Beruflich Dokumente
Kultur Dokumente
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
EFFECTIVITY PAGE
ii
TL1055, TL1255
31200293
SECTION CONTENTS
Section
Subject
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Page
1-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
1-2
1-2
1-2
1-3
1-4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2.1
2.2
2.3
2.4
2.5
2.6
2-2
2-3
2-11
2-14
2-17
2-20
...........................................................
3-1
3-3
3-4
3-4
3-5
3-6
3-16
3-18
3-21
3-22
3-22
3-23
3-25
3-29
3-30
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
Section 3
Boom
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
4.1
4.2
4.3
4.4
4.5
TL1055, TL1255
4-2
4-3
4-3
4-8
4-9
Section
Subject
Page
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5-1
5-2
5-3
5-3
5-9
5-10
5-11
5-11
Section 6
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6-2
6-3
6-3
6-3
6-6
6-6
6-8
Section 7
Engine: CAT C4.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2
7-4
7-4
7-4
7-9
7-9
7-11
7-12
7-14
7-16
7-17
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
ii
8-2
8-3
8-3
8-4
8-12
8-13
8-14
8-20
TL1055, TL1255
Section
Subject
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
9.14
TL1055, TL1255
Page
9-1
9-2
9-4
9-4
9-4
9-7
9-16
9-20
9-21
9-22
9-23
9-24
9-28
9-29
9-31
iii
Section
iv
Subject
Page
TL1055, TL1255
Section 1
Safety Practices
Contents
PARAGRAPH
1.1
1.2
1.3
1.4
1.5
1.6
1.7
TL1055, TL1255
TITLE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5.1
Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.1
Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.2
Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.3
General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.4
Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE
1-2
1-2
1-2
1-2
1-2
1-2
1-3
1-3
1-3
1-3
1-4
1-4
1-1
Safety Practices
1.1
INTRODUCTION
1.4
1.5
SAFETY INFORMATION
1.5.1
1.2
DANGER
WARNING
DISCLAIMER
1.3
CAUTION
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
TL1055, TL1255
Safety Practices
1.6
SAFETY INSTRUCTIONS
1.6.1
Personal Hazards
1.6.2
Equipment Hazards
1.6.3
General Hazards
HAND TOOLS: Always use the proper tool for the job;
keep tools clean and in good working order, and use
special service tools only as recommended.
TL1055, TL1255
1-3
Safety Practices
1.6.4
Operational Hazards
1.7
SAFETY DECALS
1-4
TL1055, TL1255
Section 2
General Information and Specifications
Contents
PARAGRAPH
2.1
2.2
2.3
2.4
2.5
2.6
TL1055, TL1255
TITLE
PAGE
2-2
2-3
2-3
2-7
2-10
2-11
2-11
2-11
2-11
2-12
2-12
2-13
2-14
2-17
2-17
2-18
2-19
2-20
2-20
2-21
2-22
2-1
2.1
MAL0350
2-2
TL1055, TL1255
2.2
TORQUE CHARTS
2.2.1
Torque
(Dry)
Tensile
Clamp Load
Stress Area
Torque
Torque
(Loctite 242TM or 271TM
(Loctite 262TM or VibraTM
OR Vibra-TITE 111 or
TITETM 131)
140)
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
IN-LB
[N.m]
40
48
32
40
32
36
24
32
20
28
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
380
420
580
610
900
940
1120
1285
2020
2320
8
9
16
18
30
31
43
49
96
120
0.9
1.0
1.8
2.0
3.4
3.5
4.8
5.5
10.8
13.5
6
7
12
13
22
23
32
36
75
86
0.7
0.8
1.4
1.5
2.5
2.6
3.5
4
9
10
105
135
12
15
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
3340
3700
4940
5600
6800
7550
9050
10700
11600
12950
14400
16300
21300
23800
29400
32400
38600
42200
42300
47500
53800
59600
64100
73000
78000
87700
FT-LB
17
19
30
35
50
55
75
90
110
120
150
170
260
300
430
470
640
700
800
880
1120
1240
1460
1680
1940
2200
[N.m]
23
26
41
47
68
75
102
122
149
163
203
230
353
407
583
637
868
949
1085
1193
1518
1681
1979
2278
2630
2983
FT-LB
13
14
23
25
35
40
55
65
80
90
110
130
200
220
320
350
480
530
600
660
840
920
1100
1260
1460
1640
[N.m]
18
19
31
34
47
54
75
88
108
122
149
176
271
298
434
475
651
719
813
895
1139
1247
1491
1708
1979
2224
FT-LB
19
21
35
40
55
60
85
100
120
135
165
190
285
330
475
520
675
735
840
925
1175
1300
1525
1750
2025
2300
[N.m]
26
29
48
54
75
82
116
136
163
184
224
258
388
449
646
707
918
1000
1142
1258
1598
1768
2074
2380
2754
3128
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
NOTES:
IN-LB
[N.m]
FT-LB
16
17
28
32
45
50
68
80
98
109
135
153
240
268
386
425
579
633
714
802
1009
1118
1322
1506
1755
1974
[N.m]
22
23
38
43
61
68
92
108
133
148
183
207
325
363
523
576
785
858
968
1087
1368
1516
1792
2042
2379
2676
NO. 5000059
REV. J
MY3141
TL1055, TL1255
2-3
Torque
(Dry or Loctite 263)
K= 0.20
Torque
Torque
(Loctite 242TM or 271TM (Loctite 262TM or VibraOR Vibra-TITE TM 111 or
TITETM 131)
140)
K=.18
K=0.15
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
40
48
32
40
32
36
24
32
20
28
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
1320
1580
1800
2860
3280
43
60
68
143
164
5
7
8
16
19
129
148
15
17
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
FT-LB
25
25
45
50
70
80
105
120
155
170
210
240
375
420
605
670
860
995
1290
1445
1815
2015
2385
2705
3165
3555
[N.m]
35
35
60
70
95
110
145
165
210
230
285
325
510
570
825
910
1170
1355
1755
1965
2470
2740
3245
3680
4305
4835
FT-LB
20
25
40
45
65
70
95
110
140
155
190
215
340
380
545
600
770
895
1160
1300
1635
1810
2145
2435
2845
3200
[N.m]
25
35
55
60
90
95
130
150
190
210
260
290
460
515
740
815
1045
1215
1580
1770
2225
2460
2915
3310
3870
4350
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
NOTES:
IN-LB
[N.m]
FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665
[N.m
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625
NO. 5000059
REV. J
MY3151
2-4
TL1055, TL1255
Torque
(Dry) K = .17
Torque
(Loctite 242TM or 271TM
OR Vibra-TITE TM 111 or
140 OR Precoat 85
K=0.16
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
40
48
32
40
32
36
24
32
20
28
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
2860
3280
122
139
14
16
114
131
13
15
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
FT-LB
20
25
35
40
60
65
90
100
130
145
180
205
320
355
515
570
730
845
1095
1225
1545
1710
2025
2300
2690
3020
[N.m]
25
35
50
55
80
90
120
135
175
195
245
280
435
485
700
775
995
1150
1490
1665
2100
2325
2755
3130
3660
4105
FT-LB
20
20
35
40
55
60
85
95
125
135
170
190
300
335
485
535
685
795
1030
1155
1455
1610
1905
2165
2530
2845
[N.m]
25
25
50
55
75
80
115
130
170
185
230
260
410
455
660
730
930
1080
1400
1570
1980
2190
2590
2945
3440
3870
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
Torque
(Loctite 262TM
TM
or Vibra-TITE 131)
K=0.15
IN-LB
[N.m]
FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665
[N.m]
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625
MY3161
TL1055, TL1255
2-5
Clamp Load
See Note 4
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
2860
3280
143
164
16
19
129
148
15
17
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
FT-LB
25
25
45
50
70
80
105
120
155
170
210
240
375
420
605
670
860
995
1290
1445
1815
2015
2385
2705
3165
3555
[N.m]
35
35
60
70
95
110
145
165
210
230
285
325
510
570
825
910
1170
1355
1755
1965
2470
2740
3245
3680
4305
4835
FT-LB
20
25
40
45
65
70
95
110
140
155
190
215
340
380
545
600
775
895
1160
1300
1635
1810
2145
2435
2845
3200
[N.m]
25
35
55
60
90
95
130
150
190
210
260
290
460
515
740
815
1055
1215
1580
1770
2225
2460
2915
3310
3870
4350
Size
TPI
Bolt Dia
40
48
32
40
32
36
24
32
20
28
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
Torque
(Loctite 242TM or 271TM
OR Vibra-TITE TM 111 or
140 OR Precoat 85
K=0.18
Torque
(Dry)
K = .20
Torque
(Loctite 262TM
TM
or Vibra-TITE 131)
K=0.15
IN-LB
[N.m]
FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665
[N.m]
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625
MY3400
2-6
TL1055, TL1255
SizePITCH
Tensile
Stress
Area
Sq mm
Clamp
Load
Torque
(Dry or Loctite
263TM)
Torque
(Lub)
KN
[N.m]
[N.m]
Torque
(Loctite
Torque
TM
TM
242 or 271TM
(Loctite 262
OR VibraOR VibraTITETM 131)
TITETM 111 or
140)
[N.m]
[N.m]
0.5
5.03
2.19
1.3
1.0
1.2
1.4
3.5
0.6
6.78
2.95
2.1
1.6
1.9
2.3
0.7
8.78
3.82
3.1
2.3
2.8
3.4
0.8
14.20
6.18
6.2
4.6
5.6
6.8
20.10
8.74
11
7.9
9.4
12
28.90
12.6
18
13
16
19
1.25
36.60
15.9
26
19
23
28
10
1.5
58.00
25.2
50
38
45
55
12
1.75
84.30
36.7
88
66
79
97
14
16
2
2
115
157
50.0
68.3
140
105
126
154
219
164
197
241
18
2.5
192
83.5
301
226
271
331
20
2.5
245
106.5
426
320
383
469
22
2.5
303
132.0
581
436
523
639
24
353
153.5
737
553
663
811
27
459
199.5
1080
810
970
1130
30
3.5
561
244.0
1460
1100
1320
1530
33
3.5
694
302.0
1990
1490
1790
2090
36
817
355.5
2560
1920
2300
2690
42
4.5
1120
487.0
4090
3070
3680
4290
NO. 5000059
MY3171
TL1055, TL1255
REV. J
2-7
SizePITCH
Tensile
Stress
Area
Clamp
Load
Torque
(Dry or Loctite
263TM)
K = 0.20
Sq mm
KN
[N.m]
Torque
(Lub OR Loctite
242TM or 271TM OR
Vibra-TITE TM 111 or
140)
K= 0.18
Torque
(Loctite 262TM OR
Vibra-TITE TM 131)
K=0.15
[N.m]
[N.m]
0.5
5.03
3.13
3.5
0.6
6.78
4.22
0.7
8.78
5.47
0.8
14.20
8.85
20.10
12.5
28.90
18.0
25.2
22.7
18.9
1.25
36.60
22.8
36.5
32.8
27.4
10
1.5
58.00
36.1
70
65
55
12
1.75
84.30
52.5
125
115
95
14
16
2
2
115
157
71.6
97.8
200
180
150
315
280
235
18
2.5
192
119.5
430
385
325
20
2.5
245
152.5
610
550
460
22
2.5
303
189.0
830
750
625
24
353
222.0
1065
960
800
27
459
286.0
1545
1390
1160
30
3.5
561
349.5
2095
1885
1575
33
3.5
694
432.5
2855
2570
2140
36
817
509.0
3665
3300
2750
42
4.5
1120
698.0
5865
5275
4395
NO. 5000059
REV. J
2-8
TL1055, TL1255
Tensile
Stress
Area
SizePITCH
Sq mm
Torque
Torque
(Lub OR Loctite
Torque
(Loctite 262TM
TM
TM
Clamp Load (Dry or Loctite 242 or 271
OR Vibra-TITE TM
See Note 4
263TM)
OR Vibra-TITE TM
131)
K = .17
111 or 140)
K = .15
K = .16
kN
[N.m]
[N.m]
[N.m]
11
0.5
3.5
0.6
5.03
6.78
0.7
8.78
0.8
14.20
20.10
12.5
13
12
28.90
18.0
21
20
19
1.25
36.60
22.8
31
29
27
10
1.5
58.00
36.1
61
58
54
12
1.75
84.30
52.5
105
100
95
14
16
2
2
115
157
71.6
170
160
150
97.8
265
250
235
18
2.5
192
119.5
365
345
325
20
2.5
245
152.5
520
490
460
22
2.5
303
189.0
705
665
625
24
353
220.0
900
845
790
27
459
286.0
1315
1235
1160
30
3.5
561
349.5
1780
1680
1575
33
3.5
694
432.5
2425
2285
2140
36
817
509.0
3115
2930
2750
42
4.5
1120
698.0
4985
4690
4395
NO. 5000059
REV. J
TL1055, TL1255
2-9
Size
ORFS
JIC
Flats Method
13 lb-ft
(18 Nm)
13 lb-ft
(18 Nm)
1.5 to 1.75
23 lb-ft
(31 Nm)
23 lb-ft
(31 Nm)
1 to 1.5
40 lb-ft
(54 Nm)
40 lb-ft
(54 Nm)
1.5 to 1.75
10
60 lb-ft
(81 Nm)
60 lb-ft
(81 Nm)
1.5 to 1.75
12
74 lb-ft
(100 Nm)
85 lb-ft
(115 Nm)
1.0 to 1.5
16
115 lb-ft
(156 Nm)
115 lb-ft
(156 Nm)
0.75 to 1.0
20
170 lb-ft
(230 Nm)
170 lb-ft
(230 Nm)
0.75 to 1.0
24
200 lb-ft
(271 Nm)
200 lb-ft
(271 Nm)
0.75 to 1.0
32
N/A
270 lb-ft
(366 Nm)
0.75 to 1.0
Flats Method:
1. If equipped, lubricate o-ring with hydraulic oil. Hand
tighten the swivel nut until no lateral movement of
the swivel nut can be detected. Average hand torque
is 3 lb-ft (4 Nm).
2. Mark a dot on one of the swivel nut flats and another
dot in line on the hex of the adapter its connecting
to.
3. Use the double wrench method while tightening to
avoid hose twist.
4. After the connection has been properly tightened,
mark a straight line across the connecting parts, not
covering the dots indicating that the connection has
been properly tightened.
2-10
TL1055, TL1255
2.3
SPECIFICATIONS
2.3.1
Travel Speeds
TL1055
TL1255
First Gear
Second Gear
Third Gear
Fourth Gear
2.3.2
Note: Machine with no attachment or load, engine at full throttle, hydraulic oil above 130 F (54 C) minimum, engine
at operating temperature.
FUNCTION
TL1255
17.7
17.6
15.3
13.9
Boom Lift
13.3
15.7
Boom Lower
11.0
13.9
5.9
6.7
7.0
7.85
7.5
9.8
5.0
10.0
Outrigger - Down
4.8
5.0
Outrigger - Up
3.8
4.2
2.3.3
Cylinder Drift
CYLINDER
Lift/Lower Cylinder
Extend/Retract Cylinder
TL1055, TL1255
2-11
Electrical System
Battery
Type, Rating
Quantity
Reserve Capacity
Group/Series
Group 31
Alternator
TL1055 - Before S/N TBM00366
TL1255 - Before S/N TBN00206
12V, 85 Amps
2.3.5
TL1055
TL1255
Low Idle
1000 rpm
900 rpm
High Idle
Horsepower
Peak Torque
Fuel Delivery
Engine Make/Model
Displacement
Air Cleaner
2-12
TL1055, TL1255
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
Ply/Star
Rating
14.00 x 24
12 Ply
14.00 x 24
12 Ply
14.00 x 24
G-2/L-2 Radial
1 Star
14.00 x 24
Fill Type
Pressure
Pneumatic
Pneumatic
Pneumatic
17.50 x 25
12 Ply
17.50 x 25
12 Ply
17.50 x 25
E-2/L-2 Radial
1 Star
400/75x28
DuraForce
14 Ply
Size
Tire Type
Minimum Ply/
Star Rating
17.50 x 25
12 Ply
17.50 x 25
12 Ply
17.50 x 25
E-2/L-2 Radial
1 Star
400/75x28
DuraForce
14 Ply
Pneumatic
Pneumatic
Pneumatic
Pneumatic
Fill Type
Pressure
Pneumatic
Pneumatic
Pneumatic
Pneumatic
b. TL1255
TL1055, TL1255
2-13
2.4
a. Fluids
Ambient Temperature Range
Compartment or
System
Min
Max
SAE 0W-20
-40
50
-40
10
SAE 0W-30
-40
86
-40
30
SAE 0W-40
-40
104
-40
40
SAE 5W-30
-22
86
-30
30
SAE 5W-40
-22
122
-30
50
SAE 10W-30
104
-18
40
SAE 10W-40
122
-18
40
SAE 15W-40
15
122
-9.5
50
Cat MTO
-10
104
-23
40
-40
14
-42
-1
Axle Differentials*
and Wheel Ends
SAE 75W-140
-22
113
-30
45
SAE 80W-90
-10
120
-23
49
SAE 85W-140
10
120
-12
59
Cat TDTO-TMS
Cat TDTO-TMS
-4
122
-20
50
SAE 0W-20
-40
104
-40
40
SAE 0W-30
-40
104
-40
40
SAE 5W-30
-22
104
-30
40
SAE 5W-40
-22
104
-30
40
SAE 10W
-4
104
-20
40
SAE 30
50
122
10
50
SAE 10W-30
-4
104
-20
40
SAE 15W-40
122
-15
50
Cat TDTO-TMS
-4
122
-20
50
Cat TDTO
Hydraulic System
C
Max
Transmission and
Transfer Case
F
Min
Viscosities
Cat TDTO-TMS
Cat Arctic TDTO SYN
Commercial TO-4
NLGI Grade 2
-4
104
-20
40
Cat Multipurpose
NLGI Grade 2
-22
104
-30
40
50/50 Mix
Standard
60/40 Mix
Cold Weather
Engine Coolant
2-14
TL1055, TL1255
Viscosities
F
Min
#2 Diesel
Fuel
Air Conditioning
C
Max
Min
Max
Standard
Low Sulfur
Refrigerant R-134a
Cold Weather
Tetrafluorethane
Note: Friction Modifier (CAT Brake Oil Additive) required for axle differentials, see Section b, Capacities.
b. Capacities
Engine Crankcase Oil
Capacity with Filter Change
TL1055 Before S/N TBM01316 excluding TBM01298
TL1255 Before S/N TBN00799 excluding TBN00785
TL1055 S/N TBM01316 & After including TBM01298
TL1255 S/N TBN00799 & After including TBN00785
Fuel Tank
Capacity
Cooling System
System Capacity
TL1055 Before S/N TBM01316 excluding TBM01298
TL1255 Before S/N TBN00799 excluding TBN00785
TL1055 S/N TBM01316 & After including TBM01298
TL1255 S/N TBN00799 & After including TBN00785
Hydraulic System
System Capacity
TL1055
TL1255
Reservoir Capacity
TL1055 Before S/N TBM01316 excluding TBM01298
TL1255 Before S/N TBN00799 excluding TBN00785
TL1055 S/N TBM01316 & After including TBM01298
TL1255 S/N TBN00799 & After including TBN00785
Auxiliary Hydraulic Circuit Max Flow
TL1055, TL1255
Transmission
Capacity with Filter Change
Transfer Case
Capacity
Axles
Differential Housing Capacity
Front Axle
Rear Axle
32 oz (946 ml)
Rear Axle
26 oz (768 ml)
2-16
2.5 lb (1134 g)
TL1055, TL1255
2.5
2.5.1
EVERY
10
Air Filter
Restriction
Indicator
Check Fuel
Level
Check Engine
Oil Level
Check Hydraulic
Oil Level
Check Tire
Condition &
Pressure
Check Washer
Fluid Level
(if equipped)
Lubrication
Schedule
A
Check AutoSway Function
(if equipped)*
Check
Transmission
Oil Level
1st
50
LB/F
T (N
m)
Check Wheel
Lug Nut
Torque
EVERY
50
Drain Fuel/
Water
Separator
Check Engine
Coolant Level
Check
Battery
MAL0153
Note: Auto-Frame Level Function Check TL1055 Before S/N TBM01168 & TL1255 Before S/N TBN00664.
