refer to Section 8.5.2, machine should not be operated.
“Hydraulic Oil Reservoir Filling.” 3. Open the engine cover. Allow the system fluids to
7. Prime the pump by filling the case drain port with fresh, cool.
filtered hydraulic oil from a clean container before 4. Properly disconnect the battery.
installing the case drain connector and hose.
5. Close the engine cover.
8. Check all routing of hoses and tubing for sharp
bends or interference with any rotating members. All 6. Remove the main valve cover.
tube and hose clamps must be tight. 7. Thoroughly clean the main control valve and
9. Remove the 10 amp fuse from location F3 in power surrounding area, including all hoses and fittings,
distribution unit located in the engine compartment. before proceeding.
This will allow the engine to crank, but not start while 8. Drain the hydraulic fluid reservoir. Refer to Section
air is worked out of the new pump. 8.5.1, “Hydraulic Oil Reservoir Draining.”
10. Connect a hose to the “P1” port on the pump. Direct 9. Place a suitable container to catch hydraulic fluid
the open end of the hose into a fluid drip pan. drainage beneath the frame.
11. Properly connect the battery. Note: Slowly remove the hydraulic hoses attached to
12. Turn the machine ignition switch to START and back the main control valve to relieve any possible trapped
OFF in 3 to 5 second intervals. Monitor the open end pressure in the hydraulic line.
of the drain hose for a constant flow of fluid (no air) 10. Label, disconnect and cap all the hydraulic hoses,
while engine is cranking. tubes and wires at the main control valve.
13. Once a constant flow is achieved at the open end of 11. Wipe up any hydraulic fluid spillage in, on, near and
the drain hose, disconnect the hose and reinstall the around the machine and the work area.
10 amp fuse to location F3 in the power distribution
unit.
14. Inspect for leaks and check all fluid levels. The
hydraulic reservoir oil level must be to the middle of
the sight gauge.
c. Pump Test
Refer to Section 8.3.1, “Pressure Checks and
Adjustments.”
8-14 TL1055, TL1255

Hydraulic System
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
1 sections then remove each control spool.
5. Remove any check valves, compensator valves,
1 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

1
Clean all components with a suitable cleaner, such as
triclorethylene, before continuing. Blow dry.
1 d. Main Control Valve Parts Inspection
MAL0730 Inspect all parts and internal passageways for wear,

damage, etc. If inner surfaces of any component DO NOT
12. Remove the four bolts, washers and nuts (1)
display an ultra-smooth, polished finish, or are damaged
securing the main control valve to the frame.
in any way, replace the damaged part. Often, dirty
hydraulic fluid causes failure of internal seals, damage to
b. Main Control Valve Disassembly
the polished surfaces within the component, and wear of
and/or harm to other parts.
2 8.7.2 Main Control Valve Assembly

Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
hydraulic oil.
Assemble each Valve Section

1. Reassemble any check valves, compensator valves,
anti-cavitation valves or shock valves from each
MY1200 individual valve sections if equipped.
1. To disassemble the individual sections of the main 2. Install the control spool being careful not to nick or
control valve, remove the nuts from one end of the scratch the valve section bore or the control spool.
tie rods (2). Pull the tie rods out through the sections. 3. Install the end caps on each end of the valve
2. Disassemble each section assembly as required. section.
Some sections include a pre-adjusted relief valve that Assemble the Main Control Valve.
regulates pressure in a specific circuit.
1. Place all three tie rods (2) with the washers and nuts
Note: DO NOT adjust any of the relief valve assemblies! through the end main control valve section.
Tampering with a relief valve will irrevocably alter
pressure in the affected circuit, requiring recalibration or a 2. Stand the end main control valve section on end.
new relief valve. 3. Install the proper o-rings and load sense shuttle on
the inner face of the end main control valve section.
Disassemble each Valve Section Align the tilt control valve section over the three tie
rods and slide onto the end main control valve
1. Carefully separate the load sense outlet section from the
section.
lift/lower section.
2. Remove the o-rings from between the two sections.
TL1055, TL1255 8-15

Hydraulic System
4. Using the proper o-rings and load sense shuttle, 8.7.3 Service Brake Valve
repeat step three for the remaining valve sections
and lastly the inlet end valve section. a. Service Brake Valve Removal
5. Install the three washers and nuts on the tie rods. 1. Park the machine on a firm, level surface, level the
Torque to 30 lb-ft (41 Nm). machine, fully retract the boom, lower the boom,
e. Main Control Valve Installation engage the park brake and shut the engine OFF.
1. Install the main control valve onto the frame, aligning 2. Place a Do Not Operate Tag on both the ignition key
the bolts with the holes in the end sections of the switch and the steering wheel, stating that the
main control valve. Slide the main control valve into machine should not be operated.
position, and tighten the bolts. 3. Open the engine cover. Allow the system fluids to
2. Prime the main control valve by filling the inlet cool.
openings with fresh, filtered hydraulic oil from a 4. Properly disconnect the battery.
clean container, before attaching the hoses.
5. Label, disconnect and cap all hose attached to the
3. Use new oiled o-rings as required. Uncap and service brake valve.
connect all previously labeled hoses, clamps, etc. to
the main control valve. 6. Remove the service brake pedal. Refer to Section
4.3.2, “Service Brake Pedal.”
4. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating 4
members, and install tie wraps and/or protective
conduit as required. Tighten all tube and hose
clamps.
5. Fill the hydraulic fluid reservoir. Refer to Section 3
8.5.2, “Hydraulic Oil Reservoir Filling.” 3
7. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
5
moving the machine or operating any hydraulic
functions.
8. 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.
9. Wipe up any hydraulic fluid spillage in, on, near and MAL1740
around the machine, work area and tools.
7. Remove the four capscrews, four nuts and four
10. Install the main control valve cover. lockwashers (3) mounting the service brake valve
11. Close and secure the engine cover. (4) to the service brake bracket (5).
12. Remove the Do Not Operate Tags from both the Note: DO NOT disassemble the service brake valve.
ignition key switch and the steering wheel. The service brake valve is not serviceable and must be
replaced in its entirety, if defective.
f. Main Control Valve Test
Conduct a pressure check of the hydraulic system in its
entirety. Adjust pressure(s) as required. Refer to Section
8.3.1, “Pressure Checks and Adjustments.”
8-16 TL1055, TL1255

Hydraulic System
b. Service Brake Valve Installation

1. Install the service brake valve (4) with the four 6
capscrews, four lockwashers and four nuts (3) onto
the service brake bracket (5).
2. Install the service brake pedal. Refer to Section
4.3.2, “Service Brake Pedal.”
with new parts to help ensure proper sealing and
hydraulic oil.
3. Use new oiled o-rings as required. Uncap and
connect the previously labeled hoses to the service
brake valve.
4. Check the routing of all hoses, and tubing for sharp 6
bends or interference with any rotating members, MAL0750
and install tie wraps and/or protective conduit as
required. Tighten all tube and hose clamps. 2. Remove the plastic cap from one service brake
bleeder (6). Attach one end of a length of
transparent tubing over the brake bleeder. Place the
6. Start the engine and run at approximately one-third other end of this tubing in a suitable transparent
to one-half throttle for about one minute, without container that is partially filled with hydraulic oil. The
moving the machine or operating any hydraulic end of the tubing must be below the oil level in the
functions. container.
7. Inspect the service brake valve and connections for 3. Have the assistant depress the brake pedal.
leaks, and check the level of the hydraulic fluid in the DO NOT open the service brake bleeder without
reservoir. Shut the engine OFF. holding the tubing firmly on the bleeder. There is
Note: Check for leaks, and repair as required before pressure at the brakes. Carefully open the bleeder
continuing. Add hydraulic fluid to the reservoir as with a 12 mm wrench. Close the service brake
needed. bleeder when air bubbles no longer appear in the oil.
Release the brake pedal. Remove the tubing from
8. Wipe up any hydraulic fluid spillage in, on, near and the service brake bleeder.
4. Repeat Steps 2 and 3 for the remaining service
9. Close and secure the engine cover. brake bleeders.
10. Remove the Do Not Operate Tags from both the 5. Check hydraulic oil level and add if necessary.
6. Conduct a pressure and function check of the
service brake. Refer to Section 8.4.1, “Hydraulic
8.7.4 Service Brake Bleeding Pressures.”
Carefully bleed the brake lines as soon as the brake valve
is installed in the machine. Air in the system will not allow 8.7.5 Service Brake Test
the brakes to apply properly. There are four brake
This procedure is used in order to determine if the service
bleeder located on the front axle (two inner service brake
brake is functional. This procedure is not intended to
bleeders and two outer park brake bleeders) and two
measure the maximum brake performance. the brake
service brake bleeders on the rear axle). Work with an
holding torque that is required to sustain an engine torque
assistant to perform this procedure.
at a specific engine rpm varies depending on the machine
1. Place the travel select lever in (N) NEUTRAL, configuration. The variations are the differences in the
engage the park brake, and start the engine. engine settings, power train efficiency and in the brake
holding ability, etc.
Conduct the following service brake test on a dry level
surface, clear of any personnel and/or obstacles.
TL1055, TL1255 8-17

Hydraulic System
1. Place the travel select lever in (N) NEUTRAL, 8. If the machine does not remain stationary during this
engage the park brake, and start the engine. test, contact the local Caterpillar dealer for proper
2. Raise the boom to a travel position. service.
3. Depress the service brake, disengage the parking 9. Engage the park brake, place the travel select lever
brake and place the travel select lever in third gear in (N) NEUTRAL, lower the boom and shut engine
forward. OFF.
4. Smoothly and controllably depress the throttle pedal. 8.7.7 Steering Orbitrol Valve
Note: Do Not hold the accelerator pedal in the fully
depressed position for more than ten seconds. Damage
to the power train could occur.
5. Smoothly and controllably fully release the throttle
pedal.
6. The machine should remain stationary during the
test.
7. If the machine does not remain stationary during this
test, contact the local Caterpillar dealer for proper
service.
8. Engage the park brake, place the travel select lever
in (N) NEUTRAL, lower the boom and shut engine
OFF.
8.7.6 Park Brake Test

This procedure is used in order to determine if the parking
brake is functional. This procedure is not intended to
measure the maximum brake performance. the brake
holding torque that is required to sustain an engine torque
at a specific engine rpm varies depending on the machine MY4280 7
configuration. The variations are the differences in the
engine settings, power train efficiency and in the brake The steering orbitrol valve (7) is located at the base of the
holding ability, etc. steering wheel shaft, concealed by the lower dash cover.
The valve is not serviceable and must be replaced in its
Conduct the following parking brake test on a dry level
entirety if defective. For detailed information refer to
surface, clear of any personnel and/or obstacles.
Section 4.3.1, “Steering Column and Orbitrol Valve.”
1. Place the travel select lever in (N) NEUTRAL,
engage the park brake, and start the engine.
2. Raise the boom to a travel position.
3. Depress the service brake, disengage and place the
travel select lever in first gear forward.
4. Smoothly and controllably release the service brake.
5. Smoothly and controllably depress the throttle pedal.
Note: Do Not hold the accelerator pedal in the fully
depressed position for more than ten seconds. Damage
to the power train could occur.
6. Smoothly and controllably fully release the throttle
pedal.
7. The machine should remain stationary during the
test.
8-18 TL1055, TL1255

Hydraulic System
8.7.8 Steer Select Valve 1. Place the steer select assembly on a suitable work
surface.
2. Separate the steer select valve from the manifold by
removing the four socket head capscrews. Discard
the four o-rings.
3. Remove the solenoid valves and cartridges from the
8 steer select housing.
4. Clean all components with a suitable cleaner before
inspection.
5. Inspect the solenoid cartridges for proper operation.
Check by shifting the spool to ensure that it is
functioning properly. Check that the spring is intact.
MY4290 Inspect the cartridge interior for contamination.
The machine can be used in the front-wheel, four-wheel 6. Inspect internal passageways of the steer select
or crab steering mode. The steer select valve (8) controls manifold and valve for wear, damage, etc. If inner
the direction of hydraulic fluid flow to the steering cylinder surfaces of the manifold DO NOT display an ultra-
mounted on each axle. The steer select valve is attached smooth, polished finish, or components are
to a mounting plate under the frame near the left front damaged in any way, replace the manifold or
corner of the cab. appropriate part. Often, dirty hydraulic fluid causes
Verify the correct operation of the steer select valve failure of internal seals and damage to the polished
solenoids before considering replacement of the valve. surfaces within the secondary function manifold.
Refer to Section 9.5, “Electrical System Schematics,” and Note: ALWAYS replace seals, o-rings, gaskets, etc.,
Section 9.12, “Display Monitor and Gauges.” The housing with new parts to help ensure proper sealing and
of the steer select valve is not serviceable and must be operation. Lubricate seals and o-rings with clean
replaced if defective. hydraulic oil.
a. Steer Select Manifold and Valve Removal 7. Install the solenoid valves and cartridges in the steer
select housing.
8. Attach the steer select valve to the manifold using
four new, oiled o-rings and the four socket head
capscrews.
engage the park brake and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key c. Steer Select Valve and Manifold Installation
machine should not be operated. 1. Install the steer select valve to the mounting plate
under the left front side of the frame using the two
3. Open the engine cover. Allow the system fluids to bolts.
cool.
2. Connect all the hydraulic hoses, fittings, solenoid
4. Properly disconnect the battery. wire terminal leads, etc., to the steer select valve
5. Label, disconnect and cap the hydraulic hoses and 3. Check the routing of all hoses, wiring and tubing for
the electrical plugs connected to the steering select sharp bends or interference with any rotating
valve. members, and install tie wraps and/or protective
6. Remove the bolts holding the steer select valve to conduit as required. Tighten all hose clamps.
the mounting plate on the frame. 4. Properly connect the battery.
7. Remove the steer select manifold with the attached 5. Start the engine and run at approximately 1/3-1/2
steer select valve from the machine. Wipe up any throttle for about one minute without moving the
hydraulic fluid spillage in, on, near and around the machine or operating any hydraulic functions.
machine.
6. Inspect for leaks and check the level of the hydraulic
b. Steer Select Manifold and Valve Disassembly, fluid in the reservoir. Shut the engine OFF.
Cleaning, Inspection and Assembly 7. Remove the Do Not Operate Tags from both the
TL1055, TL1255 8-19
Hydraulic System
Note: Check for leaks and repair as required before 2. Clamp the barrel end of the cylinder in a soft-jawed
continuing. Add hydraulic fluid to the reservoir as vise or other acceptable holding equipment if
needed. possible.
8. Wipe up any hydraulic fluid spillage in, on, near and
WARNING
Significant pressure may be trapped inside the cylinder.
10. Remove the Do Not Operate Tags from both the Exercise caution when removing a counterbalance valve
ignition key switch and the steering wheel. or a pilot-operated check valve from a cylinder.
d. Steering Test Note: Avoid using excessive force when clamping the
cylinder in a vise. Apply only enough force to hold the
Refer to Section 8.4.1, “Hydraulic Pressures.”
cylinder securely. Excessive force can damage the
1. Conduct a pressure check of the steering hydraulic cylinder tube.
circuit.
1
2. Check each steering mode for proper function.
8.8 HYDRAULIC CYLINDERS
8.8.1 General Cylinder Removal 6

2
Instructions
1. Remove any attachment from the machine. Park the 5
machine on a firm level surface and fully retract the
boom. Allow sufficient work space around the
hydraulic cylinder being removed. Support the boom
if the lift/lower cylinder is being removed. Place the
travel select lever in (N) NEUTRAL, engage the park
brake, shut the engine OFF and chock wheels.
4
cool. 3
5. Label, disconnect and cap or plug hydraulic hoses in MY4300
relation to the cylinder.
3. If applicable, remove the counterbalance valve (1)
6. Attach a suitable sling to an appropriate lifting device from the side of the cylinder barrel (2).
and to the cylinder. Make sure the device used can
actually support the cylinder. Note: DO NOT tamper with or attempt to adjust the
counterbalance valve cartridge. If adjustment or
7. Remove the lock bolt and/or any retaining clips
replacement is necessary, replace the counterbalance
securing the cylinder pins. Remove the cylinder pins.
valve with a new part.
8. Remove the cylinder.
4. Extend the rod (3) as required to allow access to the
9. Wipe up any hydraulic fluid spillage in, on, near and base of the cylinder.
Note: Protect the finish of the rod at all times. Damage
a. General Cylinder Disassembly to the surface of the rod can cause seal failure.
1. Clean the cylinder with a suitable cleaner before 5. Using a pin spanner wrench, unscrew the head
disassembly. Remove all dirt, debris and grease gland (4) from the tube (2). A considerable amount
from the cylinder. of force will be needed to remove the head gland.
8-20 TL1055, TL1255

