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.
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.
Index 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.1 1.2 1.3 1.4 1.5 2 Warranty and Maintenance . . . . . . . . . . . . Copyright . . . . . . . . . . . . . . . . . . . . . Notes on using the Operating Manual . . . . . . Regulations concerning environmental protection Pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 4 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 4.1 4.2 4.3 Initial familiarization . . . . . . . . . . . . . . . . . . . . . . . . . . . Display elements and operator controls . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.2 Monitoring the machine during operation . . . . . . . . . . . . . . 4.3.
Index 7.8.8 Brakes . . . . . . . . . . . . . . . . . . 7.8.9 Hydraulic oil tank . . . . . . . . . . . . . 7.8.10 Hydraulic oil return filter . . . . . . . . . 7.8.11 Replacing the breather . . . . . . . . . . 7.8.12 Axles . . . . . . . . . . . . . . . . . . . 7.8.13 Wheels . . . . . . . . . . . . . . . . . . 7.8.14 Injection valves . . . . . . . . . . . . . . 7.8.15 Electrical equipment . . . . . . . . . . . 7.8.16 Cab ventilation dust filter . . . . . . . . . 7.8.17 Windshield washer system . . . . . . . .
Index 6 Operating Instructions Wheel Loader TL120
Introduction 1 1 Introduction 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.
1 1.1 Introduction 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.
Introduction 1.4 1 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.
Introduction 1 1.5 Pictograms The following Table explains the meaning of the pictograms which may be attached to the machine.
Introduction Symbol V Description Symbol 1 Description 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 R Table 1 Pictograms on the machine Operating Instructions Wheel Loa
1 12 Introduction Operating Instructions Wheel Loader TL120
Safety and Accident Prevention 2 Safety and Accident Prevention 2.1 Declaration of Conformity 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. 2.
Safety and Accident Prevention 2 2.4 General safety instructions 2.5 Operation • It is important to refrain from any working methods which impair safety. Earth-moving machines are only to be independently operated and serviced by persons who: • The earth-moving machine is only to be used with a cabin or canopy. – are physically and mentally suitable • The earth-moving machine is only to be used if it is in a safe and operational condition.
Safety and Accident Prevention 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 earthmoving machine, its work implements and attachments, or by swinging out or falling loads. – The machine operator is only to work the earthmoving machine if no-one is in the danger zone.
2 2.9 Safety and Accident Prevention 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.
Safety and Accident Prevention 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, earthmoving machines must be positioned and operated in such a way that the driver’s seat and entry to the driver’s seat are not situated on the side facing the wall.
2 Safety and Accident Prevention 2.15 Operation in closed spaces If earth-moving machines are to be used in closed rooms, these areas must be sufficiently ventilated and 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.
Safety and Accident Prevention 2 2.17 Change of work attachments, maintenance, repair • Before working on the electric system or when performing arc-welding on the machine, the connection to the battery must be disconnected. 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.
2 Safety and Accident Prevention 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 machines and all necessary auxiliary equipment must be secured against unwanted movement.
Safety and Accident Prevention 2 2.21 Emergency exit The right-hand cab door acts as an emergency exit. 2.
2 22 Safety and Accident Prevention Operating Instructions Wheel Loader TL120
Technical Specifications 3 Technical Specifications 3.1 Views 3.1.1 Dimensioned drawing with generalpurpose bucket 800 487 460 90 2290 ° 35° 50° 2780 2750 3530 45° 3 1280 116 1980 40° 80° 5635 L854-6454000012 40 16 00 21 R2 11 5 R4640 Fig.
3 Technical Specifications 3.1.2 Dimensioned drawing with multi-purpose bucket 813 3045 2785 3530 45° 90 45° 1050 2055 ° 116 2290 1280 80° 1980 40° 5625 L854-6454000014 40 16 00 21 R2115 R4640 Fig.
Technical Specifications 3.1.3 3 Dimensioned drawing with fork lift attachment 425 3365 1445 1475 825 80 500 1980 80° 40° 6060 L844-6454000013 x. ma 36 12 R2 115 R4335 Fig.
3 Technical Specifications 3.2 Engine Engine Manufacturer Perkins Type 1104C-44 four-stroke diesel engine Design 4-cylinder in-line engine 4-stroke diesel engine with direct fuel injection, exhaust-gas optimized (EPA TIER 2) Displacement 4400 cm3 Power output according to DIN 70020 61.5 kW at 2200 rpm Max.
