Terex TL160, Operating Manual

Page 1: ...TL160 Keep in a safe place for later use Place of safe keeping Behind the driver s seat Ausgabe Edition 2006 10 G LTIG AB FZ ID NR VALID FROM SERIAL NO A PARTIR DU NO DE SERIE TL01600101 TL01600198 T...

Page 2: ...D 74595 Langenburg Schaeffstr 8 D 74595 Langenburg Phone 49 0 7905 58 0 Fax 49 0 7905 58 114 Terex GmbH Postfach 12 64 D 91534 Rothenburg Erlbacher Str 115 D 91541 Rothenburg Phone 49 451 9861 972 0...

Page 3: ...8 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 concernin...

Page 4: ...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...

Page 5: ...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 Winds...

Page 6: ...Index 6 112 TL160 Operating Manual 12 9 08 Version 1 0...

Page 7: ...e 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 impen...

Page 8: ...a 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 produc...

Page 9: ...ating 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 disp...

Page 10: ...ne 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 temperat...

Page 11: ...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 cr...

Page 12: ...12 112 TL160 Introduction 1 Operating Manual 12 9 08 Version 1 0...

Page 13: ...on 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 ot...

Page 14: ...ters A check must be carried out to ensure that the first aid box is at hand and that its contents comply with regulations Personnel must be aware of the location and method of operation of the fire e...

Page 15: ...scaffolding other machines etc If the above safety distance cannot be maintained the area between solid objects and the working zone of the earth moving machine must be blocked off If conditions are...

Page 16: ...he 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 ap...

Page 17: ...if need be 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...

Page 18: ...ork equipment onto the ground or secure it so that it cannot move The driver is not to leave the earth moving machine if the work equipment has not been lowered to the ground or secured Earth moving m...

Page 19: ...nnot be performed without the engine motor s running When performing maintenance and repair work on the hydraulic system the hydraulic system must be relieved of pressure With the engine turned off lo...

Page 20: ...after essential modifications have been made at least once a year in the meantime according to operating conditions and local environments The results of this inspection have to be recorded in writing...

Page 21: ...22 Notes concerning residual dangers Failure of hydraulic system If the hydraulic system fails because the diesel engine is not running the hydraulic pump is damaged or hydraulic oil has been lost onl...

Page 22: ...Safety and Accident Prevention 2 22 112 TL160 Operating Manual 12 9 08 Version 1 0...

Page 23: ...2 9 08 Version 1 0 3 Technical Specifications 3 1 Views 3 1 1 Dimensioned drawing with bucket directly mounted Fig 2 Dimensioned drawing with bucket and tires 15 5 R 25 2760 880 45 3030 3 5 1635 540 6...

Page 24: ...ating Manual 12 9 08 Version 1 0 3 1 2 Dimensioned drawing with bucket and quick attach system Fig 3 Dimensioned drawing with bucket and tires 15 5 R 25 6730 1635 2760 540 100 3895 2890 910 45 5 0 303...

Page 25: ...Technical Specifications 3 25 112 TL160 Operating Manual 12 9 08 Version 1 0 3 1 3 Dimensioned drawing with multi purpose bucket Fig 4 Dimensioned drawing with bucket and tires 15 5 R 25...

Page 26: ...g Manual 12 9 08 Version 1 0 3 1 4 Dimensioned drawing with fork lift attachment Fig 5 Dimensioned drawing with fork lift attachment and tires 15 5 R 25 700 1700 986 500 2760 1635 7216 540 3030 140 35...

Page 27: ...r 24 V 4 5 kW Cold starting aid 1 glow element per cylinder Lighting system in compliance with German Road Traffic Regulations StVZO with Halogen H 4 headlamps 2 front and 2 rear working floodlights T...

Page 28: ...ly acting articulated steering Two double acting steering cylinders Total steering angle 80 Loader installation Double acting work cylinders two lift cylinders and one tilt cylinder Control block with...

Page 29: ...measures must be taken and restrictions apply Attention The tire pressure refers to standard equipment During fork lift operations the tire pressure of the front wheels must be increased by at least...

Page 30: ...ding to customer specifications Brand label on machine The same viscosity specifications apply as for mineral hydraulic oils Machine damage caused by non mixable bio oils Do not mix bio oils from diff...