Hydraulic System
Carefully slide the head gland down along the rod 2. Clean all metal parts with an approved cleaning
toward the rod eye, away from the cylinder barrel. solvent such as trichlorethylene. Carefully clean
cavities, grooves, threads, etc.
Note: When sliding the rod and piston assembly out of
the barrel, prevent the threaded end of the barrel from Note: If a white powdery residue is present on threads
damaging the piston. Keep the rod centered within the or parts, it can be removed by using a soft brass wire
barrel to help prevent binding. brush. Wipe clean with Loctite® Cleaner prior to
reassembly.
6. Carefully pull the rod assembly (3) along with the
head gland (4) out of the cylinder barrel.
8.8.2 Cylinder Inspection
7. Fasten the rod eye in a soft-jawed vise, and place a
padded support under and near the threaded end of 1. Inspect internal surfaces and all parts for wear,
the rod to prevent any damage to the rod. damage, etc. If the inner surface of the cylinder
barrel does not display a smooth finish, or is scored
8. Remove the set screw from the piston head (5). or damaged in any way, replace the barrel.
9. If equipped, remove the piston head (5) mounting 2. Remove light scratches on the piston, head gland,
nut (6). rod or inner surface of the cylinder barrel with a 400-
Note: It may be necessary to apply heat to break the 600 grit emery cloth. Use the emery cloth in a rotary
bond of the sealant between the piston and the rod motion to polish out and blend the scratch(es) into
before the piston can be removed. the surrounding surface.
Some cylinder parts are sealed with a special organic 3. Check the piston rod assembly for run-out. If the rod
sealant and locking compound. Before attempting to is bent, it must be replaced.
disassemble these parts, remove any accessible seals
from the area of the bonded parts. Wipe off any hydraulic c. General Cylinder Assembly Instructions
oil, then heat the part(s) uniformly to break the bond. A 1. Use the proper tools for specific installation tasks.
temperature of 300-400° F (149-204° C) will destroy the Clean tools are required for installation.
bond. Avoid overheating, or the parts may become
2. Install new seals, back-up rings and o-rings on the
distorted or damaged. Apply sufficient torque for removal
piston and new seals, back-up rings, o-rings and
while the parts are still hot. The sealant often leaves a
bearing on the head gland.
white, powdery residue on threads and other parts, which
must be removed by brushing with a soft brass wire brush Note: The extend/retract cylinder has a spacer that
prior to reassembly. MUST be installed over the rod AFTER the head gland
10. Remove the piston head (5) from the rod (3) and and BEFORE the piston head.
carefully slide the head gland (4) off the end of the 3. Fasten the rod eye in a soft-jawed vise, and place a
rod. padded support under and near the threaded end of
11. Remove all seals, back-up rings and o-rings from the the rod to prevent any damage to the rod.
piston head and all seals, back-up rings and o-rings
Note: Protect the finish on the cylinder rod at all times.
from the head gland.
Damage to the surface of the rod can cause seal failure.
Note: The head gland bearing will need to be inspected
4. Lubricate and slide the head gland over the cylinder
to determine if replacement is necessary.
rod. Install the piston head on to the end of the
DO NOT attempt to salvage cylinder seals, sealing rings cylinder rod. Loctite® 243TM and install the set screw
or o-rings. ALWAYS use a new, complete seal kit when in the piston head. Refer to Section 8.8.5, “Cylinder
rebuilding hydraulic components. Consult the parts Torque Specifications” for torque specifications for
catalog for ordering information. the piston head and the set screw.
Note: Avoid using excess force when clamping the
b. Cylinder Cleaning Instructions
cylinder barrel in a vise. Apply only enough force to hold
1. Discard all seals, back-up rings and o-rings. Replace the cylinder barrel securely. Excessive force can
with new items from seal kit to ensure proper damage the cylinder barrel.
cylinder function.
5. Place the cylinder barrel in a soft-jawed vise or other
acceptable holding devise.
TL1055, TL1255 8-21

Hydraulic System
Note: When sliding the rod and piston assembly into the 8.8.3 Cylinder Pressure Checking
cylinder barrel, prevent the threaded end of the cylinder
Attach a 5000 psi (345 bar) gauge to the test port on the
barrel from damaging the piston head. Keep the cylinder
P1 port on the hydraulic manifold to check the system
rod centered within the barrel to prevent binding.
pressure. For more information, refer to Section 8.4.1,
6. Carefully insert the cylinder rod assembly into the “Hydraulic Pressures.”
cylinder barrel.
Note: If a hydraulic cylinder pressure is greater than the
7. Screw the head gland into the cylinder barrel and main control valve pressure, increase the main control
tighten with a spanner wrench. Refer to Section valve pressure by adjusting the main relief. Generally,
8.8.5, “Cylinder Torque Specifications” for torque one half turn clockwise will be adequate to check an
specifications for the head gland. individual circuit. Activate the circuit and if pressure is
8. If applicable, install new counter balance valve into obtained turn the main relief counter clockwise one half
block on the cylinder barrel. turn. Re-check the main relief setting and adjust if
necessary.
d. General Cylinder Installation
8.8.4 Steering Cylinders
1. Grease the bushings at the ends of the hydraulic
cylinder. Using an appropriate sling, lift the cylinder
into it’s mounting position. STEERING CYLINDER
2. Align cylinder bushing and install pin, lock bolt or

retaining clip.
3. Connect the hydraulic hoses in relation to the labels
or markings made during removal.
4. Before starting the machine, check fluid level of the
hydraulic fluid reservoir and if necessary fill to full
mark with hydraulic oil. AXLE CENTER SECTION

6. Start the machine and run at low idle for about one
MY4310
minute. Slowly activate hydraulic cylinder function in
both directions allowing cylinder to fill with hydraulic The steer cylinder is attached to each axle center
oil. housing.The steer cylinder assembly can be found in
7. Inspect for leaks and check level of hydraulic fluid in Section 5.3, “Axle Assemblies.” The steer cylinder is
reservoir. Add hydraulic fluid if needed. Shut the covered in the appropriate manufacturer’s axle literature.
engine OFF.
8. Wipe up any hydraulic fluid spillage in, on, near and
8-22 TL1055, TL1255

Hydraulic System
8.8.5 Cylinder Torque Specifications
a. Lift/Lower Cylinder
Machine Head Nut CB Valve Valve Screw

TL1055 - S/N TBM00100 thru 550-600 lb-ft 2125-2175 lb-ft 45-50 lb-ft 28-30 lb-ft
TBM00599 (745-813 Nm) (2881-2949 Nm) (54-61 Nm) (38-41 Nm)
TL1055 - S/N TBM00600 & After 550-600 lb-ft 1600-2000 lb-ft 30-35 lb-ft 24-27 lb-ft
(745-813 Nm) (2169-2711 Nm) (40-47 Nm) (32-36 Nm)
TL1255 - S/N TBN00100 thru 550-600 lb-ft 2850-2900 lb-ft 45-50 lb-ft 28-30 lb-ft
TBN00307 (745-813 Nm) (3864-3932 Nm) (54-61 Nm) (38-41 Nm)
TL1255 - S/N TBN00308 & After 550-600 lb-ft 1600-2000 lb-ft 45-50 lb-ft 24-27 lb-ft
(745-813 Nm) (2169-2711 Nm) (54-61 Nm) (32-36 Nm)
b. Extend/Retract Cylinder
Machine Head Nut Valve (Large) Valve (Small)

TL1055 - S/N TBM00100 thru 500-550 lb-ft 1325-1375 lb-ft 110 lb-ft 35 lb-ft
TBM00631 (1796-1864 Nm) (149 Nm) (47 Nm)
TL1055 - S/N TBM00632 & After 500-550 lb-ft 1400-1700 lb-ft 110 lb-ft 35 lb-ft
(1898-2304 Nm) (149 Nm) (47 Nm)
TL1255 - S/N TBN00100 thru 500-550 lb-ft 1325-1375 lb-ft 110 lb-ft 35 lb-ft
TBN003335 (1796-1864 Nm) (149 Nm) (47 Nm)
TL1255 - S/N TBN00336 & After 500-550 lb-ft 1400-1700 lb-ft 110 lb-ft 35 lb-ft
(1898-2304 Nm) (149 Nm) (47 Nm)
c. Tilt Cylinder
Machine Head Nut CB Valve

TL1055 - S/N TBM00100 thru 550-600 lb-ft 2050-2100 lb-ft 40-45 lb-ft
TBM00631 (745-813 Nm) (2779-2847 Nm) (54-61 Nm)
TL1055 - S/N TBM00632 & After 550-600 lb-ft 2200-2400 lb-ft 40-45 lb-ft
(745-813 Nm) (2982-3254 Nm) (54-61 Nm)
TL1255 - S/N TBN00100 thru 550-600 lb-ft 2250-2300 lb-ft 40-45 lb-ft
TBN003335 (745-813 Nm) (3253-3525 Nm) (54-61 Nm)
TL1255 - S/N TBN00336 & After 550-600 lb-ft 2400-2600 lb-ft 40-45 lb-ft
(745-813 Nm) (3050-3118 Nm) (54-61 Nm)
TL1055, TL1255 8-23

Hydraulic System
d. Compensation Cylinder
Machine Head Nut

TL1055 - S/N TBM00100 thru TBM00556 550-600 lb-ft (745-813 Nm) 2050-2100 lb-ft (2779-2847 Nm)
TL1055 - S/N TBM00557 & After 550-600 lb-ft (745-813 Nm) 2200-2400 lb-ft (2982-3254 Nm)
TL1255 - S/N TBN00100 thru TBN00278 550-600 lb-ft (745-813 Nm) 2250-2300 lb-ft (3050-3118 Nm)
TL1255 - S/N TBN00279 & After 550-600 lb-ft (745-813 Nm) 1600-2000 lb-ft (2169-2711 Nm
e. Frame Level Cylinder
Machine Head Nut Check Valve

TL1055 - S/N TBM00100 thru TBM00509 300-325 lb-ft 750-800 lb-ft 15 lb-ft
(407-441 Nm) (1016-1085 Nm) (20 Nm)
TL1055 - S/N TBM00510 & After 300-325 lb-ft 1125-1375 lb-ft 33 lb-ft
(407-441 Nm) (1525-1864 Nm) (45 Nm)
TL1255 - S/N TBN00100 thru TBN00266 300-325 lb-ft 750-800 lb-ft 15 lb-ft
(407-441 Nm) (1016-1085 Nm) (20 Nm)
TL1255 - S/N TBN00267 & After 300-325 lb-ft 1125-1375 lb-ft 33 lb-ft
(407-441 Nm) (1525-1864 Nm) (45 Nm)
f. Stabilizer Cylinder
Machine Head Nut Cartridge Cartridge Nut

TL1055 - S/N TBM00100 thru TBM00546 300-325 lb-ft 775-825 lb-ft 22 lb-ft 2.5 lb-ft
(407-441 Nm) (1050-1119 Nm) (30 Nm) (3,3 Nm)
TL1055 - S/N TBM00547 & After 300-325 lb-ft 800-1000 lb-ft 22 lb-ft 2.5 lb-ft
(407-441 Nm) (1084-1355 Nm) (30 Nm) (3,3 Nm)
TL1255 - S/N TBN00100 thru TBN00313 300-325 lb-ft 775-825 lb-ft 22 lb-ft 2.5 lb-ft
(407-441 Nm) (1050-1119 Nm) (30 Nm) (3,3 Nm)
TL1255 - S/N TBN00314 & After 300-325 lb-ft 800-1000 lb-ft 22 lb-ft 2.5 lb-ft
(407-441 Nm) (1084-1355 Nm) (30 Nm) (3,3 Nm)
g. Outrigger Cylinder
Nut Valve Mount

1300-1350 lb-ft (1763-1830 Nm) 30-35 lb-ft (41-47 Nm)
8-24 TL1055, TL1255

Section 9
Electrical System
Contents

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.1.1 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.1.2 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4.1 Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4.2 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4.3 Power Distribution Unit (VEC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.4.4 Optional Power Distribution Unit (VEC) . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.5.1 Cab Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.5.2 Options Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.5.3 Chassis/Boom Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
9.5.4 Power Unit Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
9.6 Circuit Breakdowns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
9.6.1 Constant Power Circuit from Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
9.6.2 Start and Charge Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
9.7 Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.7.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.8 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.8.1 Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.9 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.9.1 Windshield/Rear Window Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . 9-22
9.10 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.10.1 Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.11 Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.11.1 Park Brake Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.11.2 Transmission Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
9.11.3 Transmission Oil Temperature Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
9.11.4 Engine Coolant Temperature Sender / Switch . . . . . . . . . . . . . . . . . . . . . 9-26
9.11.5 Engine Oil Pressure Sender/Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.11.6 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.11.7 Inclinometer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.12 Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.12.1 Analog Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.13 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.13.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.13.2 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.14 Engine Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
9.14.1 Engine Diagnostic and Event Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
TL1055, TL1255 9-1

Electrical System
9.1 ELECTRICAL COMPONENT

TERMINOLOGY
To understand the safety, operation, and service
the operator/mechanic be familiar with the name and
location of the electrical components of the machine. The
following illustration identifies the components that are
referred to throughout this section.
9.1.1 General Overview

TL1055 - Before S/N TBM01316 Excluding TBM01298
TL1255 - Before S/N TBN00799 Excluding TBN00785
3 IN 1 GAUGE DASH SWITCHES
OPTIONAL POWER
DISTRIBUTION UNIT
(behind dash panel)
OPTIONAL
HEATER/AC CONTROLS
MY5540
IGNITION
SWITCH
COOLANT
TEMPERATURE
SENDER
ENGINE CONTROL POWER DISTRIBUTION UNIT

MODULE (in engine compartment)
(ECM)
ALTERNATOR
OIL PRESSURE
SWITCH
OIL PRESSURE
SENDER
STARTER RELAY
STARTER MAL0320
MY4370
9-2 TL1055, TL1255

Electrical System
9.1.2 General Overview

4 IN 1 GAUGE DASH SWITCHES
OPTIONAL POWER
DISTRIBUTION UNIT
(behind dash panel)
OPTIONAL
HEATER/AC CONTROLS
MY4350
IGNITION
SWITCH
POWER DISTRIBUTION UNIT

(in engine compartment) FUSE HOLDER
COOLANT
ENGINE CONTROL
TEMPERATURE
MODULE
SENDER
(ECM)
ALTERNATOR
MY4550
STARTER RELAY
STARTER
MY6000
TL1055, TL1255 9-3

Electrical System
9.2 SPECIFICATIONS 9.4.2 Cab
Electrical system specifications are listed in Section 2,

“General Information and Specifications.”
3
9.3 SAFETY INFORMATION
WARNING
Practices,” of this manual.
9.4 FUSES AND RELAYS

MAL0410
9.4.1 Engine Compartment
The optional power distribution unit is located in the cab.
2 For access, remove the screws securing the load chart
panel (3) to the dash.
1
1
MAL0320
1 MY4550
The starter relay (1) and power distribution unit (2) is

located on the power distribution unit bracket in the
engine compartment.
9-4 TL1055, TL1255

Electrical System
9.4.3 Power Distribution Unit (VEC)
F8 F3
IGN1
F15 F4
F16 F14 F13 F1
F9 F7
IGN3
F10
ACCY1
F11 F2
F12 F5
ACCY2
F6
MAL1400
Connector Legend
No. Function Amp Rating
F1 Trans/Park Brake Power 15
F2 Alternator Excite 5
F3 Engine ECU Ignition Power 10
F4 Gauge Power 10
F5 Spare Accessory Power 15
F6 Auxiliary Electric Power 10
F7 Horn Power 15
F8 Spare Battery Power 25
F9 Engine ECU Battery Power 25
F10 Steer/Frame Level Power 10
F11 Rear Axle Stabilizer/Tilt Power 10
F12 Key Battery Power 15
F13 Options Power 3 20
IGN1 Ignition 1
IGN 2 Ignition 2
ACCY1 Accessory 1
ACCY2 Accessory 2
TL1055, TL1255 9-5