Technical Specifications 3.5 3 Brakes Brakes Service brake (standard) Hydraulically actuated center-mounted drum brake, acting on all four wheels via four-wheel drive. Service brake (high-speed version) Hydraulically actuated center-mounted drum brake, acting on all four wheels via four-wheel drive, and inboard-mounted disc brake on rear axle. Parking brake Mechanically actuated center-mounted drum brake on front axle. Additional brake Hydrostatic through closed-circuit travel drive.
3 Technical Specifications 3.8 Tires Tire size Type Profile Tire pressure in bar front Tire pressure in bar rear 405/70 425/75 R 20 EM 01 3.2 3.0 R 20 XM 27 TL 2.0 1.5 14.5-20 MPT 10 PR E 91 3.2 2.0 16/70-20 EM 10 PR E 91-2 3.2 2.4 365/80 R 20 EM 4.0 3.2 375/75 R 20 XM 3.2 2.4 27 TL Michelin Table 9 Technical specifications - tires Special tires available on request! If solid-rubber or foamed tires are used, special measures must be taken and restrictions apply.
Technical Specifications 3.9.
3 Technical Specifications Alternative recommendation for other temperature ranges Engine oil Hydraulic oil In compliance with API CG 4 or CH 4 and in compliance with ACEA E3 or E5 In compliance with DIN 51524.T3 HVLP 0W 5W20 10W30 15W40 20W50 20 30 40 Ambient temperature Fig. 5 Recommended viscosity classes applying to engine oil Ambient temperature Fig. 6 Recommended viscosity classes applying to hydraulic oil 3.
Technical Specifications 3 3.12 Dimensions and weights Dimensions and weights Operating weight, standard equipment1 approx.
3 Technical Specifications Fork lift attachment mm Width of fork carrier 1240 Length of forks 1120 Fork cross section 140 x 50 Max. stacking height 3365 Table 18 Dimensions of fork-arm connection in compliance with ISO/FEM Class 2 Form B, DIN 15 173 / ISO 2328 respectively The payloads are determined in compliance with DIN 24094 / ISO 8313 respectively with a stability factor of 1.25 or 80% of the tipping load and the machine moving over level ground.
Technical Specifications 3 3.13 Optional accessories – Orthopedic air-cushioned driver’s seat – Fire extinguisher – Height and tilt-adjustable steering wheel – Pressurized cab – Air-conditioning – Engine-independent diesel heater with timer – Diverse electrical accessories such as working floodlights, rotating beacon, radio, etc.
3 34 Technical Specifications Operating Instructions Wheel Loader TL120
Operation 4 Operation 4.1 Initial familiarization 4 Danger to life due to unintentional operation of controls. • The machine must be entered from the left-hand side as seen in the direction of travel. The right-hand cab door acts as an emergency exit. If the cab is entered by the right-hand door, the joystick may be operated unintentionally. • If you are not familiar with the controls and indicators of this machine, read this Chapter thoroughly before operating the machine.
4 4.2 Operation Display elements and operator controls Attention The following list includes non-standard equipment! 14 1 2 3 4 5 6 7 8 9 10 11 12 L824-010 13 15 Fig.
Operation 4 Legend Fig.
4 Operation 24 25 26 27 28 29 23 22 30 P 21 31 20 32 II 33 34 35 36 37 61 Option "S"-version 58 38 39 40 41 42 51 43 50 I II 45 I 59 0 44 47 60 48 N 3 6 9 0 52 62 53 46 54 49 55 56 L844-010-1 57 Fig.
Operation 4 Legend Fig. 8 20 Not assigned 44 Fan switch - heating 21 ORANGE - pre-heating monitor 45 Not assigned* 22 RED - battery charge indicator 46 Option - Preselection switch Ride Control System 23 RED - parking brake 24 GREEN - travel direction, forward 25 Coolant temperature 47 Preselection switch - operation of additional control circuit (Pos.
4 Operation 4.3 Engine 4.3.1 Starting Attention Each time before putting the machine into operation, the inspections according to (Î 7.8, 72) must be carried out. Danger to life due to presence in the danger zone. • Always ensure that no-one is in the danger zone of the machine before switching on the engine. • All gearshift levers to neutral. • Parking brake (9/9) applied, direction-of-travel preselectors (9/7; 9/36) in position "0".
