Terex TL120 User manual
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 +49 (0) 79 05 / 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 +49 (0) 98 61 / 9 72-4 60
Terex Ersatzteile GmbH
Postfach 12 64 • D-91534 Rothenburg
Erlbacher Str. 115 • D-91541 Rothenburg
Phone +49 (0) 98 61 / 9 72-0
Fax +49 (0) 98 61 / 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
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
Introduction
11
Operating Instructions Wheel Loader TL120
1
Hydraulic oil filter clogging indicator Observe guidelines given in the Operating
Manual
Fan for heating/ventilation Grease gun
Windshield washer and wiper system Operating mode indicator
Operating hours
Parking brake Lashing points
Travel direction
FWD/REV Suspension points for loading by crane
Travel speed, FAST First-aid kit
Travel speed, SLOW Fire extinguisher
Symbol Description Symbol Description
Table 1 Pictograms on the machine
V
R
V
R
Safety and Accident Prevention
13
Operating Instructions Wheel Loader TL120
2
2 Safety and Accident Prevention
2.1 Declaration of Conformity
2.2 Introductory remarks
Before putting the earth-moving machine into
operation, read theseOperating Instructions carefully
and strictly observe the indicated references for safe
operation.
National safety regulations - e.g. the Accident
Prevention Regulations, "Earth-Moving Machinery"
(BGR 500, 2.12) and "Vehicles" (BGV D29) in the
FederalRepublicofGermany-must alsobecomplied
with when operating the earth-moving machine.
In addition to the Operating Instructions, legal
regulations governing road traffic and accident
prevention must also be observed. Such
requirements could also apply in respect of handling
hazardous goods or the wearing of personal safety
gear, for example.
Furthermore, safety laws governing work in particular
locations (tunnels, adits, quarries, pontoons,
contaminated areas, etc.) must likewise be observed.
2.3 Proper use
The earth-moving machine with standard bucket
equipment is intended solely for work which is
suitable for the function of the machine and its work
implements.
Such work involves loosening, taking up, transporting
and dumping soil, rock or other materials as well as
loading these materials on trucks, conveyor belts or
other means of transport, when the transport of the
material is normally done by positioning the earth-
moving machine.
The mounting of special work implements such as
multi-purpose buckets, side-dump buckets,
sweepers, fork lift attachments, etc. allows the
machine to perform above mentioned work.
Anyusageaboveandbeyondthatspecifiedhere,e.g.
the transport of persons or the usage of the lift
equipment as work platform is regarded as improper
use. The supplier cannot be held responsible for any
damage resulting from improper use. The risk is
carried solely by the user.
Compliance with the operating and maintenance
instructions,theperformanceofmaintenanceworkas
specified and adherence to replacement intervals all
form part of the concept of proper use.
Declaration of Conformity
The machine conforms to all basic
requirements of the relevant European
guidelines.
Conformity has been proven. The
corresponding documentation and
original of the Declaration of Conformity
are kept by the manufacturer.
A copy of the Declaration of Conformity
is attached to the sales documentation.
14 Operating Instructions Wheel Loader TL120
Safety and Accident Prevention2
2.4 General safety instructions
• It is important to refrain from any working methods
which impair safety.
• The earth-moving machine is only to be used with
a cabin or canopy.
• The earth-moving machine is only to be used if it
is in a safe and operational condition.
• The manufacturer’s Operating Instructions must
be complied with for operation, maintenance,
repair, assembly and transportation.
• The plant operatormust provide additional special
safety instructions, wherever necessary, for
specific local conditions.
• The Operating Instructions and any information
pertaining to safety must be carefully kept in the
driver’s cab.
• The Operating Instructions and safety notes must
be complete and fully readable.
• Safetyequipmentonearth-movingmachinesmust
not be deactivated or removed.
• Protectiveclothingmust beworn duringoperation.
Rings, scarves and unbuttoned jacket should be
avoided. Protective goggles, protective boots,
helmets, gloves, reflecting jackets, ear-muffs, etc.
may be required.
• Before commencing work, information must be
obtained on first aid and possible means of rescue
(emergency ambulance, fire brigade, helicopters).
• A check must becarried out to ensure thatthe first
aidboxisathandandthat itscontents complywith
regulations.
• Personnel must be aware of the location and
method of operation of the fire extinguishers on
the earth-moving machine as well as on-site fire-
warning and fire-fighting equipment.
• Loose parts such as tools or other accessories
must be secured to the earth-moving machine.
• Doors, windows, covers, flaps etc. must be closed
or secured against slamming shut if in an open
condition.
2.5 Operation
Earth-moving machines are only to be independently
operated and serviced by persons who:
– are physically and mentally suitable
– have been instructed in the operation or
maintenance of earth-moving machines and have
demonstrated this ability to the plant operator
– and who can be expected to perform their
allocated duties reliably.
