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Terex TL160 Operating Manual

Terex TL160 Operating Manual

Wheel loader
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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

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Summary of Contents for Terex TL160

  • Page 1 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...
  • Page 2 Central Administration/Sales Service Department Spare parts Terex GmbH Terex GmbH Terex | Ersatzteile GmbH Postfach 61 • D-74595 Langenburg Postfach 12 64 • D-91534 Rothenburg Postfach 12 64 • D-91534 Rothenburg Schaeffstr. 8 • D-74595 Langenburg Erlbacher Str. 115 • D-91541 Rothenburg Erlbacher Str.
  • Page 3 3.13 Optional accessories (options) ........34 TL160 3/112 Operating Manual 12.9.08 Version 1.0...
  • Page 4 V-belt ..........87 4/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 5 Index ..........111 TL160 5/112 Operating Manual 12.9.08 Version 1.0...
  • Page 6 Index 6/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 7 Introduction Introduction 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.

  • Page 8: Warranty And Maintenance

    Pictogram "Danger of injury/machine damage" Insist that only original Terex spare parts are used in the event of any repair work. In this way, you will have Danger of injury/machine damage a product of lasting high quality, thereby ensuring that your machine maintains its original condition.
  • Page 9 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. TL160 9/112 Operating Manual 12.9.08 Version 1.0...
  • Page 10 Coolant level Locked Air filter Float position Fuel, fuel level On machine: Safety distance Hydraulic oil Danger of injury Hydraulic oil level Hydraulic oil temperature Danger of crushing Tab. 1 Pictograms on the machine 10/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 11 Operating mode indicator Operating hours Parking brake Lashing points Travel direction Suspension points for loading by crane FWD/REV Travel speed, FAST First-aid kit Travel speed, SLOW Fire extinguisher Tab. 1 Pictograms on the machine TL160 11/112 Operating Manual 12.9.08 Version 1.0...
  • Page 12 Introduction 12/112 TL160 Operating Manual 12.9.08 Version 1.0...

  • Page 13: Safety And Accident Prevention

    Furthermore, safety laws governing work in particular locations (tunnels, adits, quarries, pontoons, contaminated areas, etc.) must likewise be observed. TL160 13/112 Operating Manual 12.9.08 Version 1.0...

  • Page 14: General Safety Notes

    Loose parts such as tools or other accessories must be secured to the earth-moving machine. • Open doors, windows, covers, flaps, etc. must be closed or secured against slamming shut if in an open condition. 14/112 TL160 Operating Manual 12.9.08 Version 1.0...

  • Page 15: Danger Zone

    Transport of persons The transport of persons on the machine is forbidden. TL160 15/112 Operating Manual 12.9.08 Version 1.0...
  • Page 16 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. 16/112 TL160 Operating Manual 12.9.08 Version 1.0...

  • Page 17: Danger Of Falling Objects

    If underground power lines are encountered unexpectedly or they or their protective covers are – Cabling, or damaged, the machine operator must discontinue – Limiting the operating zone of earth-moving work immediately and notify the supervisor. machines TL160 17/112 Operating Manual 12.9.08 Version 1.0...

  • Page 18: Operation In Closed Spaces

    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). 18/112 TL160 Operating Manual 12.9.08 Version 1.0...

  • Page 19: Change Of Work Attachments, Maintenance, Repair

    With the engine turned off, lower the work equipment to the ground and actuate all hydraulic control levers until there is no more pressure in the hydraulic system. TL160 19/112 Operating Manual 12.9.08 Version 1.0...

  • Page 20: Monitoring And Inspections

    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. 20/112 TL160 Operating Manual 12.9.08 Version 1.0...

  • Page 21: Emergency Exit

    – manual steering (without servo assistance) and – lower work equipment (only if ignition is switched on). TL160 21/112 Operating Manual 12.9.08 Version 1.0...
  • Page 22 Safety and Accident Prevention 22/112 TL160 Operating Manual 12.9.08 Version 1.0...

