Terex TL310 Manual

tl310
Wheel Loader
OPERATING INSTRUCTIONS
tl310
Wheel Loader
Language version: US
Edition: 2010-09
Order number: 5780200604
From vehicle ID No: TL03100100>
Original operating instructions

Terex Compact Germany GmbH
Kraftwerkstrae 4
74564 Crailsheim
Germany
Tel. +49(0)79 51/9 35 70
Fax +49(0)79 51/9 35 76 71
www.terexconstruction.com
e-mail: info@terex-compact.com
Please complete before commissioning the wheel loader:
Vehicle model: .........................................................................................
Vehicle ID-No: .........................................................................................
Year of construction: .........................................................................................
Commissioned on: .........................................................................................
Dealer:
This Operating Manual is protected by limited copyright. It may be reproduced

for and used by the driver / plant operator.
Table of Contents
1
1 Table of Contents
1 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Concerning these operating instructions . . . . . . . . . . . . . . . . . 5
2.2 Notes on using the operating manual . . . . . . . . . . . . . . . . . . . . 7
2.3 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Unintended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7 Product Identifikation Number (PIN) plate . . . . . . . . . . . . . . . 10
3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 General safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1.1 Safety symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1.2 Hazard Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1.3 Descriptions of hazard pictorials . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Location of safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.1 Symbols/Pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3.1 Personal safety gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4 Work zone safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.1 General work zone regulations and safe work practices . . . . . . . 18
3.4.2 Deactivation and protection against re-activation . . . . . . . . . . . . 18
3.5 General safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.7 Hazard zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.8 Transporting persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.9 Stability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.9.1 Stability on sloping ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.10 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.11 Working Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.12 Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.13 Use under the danger of falling objects . . . . . . . . . . . . . . . . . 23
3.14 Working in the vicinity of underground power lines . . . . . . . 23
3.15 Working in the vicinity of overhead power lines . . . . . . . . . . 24
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3.16 Operation in closed spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

3.17 Work stoppages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.18 Load hook applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.19 Conversions, maintenance and repairs . . . . . . . . . . . . . . . . . .27
3.20 Recovery, loading and transporting . . . . . . . . . . . . . . . . . . . . .29
3.21 Monitoring and inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
3.22 Fire prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.23 Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.24 Notes concerning residual dangers . . . . . . . . . . . . . . . . . . . . .30
3.24.1 Failure of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4 Initial installation and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4.1 Initial familiarization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4.1.1 Handing over the machine and instructing the operator . . . . . . . .31
5 Description of the Wheel Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
5.1 Overview of wheel loader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
5.1.1 Overview filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
5.2 Display elements and operating controls in operator's stand35
5.2.1 Operating controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
5.2.2 Front control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
5.2.3 Lateral control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
5.2.4 Control unit heating / Klimatronic . . . . . . . . . . . . . . . . . . . . . . . . .38
5.2.5 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
5.2.6 Fuse and relay box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
5.2.7 Driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
6.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
6.2 Care and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
6.3 Inspection intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
6.3.1 Regular oil analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
6.3.2 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
6.4 Inspection means . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
6.4.1 Service parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
6.4.2 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
6.5 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
6.5.1 Lubrication plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
6.6 Maintenance and Inspection Plan . . . . . . . . . . . . . . . . . . . . . . .57
6.6.1 Daily tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
6.6.2 Tasks to be performed weekly . . . . . . . . . . . . . . . . . . . . . . . . . . .58
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6.6.3 Inspection plan machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6.7 Maintenance and inspection work . . . . . . . . . . . . . . . . . . . . . . 62
6.7.1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.7.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.7.3 Engine - cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.7.4 Air intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.7.5 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.7.6 V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.7.7 Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.7.8 Hydraulic oil suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.7.9 Hydraulic oil return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.7.10 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.7.11 Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.7.12 Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.7.13 Cab ventilation dust filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.7.14 Windshield washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.8 Taking out of service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.8.1 Preservation (temporary immobilization ) . . . . . . . . . . . . . . . . . 104
6.8.2 While being taken out of service . . . . . . . . . . . . . . . . . . . . . . . . 105
6.8.3 After the machine had been taken out of service . . . . . . . . . . . 105
6.8.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.1 Before operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.1.1 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.2.1 Monitoring the machine during operation . . . . . . . . . . . . . . . . . 119
7.2.2 Driving, steering and braking . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.2.3 Working operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.2.4 Changing work attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7.2.5 Loading, grading, excavating. . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.2.6 Ride control system (RCS) (option) . . . . . . . . . . . . . . . . . . . . . . 140
7.2.7 Notes for winter operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
8.1 Recovering the wheel loader . . . . . . . . . . . . . . . . . . . . . . . . . 143
8.2 Lifting with a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
8.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
9.1 Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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9.1.1 Dimensioned drawing with bucket, directly mounted . . . . . . . . .149

9.1.2 Dimensioned drawing with bucket and quick-attach system. . . .150
9.1.3 Dimensioned drawing with light-material bucket and quick-attach system151
9.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
9.2.1 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
9.2.2 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
9.2.3 Travel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
9.2.4 Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
9.2.5 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
9.2.6 Permissible loads in compliance with German Road Traffic Regulations (StVZO)155
9.2.7 Sound level values, vibration . . . . . . . . . . . . . . . . . . . . . . . . . . .155
9.3 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
9.3.1 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
9.3.2 ---- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
9.3.3 Optional accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
10.1 Who is allowed to rectify malfunctions? . . . . . . . . . . . . . . . .163
10.2 Before trouble shooting and fault rectification . . . . . . . . . . .163
10.3 Trouble shooting and fault rectification . . . . . . . . . . . . . . . . .164
10.3.1 Immobilizer faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
11 Service and spare parts information. . . . . . . . . . . . . . . . . . . . . . . . . .171
11.1 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
11.2 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
12 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
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Introduction
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2 Introduction
2.1 Concerning these operating instructions

Economical The operating manual contains important information regarding the safe, correct
operation and economical operation of the wheel loader. Strict compliance with these
instructions helps to avoid dangers, to reduce repair costs and downtimes and
to enhance the reliability and service life of the wheel loader.
Reading the Read these operating instructions thoroughly to become acquainted with correct
operating handling and operation.
instructions
Deployment These operating instructions must always be available at the deployment

location location of the wheel loader.
Technical Items described in this manual are subject of changes without prior notification.
modifications
Copyright This operating manual is copyrighted. It must not be copied, disseminated or

used for competitive purposes, either fully or in part, without prior written
permission.
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2 Introduction
Definition of The contents of these operating instructions are aimed at a diverse target
target groups audience. The level of knowledge each target group must have is defined here.
All target groups must have read these operating instructions and understood
their contents.
Operating personnel must
be physically and mentally fit and suitable.
be of the legal minimum age.
have been instructed in handling the wheel loader.
have proven their ability to operate the wheel loader to the operating
company.
have been appointed by the operating company to operate the wheel loader.
be familiar with the country-specific accident-prevention regulations.
Maintenance personnel must
know the maintenance points on the wheel loader.
have proven their ability to perform maintenance work on the wheel loader to
the operating company.
have been appointed by the operating company to perform maintenance
work on the wheel loader.
know the country-specific environmental regulations for the disposal of
lubricants. See chapter "Regulations concerning environmental protection",
page 19.
Service personnel must
have sound school education and vocational training.
have been trained by Terex for service work on the wheel loader.
must have been trained in the rules and procedures related to a case of
malfunction.
6 / 178 TL310 02_Introduction_us.fm - V 0.1 - 4.5.11
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Introduction
2
2.2 Notes on using the operating manual

Safety symbol
The safety alert symbol is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or
death.
2.3 Intended use

The Terex wheel loader TL310 with standard equipment is solely intended for
the following type of work:
Loosening, picking up, transporting and dumping soil, rock or other materials
Loading these materials on trucks, conveyor belts or other means of
transport, when the transport of the material is normally done by positioning
the earth-moving machine
After installation of additionally approved special work attachments, such as
e. g. :
Multi-purpose bucket
High-tip bucket
Fork lift attachment
etc.
the equipment can be used for corresponding applications.
Strict compliance with the operating and maintenance instructions and the
performance of maintenance work, as well as adherence to the maintenance
intervals is also part of intended use. The operator must also follow the enclosed
operating instructions for externally supplied components.
2.4 Unintended use

Using the Terex wheel loader TL310 for following types of work is considered
unintended:
transport of persons
transport of material on public roads
used as man-platform
Terex or our supplier cannot be held responsible for any injuries or resulting
from improper use. This risk is borne solely by the user.
2.5 Warranty
The warranty period covers 12 months, beginning with the day the machine is
handed over or put into operation.