Page 31: ...W40 20W50 20 30 40 Ambient temperature Ambient temperature Permissible loads in compliance with German Road Traffic Regulations StVZO Permissible total weight see type label and or General Certificati...

Page 32: ...ucket hinge pin height 3895 mm 3895 mm Tilt back angle 50 50 Dump angle at max dump height 45 45 Digging depth horizontal bucket 100 mm 75 mm Lift capacity at ground level1 85 5 kN 85 5 kN Ripping for...

Page 33: ...ing height 3570 Tab 18 Dimensions of fork arm connection in compliance with ISO FEM Class 3 Form B DIN 15 173 ISO 2328 respectively Total lift range S 2 0 S 1 25 kg 2000 3200 lbs 4710 7040 kg 2180 350...

Page 34: ...val procedure as stipulated by StVZO in Germany Ride control system LSD Anti theft device Back up alarm system Electric refueling pump Quick attach system hydraulically operated Snow blade Sweeper Loa...

Page 35: ...d to a thorough visual inspection Ensure that there is no damage loose or missing screws oil accumulations oil or fuel leakage Shortcomings must be remedied immediately In the event of shortcomings wh...

Page 36: ...TL160 Operating Manual 12 9 08 Version 1 0 4 2 Display elements and operator controls Attention The following list includes non standard equipment Fig 8 Operator controls 00014 0 h 12 Km h 0 4 4 1 2...

Page 37: ...column switch 2 Brake inching pedal 3 Accelerator pedal 4 Tilt adjustment of steering wheel option height adjustment 5 Operation additional control circuit left OFF right ON 6 Control lever loader in...

Page 38: ...strument panel 00014 0 h 0 4 4 1 2 P 00014 0 h 21 Km h 00014 0 h 12 Km h 12 Km h 00014 0 h 00 Km h N AUTO OFF 20 21 22 23 24 25 26 28 32 31 30 29 27 33 34 35 36 37 38 39 40 41 42 43 44 49 55 58 45 46...

Page 39: ...battery charge indicator 23 RED parking brake 24 GREEN travel direction forward 25 Coolant temperature 26 Operating hour meter 27 Fuel level indicator 28 GREEN travel direction reverse 29 GREEN direct...

Page 40: ...The indicator lamps should go out If the engine has not started after max 20 seconds turn the ignition key to 1 or 0 and pause for at least 1 minute before trying again Repeat the start up procedure...

Page 41: ...s cooled down turn it off and determine the cause of overheating If necessary call for service personnel If the air filter service indicator lamp 11 32 lights up perform the necessary air filter maint...

Page 42: ...t adjustment 3 Seat back adjustment 4 Armrest option 5 Vertical adjustment Raising seat Raise seat until it clicks audibly into place Lowering seat Raise seat as far as the stop the seat then sinks to...

Page 43: ...ressing the button 14 63g The cabin temperature is measured by the interior temperature sensor 14 63l If the air conditioning unit is in cooling air mode the outside temperature is shown on the displa...

Page 44: ...63f 63g 63h 63i 63k 63l AUTO OFF 22 MED HI LO Attention The air conditioning unit should be switched on for approx 5 minutes at least once a month to lubricate the compressor seals How to achieve goo...

Page 45: ...the LED does not light up fresh air mode is activated Inside outside temperature button 16 63d The inside temperature is shown on the display for approx 6 sec by pressing the button 16 63g The cabin...

Page 46: ...he loader is switched on and off by turning the steering column switch 17 1 Fig 17 Lighting 00014 0 h 12 Km h 0 4 4 1 2 P 00014 0 h 12 Km h 0 4 4 1 2 P 30 1 Setting 0 Light OFF Setting 1 Parking light...

Page 47: ...magnesium chloride Observe the following items when handling magnesium chloride Always pour magnesium chloride into the water not the other way round Do not allow the solution to come into contact wit...

Page 48: ...selected using the travel direction preselection switch on the joystick 18 7 Fig 18 Driving and steering 00014 0 h 12 Km h 0 4 4 1 2 P 00014 0 h 12 Km h 0 4 4 1 2 P 36 7 35 Attention When driving on p...

Page 49: ...lamp 19 24 or 19 28 lights up Press accelerator pedal 19 3 The machine only drives off once a certain engine speed is reached Travel speed is increased and decreased using the accelerator pedal Trave...

