Cat TL642C TL943C Service Manual – PDF DOWNLOAD

Description

Cat TL642C TL943C Service Manual – PDF DOWNLOAD

DESCRIPTION:

Cat TL642C TL943C 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 TL642C TL943C Service Manual – PDF DOWNLOAD

31200794_H_TL642C TL943C_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 Thread Locking Compound................................................................... 14
		2.3 Torque Charts............................................................................. 15
			2.3.1 SAE Fastener Torque Chart........................................................... 15
			2.3.2 Metric Fastener Torque Chart........................................................ 21
			2.3.3 Hydraulic Hose Torque Chart......................................................... 25
		2.4 Specifications............................................................................ 26
			2.4.1 Travel Speeds....................................................................... 26
			2.4.2 Hydraulic Cylinder Performance...................................................... 26
			2.4.3 Cylinder Drift...................................................................... 26
			2.4.4 Electrical System................................................................... 26
			2.4.5 Engine Performance Specifications................................................... 28
			2.4.6 Tires............................................................................... 29
		2.5 Fluids and Lubricant Capacities........................................................... 30
		2.6 Service and Maintenance Schedules......................................................... 35
			2.6.1 10, 1st 50 & 50 Hour................................................................ 35
			2.6.2 1st 250, 250 & 1st 500 Hour......................................................... 36
			2.6.3 500, 1000, & 1500 Hour.............................................................. 37
			2.6.4 3000 Hour........................................................................... 38
		2.7 Lubrication Schedules..................................................................... 39
	Section 3 Boom.................................................................................... 43
		3.1 Boom System Component Terminology......................................................... 45
		3.2 Boom System - Three Section............................................................... 46
			3.2.1 Boom System Operation............................................................... 46
		3.3 Boom Assembly Maintenance................................................................. 46
		3.4 Complete Boom Removal/ Installation....................................................... 47
			3.4.1 Complete Boom Removal............................................................... 47
			3.4.2 Complete Boom Installation.......................................................... 47
		3.5 Boom Section Removal/ Installation........................................................ 48
			3.5.1 Second and Third Boom Section Removal............................................... 48
			3.5.2 Third Boom Section Removal.......................................................... 49
			3.5.3 Push Beam - Extend/Retract Cylinder Removal......................................... 50
			3.5.4 Push Beam - Extend/Retract Cylinder Installation and Third Boom Section Assembly.... 51
			3.5.5 Third Boom Section Installation..................................................... 52
			3.5.6 Second and Third Boom Section Installation.......................................... 54
		3.6 Extend/Retract Chain Removal/Installation................................................. 56
			3.6.1 Extend/Retract Chain Removal........................................................ 56
			3.6.2 Extend/Retract Chain Installation................................................... 57
		3.7 Push Beam - Extend/Retract Cylinder Removal/ Installation................................. 58
			3.7.1 Push Beam - Extend/Retract Cylinder Removal......................................... 58
			3.7.2 Push Beam - Extend/Retract Cylinder Installation.................................... 60
		3.8 Boom Adjustments.......................................................................... 62
			3.8.1 Chain Tension Inspection—TL642C..................................................... 62
			3.8.2 Chain Tension Adjustment—TL642C..................................................... 63
			3.8.3 Chain Tension Inspection— TL943C.................................................... 64
			3.8.4 Chain Tension Adjustment— TL943C.................................................... 65
		3.9 Quick Coupler Assembly.................................................................... 67
			3.9.1 Quick Coupler Removal............................................................... 67
			3.9.2 Quick Coupler Installation.......................................................... 67
		3.10 Boom Head - Mounted Winch................................................................ 67
			3.10.1 Boom Head-Mounted Winch Removal.................................................... 67
			3.10.2 Boom Head-Mounted Winch Installation............................................... 67
		3.11 Boom Wear Pads........................................................................... 68
			3.11.1 Wear Pad Inspection................................................................ 68
			3.11.2 Wear Pad Installation and Lubrication.............................................. 68
		3.12 Boom Extend and Retract Chains........................................................... 69
			3.12.1 Boom Chain Inspection.............................................................. 69
			3.12.2 Expose Chains for Inspection....................................................... 69
			3.12.3 Inspection Guidelines.............................................................. 70
			3.12.4 Chain Lubrication.................................................................. 71
		3.13 Forks.................................................................................... 72
		3.14 Emergency Boom Lowering Procedure........................................................ 73
			3.14.1 Equipment and Supplies Required.................................................... 73
			3.14.2 Lowering Procedure................................................................. 73
		3.15 Troubleshooting.......................................................................... 75
		3.16 Push Beam Temporary Brackets............................................................. 78
	Section 4 Cab and Covers.......................................................................... 79
		4.1 Operator Cab and Covers Component Terminology............................................. 80
			4.1.1 General Overview.................................................................... 80
		4.2 Operator Cab.............................................................................. 81
			4.2.1 Cab Safety.......................................................................... 81
			4.2.2 Serial Number Decal................................................................. 81
		4.3 Cab Components............................................................................ 81
			4.3.1 Steering Column and Orbitrol Valve.................................................. 81