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2 Introduction
2.6 Declaration of Conformity

The wheel loader meets the general requirements of the applicable European
directives.
Conformity has been proven. The respective documents and the original of the
Certificate of Conformity are kept by the manufacturer.
A copy of the Certificate of Conformity is attached to the sales documents.
EC declaration of conformity
according to the Machinery Directive 2006/42/EC
1. We hereby declare that the earth-moving machine of type TL 310:
Wheel loader: TL 310
Vehicle ID No.: TL0310
Actual productivity: 149 kW/200 HP
2. complies with all the relevant requirements of Machinery Directive 2006/42/EC:
3. The machine also complies with the relevant requirements of the following directives:
2004/108/EC (EMC), Directive 2000/14/EC Annex VIII (noise emission)
4. Representative sound power level:
106 dB(A)
5. Guaranteed sound power level:

106 dB(A)
6. Applied harmonized standards:

EN ISO 12100-2
EN 474-1
EN 474-3
7. Document editor, who is authorized to compile technical documentation:

Maik Schulze, D 74564 Crailsheim, Kraftwerkstrasse 4
8. Voluntary type examination performed as well as certification in accordance with

RL 2000/14/EC Appendix VIII at:
Fachausschsse Bau (BAU) und Tiefbau (TB)
Prf- und Zertifizierungsstelle im BG-PRFZERT
80687 Munich, Germany
The EC declaration of conformity only applies if the earth-moving machine is used in accordance
with the operating instructions. It includes the use of original Terex work attachments and other
work attachments, which are mentioned in the operating instructions or in other Terex
documentation for application on this earth-moving machine.
Replaceable attachments manufactured by Terex or third party manufacturers may only be

installed and used if the installation on the affected earth-moving machine is performed by Terex.
In all other cases, special written approval is required from Terex.
Date of the declaration of conformity 08.04.2010.
Langenburg
Terex GmbH Schaeffstrasse 8

Geschftsbereich Terex Schaeff 74595 Langenburg, Germany
10
Introduction
2
Read the operating instructions thoroughly and follow the notes on safe
operation before putting the earth-moving machine into operation.
National safety regulations - e.g. the Accident Prevention Regulations, Earth-
Moving Machinery (BGR 500) and Vehicles (BGV D29) in the Federal
Republic of Germany - must also be complied with when operating the earth-
moving machine.
In addition to the Operating Instructions, legal regulations governing road traffic
and road safety measures must also be observed. Such duties could also apply
in respect of e.g. handling hazardous goods or the wearing of personal safety
gear.
Furthermore, safety laws governing work in particular locations (tunnels, adits,
quarries, pontoons, contaminated areas, etc.) must likewise be observed.

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2 Introduction
2.7 Product Identifikation Number (PIN) plate

Vehicle type and product identification number are stamped on the PIN plate.
Note
Please state the vehicle type and product identification number when
making inquiries or placing orders, and in all written correspondence.
Fig. 2-1 Type label
1 Vehicle type
2 Product identification numbers
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Safety
3
3 Safety
3.1 General safety notes

3.1.1 Safety symbol
The safety alert symbol is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or
death.
3.1.2 Hazard Classification

DANGER indicates an imminently hazardous
DANGER situation which, if the safety regulations are not
observed, will result in death or serious injury.
WARNING indicates a potentially hazardous

WARNING situation which, if the safety regulations are not
observed, may result in death or serious injury.
CAUTION indicates a potentially hazardous

CAUTION situation which, if the safety regulations are not
observed, may result in property or equipment
damage, or minor or moderate personal injury.
NOTICE indicates a potentially hazardous

NOTICE situation which, if the safety regulations are not
observed, may result in property or equipment
damage.
Notes Note
This symbol is employed for information containing important notes about
the correct use and/or how to proceed. Non-compliance may lead to
malfunction.
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3 Safety
3.1.3 Descriptions of hazard pictorials

The symbols used in this Manual and/or on the Wheeled Excavator identify the
following hazards:
Warning of explosion / burn hazard

If the required precautionary measures are not taken, death, burns or blindness
due to ignition of explosive gases or contact with corrosive acid may occur.
Warning of injection hazard

If the required precautionary measures are not taken, escaping fluid under
pressure can penetrate skin, causing serious injury.
Warning of burn hazard

If the required precautionary measures are not taken, contact with hot surfaces
can cause burns.
Warning of entanglement hazard

If the required precautionary measures are not taken, death or serious injury can
result from contact with rotating drivelines.
Warning of entanglement hazard

If the required precautionary measures are not taken, rotating parts can cause
personal injury.
Warning of crush hazard

If the required precautionary measures are not taken, severe injury and death
from crushing can occur in articulating area when machine turns.

If the required precautionary measures are not taken, death or serious injury can
result from contact with moving loader arm or bucket.

If the required precautionary measures are not taken, death or injury can result
from sudden or accidential movement of loader arm.
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3.2 Location of safety signs

The safety signs are located in the following machine positions:
3 5
4
30
35
12
Frame - engine hood Guard
34
32
310
9 8 7 6
15 31
9
29
Fig. 3-1 Locations of safety signs
1 Crush hazard
2 Crush hazard
3 Burn hazard
4 Entanglement hazard
5 Explosion / Burn hazard
6 Crush hazard
7 Entanglement hazard
8 Injection hazard
9 Crush hazard
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3 Safety
Servicing and replacing safety signs

The safety of the operator always has to come first.
Safety signs must always be kept in good condition and legible.
Replace any safety sign which has been damaged or disappeared.
Use mild detergents and water to clean the safety signs.
Do not use any solvent containing cleansers.
Always specify machine serial number and language when ordering safety
signs.
3.2.1 Symbols/Pictograms
The following symbols/pictograms may be attached to the machine:
Symbols/ Description Symbols/ Description

pictograms pictograms
Brake Preheating
accumulator
pressure
Battery charge Parking brake

indicator
- + P P
Coolant Travel direction

temperature V FWD/REV
Direction High-beam
indicator LT/RT indicator
Engine oil Air filter

pressure
Fuel Travel speed,

FAST
High gear Working

hydraulics shut-
II off
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Bucket return Changeover fan/
positioner engine cooling
Windshield wiper Windshield

washing function
Working Hazard warning

floodlights system
Ride control Float position

system
Unlocked Emergency
steering
Fan levels Cooling
Circulating air Temperature
Carbon filter Coolant level

contamination
Hydraulic oil Hydraulic oil

level
Horn Grease gun
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3 Safety

Lashing points Suspension
points for loading
by crane
First-aid kit Fire extinguisher
Intermediate Battery cutoff

lubrication
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3.3 Personal safety

The Operating Instructions and the symbols described have to be read and
understood by all persons working on and with the machine.
3.3.1 Personal safety gear

The mandatory signs used in this Manual and on the machine require the
following safety measures:
Working with protective clothing

If the required protective clothing is not worn during work, personal injury may
result.
Working with protective gloves

If the required protective gloves are not worn during work, hand injuries may
result.
Working with protective goggles

If the required protective goggles are not worn during work, eye injuries or a total
loss of sight may result.
Working with hearing protection

If the required hearing protection is not worn during work, hearing defects may
result.
Working with respiratory protection

If the required respiratory protection is not worn during work, health effects may
result.
Working with protective face shield

If the required protective face shield is not worn during work, facial injuries may
result.
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3 Safety
3.4 Work zone safety

3.4.1 General work zone regulations and safe work practices
Read the operating instructions thoroughly and follow the notes regarding safe
operation before starting up the machine.
In addition to the operating instructions observe also the national legal and
miscellaneous regulations applicable at the deployment location of the machine:
Industrial safety
Accident prevention
Health protection
Environmental protection
Public traffic
Such duties could also apply in respect of e. g. handling hazardous goods or the
wearing of personal safety gear.
Furthermore, safety laws governing work in particular locations (tunnels, adits,
quarries, pontoons, contaminated areas, etc.) must likewise be observed, e. g.:
Working in the vicinity of tracks (BGV D33)
Construction work (BGV C22)
Safety rules for construction work underground (BGR 160)
Tunnel excavating machines (DIN EN 12111)
The plant operator and the machine driver are responsible for ensuring that the
safety regulations are upheld. The customer must in any case become familiar
with the locally valid rules and regulations.
3.4.2 Deactivation and protection against re-activation

Ensure all the following safety instructions are read prior to using or servicing
the machine, to avoid personal injury.
Before breaks and the end of work park the machine on a solid and level
base.
The machine is only to be parked in places where it does not obstruct e. g.
the public or the construction site traffic.
Place the working attachment on the floor.
Shut down the engine and pull out the ignition key.
Close or lock windows and doors.
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3.5 General safety notes

