Cat Caterpillar TL1055 Telehandler Service Repair Manual + Operation and Maintenance Manual + Parts Manual on CD

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your CAT. Read and print pages directly from the CD, or copy the entire manual to your hard drive.

1200 Pages

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SERIAL NUMBERS:

S/N TBM00100 & After

S/N TBN00100 & After   

MANUAL COVERS:

SERVICE REPAIR MANUAL:

Table of Contents

Section 1 Safety Practices:
1.1 Introduction
1.2 Disclaimer
1.3 Operation & Maintenance Manual
1.4 Do Not Operate Tags
1.5 Safety Information
1.5.1 Safety Alert System and Signal Words
1.6 Safety Instructions
1.6.1 Personal Hazards
1.6.2 Equipment Hazards
1.6.3 General Hazards
1.6.4 Operational Hazards
1.7 Safety Decals

Section 2 General Information and Specifications:
2.1 Replacement Parts and Warranty Information
2.2 Thread Locking Compound
2.3 Torque Charts
2.3.1 SAE Fastener Torque Chart
2.3.2 Metric Fastener Torque Chart
2.3.3 Hydraulic Hose Torque Chart
2.4 Specifications
2.4.1 Travel Speeds
2.4.2 Hydraulic Cylinder Performance
2.4.3 Cylinder Drift
2.4.4 Electrical System
2.4.5 Engine Performance Specifications
2.4.6 Tires
2.5 Fluids and Lubricant Capacities
2.6 Service and Maintenance Schedules
2.6.1 10, 1st 50 & 50 Hour
2.6.2 1st 250, 250 & 500 Hour
2.6.3 1000 & 1500 Hour
2.7 Lubrication Schedules
2.7.1 50 Hour
2.7.2 250 Hour
2.7.3 1000 Hour

Section 3 Boom:
3.1 Boom System Component Terminology
3.2 Boom System - Four Section
3.2.1 Boom System Operation
3.3 Boom Assembly Maintenance
3.4 Complete Boom Removal/ Installation
3.4.1 Complete Boom Removal
3.4.2 Complete Boom Installation
3.5 Boom Section Removal/ Installation
3.5.1 Second, Third & Fourth Boom Section Removal
3.5.2 Third & Fourth Boom Section Removal
3.5.3 Fourth Boom Section Removal
3.5.4 Hose Carrier Removal
3.5.5 Fourth Boom Section Assembly
3.5.6 Hose Carrier Installation
3.5.7 Third Boom Section Assembly
3.5.8 Fourth Boom Section Installation
3.5.9 Second Boom Section Assembly
3.5.10 Third & Fourth Boom Section Installation
3.5.11 Second, Third and Fourth Boom Section Installation
3.6 Boom Section Separation Adjustment
3.7 Hose Carrier Assembly Removal/Installation
3.7.1 Hose Carrier Assembly Removal
3.7.2 Assembling the Hose Carrier Assembly
3.7.3 Hose Carrier-Assembly Installation
3.7.4 Boom Hose Take-up Adjustment
3.7.5 Boom Hose Adjustment
3.8 Quick Coupler Assembly
3.8.1 Connecting with a Mechanical Quick Coupler Device
3.8.2 Connecting with a Hydraulic Quick Coupler Device
3.8.3 Connecting with a Quick Coupler to a Hydraulic Operated Attachment
3.8.4 Quick Coupler Removal
3.8.5 Quick Coupler Installation
3.9 Boom Head - Mounted Winch
3.9.1 Boom Head-Mounted Winch Removal
3.9.2 Boom Head-Mounted Winch Installation
3.10 Boom Wear Pads
3.10.1 Wear Pad Inspection
3.10.2 Wear Pad Installation and Lubrication
3.11 Boom Chain Removal/ Installation
3.11.1 Retract Chain Removal
3.11.2 Retract Chain Installation
3.11.3 Extend Chain Removal
3.11.4 Extend Chain Installation
3.12 Boom Chain Inspection and Lubrication
3.12.1 Boom Chain Inspection
3.12.2 Inspection Guidelines
3.12.3 Expose Chains for Inspection
3.12.4 Chain Lubrication
3.13 Forks
3.14 Emergency Boom Lowering Procedure
3.14.1 Equipment and Supplies Required
3.14.2 Lowering Procedure
3.15 Troubleshooting