Operation 4.3.2 4 Monitoring the machine during operation Engine damage due to fault which has not been remedied. • The fault must be remedied before starting the engine and operating the machine. • • If the battery charge indicator lamp (10/22) or the engine oil pressure indicator lamp (10/31) lights up, switch off the engine immediately and determine the cause, or call for service personnel.
4 Operation 4.4 Driver's seat / Steering wheel tilt adjustment The comfort seat is spring-mounted with oil-pressure operated shock absorbers and lap belt. The seat meets international quality and safety standards in compliance with ISO 7096 and ISO 6683 (Fig. 11). 1 Horizontal adjustment 2 Weight adjustment 3 Seat back adjustment 4 Armrest (option) 5 Vertical adjustment • Raising seat: Raise seat until it clicks audibly into place.
Operation 4.5 4 Heating/ventilation Heating • The heater is connected to the engine oil circuit. • The fan is operated using the switch (13/44); temperature is adjusted using the control (13/57) and can be operated with fresh air and re-circulating air. • Open aspirating hole (13/12) for re-circulating air mode. • The air is distributed by adjusting the air vents. 30 1 Ventilation • In ventilation mode, the valve towards the engine coolant circuit remains closed.
4 Operation 4.7 Hydroinflation of tires When the loader is used with a fork lift attachment, the rear wheels may be filled with a water-antifreeze mixture to increase the lifting capacity. Prepare the mixture in an appropriately sized container. Allow it to cool and stir until there are no more lumps. Danger to health due to incorrect handling of magnesium chloride.
Operation 4.8 Driving, steering and braking 4.8.1 Driving 4 Attention When driving on public roads, the wheel loader, as a self-propelled work machine, is subject to the legal regulations valid in the user's country. (For example, in the Federal Republic of Germany, StVZO and StVO). The machine has two preselection switches for travel direction which are alternately active. Change-over by means of the multi-function switch (14/35).
4 Operation Driving off • Set the travel direction preselection rocker switch on the joystick (15/7) and on the instrument panel (15/36) to "0" (neutral position). • The indicator lamps (15/24 and 15/28) must not light up. • Start engine. • Raise lift frame as far as the "Travel” height mark (16/1). • Select speed range "FAST" or "SLOW" (15/33) as required. • High-speed version (option) select speed range I or II. • Observe the indicator lamp (15/58-60). • Release the parking brake (15/9).
Operation 4.8.2 4 Steering • The wheel loader features a fully hydraulic, proportionally acting articulated steering. • Priority supply of hydraulic oil to steering through load-sensing system. Machine damage due to fault which has not been remedied. • In the event of steering malfunctions, determine the cause immediately (see Trouble-Shooting Table) and call for service personnel if necessary. 4.8.
4 Operation 4.8.4 • Driving on roads Before driving on open roads, the following points have to be observed: 1 Endangerment of road-traffic due to missing equipment. Ensure that the wheel loader is equipped as stipulated by the regulations authorizing the use of vehicles for road traffic in the user's country. • Empty the bucket and tilt back completely. • Attach the protective device on the front bucket edge. • Secure the side-dump bucket with socket pins.
Operation 4.8.5 4 Switching off the machine (parking) • Set the direction-of-travel preselection rocker switches (20/7 and 20/36) to "0". • Lower the work tool onto the ground. • Switch off the working hydraulics (20/35). • Apply the parking brake (20/9). • Stop the engine and remove the ignition key. • Lock the cab after finishing work to keep unauthorized persons from getting in. Danger to life due to rolling away of machine.
4 50 Operation Operating Instructions Wheel Loader TL120
Working Operation 5 5 Working Operation Danger to life due to incorrectly fastened work attachments. • Daily before commencing work and after every change of work attachments, a check must be carried out to ensure that the work attachment is correctly fastened, and the quick-mount hitch is properly locked. • The bucket must be moved carefully at a low height. • Before commencing loading work, memorize the lever controls well.
5 Working Operation Continuous operation - Additional control circuit • Additional control circuit (22/47) in Position 2 red indicator lamp lights up. Danger to life due to incorrect operation. • Observe the function of the attachment (e.g. rotating direction of attachment). Attention The additional control circuit must always be switched off unless additional equipment is operated. Operation - Float position of lift frame Attention The float position must always be switched off unless operated.