It is important to refrain from any working methods which impair safety.
The machine may only be operated with cabin or canopy.
The machine is only to be used if it is in a safe, operational condition.
The manufacturers instructions must be complied with for operation,
maintenance, repair, assembly, and transportation.
The plant operator must provide additional special safety instructions,
wherever necessary, for specific local conditions.
The operating instructions and any information pertaining to safety must be
carefully kept in the driver's cab.
The operating instructions and safety notes must be complete and fully
readable.
Before starting Before starting work become acquainted with the First Aid and Rescue
work: Possibilities (Emergency Doctor, Fire Brigade, Rescue Services).
Check that the first aid kit is available and properly stocked.
Become familiar with the location and the operation of fire extinguishers on
the machine, as well as the local fire alarm and fire fighting facilities.
Fasten any loose parts, e. g. tools and other accessories.
Close all doors, windows, hoods, flaps, or secure these in open condition
against unintended closing.
During work Do not make any safety features ineffective and do not remove any safety
features.
Wear protective clothing for operation. Take off rings, scarves, open jackets.
Protective goggles, protective boots, helmets, gloves, reflecting jackets, ear-
muffs, etc. may be required for certain work.
Regulations Comply with the valid environmental regulations when working on or with the
concerning machine.
environmental Take special care that no environmentally harmful substances, like
protection lubrication grease and oils, hydraulic oils, fuels, coolants and solvent
containing cleaning fluids do not seep into the ground or the sewer when
performing installation, repair and maintenance work. These substances
must be collected, transported, kept and disposed of in suitable containers.
If the substances listed above enter into the soil, the leak or outlet must be
stopped immediately and the fluid must be cleaned up with a suitable
absorbent material. If necessary, the soil involved must be removed.
Properly dispose of binding agent and excavated material, comply with valid
environmental regulations.
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3 Safety
3.6 Operation
Operate the control equipment only from the driver's seat.
To access and exit the machine use only the steps and areas provided for
this purpose.
Make sure that the operators stand, access steps and other surfaces on the
machine, which have to be stepped on, are kept free of dirt, grease, oil, ice,
and snow.
3.7 Hazard zone

Nobody is allowed to remain in the machines hazard zone.
The hazard zone encompasses the area around the machine in which persons
may be injured by movements of the machine during operation, its work
implements and attachments, or by swinging out or falling loads.
The machine operator is only to work the machine if nobody is in the hazard
zone.
The machine operator must give a warning signal to persons who may be in
danger.
Stop work with the machine, if persons remain in the hazard zone despite the
warning.
To ensure no danger of crushing, a sufficient safety distance (min. 0.55 yd)
must be kept from solid objects, e. g. buildings, excavation slopes,
scaffolding, other crawler excavators, etc.
If the safety distance cannot be kept, fence off the area between solid
construction elements and the working range of the machine.
If conditions are such that the machine operators view of the driving and
working zone is restricted, he must be guided or the driving and working zone
must be secured by means of a solid barricade.
3.8 Transporting persons

The machine must not be used to transport persons.
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3.9 Stability
The machine must be used, driven and operated in such a manner that its
stability against overturning is ensured at all times.
Match the travel speed to the local conditions.
Do not exceed the permissible load for the machine.
Keep the machine away from the edges of quarries, pits, mounds and slopes,
to ensure there is no risk of falling. If this is not possible, the machine must
be secured to prevent rolling or slipping.
3.9.1 Stability on sloping ground

There is danger of overturning on sloped base.
There is particular danger when working (digging and lifting) on soft bases.
An increased degree of caution is required on slopes over 10 (17.6%).
The tilt angle increases when driving over obstacles one-sided.
Maximum
inclination Always drive straight up or down inclines. Driving at an angle on an incline or
cross-wise over an incline is extremely dangerous.
Do not turn on the incline and do not drive cross-wise over it. Always return
to a level spot to change the position of the machine and then drive back on
the incline.
Test the standing stability of the machine before beginning work.

Observe the stability specifications. The stability specifications are based on
a level, solid and even base.
All stability calculations must be made with a horizontally positioned machine
on a uniform and solid ground. If the machine is used while working under
conditions that do not meet this requirement (such as loose and irregular
ground, no horizontal position, side loads, etc.) these conditions must be
taken into consideration by the operator.
Never exceed the maximum allowable inclination angle of the machine.
Secure the machine against rolling or sliding.
Begin work slowly.
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3 Safety
3.10 Driving
Before putting the machine into operation, the driver's seat, mirrors and
operator controls must be adjusted so as to ensure safe working.
Always wear the seat belt.
Keep windows clean and free of ice.
Driving tracks must be designed so as to ensure smooth, safe operation, i.e.
they must be sufficiently wide, on ground which has as few slopes as possible
and sufficient carrying capacity.
Downhill tracks must be set out in such a way that machines can be safely
braked.
Before driving downhill, the appropriate gear for the terrain must be selected
and the gear lever not be moved during downhill travel (road or off-road
gear). On steep drops and uphill gradients, the load must be carried on the
uphill side, if possible, in order to increase stability.
The carrying capacity of bridges, cellar roofs, vaults, etc. must be verified
before the earth-moving machine can drive over them.
Check the clear dimensions of constructions before entering into subways,
tunnels, etc.
It is the plant operator's responsibility to ensure that equipment such as first-aid
box, warning triangle, hazard lights are kept with the machine according to the
traffic regulations valid in the users country and that the driver has the
appropriate license as required by the national traffic laws of the country in
question.
Outside areas covered by general traffic regulations, e. g. on factory premises,
traffic regulations should be applied in the proper manner. This should also
apply with regard to drivers licenses.
3.11 Working Operation

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. Move the working
attachment carefully in low height. During this check nobody must be allowed
to remain in the danger zone of the earth-moving machine.
You should only swing the work equipment over occupied drivers' seats,
operator consoles and workplaces of other machines if these are protected
by canopies (FOPS).
If a cab does not have the required protection, the driver of this vehicle must
leave the operators stand while the work equipment is being swung
overhead.
Load the machine in such a manner, that it is not overloaded and no material
is lost while the machine is driving. Load the machine from the lowest
possible height.
At dumping points, the machine may only be operated if suitable measures
have been taken to prevent rolling or falling.
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3.12 Guides
Guides must be easily recognizable, e. g. by means of reflective clothing. They
must remain within the machine operators field of vision.
While guiding the machine, guides shall not be given other jobs which may
distract them from their task.
3.13 Use under the danger of falling objects

If there is danger of falling objects use the machine only if the driver's seat is
protected by 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, the machine must be operated and
positioned 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.
Only use the machine for demolition work if no persons are endangered and
if the machine is equipped with protective roof (FOPS) and front protection
mounted to the operator's stand. See regulations book "Demolition work"
(BGI 665) published by the German Tiefbau-Berufsgenossenschaft (Civil
Engineering Employers Liability Insurance Association).
3.14 Working in the vicinity of underground power

lines
Before commencing excavating work using the machine, it must be
determined whether any underground power lines are present in the intended
working zone which may present a hazard to persons.
If underground power lines are present, their exact position and course must
be determined in consultation with the proprietor or operator of the lines, and
the necessary safety precautions decided and implemented.
Before starting any earth work clearly mark the route of lines in the
construction site area under supervision. If the position of lines cannot be
determined, search ditches must be dug - manually, if need be.
In case of unexpected detection or damaging of underground power lines or
their protective coverings stop work immediately and inform the supervisor.
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3 Safety
3.15 Working in the vicinity of overhead power lines

If the machine is being used in the vicinity of overhead power lines and trolley
wires, a safety distance which varies depending on the nominal voltage of the
overhead line must be maintained between the lines and the machine and its
work equipment, to prevent current overspill. This also applies to the distance
between these lines and attached implements or loads.
Specified safety The safety distance depends on the rated voltage of the overhead power line.
distance
Nominal voltage Safety distance
> 1,000 V 1.0 m/32.8 ft
more than 1 kV > 110 kV 3.0 m/9.8 ft
more than 110 kV > 220 kV 4.0 m/13.1 ft
more than 220 kV > 1,380 kV 5.0 m/16.4 ft
nominal voltage unknown 5.0 m/16.4 ft
Tab. 3-1 Prescribed safety distances
Also consider all working movements of the machine, e. g. positions of the

work equipment and the dimensions of attached loads.
Consider also uneven ground which could cause a slanted position of the
machine and thus bring it closer to the overhead power line.
During work in windy conditions, both overhead lines and work equipment
may swing out, thus reducing the safety distance.
If it is impossible to maintain sufficient distance from overhead power lines and
trolley wires, the plant operator must consult with the proprietor or operator of
the overhead lines to find other safety precautions to prevent current overspill.
Such measures could be, e. g.
Switching off the current
Re-routing the overhead line
Wiring
Limitation of the working range of the machine.
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3.16 Operation in closed spaces

If machines are to be used in closed spaces, these areas must be sufficiently
ventilated and special regulations observed.
3.17 Work stoppages

