Cat TL642 TL943 Service Manual – PDF DOWNLOAD

Cat TL642 TL943 Service Manual – PDF DOWNLOAD

DESCRIPTION:

Cat TL642 TL943 Service Manual – PDF DOWNLOAD

1.1 INTRODUCTION

• This service manual provides general directions for accomplishing service and repair procedures. Following the procedures in this manual will help assure safety and equipment reliability.
• Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes, regulations and laws. These instructions cannot cover all details or variations in the equipment, procedures, or processes described, nor provide directions for meeting every possible contingency during operation, maintenance, or testing. When additional information is desired consult the local Caterpillar dealer.
• Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. For optimal safety, encourage everyone to think, and to act, safely.
• Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the machine.
• All references to the right side, left side, front and rear are given from the operator seat looking in a forward direction. Supplementary information is available from the manufacturer in the form of Service Bulletins, Service Campaigns, Service Training Schools, the service website, other literature, and through updates to the manual itself.

1.2 DISCLAIMER

All information in this manual is based on the latest product information available at the time of publication. The manufacturer reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation

1.3 OPERATION & MAINTENANCE MANUAL

• The mechanic must not operate the machine until the Operation & Maintenance Manual has been read & understood, training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator.
• An Operation & Maintenance Manual is supplied with each machine and must be kept in the manual holder located in the cab. In the event that the Operation & Maintenance Manual is missing, consult your local service distributor before proceeding.

1.4 DO NOT OPERATE TAGS

Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.

1.5 SAFETY INFORMATION

To avoid possible death or injury, carefully read, understand and comply with all safety messages. In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help assure personal safety.

TABLE OF CONTENTS:

