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Caterpillar cat tl1055 tl1255 telehandler parts catalogue manual (sn tbn00100 & after)
1.
Parts Manual Models TL1055 TL1255 S/N TBM00100
& After S/N TBN00100 & After 31200257 Revised June 29, 2012
2.
TABLE OF CONTENTS FIGURE
NO. TITLE PAGE NO. 31200257 TL1055, TL1255 iii SECTION 1 – FRAME & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 Frame Shrouding & Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2 Axle & Wheel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1-3 Outrigger Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 SECTION 2 – BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-1 First Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-2 Bearings, Pads, Spacers & Shims, (First Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2-3 Second Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2-4 Bearings, Pads, Spacers & Shims, (Second Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 2-5 Third Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 2-6 Bearings, Pads, Spacers & Shims, (Third Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 2-7 Fourth Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 2-8 Bearings, Pads, Spacers & Shims, (Fourth Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 2-9 Quick Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 2-10 Hydraulic Quick Coupler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 SECTION 3 – ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1 Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-2 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3-3 Winch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3-4 Side Tilt Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3-5 Fork Clamp Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3-6 Fork Mounted Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3-7 Fork Mounted Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 3-8 Dual Fork Positioning Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 3-9 100 Degree Swing Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 3-10 180 Degree Swing Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 3-11 Side Shift Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 SECTION 4 – ENGINE & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4-2 CAT Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4-3 Fuel Tank & Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 4-4 Radiator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 4-5 Air Cleaner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 4-6 Exhaust Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 4-7 ZF Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 4-8 ZF Transmission - Converter & Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 4-9 ZF Transmission - Gearbox Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
3.
TABLE OF CONTENTS FIGURE
NO. TITLE PAGE NO. TL1055, TL1255 31200257iv 4-10 ZF Transmission - Forward Gear Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 4-11 ZF Transmission - Reverse Gear Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 4-12 ZF Transmission - 1st Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 4-13 ZF Transmission - 2nd Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 4-14 ZF Transmission - 3rd Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48 4-15 ZF Transmission - 4th Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50 4-16 ZF Transmission - Power Take-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52 4-17 ZF Transmission - Control Unit & Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54 4-18 ZF Transmission - Gearshift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56 4-19 ZF Transmission - Oil Pump, Filter & Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58 4-20 ZF Transmission - Transfer Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60 SECTION 5 – DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1 Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5-2 Front Axle - Central Housing & Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5-3 Front Axle - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 5-4 Front Axle - Hub Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5-5 Front Axle - Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 5-6 Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 5-7 Rear Axle - Central Housing & Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 5-8 Rear Axle - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 5-9 Rear Axle - Hub Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 5-10 Rear Axle - Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 5-11 Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 5-12 Tires & Rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 SECTION 6 – CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1 Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6-2 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 6-3 Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 6-4 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 6-5 Heating Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 6-6 Open Cab Heater Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 6-7 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 6-8 Air Conditioning Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44 SECTION 7 – CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-1 Boom Joystick with Adjustable Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7-2 Hydraulic Controller - Outrigger & Sway/Aux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7-3 Steering Column & Attaching Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 7-4 Brake Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
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NO. TITLE PAGE NO. 31200257 TL1055, TL1255 v 7-5 Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 SECTION 8 – HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8-1 Supply Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8-2 Dump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 8-3 Steer Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20 8-4 Service/Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22 8-5 Boom Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24 8-6 Sway/Auxiliary Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26 8-7 Outrigger Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32 8-8 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34 8-9 Crowd Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38 8-10 Tilt & Tilt Compensating Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42 8-11 Auxiliary Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46 8-12 Boom Hydraulics Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54 8-13 Sway Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56 8-14 Outrigger Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-62 SECTION 9 – HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9-1 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9-2 Crowd Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16 9-3 Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22 9-4 Compensating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34 9-5 Sway Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46 9-6 Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52 9-7 Outrigger Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-58 9-8 Dual Fork Positioning Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-62 9-9 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64 9-10 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70 9-11 Hydraulic Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-76 9-12 Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-82 9-13 Hydraulic Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-86 9-14 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-88 9-15 Quick Coupler Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-90 9-16 Decompression Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-92 9-17 Swing Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-94 9-18 180 Degree Swing Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-96 9-19 Side Shift Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-98 SECTION 10 – ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10-1 Battery & Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
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TABLE OF CONTENTS FIGURE
NO. TITLE PAGE NO. TL1055, TL1255 31200257vi 10-2 Battery Disconnect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 10-3 Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 10-4 Chassis Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24 10-5 Dash Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34 10-6 Transmission Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38 10-7 Transmission Relay Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42 10-8 Enclosed Cab Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46 10-9 VEC Options Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48 10-10 A/C Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52 10-11 Auxiliary Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54 10-12 Cab Work Light Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56 SECTION 11 – DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 11-1 Cab & Frame Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 11-2 Boom Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8 SECTION 12 – OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 12-1 Work Light Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 12-2 Fender Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10 12-3 Pintle Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12 12-4 8 IN Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14 12-5 Winch Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18 12-6 Pressure Reducer Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20 12-7 Block Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22 12-8 Boom Lights Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-24 12-9 Skylight Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26 12-10 Road Lights Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28 12-11 Top Cab Glass Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32 12-12 Front Cab Glass Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34 12-13 Cold Weather Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-36 12-14 Arctic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-38 12-15 Beacon Light Mount with AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-40 12-16 Boom Work Light Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-42 12-17 Work Light Cab Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-44 12-18 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-46 SECTION 13 – MAINTENANCE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 SECTION 14 – PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
6.
