Terex TL120 User manual

Operating Instructions
Wheel Loader
TL120
Keep in a safe place for later use!
Place of safe keeping: Behind the driver's seat.
Ausgabe • Edition
2006-10
GÜLTIG AB FZ-ID.NR. • VALID FROM SERIAL NO. • A PARTIR DU NO. DE SERIE
TL01200101 > TL01200279
TEREX GMBH • D-74595 LANGENBURG

Hauptverwaltung/Verkauf
Direction générale/Vente
Headquarters/Sales
Kundendienst
Service après-vente
Customer Service
Ersatzteile
Pièces de rechange
Spare Parts
TEREX GmbH
Postfach 61 • D-74595 Langenburg
Schaeffstr. 8 • D-74595 Langenburg
Phone +49 ( 0) 79 05 / 58-0
Fax [phone] / 58-1 14
TEREX GmbH
Postfach 12 64 • D-91534 Rothenburg
Erlbacher Str. 115 • D-91541 Rothenburg
Phone +49 ( 0) 98 61 / 9 72-4 51
Fax [phone] / 9 72-4 60
Terex Ersatzteile GmbH
Postfach 12 64 • D-91534 Rothenburg
Erlbacher Str. 115 • D-91541 Rothenburg
Phone [phone] / 9 72-0
Fax [phone] / 9 72-4 10
Order number: 5 780 200 343 englisch

Index
3
Operating Instructions Wheel Loader TL120
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Warranty and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Notes on using the Operating Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Regulations concerning environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Safety and Accident Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.1 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Introductory remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.7 Transport of persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.8 Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.9 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.10 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.11 Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.12 Danger of falling objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.13 Working in the vicinity of underground power lines . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.14 Working in the vicinity of overhead power lines . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.15 Operation in closed spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.16 Work stoppages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.17 Change of work attachments, maintenance, repair . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.18 Recovery, loading and transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.19 Monitoring and inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.20 Fire protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.21 Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.22 Notes concerning residual dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.1 Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1.1 Dimensioned drawing with general-purpose bucket . . . . . . . . . . . . . . . . . . . . . . . 23
3.1.2 Dimensioned drawing with multi-purpose bucket . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1.3 Dimensioned drawing with fork lift attachment . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4 Travel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.5 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.6 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.7 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.8 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.9 Fuels, lubricants and coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.9.1 Fluid capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.9.2 Fuel, lubricant and coolant specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.10 Permissible loads in compliance with German Road Traffic Regulations (StVZO) . . . . . . . . . . 30
3.11 Sound level values, vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.12 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.13 Optional accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4Operating Instructions Wheel Loader TL120
Index
4 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1 Initial familiarization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2 Display elements and operator controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.3.1 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.3.2 Monitoring the machine during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.3.3 Switching off the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.4 Driver's seat / Steering wheel tilt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.5 Heating/ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.6 Lighting in compliance with German Road Traffic Regulations (StVZO) . . . . . . . . . . . . . . . 43
4.7 Hydroinflation of tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.8 Driving, steering and braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.8.1 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.8.2 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.8.3 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.8.4 Driving on roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.8.5 Switching off the machine (parking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5 Working Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1 Operation - Loader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.2 Changing work attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.2.2 Assembly of work attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.3 Notes on how to work with the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.3.1 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.3.2 Scraping and grading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.3.3 Excavating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6 Recovery, Loading and Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.1 Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.2 Loading with a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.3 Transport of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7 Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.1 Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.2 Regular oil analyses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.3 Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.4 Inspection parts and aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.5 Care and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.6 Notes for operation in winter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.7 Checking, maintenance and inspection plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.7.1 Initial inspection (hand-over inspection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.7.2 Daily and weekly tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.7.3 Overview of lubricating points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.7.4 Inspection plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.8 Inspection and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.8.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.8.2 Changing the engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.8.3 Cooling system - combined hydraulic oil-water cooler . . . . . . . . . . . . . . . . . . . . . . 74
7.8.4 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.8.5 Air filter, air intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.8.6 Double V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.8.7 Checking the valve lash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Index
5
Operating Instructions Wheel Loader TL120
7.8.8 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.8.9 Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.8.10 Hydraulic oil return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.8.11 Replacing the breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.8.12 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
7.8.13 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.8.14 Injection valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.8.15 Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.8.16 Cab ventilation dust filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.8.17 Windshield washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.9 Immobilization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.9.1 Preservation (temporary immobilization). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.9.2 During the immobilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.9.3 After immobilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8 Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
8.1 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
8.2 Table of faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
9.1 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
9.2 Equipment options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.2.1 Ride control system (LSD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
10 Keyword index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