			4.3.2 Service Brake Pedal................................................................. 82
			4.3.3 Throttle Pedal...................................................................... 83
			4.3.4 Boom Joystick....................................................................... 83
			4.3.5 Frame Level, Auxiliary Hydraulic (if equipped) and Outrigger Joysticks.............. 84
			4.3.6 Windshield Wiper Assembly........................................................... 85
			4.3.7 Heater/Air Conditioning System (if equipped)........................................ 85
		4.4 Cab Removal............................................................................... 86
		4.5 Cab Installation.......................................................................... 88
	Section 5 Axles, Drive Shafts, Wheels and Tires................................................... 91
		5.1 Axles, Drive Shafts, Wheels and Tires Component Terminology............................... 92
		5.2 Axle Serial Number........................................................................ 93
		5.3 Axle Specifications and Maintenance Information........................................... 93
		5.4 Axle Replacement.......................................................................... 93
			5.4.1 Axle Removal........................................................................ 93
			5.4.2 Axle Installation................................................................... 94
			5.4.3 Axle Assembly and Drive Shaft Troubleshooting....................................... 96
		5.5 Drive Shafts.............................................................................. 99
			5.5.1 Drive Shaft Inspection and Service.................................................. 99
			5.5.2 Drive Shaft Maintenance............................................................. 99
			5.5.3 Drive Shaft Removal................................................................. 99
			5.5.4 Drive Shaft Cleaning and Drying..................................................... 99
			5.5.5 Drive Shaft Installation............................................................ 99
		5.6 Wheels and Tires..........................................................................100
			5.6.1 Removing Wheel and Tire Assembly from Machine.......................................100
			5.6.2 Installing Wheel and Tire Assembly onto Machine.....................................100
		5.7 Brakes....................................................................................101
		5.8 Towing a Disabled machine.................................................................101
			5.8.1 Manually Releasing the Park Brake...................................................101
			5.8.2 Manually Resetting the Park Brake...................................................101
	Section 6 Transmission............................................................................103
		6.1 Transmission Assembly Component Terminology...............................................104
		6.2 Transmission Serial Number................................................................105
		6.3 Transmission Specifications and Maintenance Information...................................105
		6.4 Transmission Replacement..................................................................105
			6.4.1 Transmission Removal................................................................105
			6.4.2 Transmission Inspection and Internal Repair.........................................106
			6.4.3 Transmission Installation...........................................................106
			6.4.4 After Transmission Service or Replacement...........................................107
		6.5 Transmission Cooler Thermal By-Pass Valve.................................................107
			6.5.1 Thermal By-pass Valve Cartridge Removal.............................................107
			6.5.2 Thermal Bypass Valve Cartridge Installation.........................................108
		6.6 Torque Convertor Diaphragm................................................................109
			6.6.1 Torque Convertor Diaphragm Removal..................................................109
			6.6.2 Torque Convertor Diaphragm Installation.............................................109
		6.7 Troubleshooting...........................................................................110
			6.7.1 Transmission Troubleshooting........................................................110
	Section 7 Engine..................................................................................115
		7.1 Introduction..............................................................................116
			7.1.1 Disclaimer and Scope................................................................116
			7.1.2 Component Terminology...............................................................117
		7.2 Engine Serial Number......................................................................118
		7.3 Specifications and Maintenance Information................................................118
		7.4 Engine Cooling System.....................................................................119
			7.4.1 Surge Tank Cap......................................................................119
			7.4.2 Thermostat Replacement..............................................................119
			7.4.3 Radiator Assembly Replacement.......................................................120
		7.5 Engine Electrical System..................................................................124
		7.6 Fuel System...............................................................................125
			7.6.1 Diesel Fuel.........................................................................125
			7.6.2 Fuel Tank...........................................................................125
			7.6.3 After Fuel System Service...........................................................126
		7.7 Engine Exhaust System.....................................................................126
			7.7.1 Exhaust System Removal..............................................................126
			7.7.2 Exhaust System Installation.........................................................127
			7.7.3 Exhaust System Removal..............................................................127
			7.7.4 Exhaust System Installation.........................................................128
		7.8 Air Cleaner Assembly......................................................................128
			7.8.1 Air Cleaner Assembly Removal........................................................128
			7.8.2 Air Cleaner Assembly Installation...................................................129
		7.9 Engine Replacement........................................................................129
			7.9.1 Engine/Transmission Removal.........................................................129
			7.9.2 Engine/Transmission Installation....................................................130
		7.10 Engine Indicator Lamps...................................................................132
	Section 8 Hydraulic System........................................................................133
		8.1 Hydraulic Component Terminology...........................................................134
		8.2 Safety Information........................................................................135
		8.3 Hydraulic Pressure Diagnosis..............................................................135