Electrical System
9.4.4 Optional Power Distribution Unit (VEC)
F1
R1 R5
F2
F3
R2 R6
F4
F5
R3 R7
F6
F7
R4 R8
F8
MY1260
Connector Legend
No. Function Amp Rating
F1 Wiper 20
F2 Option 15
F3 Option 15
F4 Option 15
F5 Heater 20
F6 Lights 20
F7 Beacon 10
F8 Dash Fan 10
R1 Wiper
R2 Heater Blower
R3 Aux Elec 1
R4 Aux Elec 2
R5 Option 15
R6 Option 25
R7 Lights
R8 Beacon/Fan
9-6 TL1055, TL1255

9.5
9.5.1
TL1055, TL1255
8 7 6 5 4 3 2 1
MAIN DASH PANEL TL1055/TL1255

STONERIDGE WAIT TO START CAB REVERSE WARN LIGHT
GAUGE (RED, 18 GA GXL)
TILT
RELAY TEST RELAY SPEED
TRANSMISSION SHIFTER THROTTLE
6 5 4 HOBBS WILLIAMS STANDARD
TRANS TMP WRN
(SHIELD/020) (RED, 18 GA GXL) (SUSPENDED) JOYSTICK
30
87
86
85
30
87
86
85
3 2
87a
87a
(CAN L/905, GREEN) 1
F F
(CAN H/904, YELLOW) SW1 SW2
3
1
4
5
2
3
1
4
5
2
N N TILT TILT
ENG WARN
UP DOWN
(RED, 18 GA GXL)
R R
YEL
RED
ENG STOP
4 4
(RED, 18 GA GXL) A B C D E F
Cab Schematic
D D
PLUGGED
3 3 1 2
PLUGGED
SW3 SW4
REVERSE
KEY START
SHIFTER GND
SHIFTER GND
SHIFTER GND
TRAN/BRK PWR
TRANS SOL Y2
2 2
TRANS TMP SW
1 1
BLK
GRY
BLU
RED
PLUG
PLUG
IVS
PLUGGED
PLUGGED
1 2 3 4 5 6
THR SGN/915
THR RTN/914
THR SUP/911
STD JOY PWR
STAB/TILT PWR
1 2 3 4 5 6 7 8 12 TURNS
STEER MODE PER FOOT
CRAB DASH GND TWIST
7
1 4
TILT UP
TILT DN
PLUGGED
PLUGGED
2 5
STD JOY PWR

STD JOY PWR
3 6
ALL WHL
(BLK, 18 GA GXL)
(RED, 18 GA GXL)
(ORG, 18 GA GXL)
(ORG, 18 GA GXL)
(WHT, 18 GA GXL)
PLUGGED
PK BRK SOL
(D BLU, 18 GA GXL)
(D BLU, 18 GA GXL)
KEY START
PK BRK SOL
HORN
SHIFT PWR 1
TRANS SOL Y1
TRANS SOL Y3
TRANS SOL Y5
TRANS SOL Y4
TRANS SOL Y2
OFF
PARK BRAKE
1 2 3 4 5 6 7 8 2 OFF
7
3
1 4
ON 2 5
3 6
ON
DASH GND
C C
HORN
FUL LVL
STR AW
ST RLY
DASH GND
GAGE PWR
STR CRB
HORN PWR
ENG WARN LT
PK BRK SOL
ENG STOP LT
TRANS TMP SW
SHIFT PWR 1
TRAN/BRK PWR
STEER/SWAY PWR
WAIT TO START LT
ELECTRICAL SYSTEM SCHEMATICS
TRANSMISSION LEGEND
GEAR ACTIVATED TRANS SOLENOIDS
F1 Y1, Y3, Y4, Y6

SP-1
SP-2
F2 Y1, Y3, Y5, Y6 SP-3
SP BAT PWR
F3 Y1, Y3, Y6 SP ACCY PWR
SP CAB GND 1
SP CAB GND 2
F4 Y1, Y6
AC CLUTCH SEE
SHEET 2
R1 Y2, Y3, Y4, Y6
R2 Y2, Y3, Y5, Y6
R3 Y2, Y3, Y6
B SHIELDED
B
CABLE R4 Y2, Y6
(CAN H/904, YELLOW) A
(CAN L/905,GREEN) B (CAN H/904) N1 Y6 (ONLY IF PARK BRAKE OFF)
(SHIELD/020) A
C (CAN L/905)
B
C (SHIELD/020) N2 Y6 (ONLY IF PARK BRAKE OFF)
A
B
120 OHM C N3 Y6 (ONLY IF PARK BRAKE OFF)
SP-1
SP-2
SP-3
TILT UP
TILT DN
CAN TERMINATOR
PLUGGED
REVERSE
TILT UP
TILT DN
IVS
PLUGGED
PLUGGED
KEY/IGN
KEY START
AC CLUTCH
SHIFTER GND
PK BRK SOL
SP BAT PWR
SP BAT PWR
N4 Y6 (ONLY IF PARK BRAKE OFF)

SHIFT PWR 1
SHIFTER GND
THR SUP/911
THR SGN/915
THR RTN/914
SP ACCY PWR
STAB/TILT PWR
B A
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
TRAN/BRK PWR
SP CAB GND 1
SP CAB GND 2
TRANS TMP SW
STAB/TILT PWR
I
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4
SHIFTER HARNESS
SHIFTER HARNESS DT06-4S
TO CHASSIS ASSEMBLY HD34-24-31PT TO TILT ON JOYSTICK
ROLLER OPTION
KEY ACC
KEY START
KEY IGN
KEY BAT PWR

A A
HORN
STR AW
ST RLY
KEY IGN
KEY ACC
STR CRB
FUL LVL
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
CAN H
CAN L
SHIELD
DASH GND
GAGE PWR
HORN PWR
KEY START
PK BRK SOL
KEY BAT PWR

SHIFT PWR 1
WAIT TO START LT
ENG WARN LT
TRANS TMP SW
ENG STOP LT
TRAN/BRK PWR
STEER/SWAY PWR
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
DASH PANEL HARNESS
HD34-24-31ST
MAL0161B
8 7 6 5 4 3 2 1
Electrical System
9-7
9-8
9.5.2
8 7 6 5 4 3 2 1
TL1055/TL1255 ROOF WIPER

AUX HYD PANEL MOTOR
OPTIONS
D STOPLIGHT WINDSHIELD
M D
SWITCH WASHER DASH BLOWER HEATER
CAB LIGHTS M WIPER MOTOR
8 7 DOME MOTOR
BEACON LEFT RIGHT FAN MOTOR VALVE
OPTIONS VEC LIGHT M RIGHT DASH PANEL
1 4
WIPER HEATER/BLOWER WIPER PWR M M M
Electrical System
F1 20
A WORKLIGHTS BEACON WIPER
F5 20 HEATER PWR 1 2 3 4 5 6 7 8 9 10
OFF OFF
30
87
86
85
30
87
86
85
B
87a
87a
2 5 KEY ACC 1 4
C H
F7 10 BCN PWR 2 5 2 LW
D B
3 6 F8 10 D FAN PWR 3 6 3
P
E
Options Schematic
LIGHTS BCN/FAN
F6 20 DOME LT ON ON
GREEN-4
F A A B A B A B
CAB LT PWR A B A B C D
G
30
87
86
85
30
87
86
85
87a
87a
S/W LT PWR
H
AUX ELEC1
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
SW1 86
BCN LT
A
CAB LTS
WORK LT
BCN PWR
30
87
86
85
87a
HEATER GND
HEATER GND
HEATER PWR
OPTION (15A) OPTION (25A)
HTR CNTRL B
B
CAB LT PWR
S/W LT PWR
CAB LT GND
EMPTY
EMPTY
WASHER
30
87
86
85
30
87
86
85
87a
87a
WIPER LO
WIPER HI
WIPER HI
WIPER LO
DOME/BCN GND
WIPER PWR
WIPER PARK
WIPER PARK
AUX ELEC2
BCN LT
WASHER
AUX RLYS PWR
STOP LT
DOME LT
CAB LTS
CAB LTS
E
SW1 87A
S/W LT PWR
CAB LT GND
CAB LT GND
BLUE-3
30
87
86
85
F
87a
DOME/BCN GND
DOME/BCN GND
F4
F3
F2
SW2 86
D FAN PWR
D FAN GND
HEATER HI
G
HEATER MED
HEATER LOW
HEATER GND
SW2 87A
H
25
15
BLACK-1 GRAY-2 HEATER HI
H G F E D C B A H G F E D C B A HEATER MED
HEATER LOW
HTR TEMP BLOWER
PWR
8K OHM
GND
QC PWR
M H
QC GND
QC GND
PLUGGED
PLUGGED
PLUGGED
QC PWR
PLUGGED
PLUGGED
PWR
L B
STOP LT
BCN PWR
DOME LT
WORK LT
RESISTOR LOCATED C
S/W LT PWR
CAB LT PWR
CAB LT GND
24 KOHM,1W
DOME/BCN GND
C APPROX 10" BEHIND C
AUX WORKLIGHT/ HEATER TEMP SWITCH A B C
25A OPT
PLUGGED
PLUGGED
ELECTRIC
15A OPT 2
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4
OPT GND 1
OPT GND 2
D FAN GND
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8
AUX SW GND
BEACON CONNECTION IN
25A OPT GND

OPTION
15A OPT 2 GND

PLUGGED
OPTION ENCLOSED CAB
D FAN PWR
WIPER PWR
D FAN GND
HEATER PWR
HEATER GND
OPTIONS HARNESS
5A ROOF WIPER PWR

5A ROOF WIPER GND
5A ROOF WIPER PWR
FAN SW C
5A ROOF WIPER GND

HEATER PWR
ENCLOSED CAB
A B C D E F
15A OPT 2 OPTION
HTR CNTRL A
HEATER GND
A OPTION 2
HEATER PWR
15A OPT 2 GND
QC PWR
QC PWR
B 15 A
QC GND
QC GND
STOP LT
BCN PWR
DOME LT
WORK LT
SW2 86
SW1 86
SW2 87A
SW1 87A
PLUGGED
PLUGGED
PLUGGED
S/W LT PWR
CAB LT PWR
CAB LT GND
(RED)
25A OPT
AUX SW GND
DOME/BCN GND
A
25A OPT GND
B
OPTION
25 A
A/C SWITCH
PLUGGED
D FAN PWR
WIPER PWR
D FAN GND
HEATER PWR
HEATER GND
(BLACK)
(RED/WHITE)
B B
OPTIONS
FUSE LEGEND
F1 20A WIPER PWR THERMOSTATIC

F2 15A 15A OPTION 1 PWR SWITCH A/C PRESSURE SWITCH
F3 15A 15A OPTION 2 PWR
PRS SW AC SW
F4 25A 25A OPTION PWR
F5 20A HEATER/BLOWER PWR
F6 20A LIGHT PWR
F7 10A BEACON PWR
F8 10A DASH FAN PWR
25A OPT GND
QC PWR
QC GND
QC GND
KEY ACC
STOP LT
WORK LT
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
OPT PWR 1
QC PWR
OPT PWR 2
OPT PWR 3
OPT PWR 4
OPT GND 1
OPT GND 2
AC SW
AUX RLYS PWR

RLY 87
RLY 87
A
25A OPT GND
B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 86 87a 87
OPTIONS HARNESS A/C M 17A M CONDENSER FANS
HD36-24-19PE (ON ROOF)
RELAY
TO CHASSIS ASSEMBLY
AC CLUTCH
85 30
25A OPT GND
25A OPT
A A
SEE SHEET 1
MAL0171B
8 7 6 5 3 2 1
TL1055, TL1255
9.5.3
TL1055, TL1255
8 7 6 5 4 3 2 1
1
2
(OPT) (OPT)
REVERSE (OPT)
FRONT RIGHT TAIL LIGHT HORN TILT-ON
ALARM TO CAB ASSEMBLY A/C QC DIVERTOR (OPT)
WORKLIGHT JOYSTICK FUEL
BU STOP TAIL TO DASH PANEL HARNESS TO SHIFTER HARNESS TO OPTIONS HARNESS COMPRESSOR A B C D E F VALVE AUXILIARY
VALVE SNDR ELECTRIC
HD36-24-31PT HD36-24-31ST HD34-24-19SE
D CHASSIS HARNESS CHASSIS HARNESS CHASSIS HARNESS M D
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
POWER DISTRIBUTION
A B
BLK
RED
YEL
BLU
ORG
(OPT)
(-)
A B A B A B
GRN
RED
BLK
FUSE/BREAKER LEGEND
PLUGGED
AUXILIARY
CB1 20A OPTIONS POWER 3 ELECTRIC
A B A B C D
CB2 20A OPTIONS POWER 4
A B C D E F
CB3 20A OPTIONS POWER 1 A S LT RT TM
SP-3
SP-2
SP-1
HORN
HORN
SP-1
SP-2
SP-3
QC PWR
LT GND
QC GND
QC GND
REVERSE
SP GND 1
SP GND 2
STR AW
ST RLY
AC CLUTCH
F1 15A TRANS/PARK BRK PWR
PLUGGED
PLUGGED
PLUGGED
KEY IGN
KEY ACC
STR CRB
FUL LVL
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
CAN H
CAN L
SHIELD
PLUGGED
REVERSE
TILT UP
TILT DN
IVS
ENG GND
PLUGGED
KEY ACC
STOP LT
WORK LT
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
SP BAT PWR
DASH GND
GAGE PWR
HORN PWR
SP ACCY PWR
FUL LVL
KEY START
KEY START
AC CLUTCH
OPT PWR 1
QC PWR
OPT PWR 2
OPT PWR 3
OPT PWR 4
OPT GND 1
OPT GND 2
PK BRK SOL
PK BRK SOL
SP BAT PWR
SP BAT PWR
F2 5A ALTERNATOR EXCITE
KEY BAT PWR

SHIFT PWR 1
ENG WARN LT
SHIFT PWR 1
SHIFTER GND
THR SUP/911
THR SGN/915
THR RTN/914
SP ACCY PWR
REMOVE DIODES
TRANS TMP SW
ENG STOP LT
TRAN/BRK PWR
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
TRAN/BRK PWR
SP CAB GND 1
SP CAB GND 2
TRANS TMP SW
AUX RLYS PWR
WAIT TO START
STAB/TILT PWR
FUL/STAB GND
FOR OPTIONAL
STEER/SWAY PWR
F3 10A ENGINE ECU IGN PWR CABLE NEGATIVE CABLE
ROLLER TILT
a. TL1055 Before S/N TBM00941
ON JOYSTICK TO CAB FIREWALL
LT GND
LT GND
F4 10A GAGE (INST PANEL) PWR
WORK LT
REVERSE
STOP LT
WORK LT
AND INSTALL
QC GND 7
QC GND 5
PLUGGED
"EMPTY" PLUG
QC PWR 2
TILT DN
TILT UP
BLK
YEL
BLU
QC PWR 1
RED
F5 15A SPARE ACCESSORY PWR

ORG
AUX ELEC GND
FUL/STAB GND
FUL/STAB GND
F6 10A AUX ELECTRIC PWR
PLUGGED
F7 15A HORN PWR

F8 25A SPARE BATTERY PWR
F9 25A ENGINE ECU BAT PWR
F10 10A STEER/SWAY PWR
A B C D E F
F11 10A R. AXLE STAB/TILT PWR
Chassis/Boom Schematic
F12 15A KEY BATTERY PWR
+ -
12 VDC
ALL WHEEL STR AW BATTERY
1
STEER STR/SWAY GND
MODE 2
VALVE
POSITIVE CABLE
STR CRB TO STARTER
CRAB 1
MAST
EXTRA
SWING
STR/SWAY GND AND ALTERNATOR