Page 50: ...ry Brake inching mechanism The machine features a brake inching mechanism altering the relationship between travel speed and engine speed When the brake inching pedal 21 2 is operated travel speed is...

Page 51: ...the travel direction preselection rocker switches on the joystick 23 7 and on the instrument panel 23 36 to 0 neutral position Switch off the working hydraulics 23 35 Check the function of the direct...

Page 52: ...itch off the working hydraulics 24 35 Apply the parking brake 24 54 Stop the engine and remove the ignition key Lock the cabin after finishing work to keep unauthorized persons from getting in Fig 24...

Page 53: ...purpose bucket Move the attachment to operating position Operate the turning knob 25 49 to adjust hydraulic power e g rotational speed Danger to life due to incorrectly fastened work attachments Daily...

Page 54: ...Float position is activated Continuous operation Lower the bucket onto the ground Switch 26 52 in Position 2 green indicator lamp lights up Danger to life due to incorrect operation Observe the functi...

Page 55: ...ol circuit is required Attention Under certain circumstances it is possible to use the work attachments of predecessor models on our machines When mounting work attachments of predecessor models howev...

Page 56: ...e linkage and the pin of the lift frame Move the lift frame out of the work attachment and install a new tool Attention Ensure that the bearings of the lift frame work attachment and quick mount hitch...

Page 57: ...tachment and lock by press ing the push button switch 27 5 Switch off the diesel engine Switch on the ignition Operate the push button switches 27 5 for pres sure relief Ball valve in position Quick m...

Page 58: ...is only to be lev eled by moving the bucket in and out 5 3 3 Excavating To dig out an excavation strip layers which are as regular as possible Plan the excavating work in such a way as to en able the...

Page 59: ...ened so that the hydrostatic transmission no longer acts as an auxiliary brake At the two high pressure relief valves 29 1 with bypass loosen the screw 30 1 by no more than 3 turns After towing screw...

Page 60: ...erating the switch 31 54 If the spring loaded brake cannot be released release it in both axles by screwing in the adjusting screws 32 1 Fig 31 Releasing the parking brake 00014 0 h 12 Km h 0 4 4 1 2...

Page 61: ...e onto a flat bed trailer railway goods wagon etc the following measures must be taken Empty the bucket and tilt back Drive the machine onto the flat bed trailer goods wagon etc or lift by crane if re...

Page 62: ...Recovery Loading and Transporting 6 62 112 TL160 Operating Manual 12 9 08 Version 1 0...

Page 63: ...are contained in every Instruction Book It is essential that the recommendations in the Chapter Safety and Prevention of Accidents are observed 2 13 7 1 Intervals Initial inspection once before first...

Page 64: ...ge Sequential damage can be avoided How often should the oil be analyzed Periodic oil analyses reveal trends in the condition of the oil and the machine The oils should be analyzed at the following in...

Page 65: ...650 362 Engine oil filter 5 568 656 650 Fuel filter with seal 5 568 664 196 Air filter main cartridge 5 501 660 932 Air filter safety cartridge 5 501 660 934 V belt 13 x 1375 air conditioning system X...

Page 66: ...sure good contact of terminal connections Only tighten terminal screws so that they are hand tight to prevent deformation of the terminal cones Attention The machine must be cleaned on a suitable surf...

Page 67: ...nt Only use commercially available brand named diesel fuel with a sulfur content of less than 0 5 Winter fuel Use only winter diesel fuel in winter to prevent line connections becoming blocked through...

Page 68: ...nd Maintenance 7 68 112 TL160 Operating Manual 12 9 08 Version 1 0 7 7 Checking maintenance and inspection plans 7 7 1 Initial inspection Handing over inspection Fig 35 Initial inspection 5 6 5 6 4 8...

Page 69: ...axle hubs 7 8 14 2 97 6 Check tire pressure and tightness of wheel nuts 7 8 15 99 7 Check the battery fluid level and charge condition 7 8 17 100 8 Top up windshield washer system 7 8 20 102 9 Grease...

Page 70: ...0 112 TL160 Operating Manual 12 9 08 Version 1 0 7 7 2 Daily and weekly tasks Inspection and maintenance jobs to be performed by operating personnel Fig 36 Inspection and maintenance plan 14 15 4 3 13...