All such persons must be of the legal minimum age.
They must be designated by the plant operator to
operate or service the earth-moving machine.
Operating equipment and controls are only to be
operated from the driver's seat.
The earth-moving machine is only to be ascended
and entered using the entrances and surfaces
intended for this purpose.
It is the driver’s responsibility to ensure that the
operator’s stand, entrances and other surfaces of the
earth-moving machine which have to be stepped on
are kept free of dirt, grease, oil, ice and snow.
Safety and Accident Prevention
15
Operating Instructions Wheel Loader TL120
2
2.6 Danger zone
– No-one is allowed to enter the danger zone of
earth-moving machines.
– The danger zone encompasses the area around
the earth-moving machine in which persons may
be injured by operational movements of the earth-
moving machine, its work implements and
attachments, or by swinging out or falling loads.
– The machine operator is only to work the earth-
moving machine if no-one is in the danger zone.
– The machine operator must give a warning signal
to anyone who might be in danger.
– The machine operator must stop work with the
earth-moving machine if someone remains in the
danger zone despite the warning.
– To ensure no danger of crushing, a sufficient
safety distance (min. 0.5 m) must be kept from
solid objects, e.g. buildings, excavation slopes,
scaffolding, other machines, etc.
– Ifthe abovesafety distance cannotbe maintained,
the area between solid objects and the working
zone of the earth-moving machine must be
blocked off.
– If conditions are such that the machine operator’s
view of the driving and working zone is restricted,
hemust be guidedor thedriving and workingzone
must be marked by a solid barricade.
2.7 Transport of persons
The transport of persons on the machine is forbidden.
2.8 Stability
– The earth-moving machine must be used, driven
and operated in such a manner that its stability
against overturning is ensured at all times.
– The machine operator must driveat speeds which
are suitable for local conditions.
– The permitted payload of the earth-moving
machine must not be exceeded.
– The earth-moving machine must remain at a
sufficient distancefromthe edges of quarries, pits,
mounds and slopes to ensure there is no risk of
falling. Earth-moving machines must be secured
so that they cannot roll or slip when in the vicinity
of excavations, shafts, ditches, pits and slopes.
16 Operating Instructions Wheel Loader TL120
Safety and Accident Prevention2
2.9 Driving
Before putting the earth-moving machine into
operation, the driver's seat, mirrors and operator's
controls must be adjusted so as to ensure safe
working.
The safety belt must be fastened.
The windows must be clean and clear of ice.
Driving tracks must be designed so as to ensure
smooth, safe operation, i.e. they must be sufficiently
wide, on ground which has as few slopes as possible
and sufficient carrying capacity.
Downhill tracks must be set out in such a way that
earth-moving machines can be safely braked.
Before driving downhill, the appropriate gear must be
selected and the gear lever not be moved during
downhill travel (road or off-road gear).
On steep drops and uphill gradients, the load must be
carried on the uphill side, if possible, to increase
stability.
The carrying capacity of bridges, cellar roofs, vaults,
etc. must be verified before the earth-moving
machine can drive over them.
The internal dimensions of constructions must be
observed before entering underground passages,
tunnels, etc.
It is the plant operator's responsibility to ensure that
equipment such as first-aid box, warning triangle,
hazard lights are kept with the machine according to
the traffic regulations valid in the user’s country
(e.g. in Germany "StVZO") and that the driver has the
appropriate license as required by the national traffic
laws of the country in question.
Outside areas covered by general traffic regulations,
e.g. on factory premises, traffic regulations should be
applied in the proper manner. This should also apply
with regard to drivers' licenses.
2.10 Operation
Daily before commencing work and after every
change of work attachments, the machine operator
must check the correct fastening of the work
attachments as well as the correct lock of the quick-
mount hitch. Work attachments are to be carefully
moved at low height. During this check the danger
zones of earth-moving machines have to be free of
personnel.
The machine operator must only swing the work
equipment over occupied driver’s seats, operator
consoles and workplaces of other machines if these
are protected by canopies (FOPS).
If a cab does not have the required protection, the
driver of this vehicle must leave the driver’s stand
while the work equipment is being swung overhead.
The vehicles must be loaded in such a manner as to
ensure that there is no overloading and no material
can be lost as long as the machine is moving. The
vehicle must be loaded from the lowest possible
height.
At dumping points, earth-moving machines may only
be operated if suitable measures have been taken to
prevent rolling or falling.
2.11 Guides
Guides must be easily recognizable, for example by
means of reflective clothing. They must remain within
the machine operator's vision field.
While guiding the machine, guides must not be given
other jobs which may distract them from their task.