TL1055, TL1255
2-17
1st
250
Change
Axle Oil
Change Wheel
End Oil
Change
Transmission
Oil & Filter
Change
Transfer Case
Oil
EVERY
250
Change Engine
Oil and
Filter*
Check Axle
Oil Level
Check Wheel
End Oil Levels
Air Filter
Vacuator
Valve
Check
Fan Belt
Check Boom
Extend Chains
Check Boom
Wear Pads
Check Transfer
Case Oil Level
Check
Rear Axle
Stabilization
Lubrication
Schedule
EVERY
500
LB/F
T (N
m)
Change Fuel
Filters
Check Wheel
Lug Nut
Torque
MAL0791
Note: Engine oil and filter service interval can be extended. See Engine Manual for details.
2-18
TL1055, TL1255
EVERY
1000
Change
Transmission
Oil & Filter
Change
Transfer Case
Oil
Check Boom
Retract Chains
Lubrication
Schedule
Change
Axle Oil
Change Wheel
End Oil
Check
Air Intake
System
EVERY
1500
Change
Engine Coolant
Change
Hydraulic
Fluid & Filters
Change
Hydraulic Tank
Breather
OAL2291
TL1055, TL1255
2-19
2.6
2.6.1
LUBRICATION SCHEDULES
50 Hour
EVERY
50
OAL0450
2-20
TL1055, TL1255
250 Hour
EVERY
250
OW1211
TL1055, TL1255
2-21
1000 Hour
EVERY
1000
OY2080
2-22
TL1055, TL1255
Section 3
Boom
Contents
PARAGRAPH
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
TL1055, TL1255
TITLE
PAGE
3-3
3-4
3-4
3-4
3-5
3-5
3-5
3-6
3-6
3-8
3-9
3-10
3-10
3-11
3-12
3-12
3-13
3-13
3-15
3-16
3-18
3-18
3-19
3-19
3-20
3-21
3-21
3-21
3-21
3-21
3-21
3-1
Boom
3.9
3.10
3.11
3.12
3.13
3.14
3-2
3-22
3-22
3-22
3-22
3-22
3-22
3-23
3-23
3-24
3-24
3-25
3-25
3-25
3-26
3-28
3-28
3-29
3-30
TL1055, TL1255
Boom
3.1
THIRD
BOOM
SECTION
FOURTH BOOM
SECTION
EXTEND
CHAINS
SECOND BOOM
SECTION
FIRST
BOOM
SECTION
AUXILIARY
HYDRAULIC
CONNECTIONS
TILT CYLINDER
QUICK COUPLER
HOSE CARRIER
ASSEMBLY
(INSIDE BOOM)
RETRACT
CHAINS
EXTEND/RETRACT
CYLINDER
(UNDERSIDE OF BOOM)
HOSE
SHEAVE
PIVOT PIN
MY0101
TL1055, TL1255
3-3
Boom
3.2
3.2.1
3.3
The boom section lifts and lowers via action of the lift/
lower cylinder.
WARNING
NEVER weld or drill the boom unless approved in
writing by the manufacturer. The structural integrity of
the boom will be impaired if subjected to any repair
involving welding or drilling.
3-4
TL1055, TL1255
Boom
3.4
3.4.1
3.4.2
TL1055, TL1255
3-5
Boom
3.5
3.5.1
MY4130
13. Loosen the jam nut and lock nut (6) to release
tension from the hoses on the hose take-up
weldment (7).
13
12
11 10
4
5
MY3580
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
3-6
TL1055, TL1255
Boom
21
19
14
24
9
22
23
23
20
MY3540
MY3440
17. Pull the three extend chain clevises (9) off of each
chain roller (14) and lay each assembly on the third
and fourth boom sections respectively.
Note: It may be necessary to remove the extend chain
rollers to help in the removal of the top wear pads.
18. Verify all fittings, tubes and hoses are properly
capped and /or plugged.
19. Extend the second boom section to access the
retract chain adjusting block.
25. Remove the adjusting nut and lock nut (19), retract
chain and clevis (20), spring stop (21) and spring
(22). Loosen bolts (23) and adjusting block (24).
26. Properly disconnect the battery.
30
30
31
31
27
26
28
32
29
25
25
MY3420
17
18
15
16
MY4120
TL1055, TL1255
3-7
Boom
32. Remove the top rear wear pads, spacers, shims and
hardware (30) from the rear of the second boom
section.
33. Remove the left (or right) side rear wear pad, spacer,
shims and hardware (31) from the rear of the second
boom section.
3.5.2
29
28
28
MY4150
28
28
30
30
3
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.
40. Adjust sling(s) around the second boom section to
help balance the second, third and fourth boom
sections.
41. Remove the remainder of the second, third and
fourth boom sections from the first boom section and
set on suitable supports.
3-8
MY3590
TL1055, TL1255
Boom
6. Place a sling around the third boom section. With a
suitable lifting device, slowly pull the third and fourth
boom sections approximately 25% out of the second
boom section.
6
7
6
MY3450
TL1055, TL1255
3.5.3
10
MY3510
3-9
Boom
3.5.4
12
13
13
MY3470
MY3630
MY3490
14
FRONT OF BOOM
MY3610
3.5.5
3-10
Boom
3.5.6
13
MY3610
FRONT OF BOOM
MY3480
11
12
12
15
MY3750
MY3470
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
16
MY3480
3.5.7
MY3630
3.5.8
7
3
3
MY3500
MY3510
3-12
TL1055, TL1255
Boom
3. Install the wear pad, support plates and spacers (7)
with existing hardware at the inside top front of the
third 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.
3.5.9
14
15
15
13
9
16
16
MY4160
11
11
MY3510
12
10
10
12
3.5.10
TL1055, TL1255
3-13
Boom
21
22
17
20
18
27
18
19
28
28
29
29
MY3540
MY3450
24
30
30
23
MY3650
25
25
26
26
31
MY3450
MY3590
TL1055, TL1255
Boom
11. Install the bracket and clevis assembly (31) at the
rear of the fourth boom section. Torque mounting
bolts.
3.5.11
3
2
2
1
MY4140
8
7
MY3420
3-15
Boom
9. Install both hose sheave covers (9).Torque mounting
bolts as required.
10
3.6
11
MY3440
1
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
Adjustment, for proper boom section adjustments.
MY3800
3-16
TL1055, TL1255
Boom
2
4
MY3820
MY3790
TL1055, TL1255
3-17
Boom
3.7
3.7.1
MY2710
MY2720
1
MY2690
3-18
MY2700
TL1055, TL1255
Boom
13. When the hose carrier is pulled approximately 25%
out of the boom, fasten the two hydraulic carriers
together using plastic tie wraps or nylon straps to
keep them from separating.
Note: Do Not wrap the hose carrier since it will not
prevent the two hydraulic carriers from moving apart
sideways.
3.7.3
3.7.2
MY2740
FRONT
TL1055, TL1255
MY2700
3-19
Boom
11. Uncap and reconnect the previously labeled tilt and
auxiliary hydraulic hoses to the proper fittings at the
front of the fourth boom section.
12. If equipped, reconnect any electrical connections at
the front and rear of the boom assembly.
87 6
12
11
MY4470
5
9
MY2691
3.7.4
10
3-20
MY4480
TL1055, TL1255
Boom
3.8
3.8.1
3.8.3
2
1
3.8.4
3
MAL0130
3.8.2
TL1055, TL1255
1. Remove the lock bolt holding the tilt cylinder rod end
pin to the quick coupler assembly. Remove the Tilt
Cylinder pin.
2. Support the quick coupler assembly.Remove the
capscrew and locknut securing the head pin to the
boom head.
3. Inspect the above pins for nicks or surface corrosion.
Use fine emery cloth to fix minor nicks or corrosion.
If damaged or if it cannot be repaired the pin must be
replaced.
3.8.5
3-21
Boom
3.9
3.9.1
3.10
3.10.1
6
4
5
Ma2070
MY3710
3.9.2
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
worn or damaged.
3.10.2
3
2
3-22
TL1055, TL1255
Boom
3.11
5
3.11.1
MX0510
3-23
Boom
13. Untie the rope and leave it in place for reinstallation
of the chain.
To remove the retract chain from the fourth to second
boom sections:
1. Remove the jam nut (4) from the chain clevis
installed in the chain adjustment block.
2. Back off the adjusting nut fully on the chain clevis.
Do not remove the nut from the clevis.
3. Remove the chain from the clevis, install a nylon tiewrap through the holes in the chain, making a loop
with the tie-wrap and tie a rope to the loop.
3.11.3
3.11.2
TL1055, TL1255
Boom
3.11.4
3.12
3.12.1
WARNING
Worn pins, stretched or cracked links or corrosive
environments can cause chain failure. A chain failure
could result in uncontrolled boom movement, loss of
load or machine instability.
Under normal operating conditions the extend chains will
need to be inspected and lubricated every 250 hours of
operation. The retract chains need to be exposed,
inspected and lubricated every 1000 hours of operation.
Environmental conditions and dynamic impulse/shock
loads can drastically affect normal operating conditions
and require more frequent inspection intervals.
Environments in which material handling vehicles
operate can vary widely from outdoor moisture to
temperature to mildly corrosive or highly corrosive
industrial atmospheres, in addition to abrasive
exposures such as sand and grit. Some effects can be
as follows:
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
which can impose abnormal loads above the endurance
limit of a leaf chain.
Edge Wear
3.12.2
Inspection Guidelines
MZ1463
MY1360
3-26
TL1055, TL1255
Boom
Cracked Plates
85
MZ1466
8
MZ1465
TL1055, TL1255
9
MZ1467
MZ1468
MZ1469
MZ1470
Tight Joints
- All joints in
the chain
should flex
freely. Tight
MZ1471
13
joints (13)
resist flexing.
If the problem is caused by dirt or foreign substance
packed in the joints, clean and lubricate thoroughly
before re-installing the chain.
If the problem is caused by corrosion and rust or
bent pins, replace the chain.
3-27
Boom
3.12.3
c. Extend Chains
1. Park the machine on a firm, level surface. Place the
transmission control lever in (N) NEUTRAL, engage
the park brake switch and raise the boom to a
horizontal (level) position.
2. Fully extend the boom until both extend chains are
taut. Shut the engine OFF.
The extend chains will be visible for inspection with the
machine in this state.
While doing the chain inspection, check all chain clevis
ends for distortion or cracking and sheaves for bearing
wear or grooving from the chain.
If during the inspection, any chain is found to be damaged
or stretched, the chain must be replaced. It is
recommended that when any chain is replaced, that all
the chains and clevises be replaced at the same time.
d. Retract Chains
The three retract chains are only partially visible through
the rear of the boom with all the sections retracted. It is
possible to see a section of the retract chain as the boom
is slowly extended. If there is ANY question that one or all
the retract chains are damaged, the chains should be
removed and inspected. Refer to Section 3.11, Boom
Chain Removal/Installation for detailed information.
Replace chains if necessary.
3.12.4
Chain Lubrication
3-28
TL1055, TL1255
Boom
3.13
FORKS
2
1
9
8
11
10
MH6460
TL1055, TL1255
3-29
Boom
3.14
TROUBLESHOOTING
Problem
1. Boom will not extend or
retract
Cause
Remedy
1. Insufficient lubrication.
2. Worn bearing(s).
1. Insufficient lubrication.
2. Worn bushing(s).
4. Excessive Compensation
cylinder pivot pin noise and/
or wear.
3-30
TL1055, TL1255
Boom
Problem
5. Drooping chain, or jerky
boom extend or retract
functions.
TL1055, TL1255
Cause
Remedy
1. Adjust chain(s).
4. Contaminated, corroded or
rusted wear pad sliding
surfaces.
5. Extend/Retract hydraulic
system not operating properly.
4. Replace bearing.
1. Insufficient lubrication.
3-31
Boom
Problem
8. Rapid boom pad wear.
3-32
Cause
Remedy
3. Contaminated, corroded or
rusted wear pad sliding
surfaces.
TL1055, TL1255
Section 4
Cab and Covers
Contents
PARAGRAPH
4.1
4.2
4.3
4.4
4.5
TL1055, TL1255
TITLE
PAGE
4-2
4-3
4-3
4-3
4-3
4-3
4-4
4-5
4-5
4-6
4-6
4-6
4-8
4-9
4-1
4.1
FRAME LEVEL
INDICATOR
STEERING WHEEL
INSTRUMENT
PANEL
FRAME LEVEL
CONTROL JOYSTICK
AUXILIARY CONTROL
JOYSTICK
TRANSMISSION
CONTROL LEVER
OUTRIGGER CONTROL
JOYSTICK
IGNITION
SWITCH
FUEL TANK
SERVICE BRAKE
PEDAL
ACCELERATOR
PEDAL
4-2
MY0930
TL1055, TL1255
4.2
OPERATOR CAB
WARNING
4.2.1
Cab Safety
WARNING
4.2.2
4.3
4.3.1
CAB COMPONENTS
Steering Column and Orbitrol Valve
1
MY0120
4-3
3
1
c. Steering Test
Conduct a pressure check of the steering hydraulic
circuits at the main control valve. Refer to Section 8.3.1,
Pressure Checks and Adjustments.
4.3.2
MY0140
4-4
TL1055, TL1255
4.3.4
Throttle Pedal
6
7
5
4
MY0950
4-5
4.3.5
a. Joystick Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake and turn the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
should not be operated.
3. Properly disconnect the battery.
b. Joystick Installation
1. Uncap and connect the previously labeled hydraulic
hoses to their appropriate locations.
2. Install the bolts securing the joystick to the cab.
3. Install the dash panel to its original position with the
previously used hardware.
4. Properly connect the battery.
5. Test the complete range of the joystick functions.
6. Close and secure the engine cover.
7. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
4.3.6
4.3.7
8
MY0960
4-6
TL1055, TL1255
14
MY4390
16
14
16
13
MY0190
10. Remove the bolts securing the front plate (10) to the
seat riser weldment (11).
11. Remove the bolts securing the seat riser weldment
to the cab. Remove the riser weldment.
12
MAL0420
12. Loosen the hose and disconnect the heater air duct
hoses (12).
TL1055, TL1255
4-7
4.4
CAB REMOVAL
WARNING
The protection offered by this ROPS/FOPS will be
impaired if subjected to any modification or structural
damage, at which time replacement is necessary.
ROPS/FOPS must be properly installed using
fasteners of correct size and grade, and torqued to
their specified value.
Note: To help ensure safety and optimum performance,
replace the cab if it is damaged. Refer to the appropriate
parts manual for ordering information.
Inspect the cab, its welds and mounts. If modification,
damage, a cracked weld and/or fatigued metal is
discovered, replace the cab. Contact the local Caterpillar
dealer with any questions about the suitability or
condition of a cab.
Note: Remove and label cab components as needed
before removing the cab from the machine. Label,
disconnect and cap hydraulic hoses. Transfer cab parts
to the replacement cab after the replacement cab is
securely mounted on the machine.
4-8
TL1055, TL1255
14
15
MY0610
4.5
CAB INSTALLATION
14
16
16
15
MY0610
MY4170
17
17
TL1055, TL1255
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.