31200257 TL1055, TL1255 SECTION
1 FRAME & ATTACHING PARTS
7.
FRAME & ATTACHING
PARTS TL1055, TL1255 312002571-2 Figure 1-1 Frame Shrouding & Trim PAP7090 17 27 15 15 3 19 8 15 5 10 13 4 25 15 2315 1 12 105 105 106 2 1 6 16 21 20 7 15 101 102 103 502 502 503 502 303 3 26 202 203 505 504 501 2928 15 10 606 602 102 603 604 605 506 507 509 510 507 506 510 508 107 104 201 TL1055 Before S/N TBM01320 excluding TBM01298 TL1255 Before S/N TBN00801 excluding TBN00785
8.
FRAME & ATTACHING
PARTS 31200257 TL1055, TL1255 1-3 Figure 1-1 Frame Shrouding & Trim (Continued) PAP9520 311 310 306 304304 308 307 313 312 305 309 302401 402 708 708 601 701 702 703 701 702 704 705 706 707 606 803 804 802 801 805 806 807 810 811 808 809 301 CAB WALL FRAME MOUNT WELDMENT LOWER CAB MOUNT CAB MOUNT WELDMENT FRAME MOUNT WELDMENT UPPER CAB MOUNT SHOWN WITH WORK LIGHT TL1055 Before S/N TBM01320 excluding TBM01298 TL1255 Before S/N TBN00801 excluding TBN00785
9.
FRAME & ATTACHING
PARTS TL1055, TL1255 312002571-4 Figure 1-1 Frame Shrouding & Trim Item Part Number Qty. Description Rev. 299-1305 1 COVER INSTALLATIONS, (includes items 1 thru 29) F 1 AR LOCTITE® 242TM 2 298-1537 1 ENGINE COVER, (includes items 101 thru 107) H 3 297-7031 8 HEX HD CAPSCREW, 3/8-16X1, GR5 4 297-7032 1 HEX HD CAPSCREW, 3/8-16X1-1/4, GR5 5 297-7035 6 HEX HD CAPSCREW, 3/8-16X2-3/4, GR5 6 8T-4138 2 HEX HD CAPSCREW, M6X20 7 298-7244 Ref ROUND TUBE CLAMP, (no longer available, use 353-6855 for replacement) 353-6855 5 ROUND TUBE CLAMP 8 298-0531 2 OFFSET HINGE 10 298-0555 8 HEX LOCKNUT, 3/8-16 12 298-0569 8 BUTTON HD CAPSCREW, 3/8-16X5/8 13 299-0318 2 GAS SPRING 15 298-7365 36 FLAT WASHER, 3/8 16 298-7373 2 FLAT WASHER, 5/16 17 297-7030 5 HEX HD CAPSCREW, 3/8-16X7/8, GR5 19 298-1609 6 TINNERMAN NUT 20 299-0334 1 MIRROR 21 298-8641 1 MIRROR BRACKET 23 299-0319 1 ENGINE COVER WELDMENT 25 300-6128 1 COVER MOUNT BRACKET 26 300-6126 1 COVER PLATE 27 298-8421 1 FRONT COVER 28 298-1360 2 HEX HD CAPSCREW, 3/8-16X1-1/4, GR5 29 300-6129 1 LATCH CATCH BRACKET 101 303-4836 1 LATCH, (includes items 102 & 103) 5P-8500 1 KEY 102 298-7363 6 LOCKWASHER 103 303-4779 4 LOCKNUT 104 305-5511 1 PLEATED SCREEN 105 304-2618 1 ADHESIVE KIT, (includes 3 tubes and applicator) 106 305-5510 1 8 PIECE SCREEN KIT 107 AR BULB SEAL 201 303-4989 1 COUNTERWEIGHT, (no pintle hook) 