2
PLUGGED
SIDESHIFT
NEGATIVE CABLE
AUX ELEC GND
TO ENG BLOCK
C NEGATIVE CABLE C
FLAG TO
CHASSIS FRAME
ECU IGN/012
1
ECU BAT/022
2
ECU GND/050
3
BAT GND
BAT GND
BAT POS
BAT POS
ENG GND
4
PLUGGED
5
PK BRK SOL
6
ENG WARN LT
A C A C POWER DIST 7
ENG STOP LT
8
BLACK-6 GRAY-5 VEC ALT EXC
9
THR SUP/911
10
THR SGN/915
DASH GND 11
A THR RTN/914
F2 5 ALT EXC 12
B ST RLY
ACCY-2 IGNITION-2 F5 15 SP ACCY PWR 13
C PLUGGED
F6 10 AUX RLYS PWR 12 TURNS 14
30
87
86
85
30
87
86
85
D
87a
87a
PLUGGED
OPT GND 1 PER FOOT 15
E PLUGGED
KEY ACC TWIST 16
GREEN-4
F TRANS TMP SW
F1 15 TRAN/BRK PWR 17
G IVS
OPT GND 2 18
IGNITION-1 ACCY-1 H TRANS SOL Y1
19
CHASSIS HARNESS
HD34-24-29PE
WAIT TO START LT
30
87
86
85
30
87
86
85
20
87a
87a
SP CAB GND 1
A TRANS SOL Y2
SP CAB GND 2 21
B TRANS SOL Y3
SP GND 1 22
C PLUGGED
SP GND 2 23
TO POWER UNIT ASSEMBLY
B D
AUX ELEC GND
PLUGGED
24
B
E TRANS SOL Y4
25
F8
F3
F4
F9
F7
LT GND
BLUE-3
CB4
CB3
CB1
F10
CB2
F11
F12
F TRANS SOL Y5
STR/SWAY GND 26
20
20
20
20
G CAN H
25
10
10
25
15
10
10
15
FUL/STAB GND 27
H CAN L
28
SHIELD
29
BLACK-1 GRAY-2 CABLE

H G F E D C B A H G F E D C B A
6A 6A
STAB VLV
KEY IGN
ENG GND
GAGE PWR
HORN PWR
FUL/STAB GND
OPT PWR 2
OPT PWR 1
OPT PWR 3
OPT PWR 4
STAB/TILT PWR
STAB/TILT PWR
SP BAT PWR
SHIFTER GND
ECU IGN/012
ECU BAT/022
KEY BAT PWR
ECU GND/050
STAB/TILT PWR
STEER/SWAY PWR
STAB VLV
STAB VLV
PLUG
PLUG
A B C D
FUL/STAB GND
FUL/STAB GND
SWAY ENABLE
PLUS 15
MINUS 15
STR/SWAY GND
STEER/SWAY PWR
STEER/SWAY PWR
SWAY LT
SWAY RT
STR/SWAY GND
STR/SWAY GND
SWAY ENABLE
SWAY ENABLE
SWAY LOCK
SWAY LOCK
SWAY LOCK
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
BLK
BLU
RED
WHT
ORG
A B C D
1 2 3 4 1 2 3 4 A B A B
1 2 1 2 1 2 1 2 1 2
BLK
BLU
SWAY RT
PLUS 15
SWAY LT
RED
WHT
ORG
MINUS 15
+
STR/SWAY GND
STR/SWAY GND
RED
RED
STEER/SWAY PWR
STEER/SWAY PWR
GREEN
BLACK
GREEN
BLACK
2
5
4
1
3
2
5
4
1
3
YELLOW
YELLOW
STABILIZER
STABILIZER PROXIMITY
85
86
87
30
85
86
87
30
ENGINE SIDE CAB SIDE VALVE SWITCH

87a
87a
SV2 SV1 SV4 SV5 SV3

(-)15 DEG (+)15 DEG
+
LT
SWAY PILOT RT LAT TILT LAT TILT
VALVE (-)15 DEG RLY (+)15 DEG RLY SWITCH SWITCH
A SWAY PROXIMITY A
SWITCH
8 7 6 5 4 3 2 1
MAL0181B
Electrical System
9-9
9-10
8 7 6 5 4 3 2 1
1
2
(OPT) (OPT)
REVERSE (OPT)
VALVE SNDR ELECTRIC
HD36-24-31PT HD36-24-31ST HD34-24-19SE
D CHASSIS HARNESS CHASSIS HARNESS CHASSIS HARNESS M D
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
POWER DISTRIBUTION
A B
BLK
RED
YEL
BLU
ORG
(OPT)
(-)
A B A B A B
GRN
RED
BLK
FUSE/BREAKER LEGEND
PLUGGED
Electrical System
AUXILIARY
A B A B C D
A B C D E F
SP-3
SP-2
SP-1
HORN
HORN
SP-1
SP-2
SP-3
QC PWR
LT GND
QC GND
QC GND
REVERSE
SP GND 1
SP GND 2
STR AW
ST RLY
AC CLUTCH
PLUGGED
PLUGGED
PLUGGED
KEY IGN
KEY ACC
STR CRB
FUL LVL
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
YEL (CAN H)
GRN (CAN L)
PLUGGED
REVERSE
TILT UP
TILT DN
IVS
ENG GND
PLUGGED
KEY ACC
STOP LT
WORK LT
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
SP BAT PWR
DASH GND
GAGE PWR
HORN PWR
SP ACCY PWR
FUL LVL
KEY START
KEY START
AC CLUTCH
OPT PWR 1
QC PWR
OPT PWR 2
OPT PWR 3
OPT PWR 4
OPT GND 1
OPT GND 2
PK BRK SOL
PK BRK SOL
SP BAT PWR
SP BAT PWR
KEY BAT PWR

SHIFT PWR 1
ENG WARN LT
SHIFT PWR 1
SHIFTER GND
THR SUP/911
THR SGN/915
THR RTN/914
SP ACCY PWR
REMOVE DIODES
TRANS TMP SW
ENG STOP LT
TRAN/BRK PWR
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
TRAN/BRK PWR
SP CAB GND 1
SP CAB GND 2
TRANS TMP SW
AUX RLYS PWR
WAIT TO START
STAB/TILT PWR
FUL/STAB GND
FOR OPTIONAL
BRN/BLK (CAN SHIELD)
STEER/SWAY PWR
F3 10A ENGINE ECU IGN PWR CABLE ROLLER TILT NEGATIVE CABLE
LT GND
LT GND
WORK LT
REVERSE
STOP LT
WORK LT
AND INSTALL
QC GND 7
QC GND 5
PLUGGED
QC PWR 2
"EMPTY" PLUG
TILT DN
TILT UP
BLK
YEL
BLU
QC PWR 1
RED

ORG
AUX ELEC GND
FUL/STAB GND
FUL/STAB GND
PLUGGED
F7 15A HORN PWR

A B C D E F
+ -
TL1255 S/N TBN00483 thru TBN00658
12 VDC
STR AW
b. TL1055 S/N TBM00941 thru TBM01168
ALL WHEEL 1 BATTERY

STEER STR/SWAY GND
MODE 2
VALVE
POSITIVE CABLE
STR CRB TO STARTER
CRAB 1
MAST
EXTRA
SWING

2
PLUGGED
SIDESHIFT
NEGATIVE CABLE
AUX ELEC GND
TO ENG BLOCK
C NEGATIVE CABLE
C
FLAG TO
CHASSIS FRAME
ECU IGN/012
1
ECU BAT/022
2
ECU GND/050
3
BAT GND
BAT GND
BAT POS
BAT POS
ENG GND
4
12 TURNS PER PLUGGED
5
FOOT TWIST PK BRK SOL
6
ENG WARN LT
ENG STOP LT
8
9
THR SUP/911
10
THR SGN/915
DASH GND 11
A THR RTN/914
F2 5 ALT EXC 12
B ST RLY
C YEL (CAN H)
F6 10 AUX RLYS PWR 14
30
87
86
85
30
87
86
85
D
87a
87a
GRN (CAN L)
OPT GND 1 15
E BRN/BLK (CAN SHIELD)
KEY ACC 16
GREEN-4
F TRANS TMP SW
G CABLE IVS
OPT GND 2 18
19
CHASSIS HARNESS
HD34-24-29PE
WAIT TO START LT
30
87
86
85
30
87
86
85
20
87a
87a
SP CAB GND 1
A TRANS SOL Y2
SP CAB GND 2 21
B TRANS SOL Y3
SP GND 1 22
B C PLUGGED B
SP GND 2 23
D PLUGGED
AUX ELEC GND 24
E TRANS SOL Y4
25
F8
F3
F4
F9
F7
LT GND
BLUE-3
CB4
CB3
CB1
F10
CB2
F11
F12
F TRANS SOL Y5
STR/SWAY GND 26
20
20
20
20
G PLUGGED
25
10
10
25
15
10
10
15
FUL/STAB GND 27
H PLUGGED
28
PLUGGED 29
BLACK-1 GRAY-2
6A 6A
STAB VLV
KEY IGN
ENG GND
GAGE PWR
HORN PWR
FUL/STAB GND
OPT PWR 2
OPT PWR 1
OPT PWR 3
OPT PWR 4
STAB/TILT PWR
STAB/TILT PWR
SP BAT PWR
SHIFTER GND
ECU IGN/012
ECU BAT/022
KEY BAT PWR
ECU GND/050
STAB/TILT PWR
STEER/SWAY PWR
STAB VLV
STAB VLV
PLUG
PLUG
A B C D
FUL/STAB GND
FUL/STAB GND
SWAY ENABLE
PLUS 15
MINUS 15
STR/SWAY GND
STEER/SWAY PWR
STEER/SWAY PWR
SWAY LT
SWAY RT
STR/SWAY GND
STR/SWAY GND
SWAY ENABLE
SWAY ENABLE
SWAY LOCK
SWAY LOCK
SWAY LOCK
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
BLK
BLU
RED
WHT
ORG
A B C D
1 2 3 4 1 2 3 4 A B A B
1 2 1 2 1 2 1 2 1 2
BLK
BLU
SWAY RT
PLUS 15
SWAY LT
RED
WHT
ORG
MINUS 15
+
STR/SWAY GND
STR/SWAY GND
RED
RED
STEER/SWAY PWR
STEER/SWAY PWR
GREEN
BLACK
GREEN
BLACK
2
5
4
1
3
2
5
4
1
3
YELLOW
YELLOW
STABILIZER
85
86
87
30
85
86
87
30
ENGINE SIDE CAB SIDE VALVE SWITCH

87a
87a
SV2 SV1 SV4 SV5 SV3

(-)15 DEG (+)15 DEG
+
LT
SWAY PILOT RT LAT TILT LAT TILT
A VALVE (-)15 DEG RLY (+)15 DEG RLY SWITCH SWITCH A
SWAY PROXIMITY
SWITCH
8 7 6 5 4 3 2 1
MAL0760C
TL1055, TL1255
TL1055, TL1255
8 7 6 5 4 3 2 1
1
2
(OPT) (OPT)
REVERSE (OPT)
VALVE SNDR ELECTRIC
HD36-24-31PT HD36-24-31ST HD34-24-19SE
CHASSIS HARNESS CHASSIS HARNESS CHASSIS HARNESS M
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
D POWER DISTRIBUTION D
A B
BLK
RED
YEL
BLU
ORG
(OPT)
(-)
A B A B A B
GRN
RED
BLK
FUSE/BREAKER LEGEND
PLUGGED
AUXILIARY
A B A B C D
A B C D E F
SP-3
SP-2
SP-1
HORN
HORN
SP-1
SP-2
SP-3
QC PWR
LT GND
QC GND
QC GND
REVERSE
SP GND 1
SP GND 2
STR AW
ST RLY
AC CLUTCH
PLUGGED
PLUGGED
PLUGGED
KEY IGN
KEY ACC
STR CRB
FUL LVL
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
YEL (CAN H)
GRN (CAN L)
PLUGGED
REVERSE
TILT UP
TILT DN
IVS
ENG GND
PLUGGED
KEY ACC
STOP LT
WORK LT
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
SP BAT PWR
DASH GND
GAGE PWR
HORN PWR
SP ACCY PWR
FUL LVL
KEY START
KEY START
AC CLUTCH
OPT PWR 1
QC PWR
OPT PWR 2
OPT PWR 3
OPT PWR 4
OPT GND 1
OPT GND 2
PK BRK SOL
PK BRK SOL
SP BAT PWR
SP BAT PWR
KEY BAT PWR

SHIFT PWR 1
ENG WARN LT
SHIFT PWR 1
SHIFTER GND
THR SUP/911
THR SGN/915
THR RTN/914
SP ACCY PWR
REMOVE DIODES
TRANS TMP SW
ENG STOP LT
TRAN/BRK PWR
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
TRAN/BRK PWR
SP CAB GND 1
SP CAB GND 2
TRANS TMP SW
AUX RLYS PWR
WAIT TO START
STAB/TILT PWR
FUL/STAB GND
FOR OPTIONAL
STEER/SWAY PWR
F3 10A ENGINE ECU IGN PWR CABLE ROLLER TILT NEGATIVE CABLE
LT GND
LT GND
WORK LT
REVERSE
STOP LT
WORK LT
AND INSTALL
QC GND 7
QC GND 5
PLUGGED
"EMPTY" PLUG
QC PWR 2
TILT DN
TILT UP
BLK
YEL
BLU
QC PWR 1
RED

ORG
AUX ELEC GND
FUL/STAB GND
FUL/STAB GND
PLUGGED
F7 15A HORN PWR

A B C D E F
+ -
12 VDC
ALL WHEEL STR AW BATTERY
1
STEER STR/SWAY GND
2
TL1255 S/N TBN00659 thru TBN00798
MODE POSITIVE CABLE

c. TL1055 S/N TBM01169 thru TBM01315
VALVE STR CRB

CRAB 1 TO STARTER
MAST
EXTRA
SWING

2
PLUGGED
SIDESHIFT
NEGATIVE CABLE
AUX ELEC GND
TO ENG BLOCK
NEGATIVE CABLE
C FLAG TO C
CHASSIS FRAME
ECU IGN/012
1
ECU BAT/022
2
ECU GND/050
3
BAT GND
BAT GND
BAT POS
BAT POS
ENG GND
4
5
6
ENG WARN LT
ENG STOP LT
8
9
THR SUP/911
10
THR SGN/915
DASH GND 11
A THR RTN/914
F2 5 ALT EXC 12
B ST RLY
C YEL (CAN H)
30
87
86
85
30
87
86
85
D
87a
87a
GRN (CAN L)
OPT GND 1 15
E BRN/BLK (CAN SHIELD)
KEY ACC 16
GREEN-4
F TRANS TMP SW
G CABLE IVS
OPT GND 2 18
19
CHASSIS HARNESS
HD34-24-29PE
WAIT TO START LT
30
87
86
85
30
87
86
85
20
87a
87a
SP CAB GND 1
A TRANS SOL Y2
SP CAB GND 2 21
B TRANS SOL Y3
SP GND 1 22
C PLUGGED
SP GND 2 23
D PLUGGED
AUX ELEC GND 24
B E TRANS SOL Y4 B
25
F8
F3
F4
F9
F7
LT GND
BLUE-3
CB4
CB3
CB1
F10
CB2
F11
F12
F TRANS SOL Y5
STR/SWAY GND 26
20
20
20
20
G PLUGGED
25
10
10
25
15
10
10
15
FUL/STAB GND 27
H PLUGGED
28
PLUGGED 29
BLACK-1 GRAY-2
6A 6A
STAB VLV
KEY IGN
ENG GND
GAGE PWR
HORN PWR
FUL/STAB GND
OPT PWR 2
OPT PWR 1
OPT PWR 3
OPT PWR 4
STAB/TILT PWR
STAB/TILT PWR
SP BAT PWR
SHIFTER GND
ECU IGN/012
ECU BAT/022
KEY BAT PWR
ECU GND/050
STAB/TILT PWR
STEER/SWAY PWR
STAB VLV
STAB VLV
PLUG
PLUG
A B C D
FUL/STAB GND
FUL/STAB GND
SWAY ENABLE
PLUS 15
MINUS 15
STR/SWAY GND
STEER/SWAY PWR
STEER/SWAY PWR
SWAY LT
SWAY RT
STR/SWAY GND
STR/SWAY GND
SWAY ENABLE
SWAY ENABLE
SWAY LOCK
SWAY LOCK
SWAY LOCK
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
BLK
BLU
RED
WHT
ORG
A B C D
1 2 3 4 1 2 3 4 A B A B
1 2 1 2 1 2 1 2 1 2
SWAY RT
PLUS 15
SWAY LT
MINUS 15
+
STR/SWAY GND
STR/SWAY GND
STEER/SWAY PWR
STEER/SWAY PWR
2
5
4
1
3
2
5
4
1
3
STABILIZER
85
86
87
30
85
86
87
30
VALVE SWITCH
87a
87a
(-)15 DEG RLY (+)15 DEG RLY
A A
MAL0780F
8 7 6 5 4 3 2 1
Electrical System
9-11
9-12
8 7 6 5 4 3 2
1
2
(OPT) (OPT)
REVERSE (OPT)
ALARM TO CAB ASSEMBLY A/C OC DIVERTOR (OPT)
VALVE SNDR ELECTRIC
HD36-24-31PT HD36-24-31ST HD34-24-19SE
CHASSIS HARNESS CHASSIS HARNESS CHASSIS HARNESS M
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
POWER DISTRIBUTION
BLK
RED
YEL
BLU
ORG
A B
(-)
BLK
RED
GRN
A B A B A B
(OPT)
PLUGGED
FUSE/BREAKER LEGEND
AUXILIARY
F1 15A TRANS/PARK BRK PWR ELECTRIC
A B A B C D
A B C D E F A S LT RT TM
F3 10A ENGINE ECU IGN PWR
SP-3
SP-2
SP-1
IVS
IVR
SP-1
SP-2
SP-3
HORN
LT GND
D F4 10A GAGE (INST PANEL) PWR D
HORN
ST RLY
TILT UP
TILT DN
STR AW
REVERSE
FUL LVL
QC GND
QC GND
KEY IGN
ON-IDLE
STOP LT
QC PWR
QC PWR
KEY ACC
KEY ACC
STR CRB
WORK LT
SP GND 1
SP GND 2
YEL (CAN H)
REVERSE
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
GRN (CAN L)
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
DASH GND
OPT GND 1
OPT GND 2
AC CLUTCH
KEY START
KEY START
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4
GAGE PWR
HORN PWR
AC CLUTCH
PK BRK SOL
PK BRK SOL
SP BAT PWR
SP BAT PWR
SP BAT PWR
THR SUP/911
SHIFT PWR 1
SHIFT PWR 1
THR RTN/914
THR SGN/915
ENG STOP LT
KEY BAT PWR