19. Close and secure the engine cover.
20. Unblock the wheels.
21. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
MY4170
17
17
4-10
TL1055, TL1255
Section 5
Axles, Drive Shafts, Wheels and Tires
Contents
PARAGRAPH
5.1
5.2
5.3
5.4
5.5
5.6
5.7
TL1055, TL1255
TITLE
PAGE
5-2
5-3
5-3
5-3
5-3
5-3
5-3
5-4
5-4
5-6
5-9
5-9
5-9
5-9
5-9
5-9
5-10
5-10
5-11
5-11
5-11
5-11
5-12
5-1
5.1
REAR STEERING
CYLINDER
REAR AXLE
ASSEMBLY
CARRIER
BEARING
TRANSMISSION
TRANSFER CASE
REAR DRIVE SHAFT
FRONT STEERING
CYLINDER
REAR AXLE
WHEEL HUBS (2)
FRONT AXLE
ASSEMBLY
FRONT AXLE
WHEEL HUBS
(2)
MAL2070
5-2
TL1055, TL1255
5.2
GENERAL INFORMATION
WARNING
DO NOT service the machine without following all
safety precautions as outlined in Section 1, Safety
Practices, of this manual.
Note: To help ensure optimum performance, the drive
shaft assemblies are specially balanced as a unit at the
factory. When servicing any flange yoke, slip yoke or
drive shaft tube, order a complete assembly if
components are bent or damaged. Refer to the
appropriate parts manual for ordering information.
Before performing any inspection, maintenance or
service operation, thoroughly clean the unit. The axles
and drive shafts should be checked and repaired only by
experienced service technicians who are aware of all
safety instructions and particular component features.
Use suitable products to thoroughly clean all
disassembled mechanical parts to help prevent personal
injury to the worker and prevent damage to the parts.
Carefully inspect the integrity of all moving parts
(bearings, yokes, tubes, gears, shafts, etc.) and fasteners
(nuts, bolts, washers, etc.) as they are subject to major
stress and wear. Always replace elastic locknuts and any
damaged, worn, cracked, seized or otherwise improper
parts that could affect the safe and proper functioning of
the machine, axles and drive shafts.
5.3
5.3.1
AXLE ASSEMBLIES
Axle Serial Number Plate
5.3.2
Axle Specifications
5.3.3
5.3.4
Axle Maintenance
TL1055, TL1255
5-3
Axle Removal
The front and rear axle assemblies differ in that the front
axle assembly is equipped with a parking brake
mechanism and a limited-slip feature; the rear axle has
neither. The following steps outline a typical axle removal
procedure, suitable for either the front or the rear axle
assembly.
Cleanliness is extremely important. Before attempting to
remove the axle, thoroughly clean the machine. Avoid
spraying water or cleaning solution on electrical
components. If using a steam cleaner, seal all openings
before steam cleaning.
Note: Clear the work area of all debris, unnecessary
personnel, etc. Allow sufficient space to raise the
machine and to remove the axle.
15. Remove the axles from the machine using the jack,
hoist or overhead crane and sling supporting the
axle. DO NOT raise or otherwise disturb the
machine while removing the axle. Balance the axle
and prevent it from tipping, turning or falling while
removing it from beneath the machine. Place the
axle on a suitable support or holding stand.
5.3.6
MY4180
Axle Installation
TL1055, TL1255
MY4180
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.
3
LEVEL
MT0220
TL1055, TL1255
5-5
Problem
1. Excessive axle noise while
driving.
5-6
Cause
Remedy
TL1055, TL1255
Problem
4. Oil leaking from axle
(differential housing and/or
axle housings).
TL1055, TL1255
Cause
Remedy
2. Tighten fittings.
2. Replace o-ring.
1. Tighten fittings.
5-7
Problem
7. Axle overheating.
5-8
Cause
Remedy
TL1055, TL1255
5.4
DRIVE SHAFTS
TO AXLE
5.4.1
1 2
TO
TRANSMISSION
3
4
MT0350
5.4.2
5.4.3
5.4.4
5.4.5
TL1055, TL1255
5-9
5.5
WARNING
Mismatched tire sizes, ply ratings or mixing of tire
types (radial tires with bias-ply tires) may compromise
machine stability and may cause machine to tip over.
It is recommended that a replacement tire to be the same
size, ply and brand as originally installed. Refer to the
appropriate parts manual for ordering information. If not
using an approved replacement tire, It is recommended
that replacement tires have the following characteristics:
Equal or greater ply/load rating and size of original.
Tire tread contact width equal or greater than
original.
Wheel diameter, width and offset dimensions equal
to the original.
Approved for the application by the tire manufacturer
(including inflation pressure and maximum tire load).
The rims installed have been designed for stability
requirements which consist of track width, tire pressure
and load capacity. Size changes such as rim width,
center piece location, larger or smaller diameter, etc.,
without written factory recommendations, may result in
unsafe condition regarding stability.
Foam filled tires have a positive effect on the weight,
stability and handling characteristics of the machine,
especially under load. The use of hydrofill as a tire-fill
substance is not recommended because of possible
environmental impact.
Large-bore valve stems are used to help expedite tire
inflation and deflation. An inner tube may be used if a tire
does not provide an airtight seal. Check tire inflation
pressures when the tires are cold. When mounting a tire
on the wheel, the tire must be mounted on the wheel
respective of the directional tread pattern of the tire; this
produces a left or right tire and wheel assembly.
5-10
MY4190
5.5.1
TL1055, TL1255
5.6
BRAKES
5.7
5.7.1
MAH0460
MZ1020
10
MY4200
5
MZ1020
5-12
TL1055, TL1255
Section 6
Transmission
Contents
PARAGRAPH
6.1
6.2
6.3
6.4
6.5
6.6
6.7
TL1055, TL1255
TITLE
PAGE
6-2
6-3
6-3
6-3
6-3
6-4
6-4
6-5
6-6
6-6
6-6
6-6
6-6
6-7
6-8
6-1
Transmission
6.1
TRANSMISSION ASSEMBLY
COMPONENT TERMINOLOGY
TRANSMISSION
FILTER
TORQUE CONVERTER
SHIFT SOLENOIDS
SHIFT SOLENOIDS
6-2
TL1055, TL1255
Transmission
WARNING
DO NOT service the machine without following all
safety precautions as outlined in Section 1, Safety
Practices, of this manual.
6.2
6.4.1
Transmission Removal
WARNING
NEVER lift a transmission alone; enlist the help of at
least one assistant or use a suitable hoist or overhead
crane and sling with a minimum lifting capacity of
1000 lb (454 kg).
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
should not be operated.
3. Open the engine cover. Allow the system fluids to cool.
MY0990
6.3
TRANSMISSION SPECIFICATIONS
AND MAINTENANCE INFORMATION
6.4
TRANSMISSION REPLACEMENT
TL1055, TL1255
MY0980
6-3
Transmission
facility. Clean and reinstall the transmission drain
plug.
4
6-4
MY0990
6.4.2
6.4.3
Transmission Installation
WARNING
NEVER lift a transmission alone; enlist the help of at
least one assistant or use a suitable hoist or overhead
crane and sling.
1. Install both rear transmission mounts on the
transmission. Torque capscrews to 125-140 lb-ft
(170-190 Nm).
2. Install two guide studs near the top of the bell
housing holes.
3. Use a hoist or overhead crane and sling attached to
the lifting eye at the top of the transmission. Raise
and position the transmission within the chassis.
4. Align the torque converter, align the transmission
bolt holes with the two studs in the bell housing.
Install the eight bolts and washers and torque to
53 lb-ft (72 Nm). Remove the two alignment studs
and install and torque the last two transmission
mounting bolts.
TL1055, TL1255
Transmission
5. Install the two rear transmission mounting bolts on
the frame with two capscrews and two lockwashers.
Apply Loctite 242TM to the transmission mount bolts
and torque to 125-140 lb-ft (169-190 Nm)
6. Turn the engine over slowly by hand and align each
of the four torque convertor diaphragm bolts through
the access plug in the bell housing. Install them one
at a time. DO NOT fully tighten until all of the
capscrews and locknuts are in place. Torque to
26-39 lb-ft (35-59 Nm). Replace access plug.
7. Remove the hoist or overhead crane and sling.
8. Connect the transmission temperature switch
connector and shift solenoid wiring harness
connectors.
6.4.4
In general:
1. Check the transmission oil level and add oil as
required.
2. Disconnect and clean all transmission cooler hoses.
When possible, remove transmission lines from the
machine for cleaning.
3. Drain and flush the entire transmission cooling
system.
4. Thoroughly clean transmission filter screens and
cases, and replace transmission filter elements.
5
MY0990
TL1055, TL1255
6-5
Transmission
6.5
6.5.1
6.6
6.6.1
6.5.2
1
MY0980
6-6
TL1055, TL1255
Transmission
6.6.2
6
MAL1410
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
Problem
1. Transmission will not engage
or will not shift properly.
6-8
Cause
Remedy
6. Replace o-rings.
8. Replace couplings.
TL1055, TL1255
Transmission
Problem
2. Low or no pump flow or
pressure.
4. Lack of power.
TL1055, TL1255
Cause
Remedy
5. Transmission overheating.
Transmission
Problem
5. Transmission overheating
(oil above 248 F (120 C)).
Cause
Remedy
2. Clogged radiator.
4. Excessive roading.
6-10
4. Internal damage.
7. Tighten capscrews.
TL1055, TL1255
Transmission
Problem
7. Oil leaking from transmission.
Cause
1. Oil leaking from vent (high oil
level).
3. Tighten fittings.
TL1055, TL1255
Remedy
6-11
Transmission
6-12
TL1055, TL1255
Section 7
Engine: CAT C4.4
Contents
PARAGRAPH
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
TL1055, TL1255
TITLE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1
Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.2
Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . .
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.1
Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.2
Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.3
Radiator/Transmission Cooler Replacement . . . . . . . . . . . . . . . . . . . . . .
7.4.4
Radiator/Transmission/Cooler Replacement . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.1
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.2
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.3
After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.1
Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.2
Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.3
Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.4
Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8.1
Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8.2
Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8.3
Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8.4
Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.9.1
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.9.2
Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE
7-2
7-2
7-3
7-4
7-4
7-4
7-4
7-4
7-5
7-7
7-9
7-9
7-9
7-9
7-11
7-11
7-11
7-11
7-12
7-12
7-12
7-12
7-13
7-13
7-13
7-14
7-14
7-15
7-16
7-17
7-1
7.1
7.1.1
INTRODUCTION
Disclaimer and Scope
7-2
TL1055, TL1255
Component Terminology
THERMOSTAT
FUEL FILTER
FUEL INJECTOR
PUMP
ALTERNATOR
WATER PUMP
TURBOCHARGER
MAL0261
OIL FILTER
STARTER
THERMOSTAT
FUEL FILTER
ALTERNATOR
FUEL INJECTOR
PUMP
TURBOCHARGER
WATER PUMP
MAL1390
OIL FILTER
TL1055, TL1255
STARTER
FUEL FILTER
(PRIMARY)
7-3
7.2
7.3
7.4
7.4.1
TYPICAL THERMOSTAT
7.4.2
Thermostat Replacement
7-4
MY4260
TL1055, TL1255
5
7
7
4
7.4.3
Radiator/Transmission Cooler
Replacement
MY4220
10
10
16
15
15
12
11
4
13
13
14
MY4210
7
5
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
side of the charge air cooler (11).
MY4220
21. Loosen and remove the nuts and washers from two
isolator mounts at the bottom of the radiator (13).
22. Loosen and remove the three bolts from the bottom
of the hydraulic oil cooler (14).
7-6
TL1055, TL1255
6. Slowly turn the radiator cap to the first stop and allow
any pressure to escape. Remove the radiator cap.
13. Open the radiator cap and fill the radiator completely
with coolant. Replace and tighten the radiator cap.
Refer to Section 2.4, Fluids and Lubricant
Capacities, for proper capacities.
7.4.4
Radiator/Transmission/Cooler
Replacement
MY5890
TL1055, TL1255
7-7
8
6
11
6
10
MY5890
MY5880
12
12
16. Loosen and remove the nut and washer from the
isolator mount at the top of the radiator (11).
7-8
TL1055, TL1255
7.6
4
FUEL SYSTEM
8
6
7.6.1
Diesel Fuel
6
10
MY5880
7.5
7.6.2
Fuel Tank
8
10
11
d. Assembly
9
MY4230
5. Remove fuel tank drain plug (8), and drain fuel into
an approved, clean and suitable container. Dispose
of fuel properly if contaminated.
e. Inspection
TL1055, TL1255
7.6.3
10
4
1
3
7.7.1
6
2
3. Fill the fuel tank with fresh, clean diesel fuel as required.
7.7
MY4240
7.7.2
TL1055, TL1255
7-11
7.7.4
7.7.3
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.
3. Install the exhaust pipe (6) to the exhaust pipe (8).
4. Install the muffler (3) to the exhaust pipe (6).
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.
7. Adjust the muffler, exhaust and tail pipes for proper
clearance then tighten all clamps.
8. Install the exhaust heat shield (1).
7.8
2
WARNING
3
2
5
6MY5900
7-12
7.8.1
TL1055, TL1255
7.8.3
13
16
17
11
12
18
MY4250
7.8.2
MY5070
7.8.4
TL1055, TL1255
7-13
12. Disconnect and cap the fuel inlet line at the fuel filter
head.
7.9
7.9.1
ENGINE REPLACEMENT
Engine Removal
13. Disconnect and cap the fuel return line from the fuel
filter head.
14. Remove the exhaust pipe from the exhaust
manifold. Refer to Section 7.7.1, Exhaust System
Removal.
15. Loosen the clamps on the sleeve reducer at the
engine and on the air suction pipe.
16. Remove the air cleaner tube assembly.
17. Remove the access plug from bottom of the engine
bell housing. This will allow access to remove the
bolts holding the torque convertor diaphragm to the
engine flywheel.
18. Turn the engine over slowly by hand and align each
of the four torque convertor diaphragm bolts to be
accessed. Remove them one at a time.
7-14
1
MY4270
Engine Installation
10. Connect the fuel inlet line to the fuel filter head.
11. Connect the fuel return line to the fuel filter head.
TL1055, TL1255
7-15
7.10
Warning
Lamp
Shutdown
Lamp
Lamp State
Lamp Indication
Engine State
ON
ON
Bulb Check
OFF
OFF
No Faults Present
ON
OFF
Active Diagnostic
Engine is running
normally but has one or
more faults with engine
management system
ON
FLASH
Derate
(Invoked by Active
Diagnostic)
FLASH
OFF
Warning
(Warning only)
Engine is running
normally but has one or
more monitored engine
parameters outside of the
acceptable range
FLASH
FLASH
Derate
(Warning and
Derate)
7-16
TL1055, TL1255
7.11
TROUBLESHOOTING
Trouble
1, 2, 3, 4
5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
Difficult Starting
5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61, 63
Lack of Power
8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 61, 63
Misfiring
8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32
11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63
Black Exhaust
11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 61, 63
Blue/White Exhaust
4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56, 62
Knocking
9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59
Erratic Running
7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59
Vibration
13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 49
4, 38, 41
Overheating
11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57
Poor Compression
11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
10, 11, 12
Key to Possible Causes
TL1055, TL1255
7-17
Trouble
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
7-18
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
TL1055, TL1255
Section 8
Hydraulic System
Contents
PARAGRAPH
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
TL1055, TL1255
TITLE
PAGE
8-2
8-3
8-3
8-3
8-4
8-4
8-4
8-8
8-12
8-12
8-12
8-12
8-13
8-13
8-14
8-14
8-15
8-16
8-17
8-17
8-18
8-18
8-19
8-20
8-20
8-21
8-22
8-22
8-23
8-1
Hydraulic System
8.1
HYDRAULIC COMPONENT
TERMINOLOGY
EXTEND/RETRACT
CYLINDER
HYDRAULIC
FLUID RESERVOIR
LIFT/LOWER
CYLINDER(S)
COMPENSATION
CYLINDER
TILT CYLINDER
MAL0380
OUTRIGGER
CYLINDER(S)
8-2
FRAME LEVEL
CYLINDER
STEERING
CYLINDER(S)
MAIN CONTROL
VALVE
STEERING
CYLINDER(S)
STABILIZER
CYLINDER
TL1055, TL1255
Hydraulic System
8.2
SAFETY INFORMATION
WARNING
DO NOT service the machine without following all
safety precautions as outlined in Section 1, Safety
Practices, of this manual.
Petroleum-based hydraulic fluids are used in this
machine. The temperature of hydraulic fluid increases
during the operation of various hydraulic functions. A
heated petroleum-based hydraulic fluid presents a fire
hazard, especially when an ignition source is present.
Hydraulic fluid has a flash point that ranges from
300-600 F (150-318 C) and an auto-ignition temperature
of 500-750 F (262-402 C).
Accordingly, periodically inspect all hydraulic system
components, hoses, tubes, lines, fittings, etc. Carefully
examine any deterioration and determine whether any
further use of the component would constitute a hazard.
If in doubt, replace the component.
Operate the hydraulic controls after the engine has
stopped to relieve trapped pressure.
Note: Residual pressure may remain in hydraulic
cylinders, hoses, valve bodies, components, etc. If the
hydraulic lines going to or coming from a component are
taut, slowly and cautiously relieve (bleed off) pressure.
Whenever you disconnect a hydraulic line, coupler, fitting
or other component, slowly and cautiously loosen the part
involved. A hissing sound or slow seepage of hydraulic
fluid may occur in most cases. After the hissing sound
has ceased, continue removing the part. Any escaping oil
should be directed into an appropriate container. Cap or
otherwise block off the part to prevent further fluid seepage.
Hydraulic system maintenance will, at times, require that
the engine be operated. Always follow safety precautions.
A major cause of hydraulic component failure is
contamination. Keeping the hydraulic fluid as clean as
possible will help avoid downtime and repairs. Sand, grit
and other contaminants can damage the finely machined
surfaces within hydraulic components. If operating in an
exceptionally dirty environment, change filters and
inspect the fluid more often. When servicing the system,
cap or plug hydraulic fittings, hoses and tube assemblies.
Plug all cylinder ports, valves and the hydraulic reservoir,
and pump openings until installation occurs. Protect
threads from contamination and damage.
TL1055, TL1255
8.3
8.3.1
8-3
Hydraulic System
8. Start the engine and check the pressure again. Turn
the engine OFF. If there is pressure reading in the
gauge, bleed it off then disconnect or remove the
pressure gauge from the machine.