Cat TL642 TL943 Service Manual – PDF DOWNLOAD

31200292_J_TL642 TL943_CAT_Service..........................................................................................................  1
Effectivity Page............................................................................................................................  3
Table of Contents...........................................................................................................................  5
Section 1 Safety Practices..................................................................................................................  9
	1.1 Introduction........................................................................................................................ 10
	1.2 Disclaimer.......................................................................................................................... 10
	1.3 Operation & Maintenance Manual...................................................................................................... 10
	1.4 Do Not Operate Tags................................................................................................................. 10
	1.5 Safety Information.................................................................................................................. 10
		1.5.1 Safety Alert System and Signal Words.......................................................................................... 10
	1.6 Safety Instructions................................................................................................................. 11
		1.6.1 Personal Hazards.............................................................................................................. 11
		1.6.2 Equipment Hazards............................................................................................................. 11
		1.6.3 General Hazards............................................................................................................... 11
		1.6.4 Operational Hazards........................................................................................................... 12
	1.7 Safety Decals....................................................................................................................... 12
Section 2 General Information and Specifications............................................................................................ 13
	2.1 Replacement Parts and Warranty Information.......................................................................................... 14
	2.2 Torque Charts....................................................................................................................... 15
		2.2.1 SAE Fastener Torque Chart..................................................................................................... 15
		2.2.2 Metric Fastener Torque Chart.................................................................................................. 19
		2.2.3 Hydraulic Hose Torque Chart................................................................................................... 22
	2.3 Specifications...................................................................................................................... 23
		2.3.1 Travel Speeds................................................................................................................. 23
		2.3.2 Hydraulic Cylinder Performance................................................................................................ 23
		2.3.3 Cylinder Drift................................................................................................................ 23
		2.3.4 Electrical System............................................................................................................. 24
		2.3.5 Engine Performance Specifications............................................................................................. 24
		2.3.6 Tires......................................................................................................................... 25
	2.4 Fluids and Lubricant Capacities..................................................................................................... 26
	2.5 Service and Maintenance Schedules................................................................................................... 29
		2.5.1 10, 1st 50 & 50 Hour.......................................................................................................... 29
		2.5.2 1st 250, 250 & 500 Hour....................................................................................................... 30
		2.5.3 1000 & 1500 Hour.............................................................................................................. 31
	2.6 Lubrication Schedules............................................................................................................... 32
Section 3 Boom.............................................................................................................................. 35
	3.1 Boom System Component Terminology................................................................................................... 37
	3.2 Boom System - Three Section......................................................................................................... 38
		3.2.1 Boom System Operation......................................................................................................... 38
	3.3 Boom Assembly Maintenance........................................................................................................... 38
	3.4 Complete Boom Removal/ Installation................................................................................................. 39
		3.4.1 Complete Boom Removal......................................................................................................... 39
		3.4.2 Complete Boom Installation.................................................................................................... 39
	3.5 Boom Section Removal/ Installation.................................................................................................. 40
		3.5.1 Second and Third Boom Section Removal......................................................................................... 40
		3.5.2 Third Boom Section Removal.................................................................................................... 41
		3.5.3 Push Beam - Extend/Retract Cylinder Removal................................................................................... 42
		3.5.4 Push Beam - Extend/Retract Cylinder Installation and Third Boom Section Assembly.............................................. 43
		3.5.5 Third Boom Section Installation............................................................................................... 44
		3.5.6 Second and Third Boom Section Installation.................................................................................... 46
	3.6 Extend/Retract Chain Removal/Installation........................................................................................... 48
		3.6.1 Extend/Retract Chain Removal.................................................................................................. 48
		3.6.2 Extend/Retract Chain Installation............................................................................................. 49
	3.7 Push Beam - Extend/Retract Cylinder Removal/ Installation........................................................................... 50
		3.7.1 Push Beam - Extend/Retract Cylinder Removal................................................................................... 50
		3.7.2 Push Beam - Extend/Retract Cylinder Installation.............................................................................. 52
	3.8 Boom Adjustments.................................................................................................................... 54
		3.8.1 Chain Tension Inspection—TL642................................................................................................ 54
		3.8.2 Chain Tension Adjustment—TL642................................................................................................ 55
		3.8.3 Chain Tension Inspection— TL943............................................................................................... 56
		3.8.4 Chain Tension Adjustment— TL943............................................................................................... 57
	3.9 Boom Head - Mounted Winch........................................................................................................... 59
		3.9.1 Boom Head-Mounted Winch Removal............................................................................................... 59
		3.9.2 Boom Head-Mounted Winch Installation.......................................................................................... 59
	3.10 Boom Wear Pads..................................................................................................................... 59
		3.10.1 Wear Pad Inspection.......................................................................................................... 59
		3.10.2 Wear Pad Installation and Lubrication........................................................................................ 59
	3.11 Boom Extend and Retract Chains..................................................................................................... 60
		3.11.1 Boom Chain Inspection........................................................................................................ 60
		3.11.2 Inspection Guidelines........................................................................................................ 61
		3.11.3 Chain Lubrication............................................................................................................ 63
	3.12 Forks.............................................................................................................................. 63
	3.13 Emergency Boom Lowering Procedure.................................................................................................. 64
		3.13.1 Equipment and Supplies Required.............................................................................................. 64
		3.13.2 Lowering Procedure........................................................................................................... 64
	3.14 Troubleshooting.................................................................................................................... 66
	3.15 Push Beam Temporary Brackets....................................................................................................... 69
Section 4 Cab and Covers.................................................................................................................... 71
	4.1 Operator Cab and Covers Component Terminology....................................................................................... 72
		4.1.1 General Overview.............................................................................................................. 72