SHIFTER GND
ENG WARN LT
SP ACCY PWR
SP ACCY PWR
SP CAB GND 1
SP CAB GND 2
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
TRANS SOL Y6
FUL LVL
STAB/TILT PWR
AUX RLYS PWR
WAIT TO START
TRANS TMP SW
TRANS TMP SW
TRAN/BRK PWR
TRAN/BRK PWR
STEER/SWAY PWR
REMOVE DIODES
LT GND
FUL/STAB GND
LT GND
FOR OPTIONAL
STOP LT
WORK LT
F7 15A HORN PWR CABLE
WORK LT
REVERSE
ROLLER TILT
ON JOYSTICK
TILT UP
TILT DN
Electrical System
F8 25A SPARE BATTERY PWR AND INSTALL
QC GND 5
QC GND 7
PLUGGED
QC PWR 1
QC PWR 2
"EMPTY" PLUG
BLK
YEL
BLU
RED
ORG
FUL/STAB GND
FUL/STAB GND
AUX ELEC GND

PLUGGED

F13 20A OPTIONS POWER 3
A B C D E F
TL1255 S/N TBN00799 & After

d. TL1055 S/N TBM01316 & After
ALL WHEEL
STR AW
1
STEER STR/SWAY GND
MODE 2
VALVE STR CRB
1
MAST
CRAB
EXTRA
SWING
STR/SWAY GND
2
PLUGGED
SIDESHIFT
AUX ELEC GND
NEGATIVE CABLE
TO CAB FIREWALL
125
C C
ECU IGN/012
1
ECU BAT/022
2
ECU GND/050
3
BAT GND
BAT GND
BAT POS
BAT POS
ENG GND
4
5
6
ENG WARN LT
ENG STOP LT
8
+ - 9
THR SUP/911
12 VDC 10
THR SGN/915
BATTERY DASH GND 11
A THR SUP/914
F2 5 ALT EXC 12
POSITIVE CABLE B ST RLY
ACCY-2 IGNITION-2 13
F5 15 SP ACCY PWR
TO STARTER C YEL (CAN H)
30
87
86
85
87
30
86
85
87a
87a
D GRN (CAN L)
OPT GND 1 15
NEGATIVE CABLE E BRN/BLK (CAN SHIELD)
KEY ACC 16
GREEN-4
TO ENG BLOCK F TRANS TMP SW
G IVS
CHASSIS HARNESS
HD34-24-29PE
CABLE 18
NEGATIVE CABLE IGNITION-1 ACCY-1
OPT GND 2
H TRANS SOL Y1
FLAG TO 19
WAIT TO START LT
30
87
86
87
85
30
86
85
87a
87a
CHASSIS FRAME SP CAB GND 1 20
A TRANS SOL Y2
SP CAB GND 2 21
B TRANS SOL Y3
SP GND 1 22
C ON-IDLE
SP GND 2 23
D IVR
AUX ELEC GND 24
E TRANS SOL Y4
F8
F3
F4
F9
F7
25
BLUE-3
LT GND
F13
F14
F15
F10
F16
F11
F12
F TRANS SOL Y5
STR/SWAY GND 26
G PLUGGED
20
25
10
20
10
25
20
15
10
20
10
15
FUL/STAB GND 27
H TRANS SOL Y6
28
PLUGGED 29
BLACK-1 GRAY-2
B H G F E D C B A H G F E D C B A B
6A 6A
KEY IGN
ENG GND
STAB VLV
OPT PWR 2
OPT PWR 1
OPT PWR 3
OPT PWR 4
GAGE PWR
HORN PWR
SP BAT PWR
ECU IGN/012
ECU BAT/022
ECU GND/050
KEY BAT PWR
SHIFTER GND
STAB/TILT PWR
FUL/STAB GND
STAB/TILT PWR
STAB/TILT PWR
STEER/SWAY PWR
STAB VLV
STAB VLV
FUL/STAB GND
FUL/STAB GND
PLUG
PLUG
A B C D
PLUS 15
SWAY ENABLE
MINUS 15
STR/SWAY GND
STEER/SWAY PWR
STEER/SWAY PWR
SWAY LT
SWAY ENABLE
SWAY ENABLE
SWAY RT
STR/SWAY GND
STR/SWAY GND
SWAY LOCK
SWAY LOCK
SWAY LOCK
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
BLK
BLU
RED
WHT
ORG
A B C D
1 2 3 4 1 2 3 4 A B A B
1 2 1 2 1 2 1 2 1 2
PLUS 15
SWAY LT
SWAY RT
MINUS 15
+
STR/SWAY GND
STR/SWAY GND
STEER/SWAY PWR
STEER/SWAY PWR
STABILIZER
85 2
86 5
87 4
30 1
85 2
86 5
87 4
30 1
87a 3
87a 3
VALVE SWITCH
(-)15 DEG RLY (+)15 DEG RLY
A A
TO OPTIONS HARNESS
MAL1371B
8 7 6 5 4 3 2 1
TL1055, TL1255
9.5.4
TL1055, TL1255
8 7 6 5 4 3 2 1
TRANSMISSION LEGEND
TL1055/TL1255
POWER UNIT
D D
F1 Y1, Y3, Y4, Y6
F2 Y1, Y3, Y5, Y6

NEGATIVE CABLE
TO BATTERY (3/0 AWG, BLACK)
F3 Y1, Y3, Y6
F4 Y1, Y6
POSITIVE CABLE
TO BATTERY (3/0 AWG, RED)
R1 Y2, Y3, Y4, Y6
a. TL1055 Before S/N TBM00941
R2 Y2, Y3, Y5, Y6 STARTER

RELAY
Power Unit Schematic
30
R3 Y2, Y3, Y6 ST RLY PWR
STRT SOL 87
ST RLY 86
R4 Y2, Y6
ENG GND 85
N1 Y6 (ONLY IF PARK BRAKE OFF) (3/0 AWG, RED)
N2 Y6 (ONLY IF PARK BRAKE OFF) (3/0 AWG, BLACK)

STARTER
ECU IGN/012
1 N4 Y6 (ONLY IF PARK BRAKE OFF)
ECU BAT/022
2
ECU GND/050 STRT SOL
3
ENG GND M
4
PLUGGED
5
PK BRK SOL
C 6 ST RLY PWR C
ENG WARN LT
7 (3/0 AWG, RED)
ENG STOP LT
8 (4 AWG, RED)
ALT EXC 6A/400V
9
THR SUP/911
10 CSA RLY PWR
THR SGN/915
11
THR RTN/914
12
ST RLY
13 ALTERNATOR
PLUGGED
14 ALT PWR
PLUGGED B+
15
PLUGGED G
16 ALT EXC A
TRANS TMP SW A D+
17
IVS 6A/400V
18
HD36-24-29SE
POWER UNIT HARNESS
TRANS SOL Y1
19
WAIT TO START
20
TRANS SOL Y2
21
TRANS SOL Y3
TO CHASSIS ASSEMBLY
22
PLUGGED
23
PLUGGED
24
TRANS SOL Y4
25
TRANS SOL Y5
26
CAN H/904
27
CAN L/905
28 AMBIENT TEMPERATURE SENSOR
SHIELD/020
29
AMB SNR PWR +5V A
AMB SNG RTN B

AMB SNR SIG C
PK BRK SOL
1 PARK
ENG GND BRAKE
2
B VALVE B
SHIELDED
CAN TERMINATOR CABLE
F5 RELAY
(CAN H/904)
A
(CAN L/905) 30
B 50 CSA RLY PWR
120 OHM (SHIELD/020)
C
ECU IGN/012 86
COLD START AID 85
GLOW PLUG PWR 87

ENG GND
ENG GND
ENG GND
ENG GND
ENG GND
ENG GND
ENG GND
PK BRK SOL
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
TRANS TMP SW
TO GLOW PLUGS
AMB SNR PWR +5V

AMB SNR SIG
ECU GND/050
ECU BAT/022
CAN H/904
CAN L/905
SHIELD/020
RTN
ECU IGN/012
THR SUP/911
IVS
THR SGN/915
COLD START AID
ENG WARN LT
ENT STOP LT
WAIT TO START LT
A B A B A B A B A B A B A B
1
2
3
7
8
9
42
56
10
15
16
20
21
22
33
40
41
45
54
57
59
60
63
Y1 Y2 Y3 Y4 Y5 Y6 250 F
CAT ECM TRANSMISSION

64 PIN
A A
8 7 6 5 4 3 2 1
MAL0191B
Electrical System
9-13
9-14
8 7 6 5 4 3 2 1
TRANSMISSION LEGEND
TL1055/TL1255
POWER UNIT
D D
F1 Y1, Y3, Y4, Y6
F2 Y1, Y3, Y5, Y6

Electrical System
NEGATIVE CABLE
F3 Y1, Y3, Y6
F4 Y1, Y6
POSITIVE CABLE
R1 Y2, Y3, Y4, Y6
R2 Y2, Y3, Y5, Y6 STARTER

RELAY
30
R3 Y2, Y3, Y6 ST RLY PWR
STRT SOL 87
ST RLY 86
R4 Y2, Y6
ENG GND 85
N1 Y6 (ONLY IF PARK BRAKE OFF) (3/0 AWG, RED)
N2 Y6 (ONLY IF PARK BRAKE OFF) (3/0 AWG, BLACK)

STARTER
ECU IGN/012
1 N4 Y6 (ONLY IF PARK BRAKE OFF)
ECU BAT/022
2
ECU GND/050 STRT SOL
3
ENG GND M
4
PLUGGED
5
PK BRK SOL
C 6 ST RLY PWR C
ENG WARN LT
7 (3/0 AWG, RED)
ENG STOP LT
8 (4 AWG, RED)
ALT EXC 6A/400V
9
THR SUP/911
10 CSA RLY PWR
THR SGN/915
11
THR RTN/914
12
ST RLY
13 ALTERNATOR
14
YEL (CAN H/904)
ALT PWR B+
GRN (CAN L/905)
15
BRN/BLK (CAN SHIELD/020) G
16 ALT EXC A
TRANS TMP SW A D+
17
IVS 6A/400V
18
HD36-24-29SE
POWER UNIT HARNESS
TRANS SOL Y1
19
WAIT TO START
20
TRANS SOL Y2
21
TRANS SOL Y3
TO CHASSIS ASSEMBLY
22
PLUGGED
23
PLUGGED
24
TRANS SOL Y4
25
TRANS SOL Y5
26
PLUGGED
27
28
PLUGGED
AMBIENT TEMPERATURE SENSOR
29 PLUGGED
AMB SNR PWR +5V A
AMB SNG RTN B

AMB SNR SIG C
TL1255 S/N TBN00483 thru TBN00798 excluding TBN00785
SHIELDED
SHIELDED CABLE PK BRK SOL
b. TL1055 S/N TBM00941 thru TBM01315 excluding TBM01298
CAN TERMINATOR CABLE 1 PARK

ENG GND BRAKE
YEL (CAN H/904) 2
A VALVE
B B
GRN (CAN L/905) B
120 OHM BRN/BLK (CAN SHIELD/020)
C
F5 RELAY
50 30
CSA RLY PWR
ECU IGN/012 86
COLD START AID 85
GLOW PLUG PWR 87

ENG GND
ENG GND
ENG GND
ENG GND
ENG GND
ENG GND
ENG GND
PK BRK SOL
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
TRANS TMP SW
TO GLOW PLUGS
AMB SNR PWR +5V

AMB SNR SIG
ECU GND/050
ECU BAT/022
YEL (CAN H/904)
GRN (CAN L/905)
RTN
ECU IGN/012
THR SUP/911
IVS
THR SGN/915
COLD START AID
ENG WARN LT
ENT STOP LT
WAIT TO START LT
BRN/BLK (CAN SHIELD/020)

A B A B A B A B A B A B A B
1
2
3
7
8
9
42
56
10
15
16
20
21
22
33
40
41
45
54
57
59
60
63
Y1 Y2 Y3 Y4 Y5 Y6 250 F
CAT ECM TRANSMISSION

64 PIN
A A
MAL0770C
8 7 6 5 4 3 2 1
TL1055, TL1255
TL1055, TL1255
8 7 6 5 4 3 2 1
CAT SUPPLIED ENGINE HARNESS
A4E2 ECU
J2 CONNECTOR
T960 BK 1 X929 BU 34 INJECTOR CYLINDER 4 RETURN

PARK RELAY
T954 BK 2 X923 OR 58 INJECTOR CYLINDER 4 POWER UNIT TO CHASSIS ASSEMBLY BRAKE 87 a
INJECTOR CYLINDER 4 HD36-24-29SE VALVE
86 85
TRANSMISSION LEGEND POWER UNIT HARNESS 30
T959 BK 3 X928 GN 8 INJECTOR CYLINDER 3 RETURN
1
9
2
3
5
7
8
4
6
21
11
29
20
22
23
25
26
27
28
24
19
10
12
13
15
16
17
18
14
T953 BK 4 X922 WH 64 INJECTOR CYLINDER 3 GEAR ACTIVATED TRANS SOLENOIDS
INJECTOR CYLINDER 3
F1 Y1,Y3,Y4,Y6
NEGATIVE CABLE
TO BATTERY
T958 BK 1 X927 YL 7 INJECTOR CYLINDER 2 RETURN 1 2

Y1 ENG GND
A B
T952 BK 2 X921 PK F2 Y1,Y3,Y5,Y6
ST RLY
D 63 INJECTOR CYLINDER 2 ENG GND
STRT SOL
ST RLY PWR
INJECTOR CYLINDER 2 TRANS SOL Y2