8.4
HYDRAULIC CIRCUITS
8.4.2
8.4.1
Hydraulic Pressures
a. Checking Pressure
1. Start the machine and warm the hydraulic system to
operating temperature.
2. Shut off the machine and install a digital or a
5000 psi (345 bar) gauge to the appropriate test port
on the hydraulic manifold.
3. Start the machine, run the engine at high idle and
bottom the appropriate hydraulic function. Refer to
Section 8.4.1, Hydraulic Pressures, for the correct
pressure rating.
b. Adjusting Hydraulic Pressure
1. Shut the machine off. Remove the cap on the relief
(if necessary).
MY4500
8-4
TL1055, TL1255
Hydraulic System
9. Tilt the forks down to allow the tilt cylinder to fully
retract.
10. Monitor the gauge and slowly raise the boom. The
gauge should read 4100 psi (282 bar).
11. If pressure is correct, proceed to step 14.
A
A
HUSCO
REXROTH
MY4490
FRONT OF MACHINE
HUSCO
REXROTH
MY4490
FRONT OF MACHINE
24. Slowly remove the gauge, line and tee fitting from
the compensation cylinder (1 & 2). Reinstall each
hose and torque as required.
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
the compensation cylinder.
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
TL1055 - Before S/N TBM00895
TL1255 - Before S/N TBM00436
Hydraulic Circuit
Test Port
Function Used to
Test
Adjustment
Location
Pressure Range
Main
P1 (A)
3600-3650 psi
(248-252 Bar)
Pilot
JS1 (B)
No Function
500-550 psi
(34-38 Bar)
Standby
P1 (A)
No Function
750-775 psi
(52-53 Bar)
Service Brake
Supply
BV1 (C)
Bottom Steering,
Any Mode
1000-1100 psi
(69-76 Bar)
Steering
GLS (D)
Bottom Steering,
Any Mode
2400-2500 psi
(165-172 Bar)
Lift
LS2 (E)
3500-3525 psi
(241-243 Bar)
Boom Retract
LS2 (E)
Bottom Boom
Retract
3050-3075 psi
(210-212 Bar)
HYDRAULIC
MANIFOLD
HYDRAULIC
MANIFOLD
3
1
3
1
MY1141
MY1831
MY1300
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.
Hydraulic Circuit
Test Port
Function Used to
Test
Adjustment
Location
Pressure Range
GLS (A)
3250-3350 psi
(224-231 Bar)
Standby
P1 (B)
500-515 psi
(34-35 Bar)
Main
P1 (B)
3575-3675 psi
(246-253 Bar)
Pilot
JS1 (C)
500-550 psi
(34-38 Bar)
Service Brake
BV1 (D)
1050-1150 psi
(72-79 Bar)
Priority Load
Sense
GLS (A)
2375-2475 psi
(164-171 Bar)
Boom Extend
GLS (A)
No Adjustment
3250-3350 psi
(224-231 Bar)
Boom Retract
GLS (A)
No Adjustment
3250-3350 psi
(224-231 Bar)
Boom Lift
GLS (A)
No Adjustment
3250-3350 psi
(224-231 Bar)
10
Auxiliary Hydraulic
GLS (A)
No Adjustment
2900-3100 psi
(200-214 Bar)
1
3
2
B
HYDRAULIC
MANIFOLD
MAL2150
MY4361
A
TL1055, TL1255
8-7
8-8
GP
MAN0040
FRONT STEERING
CYLINDER
3.66 CID
STEERING ORBITROL
BV1
L,L1
1100 PSI
BV
A1
B1
LS2
LS
JS1
JS
500 PSI
PR
SL
P T
STEER SELECT
VALVE
PB
ST
SR
A2
B2
GLS
SLS
PLS
BLS
70 PSI
RETURN
FILTER
B 8 = 75
10 MICRON
BREATHER
HYDRAULIC OIL
COOLER
SERVICE
BRAKE VALVE
TANK
BT
.030
STABILIZER
CYLINDER
W/O LOCK
BLS
LOAD
SENSE
OUTLET
FSB
INLET
BV
OUTLET
RSB
.030
PARK
BRAKES
FRONT
SERVICE
BRAKES
REAR
SERVICE
BRAKES
T2
SLS
LS
JS
PR
TO MAIN
CONTROL
VALVE
(SEE SHEET 2)
8.4.3
25 PSI
P T
Hydraulic System
Hydraulic Schematic
3625PSI
261PSI
TL1055, TL1255
REAR STEERING
CYLINDER
T2
SLS
LS
JS
PR
LS
PRLS
PR
LIFT
3500 PSI
RTT
b1
LUP
a1
1
CIN
B1
A1
LDN
JOYSTICK
4100 PSI
COUT
CROWD
b2
5000
PSI
a2
B2
A2
4100 PSI
5000
PSI
b3
1
2
LOU
a3
B3
1
ROD
A3
2
ROU
OUTRIGGER
LOD
5000
PSI
4100 PSI
OUTRIGGER
b4
a4
5000
PSI
B4
A4
1
2
SWAY
AUX
RIGHT OUTRIGGER
CYLINDER
4100 PSI
LEFT OUTRIGGER
CYLINDER
b5
SWAY
.040
a5
B5
A5
.050
SWAY CYLINDER
AUX
b6
a6
SV2
SV1
A6
SV4
B6
SV3
"QD'S"
THIS
LOC'N
ON STD.
MACHINE
SEE
SHT. 3
SV5
TILT
B7
A7
X
COMPENSATING
CYLINDER
5000
PSI
TILT CYLINDER
DECOMPRESSION
VALVE
COMBINATION VALVE
3000 PSI
CROWD CYLINDER
3000 PSI
LIFT CYLINDER
4100 PSI
TL1055, TL1255
4100 PSI
LIFT CYLINDER
T2
LSb
P2
Hydraulic System
MAL0050
8-9
2600 PSI
8-10
T2
SLS
LS
JS
PR
INLET
GAGE
GAGE
SLS
LS
3400psi
2600psi
PR
HPCO
TO PUMP
(SEE SHEET 1)
RTT
PPA
LUP
LIFT
CIN
LDN
JOYSTICK
5000
PSI
LIFT CYLINDER
3300psi
COUT
PPA
5000
PSI
CROWD
3300psi
LIFT CYLINDER
B
3300psi
LOD
5000
PSI
LEFT OUTRIGGER
CYLINDER
PPA
2
LOU
LEFT O/R
4100psi
1
ROD
ROU
CROWD CYLINDER
4100psi
RIGHT O/R
PPA
5000
PSI
A
B
1
2
SWAY
AUX
RIGHT OUTRIGGER
CYLINDER
SWAY
PPA
.040
.050
SWAY CYLINDER
PPA
AUX
3000psi
B
3000psi
TILT
4100psi
DECOMPRESSION
VALVE
"QD'S"
OUTLET
4100psi
PILOT
COMPENSATING
CYLINDER
5000
PSI
TILT CYLINDER
SUMP
Hydraulic System
MAL0710-C
TL1055, TL1255
Hydraulic System
8.4.3Hydraulic Schematic (Continued)
OPTIONAL REMOTE
HYDRAULIC QUICK ATTACH
QA CYLINDER
C2 C3
AUXILIARY
HYD. PORTS
C1 C4
P1 P2
LEFT
DWN
QA EXTD.
MAL0060
TL1055, TL1255
RIGHT,
UP,
QA RET.
AUXILIARY HYD.
PORTS @ BOOM NOSE
8-11
Hydraulic System
8.5
HYDRAULIC RESERVOIR
TL1055 - BEFORE S/N TBM00776
TL1255 - BEFORE S/N TBN00388
8.5.3
MY6010
8.5.1
8.5.2
TL1055, TL1255
Hydraulic System
Note: If a leak is suspected in the hydraulic oil reservoir,
contact your local Caterpillar dealer.
To clean the hydraulic oil reservoir:
1. Have a dry chemical (Class B) fire extinguisher near
the work area.
2. Remove the hydraulic oil reservoir drain plug, and
safely drain any hydraulic oil into a suitable
container. Dispose of hydraulic oil properly.
3. Clean the hydraulic oil reservoir with a high-pressure
washer, or flush the tank with hot water for five
minutes and drain the water. Dispose of
contaminated water properly.
d. Inspection
8.6
IMPLEMENT PUMP
8.6.1
a. Pump Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N) NEUTRAL,
engage the park brake and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
e. Reservoir Installation
1. Place the hydraulic oil reservoir into its original
orientation.
2
2
8-13
Hydraulic System
Note: DO NOT disassemble the operating pump. The
pump is pre-set from the manufacturer. Any adjustments
or repairs performed by anyone other than your local
Caterpillar dealer could void the warranty.
b. Pump Installation
1. Place the pump and a new, oiled o-ring into position
on the transmission. Align the pump shaft with the
internal transmission gear, so that the machined
teeth mesh together.
2. Align the bolt holes with the pump mount holes.
3. Apply Loctite 242TM to the previously removed bolts.
4. Secure the pump to the transmission with the four
bolts and washers. Torque as required.
5. Uncap and connect the previously labeled hydraulic
hoses to their appropriate locations.
6. Fill the hydraulic reservoir. Refer to Section 8.5.2,
Hydraulic Oil Reservoir Filling.
7. Prime the pump by filling the case drain port with fresh,
filtered hydraulic oil from a clean container before
installing the case drain connector and hose.
8. Check all routing of hoses and tubing for sharp
bends or interference with any rotating members. All
tube and hose clamps must be tight.
9. Remove the 10 amp fuse from location F3 in power
distribution unit located in the engine compartment.
This will allow the engine to crank, but not start while
air is worked out of the new pump.
10. Connect a hose to the P1 port on the pump. Direct
the open end of the hose into a fluid drip pan.
11. Properly connect the battery.
12. Turn the machine ignition switch to START and back
OFF in 3 to 5 second intervals. Monitor the open end
of the drain hose for a constant flow of fluid (no air)
while engine is cranking.
13. Once a constant flow is achieved at the open end of
the drain hose, disconnect the hose and reinstall the
10 amp fuse to location F3 in the power distribution
unit.
8.7
8.7.1
CONTROL VALVES
Main Control Valve
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
sections then remove each control spool.
MAL0730
8.7.2
MY1200
8-15
Hydraulic System
4. Using the proper o-rings and load sense shuttle,
repeat step three for the remaining valve sections
and lastly the inlet end valve section.
5. Install the three washers and nuts on the tie rods.
Torque to 30 lb-ft (41 Nm).
e. Main Control Valve Installation
1. Install the main control valve onto the frame, aligning
the bolts with the holes in the end sections of the
main control valve. Slide the main control valve into
position, and tighten the bolts.
2. Prime the main control valve by filling the inlet
openings with fresh, filtered hydraulic oil from a
clean container, before attaching the hoses.
3. Use new oiled o-rings as required. Uncap and
connect all previously labeled hoses, clamps, etc. to
the main control valve.
4. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
members, and install tie wraps and/or protective
conduit as required. Tighten all tube and hose
clamps.
8.7.3
3
3
MAL1740
8-16
TL1055, TL1255
Hydraulic System
b. Service Brake Valve Installation
6
8.7.4
6
MAL0750
8.7.5
TL1055, TL1255
8-17
Hydraulic System
8.7.7
8.7.6
MY4280
8-18
TL1055, TL1255
Hydraulic System
8.7.8
MY4290
Hydraulic System
Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as
needed.
WARNING
Significant pressure may be trapped inside the cylinder.
Exercise caution when removing a counterbalance valve
or a pilot-operated check valve from a cylinder.
Note: Avoid using excessive force when clamping the
cylinder in a vise. Apply only enough force to hold the
cylinder securely. Excessive force can damage the
cylinder tube.
1
8.8
8.8.1
HYDRAULIC CYLINDERS
General Cylinder Removal
Instructions
4
3
MY4300
Hydraulic System
Carefully slide the head gland down along the rod
toward the rod eye, away from the cylinder barrel.
Note: When sliding the rod and piston assembly out of
the barrel, prevent the threaded end of the barrel from
damaging the piston. Keep the rod centered within the
barrel to help prevent binding.
6. Carefully pull the rod assembly (3) along with the
head gland (4) out of the cylinder barrel.
7. Fasten the rod eye in a soft-jawed vise, and place a
padded support under and near the threaded end of
the rod to prevent any damage to the rod.
8. Remove the set screw from the piston head (5).
9. If equipped, remove the piston head (5) mounting
nut (6).
Note: It may be necessary to apply heat to break the
bond of the sealant between the piston and the rod
before the piston can be removed.
Some cylinder parts are sealed with a special organic
sealant and locking compound. Before attempting to
disassemble these parts, remove any accessible seals
from the area of the bonded parts. Wipe off any hydraulic
oil, then heat the part(s) uniformly to break the bond. A
temperature of 300-400 F (149-204 C) will destroy the
bond. Avoid overheating, or the parts may become
distorted or damaged. Apply sufficient torque for removal
while the parts are still hot. The sealant often leaves a
white, powdery residue on threads and other parts, which
must be removed by brushing with a soft brass wire brush
prior to reassembly.
10. Remove the piston head (5) from the rod (3) and
carefully slide the head gland (4) off the end of the
rod.
11. Remove all seals, back-up rings and o-rings from the
piston head and all seals, back-up rings and o-rings
from the head gland.
Note: The head gland bearing will need to be inspected
to determine if replacement is necessary.
DO NOT attempt to salvage cylinder seals, sealing rings
or o-rings. ALWAYS use a new, complete seal kit when
rebuilding hydraulic components. Consult the parts
catalog for ordering information.
b. Cylinder Cleaning Instructions
1. Discard all seals, back-up rings and o-rings. Replace
with new items from seal kit to ensure proper
cylinder function.
TL1055, TL1255
8.8.2
Cylinder Inspection
8-21
Hydraulic System
Note: When sliding the rod and piston assembly into the
cylinder barrel, prevent the threaded end of the cylinder
barrel from damaging the piston head. Keep the cylinder
rod centered within the barrel to prevent binding.
6. Carefully insert the cylinder rod assembly into the
cylinder barrel.
7. Screw the head gland into the cylinder barrel and
tighten with a spanner wrench. Refer to Section
8.8.5, Cylinder Torque Specifications for torque
specifications for the head gland.
8. If applicable, install new counter balance valve into
block on the cylinder barrel.
8.8.3
Attach a 5000 psi (345 bar) gauge to the test port on the
P1 port on the hydraulic manifold to check the system
pressure. For more information, refer to Section 8.4.1,
Hydraulic Pressures.
Note: If a hydraulic cylinder pressure is greater than the
main control valve pressure, increase the main control
valve pressure by adjusting the main relief. Generally,
one half turn clockwise will be adequate to check an
individual circuit. Activate the circuit and if pressure is
obtained turn the main relief counter clockwise one half
turn. Re-check the main relief setting and adjust if
necessary.
8.8.4
Steering Cylinders
STEERING CYLINDER
MY4310
8-22
TL1055, TL1255
Hydraulic System
8.8.5
a. Lift/Lower Cylinder
Machine
Head
Nut
CB Valve
Valve Screw
550-600 lb-ft
(745-813 Nm)
2125-2175 lb-ft
(2881-2949 Nm)
45-50 lb-ft
(54-61 Nm)
28-30 lb-ft
(38-41 Nm)
550-600 lb-ft
(745-813 Nm)
1600-2000 lb-ft
(2169-2711 Nm)
30-35 lb-ft
(40-47 Nm)
24-27 lb-ft
(32-36 Nm)
550-600 lb-ft
(745-813 Nm)
2850-2900 lb-ft
(3864-3932 Nm)
45-50 lb-ft
(54-61 Nm)
28-30 lb-ft
(38-41 Nm)
550-600 lb-ft
(745-813 Nm)
1600-2000 lb-ft
(2169-2711 Nm)
45-50 lb-ft
(54-61 Nm)
24-27 lb-ft
(32-36 Nm)
Machine
Head
Nut
Valve (Large)
Valve (Small)
500-550 lb-ft
1325-1375 lb-ft
(1796-1864 Nm)
110 lb-ft
(149 Nm)
35 lb-ft
(47 Nm)
500-550 lb-ft
1400-1700 lb-ft
(1898-2304 Nm)
110 lb-ft
(149 Nm)
35 lb-ft
(47 Nm)
500-550 lb-ft
1325-1375 lb-ft
(1796-1864 Nm)
110 lb-ft
(149 Nm)
35 lb-ft
(47 Nm)
500-550 lb-ft
1400-1700 lb-ft
(1898-2304 Nm)
110 lb-ft
(149 Nm)
35 lb-ft
(47 Nm)
b. Extend/Retract Cylinder
c. Tilt Cylinder
Machine
Head
Nut
CB Valve
550-600 lb-ft
(745-813 Nm)
2050-2100 lb-ft
(2779-2847 Nm)
40-45 lb-ft
(54-61 Nm)
550-600 lb-ft
(745-813 Nm)
2200-2400 lb-ft
(2982-3254 Nm)
40-45 lb-ft
(54-61 Nm)
550-600 lb-ft
(745-813 Nm)
2250-2300 lb-ft
(3253-3525 Nm)
40-45 lb-ft
(54-61 Nm)
550-600 lb-ft
(745-813 Nm)
2400-2600 lb-ft
(3050-3118 Nm)
40-45 lb-ft
(54-61 Nm)
TL1055, TL1255
8-23
Hydraulic System
d. Compensation Cylinder
Machine
Head
Nut
f.