Page 71: ...Chapter 10 Drain fuel filter 7 8 5 3 82 11 Check the cooling fins of the combined cooler 7 8 4 4 80 Machine damage due to strong accumulation of dust Clean the combined cooler by hand 12 Check that d...

Page 72: ...2 9 08 Version 1 0 7 7 3 Overview of lubricating points Machine damage due to damaged lubricating nipples Replace damaged grease nipples immediately and check if grease passes through Fig 37 Overview...

Page 73: ...oints Item Lubricating point Number Daily Weekly Chapter 1 Tilt cylinder Tilt control lever 1 X 2 Lift frame Tilt control lever 1 X 3 Lift cylinder Lift frame 2 X 4 Tilt cylinder Front end 1 X 5 Lift...

Page 74: ...her in valve cover O 17 Check acid level and battery connections O O 7 8 17 1 100 18 Check condition of tires tire pressure and tightness of wheel nuts O O 7 8 15 99 19 Check fastening of axles and pr...

Page 75: ...O 7 7 3 72 36 Check function condition and completeness of safety devices O O 37 Hydraulic function check with pressure function test O O 38 Test run and test work O O 39 Initial inspection card and r...

Page 76: ...th the machine standing on level ground Observe the level indicator on the display of the instrument panel Insert the oil dipstick 39 1 until the stop The notches on the dipstick indicate the minimum...

Page 77: ...ce the engine oil filter 40 2 7 8 3 78 Top up engine oil to the MAX mark on the oil dipstick 40 3 using the filling hole 40 4 Start the engine and run at low idle speed for approx 2 min Stop the engin...

Page 78: ...l topping up coolant The coolant level is monitored automatically If the coolant level is insufficient the coolant level indicator appears on the display as soon as the ignition is switched on 42 73 T...

Page 79: ...ain hose using the drain plug Re install the rear maintenance cover Fill the cooling system with coolant 3 9 29 and close the cap Start the engine and bring to operating temperature turn off the engin...

Page 80: ...e of strong exposure to dust If necessary e g in case of an oiled combined cooler clean with cleaning agents or a steam jet device After cleaning run the engine until it reaches operating temperature...

Page 81: ...uired Open the drain 49 2 and collect any escaping water in a suitable container Dispose of the water according to regulations Close again the drain 49 2 Fig 48 Checking the fuel level Fig 49 Draining...

Page 82: ...ment 51 1 against the springs and turn to the right to snap it into place in the filter housing 51 4 Install the new seal 51 3 on the filter housing Slightly wet the surface of the seal with clean fue...

Page 83: ...y squeezing the valve together 7 8 6 2 Cleaning or replacing the air intake Check the air filter attachment and retaining straps for damage Check the tightness of the air intake between the air filter...

Page 84: ...ghts up during operation 7 8 6 4 Replace the air filter safety cartridge after the third maintenance of the main cartridge after 2 years of operation at the latest if the service indicator switches on...

Page 85: ...eners in the groove of the flange on the filter housing and tighten 7 8 6 6 Changing the safety cartridge Remove the main cartridge Using a suitable tool e g screwdriver pierce the seal 56 5 of the sa...

Page 86: ...e Blow out the main cartridge from the inside to the outside with dry compressed air max 5 bar by moving the pipe up and down in the cartridge and continue until no more dust escapes Check the clean m...

Page 87: ...V belt is used If the V belt must be replaced observe the size of the V belt when ordering the spare part Danger of injury due to rotating V belts Only check and tension V belts with the engine off S...

Page 88: ...fastening screws 58 1 58 3 and 59 1 Rotate the generator against the direction of tensioning Remove the V belt and fit on an appropriately sized new one Rotate the generator 58 2 in the direction of...

Page 89: ...cylinder no 1 and adjust if required Adjust the valves 61 3 and 61 4 of cylinder no 2 as described above for the valves of cylinder no 4 for overlap Then check the valve lash of valves 61 5 and 61 6...

Page 90: ...e pedal Connect the bleeder hose to the first bleeder screw 64 1 of the front axle and route it into the collection bottle Open the bleeder screw 64 1 until the brake fluid hydraulic oil escapes witho...

Page 91: ...fluid hydraulic oil escapes without bubbles Remove the bleeder hose and re tighten the bleeder screw Re mount the cover on the front end 7 8 9 3 Adjusting the brake disc play Place the machine on a l...