6Operating Instructions Wheel Loader TL120
Index

Introduction
7
Operating Instructions Wheel Loader TL120
1
1Introduction
You decided to buy a TEREX TL120 Wheel Loader.
The confidence you have placed in this model will be
rewarded by efficient and economical performance of
the machine.
These Operating Instructions contain all information
necessary for the correct use of the machine.
This instruction book is intended for use by personnel
responsible for operation, maintenance, repair, and
supervision of the machine.
This Operating Manual must be read thoroughly and
understoodbeforecommissioningthemachine andis
always to be kept within reach at all times.
Please contact your dealer immediately if you need
any further explanations or anything is unclear.
Special equipment and attachments are not included
in this Operating Manual.
We reserve the right to make improvements on the
machine within the scope of impending technical
developments, without incurring any obligation to
change these Operating Instructions.
Please always quote the vehicle type and vehicle
identification number when making an inquiry and for
all correspondence.
Attention
Any modifications of TEREX products and
their equipment using extras and work
attachments which are not included in our
product range require our written approval. If
our approval is not sought, our warranty
expires, as does our product liability for any
resulting consequential damage.
Attention
The vehicle identification number of the
machine is stamped onto the type plate (1/1).
Fig. 1 Type plate
L844-001
1

8Operating Instructions Wheel Loader TL120
Introduction1
1.1 Warranty and Maintenance
The warranty period covers 12 months, beginning
with the day the machine is handed over or put into
operation.
Safe working conditions and good working order of
the machine are prerequisites for efficient work.
Your TEREX wheel loader fulfils these requirements
when correctly handled and when serviced and
maintained as specified.
Careful observation of the machine whilst in function
and the use of the specified fuels, lubricants, and
coolants will prevent malfunction.
Trained specialist personnel are responsible for any
servicing of the machine which requires expert
knowledge. This means that inspections and repair
work must be performed by your dealer's customer
service personnel.
In respect of possible claims for damages during the
warrantyperiod,allworkspecifiedinthemaintenance
and inspection plan must be carried out at the
specified intervals.
After the warranty period, too, regular maintenance
must be performed to ensure that the machine is
constantly in good working order and enjoys a
reasonable service life.
Insist that only original TEREX spare parts are used
for all repair work which may arise. In this way, you
will have a product of lasting high quality, thereby
ensuring that your machine maintains its original
condition.
1.2 Copyright
The Operating Manual isprotected by copyright laws.
It must not be copied, disseminated or used for
competitive purposes, either fully or in part, without
prior written permission.
1.3 Notes on using the Operating
Manual
Presentation of Figures and Items
(1/1) = Figure 1, Item number 1
Presentation of cross references to Chapters and
activities
Î1.4, 7 = Chapter/Section 1.4, Page 7
Pictogram "Danger to life"
Pictogram "Danger of injury/machine damage"
Pictogram "Attention"
Danger to life
Thisindicatesapotentialdangerrepresented
by the machine which, if appropriate
precautions are not taken, may result in
death.
Danger of injury/machine damage
This indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury, or
property/equipment damage.
Attention
This symbol is employed for information
containing important notes about the correct
use and/or how to proceed. Non-compliance
may lead to malfunction.

Introduction
9
Operating Instructions Wheel Loader TL120
1
1.4 Regulations concerning
environmental protection
Applicable environmental requirements must be
observed for all tasks performed on and with the
machine.
During installation, repair and maintenance tasks,
particular care must be taken that substances that
would damage the environment such as:
– lubricating grease and oils
– hydraulic oils
–fuels
–coolants
– cleaners containing solvents
are not allowed to come in contact with the soil or the
water system.
These substances must be stored in suitable
containers and must be properly transported,
collected and disposed of.
If the substances listed above do reach the soil, the
leak or outlet must be stopped immediately and the
fluid must be cleaned up with a suitable absorbent
material. If necessary, the soil involved must be
removed. Absorbentmaterialsandremovedsoilmust
be disposed of properly. Applicable environmental
requirements must be observed.

10 Operating Instructions Wheel Loader TL120
Introduction1
1.5 Pictograms
The following Table explains the meaning of the
pictograms which may be attached to the machine.
Symbol Description Symbol Description
Danger to life Horn
On machine:
Caution, maintain safety distance
In Operating Manual:
Danger of injury/machine damage
Direction indicator LT/RT
Attention Working floodlight
Battery charge indicator High-beam indicator
Preheating Rotating beacon
Engine oil pressure Hazard warning system
Engine oil temperature Hydraulic rock breaker
Engine oil level Working hydraulics shut-off
Coolant temperature Unlocked
Coolant level Locked
Air filter Float position
Fuel, fuel level On machine:
Safe distance
Hydraulic oil
Hydraulic oil level Danger of injury
Hydraulic oil temperature Danger of crushing
Table 1 Pictograms on the machine