308-7035 1 COUNTERWEIGHT, (with pintle hook) 202 298-7923 4 HEX HD CAPSCREW, 1-8X8-1/2, GR8 203 298-7875 4 SPECIAL WASHER 301 NSS 1 FRAME WELDMENT 302 Ref CAB ASSY, (see Figure 6-1 for details) 303 Ref HYDRAULIC TANK, (see Figure 9-11 for details) 304 298-8665 4 MOUNT, CENTER BONDED 305 298-7030 4 MOUNT, CENTER BONDED 306 297-7086 2 HEX HD CAPSCREW, 1-8X6-1/2, GR8, (torque to 680-720 lb-ft) 307 303-4744 4 HEX HD CAPSCREW, 3/4-10X3-3/4, (torque to 280-305 lb-ft) 308 298-8054 2 HEX NUT, 1-8 309 298-8052 4 HEX NUT, 3/4-10 310 298-8398 2 FLAT WASHER 311 298-8399 2 FLAT WASHER 312 298-1740 4 TAIL WASHER TL1055 Before S/N TBM01320 excluding TBM01298 TL1255 Before S/N TBN00801 excluding TBN00785
10.
FRAME & ATTACHING
PARTS 31200257 TL1055, TL1255 1-5 313 298-7976 4 HARDENED WASHER, 3/4 401 299-0402 1 CAB FENDER 402 298-7840 4 WHIZ-LOCK BOLT, 3/8-16X1 501 Ref ENGINE POD WELDMENT, (see Figure 1-2 for details) 502 299-0387 7.3 ft TRIM-LOCK 503 298-7248 1 FOAM GASKET SEAL 504 304-3825 1 OIL PAN COVER PLATE 505 297-7038 6 HEX HD CAPSCREW, 1/2-13X7/8 506 298-7380 6 LOCKWASHER, 3/8 507 303-4789 6 HARDENED WASHER, 3/8 508 331-2456 1 SKID PLATE 509 331-2457 3 SKID PLATE CLAMP 510 303-4743 6 HEX HEAD CAPSCREW, 3/8-16X1-1/4 601 Ref CHASSIS HARNESS, (see Figure 10-4 for details) 602 298-7293 1 BACK-UP ALARM 603 297-7011 2 HEX HD CAPSCREW, 1/4-20X3/4 604 298-7363 2 FLAT WASHER, 1/4 605 298-7900 2 HEX LOCKNUT, 1/4-20 606 299-1353 2 STABILITY SENSOR ASSY 701 297-7016 3 HEX HD CAPSCREW, 5/16-18X3/4, GR5 702 298-7379 3 LOCKWASHER, 0.31 703 298-6870 1 HORN 704 298-0550 2 HEX NUT, 5/16-18 705 297-7010 4 HEX HD CAPSCREW, 1/4-20X5/8 706 298-7372 4 WASHER, 1/4 707 298-0548 4 HEX NUT, 1/4-20 708 298-8450 2 INCLINOMETER SWITCH 315-3423 1 LH MIRROR INSTALLATION, (includes items 801 thru 811) B 801 315-3422 1 MIRROR BRACKET 802 317-0088 1 MIRROR MOUNT ARM ASSY 803 317-0089 1 MIRROR HEAD 804 317-0090 AR DOUBLE SIDED TAPE 805 315-3424 1 BOLT, 1/2-13 806 298-7375 1 WASHER, 1/2 807 298-7382 1 LOCKWASHER, 1/2 808 8T-4970 2 HEX HD CAPSCREW, M6X1X14 mm, GR8.8 809 303-4787 2 LOCKWASHER, M6 810 298-8050 1 HEX NUT, 1/2-13 811 298-1755 1 SPACER Figure 1-1 Frame Shrouding & Trim (Continued) Item Part Number Qty. Description Rev. TL1055 Before S/N TBM01320 excluding TBM01298 TL1255 Before S/N TBN00801 excluding TBN00785
11.