  • Page 23: Technical Specifications

    Technical Specifications Technical Specifications Views 3.1.1 Dimensioned drawing with bucket, directly mounted 2760 1635 6690 Fig. 2 Dimensioned drawing with bucket and tires 15.5 R 25 TL160 23/112 Operating Manual 12.9.08 Version 1.0...
  • Page 24 Technical Specifications 3.1.2 Dimensioned drawing with bucket and quick-attach system 1635 2760 6730 Fig. 3 Dimensioned drawing with bucket and tires 15.5 R 25 24/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 25 Technical Specifications 3.1.3 Dimensioned drawing with multi-purpose bucket Fig. 4 Dimensioned drawing with bucket and tires 15.5 R 25 TL160 25/112 Operating Manual 12.9.08 Version 1.0...
  • Page 26 Technical Specifications 3.1.4 Dimensioned drawing with fork lift attachment 1700 1635 2760 7216 5600 Fig. 5 Dimensioned drawing with fork lift attachment and tires 15.5 R 25 26/112 TL160 Operating Manual 12.9.08 Version 1.0...

  • Page 27: Electrical System

    High-speed version featuring rear axle manual transmission shiftable in standstill position. Suction and return filter in the form of a tank insert filter. Travel speeds Forward - Reverse TL160 TL160S Travel range I Travel range II Travel range "Work"...

  • Page 28: Hydraulic System

    Rear axle (high-speed version) Planetary drive axle with self-locking differential and integrated 2-stage reduction gear, oscillating. All-wheel drive through propeller shaft to front axle. Rear axle oscillating angle ± 12° Tab. 8 Technical specifications - axles 28/112 TL160 Operating Manual 12.9.08 Version 1.0...

  • Page 29: Fuels, Lubricants, And Coolants

    Wheel hubs, front / rear axle 1.7 each Transmission oil Coolant 28.0 Mixture of water, additives and glycol (50 / 50) Tab. 10 Fluid capacities * The hydraulic oil quantity depends on the equipment level of the machine. TL160 29/112 Operating Manual 12.9.08 Version 1.0...
  • Page 30 EN 590 Attention ASTM D975 1-D / 2-D Before using RME fuels (rape oil methyl ester), it is essential to consult your responsible Terex dealer for further details. Engine EO 1540 A Engine oil SAE 15W-40 See also engine manufacturer's Operating Manual.

  • Page 31: Permissible Loads In Compliance With German Road Traffic Regulations (Stvzo)

    Tab. 13 Sound level values in compliance with directive 2000/14/EC and EN 474 Vibration values Effective values of acceleration below 0.5 m/s for entire body 2.5 m/s for upper limbs. Tab. 14 Vibration values in compliance with directive 98/37/EEC and EN 474 TL160 31/112 Operating Manual 12.9.08 Version 1.0...

  • Page 32: Dimensions And Weights

    1.25 / - Light-material bucket with bolt-on cutting edge 2300 2.2 / - Light-material bucket with bolt-on cutting edge 2500 2.6 / - High-tip bucket 2300 Tab. 17 Bucket dimensions Quick-attach system / directly mounted 32/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 33 Tab. 20 Transport position of fork lift attachment If screw-on rear axle weights or rear tires with hydroinflation are used. Attention During fork lift operations, the tire pressure of the front wheels must be increased by at least 0.5 bar. TL160 33/112 Operating Manual 12.9.08 Version 1.0...

  • Page 34: Optional Accessories (Options)

    Further optional equipment available on request! Machine damage due to unauthorized alterations to the design, additional equipment and work attachments of Terex products. • Please note that any modification requires the written approval from the manufacturer. If our approval is not...

  • Page 35: Operation

    • Before putting the machine into operation, the inspections according to 7.8, 76 must be carried out. TL160 35/112 Operating Manual 12.9.08 Version 1.0...
  • Page 36 Operation Display elements and operator controls Attention The following list includes non-standard equipment! 12 Km/h 00014,0 h Fig. 8 Operator controls 36/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 37 Tilt adjustment of steering wheel (option: height adjustment) Operation – additional control circuit (left OFF, right ON) Control lever - loader installation Travel direction preselection (without function if working hydraulics are disabled) Impulse mode - float position TL160 37/112 Operating Manual 12.9.08 Version 1.0...
  • Page 38 50 51 52 53 54 12 Km/h 56 57 00014,0 h 21 Km/h 00014,0 h 59 60 00 Km/h 00014,0 h 12 Km/h 69 70 71 72 73 AUTO Fig. 9 Instrument panel 38/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 39 49 Flow rate adjustment for 3rd control circuit 50 Option – preselection switch for 4th control circuit OFF/Impulse/Continuous operation 51 Option – ride control system 52 Preselection switch - float position - OFF/Impulse/Continuous operation TL160 39/112 Operating Manual 12.9.08 Version 1.0...
  • Page 40 Engine damage Avoid damaging the engine by: Fig. 10 Starting the engine • not driving the engine at full throttle straight away. • driving with restraint until the engine has reached its operating temperature. 40/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 41 Do not switch off the engine when running at full throttle, but allow it to run for a short time without load at low idle-running speed. • Turn the ignition key to "0". • The engine stops automatically. TL160 41/112 Operating Manual 12.9.08 Version 1.0...