Working Operation 5.2 Changing work attachments 5.2.1 General 5 To achieve maximum utilization of the machine for a variety of applications, a great number of work attachments and accessories are available. The machine is equipped with a quick-attach system, to shorten the time it takes to change attachments. When mounting a multi-purpose bucket, front sweeper, etc., an additional control circuit is required.
5 Working Operation 5.2.2 Assembly of work attachments Attention • Ensure that the bearings of the lift frame, work attachment and quick-mount hitch are free from dirt. • Before disconnecting hydraulic connections, the system must be released from pressure. Procedure for changing directly mounted work attachments Attention • In the event of a hydraulically operated attachment, first of all the hydraulic connection must be disconnected (system must be without pressure).
Working Operation 5 Procedure for changing work attachments with hydraulic quick-attach system • Lower the work tool to the ground and position so that it cannot tip over. • Switch off the diesel engine. • Switch on the ignition. • Operate the push-button switches (24/5) for pressure relief. • In the case of a hydraulically operated work attachment: The hydraulic connections on both manifold blocks must be disconnected. • Ball valve in position "Unlock quick-mount hitch” (Fig. 25).
5 Working Operation 5.3 Notes on how to work with the machine 5.3.1 Loading During transport, the bucket - either filled or empty must be kept as close to the ground as possible. If possible, avoid long transport distances! Attention • For loading, lower the bucket and position the cutting edge parallel to the ground. Reduce driving speed by inching as required. • Move the bucket into the material to be loaded. • As soon as the bucket is filling, slightly raise the lift frame and tilt back the bucket.
Recovery, Loading and Transporting 6 Recovery, Loading and Transporting 6.1 Recovery 6 Towing of the wheel loader must be restricted to clearing a junction or a road, to prevent damage to the hydrostatic travel drive. If possible, let the diesel engine run at low idle during towing. Machine damage due to excessively fast towing. • Tow the machine at walking speed. Towing lugs • Front: right and left on the axle plates. • Rear bottom right and left on the side plates of the rear end. 1 La85327 Fig.
6 Recovery, Loading and Transporting 6.2 Loading with a crane Danger to life through exceeding the maximum lifting capacity. • Ensure that the maximum lifting capacity of the crane and the crane harness is not exceeded. To load the machine by use of a crane, the following preparations are required: • Empty the bucket and tip back. • Move the lift frame to travel position. • Apply the pin of the articulation lock (28/1 on the articulation). • Switch off the engine.
Care and Maintenance 7 7 Care and Maintenance The good operating condition and life expectancy of machines are largely influenced by care and maintenance. For this reason, it is in every machine owner’s interest to perform the specified maintenance work and comply with the service intervals. This Chapter deals in detail with periodic maintenance, inspection and lubricating tasks. The type-specific maintenance and inspection plan lists all work to be performed on the machine at regular intervals.
7 7.2 Care and Maintenance Regular oil analyses Oil analyses are not intended as a substitute for the oil change intervals but – apart from a possible reduction of maintenance costs and as a form of preventive maintenance – they take into account the increasing environmental awareness.
Care and Maintenance 7.
7 Care and Maintenance 7.5 Care and cleaning Attention The machine must be cleaned on a suitable surface with an oil separator. • • Neither a steam-jet appliance nor a high-pressure cleaning apparatus are to be used for cleaning during the first two months after the machine is used for the first time or when newly painted to allow the paint to harden. Do not use aggressive detergents for cleaning the machine. We recommend using commercially available cleaning agents for passenger cars.
Care and Maintenance 7 Fuel specification The use of high-quality fuel is a prerequisite for achieving the engine output specified. Recommended fuel specification • N590-diesel engines - Auto/C0/C1/C2/C3/C4 • BS2869 Class A2 • ASTM D975-91 Class 2-2DA, US DF1, US DF2, US DFA • JIS K2204 (1992) Class 1, 2, 3 and special class 3. Attention If sulfur-free fuel is used, additions to lubricants must be used.
7 Care and Maintenance 7.7 Checking, maintenance and inspection plans 7.7.1 Initial inspection (hand-over inspection) 5 6 4 6 5 9 8 3 7 2 L854-6454_R001 Fig.