FRAME & ATTACHING
PARTS TL1055, TL1255 312002571-6 Figure 1-1 Frame Shrouding & Trim PAP7041 1 7 221 7 23 1009 1015 1301 601 2 2 5 9 17 11 4 12 3 6 8 15 351 201 204 203 205 16 206 702 815 703 704 705 706 1111 1117 202 5 18 2 5 19 21 101 102 103 106 106 109 104 105 107 104 105 108 1015 1009 525 526 504 504 105 104 1015 504 551 514 110 TL1055 S/N TBM01320 & After including TBM01298 TL1255 S/N TBN00801 & After including TBN00785
12.
FRAME & ATTACHING
PARTS 31200257 TL1055, TL1255 1-7 Figure 1-1 Frame Shrouding & Trim (Continued) 1201 803 350 308 311 304 306 310 307313 305 312 309 401 402 352 939 PAL5720 TL1055 S/N TBM01320 & After including TBM01298 TL1255 S/N TBN00801 & After including TBN00785
13.
FRAME & ATTACHING
PARTS TL1055, TL1255 312002571-8 Figure 1-1 Frame Shrouding & Trim Item Part Number Qty. Description Rev. 383-7331 Ref HOOD INSTALL, (not available to order, see items 1 thru 23 for service) B 1 8 HEX HD CAPSCREW, 1/4-20X1-1/8, GR5 2 297-7031 16 HEX HD CAPSCREW, 3/8-16X1, GR5 3 298-1360 2 WHIZ-LOCK SCREW, 3/8-16X1-1/4 4 4 WHIZ-LOCK SCREW, 3/8-16X1-1/2 5 298-7365 16 WASHER, 3/8 6 298-7374 2 WIDE WASHER, 3/8 7 298-7378 8 LOCK WASHER, 1/4 8 298-8049 2 NUT, 3/8-16 9 298-1609 6 TINNERMAN NUT 10 Ref BAND CLAMP, (not shown), (see Figure 4-5 for details) 11 364-5679 1 LATCH MOUNT BRACKET 12 364-5678 1 LATCH CATCH BRACKET 13 Ref AIR FILTER INTAKE ADAPTER, (not shown), (see Figure 4-5 for details) 14 Ref FOAM SEAL, (not shown), (see Figure 4-5 for details) 15 364-5674 1 ENGINE COVER, (includes items 101 thru 110) J 16 364-5698 1 RH MIRROR, (includes items 201 thru 206) 17 1 FRONT COVER 18 1 HOOD HINGE SUPPORT PLATE 19 2 ENGINE HOOD SHIM 21 384-3145 1 HOOD HINGE MOUNT PLATE 22 1 FRONT GAS STRUT BRACKET 23 1 REAR GAS STRUT BRACKET 101 303-4836 1 COMPRESSION LATCH 102 8T-4205 4 WASHER, 6 mm 103 303-4779 4 HEX LOCK NUT, 6X1 mm 104 298-7365 8 WASHER, 3/8 105 298-0570 8 BUTTON HD SCREW 106 364-5685 2 GAS SPRING 107 364-5686 1 FRONT ENGINE COVER HINGE 108 364-5687 1 REAR ENGINE COVER HINGE 109 364-5688 1 ENGINE COVER SUPPORT BAR 110 367-3291 1 BULB SEAL 201 2 HEX HD CAPSCREW, 1/4-20X1/8, GR5 202 298-0549 2 HEX LOCK NUT, 1/4-20, GR2 203 298-0565 2 PLUG 204 298-7372 4 WASHER, 1/4 205 309-2991 1 MIRROR 206 364-5697 1 MIRROR BRACKET 299-6707 Ref CAB INSTALL, (not available to order, see items 304 thru 313 for service) D 304 298-8665 4 CAB MOUNT ISOLATOR 305 298-7030 4 CENTER BONDED MOUNT 306 297-7086 2 HEX HD CAPSCREW, 1-8X6-1/2, GR8, (torque to 680-720 lb-ft) 307 303-4744 4 HEX HD CAPSCREW, 3/4-10X3-3/4, GR8, (torque to 280-305 lb-ft) 308 298-8054 2 HEX NUT, 1-8 309 298-8052 4 HEX NUT, 3/4-10 310 2 TAIL WASHER 311 298-8399 2 WASHER TL1055 S/N TBM01320 & After including TBM01298 TL1255 S/N TBN00801 & After including TBN00785
14.