  • Page 42: Driver's Seat / Steering Wheel Tilt Adjustment

    12 Km/h 00014,0 h • Release lever. Height adjustment of steering wheel (option) • Push up lever (13/4). • Adjust steering-wheel height. • Release lever. Fig. 13 Tilt and height adjustment of steering wheel 42/112 TL160 Operating Manual 12.9.08 Version 1.0...

  • Page 43: Heating / Ventilation / Air- Conditioning

    Each time the button is pressed (14/63i), the fan speed increases by one step. Each time the button is pressed (14/63k), the fan speed decreases by one step. • The air is distributed by adjusting the air vents. TL160 43/112 Operating Manual 12.9.08 Version 1.0...
  • Page 44 • Keep windows and doors closed. • It is recommended to cool down the vehicle interior temperature by no more than 6 °C to 8 °C below outside temperature. AUTO Fig. 15 Air-conditioning 44/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 45 Fan speed buttons (16/63i 63k) Each time the button is pressed (16/63i), the fan speed increases by one step. Each time the button is pressed (16/63k), the fan speed decreases by one step. TL160 45/112 Operating Manual 12.9.08 Version 1.0...

  • Page 46: Lighting In Compliance With German Road Traffic Regulations (Stvzo)

    Driving light (low beam / high beam). 00014,0 h Switch from one to another by lifting (17/1) the steering-column switch (17/30) Blue indicator lamp lights up. 12 Km/h 00014,0 h Fig. 17 Lighting 46/112 TL160 Operating Manual 12.9.08 Version 1.0...

  • Page 47: Hydroinflation Of Tires

    15.5 R25 17.5 R 25 455/70 R 24 Tab. 21 Water-antifreeze mixture – Recommendation when filled to 75 % with antifreeze protection to - 30 °C MgCl = Magnesium chloride O = Water TL160 47/112 Operating Manual 12.9.08 Version 1.0...

  • Page 48: Driving, Steering And Braking

    (18/35). By doing so, the switch (18/36) on the instrument panel is without function. The direction of travel is preselected using the travel direction preselection switch on the joystick (18/7). 48/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 49 Fig. 19 Driving off and coming to a halt • Operate the brake-inching pedal (19/2) as required. • Also refer to 4.8.3, 50 Fig. 20 Height color mark TL160 49/112 Operating Manual 12.9.08 Version 1.0...
  • Page 50 - irrespective of engine speed - until the machine comes to a stop. This mechanism permits sensitive driving at maximum engine speed, e. g. when loading a truck, where fast working cycles are required. 50/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 51 12 Km/h Only press when machine is stationary! 00014,0 h • Check the function of the direction indicators, hazard warning lights, horn, low/high beam. • Close the cabin door. Fig. 23 Driving on roads TL160 51/112 Operating Manual 12.9.08 Version 1.0...
  • Page 52 Danger to life due to the machine rolling away. If there is a danger of the machine rolling away, secure it with chocks. 12 Km/h 00014,0 h Fig. 24 Switching off the machine (parking) 52/112 TL160 Operating Manual 12.9.08 Version 1.0...

  • Page 53: Working Operation

    • Move the attachment to operating position. • Operate the turning knob (25/49) to adjust hydraulic power (e. g. rotational speed). Fig. 25 Operating the loader TL160 53/112 Operating Manual 12.9.08 Version 1.0...
  • Page 54 Press switch (26/8). Float position is activated. Continuous operation • Lower the bucket onto the ground. • Switch (26/52) in Position "2" - green indicator lamp lights up. Fig. 26 Operating the loader 54/112 TL160 Operating Manual 12.9.08 Version 1.0...

  • Page 55: Changing Work Attachments

    Danger of injury due to unsecured work attachments. • When attachments have been removed, they must be secured against overturning to avoid possible injury to persons. TL160 55/112 Operating Manual 12.9.08 Version 1.0...
  • Page 56 • Remove the pin of the linkage and the pin of the lift frame. • Move the lift frame out of the work attachment and install a new tool. 56/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 57 • The additional control circuit (27/53) must be switched off unless a hydraulically op- erated additional attachment is connected. L864-504 Fig. 28 Releasing and locking the hydraulic quick-attach system TL160 57/112 Operating Manual 12.9.08 Version 1.0...