Care and Maintenance 7 Work to be carried out by trained dealer service personnel. Activities Chapter 1 Check whether machine-specific instruction book is in the machine. 2 Check the engine oil level. Î 7.8.1, 72 3 Check the hydraulic oil level. Î 7.8.9, 87 4 Check the fuel level. Î 7.8.4.1, 76 5 Check oil level of differential and axle hubs. Î 7.8.12.2, 91 6 Check tire pressure and tightness of wheel nuts. Î 7.8.13, 92 7 Check brake oil level. Î 7.8.
7 7.7.2 Care and Maintenance Daily and weekly tasks Inspection and maintenance jobs to be performed by operating personnel. 14 15 3 16 17 13 15 22 4 1 20 11 18 12 14 2 19 L854-6454_R002 Fig.
Care and Maintenance Daily 7 Chapter 1 Check the hydraulic oil level. Î 7.8.9, 87 2 Check the engine oil level. Î 7.8.1, 72 3 Check the fuel level (fuel gauge on instrument panel). Î 7.8.4.1, 76 4 Check windshield washer-fluid level. Î 7.8.17, 95 5 General visual inspection for material cracks, external damage, completeness, etc. 6 Check for leaks in pipes, hoses, control unit, hydraulic pumps, cylinders, etc.
7 7.7.3 Care and Maintenance Overview of lubricating points Machine damage due to damaged lubricating nipples. • Replace damaged grease nipples immediately and check if grease passes through. 10 8 16 2 1 9 7 3 17 6 4 5 11 15 12 13 14 L854-6454_R003 Fig.
Care and Maintenance • 7 Grease all lubricating points with multi-purpose grease. Attention The intervals stated are only valid for singleshift operation. • Shorten the intervals for special operating conditions, for example sandy ground, in order to achieve self-cleaning of the bearing points.
7 Care and Maintenance 7.7.4 Inspection plan Work to be carried out by trained specialist dealer personnel. O = Checking, maintenance X = Replace Perform work with machine at operating temperature 1 Check whether machine-specific instruction book is in the machine. Operating hours min. 2x min. 1x after every every every annu- annu- Chapter ally 100 500 1000 2000 ally O O 2 Change engine oil. X X Î 7.8.1.2, 72 3 Change engine oil filter. X X Î 7.8.2, 74 4 Drain water from fuel tank.
Care and Maintenance O = Checking, maintenance X = Replace Perform work with machine at operating temperature 28 Check for leaks in all pipes, hoses, control valves, hydraulic pumps, cylinders, etc. Operating hours min. 2x 7 min. 1x after every every every annu- annu- Chapter ally 100 500 1000 2000 ally O O 29 Check or change hydraulic oil. O O 30 Replace insert of hydraulic oil return suction filter. X X 32 Check function of brakes, replace brake oil. O O 33 Bleed brake.
7 Care and Maintenance 7.8 Inspection and maintenance work 7.8.1 Engine oil 7.8.1.1 Checking the engine oil level • The oil level must be checked daily before start-up with the machine standing on level ground. • Insert the oil dipstick (33/1) until the stop. The notches on the dipstick indicate the minimum and maximum oil levels. • Top up engine oil if necessary. Open the filler neck (33/2) and add oil using a clean container. Close the filler neck again. 7.8.1.
Care and Maintenance • Screw the oil drain hose onto the oil-change valve (34/3). • Remove the oil drain hose and screw the protective cap onto the valve (34/3). • Close the service opening with the cover. • Replace the engine oil filter (34/4) (Î 7.8.2, 74). • Top up engine oil to the "MAX” mark on the oil dipstick using the filling hole (34/2) (34/1). 2 Machine damage 1 due to excess oil. Observe the permissible filling level of the engine oil pan and avoid overfilling.
7 Care and Maintenance 7.8.2 Changing the engine oil filter The engine oil filter must be replaced every time the engine oil is changed. • Place oil drip pan below the engine oil filter. • Clean the outside of the engine oil filter. • Unscrew the filter cartridge (35/4) using a commercially available tool and check that the fastening stud is firmly secured in the filter head. • Dispose of the filter cartridge according to regulations. • Check filter head condition and clean.