Before rest periods and the end of work park the machine on a level base of
sufficient load bearing capacity and secure it reliably against unintended
moving.
Before rest periods and the end of work lower the working attachment to the
ground to prevent it from moving.
Do not leave the machine before you have lowered and secured the work
equipment.
Machines are only to be parked in places where they do not obstruct, e. g. public
or construction site traffic. Warning devices, e. g. triangles, warning cordons,
flashing or hazard lights are to be used if necessary.
Before leaving the operator's stand return all control elements to neutral
position, apply the brakes and switch off the working hydraulics.
Before exiting the machine shut down the engine and secure it against
unauthorized restarting (e. g. by pulling out the ignition key and
disconnecting the battery if necessary).
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3 Safety
3.18 Load hook applications

Load hook applications are the hoisting, transporting and lowering of loads with
the aid of a fixing device (rope, chain, etc.), whereby the assistance of personnel
is required to attach and release the load. Such work covers e. g. the lifting and
lowering of pipes, tubbing rings or containers using earth-moving machines.
Earth-moving machines are only to be used for load hook applications if the
prescribed safety devices are present and in full working order. For earth-
moving machines, these are:
Secure attachment of loading implements
Carrying capacity
Loads must be attached in such a way that they cannot slip or fall out.
Personnel guiding the machine and attaching loads must always remain in
the machine operators field of vision.
Keep loads as close above the ground as possible and avoid swinging about.
Move the machine with the suspended load only if the travel ground is level
or almost level.
If the machine is used for load hook applications, personnel attaching loads
is only to approach the lifting frame from the side and with the machine
operators permission. The machine operator is only to give his permission if
the machine is standing still and the work equipment is not in motion.
Do not use fixing devices (ropes, chains, shackles) which are damaged or of
inadequate dimensions.
Always wear protective gloves when working with lifting tackle
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3.19 Conversions, maintenance and repairs

The machine must only be converted, maintained or repaired under the
guidance of a suitable person designated by the plant operator and following the
manufacturers Operating Instructions.
After changing the work attachments convince yourself of the correct
fastening of the work attachments.
Work on e. g.
brake systems,
steering systems,
hydraulic systems,
electric systems
of the machine is only to be carried out by expert personnel specially trained in
these areas.
Stability must be ensured during all type of work on the machine at all times.
Always secure the machine with wheel chocks against rolling when working
on or especially under the machine.
Secure the work equipment against movement by lowering it to the ground or
by applying equivalent measures, e. g. cylinder supports, trestles.
As long as the engine is running, the unprotected working range must not be
entered.
Attach the lifting gear for jacking up the machine so that it cannot slip off.
Make sure that the jacks are placed exactly vertically.
The raised machine must be supported with suitable structures, e. g.
crosswise stacked planks, square timbers or steel trusses.
Stabilize the machine that has been lifted with the work equipment,
immediately after lifting with a supporting structure. Work under raised
machines which are only supported by their hydraulics is forbidden.
Shut down the engine before any maintenance and repair work. These
requirements may only be ignored in the case of maintenance or repair work
which cannot be performed without the engine/motor(s) running.
Always depressurize the hydraulic system before starting corresponding
maintenance and repair work. 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.
Before starting work in the electric system or for welding work on the machine
disconnect the battery connection.
When disconnecting the battery disconnect the minus pole first and the plus
pole after. Reconnect in reverse order.
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3 Safety
When performing repair work in the area of the battery cover the battery with
insulating material. Do not lay any tools on the battery.
Open or remove the safety features from moving parts of the machine only
after the machine has been shut down and the drive is properly secured
against unauthorized restarting. Protective devices are e. g. engine/motor
covers, doors, protective grating, trim.
Upon completion of assembly, maintenance or repair work, all protective
devices must once more be attached in the proper manner.
Welding work on load-bearing parts of the machine are only permitted after
consultation with the manufacturer and in accordance with recognized
welding principles.
Do not perform welding or drilling work on safety structures (ROPS, FOPS).
Alterations, e. g. welding of the hydraulic system, are only to be undertaken
with the manufacturers permission.
Before commencing work on the hydraulic system, the operating pressure,
pilot pressure, back pressure and pressure inside the tank must be relieved.
Observe the safety data sheets issued by the mineral oil companies.
Swallowing lubricants as well as long and repeated skin contact can be
hazardous to health and should therefore be avoided. When used properly,
there is no particular danger to health.
Use only hydraulic hoses specified by the manufacturer.
Route and assemble hydraulic hoses correctly.
In the vicinity of fuel or batteries, smoking and naked flames are prohibited.
Safe working conditions and good working order of the machine are
prerequisites for efficient work. Your Terex wheel loader TL310 fulfils these
requirements when correctly handled and when serviced and maintained as
specified.
Avoid malfunctions by cautiously watching the machines functions and by
using the specified fuels and lubricants.
Trained specialist personnel are responsible for any servicing of the machine
which requires expert knowledge. Inspections and repairs must therefore be
carried out by your dealers customer service.
Within the warranty period damage claims can only be lodged if the specified
intervals for maintenance and inspection work have been complied with.
After the warranty period, too, regular maintenance must be performed in
order to ensure that the machine is constantly in good working order and
enjoys a reasonable service life.
Insist that only original Terex spare parts are used in the event of any repair
work. In this way, you will have a product of lasting high quality, thereby
ensuring that your machine maintains its original condition.
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3.20 Recovery, loading and transporting

Machines shall only be loaded onto recovery vehicles when adequate towing
vehicles are used.
Use the lifting points specified by the manufacturer.
For loading and transportation secure the machine and the required auxiliary
devices against unintended movements.
Clean running gear and chassis of the machine from slurry, snow and ice, so
that the loading ramp can be approached without the risk of slipping.
For transport by truck, low loader or railway secure the machine reliably with
wheel chocks and by fastening it at the lashing points.
Before setting off, the route to be taken must be examined to determine
whether the roads are wide enough, entrances and passages under bridges
are large enough and that roads and bridges have sufficient carrying
capacity.
3.21 Monitoring and inspections

Have the machine inspected by an expert (e. g. machine engineer or
machine foreman) according to the regulations in force in the user's country
(e.g. Accident Prevention Regulations in Germany):
Before the machine is put into operation for the first time and after
significant modifications have been made
At least once a year
In the meantime, according to operating conditions and local
environments
Keep record of the inspection report and file it until the next inspection.
Before the beginning of the shift check the machine following the inspection
plan.
Replace hydraulic hoses as soon as the following damage is noticed:
Damage to the outer layer which reaches the intermediate layer.
Embrittled patches on the outer layer.
Deformations when under pressure or without pressure which differ from
the original shape of the installed hose.
Leaks.
Damage to hose fittings or to the connection between the fitting and the
hose.
Check the coolant level only with the engine shut down, carefully turn the
cover to relieve overpressure.
Check the function of the safety devices before using the machine.
In case of any faults inform the supervisor immediately, at change of shifts
inform also the new operator.
In case of faults that could endanger the operating safety of the machine stop
operation until the fault is corrected.
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3 Safety
3.22 Fire prevention

Shut down the engine before refueling and take care when the engine is hot.
Never smoke or handle open flames whilst refueling the tank of the machine.
Keep the fire extinguisher near the operator's stand.
Its location must be identified by the fire extinguisher symbol.
3.23 Emergency exit

The right-hand cab door acts as an emergency exit.
3.24 Notes concerning residual dangers

3.24.1 Failure of hydraulic system
If the hydraulic system fails because the engine is not running, the hydraulic
pump is damaged or hydraulic oil has been lost, only the following emergency
functions can still be performed:
Manual steering
Emergency support through auxiliary pump (1-2 min.) and
Lowering work equipment (only if ignition is switched on).
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Initial installation and adjustments
4
4 Initial installation and adjustments
4.1 Initial familiarization

Note
Initial inspection must be carried out before commissioning. See chapter 6.6
"Maintenance and Inspection Plan", page 57.
The machine must only be operated by properly trained and instructed

personnel. For this purpose a corresponding instruction session and training is
conducted when the machine is handed over.
4.1.1 Handing over the machine and instructing the operator

The following checklist should be followed when handing over the machine to
the operator:
Operating Go through the Operating Instructions (page by page) and explain them in
instructions detail through practical training on the machine.
Items which are particularly important include:
Safety section
Accident Prevention Regulations published by the employers liability
insurance associations in the users country
Technical data
Operator controls, indicating and warning elements
Checks before putting the machine into operation
Engine running-in instructions
Starting and shutting down the engine
Driving
Recovery and transport of the machine
Operation of all functions
Explanation of maintenance intervals and points according to
Maintenance and Inspection Plan by demonstrating and explaining
maintenance points on machine
Lubrication intervals and points of lubrication according to lubrication chart
and demonstration of these points on the machine
Spare parts list Explain the structure of spare parts list, figures and the associated texts.
Explain that spare parts orders must always be accompanied by machine
type, vehicle identification number ("Fz-Id.Nr."), parts designation, complete
spare part number, quantity, delivery address, etc.
Warranty Explain the warranty conditions.