FRAME & ATTACHING
PARTS 31200257 TL1055, TL1255 1-9 312 298-1740 4 TAIL WASHER 313 298-1631 4 HARD WASHER, 3/4 350 NSS 1 FRAME WELDMENT 351 Ref HYDRAULIC TANK, (see Figure 9-11 for details) 352 Ref CAB WELDMENT, (see Figure 6-2 for details) 401 299-0402 1 CAB FENDER 402 298-7840 4 WHIZ-LOCK BOLT, 3/8-16X1 504 298-7342 2 SCREW 514 180 in TRIM-LOCK 551 384-0204 1 FILTER COVER PLATE 525 360-6618 1 ENGINE DRAIN COVER 526 360-6619 1 COOLER HOSES COVER 601 303-4989 1 COUNTERWEIGHT, (without pintle hitch) 304-2660 1 COUNTERWEIGHT, (with pintle hitch) 702 298-7293 1 BACK-UP ALARM 703 297-7011 2 HEX HD CAPSCREW, 1/4-20X3/4, GR5 704 298-7363 2 WASHER, 1/4 705 298-7900 2 LOCK NUT, 1/4-20 706 299-1353 1 PROXIMITY SENSOR 803 1 HORN 815 367-4967 1 MOLDED RESISTOR 939 299-0354 1 TILT ANGLE GAUGE 1009 8 HEX HD CAPSCREW, 7/8-9X2-1/2, GR8, (torque to 530-565 lb-ft) 1015 298-7395 8 WASHER, 7/8 1111 298-7923 4 HEX HD CAPSCREW, 1/8X8-1/2, GR8 1117 298-7875 4 SPECIAL WASHER 1201 Ref HEX HD CAPSCREW, (see Figure 8-14 for details) 1301 1 ENGINE POD Figure 1-1 Frame Shrouding & Trim (Continued) Item Part Number Qty. Description Rev. TL1055 S/N TBM01320 & After including TBM01298 TL1255 S/N TBN00801 & After including TBN00785
15.
FRAME & ATTACHING
PARTS TL1055, TL1255 312002571-10 Figure 1-2 Axle & Wheel Mounting PAP9110 14 201 15 10 201 11 12 13 23 201 119 201 21 1 22 19 20 201 1 17 18 2 4 3 5 6 8 7 201 8 6 101 103 102 5 86 6 8 7 201 16 201 7 201 7 201 24
16.
FRAME & ATTACHING
PARTS 31200257 TL1055, TL1255 1-11 Figure 1-2 Axle & Wheel Mounting Item Part Number Qty. Description Rev. 299-6706 1 DRIVETRAIN INSTALLATION, (includes items 1 thru 24) J 1 Ref FRONT DRIVESHAFT, (see Figure 5-11 for details) 2 Ref REAR DRIVESHAFT, (see Figure 5-11 for details) 3 Ref SWAY CYLINDER, (see Figure 9-5 for details) 4 Ref STABILIZER CYLINDER, (see Figure 9-6 for details) 5 298-7280 2 SPERICAL BEARING 6 298-0562 4 CYLINDER PIN 7 298-8008 4 HEX HD CAPSCREW, 1/2-13X4, GR5 8 298-1580 4 LOCKNUT, 1/2-13 9 299-7084 8 HEX HD CAPSCREW, 3/4-10X2, GR8 10 297-7053 2 HEX HD CAPSCREW, 3/4-10X4, GR5, (torque to 240-255 lb-ft) 11 298-7394 12 HARDENED WASHER, 3/4 12 305-2035 4 HEX NUT, 3/4-10 13 303-4813 2 BACKING PLATE 14 297-7085 16 HEX HD CAPSCREW, 7/8-9X5-1/2, GR8, (torque to 530-565 lb-ft) 15 298-7395 16 HARDENED WASHER, 7/8 16 297-7037 2 HEX HD CAPSCREW, 7/16-14X2, GR5 17 298-0556 2 LOCKNUT, 7/16-14 18 298-7366 4 FLAT WASHER, 7/16 19 298-8599 10 STRAP 20 298-1791 20 STRAP BOLT, (torque to 55-60 lb-ft), (If strap bolts are removed, they must be replaced. Do not re-torque) 21 298-1612 2 LUBE FITTING, STRAIGHT, 1/8 22 298-1744 40 LUG NUT, (torque to 350-400 lb-ft) 23 297-7054 2 HEX HD CAPSCREW, GR5 24 298-0510 4 FITTING PLUG, 1/8 101 299-0270 1 ENGINE POD WELDMENT 102 Ref FRONT AXLE, (see Figure 5-1 for details) 103 Ref REAR AXLE, (see Figure 5-1 for details) 201 AR LOCTITE® 242TM
17.