Machine
Head
Nut
Check Valve
300-325 lb-ft
(407-441 Nm)
750-800 lb-ft
(1016-1085 Nm)
15 lb-ft
(20 Nm)
300-325 lb-ft
(407-441 Nm)
1125-1375 lb-ft
(1525-1864 Nm)
33 lb-ft
(45 Nm)
300-325 lb-ft
(407-441 Nm)
750-800 lb-ft
(1016-1085 Nm)
15 lb-ft
(20 Nm)
300-325 lb-ft
(407-441 Nm)
1125-1375 lb-ft
(1525-1864 Nm)
33 lb-ft
(45 Nm)
Stabilizer Cylinder
Machine
Head
Nut
Cartridge
Cartridge Nut
300-325 lb-ft
(407-441 Nm)
775-825 lb-ft
(1050-1119 Nm)
22 lb-ft
(30 Nm)
2.5 lb-ft
(3,3 Nm)
300-325 lb-ft
(407-441 Nm)
800-1000 lb-ft
(1084-1355 Nm)
22 lb-ft
(30 Nm)
2.5 lb-ft
(3,3 Nm)
300-325 lb-ft
(407-441 Nm)
775-825 lb-ft
(1050-1119 Nm)
22 lb-ft
(30 Nm)
2.5 lb-ft
(3,3 Nm)
300-325 lb-ft
(407-441 Nm)
800-1000 lb-ft
(1084-1355 Nm)
22 lb-ft
(30 Nm)
2.5 lb-ft
(3,3 Nm)
g. Outrigger Cylinder
8-24
Nut
Valve Mount
TL1055, TL1255
Section 9
Electrical System
Contents
PARAGRAPH
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
9.14
TL1055, TL1255
TITLE
PAGE
9-2
9-2
9-3
9-4
9-4
9-4
9-4
9-4
9-5
9-6
9-7
9-7
9-8
9-9
9-13
9-16
9-16
9-18
9-20
9-20
9-21
9-21
9-22
9-22
9-23
9-23
9-24
9-24
9-25
9-25
9-26
9-26
9-27
9-27
9-28
9-28
9-29
9-29
9-30
9-31
9-31
9-1
Electrical System
9.1
ELECTRICAL COMPONENT
TERMINOLOGY
9.1.1
General Overview
DASH SWITCHES
OPTIONAL POWER
DISTRIBUTION UNIT
(behind dash panel)
OPTIONAL
HEATER/AC CONTROLS
MY5540
IGNITION
SWITCH
COOLANT
TEMPERATURE
SENDER
ENGINE CONTROL
MODULE
(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
COOLANT
TEMPERATURE
SENDER
FUSE HOLDER
ENGINE CONTROL
MODULE
(ECM)
ALTERNATOR
MY4550
STARTER
RELAY
STARTER
MY6000
TL1055, TL1255
9-3
Electrical System
9.2
SPECIFICATIONS
9.4.2
Cab
9.3
SAFETY INFORMATION
WARNING
DO NOT service the machine without following all
safety precautions as outlined in Section 1, Safety
Practices, of this manual.
9.4
9.4.1
Engine Compartment
The optional power distribution unit is located in the cab.
For access, remove the screws securing the load chart
panel (3) to the dash.
1
1
MAL0320
MY4550
9-4
TL1055, TL1255
Electrical System
9.4.3
F8
F3
F15
F4
F16
F14
F9
F7
F10
F11
IGN1
F13
F1
IGN3
ACCY1
F12
F5
F6
F2
ACCY2
MAL1400
Connector Legend
No.
Function
Amp Rating
F1
15
F2
Alternator Excite
F3
10
F4
Gauge Power
10
F5
15
F6
10
F7
Horn Power
15
F8
25
F9
25
F10
10
F11
10
F12
15
F13
Options Power 3
20
F14
Options Power 4
20
F15
Options Power 1
20
F16
Options Power 2
20
IGN1
Ignition 1
IGN 2
Ignition 2
ACCY1
Accessory 1
ACCY2
Accessory 2
TL1055, TL1255
9-5
Electrical System
9.4.4
F1
R1
F2
F3
R2
F4
F5
R3
F6
F7
R4
F8
R5
R6
R7
R8
MY1260
Connector Legend
9-6
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
TL1055, TL1255
CAN TERMINATOR
120 OHM
A
B
C
A
B
C
A
B
C
6 7 8
3 4 5
SHIELDED
CABLE
KEY/IGN
(CAN H/904)
(CAN L/905)
(SHIELD/020)
WAIT TO START
ON
OFF
HORN
ENG STOP
(RED, 18 GA GXL)
ENG WARN
(RED, 18 GA GXL)
(RED, 18 GA GXL)
STR CRB
STEER/SWAY PWR
STR AW
7
4
5
1
2
ON
OFF
PARK BRAKE
PK BRK SOL
4
5
6
1
2
3
ALL WHL
CRAB
STEER MODE
DASH GND
TRAN/BRK 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
1 2 3 4 5 6 7 8
2
1
SW4
SW2
N4
TO CHASSIS ASSEMBLY
N3
Y2, Y6
N2
Y2, Y3, Y6
R4
N1
R3
Y1, Y6
F4
Y2, Y3, Y4, Y6
Y1, Y3, Y6
R2
F3
R1
F2
TRANSMISSION LEGEND
F1
GEAR
SW3
SW1
HOBBS
TRANSMISSION SHIFTER
A B C D E F
WILLIAMS
(SUSPENDED)
THROTTLE
12 TURNS
PER FOOT
TWIST
REVERSE
RELAY
87a
30
3
5 4
3 2
87
4
86
5
TL1055/TL1255
CAB
WARN LIGHT
TEST RELAY
87
87a
30
1
86
STONERIDGE
GAUGE
85
2
PLUGGED
TRAN/BRK PWR
REVERSE
TRANS SOL Y2
SHIFTER GND
85
HORN PWR
HORN
SHIFTER HARNESS
HD34-24-31PT
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
TILT
SPEED
1 2
YEL
(SHIELD/020)
FUL LVL
(BLK, 18 GA GXL)
DASH GND
(D BLU, 18 GA GXL)
GAGE PWR
ENG STOP LT
TRANS TMP SW
(ORG, 18 GA GXL)
(WHT, 18 GA GXL)
PLUGGED
ENG WARN LT
WAIT TO START LT
KEY ACC
KEY START
TRANS SOL Y1
TRANS SOL Y3
TRANS SOL Y5
TRANS SOL Y4
SHIFT PWR 1
KEY START
TRANS SOL Y2
PK BRK SOL
THR SGN/915
THR RTN/914
THR SUP/911
IVS
PLUGGED
PLUGGED
RED
STAB/TILT PWR
PLUGGED
SHIFTER GND
TRANS TMP SW
KEY START
SHIFTER GND
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
PLUGGED
KEY START
SHIFT PWR 1
PK BRK SOL
REVERSE
TRAN/BRK PWR
SHIFTER GND
THR SUP/911
THR SGN/915
THR RTN/914
SP BAT PWR
SP ACCY PWR
SP CAB GND 1
SP CAB GND 2
SP-1
SP-2
SP-3
TRANS TMP SW
AC CLUTCH
STAB/TILT PWR
TILT UP
TILT DN
SP BAT PWR
IVS
PLUGGED
PLUGGED
ST RLY
SHIFT PWR 1
PK BRK SOL
WAIT TO START LT
ENG WARN LT
ENG STOP LT
TRAN/BRK PWR
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
CAN H
CAN L
SHIELD
(RED, 18 GA GXL)
(ORG, 18 GA GXL)
(D BLU, 18 GA GXL)
KEY IGN
TILT
UP
TILT
DOWN
STANDARD
JOYSTICK
SHIFTER HARNESS
DT06-4S
TO TILT ON JOYSTICK
ROLLER OPTION
1 2 3 4
STAB/TILT PWR
SHIFTER GND
TILT UP
TILT DN
TL1055, TL1255
1 2 3 4 5 6
RED
BLK
GRY
BLU
PLUG
PLUG
SP-1
SP-2
SP-3
SP BAT PWR
SP ACCY PWR
SP CAB GND 1
SP CAB GND 2
AC CLUTCH
SEE
SHEET 2
9.5.1
TILT UP
STD JOY PWR
STD JOY PWR
TILT DN
PLUGGED
PLUGGED
9.5
Electrical System
MAL0161B
9-7
DASH GND
AUX
ELECTRIC
OPTION
1 2 3 4 5 6 7 8 9 10 11 12
F1
F2
F3
F4
F5
F6
F7
F8
20A
15A
15A
25A
20A
20A
10A
10A
1 PWR
15A OPTION 2 PWR
25A OPTION PWR
HEATER/BLOWER PWR
LIGHT PWR
BEACON PWR
DASH FAN PWR
WIPER PWR
15A OPTION
OPTIONS
FUSE LEGEND
86
87
LIGHTS
87a
30
85
OPTION (15A)
87a
30
BCN/FAN
OPTION (25A)
F5 20
F7 10
F8 10
AUX ELEC1
F6 20
AUX ELEC2
25A OPT
25A OPT GND
TO CHASSIS ASSEMBLY
A OPTION 2
B 15 A
A
B
OPTION
25 A
SEE SHEET 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
OPTIONS HARNESS
HD36-24-19PE
SW2 86
SW2 87A
AC SW
86
SW1 86
HEATER GND
CAB LT GND
DOME/BCN GND
AUX RLYS PWR
SW1 87A
WIPER PWR
HEATER PWR
KEY ACC
BCN PWR
D FAN PWR
DOME LT
CAB LT PWR
S/W LT PWR
A
B
C
D
E
F
G
H
A
B
C
D
E
F
G
H
15A OPT 2
15A OPT 2 GND
GRAY-2
H G F E D C B A
BLACK-1
H G F E D C B A
87
87
87
86
86
86
86
86
F4
25
87
87
85
85
85
85
85
F3
15
87a
30
87a
30
87a
30
F1 20
87
86
87a
30
F2
5
87a
30
85
HEATER/BLOWER
87
GREEN-4
BLUE-3
OPTIONS VEC
85
87a
RLY 87
30
87
DOME/BCN GND
S/W LT PWR
STOP LT
A/C
RELAY
THERMOSTATIC
SWITCH A/C
A B
1 2 3 4 5 6 7 8
PRS SW
A B
A B
M 17A
M
A B C D
A B
BLOWER
MOTOR
DASH
FAN
CONDENSER FANS
(ON ROOF)
PRESSURE SWITCH
WORKLIGHT/
BEACON
OPTION
CAB LTS
CAB LT GND
WIPER
WASHER
DOME LT
WINDSHIELD
WASHER
CAB LIGHTS
MOTOR
BEACON LEFT RIGHT
CAB LTS
CAB LT GND
DOME
LIGHT
D FAN PWR
D FAN GND
TL1055/TL1255
OPTIONS
HEATER HI
HEATER MED
HEATER LOW
HEATER GND
87a
30
STOPLIGHT
SWITCH
1 2 3 4 5 6 7 8 9 10
HEATER
VALVE
A B C D E F
D FAN PWR
HEATER PWR
WIPER PWR
HEATER GND
D FAN GND
PLUGGED
PLUGGED
PLUGGED
A
B
WIPER MOTOR
RLY 87
25A OPT GND
ENCLOSED CAB
OPTION
ROOF WIPER
MOTOR
RESISTOR LOCATED
APPROX 10" BEHIND
HEATER TEMP SWITCH
CONNECTION IN
ENCLOSED CAB
OPTIONS HARNESS
WIPER LO
WIPER HI
WIPER PARK
EMPTY
EMPTY
QC GND
QC GND
PWR
PLUGGED
QC PWR
PWR
QC PWR
PLUGGED
GND
PLUGGED
PLUGGED
PLUGGED
QC GND
QC GND
SW2 87A
SW2 86
QC PWR
SW1 87A
QC PWR
SW1 86
AUX SW GND
PLUGGED
85
25A OPT
15A OPT 2
OPT PWR 1
AUX SW GND
5A ROOF WIPER PWR
OPT PWR 2
OPT PWR 3
OPT PWR 4
86
PLUGGED
PLUGGED
25A OPT GND
15A OPT 2 GND
5A ROOF WIPER GND
OPT GND 1
OPT GND 2
D FAN GND
KEY ACC
AUX RLYS PWR
STOP LT
WORK LT
PLUGGED
PLUGGED
QC PWR
OPT PWR 1
QC PWR
OPT PWR 2
QC GND
OPT PWR 3
QC GND
OPT PWR 4
PLUGGED
OPT GND 1
PLUGGED
OPT GND 2
PLUGGED
BCN LT
DOME/BCN GND
STOP LT
S/W LT PWR
BCN PWR
DOME LT
DOME/BCN GND
CAB LT PWR
CAB LT GND
WORK LT
STOP LT
S/W LT PWR
BCN PWR
DOME LT
DOME/BCN GND
CAB LT PWR
CAB LT GND
WORK LT
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
HEATER GND
HTR CNTRL B
EMPTY
HEATER PWR
D FAN PWR
HEATER PWR
WIPER PWR
HEATER GND
D FAN GND
PLUGGED
ON
OFF
A
B
8K OHM
HTR TEMP
HEATER HI
HEATER MED
HEATER LOW
WORKLIGHTS
24 KOHM,1W
AC SW
H
B
BLOWER
ON
OFF
BEACON
BCN PWR
BCN LT
WORK LT
S/W LT PWR
HEATER GND
HTR CNTRL A
HEATER PWR
AC CLUTCH
FAN SW C
(RED)
(RED/WHITE)
HEATER PWR
9-8
P
WIPER
H
LW
WIPER HI
WIPER LO
(BLACK)
A/C SWITCH
WIPER PARK
WASHER
9.5.2
Electrical System
Options Schematic
MAL0171B
TL1055, TL1255
WIPER PWR
CAB LT PWR
CAB LTS
87a
30
CB4
BLACK-6
IGNITION-2
1
2
1
2
ACCY-1
GRAY-5
A B
STR AW
STR/SWAY GND
F1 15
F6 10
F5 15
F2
GRAY-2
H G F E D C B A
A
B
C
D
E
F
G
H
A
B
C
D
E
F
G
H
(-)
A B C D
A B
SP CAB GND 1
SP CAB GND 2
SP GND 1
SP GND 2
AUX ELEC GND
LT GND
STR/SWAY GND
FUL/STAB GND
DASH GND
ALT EXC
SP ACCY PWR
AUX RLYS PWR
OPT GND 1
KEY ACC
TRAN/BRK PWR
OPT GND 2
POWER DIST
VEC
STR CRB
STR/SWAY GND
BLACK-1
H G F E D C B A
87a
30
IGNITION-1
87
ACCY-2
ALL WHEEL
STEER
MODE
VALVE
CRAB
OPTIONS POWER 3
OPTIONS POWER 4
OPTIONS POWER 1
OPTIONS POWER 2
TRANS/PARK BRK PWR
ALTERNATOR EXCITE
ENGINE ECU IGN PWR
GAGE (INST PANEL) PWR
SPARE ACCESSORY PWR
AUX ELECTRIC PWR
HORN PWR
SPARE BATTERY PWR
ENGINE ECU BAT PWR
STEER/SWAY PWR
R. AXLE STAB/TILT PWR
KEY BATTERY PWR
86
86
BAT GND
20A
20A
20A
20A
15A
5A
10A
10A
15A
10A
15A
25A
25A
10A
10A
15A
85
85
87a
30
WORK LT
LT GND
GRN
RED
BLK
REVERSE
STOP LT
WORK LT
LT GND
FUSE/BREAKER LEGEND
F7
CB1
CB2
CB3
CB4
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F8
25
87
87
85
85
86
86
BAT POS
CB1
BAT GND
F3
10
87a
30
F9
F4
20
10
87
20
CB3
25
BAT POS
CB2
20
F11
10
SHIFTER GND
OPT PWR 2
KEY IGN
SP BAT PWR
ECU IGN/012
OPT PWR 1
GAGE PWR
ECU BAT/022
20
15
F12
15
F10
10
ENG GND
OPT PWR 3
HORN PWR
STEER/SWAY PWR
OPT PWR 4
STAB/TILT PWR
KEY BAT PWR
ECU GND/050
GREEN-4
BLUE-3
REVERSE
LT GND
POWER DISTRIBUTION
CABLE
A B C D
SWAY PROXIMITY
SWITCH
BLU
TO SHIFTER HARNESS
HD36-24-31ST
CHASSIS HARNESS
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
SV2
6A
SV4
1 2
1 2
SV5
SWAY PILOT
VALVE
SV1
1 2
LT
1 2
SWAY LT
STR/SWAY GND
SWAY LOCK
STR/SWAY GND
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
WHT
SWAY LOCK
STR/SWAY GND
TAIL
BLK
6A
RT
SV3
1 2
SWAY RT
STR/SWAY GND
STOP
RED
SWAY LOCK
STR/SWAY GND
BU
STEER/SWAY PWR
STEER/SWAY PWR
SWAY ENABLE
STR/SWAY GND
ORG
HORN
TO CAB ASSEMBLY
HORN
CAB SIDE
(+)15 DEG
LAT TILT
SWITCH
1 2 3 4
1 2 3 4
ENGINE SIDE
(-)15 DEG
LAT TILT
SWITCH
TO OPTIONS HARNESS
HD34-24-19SE
CHASSIS HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
SWAY ENABLE
MINUS 15
PLUG
STR/SWAY GND
RED
YELLOW
GREEN
BLACK
SWAY ENABLE
PLUG
PLUS 15
STR/SWAY GND
RED
YELLOW
GREEN
BLACK
KEY ACC
AUX RLYS PWR
STOP LT
WORK LT
PLUGGED
PLUGGED
QC PWR
OPT PWR 1
QC PWR
OPT PWR 2
QC GND
OPT PWR 3
QC GND
OPT PWR 4
PLUGGED
OPT GND 1
PLUGGED
REVERSE
ALARM
A B
12 TURNS
PER FOOT
TWIST
STABILIZER
VALVE
A B
STAB VLV
FUL/STAB GND
(OPT)
TAIL LIGHT
4
85
A B C D
A/C
COMPRESSOR
(OPT)
STABILIZER PROXIMITY
SWITCH
BLK
(OPT)
FRONT RIGHT
WORKLIGHT
1
86
BLU
A B A B
TILT-ON
JOYSTICK
VALVE
ROLLER TILT
ON JOYSTICK
AND INSTALL
"EMPTY" PLUG
REMOVE DIODES
FOR OPTIONAL
A B C D E F
CABLE
A B
FUEL
SNDR
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
A B C D E F
ECU IGN/012
ECU BAT/022
ECU GND/050
ENG GND
PLUGGED
PK BRK SOL
ENG WARN LT
ENG STOP LT
ALT EXC
THR SUP/911
THR SGN/915
THR RTN/914
ST RLY
PLUGGED
PLUGGED
PLUGGED
TRANS TMP SW
IVS
TRANS SOL Y1