Explain the inspection cards with a hint to the maintenance and inspection
plan.
Fill in the warranty/handing over card correctly and send it back to us.
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4 Initial installation and adjustments
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Description of the Wheel Loader
5
5 Description of the Wheel Loader
5.1 Overview of wheel loader

2
5
1 3
4 6 7
9 13 11
12 10
4560_5001
Fig. 5-1 Overview of wheel loader
1 Bucket
2 Quick-attach system
3 Lifting frame
4 Front-end
5 Cab
6 Door catch
7 Engine
8 Articulation
9 Type label
10 Battery
11 Fuel tank
12 Hydraulic oil tank
13 Radiator and hydraulic oil cooler
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5.1.1 Overview filters
6 5
1
2
4560_5002
Fig. 5-2 Overview filters
1 Air filter
2 Fuel filter
3 Engine oil filter
4 Return filter Hydraulic oil tank
5 Suction filter Hydraulic oil tank
6 Breather filter Hydraulic oil tank
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5
5.2 Display elements and operating controls in

operator's stand
5.2.1 Operating controls
Note
The following lists include non-standard equipment!
2 4
P
+ -
UNIDECK UNIDECK
7 8
5 9
1
HAZARD
AUTO OFF
0
I
4560_5003
Fig. 5-3 Operating controls
1 Brake-inching pedal
2 Lighting, direction indicator, horn and low-high beam (steering-column switch)
3 Steering wheel
4 Tilt and height adjustment of steering wheel
5 Accelerator pedal
6 Control lever - loading equipment
7 Operation - additional control circuit OFF
8 Operation - additional control circuit ON
9 Preselection of travel direction (function only active if working hydraulics are
activated)

44
5.2.2 Front control console
6
7
5
4 8
3 9
P
2 10
+ -
1
11
13 12
UNIDECK UNIDECK
14 15 16 17 4560_5004 18 19 20 21 22
Fig. 5-4 Front control console
1 Brake accumulator pressure

2 Pre-heating monitor
3 Charge control lamp
4 Parking brake
5 Travel direction, forward
6 Display with operating hour meter
7 Travel direction, reverse
8 Direction indicator
9 High beam
10 Engine oil pressure
11 Air filter indicator
12 Fuel-level indicator
13 Coolant temperature
14 Travel speed switch - FAST/SLOW
15 --
16 Multi-function switch (lock for working hydraulics cut-off and activation of the
direction-of-travel preselection switches (9) page 35 and (17) page 36)
17 Preselection of travel direction (function only active if working hydraulics are
disabled)
18 Bucket return positioner (option)
19 Engine cooler reversing fan changeover switch automatic / temperature-controlled
/ manual
20 Windshield washing function - front/ rear
21 Windshield wiper, front
22 Windshield wiper, rear
44
5
5.2.3 Lateral control console
1 2 3 4
R HAZARD
R HAZARD
5
lubrication
Intermediate
15 6 7 8 9
schmierung
Zwischen-
10 11 12
lubrication
Intermediate
schmierung
Zwischen-
13 AUTO OFF
14
0
I
4560_5005
Fig. 5-5 Lateral control console
1 Reverse signal off

2 Working floodlight, front
3 Working floodlight, rear
4 Hazard warning switch
5 Flow rate adjustment for additional control circuit
6 Ride control system (option)
7 Preselection switch - float position - OFF/Continuous operations
8 Preselection switch of additional control circuit - OFF/Impulse/Continuous operation
9 Parking brake preselection switch ON/OFF, ON = locked
10 Motor control lights
11 Emergency steering Automatic/ON
12 Intermediate lubrication (manual operation of central lubrication)
13 Control unit heating / Klimatronic
14 Glow plug and starter switch
15 Versa steering switch

44
5.2.4 Control unit heating / Klimatronic

3 4
2 5
1 6
AUTO OFF
7
11 10 9 8 4560_5006
Fig. 5-6 Control unit heating / Klimatronic
1 Lowering temperature by 1 C/33.8 F

2 Raising temperature by 1 C/33.8 F
3 Temperature, error code display
4 Fan level display (LED)
5 Increasing fan speed by 1 level
6 Lowering fan speed by 1 level
7 Button for temperature display
8 Interior space temperature sensor
9 Circulating air button and display
10 Cooling button and display
11 Automatic diagnosis button and display
44
5
5.2.5 Display
1
2 I 12 km/h
3 00014,0 h
4 II
I 21 km/h
00014,0 h
I 12 km/h
5 6 7 8
4560_5007
Fig. 5-7 Display
1 Speed indicator
2 Monitor indicator "manual transmission range I"
3 Operating hour meter
4 Monitor - indicator "manual transmission, range II" (optional for high-speed version)
5 Soot filter clogging indicator (option)
6 Hydraulic oil filter clogging indicator
7 Hydraulic oil level
8 Coolant level

44
5.2.6 Fuse and relay box
FL1 FL2 FL3 FL4 FL5

FL11 FL12 FL13 FL14
FL6 FL7 FL8 FL9 FL10
FR1 FR2 FR3 FR4 FR5

FR11 FR12 FR13 FR14
FR6 FR7 FR8 FR9 FR10
4560_5008
Fig. 5-8 Fuse and relay box
Position Ampere Assignment

FL1 15A Heating/air-conditioning
FL2 15A Windshield wiper and washer system, front
FL3 15A Windshield wiper and washer system, back
FL4 10A Rotating beacon/interior light
FL5 15A Power supply for ZSML term.15 Versa Steer, air-
cushioned seat (10A fuse)
FL6 15A Power supply for ZMDL term.15
FL7 10A Power supply for ZSML term.15 option 4th control circuit
FL8 10A Power supply for ZSML term.15 option
FL9 10A Dashboard/immobilizer
FL10 10A Bucket return positioner
FL11 10A Reserve
FL12 10A Direction indicators term.15
FL13 10A Horn
FL14 20A Option for tank filling pump, assembly socket (15A fuse)
FR1 15A Working floodlights, front
FR2 15A Working floodlight, rear
FR3 15A Ignition switch
FR4 10A Direction indicators term.30
FR5 15A 24V socket, option for assembly socket
FR6 20A Power supply for ZMDL term.30, immobilizer
44
5

FR7 20A Reserve
FR8 10A High beam light
FR9 10A Dipped beam
FR10 10A Side marker lamp, left
FR11 10A Side marker lamp, right
FR12 10A Air conditioning control
FR13 15A Reserve
FR14 10A Radio / socket 12 V
Tab. 5-1 Assignment

44
4560_5009
Fig. 5-9 Main input fuses

F01 200A Emergency steering pump
F02 125A Fuse F005-F008
F03 125A Preheating system
F04 30A Power supply for control module ZSML
F05 30A Accelerator pedal, diagnosis socket, emergency steering
pump
F06 30A Reserve
F07 50A Power supply for main fuse
F08 30A Power supply for engine ECU
F09 5A Accelerator pedal
K1 Starting relay
K2 Preheater relay
K3 Indicator relay
K4 Emergency steering pump
K6 Terminal 15
KK1 Compressor relay
KK2 Blower relay
KK3 Blower relay
KK4 Blower relay
KK5 Circulating air flap relay
KK6 Circulating air flap relay
Tab. 5-2 Assignment Main input fuses
44
5
5.2.7 Driver's seat

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.
1 2
3 4
5
4560_5010
Fig. 5-10 Driver's seat
1 Position adjustment
2 Vertical adjustment
3 Armrest right (standard), armrest left (option)
4 Seat back adjustment
5 Inclination adjustment of back-rest
6 Horizontal adjustment
7 Weight adjustment

44
44
Maintenance
6
6 Maintenance
Note
Strictly observe all safety notes.
See chapter 3.19 "Conversions, maintenance and repairs", page 27.
6.1 General
The good operating condition and life expectancy of machines are largely
influenced by care and maintenance.
For this reason, it is in every machine owners 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. Maintenance and inspection plans for this
purpose are contained in every Instruction Book.
6.2 Care and cleaning

Cleaning the machine
Clean the machine in the parking position on a suitable base with oil
separator.
If working with a high pressure cleaner, a protective face shield and
protective clothing must be worn.
Neither a steam-jet nor a high-pressure cleaner must be used for cleaning
during the first two months after the machine has been used for the first time,
or when newly painted, to ensure that the paint can cure sufficiently.
Do not use aggressive detergents to clean the machine. We recommend
using commercially available cleaning agents for passenger cars.
Do not exceed a hot water jet temperature of 80 C/176 F and a jet pressure
of 70 bar/1,015 psi.
Linings (insulating materials, etc.) should not be exposed directly to water,
steam or high-pressure jets.
When cleaning with water or steam jets, take care not to direct the jet into
exhaust and air filter openings.
When cleaning the engine with water or steam jet, do not expose sensitive
engine parts, such as generator, wiring, oil pressure switches, etc. directly to
the jet.
After wet cleaning lubricate the machine as specified in the lubrication plan
and check all clearances, support and travel functions.
06_Maintenance_us.fm - V 0.1 - 4.5.11 TL310 45 / 178

10
6 Maintenance
6.3 Inspection intervals

Note
The reading of the operating hour meter in the control console is decisive for
the inspection intervals of the machine. See chapter 5.2.2 "Front control
console", page 36.
Interval Description See page...