Care and Maintenance 7.8.3.3 7 Cleaning the cooling fins Machine damage 1 due to overheated engine. • Thoroughly clean the cooler to prevent overheating of the engine and/or the hydraulic oil. • Clean the combined cooler (Fig. 37) from the outlet side with compressed air. • Clean with cold detergent or a steam-jet appliance if required, e.g. if there is oil in the cooler. • After cleaning, run the engine until it reaches operating temperature to dry the cooler. 7.8.3.4 Changing the coolant Fig.
7 Care and Maintenance 7.8.4 7.8.4.1 • Fuel system Checking the fuel level Check the fuel level using the fuel gauge (39/27). Danger of injury 27 due to excessive pressure while refueling. • Open the fuel tank cap when topping up fuel using the electric refueling pump to avoid excessive pressure in the fuel tank! • Top up fuel every day after use to prevent condensation from forming before the machine is next put into operation. 7.8.4.
Care and Maintenance 7.8.4.3 Draining the fuel filter • Open the fuel filter on the water drain (41/2) until pure fuel escapes. • Close again the water drain. 7.8.4.4 • 7 1 Changing the fuel filter 2 Clean the outside of the fuel filter (41/1). Attention • Collect the fuel in a suitable container and dispose of according to regulations. • Open the water drain (41/2) on the filter bottom to drain fuel from the filter.
7 Care and Maintenance 7.8.4.5 Draining the fuel tank and cleaning the screen • Drain water from the fuel tank through the waterdrain plug (44/1). • Clean the filling screen (44/2) and check for damage; replace if required. 7.8.5 2 Air filter, air intake Machine damage due to dust being drawn into the engine. • All maintenance work on the air intake system must be carried out with the engine off. • Do not start the engine while the filter cartridge is removed. 1 L844-040 7.8.5.
Care and Maintenance 7.8.5.3 7 Cartridge maintenance interval The air filter main cartridge must be replaced as soon as the filter maintenance indicator lamp (46/32) on the instrument panel lights up during operation. Attention A brief delay in maintenance does not result in lower filter efficiency. 7.8.5.
7 Care and Maintenance 7.8.5.5 • Changing the main cartridge Release the wire fasteners (47/1) and remove the bottom of the housing (47/4). 1 • Withdraw the main cartridge (47/2) by twisting slightly to and fro. 4 • Check whether the safety cartridge (47/3) must be replaced. 1. 2. 3. Attention Remove the safety cartridge only in the case of necessary maintenance work. Only open the seal (47/5) of the safety cartridge for the purpose of replacement.
Care and Maintenance 7.8.5.7 7 Cleaning the main cartridge Machine damage due to damaged main cartridge. Never wash or brush out the main cartridge. When blowing out, ensure that dust does not land on the inside of the main cartridge. • The main cartridge can be cleaned up to five times if necessary. It must be replaced once it reaches its maximum service life of two years, at the latest. The number of times it is cleaned must be marked.
7 Care and Maintenance 7.8.6 7.8.6.1 Double V-belt Checking the condition of the V-belt Danger of injury due to rotating V-belts. • Only check and tension V-belts with the engine off. • Secure the engine against unauthorized starting. Attention In the case of double V-belts, the following must be observed: • If one damaged or worn V-belt must be replaced, always change both V-belts together. • Visual examination of the complete V-belts; replace worn or damaged V-belts immediately. 7.8.6.
Care and Maintenance 7.8.6.4 7 Tensioning the V-belt • Slacken the fastening screws 49/1, 49/3 and 50/1. • Rotate the generator (49/2) until the tension is correct. • Re-tighten the fastening screws 49/1, 49/3 and 50/1. • Check the tension again. 1 2 3 Fig. 49 7.8.6.5 Tensioning and replacing V-belts Changing the V-belt • Slacken the fastening screws 49/1, 49/3 and 50/1. • Swivel the generator against the direction of tensioning. • Remove the used V-belt and fit new one.
7 Care and Maintenance 7.8.7 • Checking the valve lash Test the valve lash (51/1) on a cold engine by placing a feeler gauge between the upper part of the tappet (51/3) and the rocker arm (51/2). 2 5 The correct valve lash is as follows: Inlet valve = 0.20 mm Exhaust valve = 0.45 mm 4 1 Adjust the valve lash, where necessary, as follows: • Slacken lock nut (51/4).