  • Page 58: Notes On How To Work With The Machine

    Plan the excavating work in such a way as to en- able the wheel loader to drive forward with full bucket out of the excavation. • Keep the outward run of the excavation as flat as possible. 58/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 59 Danger to life due to machine rolling away. • Always secure the machine with chocks and relieve the hydraulic system of pressure before carrying out maintenance La85328 and repair work. Fig. 30 High-pressure relief valve TL160 59/112 Operating Manual 12.9.08 Version 1.0...
  • Page 60 (32/1). Attention After towing, re-adjust the spring-loaded brake as specified in Chapter 7.8.9.3, 91. 12 Km/h 00014,0 h Fig. 31 Releasing the parking brake 47 mm L873029 Fig. 32 Releasing the spring-loaded brake 60/112 TL160 Operating Manual 12.9.08 Version 1.0...

  • Page 61: Transport Of The Machine

    (Fig. 34) in the correct manner. Danger to life due to disregarding the total transport height. • It is essential to observe the clearance heights of tunnels, bridges, etc. Fig. 34 Lashing for transport TL160 61/112 Operating Manual 12.9.08 Version 1.0...
  • Page 62 Recovery, Loading and Transporting 62/112 TL160 Operating Manual 12.9.08 Version 1.0...

  • Page 63: Care And Maintenance

    Every 2000 operating hours After every 2000 operating hours or after 2 years 7.7.4, 74 Tab. 22 Intervals whichever comes first also applicable if new or overhauled diesel engines are put into operation. TL160 63/112 Operating Manual 12.9.08 Version 1.0...

  • Page 64: Warranty

    – Transmission oil: 500 operating hours – Engine oil: 100 operating hours Based on the first results, the laboratory recommends the interval for the next sampling. Ask your Terex dealer for an information booklet detailing the scope and procedures of the oil analysis.

  • Page 65: Inspection Parts And Aids

    Extras Terex hydraulic oil, mineral 4 312 005 050 Terex hydraulic oil, biodegradable Please contact your Terex dealer for further information. Transmission oil (SAE 85 W 90 LS) 4 314 005 775 Engine oil (SAE 15 W 40) 4 312 905 759 Tab.

  • Page 66: Care And Cleaning

    – When installing the battery, ensure good contact of terminal connections. – Only tighten terminal screws so that they are "hand-tight", to prevent deformation of the terminal cones. 66/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 67 Winter fuel Use only winter diesel fuel in winter to prevent line connections becoming blocked through paraffin deposits. At very low temperatures, troublesome deposits may also occur when winter diesel is used. TL160 67/112 Operating Manual 12.9.08 Version 1.0...

  • Page 68: Checking, Maintenance And Inspection Plans

    Care and Maintenance Checking, maintenance and inspection plans 7.7.1 Initial inspection (Handing-over inspection) Fig. 35 Initial inspection 68/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 69 Visual inspection for tightness of all hoses, pipes, cylinders, etc. Check function of electrical indicating and warning elements, and the lighting system. Initial delivery/handing-over certificate and return to manufacturer. Tab. 25 Work involved in initial start-up TL160 69/112 Operating Manual 12.9.08 Version 1.0...
  • Page 70 Care and Maintenance 7.7.2 Daily and weekly tasks Inspection and maintenance jobs to be performed by operating personnel. 14 19 Fig. 36 Inspection and maintenance plan 70/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 71 • Shorten the inspection and cleaning intervals. Check function, condition and completeness of safety devices. Grease machine according to overview of lubricating points. 7.7.3, 72 Tab. 27 Tasks to be performed weekly TL160 71/112 Operating Manual 12.9.08 Version 1.0...
  • Page 72 Care and Maintenance 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 of lubricating points 72/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 73 Lift frame – Quick-attach system Linkage – Quick-attach system Tilt control lever – Linkage Hydr. quick-mount hitch Steering cylinder – Front-end Articulation Steering cylinder – Rear-end Rear axle bearing Tab. 28 Lubricating points TL160 73/112 Operating Manual 12.9.08 Version 1.0...
  • Page 74 7.8.9.2, 90 31 Bleed brake 7.8.9.2, 90 Tab. 29 Inspection plan At least every two years. Extension of oil change intervals according to oil sample analysis and laboratory report 7.2, 64. Within warranty. 74/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 75 39 Initial inspection card and return to manufacturer. 7.3, 64 Tab. 29 Inspection plan At least every two years. Extension of oil change intervals according to oil sample analysis and laboratory report 7.2, 64. Within warranty. TL160 75/112 Operating Manual 12.9.08 Version 1.0...