		4.1.2 General Overview.............................................................................................................. 73
	4.2 Operator Cab........................................................................................................................ 74
		4.2.1 Cab Safety.................................................................................................................... 74
		4.2.2 Serial Number Decal........................................................................................................... 74
	4.3 Cab Components...................................................................................................................... 74
		4.3.1 Steering Column and Orbitrol Valve............................................................................................ 74
		4.3.2 Service Brake Pedal........................................................................................................... 75
		4.3.3 Throttle Pedal................................................................................................................ 76
		4.3.4 Boom Joystick................................................................................................................. 77
		4.3.5 Frame Level, Auxiliary Hydraulic (if equipped) and Outrigger Joysticks........................................................ 78
		4.3.6 Windshield Wiper Assembly..................................................................................................... 78
		4.3.7 Heater/Air Conditioning System (if equipped).................................................................................. 79
	4.4 Cab Removal......................................................................................................................... 80
	4.5 Cab Installation.................................................................................................................... 81
Section 5 Axles, Drive Shafts, Wheels and Tires............................................................................................. 83
	5.1 Axles, Drive Shafts, Wheels and Tires Component Terminology......................................................................... 84
	5.2 General Information................................................................................................................. 85
	5.3 Axle Assemblies..................................................................................................................... 85
		5.3.1 Axle Serial Number Plate...................................................................................................... 85
		5.3.2 Axle Specifications........................................................................................................... 85
		5.3.3 Axle Internal Service......................................................................................................... 85
		5.3.4 Axle Maintenance.............................................................................................................. 85
		5.3.5 Axle Removal.................................................................................................................. 86
		5.3.6 Axle Installation............................................................................................................. 86
		5.3.7 Axle Assembly and Drive Shaft Troubleshooting................................................................................. 88
	5.4 Drive Shafts........................................................................................................................ 91
		5.4.1 Drive Shaft Inspection and Service............................................................................................ 91
		5.4.2 Drive Shaft Maintenance....................................................................................................... 91
		5.4.3 Drive Shaft Removal........................................................................................................... 91
		5.4.4 Drive Shaft Cleaning and Drying............................................................................................... 91
		5.4.5 Drive Shaft Installation...................................................................................................... 91
	5.5 Wheels and Tires.................................................................................................................... 92
		5.5.1 Removing Wheel and Tire Assembly from Machine................................................................................. 92
		5.5.2 Installing Wheel and Tire Assembly onto Machine............................................................................... 93
	5.6 Brakes.............................................................................................................................. 93
	5.7 Towing a Disabled machine........................................................................................................... 93
		5.7.1 Manually Releasing the Park Brake............................................................................................. 93
		5.7.2 Manually Resetting the Park Brake............................................................................................. 94
Section 6 Transmission...................................................................................................................... 95
	6.1 Transmission Assembly Component Terminology......................................................................................... 96
	6.2 Transmission Serial Number.......................................................................................................... 97
	6.3 Transmission Specifications and Maintenance Information............................................................................. 97
	6.4 Transmission Replacement............................................................................................................ 97
		6.4.1 Transmission Removal.......................................................................................................... 97
		6.4.2 Transmission Inspection and Internal Repair................................................................................... 98
		6.4.3 Transmission Installation..................................................................................................... 98
		6.4.4 After Transmission Service or Replacement..................................................................................... 99
	6.5 Torque Convertor Diaphragm..........................................................................................................100
		6.5.1 Torque Convertor Diaphragm Removal............................................................................................100
		6.5.2 Torque Convertor Diaphragm Installation.......................................................................................100
	6.6 Troubleshooting.....................................................................................................................101
		6.6.1 Transmission Troubleshooting..................................................................................................101
Section 7 Engine............................................................................................................................105
	7.1 Introduction........................................................................................................................106
		7.1.1 Disclaimer and Scope..........................................................................................................106
		7.1.2 Component Terminology.........................................................................................................107
	7.2 Engine Serial Number................................................................................................................108
	7.3 Specifications and Maintenance Information..........................................................................................108
	7.4 Engine Cooling System...............................................................................................................108
		7.4.1 Radiator Pressure Cap.........................................................................................................108
		7.4.2 Thermostat Replacement........................................................................................................108
		7.4.3 Radiator/Oil Cooler and Replacement...........................................................................................109
	7.5 Engine Electrical System............................................................................................................110
	7.6 Fuel System.........................................................................................................................111
		7.6.1 Diesel Fuel...................................................................................................................111
		7.6.2 Fuel Tank.....................................................................................................................111
		7.6.3 After Fuel System Service.....................................................................................................112
	7.7 Engine Exhaust System...............................................................................................................112
		7.7.1 Exhaust System Removal........................................................................................................112
		7.7.2 Exhaust System Installation...................................................................................................113
	7.8 Air Cleaner Assembly................................................................................................................113
		7.8.1 Air Cleaner Assembly Removal..................................................................................................113
		7.8.2 Air Cleaner Assembly Installation.............................................................................................113
		7.8.3 Air Cleaner Assembly Removal..................................................................................................114
		7.8.4 Air Cleaner Assembly Installation.............................................................................................114
	7.9 Engine Replacement..................................................................................................................114
		7.9.1 Engine Removal................................................................................................................114
		7.9.2 Engine Installation...........................................................................................................115
	7.10 Engine Drive Plate.................................................................................................................117
		7.10.1 Drive Plate Removal..........................................................................................................117
		7.10.2 Drive Plate Installation.....................................................................................................117