Care and Maintenance 7.8.8 Brakes 7.8.8.1 • 7 Checking the brake oil level Visual inspection (53/1) of brake oil level. Danger to life due to incorrect brake oil. • Only top up with ATF-oil! 7.8.8.2 Changing brake oil and bleeding the brake Attention • Collect the waste oil in a suitable container and dispose of according to regulations. L854-6454_R004 1 Attention • Use a bleeding device for changing brake oil and bleeding. • Remove the cover on the front-end above the axle.
7 Care and Maintenance • Remove the bleeder hose and re-tighten the bleeder screw. Attention TL120S - The tasks listed in Chapter Î 7.8.8.3, must be performed, as well. • Dismount the bleeding device and close the brake oil container using the original cover. • Re-mount the cover on the front-end. 7.8.8.3 TL120 S - Changing the rear axle brake oil and bleeding the brake Attention • Collect the waste oil in a suitable container and dispose of according to regulations.
Care and Maintenance 7.8.9 7.8.9.1 • Hydraulic oil tank Checking hydraulic oil level Check the oil level using the oil dipstick (56/1); top up hydraulic oil if required. 7.8.9.2 7 3 1 2 Changing the hydraulic oil Danger of scalding due to hot oil getting into contact with skin or eyes. • Wear appropriate protective clothing/safety goggles. • Retract all hydraulic cylinders. • Switch off the engine. • Unscrew the oil dipstick (56/1).
7 Care and Maintenance 7.8.10 Hydraulic oil return filter Attention 1 3 • After a larger repair job, renew the filter cartridge following the test run. 2 Changing the filter insert • Switch off the engine. • Unscrew the oil dipstick (57/1). • With the aid of a tool, remove the filter cover (58/1). • Remove the filter element (58/5) along with the inlet connection (58/3) by pulling and turning at the same time.
Care and Maintenance 7 7.8.11 Replacing the breather Attention 2 • The breather must also be replaced if it is dirty, for example due to hydraulic oil vapor. 3 1 • Unscrew the oil dipstick (59/1). • Remove the breather (59/2) and dispose of according to regulations. • Clean the screen (59/4) and check for damage; replace if required. • Screw in new breather (59/2) with O-ring (59/3) and tighten by hand. • Screw back in the oil dipstick. 4 L834-054 Fig.
7 Care and Maintenance 7.8.12 Axles General The axle oil must be changed at operating temperature. Attention • Collect the waste oil in a suitable container and dispose of according to regulations. Machine damage due to insufficient oil in axles. • After filling the axles with oil, move the machine for approx. 5 minutes to ensure that the oil is evenly distributed. • After 5 minutes, check the oil level again, and top up if necessary. 7.8.12.
Care and Maintenance 7 7.8.12.2 Differential of rear axle with transmission Checking the axle oil level X Remove the inspection plug (61/1), check and top up oil if required. Changing axle oil Attention The rear axle differential and the transmission have combined oil filling. X Attention • If you have the TL120 S, please use Fig. 62 instead of Fig. 61 for the following operations. Fig. 62 shows the rear axle installed in the TL120S. • Park the machine on a level surface.
7 Care and Maintenance 7.8.12.3 Wheel hub Checking the axle oil level • Remove the inspection plug (63/1), check and top up oil if required. Changing axle oil Attention The wheel hub has a combined inspection, filler and drain plug! • Turn the wheel until the screw plug (63/2) on the hub is at the bottom. • Open the screw plug and catch the escaping oil. • Flush out if necessary. • Turn the wheel to the filling and inspection position; the inspection mark must be horizontal (63/1).
Care and Maintenance 7 7.8.14 Injection valves Injection valves must be checked by your service specialist. 7.8.15 Electrical equipment 7.8.15.1 Battery The battery is located under the right-hand side flap. Attention Instructions from the battery manufacturer must be observed when using the battery for the first time. • Only check the battery with the engine not running. • The acid level should be approximately 10 mm above the edges of the plates. Top up with pure distilled water where necessary.
7 Care and Maintenance 7.8.15.2 Removing the battery • First disconnect the battery ground cable (-) and then the positive cable (+). • Slacken clamping bracket (64/1). • Lift out the battery. 7.8.15.3 Installing the battery • Place the battery in the machine. • Secure with the clamping bracket. • Connect first the positive battery cable, then the ground cable. 1 Machine damage L854-060 due to interchange of terminals.