Initial inspection Once before first putting into operation -
Daily tasks Every 10 operating hours or every work 57
shift 1)
Weekly tasks Weekly or after 50 operating hours 1) 58
100 operating hours Once after first putting into operation 2) 59
500 operating hours After every 500 operating hours or after 59
6 months
1000 operating hours After every 1000 operating hours or 59
after 12 months
2000 operating hours After every 2000 operating hours or 59
after 2 years
1)
whichever comes first
2)
also applicable if new or overhauled engines are put into operation.
Tab. 6-1 Inspection intervals
46 / 178 TL310 06_Maintenance_us.fm - V 0.1 - 4.5.11
10
Maintenance
6
6.3.1 Regular oil analysis

Oil analysis 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.
Advantages of Extension of the oil change intervals under standard or light-duty operating
an oil analysis conditions.
Minimum wear of high-quality components with optimum use of the
lubricants.
Periodic laboratory analyses enable an early detection of imminent damage.
Repairs performed before they actually become absolutely necessary help
prevent serious and unexpected damage.
Resulting damage will also be prevented.
Oil analysis Regular oil analysis will indicate any developing trends regarding the state of the
intervals oil and the machine. The oils should be analyzed at the following intervals:
Oil Operating hours

Hydraulic oil 1000
Transmission oil 500
Engine oil 100
Tab. 6-2 Oil analysis intervals
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.

10
6 Maintenance
6.3.2 Warranty
During the warranty period thorough inspections are stipulated for the machine
which are obligatory and must be carried out by trained specialist dealer
personnel.
The engine inspections specified by the manufacturer must also be performed.
Note
The inspections are obligatory and must be paid for.
The performance of inspections as specified must be confirmed on the
inspection cards in the warranty/handing-over certificate.
Failure to do so may adversely affect our warranty coverage.
10
Maintenance
6
6.4 Inspection means

6.4.1 Service parts
Service part Spare part number
Hydraulic oil filter insert return filter 5 380 665 034
Hydraulic oil filter insert suction filter 5 003 660 861
Breather with screen element 5 003 730 010
Engine oil filter 5 106 030 089
Fuel filter with seal 5 106 030 090
Air filter main cartridge 5 501 661 140
Air filter safety cartridge 5 501 661 141
V-belt 5 106 030 097
Cylinder head cover gasket 5 106 030 096
Cab - breather 5 388 665 293
Fuel pre-cleaner 5 106 030 091
Tab. 6-3 Service parts
Note
Service parts for inspections should be ordered well in advance!
Contact your dealer!

10
6 Maintenance
6.4.2 Consumables
Property damage
Machine damage caused by non-mixable bio oils.
Z Do not mix bio-degradable oils from different manufacturers.
Property damage
Machine damage due to incorrect coolant and mix proportions.
Z Observe the information on the cooling system given in the engine manufacturer's
Operating and Maintenance Manual.
Note
When changing from mineral to bio-degradable hydraulic oils, the tank and
hydraulic system must be completely drained, cleaned and flushed.
Before changing ask your Terex dealer for further details.
10
Maintenance
6
Fuel specification
The use of high-quality fuel is a prerequisite for achieving the engine output
specified.
Recommended N590-diesel engines - Auto/C0/C1/C2/C3/C4

fuel BS2869 Class A2
specification ASTM D975-91 Class 2-2DA, US DF1, US DF2, US DFA
JIS K2204 (1992) Class 1, 2, 3 and special class 3.
Note
If sulfur-free fuel is used, additions to lubricants must be used.
Sufficient fuel Note

specification The fuel specification listed below is sufficient but may reduce the life
expectancy of the fuel injection system.
ASTM D975-91 Class 1-1DA

JP7, MIL T38219 XF63
NATO F63
Fuel with low Only use commercially available brand-name diesel fuel with a sulfur content of
sulfur content less than 0.5 %.
Sulfur content in fuel Oil change interval

in %
< 0.5 normal
0.5 to 1.0 0.75 of normal
> 1.0 0.50 of normal
Tab. 6-4 Oil change interval if sulfur content in fuel is higher

10
6 Maintenance
Stipulated consumables for use in central Europe
Application Designation Specification, stan- Remarks

dards, quality
Engine Diesel fuel EN 590 Before using RME-fuels ask your Terex
ASTM D975 1-D/2-D dealer for further details.
Engine Engine oil SAE 15W-40 See also engine manufacturer's operating
API CH4 or CI4 manual.
ACEA E3 or E4
Cooling for Coolant Antifreeze based on See also engine manufacturer's operating
engine ethylene glycol manual.
Hydraulic Hydraulic oil or HVLP 46 or The following viscosity limit values must be
system multi-grade SAE 10W-40 observed (according to ASTM 445):
engine oil at 100 C/212 F min. 8 mm2/s (cSt)
at -10 C/14 F approx. 1,500 mm2/s (cSt)
Bio-degradable Filling according to The same viscosity values apply as for
hydraulic oil customer specifications. mineral hydraulic oils.
based on Brand label on machine.
synthetic ester
Transmission ATF-oil ATF Alternative recommendations
Type A Suffix A Dexron - III F, -III G, -III H
Dexron-IID
Axles, wheel Transmission oil SAE 85W-90LS Alternative recommendations
hubs, API-GL 5 SAE 90LS
Differential SAE 80W-90LS
Lubricating Multi-purpose, K2K-30
points lithium-soap DIN 51825
based grease
Cooler Mixture of water, The antifreeze is factory-set to approx. -
additives and 25 C/-13 F.
glycol
Tab. 6-5 Consumables
10
Maintenance
6
Alternative recommendation for other temperature ranges
Engine oil According to API CH 4 or CI 4 and ACEA E3 or E4:
0W
5W20
10W30
15W40
20W50
20
30
40
Fig. 6-1 Recommended viscosity classes applying to engine oil
Hydraulic oil According to DIN 51524.T3 HVLP:

HVLP 22
HVLP 32
HVLP 46
HVLP 68
Viskohyd 20HVLP 100

-30 -20 -10 0 10 20 30 40 50 C
-22 -4 14 32 50 68 88 104 122 F
Umgebungstemperatur/Ambient temperature/Temprature ambiante
Fig. 6-2 Recommended viscosity classes for hydraulic oil

10
6 Maintenance
Fluid capacities
Fluid capacities in liters/ Fuels and lubricants
gallons
Fuel tank 250.0/66.0 Diesel fuel
Engine with oil filter 15.0/4.0 Engine oil (change quantity)
Hydraulic oil, tank, system, brakes 165.0*/43.6* Hydraulic oil
Hydraulic oil tank 126.0/33.3 Hydraulic oil (change
quantity)
Front axle center housing 20.0/5.3 Transmission oil
Rear axle center housing 20.0/5.3 Transmission oil
Drive transmission 4.25/1.1 ATF mineral oil
Wheel hubs, front / rear axle 5.0/1.3 each Transmission oil
Coolant 41.0/10.8 Mixture of water, additives
and glycol (50 / 50)
* The hydraulic oil quantity depends on the equipment level of the machine.
Tab. 6-6 Fluid capacities
Note
All values stated are approximate. The level marking is always the decisive
factor. See chapter 5.2.2 "Front control console", page 36.
10
Maintenance
6
6.5 Lubrication
Property damage
Damaged grease nipples can cause machine damage.
Z Check grease nipples for grease passing through.
Z Replace damaged grease nipples immediately.
Note
The intervals stated apply for single-shift operation.
In case of special operating conditions, e.g. working on sandy soil, the
lubrication intervals should be shortened, in order to achieve self-cleaning of
bearing points.
Lubricants The machines life expectancy and operating condition largely depend on the
use of the specified lubricants and compliance with the service intervals.
If lubricants which do not conform to our recommendations are used,
consequential damage may occur for which we will not assume liability, even
inside the warranty period.
Note
Lubricate all lubrication points with multi-purpose grease. Grease
specification: See chapter 6.4.2 "Consumables", page 50.