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

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

Section 6 Transmission:
6.1 Transmission Assembly Component Terminology
6.2 Transmission Serial Number
6.3 Transmission Specifications And Maintenance Information
6.4 Transmission Replacement
6.4.1 Transmission Removal
6.4.2 Transmission Inspection and Internal Repair
6.4.3 Transmission Installation
6.4.4 After Transmission Service or Replacement
6.5 Torque Convertor Diaphragm
6.5.1 Torque Convertor Diaphragm Removal
6.5.2 Torque Convertor Diaphragm Installation
6.6 Transmission Cooler Thermal Bypass Valve
6.6.1 Thermal Bypass Valve Removal
6.6.2 Thermal Bypass Valve Installation
6.7 Troubleshooting

Section 7 Engine:
7.1 Introduction
7.1.1 Disclaimer and Scope
7.1.2 Component Terminology
7.2 Engine Serial Number
7.3 Engine Specifications and Maintenance Information
7.4 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
7.5 Engine Electrical System
7.6 Fuel System
7.6.1 Diesel Fuel
7.6.2 Fuel Tank
7.6.3 After Fuel System Service
7.7 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
7.8 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
7.9 Engine Replacement
7.9.1 Engine Removal
7.9.2 Engine Installation
7.10 Engine Indicator Lamps
7.11 Troubleshooting

Section 8 Hydraulic Section:
8.1 Hydraulic Component Terminology
8.2 Safety Information
8.3 Hydraulic Pressure Diagnosis
8.3.1 Pressure Checks and Adjustments
8.4 Hydraulic Circuits
8.4.1 Hydraulic Pressures
8.4.2 Tilt Circuit Port Relief Adjustment
8.4.3 Pressure Specifications TL1055 - Before S/N TBM00895 TL1255 - Before S/N TBM00436
8.4.4 Pressure Specifications TL1055 - S/N TBM00895 & After TL1255 - S/N TBN00436 & After
8.4.5 Hydraulic Schematic
8.5 Hydraulic Reservoir
8.5.1 Hydraulic Oil Reservoir Draining
8.5.2 Hydraulic Oil Reservoir Filling
8.5.3 Hydraulic Oil Reservoir Removal/ Installation
8.6 Implement Pump
8.6.1 Implement Pump Replacement
8.7 Control Valves
8.7.1 Main Control Valve
8.7.2 Main Control Valve Assembly
8.7.3 Service Brake Valve
8.7.4 Service Brake Bleeding
8.7.5 Service Brake Test
8.7.6 Steering Orbitrol Valve
8.7.7 Steer Select Valve
8.8 Hydraulic Cylinders
8.8.1 General Cylinder Removal Instructions
8.8.2 Cylinder Inspection
8.8.3 Cylinder Pressure Checking
8.8.4 Steering Cylinders
8.8.5 Cylinder Torque Specifications

Section 9 Electrical System:
9.1 Electrical Component Terminology
9.1.1 General Overview
9.1.2 General Overview
9.2 Specifications
9.3 Safety Information
9.4 Fuses and Relays
9.4.1 Engine Compartment
9.4.2 Cab
9.4.3 Power Distribution Unit (VEC)
9.4.4 Optional Power Distribution Unit (VEC)
9.5 Electrical System Schematics
9.5.1 Cab Schematic
9.5.2 Options Schematic
9.5.3 Chassis/Boom Schematic
9.5.4 Power Unit Schematic
9.6 Circuit Breakdowns
9.6.1 Constant Power Circuit from Battery
9.6.2 Start and Charge Circuit
9.7 Engine Start Circuit
9.7.1 Starter
9.8 Charging Circuit
9.8.1 Alternator
9.9 Window Wiper/Washer Windshield Wiper Motor
9.9.1 Windshield/Rear Window Washer Reservoir
9.10 Cab Heater and Fan
9.10.1 Cab Heater Controls
9.11 Solenoids, Sensors and Senders
9.11.1 Park Brake Solenoid Valve
9.11.2 Transmission Solenoid Valves
9.11.3 Transmission Oil Temperature Switch
9.11.4 Engine Coolant Temperature Sender / Switch
9.11.5 Engine Oil Pressure Sender/Switch
9.11.6 Fuel Level Sender
9.11.7 Inclinometer Switch
9.12 Display Monitor and Gauges
9.12.1 Analog Gauges
9.13 Dash Switches
9.13.1 Ignition Key Switch
9.13.2 Dash Switches
9.14 Engine Diagnostic
9.14.1 Engine Diagnostic and Event Codes 

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This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

Language: English 
Format: PDF - Indexed and Searchable

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