	7.11 Troubleshooting....................................................................................................................118
Section 8 Hydraulic System..................................................................................................................119
	8.1 Hydraulic Component Terminology.....................................................................................................120
	8.2 Safety Information..................................................................................................................121
	8.3 Hydraulic Pressure Diagnosis........................................................................................................121
		8.3.1 Pressure Checks and Adjustments...............................................................................................121
	8.4 Hydraulic Circuits..................................................................................................................122
		8.4.1 Hydraulic Pressures...........................................................................................................122
		8.4.2 Tilt Circuit Port Relief Adjustment...........................................................................................122
		8.4.3 Hydraulic Schematic - TL642...................................................................................................127
		8.4.4 Hydraulic Schematic - TL943 Before S/N TBL01599 excluding TBL01551 & TBL01585.................................................129
		8.4.5 Hydraulic Schematic - TL943 S/N TBL01599 & After including TBL01551 & TBL01585................................................131
	8.5 Hydraulic Reservoir.................................................................................................................132
		8.5.1 Hydraulic Oil Reservoir Draining..............................................................................................132
		8.5.2 Hydraulic Oil Reservoir Filling...............................................................................................132
		8.5.3 Hydraulic Oil Reservoir Removal/ Installation.................................................................................132
	8.6 Engine Implement Pump...............................................................................................................133
		8.6.1 Pump Replacement..............................................................................................................133
	8.7 Control Valves......................................................................................................................136
		8.7.1 Main Control Valve............................................................................................................136
		8.7.2 Service Brake Valve...........................................................................................................138
		8.7.3 Service Brake Bleeding........................................................................................................139
		8.7.4 Steering Orbitrol Valve.......................................................................................................139
		8.7.5 Steer Select Valve............................................................................................................140
		8.7.6 Outrigger Valve (if equipped).................................................................................................141
	8.8 Hydraulic Cylinders.................................................................................................................142
		8.8.1 General Cylinder Removal Instructions.........................................................................................142
		8.8.2 Cylinder Pressure Checking....................................................................................................144
		8.8.3 Steering Cylinders............................................................................................................144
		8.8.4 Cylinder Torque Specifications - TL642........................................................................................145
		8.8.5 Cylinder Torque Specifications - TL943........................................................................................146
Section 9 Electrical System.................................................................................................................147
	9.1 Electrical Component Terminology....................................................................................................149
		9.1.1 General Overview..............................................................................................................149
		9.1.2 General Overview..............................................................................................................150
	9.2 Specifications......................................................................................................................151
	9.3 Safety Information..................................................................................................................151
	9.4 Fuses and Relays....................................................................................................................151
		9.4.1 Cab...........................................................................................................................151
		9.4.2 Engine Compartment............................................................................................................151
		9.4.3 Power Control Board...........................................................................................................152
		9.4.4 VEC Control Module............................................................................................................154
		9.4.5 Universal Ground Control Module (UGM).........................................................................................155
		9.4.6 UGM Connections...............................................................................................................156
	9.5 Electrical System Schematics........................................................................................................157
		9.5.1 Before S/N TBK01167 excluding TBK01162; Before S/N TBL01599 excluding TBL01551 & TBL01585.....................................157
		9.5.2 S/N TBK01167 & After including TBK01162; S/N TBL01599 & After including TBL01551 & TBL01585...................................164
	9.6 Circuit Breakdowns..................................................................................................................169
		9.6.1 Constant Power Circuit from Battery...........................................................................................169
		9.6.2 Start Circuit.................................................................................................................170
		9.6.3 Charging Circuit..............................................................................................................171
	9.7 Engine Start Circuit................................................................................................................172
		9.7.1 Starter.......................................................................................................................172
	9.8 Charging Circuit....................................................................................................................173
		9.8.1 Alternator....................................................................................................................173
	9.9 Window Wiper/Washer Windshield Wiper Motor..........................................................................................174
		9.9.1 Windshield/Rear Window Washer Reservoir.......................................................................................175
	9.10 Cab Heater/AC and Fan..............................................................................................................175
		9.10.1 Cab Heater/AC Controls.......................................................................................................175
	9.11 Switches, Solenoids and Senders....................................................................................................176
		9.11.1 Priority Valve...............................................................................................................176
		9.11.2 Transmission Solenoid Valves.................................................................................................177
		9.11.3 Transmission Temperature Switch..............................................................................................178
		9.11.4 Engine Coolant Temperature Sensor............................................................................................178
		9.11.5 Engine Oil Pressure Sender/Sensor............................................................................................179
		9.11.6 Fuel Level Sender............................................................................................................179
	9.12 Gauges and Display Monitor.........................................................................................................180
		9.12.1 Analog Gauges................................................................................................................180
		9.12.2 3-N-1 Digital Gauge..........................................................................................................181
	9.13 Dash Switches......................................................................................................................182
		9.13.1 Ignition Key Switch..........................................................................................................182
		9.13.2 Dash Switches................................................................................................................182
		9.13.3 Rheostat Switch (if equipped)................................................................................................183
	9.14 Hand Held Analyzer (S/N TBL01599 & After including TBL01551 & TBL01585)............................................................184
		9.14.1 Analyzer Usage...............................................................................................................184
		9.14.2 Analyzer Software Version A..................................................................................................185
		9.14.3 Personality Settings.........................................................................................................186
		9.14.4 Tilt/Auxiliary Calibration Menu..............................................................................................187
		9.14.5 Joystick Fault Codes.........................................................................................................188
	9.15 Engine Diagnostic and Event Codes (S/N TBK01167 & After including TBK01162; S/N TBL01599 & After including TBL01551 & TBL01585)....193

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