10
6 Maintenance
6.5.1 Lubrication plan
Overview of lubrication points on machine
8 2 3 5
1
4
4560_6001
7 6
Fig. 6-3 Overview of lubrication points on machine
Item Component Qty. Interval

1 Lift cylinder Front-end 2 Weekly
2 Lift frame Front-end 2 Weekly
3 Steering cylinder Rear-end 1 Weekly
4 Rear axle bearing 1 Weekly
5 Rear axle bearing 1 Weekly
6 Articulation 1 Weekly
7 Steering cylinder Front-end 2 Weekly
8 Articulation 1 Weekly
Tab. 6-7 Lubrication points on machine
10
Maintenance
6
Overview of lubrication points on working attachment
2
3
8
4560_6002
7 6
Fig. 6-4 Overview of lubrication points on working attachment
Item Component Qty. Interval

1 Linkage Bell crank 2 Weekly
2 Linkage Rod 1 Weekly
3 Tilt control lever Rod 1 Weekly
4 Bell crank Lift frame 2 Weekly
5 Tilt control lever Lift frame 1 Weekly
6 Lift cylinder Lift frame 2 Weekly
7 Quick-attach system Lift frame 2 Weekly
8 Linkage Quick-attach system 2 Weekly
9 Tilt control lever Tilt cylinder 1 Weekly
Tab. 6-8 Lubrication points on working attachment

10
6 Maintenance
6.6 Maintenance and Inspection Plan

The inspection plan lists all work that needs to be carried out on the wheel loader
in regular intervals.
6.6.1 Daily tasks

Control and maintenance work to be performed by the operating personnel
(filling, cleaning, repairing, replacing if necessary):
13 12
16
14 15 17 14 13
4 1 18
3
11
20 4 18 10 6
4560_6004
Fig. 6-5 Daily and weekly tasks
10
Maintenance
6
Item Inspection See

1 Check the hydraulic oil level P. 84
2 Check the engine oil level P. 64
3 Check fuel level (fuel gauge in control console) P. 78
4 Check windshield washer fluid level
5 Visual inspection (general), e. g. for material cracks, external damage, completeness, etc.
6 Check whether there is water and/or dirt in the fuel line of the water separator and clean P. 82
if necessary.
7 Check for leaks in pipes, hoses, control unit, hydraulic pumps, cylinders, etc.
The screw-in couplings must be locked when tightening hose or line connections
to prevent rotation.
8 Check function of electrical indicating and warning elements as well as the lighting system P. 100
9 Check smooth movement of operating controls
10 Check V-belt tension
Tab. 6-9 Daily tasks
6.6.2 Tasks to be performed weekly

Control and maintenance work to be performed by the operating personnel
(filling, cleaning, repairing, replacing if necessary):
Item Inspection See

11 Drain the fuel filter
12 Check the cooling fins of the combined cooler P. 70
Machine damage due to strong accumulation of dust
Clean the combined cooler by hand
13 Check correct function of door catches
14 Check tire pressure and tightness of wheel nuts
15 Check fastening of axles and propeller shaft
16 Check bearing bushings and pins/bolts of work equipment
17 Check pins/bolts, bushings, and the linkage assembly of the articulated steering
18 Check that pneumatic springs of engine hood function perfectly
19 Check function of brakes
20 Check if the dust filter for cab ventilation is dirty and clean if required
Machine damage due to strong accumulation of dust
Shorten the inspection and cleaning intervals
21 Check function, condition and completeness of safety devices
22 Lubricate the machine according to overview of lubricating points P. 55
Tab. 6-10 Tasks to be performed weekly

10
6 Maintenance
6.6.3 Inspection plan machine

Note
Perform all inspection work at operating temperature of the machine.
Work to be carried out by trained specialist dealer personnel:
Item Inspection Operating hours See

o = Check, x = Replace af- ev- ev- ev- min min.
ter ery ery ery 2x 1x
100 500 1000 2000 year year
1 Check machine for presence of o o
machine-specific operating
instructions
2 Change the engine oil x x P. 65
3 Change the engine oil filter x x P. 66
4 Drain water from the fuel tank o o o P. 81
5 Replace the fuel filter x x P. 79
6 Check the air intake o o P. 73
7 Replace main air filter cartridge according to the service indicator x P. 75
8 Replace the air filter safety cartridge as required 1)
9 Check antifreeze level in coolant o P. 68
10 Change coolant x P. 69
11 Check V-belt tension o o P. 82
12 Check engine mount and pump o o
attachment
13 Check engine speed setting, upper o o
and lower idle speeds
14 Check valve lash on the engine and every 5000 oh or 4 years
adjust if necessary
15 Check injection valves every 5000 oh (I= 0.25, O = 0.50)
16 Check the crankcase ventilation o
system
17 Check acid level and battery o o P. 98
connections
18 Check condition of tires, tire pressure o o
and fastening of wheel nuts
19 Check fastening of axles and propeller o o
shaft
20 Check bearing bushings and pins/bolts o o
of work equipment and adjust to "no
play"
10
Maintenance
6

100 500 1000 2000 year year
21 Check bushings and bolts of the o o
articulation and the articulated
steering, set and replace if necessary
22 Check that door catches function o o
perfectly, and replace if necessary.
23 Clean or replace the dust filter for cab o x x
ventilation.
24 Check electrical indicating and o o
warning elements and lighting
equipment
25 Check smooth running of operator o o
controls and adjust if necessary
26 Check all pipes, hoses, control valves, o o
hydraulic pumps, cylinders, etc. for
leaks
Note: When tightening hose and
line connections, the screw
couplings must be locked to
prevent rotation.
27 Check or change the hydraulic oil. o o x2) x
28 Replace insert of hydraulic oil return x x x
suction filter
29 Replace breather. x x
30 Check function of brakes and brake o o x x
disc play
31 Bleed brake o o
32 Differential rear axle oil: oil check x o x x
and/or oil change
33 Differential front axle: oil check and/ x o x x
or oil change
34 Wheel hubs of front and rear axles; oil x o x x
check or oil change
35 Crawler gear unit; oil check and/or oil x o x x
change

10
6 Maintenance

100 500 1000 2000 year year
36 Lubricate the machine according to o o
overview of lubricating points
37 Check function, condition and o o
completeness of safety devices
38 Hydraulic function check with pressure o o
function test
39 Test run and test work. o o
40 Initial inspection card and return to o o 3)
manufacturer.
1)
at least every 2 years
2)
Extension of oil change intervals according to Terexoil sample analysis and laboratory report.
See chapter 6.3.1 "Regular oil analysis", page 47.
3)
within warranty
Tab. 6-11 Inspection plan machine
10
Maintenance
6
6.7 Maintenance and inspection work

Personal injury
Eye injuries caused by parts flying around.
Z Wear protective goggles during work.
Environmentally hazardous substances

Environmental damage caused by environmentally hazardous substances.
Z Do not allow oil oil to seep into the ground.
Z Always place a receptacle for the collection of waste oil under the working area when
draining oil or removing the filter insert.
Z Collect waste oil and dispose of according to regulations!
Note
All maintenance and inspection work must be performed acc. to the
inspection plan.
See chapter 6.6 "Maintenance and Inspection Plan", page 57.

10
6 Maintenance
6.7.1 Display
Note
All checks must be carried out with the machine standing on level ground
and cooled down.
The levels of engine oil, hydraulic oil and coolant can be read on the check
display.
Note
With the diesel engine running, the level indicator is without function!
Checking the fluid levels
I 12 km/h
1 2
4560_6005
Fig. 6-6 Checking the fluid levels
Switch on the ignition.

J The symbols hydraulic oil level (1) and coolant level (2) light up for approx.
3 sec on the display.
J If the level is insufficient, the relevant level indicator lamp continues to light
up.
If required, top up the missing fluid.
10
Maintenance
6
6.7.2 Engine
Checking the engine oil level

Property damage
Machine damage due to excess oil.
Z Observe the permissible filling level of the engine oil pan and avoid overfilling.
Excess oil may enter the crankcase breathing and lead to engine-speed control
faults.
4560_6006
Fig. 6-7 Checking the engine oil level
Check the oil level every day before starting, with the machine in horizontal
position.
Push the oil dipstick (1) in until it bottoms. The notches on the dipstick
indicate the minimum and maximum oil levels.
If necessary, top up with engine oil. Open the filler neck (2) and add oil using
a clean container. Close the filler neck again.
Screw the filler cap back on.