F3 Y1,Y3,Y6 Y2 ENG GND
D
A B
IVS
T957 BK 3 X926 GY 35 INJECTOR CYLINDER 1 RETURN
F4 Y1,Y6
ST RLY
TRANS SOL Y3
A
ON-IDLE
ALT EXC
T951 BK 4 X920 BR
ENG GND
57 INJECTOR CYLINDER 1
PLUGGED
PLUGGED
PLUGGED
CAN L/905
PLUGGED
PLUGGED
PLUGGED
CAN H/904
SHIELD/020
TRANS SOL
Y3
PK BRK SOL
ENG GND
ECU IGN/012
THR SUP/911
THR RTN/914
THR SGN/915
B
ENG STOP LT
ENG WARN LT
REVERSE SOL
TRANS SOL Y1
TRANS SOL Y3
TRANS SOL Y5
TRANS SOL Y6
WAIT TO START
TRANS TMP SW
INJECTOR CYLINDER 1 INTERNAL EXTERNAL R1 Y2,Y3,Y4,Y6
TRANS SOL Y4
A
(ROCKER
ENG GND
COVER) Y4 ENG GND
B
R2 Y2,Y3,Y5,Y6
PK BRK SOL
(2/0 AWG, BLACK)
1 T997 OR 46 IMP POWER SUPPLY (5V) TRANS SOL Y5
A
INTAKE MANIFOLD R3 Y2,Y3,Y6
2 T993 BR 38 IMP RETURN Y5 ENG GND
B
PRESSURE SENSOR
ZF TRANSMISSION
3 X731 BU 55 IMP SIGNAL
R4 Y2,Y6 PRK BRK SOL
Y6
A B
6A/400V
1 L730 OR 47 OIL PRESSURE SENSOR PWR (5V)
OIL PRESSURE TRANS TMP SW
SENSOR 2 Y947 BR 39 OIL PRESSURE SENSOR RETURN N2 Y6 (ONLY IF PARK BRAKE OFF)
250 F
3 994 GY ENG GND
A B
56 OIL PRESSURE SENSOR SIGNAL
R997 OR
ST RLY PWR
1 48 FMP SENSOR POWER SUPPLY (5V) 1

FUEL MANIFOLD N4 Y6 (ONLY IF PARK BRAKE OFF) CSA RLY PWR
2 Y948 BR 40 FMP SENSOR GROUND 2
PRESSURE SENSOR
3 Y946 BU 51 FMP SENSOR SIGNAL 3
4
TRANSMISSION LEGEND 5
E1 ENG GND
A B
COOLANT TEMP 1 955 BU 43 COOLANT TEMP SIGNAL TURNER 6
80
STRT SOL
SENSOR TRANS SOL E2 7
A
2 GEAR ACTIVATED TRANS SOLENOIDS E2 ENG GND 8
B
9
M
F1 E5, E1 TRANS SOL E3
A
E3 10
ENG GND
B
INTAKE MANIFOLD 1 C967 BU 42 IMT SIGNAL 11
F2 E5, E2 ALTERNATOR
TEMP SENSOR 2 L731 BR 37 TEMPERATURE SENSOR RETURN TRANS SOL E4
A
12
E4 ALT PWR 150 (4 AWG, RED)
F3 E5, E3 ENG GND
B
B+ STARTER
TRANS SOL E5
A
F4 E6, E3
G
CRANKSHAFT SPEED/ D+
C 1 996 GN 10 SPEED SENSOR POWER (8V) E5 ENG GND
B
TIMING SENSOR 2 E965 BU 52 CRANK SPEED/TIME SENS SIG
C
R1 E4, E1 TRANS SOL E6
E6
A B
ENG GND
TURNER TRANSMISSION
R2 E4, E2 30 ECM PWR
PUMP/CAM SPEED 1
TRANS TMP SW
A
SENSOR 2 P920 BR 53 PUMP/CAM SPEED SENS SIG R3 E4, E3
250 F
86
N NO SOLENOIDS INGAUGED
85
87
60 CSA RLY PWR2

30
ALT EXC A
FUEL PUMP 1 Y950 YL 25 FUEL PUMP SOLENOID PWM SIG
SOLENOID 2 Y951 PU
a
26 FUEL PUMP SOLENOID RETURN F5

(2/0 AWG, RED)
SHIELDED
CABLE
CAN TERMINATOR
GLOW PLUG PWR
(CAN H/904)
A
(CAN L/905)
c. TL1055 S/N TBM01316 & After including TBM01298
B
ELECTRONIC 1 (SHIELD/020)
C211 BK 19 WASTEGATE RETURN 120 OHM C
WASTEGATE
2 M795 WH 17 WASTEGATE PWM SIGNAL
ACTUATOR
A 101 RD 18 BAT+ (FOR COMMS ADAPTER)

B 229 BK 45 BAT- (FOR COMMS ADAPTER)
C 944 OR 21 CDL+
D 945 BR 20 CDL-
DIAGNOSTIC
CONNECTOR (9 PIN) E Y793 YL 23 J1939-
POSITIVE CABLE
TO BATTERY
F Y792 PK 24 J1939+
G
TO GLOW PLUGS
H
J
AMBIENT TEMPERATURE
STRT AID NEG CABLE AMB SNG RTN SENSOR
B
AMB SNR PWR +5V
B A
AMB SNR SIG
B
C
ENG
BLOCK
1
1
MAIN B-
MAIN B+
*
EXTRA BATTERY MAIN BATTERY BATTERY CABLES
IVS
1
1
1
1
RTN
ON-IDLE
CAN L/905
CAN H/904
SHIELD/020
ECU IGN/012
ECU BAT/022
THR SUP/911
ENT STOP LT
THR SGN/915
ECU GND/050
AMB SNR SIG
ENG WARN LT
B- TERM
B- TERM
B+ TERM
B+ TERM
COLD START AID
WAIT TO START LT
AMB SNR PWR +5V
BTTY - BLK 2/0AWG

7
8
1
2
3
9
BTTY - BLK 2/0AWG

40
15
16
10
59
60
41
54
33
20
21
22
45
63
35
57
42
56
BTTY + RED 2/0AWG

BTTY - BLK 2/0AWG
NEG BTTY
BTTY + RED 2/0AWG

CABLE VEH GND CABLE ENG GND CABLE
ENGINE ECM 64 PIN

STRT AID POS CABLE
TO VEH GND TO VEH GND TO STRT GND, F7 TO STRT GND, F7 TO ENG GND STUD
BTTY - BLK 2/0AWG BTTY - BLK 2/0AWG BTTY - BLK 2/0AWG BTTY - BLK 2/0AWG BTTY - BLK 2/0AWG
1 1 1 1 1
VEH GND VEH GND STRT GND STRT GND ENG GND
A TO STRT PWR, F7
BTTY + RED 2/0AWG
1 A
STRT PWR
POSITIVE BATTERY CABLE
MAL1361B
8 7 6 5 4 3 2 1
Electrical System
9-15
Electrical System
9.6 CIRCUIT BREAKDOWNS
9.6.1 Constant Power Circuit from Battery

BAT POS
BAT POS NEGATIVE CABLE
NEGATIVE CABLE
TO CAB FIREWALL A C A C POWER DIST TO ENGINE ECU
POSITIVE CABLE
BLACK-6 GRAY-5 VEC TO BATTERY (3/0 AWG, RED)
STARTER
A RELAY
F2 5 ALT EXC
B 30
ACCY-2 IGNITION-2 ST RLY PWR
C 1 STRT SOL
GREEN-4
87
D 2
ST RLY
87a
87a
86
30
87
86
85
30
87
86
85
ECU BAT/022
E 85
KEY ACC 4
F 5
F1 15
G TRAN/BRK PWR (3/0 AWG, RED)
+ - 6
12 VDC IGNITION-1 ACCY-1 H 7
BATTERY 8 (3/0 AWG, BLACK)
9
87a
87a
A
30
87
86
85
30
87
86
85
POSITIVE CABLE 10
TO STARTER B 11 STARTER
AND ALTERNATOR C 12
ST RLY
BLUE-3
NEGATIVE CABLE 13
M
D
TO ENG BLOCK 14
CB4
CB3
CB1
CB2
STRT SOL
F12
E
F8
F9
F7
15
NEGATIVE CABLE F 16
FLAG TO G
20
20
20
20
17
25
10
15
15
H 18 ST RLY PWR
19
(3/0 AWG, RED)
20
21
(4 AWG, RED)
BLACK-1 GRAY-2 22
H G F E D C B A H G F E D C B A 23
24
25
26 ALTERNATOR
27 (4 AWG, RED)
SP BAT PWR 28
B+
G
ECU BAT/022
29 6A/400V ALT EXC A
A D+
6A/400V
SP BAT PWR
TRAN/BRK PWR
TRAN/BRK PWR
KEY BAT PWR
SP BAT PWR
SP BAT PWR
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4
HORN PWR
KEY ACC
KEY ACC
ST RLY
TO DASH PANEL HARNESS TO SHIFTER HARNESS

TO OPTIONS HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4
KEY ACC
TRAN/BRK PWR
HORN PWR
KEY ACC
KEY BAT PWR
ST RLY
SP BAT PWR
SP BAT PWR
TRAN/BRK PWR
REVERSE RELAY
SP BAT PWR
87a
OPT PWR 4
OPT PWR 3
OPT PWR 2
OPT PWR 1
30
87
86
85
3
1
4
5
2
KEY/IGN
KEY ACC
B A
A B C D E F G H
GRAY-2 BLACK-1
S SHIFTER HARNESS
I
H
G
F
E
BLUE-3
D
85
86
87
30
87a
85
86
87
30
87a
C
HORN PWR
B OPTION (25A) OPTION (15A)

TRAN/BRK PWR
A PARK BRAKE
HORN OFF
H
OFF 7
85
86
87
30
87a
85
86
87
30
87a
ST RLY
G
F BCN/FAN LIGHTS 1 4
GREEN-4
E 2
2 5
D 3
C 3 6
B
85
86
87
30
87a
30
85
86
87
87a
ON
A ON
HEATER/BLOWER WIPER
OPTIONS VEC
LEFT DASH PANEL
OPTIONS HARNESS DASH PANEL HARNESS

MY1100
9-16 TL1055, TL1255

Electrical System

125
BAT POS
BAT POS
NEGATIVE CABLE
TO CAB FIREWALL
POSITIVE CABLE
NEGATIVE CABLE
A C A C POWER DIST TO BATTERY (2/0 AWG, BLACK)
BLACK-6 GRAY-5 VEC

+ - STRT SOL
12 VDC
BATTERY ST RLY
86
A
F2 ALT EXC
85
5
POSITIVE CABLE ACCY-2 IGNITION-2
B
87
TO STARTER C 1 ST RLY PWR
30
GREEN-4
D 2
87a
87a
87
86
30
86
85
30
87
85
ECU BAT/022
NEGATIVE CABLE E
a
KEY ACC 4
86
TO ENG BLOCK F 5 STARTER
F1 15 TRAN/BRK PWR RELAY
85
G 6
NEGATIVE CABLE IGNITION-1
87
ACCY-1 H 7 CSA RLY PWR2
FLAG TO
30
8
CHASSIS FRAME 9
87a
87a
30
87
86
87
85
30
86
85
a
10
B 11 GLOW PLUG STARTER
C 12 60 RELAY
ST RLY
D 13
BLUE-3
M
14 80
E
15
ST
RT
F13
F14
F15
F16
F12
F8
F9
F7
F 16 SO
G 17 L
20
25
20
25
20
15
20
15
H 18 ST RLY PWR (3/0 AWG, RED)

19
20
21 ECM PWR 30
BLACK-1 GRAY-2 22
150
24
25
26 ALTERNATOR
27 (4 AWG, RED)
SP BAT PWR 28
B+
ECU BAT/022
29 6A/400V ALT EXC A G
D+
SP BAT PWR
TRAN/BRK PWR
TRAN/BRK PWR
KEY BAT PWR
SP BAT PWR
SP BAT PWR
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4
HORN PWR
KEY ACC
KEY ACC
ST RLY

TO OPTIONS HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4
KEY ACC
TRAN/BRK PWR
HORN PWR
KEY ACC
KEY BAT PWR
ST RLY
SP BAT PWR
SP BAT PWR
TRAN/BRK PWR
REVERSE RELAY
SP BAT PWR
87a
OPT PWR 4
OPT PWR 3
OPT PWR 2
OPT PWR 1
30
87
86
85
3
1
4
5
2
KEY/IGN
KEY ACC
B A
A B C D E F G H
GRAY-2 BLACK-1
S SHIFTER HARNESS
I
H
G
F
E
BLUE-3
D
85
86
87
30
87a
85
86
87
30
87a
C
HORN PWR
B OPTION (25A) OPTION (15A)

TRAN/BRK PWR
A PARK BRAKE
HORN OFF
H
OFF 7
85
86
87
30
87a
85
86
87
30
87a
ST RLY
G
F BCN/FAN LIGHTS 1 4
GREEN-4
E 2
2 5
D 3
C 3 6
B
85
86
87
30
87a
30
85
86
87
87a
ON
A ON
HEATER/BLOWER WIPER
OPTIONS VEC
LEFT DASH PANEL
OPTIONS HARNESS DASH PANEL HARNESS MY6021B
TL1055, TL1255 9-17

Electrical System
9.6.2 Start and Charge Circuit

BAT POS
BAT POS NEGATIVE CABLE
NEGATIVE CABLE
TO CAB FIREWALL A C A C POWER DIST POSITIVE CABLE
BLACK-6 GRAY-5 VEC TO BATTERY (3/0 AWG, RED)
STARTER
A RELAY
F2 5 ALT EXC
B 30
ACCY-2 IGNITION-2 ST RLY PWR
C 1 STRT SOL
GREEN-4
87
D 2
ST RLY
87a
87a
86
30
87
86
85
30
87
86
85
3
E 85
4
F 5
F1 15
G TRAN/BRK PWR (3/0 AWG, RED)
+ - 6
12 VDC IGNITION-1 ACCY-1 H 7
BATTERY 8 (3/0 AWG, BLACK)
9
87a
87a
A
30
87
86
85
30
87
86
85
POSITIVE CABLE 10
TO STARTER B 11 STARTER
AND ALTERNATOR C 12
ST RLY
BLUE-3
NEGATIVE CABLE 13
M
D
TO ENG BLOCK 14
CB4
CB3
CB1
CB2
STRT SOL
F12
E
F8
F9
F7
15
NEGATIVE CABLE F 16
FLAG TO G
20
20
20
20
17
25
10
15
15
H 18 ST RLY PWR
19
(3/0 AWG, RED)
20
21
(4 AWG, RED)
BLACK-1 GRAY-2 22
24
25
26 ALTERNATOR
(4 AWG, RED)
KEY BAT PWR
KEY IGN
27
28
B+
G
29 6A/400V ALT EXC A
A D+
6A/400V
TRAN/BRK PWR
TRAN/BRK PWR
KEY BAT PWR
KEY START
KEY START
KEY IGN
ST RLY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
KEY START
TRAN/BRK PWR
KEY START
KEY IGN
KEY BAT PWR
ST RLY
TRAN/BRK PWR
REVERSE
RELAY
3 87a
30
1
TRANSMISSION SHIFTER 4 87
5 86
HOBBS
2 85
F F
SW1 SW2
N
N
KEY/IGN
R R
B A
4 4
SW3 3 3 SW4
S
2 2
I 1 1
WARN LIGHT
TEST RELAY
KEY START
3 87a
30
1
4 87
5 86
2 85
TRAN/BRK PWR
1 2 3 4 5 6 7 8
PARK BRAKE
OFF
7
ST RLY
1 4
2 5 SHIFTER HARNESS
3 6
ON
LEFT DASH PANEL
DASH PANEL HARNESS

MY1110
9-18 TL1055, TL1255

Electrical System

125
BAT POS
BAT POS
NEGATIVE CABLE
TO CAB FIREWALL
POSITIVE CABLE
NEGATIVE CABLE
A C A C POWER DIST TO BATTERY (2/0 AWG, BLACK)
BLACK-6 GRAY-5 VEC

+ - STRT SOL
12 VDC
BATTERY ST RLY
86
A
F2 ALT EXC
85
5
POSITIVE CABLE ACCY-2 IGNITION-2
B
87
TO STARTER C 1 ST RLY PWR
30
GREEN-4
D 2
87a
87a
87
86
30
86
85
30
87
85
3
NEGATIVE CABLE E
a
4
86
TO ENG BLOCK F 5 STARTER
F1 15 TRAN/BRK PWR RELAY
85
G 6
NEGATIVE CABLE IGNITION-1
87
ACCY-1 H 7 CSA RLY PWR2
FLAG TO
30
8
CHASSIS FRAME 9
87a
87a
30
87
86
87
85
30
86
85
a
10
B 11 GLOW PLUG STARTER
C 12 60 RELAY
ST RLY
D 13
BLUE-3
M
14 80
E
15
ST
RT
F13
F14
F15
F16
F12
F8
F9
F7
F 16 SO
G 17 L
20
25
20
25
20
15
20
15
H 18 ST RLY PWR (3/0 AWG, RED)