Safety and Accident Prevention
17
Operating Instructions Wheel Loader TL120
2
2.12 Danger of falling objects
Earth-moving machines are only to be used where
there is a danger of falling objects if the operator's
stand has a canopy (FOPS). A front guard must be
employed if there is a risk of materials breaking
through into the cab.
In front of walls e.g. of stacked materials, earth-
movingmachines mustbe positionedand operatedin
such a way that the driver’s seat and entry to the
driver’s seat are not situated on the side facing the
wall.
Demolition work is only to be performed by earth-
moving machines where there is no danger to
persons and where the machine is equipped with a
canopy, cab-mounted front guard and appropriate
operating equipment.
See regulations book "Demolition work" (ZH 1/614)
published by the Tiefbau-Berufsgenossenschaft
(Civil Engineering Employer's Liability Insurance
Association).
2.13 Working in the vicinity of
underground power lines
Before commencing excavating work using earth-
moving machines, it must be determined whetherany
underground power lines are present in the intended
working zone which may present a danger to
persons.
If underground power lines are present, their exact
position and course must be determined in
consultation with the proprietor or operator of the
lines, and the necessary safety precautions decided
and implemented.
The course of power lines in the work area must be
clearly marked, under supervision, before
commencingany earth-movingwork. Ifthe position of
lines cannot be determined, search ditches must be
dug - manually, if needed.
If underground power lines are encountered
unexpectedly or they or their protective covers are
damaged, the machine operator must discontinue
work immediately and notify the supervisor.
2.14 Working in the vicinity of overhead
power lines
If the earth-moving machine is being used in the
vicinity of overhead power lines and trolley wires, a
safety distance which varies depending on the
nominal voltage of the overhead line must be
maintained between the lines and the earth-moving
machine and its work equipment, to prevent current
overspill. This also applies to the distance between
these lines and attached implements or loads.
The safety distances specified below must be
complied with.
In the observation of safety distances, all working
movements of earth-moving machines, e.g. positions
of the work equipment and the dimensions of
attached loads must be taken into consideration.
Uneven ground which would cause the earth-moving
machine to be inclined and thus nearer to overhead
lines must also be taken into account.
Both overhead lines and operating equipment may
swing out in windy conditions, thus reducing the
safety distance.
If it is impossible to maintain sufficient distance from
overhead power lines and trolley wires, the plant
operator must consult with the proprietor or operator
of the overhead lines to find other safety precautions
to prevent current overspill. Such measures could
include
– switching off the power,
– re-routing the overhead line,
– cabling, or
– limiting the operating zone of earth-moving
machines
Nominal voltage
in kV Safety distance
in meters
– 1 1.0
> 1 to 110 3.0
> 110 to 220 4.0
> 220 to 380 5.0
unknown nominal voltage 5.0
Table 2 prescribed safety distances
18 Operating Instructions Wheel Loader TL120
Safety and Accident Prevention2
2.15 Operation in closed spaces
If earth-moving machines are to be used in closed
rooms,theseareas mustbesufficientlyventilatedand
the special regulations be observed.
2.16 Work stoppages
Before rest periods and at the end of the working day,
the driver of the earth-moving machine must park the
machine on ground which has sufficient carrying
capacity and is as level as possible, and must secure
it against unintended movement.
Before rest periods and at the end of the working day,
the driver must lower the work equipment onto the
ground or secure it so that it cannot move.
The driver is not toleave the earth-moving machine if
the work equipment has not been lowered to the
ground or secured.
Earth-moving machines are only to be parked in
places where they do not present an obstacle, e.g. on
the construction site or to plant traffic. Warning
devices, e.g. triangles, warning cordons, flashing or
hazard lights are to be used if necessary.
Before leaving the operator stand, the driver must
bring all operating equipment into home position,
switch off the working hydraulics and apply the
brakes.
If the driver is leaving the earth-moving machine
unattended, he must first turn off the engine and
ensure that it cannot be started up by unauthorized
persons (e.g. removing ignition keys).
Safety and Accident Prevention
19
Operating Instructions Wheel Loader TL120
2
2.17 Change of work attachments,
maintenance, repair
Earth-moving machines are only to be converted,
maintained or serviced under the guidance of a
suitable person designated by the plant operator and
following the manufacturer’s Operating Instructions.
After every change of work attachments, the driver
must convince himself that the quick-mount hitch is
correctly fastened and locked.
Work on e.g.
–braking,
– steering,
– hydraulic and
– electric systems
of the machine is only to be carried out by expert
personnel specially trained in these areas.
Stability must be ensured during all type of work on
the machine at all times.
The machine must be suitably secured by chocks so
that it cannot roll away whenever work is performed,
particularly under the machine.
The work equipment must be secured against
movement by lowering it to the ground or equivalent
measures, e.g. cylinder supports, trestles. As long as
the engine is running, the unprotected working and
articulation range must not be entered.
