Terex TL160 User manual

Operating Manual
Wheel Loader
TL160
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
TL01600101 > TL01600198
TEREX GMBH • D-74595 LANGENBURG

Hauptverwaltung/Verkauf
Direction générale/Vente
Central Administration/Sales
Kundendienst
Service après-vente
Service Department
Ersatzteile
Pièces de rechange
Spare parts
Terex GmbH
Postfach 61 • D-74595 Langenburg
Schaeffstr. 8 • D-74595 Langenburg
Phone + 49 (0) 7905/58-0
Fax [phone]
Terex GmbH
Postfach 12 64 • D-91534 Rothenburg
Erlbacher Str. 115 • D-91541 Rothenburg
Phone + 49 (-451) 9861/972-0
Fax + 49 (0) 9861/972-460
Terex | Ersatzteile GmbH
Postfach 12 64 • D-91534 Rothenburg
Erlbacher Str. 115 • D-91541 Rothenburg
Phone + 49 (0) 9861/972-0
Fax + 49 (0) 9861/972-410
Order number: 5 780 200 363 englisch

Index
3/112TL160 Operating Manual 12.9.08 Version 1.0
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Warranty and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Notes on using the Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Preliminary remarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 General safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Working 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 Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 bucket, directly mounted. . . . . . . . . . . . . . . . . . . . . . . 23
3.1.2 Dimensioned drawing with bucket and quick-attach system . . . . . . . . . . . . . . . . . . . 24
3.1.3 Dimensioned drawing with multi-purpose bucket . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1.4 Dimensioned drawing with fork lift attachment . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.4 Travel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.5 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.6 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.7 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.8 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.9 Fuels, lubricants, and coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.9.1 Fluid capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.9.2 Fuel, lubricant, and coolant specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.10 Permissible loads in compliance with German Road Traffic Regulations (StVZO) . . . . . . . . . . 31
3.11 Sound level values, vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.12 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.13 Optional accessories (options) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Index
4/112 TL160
Operating Manual 12.9.08 Version 1.0
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 / Air-conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.6 Lighting in compliance with German Road Traffic Regulations (StVZO) . . . . . . . . . . . . . . . 46
4.7 Hydroinflation of tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.8 Driving, steering and braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.8.1 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.8.2 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.8.3 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.8.4 Driving on roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.8.5 Switching off the machine (parking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5 Working Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.1 Operation - Loader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.2 Changing work attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2.2 Assembly of work attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.3 Notes on how to work with the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.3.1 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.3.2 Scraping and grading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.3.3 Excavating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6 Recovery, Loading and Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.1 Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.2 Loading the machine by use of a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.3 Transport of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7 Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.1 Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.2 Regular oil analyses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.3 Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.4 Inspection parts and aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.5 Care and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.6 Notes for winter operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.7 Checking, maintenance and inspection plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.7.1 Initial inspection (Handing-over inspection). . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.7.2 Daily and weekly tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.7.3 Overview of lubricating points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.7.4 Inspection plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.8 Inspection and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.8.1 Checks using the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.8.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.8.3 Changing the engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.8.4 Cooling system - combined hydraulic oil-water cooler . . . . . . . . . . . . . . . . . . . . . . 78
7.8.5 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.8.6 Air filter, air intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.8.7 V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Index
5/112TL160 Operating Manual 12.9.08 Version 1.0
7.8.8 Checking the valve lash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.8.9 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
7.8.10 Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.8.11 Hydraulic oil suction filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.8.12 Hydraulic oil return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.8.13 Replacing the breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.8.14 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.8.15 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.8.16 Injection valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.8.17 Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.8.18 Cabin ventilation dust filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.8.19 Removing the dust filter for cabin ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.8.20 Windshield washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.9 Immobilization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.9.1 Preservation (temporary immobilization ) . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
7.9.2 During immobilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.9.3 After immobilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8 Trouble-shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
8.1 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
8.2 Table of faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
10 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Index
6/112 TL160
Operating Manual 12.9.08 Version 1.0

Introduction
7/112TL160
1
Operating Manual 12.9.08 Version 1.0
1Introduction
You decided to buy a Terex TL160 Wheel Loader.
The confidence placed in this model will be rewarded
by the efficient and economical performance of the
machine.
These Operating Instructions contain all information
necessary for the correct use of the machine.
They are intended for use by personnel responsible
foroperation,maintenance, repair,and supervision of
the machine.
Please read them carefully before putting the ma-
chine into operation and make sure that they are kept
at hand at all times.
Should you need further explanations or should any-
thing be unclear, please contact your dealer immedi-
ately.
Special equipment and attachments are not included
in these Operating Instructions.
We reserve the right to make improvements on the
machine within the scope of impending technical de-
velopments, without incurring any obligation to
change these Operating Instructions.
Please state the vehicle type and vehicle identifica-
tion number when making inquiries or orders, and in
all written correspondence.
Attention
Anymodifications of Terexproductsand 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 label (1/1) .
Fig. 1 Type label
1
L864-001

8/112 TL160
Introduction1
Operating Manual 12.9.08 Version 1.0
1.1 Warranty and maintenance
The warranty period covers 12 (twelve) months, be-
ginning 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 Radlader 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 knowl-
edge. Inspections and repairs must therefore be car-
ried out by your dealer’s customer service.
In respect of possible claims for damages during the
warrantyperiod,allworkspecifiedinthemaintenance
and inspection plan must be carried out at the speci-
fied intervals.
After the warranty period, too, regular maintenance
must be performed in order to ensure that the ma-
chine is constantly in good working order and enjoys
a reasonable service life.
Insist that only original Terex spare parts are used in
the event of any repair work. In this way, you will have
a product of lasting high quality, thereby ensuring that
your machine maintains its original condition.
1.2 Copyright
This Operating Manual is copyrighted. It must not be
copied, disseminated or used for competitive purpos-
es, either fully or in part, without prior written permis-
sion.
1.3 Notes on using the Operating
Instructions
Presentation of Figures and Positions
(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
9/112TL160
1
Operating Manual 12.9.08 Version 1.0
1.4 Regulations concerning
environmental protection
Applicable environmental requirements must be ob-
served for all tasks performed on and with the ma-
chine.
During installation, repair and maintenance tasks,
particular care must be taken that substances that
would damage the environment such as:
– lubricating greases and oils
– hydraulic oils
–fuels
–coolant
– cleaning fluids containing solvents
do not seep into the ground or the sewerage system.
These substances must be kept, transported, collect-
ed and disposed of in suitable containers.
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 re-
moved. Absorbent materials and removed soil must
be disposed of properly. Applicable environmental re-
quirements must be observed.

10/112 TL160
Introduction1
Operating Manual 12.9.08 Version 1.0
1.5 Pictograms
The following Table explains the meaning of the pic-
tograms which may be attached to your machine.
Symbol Description Symbol Description
Danger to life Horn
On machine: Caution, safety distance
In Operating Instructions:
Danger of injury/machine damage
Direction indicator LT/RT
Attention Working floodlight(s)
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:
Safety distance
Hydraulic oil
Hydraulic oil level Danger of injury
Hydraulic oil temperature Danger of crushing
Tab. 1 Pictograms on the machine