  • Page 76: Inspection And Maintenance Work

    Fig. 39 Checking the engine oil level Observe the permissible filling level of the engine oil pan and avoid overfilling. Excess oil may enter the crankcase breather and lead to engine-speed control faults. 76/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 77 • Start the engine and run at low idle speed for approx. 2 min. • Stop the engine. • Check the oil level and top up oil if required. TL160 77/112 Operating Manual 12.9.08 Version 1.0...
  • Page 78 • At the factory, the antifreeze protection is set to approx. - 25 °C. If temperatures are lower, the level of antifreeze must be adjusted accordingly. Fig. 43 Combined cooler 78/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 79 • Only open the cooler cap after the engine has cooled down. • Remove the cap (44/1) and top up coolant if required. With the engine cooled down, the compensation tank should be half full. TL160 79/112 Operating Manual 12.9.08 Version 1.0...
  • Page 80 Attention • Collect the detergent and waste water in a suitable container and dispose of according to regulations! • Ensure that no substances hazardous to water reach the sewerage or water systems. 80/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 81 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. 49 Draining the water separator TL160 81/112 Operating Manual 12.9.08 Version 1.0...
  • Page 82 • Before starting the engine, operate the fuel pump one minute to remove air from the filter. • Start the engine and check for leaks. Fig. 52 Replacing the fuel filter 82/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 83 Check the tightness of the air intake between the air filter and the engine. • Examine rubber parts for damage and replace if necessary. L854-42 Attention Fig. 54 Cleaning the dust ejection valve • Replace damaged parts immediately! TL160 83/112 Operating Manual 12.9.08 Version 1.0...
  • Page 84 – after 2 years of operation at the latest – if the service indicator switches on after the main cartridge has just been serviced – if the main cartridge is damaged – if the safety cartridge is damaged. 84/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 85 Grasp the safety cartridge (56/3) by the two clips (56/6), withdraw by twisting slightly to and fro, and dispose of it. • Insert a new safety cartridge and check that it is correctly positioned. • Re-install the main cartridge. TL160 85/112 Operating Manual 12.9.08 Version 1.0...
  • Page 86 Machine damage due to damaged main cartridge. Fig. 57 Cleaning the main cartridge Never continue to use damaged main cartridges. If in doubt, use a new one. 86/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 87 Attention Using medium thumb pressure of approx. 45 N (approx. 4.5 kg), the V-belt sag should equal 10 mm . TL160 87/112 Operating Manual 12.9.08 Version 1.0...
  • Page 88 Re-tighten the fastening screws 58/1, 58/3 and 59/1. • Check the tension again. Attention Fig. 59 Tensioning and checking V-belts • If V-belts have been replaced, their tension must be checked again after approx. 20 operating hours. 88/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 89 • Check the valve lash of valves 61/3 and 61/4 of cylinder no. 2 and adjust if required. Fig. 61 Valve adjustment • Re-mount the cylinder head cover along with a new gasket. TL160 89/112 Operating Manual 12.9.08 Version 1.0...
  • Page 90 (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 without bubbles. • Remove the bleeder hose and re-tighten the Fig. 64 Bleeding the brake bleeder screw. 90/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 91 7.8.9.4 Adjusting the spring-loaded cylinder • Slacken counternut (65/5). • Adjust the mechanical unlocking mechanism (65/4) to 47 mm. • Re-tighten counternut. • Adjust the spring-type actuators of the other brakes accordingly. TL160 91/112 Operating Manual 12.9.08 Version 1.0...
  • Page 92 (66/3) and suction filter (66/4). • Screw back on the drain plug carefully. • Fill up with clean hydraulic oil using the return filter; to do so, open the filter cover. • Install the return filter cover. 92/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 93 O-ring (68/3) is in exactly the right position. • Screw back on the filter cover (68/1) and tighten by hand. • Check the tightness of the filter by means of a test run. TL160 93/112 Operating Manual 12.9.08 Version 1.0...
  • Page 94 • Install the return filter cover and tighten by hand. • Check the tightness of the filter by means of a test run. Fig. 70 Changing the filter insert of the return filter 94/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 95 Clean the screen (72/3) and check for damage; replace if required. • Screw in new breather (72/1) with O-ring (72/2) and tighten by hand. L864-724 Fig. 71 Hydraulic oil tank L864-725 Fig. 72 Replacing the breather TL160 95/112 Operating Manual 12.9.08 Version 1.0...
  • Page 96 Flush out the axle if necessary. • Carefully close the drain plugs. • Pour in oil using the inspection-filling hole until oil escapes from the other inspection-filling hole. • Carefully close the inspection-filling plugs. 96/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 97 Remove the inspection plug (75/1). • Check if the oil is up to the edge of the inspection hole. • Top up oil if required. • Carefully close the inspection plug. Fig. 75 Checking the transmission oil TL160 97/112 Operating Manual 12.9.08 Version 1.0...
  • Page 98 Carefully close the drain plugs. • Pour in oil using the filling hole until oil escapes from the other inspection hole. • Carefully close the inspection-filling plug (76/1). Fig. 76 Replacing the transmission oil 98/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 99 Note that the tightening torque of 610 Nm applies to the wheel nuts M 22 x 1.5. • When fitting a wheel, tighten the nuts to the correct torque crosswise in several stages. TL160 99/112 Operating Manual 12.9.08 Version 1.0...
  • Page 100 • The acid level should be approx. 10 mm above the plates. • If necessary, top up with pure distilled water. Attention In the case of maintenance-free batteries, this check is not necessary. 100/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 101 7.8.17.4 Checking the lighting and warning equipment • Check the function of the lighting equipment. • Check the function of the indicator lamps. • Check the function of the warning equipment. TL160 101/112 Operating Manual 12.9.08 Version 1.0...
  • Page 102 Re-install the ventilation louver. 7.8.20 Windshield washer system • Top up the windshield washer tanks (81/1) as required. • Add antifreeze when temperatures are around or Fig. 81 Topping up the windshield washer tank below freezing. 102/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 103 - room. Coat connections with a little pole • Lubricate the machine according to the grease. lubrication plan. • Seal off the air intake opening of the air filter system and the exhaust pipe opening. TL160 103/112 Operating Manual 12.9.08 Version 1.0...
  • Page 104 Care and Maintenance 104/112 TL160 Operating Manual 12.9.08 Version 1.0...