When jacking up earth-moving machines, all jacking
devices must be positioned so that they cannot slip.
Jacks must be positioned and applied absolutely
straight, without tilting.
Raisedearth-movingmachinesmustbesupportedby
suitable structures such as crosswise stacks of
planks, square timbers or steel trusses.
Earth-moving machines which are raised using
operating equipment must be stabilized by a
supporting structure immediately after lifting. Work
under raised machines which are only supported by
their hydraulics is forbidden.
The engine/motor(s) must be turned off prior to all
maintenance and repair work. This requirement can
only be ignored in the case of maintenance or repair
work which cannot be performed without the
engine/motor(s) running.
When performing maintenance and repair work on
the hydraulic system, it must be relieved of pressure.
With the engine turned off, lower the work equipment
to the ground and actuate all hydraulic control levers
until there is no pressure left in the hydraulic system.
• Before working on the electric system or when
performing arc-welding on the machine, the
connection to the battery must be disconnected.
• When disconnecting the battery, first the negative
pole then the positive pole must be disconnected.
The battery must be re-connected in reverse
order.
• During repair work around the battery, it must be
covered with insulating material. Tools should
never be placed on or near the battery.
Protective devices of moving machine parts are only
to be opened or removed after the drive has been
switched off and cannot be switched on again by
unauthorized persons. Protective devices are e.g.
engine/motor covers, doors, protective grating, trim.
Upon completion of assembly, maintenance or repair
work, all protective devices must once more be
attached in the proper manner.
Load-bearing parts of earth-moving machines are
only to be welded following consultation with the
manufacturer and in accordance with recognized
welding principles.
Protective structures (ROPS, FOPS) are not to be
welded or drilled in any way.
Before commencing work on the hydraulic system,
the operating pressure, pilot pressure, back pressure
and pressure inside the tank must be let off.
Swallowing lubricants, or long and repeated skin
contact, can be hazardous to health. Used properly,
there is no particular danger to health. The safety
specification sheets from the oil companies must be
observed.
Only the hoses specified by the manufacturer may be
used.
Hydraulic hoses must be routed and assembled by
expert personnel.
Smoking and naked flames are prohibited in the
vicinity of fuel or batteries.
20 Operating Instructions Wheel Loader TL120
Safety and Accident Prevention2
2.18 Recovery, loading and
transportation
Earth-moving machines are only to be recovered if
adequate towing vehicles are used.
The tow fixing points specified by the manufacturer
must be used.
For loading and transportation, earth-moving
machinesand allnecessaryauxiliary equipmentmust
be secured against unwanted movement.
The traveling gear and crawler unit of earth-moving
machines must be sufficiently cleaned of mud, snow
and ice to ensure that ramps can be driven up without
risk of slipping.
When transporting the earth-moving machine on
trucks, flatbed trailers, or by rail, it must be sufficiently
securedwith chocks andby attachmentto the lashing
points.
Before setting off, the route to be taken must be
examined to determine whether the roads are wide
enough, entrances and passages under bridges are
large enough and that roads and bridges have
sufficient carrying capacity.
2.19 Monitoring and inspections
The machine must be submitted to a general
inspection according to the existing Accident
Prevention Regulations valid in the user's country.
This inspection must be carried out by an expert
(e.g. machine engineer or machine foreman):
– beforethemachineisputintooperationforthefirst
time and before the machine is
again put into operation after significant
modifications have been made
– at least once a year
– inthemeantime,accordingtooperatingconditions
and local environments
The results of this inspection have to be recorded in
writing and this record kept until the next inspection
takes place.
Prior to every work shift, the machine operator must
check the earth-moving machine according to the
inspection and maintenance plan.
Hydraulic hoses must be replaced as soon as the
following damage is recognized:
– damage to the outer layer which reaches the
intermediate layer,
– embrittled patches on the outer layer,
– deformations when under pressure or without
pressurewhichdifferfromtheoriginalshapeof the
installed hose,
–leaks,
– damage to hose fittings or to the connection
between the fitting and the hose.
The coolant level should only be checked after the
engine has cooled down; the cap must be turned
carefully in order to let off excess pressure.
Prior to operations, the machine operatormust check
the function of the safety devices.
The machine operator must advise the supervisor
immediately - and his replacement, if there is a
change of operator - with regard to any shortcomings.
In the event of shortcomings which jeopardize the
operatingsafetyof theearth-movingmachine, it isnot
to be used until these have been eliminated.
2.20 Fire protection
• Switch off the engine when filling the fuel tank and
take special care as long as the engine is hot.
• Never smoke or handle open flames whilst
refueling the tank of the machine.
Thefireextinguishermustbekeptinthe
cab.
The fire extinguisher symbol must be
attached.
Table of contents
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