Page 92: ...gine Remove the drain plug on the hydraulic oil tank and drain oil into a clean receptacle Flush and clean the hydraulic oil tank if required to do so remove the breather 66 2 return filter 66 3 and s...

Page 93: ...the O ring 68 3 and seals 68 5 68 7 68 11 and replace any damaged part Place surface A of the filter cover on a solid base push a new filter insert onto the centre rod and fit onto the seal 68 5 Push...

Page 94: ...70 4 6 are in perfect condition and replace any damaged part Insert a new filter element in the filter bowl Re insert the filter bowl along with the cartridge into the hydraulic oil tank Apply a ligh...

Page 95: ...check for damage replace if required Screw in new breather 72 1 with O ring 72 2 and tighten by hand Machine damage due to dirt reaching the uncovered hydraulic oil tank Before starting clean all par...

Page 96: ...s 73 1 Open the drain plugs 73 2 on the differential and brake housings and drain oil Flush out the axle if necessary Carefully close the drain plugs Pour in oil using the inspection filling hole unti...

Page 97: ...filling plugs 74 1 Open the drain plugs 74 2 on the differential and brake housings and drain oil Flush out the axle if necessary Carefully close the drain plugs Pour in oil using the inspection filli...

Page 98: ...ling plug 76 1 Open the drain plugs 76 2 on the differential and brake housings and drain oil Flush out the axle if necessary Carefully close the drain plugs Pour in oil using the filling hole until o...

Page 99: ...ntal 77 1 Fill in oil up to the lower edge of the inspection hole Carefully close the screw plug 7 8 15 Wheels 7 8 15 1 Checking the tire pressure Check the air pressure in accordance with the pressur...

Page 100: ...located in the rear end below the engine hood behind the left hand wheelhouse Only check the batteries with the engine switched off The acid level should be approx 10 mm above the plates If necessary...

Page 101: ...ve terminal of battery 1 79 5 with the negative terminal of battery 2 79 6 Connect the positive cable 79 2 to the positive terminal of battery 2 79 6 Connect the ground cable 79 1 to the negative term...

Page 102: ...rd surface Using dry compressed air max 5 bar blow against the direction of flow Check the filter for damage to the paper bellows and seal 7 8 19 2 Installation Insert new or cleaned dust filter until...

Page 103: ...etc must be changed If hydraulic oil filters such as suction and return filters as well as breathers have been out of use for more than 6 months they must be replaced Lubricate the machine according t...

Page 104: ...Care and Maintenance 7 104 112 TL160 Operating Manual 12 9 08 Version 1 0...

Page 105: ...p interrupted Check and repair suction line Hydraulic pump damaged Repair or replace Priority valve damaged Remedy fault call Service Agent Hand metering unit damaged Remedy fault call Service Agent S...

Page 106: ...ne Brake has got stuck Check remedy damage No tank pressurization Check ventilation filters and breathers replace Suction filter clogged Replace filter FAST SLOW gear not functioning due to electric o...

Page 107: ...faulty Check repair Charge pump damaged no charge pressure Remove pump and examine install new pump if necessary Switch for travel direction damaged Repair or replace if necessary Solenoid valve for t...

Page 108: ...Re seal cylinders Secondary valves damaged Check secondary valves and replace completely if necessary Faults in the electrical system Outside and or internal lighting damaged Check cables connections...

Page 109: ...ically activated as soon as the travel speed is more than 6 km h Repair Fig 82 Operation P 51 L864 901 Attention Load retaining valves option are without function as long as the ride control system is...

Page 110: ...Appendix 9 110 112 TL160 Operating Manual 12 9 08 Version 1 0...

Page 111: ...lter 83 Fuel tank 83 Fuels lubricants and coolants 30 G Guides 16 H Handing over inspection 68 Heating 43 45 Hydraulic oil 31 66 92 Hydraulic oil level 92 Hydraulic oil return filter 93 94 Hydraulic o...

Page 112: ...n 1 0 U Underground power lines 17 V Valve lash 89 90 V belt 88 Vehicle identification number 7 Ventilation 43 46 Views of the machine 23 W Warning equipment 101 Warranty 8 64 Weekly tasks 70 Winter o...

Page 113: ...points of lubrication according to lubrication chart and demonstration of these points on the machine Handing over of Diesel Engine Operating Instructions 2 Spare Parts List Structure of Spare Parts...

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