  • Page 105: Troubleshooting

    Solenoids of valve damaged Replace / repair Neutral position incorrectly adjusted Check / re-calibrate (call Service Agent) Internal damage to travel pump Replace travel pump Excessive engine idling Re-adjust engine idling Tab. 31 Table of faults TL160 105/112 Operating Manual 12.9.08 Version 1.0...
  • Page 106 Travel pump does not open fully, pilot pressure too Nozzles clogged, check, repair Internal damage to travel pump or travel motor Replace units Travel motor incorrectly adjusted Re-adjust travel motor Tab. 31 Table of faults 106/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 107 Check suction line and repair if required Main pressure relief valve damaged Check and replace if necessary Hydraulic pump damaged Check, repair or replace Hydraulic pump drive mechanically interrupted Check and repair Tab. 31 Table of faults TL160 107/112 Operating Manual 12.9.08 Version 1.0...
  • Page 108 Starting system does not work satisfactorily Check charge capacity of battery Test starter function Check connection and condition of power and battery ground cables Check function of ignition lock, replace if necessary Tab. 31 Table of faults 108/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 109 To do so, proceed as follows: • Stop the machine in the proper manner. • Switch off the ride control system (82/51). • Remove the front-end cover. • Carefully release the setscrew (83/1). Pressure is reduced. TL160 109/112 Operating Manual 12.9.08 Version 1.0...
  • Page 110 Appendix 110/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 111 Travel-drive gear unit ....97 Trouble-shooting ....105 TL160 111/112 Operating Manual 12.9.08 Version 1.0...
  • Page 112 Work stoppages ....18 Working Operation ... . . 16 112/112 TL160 Operating Manual 12.9.08 Version 1.0...
  • Page 113 Wheel Loader – Accident Prevention Regulations published by the employer’s liability insurance associations in the user’s country – Technical Specifications TL160 – Operator controls, indicating and warning elements – Checks before putting the machine into operation – Diesel engine running-in instructions –...

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