WAIT TO START LT
TRANS SOL Y2
TRANS SOL Y3
PLUGGED
PLUGGED
TRANS SOL Y4
TRANS SOL Y5
CAN H
CAN L
SHIELD
TILT DN
FUL/STAB GND
TILT UP
FUL/STAB GND
3
87
RED
BLK
RED
YEL
BLU
ORG
PLUGGED
QC PWR 1
QC PWR 2
AUX ELEC GND
QC GND 5
QC GND 7
PLUGGED
5
86
STR/SWAY GND
MINUS 15
SWAY RT
STEER/SWAY PWR
2
85
30
87a
STR/SWAY GND
PLUS 15
SWAY LT
STEER/SWAY PWR
1
4
87
WHT
OPT GND 2
PLUGGED
STAB VLV
FUL/STAB GND
SP-3
SP-2
SP-1
SP BAT PWR
SP ACCY PWR
SP GND 1
SP GND 2
AC CLUTCH
STAB/TILT PWR
STAB/TILT PWR
STAB VLV
FUL/STAB GND
ORG
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
PLUGGED
KEY START
SHIFT PWR 1
PK BRK SOL
REVERSE
TRAN/BRK PWR
SHIFTER GND
THR SUP/911
THR SGN/915
THR RTN/914
SP BAT PWR
SP ACCY PWR
SP CAB GND 1
SP CAB GND 2
SP-1
SP-2
SP-3
TRANS TMP SW
AC CLUTCH
STAB/TILT PWR
TILT UP
TILT DN
SP BAT PWR
IVS
ENG GND
PLUGGED
3
30
87a
FUL LVL
FUL/STAB GND
CHASSIS HARNESS
HD34-24-29PE
12 VDC
BATTERY
NEGATIVE CABLE
FLAG TO
CHASSIS FRAME
NEGATIVE CABLE
TO ENG BLOCK
POSITIVE CABLE
TO STARTER
AND ALTERNATOR
QC DIVERTOR
VALVE
NEGATIVE CABLE
TO CAB FIREWALL
1
2
TL1055, TL1255
A S LT
RT TM
(OPT)
AUXILIARY
ELECTRIC
AUXILIARY
ELECTRIC
(OPT)
A B C D E F
BLK
RED
YEL
BLU
ORG
PLUGGED
9.5.3
MAST
SIDESHIFT
AUX ELEC GND
SWING
EXTRA
PLUGGED
Electrical System
Chassis/Boom Schematic
MAL0181B
9-9
87a
30
BLACK-6
IGNITION-2
1
2
1
2
ACCY-1
GRAY-5
A B
STR AW
STR/SWAY GND
F1 15
F6 10
F5 15
F2
GRAY-2
H G F E D C B A
A
B
C
D
E
F
G
H
A
B
C
D
E
F
G
H
(-)
A B C D
REVERSE
LT GND
SP CAB GND 1
SP CAB GND 2
SP GND 1
SP GND 2
AUX ELEC GND
LT GND
STR/SWAY GND
FUL/STAB GND
DASH GND
ALT EXC
SP ACCY PWR
AUX RLYS PWR
OPT GND 1
KEY ACC
TRAN/BRK PWR
OPT GND 2
POWER DIST
VEC
STR CRB
STR/SWAY GND
BLACK-1
H G F E D C B A
87a
30
IGNITION-1
87
ACCY-2
ALL WHEEL
STEER
MODE
VALVE
CRAB
86
86
BAT GND
OPTIONS POWER 3
OPTIONS POWER 4
OPTIONS POWER 1
OPTIONS POWER 2
TRANS/PARK BRK PWR
ALTERNATOR EXCITE
ENGINE ECU IGN PWR
GAGE (INST PANEL) PWR
SPARE ACCESSORY PWR
AUX ELECTRIC PWR
HORN PWR
SPARE BATTERY PWR
ENGINE ECU BAT PWR
STEER/SWAY PWR
R. AXLE STAB/TILT PWR
KEY BATTERY PWR
CB3
20A
20A
20A
20A
15A
5A
10A
10A
15A
10A
15A
25A
25A
10A
10A
15A
85
85
87
87
CB1
CB2
CB3
CB4
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F7
WORK LT
LT GND
FUSE/BREAKER LEGEND
F8
25
87
CB4
20
F10
BAT GND
F3
10
86
86
85
85
87a
30
F4
20
10
87a
30
F9
25
BAT POS
CB1
20
15
GREEN-4
BLUE-3
BAT POS
CB2
20
F11
10
SHIFTER GND
OPT PWR 2
KEY IGN
SP BAT PWR
ECU IGN/012
OPT PWR 1
GAGE PWR
ECU BAT/022
10
F12
ENG GND
OPT PWR 3
HORN PWR
STEER/SWAY PWR
OPT PWR 4
STAB/TILT PWR
KEY BAT PWR
ECU GND/050
15
GRN
RED
BLK
REVERSE
STOP LT
WORK LT
LT GND
A B
CABLE
A B C D
SWAY PROXIMITY
SWITCH
BLU
POWER DISTRIBUTION
WHT
TO SHIFTER HARNESS
HD36-24-31ST
CHASSIS HARNESS
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
SV2
6A
SV4
1 2
1 2
SV5
SWAY PILOT
VALVE
SV1
1 2
LT
1 2
SWAY LT
STR/SWAY GND
BLK
SWAY LOCK
STR/SWAY GND
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
SWAY LOCK
STR/SWAY GND
TAIL
RED
SWAY LOCK
STR/SWAY GND
STOP
STEER/SWAY PWR
STEER/SWAY PWR
SWAY ENABLE
STR/SWAY GND
ORG
6A
RT
SV3
1 2
SWAY RT
STR/SWAY GND
BU
TO OPTIONS HARNESS
HD34-24-19SE
CHASSIS HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
CAB SIDE
(+)15 DEG
LAT TILT
SWITCH
1 2 3 4
ENGINE SIDE
(-)15 DEG
LAT TILT
SWITCH
1 2 3 4
SWAY ENABLE
MINUS 15
PLUG
STR/SWAY GND
RED
YELLOW
GREEN
BLACK
HORN
TO CAB ASSEMBLY
SWAY ENABLE
PLUG
PLUS 15
STR/SWAY GND
HORN
A B
STABILIZER
VALVE
A B
12 TURNS PER
FOOT TWIST
STAB VLV
FUL/STAB GND
STAB VLV
FUL/STAB GND
REVERSE
ALARM
2
85
CABLE
A/C
COMPRESSOR
(OPT)
A B C D
STABILIZER PROXIMITY
SWITCH
BLK
(OPT)
TAIL LIGHT
5
86
BLU
A B A B
TILT-ON
JOYSTICK
VALVE
REMOVE DIODES
FOR OPTIONAL
ROLLER TILT
ON JOYSTICK
AND INSTALL
"EMPTY" PLUG
A B C D E F
A B
FUEL
SNDR
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
A B C D E F
ECU IGN/012
ECU BAT/022
ECU GND/050
ENG GND
PLUGGED
PK BRK SOL
ENG WARN LT
ENG STOP LT
ALT EXC
THR SUP/911
THR SGN/915
THR RTN/914
ST RLY
YEL (CAN H)
GRN (CAN L)
BRN/BLK (CAN SHIELD)
TRANS TMP SW
IVS
TRANS SOL Y1
WAIT TO START LT
TRANS SOL Y2
TRANS SOL Y3
PLUGGED
PLUGGED
TRANS SOL Y4
TRANS SOL Y5
PLUGGED
PLUGGED
PLUGGED
TILT DN
FUL/STAB GND
TILT UP
FUL/STAB GND
(OPT)
FRONT RIGHT
WORKLIGHT
4
87
RED
BLK
RED
YEL
BLU
ORG
PLUGGED
QC PWR 1
QC PWR 2
AUX ELEC GND
QC GND 5
QC GND 7
PLUGGED
2
85
STR/SWAY GND
MINUS 15
SWAY RT
STEER/SWAY PWR
5
86
30
87a
STR/SWAY GND
PLUS 15
SWAY LT
STEER/SWAY PWR
1
4
87
WHT
KEY ACC
AUX RLYS PWR
STOP LT
WORK LT
PLUGGED
PLUGGED
QC PWR
OPT PWR 1
QC PWR
OPT PWR 2
QC GND
OPT PWR 3
QC GND
OPT PWR 4
PLUGGED
OPT GND 1
PLUGGED
OPT GND 2
PLUGGED
RED
YELLOW
GREEN
BLACK
SP-3
SP-2
SP-1
SP BAT PWR
SP ACCY PWR
SP GND 1
SP GND 2
AC CLUTCH
STAB/TILT PWR
STAB/TILT PWR
STAB VLV
FUL/STAB GND
ORG
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
PLUGGED
KEY START
SHIFT PWR 1
PK BRK SOL
REVERSE
TRAN/BRK PWR
SHIFTER GND
THR SUP/911
THR SGN/915
THR RTN/914
SP BAT PWR
SP ACCY PWR
SP CAB GND 1
SP CAB GND 2
SP-1
SP-2
SP-3
TRANS TMP SW
AC CLUTCH
STAB/TILT PWR
TILT UP
TILT DN
SP BAT PWR
IVS
ENG GND
PLUGGED
3
30
87a
FUL LVL
FUL/STAB GND
CHASSIS HARNESS
HD34-24-29PE
12 VDC
BATTERY
NEGATIVE CABLE
FLAG TO
CHASSIS FRAME
NEGATIVE CABLE
TO ENG BLOCK
POSITIVE CABLE
TO STARTER
AND ALTERNATOR
QC DIVERTOR
VALVE
NEGATIVE CABLE
TO CAB FIREWALL
1
2
A S LT
RT TM
(OPT)
AUXILIARY
ELECTRIC
AUXILIARY
ELECTRIC
(OPT)
A B C D E F
BLK
RED
YEL
BLU
ORG
PLUGGED
9-10
1
MAST
SIDESHIFT
AUX ELEC GND
SWING
EXTRA
PLUGGED
Electrical System
MAL0760C
TL1055, TL1255
87a
30
BLACK-6
IGNITION-2
1
2
1
2
ACCY-1
GRAY-5
A B
STR AW
STR/SWAY GND
F1 15
F6 10
F5 15
F2
GRAY-2
H G F E D C B A
A
B
C
D
E
F
G
H
A
B
C
D
E
F
G
H
(-)
A B C D
A B
SP CAB GND 1
SP CAB GND 2
SP GND 1
SP GND 2
AUX ELEC GND
LT GND
STR/SWAY GND
FUL/STAB GND
DASH GND
ALT EXC
SP ACCY PWR
AUX RLYS PWR
OPT GND 1
KEY ACC
TRAN/BRK PWR
OPT GND 2
POWER DIST
VEC
STR CRB
STR/SWAY GND
BLACK-1
H G F E D C B A
87a
30
IGNITION-1
87
ACCY-2
ALL WHEEL
STEER
MODE
VALVE
CRAB
86
86
BAT GND
OPTIONS POWER 3
OPTIONS POWER 4
OPTIONS POWER 1
OPTIONS POWER 2
TRANS/PARK BRK PWR
ALTERNATOR EXCITE
ENGINE ECU IGN PWR
GAGE (INST PANEL) PWR
SPARE ACCESSORY PWR
AUX ELECTRIC PWR
HORN PWR
SPARE BATTERY PWR
ENGINE ECU BAT PWR
STEER/SWAY PWR
R. AXLE STAB/TILT PWR
KEY BATTERY PWR
CB3
20A
20A
20A
20A
15A
5A
10A
10A
15A
10A
15A
25A
25A
10A
10A
15A
FUSE/BREAKER LEGEND
85
85
87
87
CB1
CB2
CB3
CB4
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
POWER DISTRIBUTION
F7
GRN
RED
BLK
REVERSE
STOP LT
WORK LT
LT GND
F8
25
87
CB4
20
F10
BAT GND
F3
10
86
86
85
85
87a
30
F4
20
10
87a
30
F9
25
GREEN-4
BLUE-3
BAT POS
CB1
20
15
WORK LT
LT GND
SHIFTER GND
OPT PWR 2
KEY IGN
SP BAT PWR
ECU IGN/012
OPT PWR 1
GAGE PWR
ECU BAT/022
10
F12
15
BAT POS
CB2
20
F11
10
ENG GND
OPT PWR 3
HORN PWR
STEER/SWAY PWR
OPT PWR 4
STAB/TILT PWR
KEY BAT PWR
ECU GND/050
REVERSE
LT GND
HORN
CABLE
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
A B C 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
TO SHIFTER HARNESS
HD36-24-31ST
CHASSIS HARNESS
TO CAB ASSEMBLY
1 2
1 2
6A
1 2
SWAY LOCK
STR/SWAY GND
SWAY LT
STR/SWAY GND
HORN
SWAY LOCK
STR/SWAY GND
REVERSE
ALARM
1 2
SWAY LOCK
STR/SWAY GND
TAIL
6A
1 2
SWAY RT
STR/SWAY GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
TO OPTIONS HARNESS
HD34-24-19SE
CHASSIS HARNESS
1 2 3 4
1 2 3 4
SWAY ENABLE
MINUS 15
PLUG
STR/SWAY GND
STOP
12 TURNS PER
FOOT TWIST
A B
STABILIZER
VALVE
A B
STAB VLV
FUL/STAB GND
(OPT)
TAIL LIGHT
STAB VLV
FUL/STAB GND
BU
2
85
CABLE
A/C
COMPRESSOR
(OPT)
A B C D
STABILIZER PROXIMITY
SWITCH
BLK
(OPT)
FRONT RIGHT
WORKLIGHT
5
86
BLU
A B A B
TILT-ON
JOYSTICK
VALVE
REMOVE DIODES
FOR OPTIONAL
ROLLER TILT
ON JOYSTICK
AND INSTALL
"EMPTY" PLUG
A B C D E F
A B
FUEL
SNDR
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
A B C D E F
ECU IGN/012
ECU BAT/022
ECU GND/050
ENG GND
PLUGGED
PK BRK SOL
ENG WARN LT
ENG STOP LT
ALT EXC
THR SUP/911
THR SGN/915
THR RTN/914
ST RLY
YEL (CAN H)
GRN (CAN L)
BRN/BLK (CAN SHIELD)
TRANS TMP SW
IVS
TRANS SOL Y1
WAIT TO START LT
TRANS SOL Y2
TRANS SOL Y3
PLUGGED
PLUGGED
TRANS SOL Y4
TRANS SOL Y5
PLUGGED
PLUGGED
PLUGGED
TILT DN
FUL/STAB GND
TILT UP
FUL/STAB GND
RED
BLK
RED
YEL
BLU
ORG
PLUGGED
QC PWR 1
QC PWR 2
AUX ELEC GND
QC GND 5
QC GND 7
PLUGGED
4
87
STR/SWAY GND
MINUS 15
SWAY RT
STEER/SWAY PWR
5
86
85
30
87a
STR/SWAY GND
PLUS 15
SWAY LT
STEER/SWAY PWR
4
87
WHT
KEY ACC
AUX RLYS PWR
STOP LT
WORK LT
PLUGGED
PLUGGED
QC PWR
OPT PWR 1
QC PWR
OPT PWR 2
QC GND
OPT PWR 3
QC GND
OPT PWR 4
PLUGGED
OPT GND 1
PLUGGED
OPT GND 2
PLUGGED
SWAY ENABLE
PLUG
PLUS 15
STR/SWAY GND
SP-3
SP-2
SP-1
SP BAT PWR
SP ACCY PWR
SP GND 1
SP GND 2
AC CLUTCH
STAB/TILT PWR
STAB/TILT PWR
STAB VLV
FUL/STAB GND
ORG
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
PLUGGED
KEY START
SHIFT PWR 1
PK BRK SOL
REVERSE
TRAN/BRK PWR
SHIFTER GND
THR SUP/911
THR SGN/915
THR RTN/914
SP BAT PWR
SP ACCY PWR
SP CAB GND 1
SP CAB GND 2
SP-1
SP-2
SP-3
TRANS TMP SW
AC CLUTCH
STAB/TILT PWR
TILT UP
TILT DN
SP BAT PWR
IVS
ENG GND
PLUGGED
3
30
87a
FUL LVL
FUL/STAB GND
CHASSIS HARNESS
HD34-24-29PE
12 VDC
BATTERY
NEGATIVE CABLE
FLAG TO
CHASSIS FRAME
NEGATIVE CABLE
TO ENG BLOCK
POSITIVE CABLE
TO STARTER
AND ALTERNATOR
QC DIVERTOR
VALVE
NEGATIVE CABLE
TO CAB FIREWALL
1
2
A S LT
RT TM
(OPT)
AUXILIARY
ELECTRIC
AUXILIARY
ELECTRIC
(OPT)
A B C D E F
BLK
RED
YEL
BLU
ORG
PLUGGED
TL1055, TL1255
1
MAST
SIDESHIFT
AUX ELEC GND
SWING
EXTRA
PLUGGED
Electrical System
MAL0780F
9-11
12 VDC
BATTERY
NEGATIVE CABLE
FLAG TO
CHASSIS FRAME
NEGATIVE CABLE
TO ENG BLOCK
POSITIVE CABLE
TO STARTER
NEGATIVE CABLE
TO CAB FIREWALL
125
HORN PWR
10A
10A
15A
10A
15A
25A
25A
F3
F5
F6
F7
F8
F9
F10
20A
F16
ACCY-2
IGNITION-1
BLACK-6
IGNITION-2
OPTIONS POWER 2
OPTIONS POWER 1
OPTIONS POWER 4
OPTIONS POWER 3
ALL WHEEL
STEER
MODE
VALVE
CRAB
20A
20A
15A
F15
10A
F12
BAT GND
F14
STEER/SWAY PWR
10A
20A
F11
F13
ALTERNATOR EXCITE
F4
5A
ACCY-1
87
BLACK-1
H G F E D C B A
87
87
87
86
86
87a
30
87a
30
F13
20
85
STR AW
STR/SWAY GND
F1
F6
F5
F2
GRAY-5
A B
15
10
15
(-)
A B C D
POWER DIST
VEC
STR CRB
STR/SWAY GND
GRAY-2
H G F E D C B
85
BAT GND
F14
20
86
86
F8
87a
30
F4
POWER DISTRIBUTION
15A
F15
20
85
85
F3
10
25
BAT POS
F7
15
WORK LT
LT GND
GRN
RED
BLK
SP CAB GND 1
SP CAB GND 2
SP GND 1
SP GND 2
AUX ELEC GND
LT GND
STR/SWAY GND
FUL/STAB GND
DASH GND
ALT EXC
SP ACCY PWR
AUX RLYS PWR
OPT GND 1
KEY ACC
TRAN/BRK PWR
OPT GND 2
REVERSE
STOP LT
WORK LT
LT GND
A B
1 2 3 4
6 7
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
CABLE
A B C D
2 3
4 5 6
1 2
SWAY LT
STR/SWAY GND
FUSE/BREAKER LEGEND
F10
10
F2
F16
20
F1
F11
10
87a
30
F9
25
10
SHIFTER GND
OPT PWR 2
KEY IGN
SP BAT PWR
ECU IGN/012
OPT PWR 1
GAGE PWR
ECU BAT/022
BAT POS
F12
15
ENG GND
OPT PWR 3
HORN PWR
STEER/SWAY PWR
OPT PWR 4
STAB/TILT PWR
KEY BAT PWR
ECU GND/050
GREEN-4
BLUE-3
TAIL
TO SHIFTER HARNESS