			8.3.1 Pressure Checks and Adjustments.....................................................135
		8.4 Hydraulic Circuits........................................................................136
			8.4.1 Hydraulic Pressures.................................................................136
			8.4.2 Tilt Circuit Port Relief Adjustment.................................................136
			8.4.3 Hydraulic Schematic - TL642C........................................................140
			8.4.4 Hydraulic Schematic - TL943C........................................................142
		8.5 Hydraulic Reservoir.......................................................................143
			8.5.1 Hydraulic Oil Reservoir Draining....................................................143
			8.5.2 Hydraulic Oil Reservoir Filling.....................................................143
			8.5.3 Hydraulic Oil Reservoir Removal/ Installation.......................................143
		8.6 Engine Implement Pump.....................................................................144
			8.6.1 Pump Replacement....................................................................144
		8.7 Control Valves............................................................................145
			8.7.1 Main Control Valve..................................................................145
			8.7.2 Service Brake Valve.................................................................147
			8.7.3 Service Brake Bleeding..............................................................148
			8.7.4 Steering Orbitrol Valve.............................................................149
			8.7.5 Steer Select Valve..................................................................149
			8.7.6 Outrigger Valve (if equipped).......................................................150
		8.8 Hydraulic Cylinders.......................................................................151
			8.8.1 General Cylinder Removal Instructions...............................................151
			8.8.2 Cylinder Inspection.................................................................153
			8.8.3 Cylinder Pressure Checking..........................................................154
			8.8.4 Steering Cylinders..................................................................154
		8.9 Cylinder Torque Specifications............................................................155
			8.9.1 TL642C..............................................................................155
			8.9.2 TL943C..............................................................................156
	Section 9 Electrical System.......................................................................157
		9.1 Electrical Component Terminology..........................................................159
			9.1.1 General Overview....................................................................159
			9.1.2 General Overview....................................................................160
		9.2 Specifications............................................................................161
		9.3 Safety Information........................................................................161
		9.4 Fuses and Relays..........................................................................161
			9.4.1 Engine Compartment..................................................................161
			9.4.2 Cab.................................................................................161
			9.4.3 Main Distribution Unit..............................................................162
			9.4.4 Accessory Power Distribution Unit...................................................163
		9.5 Accessory Module - TL943C Only............................................................164
			9.5.1 Joystick Tilt & Auxiliary Function Module...........................................164
			9.5.2 Joystick Tilt & Auxiliary Function Module...........................................165
		9.6 Electrical System Schematics..............................................................166
			9.6.1 S/N THG00150 & After S/N THH00150 & After...........................................166
			9.6.2 S/N THL00150 & After S/N SXH00150 & After...........................................172
		9.7 Circuit Breakdowns........................................................................178
			9.7.1 Constant Power Circuit from Battery.................................................178
			9.7.2 Start and Charge Circuit............................................................179
		9.8 Engine Start Circuit......................................................................180
			9.8.1 Starter.............................................................................180
		9.9 Charging Circuit..........................................................................181
			9.9.1 Alternator..........................................................................181
		9.10 Window Wiper/Washer Windshield Wiper Motor...............................................182
			9.10.1 Windshield/Rear Window Washer Reservoir............................................183
		9.11 Cab Heater/AC and Fan....................................................................183
			9.11.1 Cab Heater/AC Controls.............................................................183
		9.12 Switches, Solenoids and Senders..........................................................184
			9.12.1 Priority Valve.....................................................................184
			9.12.2 Transmission Solenoid Valves.......................................................185
			9.12.3 Transmission Oil Temperature Switch................................................186
			9.12.4 Fuel Level Sender..................................................................187
		9.13 Gauges and Display Monitor...............................................................188
			9.13.1 3-N-1 Digital Gauge................................................................188
		9.14 Dash Switches............................................................................189
			9.14.1 Ignition Key Switch................................................................189
			9.14.2 Dash Switches......................................................................189
			9.14.3 Rheostat Switch (if equipped)......................................................190
		9.15 Hand Held Analyzer - TL943C Only.........................................................190
			9.15.1 Analyzer Usage.....................................................................191
			9.15.2 Analyzer Joystick Software Version P1.2............................................192
			9.15.3 Personality Settings...............................................................193
			9.15.4 Tilt/Auxiliary Calibration Menu....................................................194
			9.15.5 Joystick Fault Codes...............................................................195
		9.16 Engine Diagnostic and Event Codes........................................................200
			9.16.1 Engine Diagnostic Codes............................................................200
			9.16.2 Pump Controller Software Version P1.4..............................................204

CAT TL642C TL943C SERVICE MANUAL – PDF DOWNLOAD:

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• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.M