19
20
21 ECM PWR 30
BLACK-1 GRAY-2 22
150
24
25
26 ALTERNATOR
27 (4 AWG, RED)
B+
28
29 6A/400V ALT EXC A G
D+
TRAN/BRK PWR
TRAN/BRK PWR
KEY BAT PWR
KEY START
KEY START
KEY IGN
ST RLY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
KEY START
TRAN/BRK PWR
HORN PWR
KEY BAT PWR
ST RLY
KEY IGN
TRAN/BRK PWR
REVERSE
RELAY
3 87a
1 30
TRANSMISSION SHIFTER 4 87
5 86
2 85
F F
SW1 SW2
N
N
KEY/IGN
R R
B A
4 4
SW3 3
SW4
S 3
2 2
I WARNING LIGHT
1 1 TEST RELAY
3 87a
KEY START
1 30
4 87
5 86
2 85
TRAN/BRK PWR
PARK BRAKE 1 2 3 4 5 6 7 8
OFF
7
ST RLY
1 4
2 5
3 6
ON
LEFT DASH PANEL
DASH PANEL HARNESS MY6031B
TL1055, TL1255 9-19

Electrical System
9.7 ENGINE START CIRCUIT 3. If the starter only “clicks” it may indicate that the
battery is discharged, or that there is a loose or
corroded battery cable connection. Check the
9.7.1 Starter battery state of charge and battery condition first,
then check the cables and cable connections.
4. For additional information on the starting circuit,
refer to Section 9.5, “Electrical System Schematics.”
c. Starter Removal
Remove the starter only if it fails. To remove the starter:
1 1. Open the engine cover.
3. Remove the wires from the solenoid stud. Remove
the positive (+) battery cable from the starter. Label
and disconnect the wire from the starter solenoid
housing stud. Record how the wires are installed to
ensure correct installation later.
MAL0280
4. Loosen, but DO NOT remove, the three fasteners
The starter (1) is located on the left side of the engine (the securing the starter to the flywheel housing. Support
right side of the machine). the starter securely, as it is relatively heavy and will
fall if not supported.
a. Testing the Starter on the Engine 5. Support the starter and remove the fasteners
If the starter does not engage when the ignition key securing the starter to the engine. Remove the
switch is turned, check the following: negative (-) ground cable from its starter mounting
bolt.
1. The main fuse may be blown, requiring replacement.
Check for the cause of the blown fuse. 6. Remove the starter from the machine.
2. There may be a defect in the ignition key switch, d. Starter Installation
ignition wiring or starter solenoid.
1. Position the starter in its mounting opening on the
3. Check battery condition. Clean the battery posts and
flywheel housing. Position the ground cable over the
the connectors at each end of the battery cables.
correct starter mounting bolt. Secure the starter with
4. Check for broken wiring and damaged insulation on the three fasteners.
the wiring. Replace all broken or damaged wiring.
2. Connect the positive (+) battery cable to the upper
5. Check all connections at the starter solenoid, key solenoid stud. Install the wires to the upper solenoid
switch and wiring harness plugs. Clean and tighten stud, and secure with lock washer and nut.
all connections.
3. Connect the wire to the solenoid mounting stud.
6. If the starter still does not operate after these checks
have been performed, check the starting circuit.
b. Starter Circuit Checks 6. Remove the Do Not Operate Tags from both the
1. Check wires and connections for looseness, ignition key switch and the steering wheel.
corrosion, damage, etc.
2. If a “whirring” noise is heard but the engine does not
turn over, the starter is spinning but not engaging the
flywheel. The starter drive or solenoid that pushes
the drive forward to engage the flywheel may be
defective. Missing or damaged teeth on the flywheel
can also prevent the starter from cranking the
engine.
9-20 TL1055, TL1255

Electrical System
9.8 CHARGING CIRCUIT Note: Record how the alternator is installed to ensure
correct installation later.
2 5. Label and disconnect the wire leads attached to the
alternator.
6. Remove the lower mounting capscrew securing the
alternator to the lower mounting hole on the engine.
7. While supporting the alternator with one hand,
remove the upper (longer) mounting hardware from
the upper alternator mount. Remove the alternator
from the machine.
b. Alternator Installation
1. Position the alternator and align with the upper
alternator mount on the engine bracket. Insert the
upper (longer) mounting hardware through the
alternator mount. Thread the longer capscrew into
the alternator front mount. DO NOT tighten
MAL0270 completely at this time.
2. Align the lower alternator mount hole with the lower
Before using a battery charger, an attempt can be made mounting bracket on the engine, and insert the lower
to recharge the battery by jump-starting the machine mounting capscrew. Tighten the lower capscrew and
(Refer to the appropriate Operation & Maintenance upper capscrew securely.
Manual). Allow the engine to run, which will enable the
alternator (2) to charge the battery. 3. Place a drive ratchet into the square hole on the
serpentine belt tensioner bracket. Apply pressure
If the engine alternator charging warning indicator against the tensioner bracket and route the
illuminates, perform the following checks: serpentine belt onto the alternator and engine
1. Check all battery cable connections at the battery, pulleys. Release and check the tensioner pulley to
and verify that they are clean and tight. verify that it is pivoting freely in order to provide the
2. Check the external alternator wiring and proper tension on the belt. Check for proper belt
connections, and verify that they are in good alignment. (Refer to the appropriate Operation &
condition. Maintenance Manual.)
3. Check the fan belt condition and tension. 4. Connect the previously labeled wire leads to the
alternator.
4. Run the engine and check the alternator for noise. A
loose drive pulley, loose mounting hardware, worn or 5. Properly connect the battery.
dirty internal alternator bearings, a defective stator 6. Close and secure the engine cover.
or defective diodes can cause noise. Replace a worn 7. Remove the Do Not Operate Tags from both the
or defective alternator. ignition key switch and the steering wheel.
9.8.1 Alternator
a. Alternator Removal
cool.
3. Install a drive ratchet into the square hole in the
serpentine belt tensioner bracket.
4. While lifting the automatic belt tensioner away from
the belt, remove the fan serpentine belt.
TL1055, TL1255 9-21

Electrical System
9.9 WINDOW WIPER/WASHER b. Disassembly

WINDSHIELD WIPER MOTOR DO NOT disassemble the motor. The motor is not
serviceable. Replace motor if found to be defective.
a. Removal
c. Inspection and Replacement
Note: It may be necessary to remove several hydraulic
hoses from behind the dash in order to remove and Inspect the motor terminals for continuity. Replace motor
install the wiper motor housing. (Refer to Section 4.3.1, if continuity is not found.
“Steering Column and Orbitrol Valve.”)
d. Installation and Testing
machine, fully retract the boom, lower the boom, 1. Install all required hardware to the motor assembly.
place the transmission control lever in 2. Align motor with the mounting holes and bolt the
(N) NEUTRAL, engage the park brake and shut the motor to the mounting bracket.
engine OFF. 3. Connect the wiper linkage to the wiper motor shaft.
Note: Align the wiper linkage arm with the flat on the
motor shaft to ensure wiper stroke covers window area,
and it does not swipe past the glass area.
cool. 4. Connect the cab harness connectors to windshield
wiper motor connectors.
5. Replace the main dash panel to its original
orientation. Secure with the previously used screws.
7. Turn ignition key switch to the RUN position, and
operate windshield wiper in both LOW and HIGH
speeds to ensure proper operation and that correct
wiper travel is achieved.
8. If previously removed, install hydraulic hoses under
the dash. (Refer to Section 4.3.1, “Steering Column
and Orbitrol Valve.”)
9.9.1 Windshield/Rear Window Washer

Reservoir
3
MY0440
4
5. Remove the screws that secure the main dash
panel. Pull out the dash panel to gain access to the
wiper motor (3).
6. Disconnect the cab harness connectors from the
wiper motor.
7. Remove the linkage attached to the wiper motor.
8. Loosen and remove the three bolts holding the wiper
motor to the mounting bracket.
MY1220
Note: Retain all hardware removed from the wiper
assembly for possible reuse on the replacement motor The windshield washer motor and reservoir (4) is located
housing. in the cab behind the seat. It is labeled as a unit and
cannot be serviced separately.
9. Remove the motor from the inside of the cab.
9-22 TL1055, TL1255

Electrical System
a. Removal 9.10 CAB HEATER AND FAN

machine, fully retract the boom, lower the boom, 9.10.1 Cab Heater Controls
Note: If the suspect component is found to be within the
heater box, the heater box must be removed as a
engine OFF.
complete unit and replaced.
switch and the steering wheel, stating that the a. Cab Heater Controls Removal
3. Open the engine cover. Allow the system fluids to machine, fully retract the boom, lower the boom,
cool. place the transmission control lever in
4. Properly disconnect the battery. (N) NEUTRAL, engage the park brake and shut the
5. Remove the nuts and the lock washers from the engine OFF.
washer mounting bolts. 2. Place a Do Not Operate Tag on both the ignition key
6. Pull the washer reservoir out and away from the switch and the steering wheel, stating that the
mounting bracket. machine should not be operated.
7. Rotate the washer reservoir, label and remove the 3. Open the engine cover. Allow the system fluids to
cab harness connectors from the washer reservoir cool.
connectors. 4. Properly disconnect the battery.
8. Remove the windshield washer hoses from the
reservoir. 5
b. Disassembly
DO NOT disassemble the pump. The pump is not
serviceable. Replace pump if found to be defective.
c. Installation and Testing

1. Connect the windshield washer hoses to the
reservoir.
2. Connect the cab wiring harness connectors to the
MY1230
reservoir connectors.
3. Install the reservoir tank onto the mounting bracket. 5. Remove the screws securing the right cab dash
4. Install the lock washers and nuts and secure. panel (5).
5. Fill the washer fluid reservoir with washer fluid. 6. Pull out the panel to gain access to the heater
control electrical connections. Disconnect the
6. Properly connect the battery. harnesses.
7. Turn the ignition key switch to the RUN position and 7. Remove the heater control knobs.
press the washer switch. Verify that fluid is sprayed
on the windshield. 8. Remove the necessary hardware securing the
heater control from the dash panel. Remove the
control from the panel.
b. Disassembly
DO NOT disassemble the cab heater and fan controls.
The controls are not serviceable. Replace controls if
found to be defective.
TL1055, TL1255 9-23

Electrical System
c. Installation and Testing

1. Check that the variable speed fan control is in the 6
OFF position.
2. Install the heater controls to the dash panel with the
previously used hardware.
3. Connect the cab electrical harness connector to the
controls.
4. Install the control knobs.
5. Install the screws securing the dash panel to the
cab.
6. Properly connect the battery 7
7. Turn the ignition key to the ON position and check
the fan speeds. If further repair is needed, refer to
Section 9.5, “Electrical System Schematics.” MY1140
8. Start the machine and allow engine to warm to

6. Remove the nut on the end of the park brake coil (6).
operating temperature. Check heat control at
different levels. 7. Remove the park brake coil.
9. Close and secure the engine cover. 8. Remove the park brake solenoid (7). (Remove only if
the electrical coil is found to not be faulty.)
b. Disassembly
9.11 SOLENOIDS, SENSORS AND DO NOT disassemble the solenoid. The solenoid is not
SENDERS serviceable. Replace solenoid if found to be defective.
c. Park Brake Solenoid Valve Installation

9.11.1 Park Brake Solenoid Valve
a. Park Brake Solenoid Valve Removal with new parts to help ensure proper sealing and
1. Park the machine on a firm, level surface, level the hydraulic oil.
place the transmission control lever in 1. If necessary, install the park brake solenoid in its
(N) NEUTRAL, engage the park brake and shut the original orientation.
engine OFF. 2. Slide the park brake coil over the solenoid. Tighten
2. Place a Do Not Operate Tag on both the ignition key the nut to secure the solenoid. DO NOT overtighten.
switch and the steering wheel, stating that the 3. Connect the wiring connector to the park brake coil
machine should not be operated. lead.
3. Open the engine cover. Allow the system fluids to 4. Properly connect the battery
cool.
4. Properly disconnect the battery
5. Disconnect the wiring connector at the park brake ignition key switch and the steering wheel.
solenoid lead.
9-24 TL1055, TL1255

Electrical System
9.11.2 Transmission Solenoid Valves 9.11.3 Transmission Oil Temperature Switch
a. Transmission Oil Temperature Switch Removal

The transmission oil temperature switch (10) is located at
the left side of the transmission housing.
9 (Y2) machine, fully retract the boom, lower the boom,
9 (Y4)
10 9 (Y5) (N) NEUTRAL, engage the park brake and shut the
engine OFF.
9 (Y1)
MY4330 3. Open the engine cover. Allow the system fluids to
cool.
Note: If the transmission is not shifting properly, the
transmission shift control switch (travel select lever), 4. Properly disconnect the battery.
wiring harness or transmission shift solenoids (9) should 5. Unplug the transmission oil temperature switch
be checked in order to determine which component is connector from the wiring harness connector.
defective. Specific information to determine which travel
6. The switch is threaded into the transmission
position and corresponding component is not responding
housing. Remove the switch.
can be found in the detailed transmission service
instructions (covering repair, disassembly, reassembly
b. Transmission Oil Temperature Switch Inspection
and adjustment information) are provided in the
and Replacement
appropriate manual.
Inspect the switch and the wiring harness connector
• Service Manual (P/N 31200241)
terminals for continuity. Replace a defective or faulty
• Parts Manual (P/N 31200257) switch with a new part.
The transmission should be checked, serviced and
repaired only by experienced service technicians who are c. Transmission Oil Temperature Switch Installation
aware of all safety instructions and particular component and Testing
features. 1. Thread the transmission oil temperature switch into
Note: Contact your local Caterpillar dealer if internal the transmission housing snugly, then connect the
transmission repair is required during the warranty switch connector to the wiring harness connector.
period. 2. Properly connect the battery.
3. Check for proper fluid level.
4. Start the engine, allow it to reach operating
temperature and observe the operator display
cluster for warning indication. If the switch is not
defective, the problem could be elsewhere; possibly
in a shorted wire, damaged transmission, improper
or low fluid, etc.
TL1055, TL1255 9-25

Electrical System
9.11.4 Engine Coolant Temperature 4. Start the engine, allow it to reach operating
Sender / Switch temperature and observe the operator instrument
cluster for warning indication. If the sender is not
a. Engine Coolant Temperature Sender Removal 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.
engine OFF. 5. Close and secure the engine cover.
2. Place a Do Not Operate Tag on both the ignition key 6. Remove the Do Not Operate Tags from both the
switch and the steering wheel, stating that the ignition key switch and the steering wheel.
9.11.5 Engine Oil Pressure Sender/Switch
cool. TL1055 - Before S/N TBM00938
4. Properly disconnect the battery. TL1255 - Before S/N TBN00482
2 1 a. Engine Oil Pressure Sender/Switch Removal

engine OFF.
cool.
MY4260
5. Unplug the engine coolant temperature sender
connector (1) from the wiring harness connector.
6. The engine coolant temperature sender (2) is
threaded into the engine block. Remove the sender.
4
b. Engine Coolant Temperature Sender / Switch
Inspection and Replacement
3
Inspect the sender/switch and the wiring harness
connector terminals for continuity. Replace a defective or
faulty sender with a new part.
c. Engine Coolant Temperature Sender Installation

and Testing
MAL0320
1. Thread the engine coolant temperature sender into
the engine block snugly, then connect the sender 5. Unplug the wiring harness connector from the
connector to the wiring harness connector. engine oil pressure sender (3) or switch (4).
2. Properly connect the battery. 6. The engine oil pressure sender/switch is threaded
into the bracket weldment. Remove the sender/
3. Check for proper coolant level. switch.
9-26 TL1055, TL1255