HD36-24-31ST
CHASSIS HARNESS
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
SWAY LOCK
STR/SWAY GND
STOP
6A
SWAY LOCK
STR/SWAY GND
BU
6A
SWAY RT
STR/SWAY GND
REVERSE
LT GND
TO CAB ASSEMBLY
SWAY LOCK
STR/SWAY GND
HORN
87a 3
HORN
TAIL LIGHT
87a 3
FRONT RIGHT
WORKLIGHT
SWAY ENABLE
MINUS 15
PLUG
STR/SWAY GND
10 11 12 13 14 15 16 17 18 19
TO OPTIONS HARNESS
HD34-24-19SE
CHASSIS HARNESS
SWAY ENABLE
PLUG
PLUS 15
STR/SWAY GND
STABILIZER
VALVE
A B
A B
12 TURNS PER
FOOT TWIST
STAB VLV
FUL/STAB GND
KEY ACC
AUX RLYS PWR
STOP LT
WORK LT
PLUGGED
PLUGGED
QC PWR
OPT PWR 1
QC PWR
OPT PWR 2
QC GND
OPT PWR 3
QC GND
OPT PWR 4
PLUGGED
OPT GND 1
PLUGGED
OPT GND 2
PLUGGED
STAB VLV
FUL/STAB GND
CABLE
A/C
COMPRESSOR
(OPT)
A B C D
STABILIZER PROXIMITY
SWITCH
TILT-ON
A B
VALVE
JOYSTICK
TILT DN
FUL/STAB GND
TILT UP
FUL/STAB GND
REVERSE
ALARM
85 2
BLU
A B C D E F
B C
ECU IGN/012
ECU BAT/022
ECU GND/050
ENG GND
PLUGGED
PK BRK SOL
ENG WARN LT
ENG STOP LT
ALT EXC
THR SUP/911
THR SGN/915
THR SUP/914
ST RLY
YEL (CAN H)
GRN (CAN L)
BRN/BLK (CAN SHIELD)
TRANS TMP SW
IVS
TRANS SOL Y1
WAIT TO START LT
TRANS SOL Y2
TRANS SOL Y3
ON-IDLE
IVR
TRANS SOL Y4
TRANS SOL Y5
PLUGGED
TRANS SOL Y6
PLUGGED
REMOVE DIODES
FOR OPTIONAL
ROLLER TILT
ON JOYSTICK
AND INSTALL
"EMPTY" PLUG
BLK
RED
YEL
BLU
ORG
PLUGGED
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
QC PWR 1
QC PWR 2
AUX ELEC GND
QC GND 5
QC GND 7
PLUGGED
(OPT)
85 2
BLK
FUEL
SNDR
FUL LVL
FUL/STAB GND
CHASSIS HARNESS
HD34-24-29PE
(OPT)
86 5
RED
87 4
TO OPTIONS HARNESS
86 5
STR/SWAY GND
MINUS 15
SWAY RT
STEER/SWAY PWR
30 1
WHT
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
TRANS SOL Y6
KEY START
SHIFT PWR 1
PK BRK SOL
REVERSE
TRAN/BRK PWR
SHIFTER GND
THR SUP/911
THR SGN/915
THR RTN/914
SP BAT PWR
SP ACCY PWR
SP CAB GND 1
SP CAB GND 2
SP-1
SP-2
SP-3
TRANS TMP SW
AC CLUTCH
STAB/TILT PWR
TILT UP
TILT DN
SP BAT PWR
IVS
ON-IDLE
IVR
87 4
STR/SWAY GND
PLUS 15
SWAY LT
STEER/SWAY PWR
30 1
SP-3
SP-2
SP-1
SP BAT PWR
SP ACCY PWR
SP GND 1
SP GND 2
AC CLUTCH
STAB/TILT PWR
STAB/TILT PWR
STAB VLV
FUL/STAB GND
ORG
OC DIVERTOR
VALVE
S LT
RT TM
AUXILIARY
ELECTRIC
(OPT)
(OPT)
AUXILIARY
ELECTRIC
A B C D E
BLK
RED
YEL
BLU
ORG
PLUGGED
MAST
SIDESHIFT
AUX ELEC GND
SWING
EXTRA
PLUGGED
TO POWER UNIT ASSEMBLY
9-12
+
Electrical System
MAL1371B
TL1055, TL1255
TO CHASSIS ASSEMBLY
HD36-24-29SE
POWER UNIT HARNESS
120 OHM
CAN TERMINATOR
A
B
C
6A/400V
(CAN H/904)
(CAN L/905)
(SHIELD/020)
ECU IGN/012
ECU BAT/022
ECU GND/050
ENG GND
PLUGGED
PK BRK SOL
ENG WARN LT
ENG STOP LT
ALT EXC
THR SUP/911
THR SGN/915
THR RTN/914
ST RLY
PLUGGED
PLUGGED
PLUGGED
TRANS TMP SW
IVS
TRANS SOL Y1
WAIT TO START
TRANS SOL Y2
TRANS SOL Y3
PLUGGED
PLUGGED
TRANS SOL Y4
TRANS SOL Y5
CAN H/904
CAN L/905
SHIELD/020
SHIELDED
CABLE
64 PIN
CAT ECM
TL1055/TL1255
POWER UNIT
Y1
Y3
Y4
A B
A B
Y5
A B
Y6
A B
PK BRK SOL
ENG GND
TRANSMISSION
Y2
A B
N3
N4
A B
N2
Y2, Y6
Y6 (ONLY IF PARK BRAKE OFF)
Y2, Y3, Y6
R3
R4
N1
R2
Y1, Y6
Y1, Y3, Y6
R1
F4
F3
F1
TRANSMISSION LEGEND
F2
GEAR
TRANS SOL Y1
ENG GND
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
TRANS SOL Y3
ENG GND
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
AMB SNR PWR +5V
AMB SNR SIG
ECU GND/050
ECU BAT/022
1
2
3
7
8
9
10
15
16
20
21
22
33
40
41
45
54
57
59
60
63
42
56
TRANS SOL Y2
ENG GND
TL1055, TL1255
TRANS SOL Y5
ENG GND
TRANS TMP SW
ENG GND
250 F
A B
50
F5
PK BRK SOL
ENG GND
ALT EXC A
B+
85
87
ECU IGN/012
COLD START AID
GLOW PLUG PWR
86
30
RELAY
PARK
BRAKE
VALVE
D+
TO GLOW PLUGS
STARTER
ALTERNATOR
6A/400V
1
2
ALT PWR
ST RLY PWR
(3/0 AWG, RED)
(4 AWG, RED)
STRT SOL
85
86
87
30
STARTER
RELAY
POSITIVE CABLE
TO BATTERY
ST RLY PWR
STRT SOL
ST RLY
ENG GND
NEGATIVE CABLE
TO BATTERY
2
1
9.5.4
TRANS SOL Y4
ENG GND
Electrical System
MAL0191B
9-13
TO CHASSIS ASSEMBLY
HD36-24-29SE
POWER UNIT HARNESS
120 OHM
CAN TERMINATOR
A
B
C
ECU IGN/012
ECU BAT/022
ECU GND/050
ENG GND
PLUGGED
PK BRK SOL
ENG WARN LT
ENG STOP LT
6A/400V
ALT EXC
THR SUP/911
THR SGN/915
THR RTN/914
ST RLY
YEL (CAN H/904)
GRN (CAN L/905)
BRN/BLK (CAN SHIELD/020)
TRANS TMP SW
IVS
TRANS SOL Y1
WAIT TO START
TRANS SOL Y2
TRANS SOL Y3
PLUGGED
PLUGGED
TRANS SOL Y4
TRANS SOL Y5
PLUGGED
PLUGGED
PLUGGED
SHIELDED
CABLE
SHIELDED
CABLE
64 PIN
CAT ECM
TL1055/TL1255
POWER UNIT
Y1
Y3
Y4
A B
A B
Y5
A B
Y6
A B
PK BRK SOL
ENG GND
TRANSMISSION
Y2
A B
N3
N4
A B
N2
Y2, Y6
R4
Y6 (ONLY IF PARK BRAKE OFF)
Y2, Y3, Y6
R3
N1
Y1, Y6
R1
Y1, Y3, Y6
F3
F4
R2
F2
TRANSMISSION LEGEND
F1
GEAR
TRANS SOL Y1
ENG GND
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
TRANS SOL Y3
ENG GND
TRANS SOL Y2
ENG GND
ECU GND/050
ECU BAT/022
1
2
3
7
8
9
10
15
16
20
21
22
33
40
41
45
54
57
59
60
63
42
56
TRANS SOL Y5
ENG GND
9-14
TRANS SOL Y4
ENG GND
TRANS TMP SW
ENG GND
250 F
A B
50
F5
PK BRK SOL
ENG GND
ALT EXC A
85
B+
85
87
ECU IGN/012
COLD START AID
GLOW PLUG PWR
86
30
RELAY
PARK
BRAKE
VALVE
D+
TO GLOW PLUGS
STARTER
ALTERNATOR
6A/400V
1
2
ALT PWR
ST RLY PWR
(3/0 AWG, RED)
(4 AWG, RED)
STRT SOL
87
86
30
STARTER
RELAY
POSITIVE CABLE
TO BATTERY
ST RLY PWR
STRT SOL
ST RLY
ENG GND
NEGATIVE CABLE
TO BATTERY
2
1
Electrical System
MAL0770C
TL1055, TL1255
EXTRA BATTERY
A
B
C
D
E
F
G
H
J
1
2
MAIN BATTERY
VEH GND
TO VEH GND
CABLE
NEG BTTY
1
STRT GND
TO STRT GND, F7
NO SOLENOIDS INGAUGED
Y6
Y5
Y4
Y3
Y2
Y1
E6
E5
E4
E3
E2
E1
1
ENG GND
STRT PWR
TO STRT PWR, F7
E4, E3
E4, E2
R2
R3
E5, E3
E6, E3
E4, E1
F3
F4
R1
E5, E2
E5, E1
F2
F1
GEAR
TRANSMISSION LEGEND
TURNER
N3
N4
Y2,Y6
N2
Y2,Y3,Y6
N1
Y2,Y3,Y5,Y6
R4
R2
R3
Y2,Y3,Y4,Y6
R1
Y1,Y3,Y6
F3
Y1,Y6
Y1,Y3,Y5,Y6
F2
F4
Y1,Y3,Y4,Y6
F1
TO STRT GND, F7
BATTERY CABLES
TO VEH GND
VEH GND
18
45
21
20
23
24
101 RD
229 BK
944 OR
945 BR
Y793 YL
Y792 PK
BAT+ (FOR COMMS ADAPTER)
BAT- (FOR COMMS ADAPTER)
CDL+
CDLJ1939J1939+
19 WASTEGATE RETURN
17 WASTEGATE PWM SIGNAL
P920 BR
C211 BK
M795 WH
996 GN
E965 BU
42 IMT SIGNAL
37 TEMPERATURE SENSOR RETURN
Y950 YL
Y951 PU
R997 OR
Y948 BR
Y946 BU
955 BU
L730 OR
Y947 BR
994 GY
C967 BU
L731 BR
T997 OR
T993 BR
X731 BU
EXTERNAL
X926 GY
X920 BR
3
4
X927 YL
X921 PK
1
2
250 F
1
2
1
2
1
2
1
2
1
2
1
2
3
1
2
3
1
2
3
INTERNAL
(ROCKER
COVER)
T957 BK
T951 BK
T958 BK
T952 BK
GEAR
TRANS SOL Y5
ENG GND
ENG GND
TRANS SOL E2
ENG GND
TRANS SOL E3
ENG GND
TRANS SOL E4
ENG GND
TRANS SOL E5
ENG GND
TRANS TMP SW
ENG GND
TRANS SOL Y4
ENG GND
ENG GND
TRANS SOL Y3
ENG GND
TRANS SOL Y2
ENG GND
POWER UNIT
TRANS SOL E6
ENG GND
TRANS TMP SW
1
3
ENG
BLOCK
120 OHM
CAN TERMINATOR
12
11
10
A
B
C
(CAN H/904)
(CAN L/905)
(SHIELD/020)
SHIELDED
CABLE
10
11
HD36-24-29SE
POWER UNIT HARNESS
TO CHASSIS ASSEMBLY
12
TRANSMISSION LEGEND
TURNER TRANSMISSION
DIAGNOSTIC
CONNECTOR (9 PIN)
ELECTRONIC
WASTEGATE
ACTUATOR
FUEL PUMP
SOLENOID
PUMP/CAM SPEED
SENSOR
CRANKSHAFT SPEED/
TIMING SENSOR
INTAKE MANIFOLD
TEMP SENSOR
COOLANT TEMP
SENSOR
FUEL MANIFOLD
PRESSURE SENSOR
OIL PRESSURE
SENSOR
INTAKE MANIFOLD
PRESSURE SENSOR
INJECTOR CYLINDER 1
INJECTOR CYLINDER 2
34
58
X929 BU
X923 OR
X928 GN
X922 WH
3
4
15
14
1
2
4
3
T959 BK
T953 BK
20
6A/400V
THR SUP/911
THR SGN/915
RTN
INJECTOR CYLINDER 3
B- TERM
B+ TERM
18
T960 BK
T954 BK
B+ TERM
16
CAN H/904
CAN L/905
SHIELD/020
1
MAIN B-
B- TERM
1
MAIN B+
17
IVS
INJECTOR CYLINDER 4
23
22
ENGINE ECM
ON-IDLE
ECU IGN/012
40
29
28
27
26
25
64 PIN
ALT EXC A
D+
B+
ALTERNATOR
ALT PWR
1 2
PARK
BRAKE
VALVE
F5
60
30
150
87
ECM PWR
STRT SOL
STARTER
AMBIENT TEMPERATURE
SENSOR
(4 AWG, RED)
80
85
30
RELAY
86
ST RLY
ENG GND
3
2
ECU GND/050
1
ECU BAT/022
8
15
16
PK BRK SOL
ENG GND
ENG WARN LT
ENT STOP LT
9
10
ST RLY PWR
STRT SOL
ST RLY PWR
19
WAIT TO START LT
NEGATIVE CABLE
TO BATTERY
(2/0 AWG, BLACK)
24
21
ECU IGN/012
PLUGGED
PLUGGED
ENG GND
PLUGGED
PK BRK SOL
ENG WARN LT
ENG STOP LT
ALT EXC
THR SUP/911
THR SGN/915
THR RTN/914
ST RLY
CAN H/904
CAN L/905
SHIELD/020
TRANS TMP SW
IVS
TRANS SOL Y1
WAIT TO START
REVERSE SOL
TRANS SOL Y3
ON-IDLE
PLUGGED
TRANS SOL
TRANS SOL Y5
PLUGGED
TRANS SOL Y6
PLUGGED
59
60
A B
41
54
33
20
21
250 F
22
ZF TRANSMISSION
A B
45
A B
63
A B
35
57
30
87
42
A B
TL1055, TL1255
A B
85
POSITIVE CABLE
TO BATTERY
86
TO GLOW PLUGS
Electrical System
MAL1361B
9-15
Electrical System
9.6
CIRCUIT BREAKDOWNS
9.6.1
BAT POS
BAT POS
85
ST RLY PWR
(3/0 AWG, RED)
(4 AWG, RED)
(4 AWG, RED)
ALT EXC A
6A/400V
TO SHIFTER HARNESS
SP BAT PWR
TRAN/BRK PWR
B+
D+
6A/400V
REVERSE RELAY
85
ST RLY
ALTERNATOR
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
TRAN/BRK PWR
OPT PWR 1
KEY/IGN
STRT SOL
SP BAT PWR
TRAN/BRK PWR
ST RLY
HORN PWR
HORN PWR
KEY ACC
OPT PWR 4
OPT PWR 3
OPT PWR 4
OPT PWR 3
OPT PWR 2
OPT PWR 2
OPT PWR 1
KEY ACC
OPT PWR 4
OPT PWR 3
OPT PWR 2
OPT PWR 1
KEY ACC
KEY ACC
KEY ACC
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
A B C D E F G H
BLACK-1
GRAY-2
86
SP BAT PWR
GRAY-2
H G F E D C B A
87
SP BAT PWR
ST RLY
30
SP BAT PWR
A
B
C
D
E
F
G
H
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
SP BAT PWR
TRAN/BRK PWR
ST RLY PWR
STRT SOL
ST RLY
TRAN/BRK PWR
KEY ACC
ECU BAT/022
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
SP BAT PWR
TO OPTIONS HARNESS
POSITIVE CABLE
TO BATTERY
ALT EXC
86
BLUE-3
F12
CB2
20
15
F7
20
15
CB1
85
86
87
87a
30
CB3
F9
10
20
F8
25
BLACK-1
H G F E D C B A
A
B
C
D
E
F
G
H
GREEN-4
85
86
87
87a
30
86
85
87
87a
30
20
NEGATIVE CABLE
FLAG TO
ACCY-1
85
CB4
POSITIVE CABLE
TO STARTER
AND ALTERNATOR
NEGATIVE CABLE
TO ENG BLOCK
86
IGNITION-1
87
12 VDC
BATTERY
F1 15
87a
30
IGNITION-2
87
F2
ACCY-2
C
GRAY-5
87a
30
BLACK-6
TO ENGINE ECU
POWER DIST
VEC
ECU BAT/022
NEGATIVE CABLE
TO CAB FIREWALL
NEGATIVE CABLE
TO BATTERY
SHIFTER HARNESS
LIGHTS
OFF
2
3
PARK BRAKE
OFF
7
1
87
86
85
87a
30
87a
30
87
86
85
ON
ST RLY
87a
30
86
87
85
87a
30
87
85
86
BCN/FAN
HORN
TRAN/BRK PWR
OPTION (15A)
HORN PWR
87a
30
87
86
85
87a
30
87
86
85
OPTION (25A)
GREEN-4
H
G
F
E
D
C
B
A
BLUE-3
H
G
F
E
D
C
B
A
6
ON
WIPER
HEATER/BLOWER
OPTIONS VEC
LEFT DASH PANEL
OPTIONS HARNESS
9-16
MY1100
TL1055, TL1255
Electrical System
TL1055 S/N TBM01316 & After including TBM01298
TL1255 S/N TBN00799 & After including TBN00785
POWER DIST
VEC
ALTERNATOR
ALT EXC A
TO SHIFTER HARNESS
B+
D+
SP BAT PWR
(4 AWG, RED)
6A/400V
SP BAT PWR
TRAN/BRK 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
85
REVERSE RELAY
TRAN/BRK PWR
A B C D E F G H
BLACK-1
30
150
SP BAT PWR
TRAN/BRK PWR
ST RLY
ST RLY
HORN PWR
KEY ACC
KEY/IGN
B
GRAY-2
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 4
OPT PWR 3
KEY ACC
OPT PWR 4
OPT PWR 3
OPT PWR 2
OPT PWR 2
OPT PWR 1
KEY ACC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
HORN PWR
TO OPTIONS HARNESS
KEY ACC
OPT PWR 4
OPT PWR 3
OPT PWR 2
OPT PWR 1
KEY ACC
ECU BAT/022
SP BAT PWR
SP BAT PWR
SO
SP BAT PWR
ST
RT
SP BAT PWR
80
TRAN/BRK PWR
STARTER
GLOW PLUG
RELAY
60
86
BLUE-3
F12
F16
E
G
15
20
F7
15
20
GRAY-2
H G F E D C B
ST RLY
87
85
86
87a
30
BLACK-1
H G F E D C B A
F15
F9
F14
25
20
F8
25
20
F13
STARTER
RELAY
A
B
87
GREEN-4
87
85