Care and Maintenance 7 7.8.16.1 Removing the dust filter for cab ventilation • Remove the ventilation louver (65/1). • Remove the angle bracket (65/2). • Remove the dust filter (65/3). • Clean the filter or replace it. 1 2 3 7.8.16.2 Cleaning the dust filter Attention Never wash or brush out the filter. • Knock the filter with the intake side (side covered by expanded metal) several times on a flat and hard surface. • Using dry compressed air (max. 5 bar), blow against the direction of flow.
7 Care and Maintenance 7.9 Immobilization 7.9.1 Preservation (temporary immobilization) Machine damage 7.9.2 due to damage to bearing (e.g. corrosion damage) if the machine has been out of use for more than three months. When the machine is out of use for 6 months, after this time all assemblies must be brought to operating temperature and maneuvered for approx. 15 minutes. • Perform the preservation measures.
Trouble-Shooting 8 8 Trouble-Shooting Operating problems are often the result of incorrect handling of the machine, the use of unsuitable materials or irregular maintenance. The following Table presents a summary of a range of problems and their probable causes. If a problem can only be eliminated through repair, then your responsible Service Agent must be called in. 8.1 Engine All faults in the diesel engine must be examined as described in their specific Engine Operating Instructions.
8 Trouble-Shooting Possible cause Remedy Hydraulic oil exceeds max.
Trouble-Shooting Possible cause 8 Remedy Transmission works in one direction only Switch for travel direction damaged Repair or replace if necessary Solenoid valve gets stuck or is damaged Repair or replace if necessary Power supply towards switch for travel direction or solenoid valve interrupted Check and repair (incl. ground connection) Pilot pressure too low on one side Nozzles clogged, check, repair High-pressure relief valve is faulty or incorrectly adjusted Swap valves around.
8 Trouble-Shooting Possible cause Remedy Decrease in machine’s performance (loader installation) Insufficient engine power Check diesel engine and adjust if necessary Hydraulic oil level too low Top up hydraulic oil to mark on dipstick Pump is sucking up air Tighten hose connections.
Appendix 9 9 Appendix Operating Instructions Wheel Loader TL120 101
Fig.
Appendix Position 9 Designation 1 Steering cylinder 2 Steering control unit 3 Priority valve 4 Steering / loading pump 5 Hydraulic oil tank 6 Hydraulic oil cooler 7 Hydraulic oil temperature control 8 Combined hydraulic oil filter 9 Breather 10 Travel motor 11 Travel pump 12 Master brake cylinder 13 Front axle brake 14 Loader control lever (Joystick, right – Working) 15 Pilot control unit 16 Control valve (triple as standard; fourfold as an option) 17 Additional control c
9 Appendix 9.2 Equipment options 9.2.1 Ride control system (LSD) Depending on the machine's operating weight, road conditions, and speed, there may be pitching oscillations when driving wheel loaders.
– The warranty/handing-over card must be filled out correctly and sent back to the manufacturer – Explanation of inspection cards and note on maintenance and inspection plan – Explanation of warranty offered by manufacturer 3. Warranty – Instructions for ordering spare parts - always state the type of machine, the vehicle identification number ("Fz-Id.Nr."), parts designation, complete spare part number, number of pieces, delivery address, etc.
min. 1x Shorten the cleaning intervals. O O O O O 19 Check acid level and battery connections. 20 Check condition of tires, tire pressure and tightness of wheel nuts. 21 Check fastening of axles and propeller shaft. 22 Check bearing bushings and bolts of work equipment and replace if necessary. 23 Check bushings and bolts of the articulation and the articulated steering and replace if necessary. 18 Check crankcase breather in valve cover. O O O O O O O 17 Check injection valves.
Keyword index 10 10 Keyword index I A Air filter . . . . . . . . . . . . . . . . . . . . . 78 Air intake . . . . . . . . . . . . . . . . . . . . 78 Antifreeze . . . . . . . . . . . . . . . . . . . . 74 B Battery . . . . . . . . . . . . . . . . . . . . . . 93 Biodegradable oils . . . . . . . . . . . . . . . 29 Breather . . . . . . . . . . . . . . . . . . . . . 89 C Canopy . . . . . . . . . . . Care . . . . . . . . . . . . . Cartridge maintenance time . Change of work attachments Check . . . . . . . . . .
10 Keyword index W Warning equipment Warranty . . . . . . Weekly tasks . . . . Weekly work . . . . Work stoppages . . Working operation . 108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, . . . .