Electrical System
b. Engine Oil Pressure Sender Inspection and 4. Turn the ignition key switch to the OFF position. The
Replacement fuel level indicator needle should return to the
EMPTY position.
Inspect the sender and the wiring harness connector
terminals for continuity. Replace a defective or faulty
b. Fuel Level Circuit Tests
sender with a new part.
If the fuel level sender (7) is suspected of giving a false
c. Engine Oil Pressure Sender Installation and reading, perform the following checks:
Testing 1. If the fuel level indicator needle does not move,
1. Thread the engine oil pressure sender into the check the fuel tank for fuel.
engine block snugly, then connect the sender 2. Check for loose or defective wiring, faulty ground
connector to the wiring harness connector. connections, and corrosion on the fuel tank sender
2. Properly connect the battery. and wiring lead.
3. Check for proper oil level. 3. If the fuel level indicator needle does not move after
the ignition key switch is turned to the RUN position,
4. Start the engine, and observe the operator display
use a test lamp to determine whether current is
for warning indication. If the sender is not defective,
flowing from the ignition switch to the fuel level
the problem could be elsewhere; possibly in a
sender.
shorted wire, improper-running engine, low oil,
obstructed or faulty oil pump, defective instrument 4. If the fuel level indicator does not move and a faulty
display. or defective fuel level sender in the fuel tank has
been ruled out, and in addition, wiring and
connectors have been checked and ruled out, the
6. Remove the Do Not Operate Tags from both the fuel level indicator is defective and must be
ignition key switch and the steering wheel. replaced.
5. Check that the ignition terminal has current and that
9.11.6 Fuel Level Sender the fuse in the fuse panel is not blown.
a. Fuel Level Indicator Testing 6. Check for broken, shorted, frayed, disconnected or
damaged wiring between the fuel level indicator
The fuel level sender wiring harness leads can be wiring at the cab, fuse and relay panel, ignition key
accessed from the top of the fuel tank. switch, and from the fuel level sender on the fuel
6 tank through the wiring in the cab.
7. Check the fuel level sender. A defective fuel level
sender in the fuel tank may also prevent the fuel
level indicator from moving. Refer to Section 9.5,
5 “Electrical System Schematics,” for further
information.
9.11.7 Inclinometer Switch

7 TL1055 - Before S/N TBM01169
TL1255 - Before S/N TBN00659
MY4340
1. Loosen and remove the four screws holding the fuel a. Inclinometer Switch Removal
sender cover (5) in place. 1. Park the machine on a firm, level surface, level the
2. Disconnect the fuel level sender wiring harness machine, fully retract the boom, raise and support
leads (6) from the fuel sender (7). With the help of an the boom, place the transmission control lever in
assistant, touch both harness leads together. (N) NEUTRAL, engage the park brake and shut the
3. From the operator cab, have the assistant turn the engine OFF.
ignition key switch to the RUN position. DO NOT 2. Place a Do Not Operate Tag on both the ignition key
start the engine. Observe the fuel level indicator switch and the steering wheel, stating that the
needle on the operator instrument cluster. The machine should not be operated.
reading must be at the FULL mark.
TL1055, TL1255 9-27
Electrical System
3. Open the engine cover. Allow the system fluids to 9.12 DISPLAY MONITOR AND GAUGES
cool.
4. Properly disconnect the battery. 9.12.1 Analog Gauges
5. Remove the inclinometer switch protective cover.
8 a. Gauge Removal
9 place the transmission control lever in
9 engine OFF.
MY1311 cool.
6. Unplug and label the inclinometer switch connector
(8) from the wiring harness connector. 10
7. Remove the hardware securing the inclinometer
switch (9) to the machine frame.
11
b. Inclinometer Switch Installation
1. Install the inclinometer switch to the machine frame
with the previously used hardware.
2. Connect the previously labeled wires to the
inclinometer switch. TL1055 Before S/N TBM00938
MAL0140

3. Install the inclinometer switch protective cover.
5. Close and secure the engine cover. 10
7. Start the engine. Fully retract and level the boom 11
and level the frame.
8. Locate a 12” curb and drive the left front and left rear
tires onto the curb. Rotate the machine frame to the
right. When the frame is out of level by 15°, the
machine will automatically rotate the frame back to TL1055 S/N TBM00938 & After MY4380
14.7°. TL1255 S/N TBN00482 & After
9. Repeat step 7 for the right side of the machine. 5. Remove the seven screws (10) securing the dash
panel.
6. Label and disconnect the wires from the gauge (11),
remove the gauge bracket.
7. Pull the gauge out from the dash.
b. Disassembly
DO NOT disassemble the gauge. The gauge is not
serviceable. Replace the gauge if found to be defective.
9-28 TL1055, TL1255

Electrical System
c. Gauge Installation and Testing 6. Remove the hex nut securing the ignition key switch
(2) to the dash.
1. Install the gauge in the dash. Install the gauge
bracket. 7. Label and disconnect the ignition switch wires and
remove the switch from the machine.
2. Connect the previously labeled wires to the gauge.
3. Install the dash panel with the previously used b. Disassembly
hardware.
DO NOT disassemble the ignition switch. Replace a
4. Properly connect the battery. defective switch with a new part.
5. Turn the ignition to the ON position to check the
gauge values. c. Inspection and Replacement
6. Close and secure the engine cover. To determine the proper operation of the ignition key
7. Remove the Do Not Operate Tags from both the switch, test the terminals on the back of the switch for
ignition key switch and the steering wheel. continuity with an ohmmeter.
BA
9.13 DASH SWITCHES 2 T AC
C
Note: For information on the front windshield wiper, rear
ACC
BAT
window wiper and washer systems, refer to Section 9.9,
“Window Wiper/Washer Windshield Wiper Motor.” ST
9.13.1 Ignition Key Switch

IG
N N
a. Ignition Switch Removal IG
MY0830
machine, fully retract the boom, lower the boom, Test the ignition key switch for continuity, by checking
place the transmission control lever in from the BAT terminal (2) to each of the remaining
(N) NEUTRAL, engage the park brake and shut the terminals in their corresponding switch position.
engine OFF.
If all terminals do not show proper continuity, replace the
2. Place a Do Not Operate Tag on both the ignition key ignition switch.
machine should not be operated. d. Ignition Switch Installation
3. Open the engine cover. Allow the system fluids to 1. Connect the ignition key switch to the previously
cool. labeled wires.
4. Properly disconnect the battery. 2. Align the ignition switch in the dash so that when it is
1 in the OFF position, the key slot is positioned vertically
(straight up and down). Install the hex nut securing
the ignition switch to the dash. DO NOT overtighten.
3. Install the dash panel with the previously used
hardware.
4. Properly connect the battery
MY4350
2 Note: If further information is needed, refer to Section

9.5, “Electrical System Schematics.”
5. Remove the seven screws (1) securing the dash
panel.
TL1055, TL1255 9-29

Electrical System
9.13.2 Dash Switches c. Inspection and Replacement

Inspect the switch terminals for continuity and shorting in
a. Switch Removal
both the engaged and disengaged positions. Replace a
1. Park the machine on a firm, level surface, level the defective or faulty switch with a new switch.
place the transmission control lever in d. Switch Installation
1. Connect the switch to the cab harness connector.
engine OFF.
2. Position the switch over the rectangular opening in
the dash and snap into position.
machine should not be operated. 3. Properly connect the battery.
3. Open the engine cover. Allow the system fluids to 4. Start the machine and check the replaced switch for
cool. proper function.
4. Properly disconnect the battery. 5. Close and secure the engine cover.
4
MAL1380
5. Each switch (3) is mounted in the dash panel (4).

6. Pull the switch out of the dash, disconnect the
harness connector to the switch in question.
b. Disassembly
DO NOT disassemble the dash switch. Replace a
defective switch with a new part.
9-30 TL1055, TL1255

Electrical System
9.14 ENGINE DIAGNOSTIC
9.14.1 Engine Diagnostic and Event Codes
3rd Party
CDL CatET J1939 Flash
Description Device J1939
Code Code Code
Code
N/A No Diagnostic Code Detected N/A N/A 551
0001-02 Cylinder #1 Injector Erratic, Intermittent, or Incorrect J651-2 651-2 111
0001-05 Cylinder #1 Injector Current Below Normal J651-5 651-5 111
0001-06 Cylinder #1 Injector Current Above Normal J651-6 651-6 111
0001-07 Cylinder #1 Injector Not Responding Properly J651-7 651-7 111
0003-07 Cylinder #3 Injector Not Responding J653-7 653-7 113
Cylinder #5 Injector Erratic, Intermittent, or Incorrect

0005-02 J655-2 655-2 115
(C6.6 engine only)
Cylinder #5 Injector Current Below Normal

0005-05 J655-5 655-5 115
(C6.6 engine only)
Cylinder #5 Injector Current Above Normal

0005-06 J655-6 655-6 115
(C6.6 engine only)
Cylinder #5 Injector Not Responding Properly

0005-07 J655-7 655-7 115
(C6.6 engine only)
Cylinder #6 Injector Erratic, Intermittent, or Incorrect

0006-02 J656-2 656-2 116
(C6.6 engine only)
Cylinder #6 Injector Current Below Normal

0006-05 J656-5 656-5 116
(C6.6 engine only)
TL1055, TL1255 9-31

Electrical System
3rd Party
Code Code Code
Code
Cylinder #6 Injector Current Above Normal

0006-06 J656-6 656-6 116
(C6.6 engine only)
Cylinder #6 Injector Not Responding Properly

0006-07 J656-7 656-7 116
(C6.6 engine only)
0041-03 8 Volt DC Supply Voltage Above Normal J678-03 678-03 517
0041-04 8 Volt DC Supply Voltage Below Normal J678-04 678-04 517
Throttle Position Sensor Erratic, Intermittent, or

0091-02 J91-02 91-02 154
Incorrect
0091-03 Throttle Position Sensor Voltage Above Normal J91-03 91-03 154
0091-04 Throttle Position Sensor Voltage Below Normal J91-04 91-04 154
Throttle Position Sensor Abnormal Frequency,

0091-08 J91-08 91-08 154
Pulse Width, or Period
0100-03 Engine Oil Pressure Sensor Voltage Above Normal J100-03 100-03 157
0100-04 Engine Oil Pressure Sensor Voltage Below Normal J100-04 100-04 157
Engine Oil Pressure Sensor Abnormal Rate of

0100-10 J100-10 100-10 157
Change
Engine Coolant Temperature Sensor Voltage Above

0110-03 J110-03 110-03 168
Normal
Engine Coolant Temperature Sensor Voltage Below

0110-04 J110-04 110-04 168
Normal
0168-00 Electrical System Voltage High J168-00 168-00 422
0168-01 Electrical System Voltage Low J168-01 168-01 422
Electrical System Voltage Erratic, Intermittent, or

0168-02 J168-02 168-02 422
Incorrect
Intake Manifold Air Temperature Sensor Voltage

0172-03 J105-03 105-03 133
Above Normal
Intake Manifold Air Temperature Sensor Voltage

0172-04 J105-04 105-04 133
Below Normal
Engine Speed Sensor Abnormal Frequency,

0190-08 J190-08 190-08 141
Pulse Width, or Period
0247-09 SAE J1939 Data Link Abnormal Update Rate - - 514
0247-12 SAE J1939 Data Link Failure - - 514
0253-02 Personality Module Erratic, Intermittent, or Incorrect J631-02 631-02 415
0261-11 Engine Timing Offset Fault J637-11 637-11 143
9-32 TL1055, TL1255

Electrical System
3rd Party
Code Code Code
Code
5 Volt Sensor DC Power Supply Voltage Above

0262-03 J1079-03 1079-03 516
Normal
5 Volt Sensor DC Power Supply Voltage Below

0262-04 J1079-04 1079-04 516
Normal
Programmed Parameter Fault Erratic, Intermittent, or

0268-02 J630-02 630-02 527
Incorrect
Secondary Engine Speed Sensor Abnormal

0342-08 J723-08 723-08 142
Frequency, Pulse Width, or Period
0526-05 Turbo Wastegate Drive Current Below Normal J1188-05 1188-05 177
0526-06 Turbo Wastegate Drive Current Above Normal J1188-06 1188-06 177
0526-07 Turbo Wastegate Drive Not Responding Properly J1188-07 1188-07 177
Secondary Throttle Position Sensor Erratic,

0774-02 J29-02 29-02 155
Intermittent, or Incorrect
Secondary Throttle Position Sensor Voltage Above

0774-03 J29-03 29-03 155
Normal
Secondary Throttle Position Sensor Voltage Below

0774-04 J29-04 29-04 155
Normal
Secondary Throttle Position Sensor Abnormal

0774-08 J29-08 29-08 155
Frequency, Pulse Width, or Period
Machine Security System Module Abnormal Update

1639-09 J1196-09 1196-09 426
Rate
Engine Operation Mode Selector Switch Erratic,

1743-02 J2882-02 2882-02 144
Intermittent, or Incorrect
Fuel Rail #1 Pressure Valve Solenoid Current Below

1779-05 J1347-05 1347-05 162
Normal
Fuel Rail #1 Pressure Valve Solenoid Current Above

1779-06 J1347-06 1347-06 162
Normal
Intake Manifold Pressure Sensor Voltage Above

1785-03 J102-03 102-03 197
Normal
Intake Manifold Pressure Sensor Voltage Below

1785-04 J102-04 102-04 197
Normal
Intake Manifold Pressure Sensor Abnormal Rate of

1785-10 J102-10 102-10 197
Change
1797-03 Fuel Rail Pressure Sensor Voltage Above Normal J157-03 157-03 159
1797-04 Fuel Rail Pressure Sensor Voltage Below Normal J157-04 157-04 159
1834-02 Ignition Keyswitch Loss of Signal J158-02 158-02 439
TL1055, TL1255 9-33

Electrical System
3rd Party
Code Code Code
Code
2246-06 Glow Plug Start Aid Relay Current Above Normal J676-06 676-06 199
3rd Party
Event CatET J1939 Flash
Code Code Code
Code
E172-1 High Air Filter Restriction J107-15 107-15 151
E194-1 High Exhaust Temperature J173-15 173-15 185
E232-1 High Fuel/Water Separator Water Level J97-15 97-15 -
E360-1 Low Oil Pressure - Warning J100-17 100-17 157
E360-3 Low Oil Pressure - Shutdown J100-01 100-01 157
E361-1 High Engine Coolant Temperature - Warning J110-15 110-15 168
E361-2 High Engine Coolant Temperature - Derate J110-16 110-16 168
E361-3 High Engine Coolant Temperature - Shutdown J110-00 110-00 168
E362-1 Engine Overspeed J190-15 190-15 141
E396-1 High Fuel Rail Pressure J157-00 157-00 159
E398-1 Low Fuel Rail Pressure J157-01 157-01 159
E539-1 High Intake Manifold Air Temperature - Warning J105-15 105-15 133
E539-2 High Intake Manifold Air Temperature - Derate J105-16 105-16 133
E2143-3 Low Engine Coolant Level J111-01 111-01 169
9-34 TL1055, TL1255

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Service Manual

September 29, 2006 - A - Original Issue Of Manual

31200293 TL1055, TL1255 i

ii TL1055, TL1255 31200293

TL1055, TL1255 iii

PARAGRAPH TITLE PAGE

TL1055, TL1255 1-1

1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

1.3 OPERATION & MAINTENANCE CAUTION indicates a potentially hazardous situation

1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards

TL1055, TL1255 1-3

1-4 TL1055, TL1255

PARAGRAPH TITLE PAGE

TL1055, TL1255 2-1

2.1 REPLACEMENT PARTS AND

Before ordering parts or initiating service inquiries, make

2-2 TL1055, TL1255

2.2 TORQUE CHARTS

2.2.1 SAE Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

TL1055, TL1255 2-3

2.2.1 SAE Fastener Torque Chart

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

2-4 TL1055, TL1255

2.2.1 SAE Fastener Torque Chart

SOCKET HEAD CAP SCREWS

TL1055, TL1255 2-5

2.2.1 SAE Fastener Torque Chart

SOCKET HEAD CAP SCREWS

2-6 TL1055, TL1255

2.2.2 Metric Fastener Torque Chart

CLASS 8.8 METRIC BOLTS

Sq mm KN [N.m] [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

TL1055, TL1255 2-7

2.2.2 Metric Fastener Torque Chart

CLASS 10.9 METRIC BOLTS

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 3.13

2-8 TL1055, TL1255

2.2.2 Metric Fastener Torque Chart

Magni Coating (Ref 4150701)*

CLASS 12.9 SOCKET HEAD CAP SCREWS

Sq mm kN [N.m] [N.m] [N.m]

TL1055, TL1255 2-9

2.2.3 Hydraulic Hose Torque Chart Flats Method:

Note: By definition the “Flats Method“ will contain some

2-10 TL1055, TL1255

2.3.1 Travel Speeds

2.3.2 Hydraulic Cylinder Performance

APPROXIMATE TIMES (seconds)

2.3.3 Cylinder Drift

MAXIMUM ROD TRAVEL

TL1055, TL1255 2-11

2.3.4 Electrical System