86
87a
30
85
87
87a
30
86
86
87
TRAN/BRK PWR
30
85
F
G
H
ST RLY 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
87
87a
30
KEY ACC
30
15
ACCY-1
85
F1
IGNITION-1
ALT EXC
B
D
86
NEGATIVE CABLE
TO ENG BLOCK
NEGATIVE CABLE
FLAG TO
CHASSIS FRAME
87
IGNITION-2
F2
ACCY-2
STRT SOL
ST RLY
85
POSITIVE CABLE
TO STARTER
86
12 VDC
BATTERY
C
GRAY-5
87a
30
BLACK-6
POSITIVE CABLE
TO BATTERY
NEGATIVE CABLE
TO BATTERY
ECU BAT/022
BAT POS
BAT POS
125
NEGATIVE CABLE
TO CAB FIREWALL
SHIFTER HARNESS
LIGHTS
OFF
2
3
PARK BRAKE
OFF
7
1
87
86
85
87a
30
87
87a
30
86
85
ON
ST RLY
87a
30
87
86
85
87
87a
30
86
85
BCN/FAN
HORN
TRAN/BRK PWR
OPTION (15A)
HORN PWR
87a
30
87
86
85
87
87a
30
86
85
OPTION (25A)
GREEN-4
H
G
F
E
D
C
B
A
BLUE-3
H
G
F
E
D
C
B
A
6
ON
WIPER
HEATER/BLOWER
OPTIONS VEC
LEFT DASH PANEL
OPTIONS HARNESS
TL1055, TL1255
MY6021B
9-17
Electrical System
9.6.2
BAT POS
BAT POS
F2
GREEN-4
BLUE-3
F12
CB2
20
15
F7
CB1
85
TRAN/BRK PWR
A
B
C
D
E
F
G
H
ST RLY
ST RLY
KEY START
30
87
86
85
STRT SOL
ST RLY PWR
(3/0 AWG, RED)
(4 AWG, RED)
(4 AWG, RED)
ALT EXC A
6A/400V
ALTERNATOR
B+
D+
6A/400V
TO SHIFTER HARNESS
KEY START
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
TRAN/BRK PWR
ST RLY
KEY START
ST RLY PWR
STRT SOL
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
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
ALT EXC
86
87
A
B
C
D
E
F
G
H
POSITIVE CABLE
TO BATTERY
GRAY-2
H G F E D C B A
KEY IGN
BLACK-1
H G F E D C B A
20
15
CB3
20
10
F8
25
F9
87a
30
ACCY-1
85
CB4
NEGATIVE CABLE
FLAG TO
86
IGNITION-1
20
POSITIVE CABLE
TO STARTER
AND ALTERNATOR
NEGATIVE CABLE
TO ENG BLOCK
85
86
87
87a
30
86
85
87
12 VDC
BATTERY
IGNITION-2
F1 15
87a
30
87
87a
30
ACCY-2
POWER DIST
VEC
C
GRAY-5
TRAN/BRK PWR
BLACK-6
KEY START
NEGATIVE CABLE
TO BATTERY
TRAN/BRK PWR
NEGATIVE CABLE
TO CAB FIREWALL
TRAN/BRK PWR
REVERSE
RELAY
3
1
TRANSMISSION SHIFTER
HOBBS
SW1
KEY/IGN
F
N
87a
30
87
86
85
SW2
A
4
SW3
S
I
SW4
WARN LIGHT
TEST RELAY
3
1
87a
30
87
86
85
1 2 3 4 5 6 7 8
PARK BRAKE
OFF
7
1
ST RLY
TRAN/BRK PWR
KEY START
SHIFTER HARNESS
ON
9-18
MY1110
TL1055, TL1255
Electrical System
TL1055 S/N TBM01316 & After including TBM01298
TL1255 S/N TBN00799 & After including TBN00785
POWER DIST
VEC
C
GRAY-5
F2
GREEN-4
87
85
86
87a
30
85
87
87a
30
86
87
85
86
A
B
BLUE-3
F12
E
F
H
ST RLY
KEY START
TRAN/BRK PWR
F16
ST RLY
15
20
F7
15
20
GRAY-2
H G F E D C B
BLACK-1
H G F E D C B A
F15
F14
F9
25
20
F8
25
20
F13
80
ST
RT
SO
ECM PWR
30
150
ALTERNATOR
(4 AWG, RED)
B+
ALT EXC A
6A/400V
D+
TO SHIFTER HARNESS
KEY START
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
TRAN/BRK PWR
REVERSE
RELAY
1
87a
30
87
86
85
TRANSMISSION SHIFTER
SW1
F
N
KEY/IGN
SW2
STARTER
TRAN/BRK PWR
ST RLY
HORN PWR
STARTER
RELAY
GLOW PLUG
RELAY
60
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
87a
30
86
87
TRAN/BRK PWR
30
85
F
G
H
ST RLY 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
87
87a
30
30
15
ACCY-1
85
F1
IGNITION-1
ALT EXC
86
NEGATIVE CABLE
TO ENG BLOCK
NEGATIVE CABLE
FLAG TO
CHASSIS FRAME
IGNITION-2
87
ACCY-2
STRT SOL
ST RLY
85
POSITIVE CABLE
TO STARTER
86
12 VDC
BATTERY
TRAN/BRK PWR
BLACK-6
POSITIVE CABLE
TO BATTERY
NEGATIVE CABLE
TO BATTERY
KEY START
BAT POS
BAT POS
125
NEGATIVE CABLE
TO CAB FIREWALL
A
4
SW3
S
I
SW4
WARNING LIGHT
TEST RELAY
1 2 3 4 5 6 7 8
PARK BRAKE
87a
30
87
86
85
OFF
7
1
ST RLY
TRAN/BRK PWR
KEY START
6
ON
TL1055, TL1255
MY6031B
9-19
Electrical System
9.7
9.7.1
Starter
MAL0280
The starter (1) is located on the left side of the engine (the
right side of the machine).
a. Testing the Starter on the Engine
If the starter does not engage when the ignition key
switch is turned, check the following:
1. The main fuse may be blown, requiring replacement.
Check for the cause of the blown fuse.
2. There may be a defect in the ignition key switch,
ignition wiring or starter solenoid.
3. Check battery condition. Clean the battery posts and
the connectors at each end of the battery cables.
4. Check for broken wiring and damaged insulation on
the wiring. Replace all broken or damaged wiring.
5. Check all connections at the starter solenoid, key
switch and wiring harness plugs. Clean and tighten
all connections.
6. If the starter still does not operate after these checks
have been performed, check the starting circuit.
TL1055, TL1255
Electrical System
9.8
CHARGING CIRCUIT
MAL0270
9.8.1
Alternator
a. Alternator Removal
1. Open the engine cover. Allow the system fluids to
cool.
2. Properly disconnect the battery.
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
WINDSHIELD WIPER MOTOR
b. Disassembly
DO NOT disassemble the motor. The motor is not
serviceable. Replace motor if found to be defective.
a. Removal
Note: It may be necessary to remove several hydraulic
hoses from behind the dash in order to remove and
install the wiper motor housing. (Refer to Section 4.3.1,
Steering Column and Orbitrol Valve.)
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
9.9.1
3
MY0440
9-22
MY1220
TL1055, TL1255
Electrical System
a. Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Remove the nuts and the lock washers from the
washer mounting bolts.
6. Pull the washer reservoir out and away from the
mounting bracket.
7. Rotate the washer reservoir, label and remove the
cab harness connectors from the washer reservoir
connectors.
9.10
9.10.1
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
reservoir connectors.
3. Install the reservoir tank onto the mounting bracket.
4. Install the lock washers and nuts and secure.
5. Fill the washer fluid reservoir with washer fluid.
6. Properly connect the battery.
7. Turn the ignition key switch to the RUN position and
press the washer switch. Verify that fluid is sprayed
on the windshield.
MY1230
TL1055, TL1255
9-23
Electrical System
c. Installation and Testing
1. Check that the variable speed fan control is in the
OFF position.
9.11
9.11.1
9-24
MY1140
6. Remove the nut on the end of the park brake coil (6).
7. Remove the park brake coil.
8. Remove the park brake solenoid (7). (Remove only if
the electrical coil is found to not be faulty.)
b. Disassembly
DO NOT disassemble the solenoid. The solenoid is not
serviceable. Replace solenoid if found to be defective.
c. Park Brake Solenoid Valve Installation
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.
1. If necessary, install the park brake solenoid in its
original orientation.
2. Slide the park brake coil over the solenoid. Tighten
the nut to secure the solenoid. DO NOT overtighten.
3. Connect the wiring connector to the park brake coil
lead.
4. Properly connect the battery
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
TL1055, TL1255
Electrical System
9.11.2
9.11.3
9 (Y5)
9 (Y1)
MY4330
TL1055, TL1255
9-25
Electrical System
9.11.4
9.11.5
MY4260
9-26
MAL0320
TL1055, TL1255
Electrical System
b. Engine Oil Pressure Sender Inspection and
Replacement
Inspect the sender and the wiring harness connector
terminals for continuity. Replace a defective or faulty
sender with a new part.
c. Engine Oil Pressure Sender Installation and
Testing
1. Thread the engine oil pressure sender into the
engine block snugly, then connect the sender
connector to the wiring harness connector.
2. Properly connect the battery.
3. Check for proper oil level.
4. Start the engine, and observe the operator display
for warning indication. If the sender is not defective,
the problem could be elsewhere; possibly in a
shorted wire, improper-running engine, low oil,
obstructed or faulty oil pump, defective instrument
display.
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
9.11.6
9.11.7
7
MY4340
Inclinometer Switch
Electrical System
3. Open the engine cover. Allow the system fluids to
cool.
9.12
9.12.1
9
9
MY1311
MAL0140
10
11
MY4380
9-28
TL1055, TL1255
Electrical System
6. Remove the hex nut securing the ignition key switch
(2) to the dash.
9.13.1
BAT
ACC
DASH SWITCHES
ST
9.13
AC
C
IG
MY0830
TL1055, TL1255
9-29
Electrical System
9.13.2
Dash Switches
a. Switch Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
MAL1380
9-30
TL1055, TL1255
Electrical System
9.14
ENGINE DIAGNOSTIC
9.14.1
CDL
Code
Description
CatET J1939
Code
3rd Party
Device J1939
Code
Flash
Code
N/A
N/A
N/A
551
0001-02
J651-2
651-2
111
0001-05
J651-5
651-5
111
0001-06
J651-6
651-6
111
0001-07
J651-7
651-7
111
0002-02
J652-2
652-2
112
0002-05
J652-5
652-5
112
0002-06
J652-6
652-6
112
0002-07
J652-7
652-7
112
0003-02
J653-2
653-2
113
0003-05
J653-5
653-5
113
0003-06
J653-6
653-6
113
0003-07
J653-7
653-7
113
0004-02
J654-2
654-2
114
0004-05
J654-5
654-5
114
0004-06
J654-6
654-6
114
0004-07
J654-7
654-7
114
0005-02
J655-2
655-2
115
0005-05
J655-5
655-5
115
0005-06
J655-6
655-6
115
0005-07
J655-7
655-7
115
0006-02
J656-2
656-2
116
0006-05
J656-5
656-5
116
TL1055, TL1255
9-31
Electrical System
CDL
Code
Description
CatET J1939
Code
3rd Party
Device J1939
Code
Flash
Code
0006-06
J656-6
656-6
116
0006-07
J656-7
656-7
116
0041-03
J678-03
678-03
517
0041-04
J678-04
678-04
517
0091-02
J91-02
91-02
154
0091-03
J91-03
91-03
154
0091-04
J91-04
91-04
154
0091-08
J91-08
91-08
154
0100-03
J100-03
100-03
157
0100-04
J100-04
100-04
157
0100-10
J100-10
100-10
157
0110-03
J110-03
110-03
168
0110-04
J110-04
110-04
168
0168-00
J168-00
168-00
422
0168-01
J168-01
168-01
422
0168-02
J168-02
168-02
422
0172-03
J105-03
105-03
133
0172-04
J105-04
105-04
133
0190-08
J190-08
190-08
141
0247-09
514
0247-12
514
0253-02
J631-02
631-02
415
0261-11
J637-11
637-11
143
9-32
TL1055, TL1255
Electrical System
CDL
Code
Description
CatET J1939
Code
3rd Party
Device J1939
Code
Flash
Code
0262-03
J1079-03
1079-03
516
0262-04
J1079-04
1079-04
516
0268-02
J630-02
630-02
527
0342-08
J723-08
723-08
142
0526-05
J1188-05
1188-05
177
0526-06
J1188-06
1188-06
177
0526-07
J1188-07
1188-07
177
0774-02
J29-02
29-02
155
0774-03
J29-03
29-03
155
0774-04
J29-04
29-04
155
0774-08
J29-08
29-08
155
1639-09
J1196-09
1196-09
426
1743-02
J2882-02
2882-02
144
1779-05
J1347-05
1347-05
162
1779-06
J1347-06
1347-06
162
1785-03
J102-03
102-03
197
1785-04
J102-04
102-04
197
1785-10
J102-10
102-10
197
1797-03
J157-03
157-03
159
1797-04
J157-04
157-04
159
1834-02
J158-02
158-02
439
TL1055, TL1255
9-33
Electrical System
CDL
Code
Description
CatET J1939
Code
3rd Party
Device J1939
Code
Flash
Code
2246-06
J676-06
676-06
199
Event
Code
Description
CatET J1939
Code
3rd Party
Device J1939
Code
Flash
Code
E172-1
J107-15
107-15
151
E194-1
J173-15
173-15
185
E232-1
J97-15
97-15
E360-1
J100-17
100-17
157
E360-3
J100-01
100-01
157
E361-1
J110-15
110-15
168
E361-2
J110-16
110-16
168
E361-3
J110-00
110-00
168
E362-1
Engine Overspeed
J190-15
190-15
141
E396-1
J157-00
157-00
159
E398-1
J157-01
157-01
159
E539-1
J105-15
105-15
133
E539-2
J105-16
105-16
133
E2143-3
J111-01
111-01
169
9-34
TL1055, TL1255
31200293