FRAME & ATTACHING
PARTS TL1055, TL1255 312002571-12 Figure 1-3 Outrigger Mounting 11 PAL0040 113 4 1 9 8 10 3 5 2 7 6 14 1 12 13 7 1
18.
FRAME & ATTACHING
PARTS 31200257 TL1055, TL1255 1-13 Figure 1-3 Outrigger Mounting Item Part Number Qty. Description Rev. 1 298-1612 4 LUBE FITTING, STRAIGHT, 1/8 2 Ref OUTRIGGER CYLINDER & VALVE, (see Figure 9-7 for details) 3 297-7039 4 HEX HD CAPSCREW, 1/2-13X1, GR5 4 298-8431 2 SHOE PIN 5 298-7375 4 WASHER, 1/2 6 298-8430 2 ARM PIN 7 298-6891 4 BUSHING 8 299-0277 2 ARM WELDMENT 9 299-0278 2 OUTRIGGER SHOE 10 298-6849 2 KEEPER 11 297-7036 2 HEX HD CAPSCREW, 3/8-16X4-1/4, GR5 12 298-8429 2 OUTRIGGER CYLINDER PIN 13 298-0541 4 HEX LOCKNUT, 3/8-16 14 298-0574 2 SOCKET HD CAPSCREW, 3/8-16X4-1/2, GR8
19.
31200257 TL1055, TL1255 SECTION
2 BOOM
20.
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21.
TL1055, TL1255 312002572-2 BOOM Figure
2-1 First Boom Section PAP5090 10 9 8 13 14 8 13 14 2 21 7 19 20 22 10 23 13 16 1 5 24 17 25 12 11 12 11 12 11 14 3 26 4 28 29 30 31 6 18 15 27 TL1055
22.
31200257 TL1055, TL1255
2-3 BOOM Figure 2-1 First Boom Section Item Part Number Qty. Description Rev. 1 354-3994 1 FIRST BOOM SECTION, (TL1055) C 2 298-0488 2 LUBE FITTING, STRAIGHT, 1/8 3 298-1577 1 HEX LOCKNUT, 3/4-10 4 298-8027 1 SOCKET HD CAPSCREW, 3/4-10X6, GR8 5 Ref SECOND BOOM SECTION, (see Figure 2-3 for details) 6 298-7382 2 LOCKWASHER, 1/2 7 Ref CROWD CYLINDER, (see Figure 9-2 for details) 8 298-6887 2 SPECIAL WASHER 9 298-6896 2 SPRING 10 303-4933 3 CHAIN CLEVIS, BL 866 11 298-7106 3 CHAIN PIN 12 298-7312 6 RETAINING RING 13 298-8061 3 HEX NUT, 7/8-14 14 298-8065 3 HEX JAM NUT, 7/8-14, (torque to 100 lb-ft) 15 300-6124 1 CROWD CYLINDER SUPPORT 16 297-7044 2 HEX HD CAPSCREW, 1/2-13X2-1/4, GR5, (torque to 76-86 lb-ft) 17 Ref RETRACT CHAIN, (see Figure 2-3, item 42 for details) 18 298-0557 2 HEX NUT, 1/2-13 19 297-7083 4 HEX HD CAPSCREW, 3/4-10X1-3/4, GR8.8 20 298-7394 4 HARDENED WASHER, 3/4 21 298-6863 2 BUSHING 22 298-8746 1 CABLE ADJUSTING BLOCK 23 298-6894 1 SPRING 24 298-6885 1 STOP BAR 25 Ref EXTEND CHAIN, (see Figure 2-5, item 2 for details) 26 298-0563 1 BOOM PIVOT PIN 27 298-7367 2 WASHER, 1/2 28 297-7029 4 HEX HD CAPSCREW, 3/8-16X3/4, GR5 29 331-3812 1 BOOM END COVER 30 298-7374 4 FLAT WASHER, 3/8 31 298-7380 4 LOCKWASHER, 3/8
23.
TL1055, TL1255 312002572-4 BOOM Figure
2-1 First Boom Section PAL0472 11 14 15 16 17 15 16 17 19 12 4 6 5 20 11 14 16 17 8 1 18 13 22 21 24 23 24 23 24 23 3 25 2 9 10 7 26 27 28 29 30 TL1255
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