10
6 Maintenance
Changing the engine oil

Danger of burning
Danger of scalding by hot oil.
Z Be careful when draining hot oil.
Z Wear suitable protective clothing and safety goggles.
1
2
4560_6007
Fig. 6-8 Changing the engine oil
Run the engine warm (engine oil temperature approx. 80 C/176 F).
Park the machine in horizontal position.
Shut down the engine.
Remove the cap from the bottom rear-end.
Place suitable oil collecting vessels under the engine block.
Screw the oil drain hose onto the oil change valve (1).
Drain off all engine oil.
Remove the oil drain hose and turn the protective cab back on the valve (1).
Close the service opening with the cover.
Replace the engine oil filter (2). See chapter "Changing the engine oil filter",
page 66.
Fill in engine oil through the filler opening (3) until the oil level reaches the
"MAX"-mark on the dipstick (4).
Start the engine and run at low idle speed for approx. 2 min.
Check the oil level and top up oil if required.
10
Maintenance
6
Changing the engine oil filter
1
4560_6008
Fig. 6-9 Changing the engine oil filter
The engine oil filter must be replaced every time the engine oil is changed.
Place suitable oil collecting vessels under the engine oil filter.
Clean the outside of the engine oil filter.
Unscrew the filter cartridge (1) using a commercially available tool.
Check that the fastening stud is firmly secured in the filter head.
Dispose of the filter cartridge environmentally.
Check the condition of the filter head and clean it.
Fill the new filter with oil.
Wet the seal ring with oil and turn the cartridge on hand-tight.
Remove oil contamination on the engine.
Perform a test run and check the engine oil filter cartridge for leaks.

10
6 Maintenance
6.7.3 Engine - cooling system
Combined hydraulic oil-water cooler

Danger of burning
Z Only open the radiator cap when the engine is cold.
Checking the coolant level
I 12 km/h
1
4560_6009
Fig. 6-10 Checking the coolant level
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. (1).
Top up coolant if the coolant level is insufficient.
10
Maintenance
6
Refilling with coolant
4560_6010
L260-711
Fig. 6-11 Topping up the combined cooler

Carefully unscrew the filler cap (1), until all pressure has been relieved from
the combined cooler.
If required, top up the coolant. When the engine has cooled down, the surge
tank must be half full.
If necessary top up the coolant with a 50/50% mixture of water and
antifreeze. See chapter 6.4.2 "Consumables", page 50.
Screw the cover (1) back onto the combined cooler.
Checking antifreeze
Check the antifreeze setting before the beginning of the cold season.
At the factory, the antifreeze protection is set to approx. -25 C/-13 F. Adjust
the antifreeze properties for lower temperatures, if required.

10
6 Maintenance
Changing coolant
Z Only open the radiator cap when the engine is cold.
3
1
2
4560_6011
L260-711
Fig. 6-12 Changing coolant

Shut down the engine and allow the cooling system to cool down.
Place a collecting vessel under the combined cooler.
Carefully unscrew the filler cap (3), until all pressure has been relieved from
Remove the cap (3) from the combined cooler.
Unscrew the water-drain plug (1) on the drain hose (2) and drain coolant.
If necessary, flush the cooling system with water.
Close the water-drain plug on the combined cooler again.
Fill the cooling system with coolant and close the radiator cap. See chapter
6.4.2 "Consumables", page 50.
Start the engine and run it until operating temperature is reached.
Shut down the engine and let it cool down.
Check the coolant level and top up coolant (if necessary, several times).
10
Maintenance
6
Cleaning the cooling fins in case of extreme exposure to dust

Property damage
Machine damage caused by overheating of engine and/or hydraulic oil.
Z Clean the radiator carefully.
Property damage
Machine damage due to strong accumulation of dust.
Z Clean the cooler fins ahead of time to prevent overheating of the engine and/or the
hydraulic oil.
Note
Collect the detergent and waste water in a suitable container and dispose of
according to regulations!
Ensure that no substances hazardous to waters come into contact with the
soil or the water system.
4560_6012
Fig. 6-13 Engine cooler fan
1 Fan
2 Hydrostatic transmission
The combined cooler features a fan (1) with hydrostatic drive (2).

10
6 Maintenance
Automatically Switch the motor cooling fan switch to the forward switch position.
J The cooling fins are automatically cleaned at regular intervals.
J Due to the automatic reverse of the running direction of the fan, the dirt is
removed from the cooling fins.
If there is increased exposure to dust, the cooler fins are subject to premature
contamination:
Switch intermittently to the rear switch position in order to additionally clean
Subsequently return to the forward switch position.
Manually Switch the motor cooling fan switch to the rear switch position.
J The fan stops rotating. Then it runs for approx. 12 sec into the opposite
direction.
J The dirt is removed from the cooling fins.
J The fan stops rotating. The switch is now in the center position.
Temperature- If the machine is used indoors (warehouses), switch the motor cooling fan
controlled switch to the center position.
J The fan does not reverse the direction of rotation.
If required, clean the equipment manually in outdoor environments.
10
Maintenance
6
Cleaning cooling fins in case of strong exposure to dust
4560_6014
Fig. 6-14 Cleaning the combined cooler
Clean the combined cooler by blowing it out with compressed air from the air
discharge side.
If necessary, e. g. in case of an oil contaminated combined cooler, clean the
combined cooler with cold cleansing agent or steam cleaning equipment. For
this work park the machine on a washing area equipped with an oil separator.
After cleaning, run the engine until it reaches operating temperature to dry the
combined cooler.

10
6 Maintenance
6.7.4 Air intake system

Property damage
Machine damage caused by dust being drawn into the engine.
Z All maintenance work on the air intake system must be carried out with the engine
shut down.
Z Do not start the engine after the filter cartridge has been removed.
Z Use only undamaged air filter cartridges.
Cleaning the dust ejection valve
4560_6015
Fig. 6-15 Cleaning the dust ejection valve
Dust ejection valves (1) are almost maintenance-free.

Remove possible dust deposits by pressing the valve together.
Checking the air intake

Clean the air intake space in front of the air filter from any dirt (foliage, etc.).
Check the air filter fastening for damage.
Check the air channel after the air filter for leaks.
Check the rubber parts for damage.
Replace damaged parts immediately.
10
Maintenance
6
Cartridge Replacing the air filter main cartridge

maintenance Replace the air filter main cartridge if the control light for filter maintenance in
intervals the control console lights up during operation.
Note
A brief delay in maintenance does not result in lower filter efficiency.
Replacing the air filter safety cartridge

Replace the air filter safety cartridge:
after the third maintenance of the main cartridge
at the latest after 2 years of operation.
if the service indicator comes on again after the main cartridge has just
been serviced
if the main cartridge is damaged
if the safety cartridge is defective

10
6 Maintenance
Changing the main cartridge

Note
Remove the safety cartridge only in the case of necessary maintenance
work. Only open the seal (5) of the safety cartridge for the purpose of
replacement.
1 3
4 5
4560_6016
Fig. 6-16 Changing the air filter cartridges
Release the wire fasteners (1) and remove the bottom of the housing (4).
Withdraw the main cartridge (2) by twisting slightly to and fro.
Check whether the safety cartridge (3) must be replaced.
Mark the maintenance in the corresponding marking fields on the safety
cartridge (3).
Insert the new or cleaned main cartridge carefully into the filter housing
starting with the open side and check that it is correctly positioned.
Fit the lower part of the housing. (Pay attention to the position of the dust
ejection valve).
Place the wire fasteners in the groove of the flange on the filter housing and
tighten.
10
Maintenance
6
Changing the safety cartridge

Property damage
Machine damage due to damaged safety cartridge.
Z Observe that the safety cartridge must not be cleaned and used again once it has
been removed.
1 3
4 5
4560_6016
Remove the main filter cartridge.

Using a suitable tool (e.g. screwdriver), pierce the seal (5) of the safety
cartridge (3) from the inside, then lift up the two clips (6).
Grasp the safety cartridge (3) by the two clips (6) and withdraw by moving
slightly to and fro.
Dispose of the safety cartridge.
Insert a new safety cartridge and check that it is correctly positioned.
Re-install the main filter cartridge.

10
6 Maintenance
Cleaning the main cartridge

Property damage
Machine damage due to damaged safety cartridge.
Z Never wash or brush out the main cartridge.
Z When blowing out, ensure that dust does not land on the inside of the main cartridge.
Z Never continue to use damaged main cartridges. If in doubt, use a new one.
1 3
4 5
4560_6016
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.
For cleaning (1), attach a pipe the end of which is bent at 90 to a
compressed-air pistol. It must be sufficiently long to reach the floor of the
cartridge. Blow out the main cartridge from the inside to the outside with dry
compressed air (max. 5 bar/73 psi) by moving the pipe up and down in the
cartridge and continue until no more dust escapes.
Check the clean main cartridge for damage to the paper bellows and rubber
seals (2). Tears and perforations in the paper bellows can be determined
using a torch.
10
Maintenance
6
6.7.5 Fuel system

Danger of injury
Personal injury due to excessive pressure while refueling.
Z Open the fuel tank cap when topping up fuel using the electric refueling pump to
avoid excessive pressure in the fuel tank!
Refueling
2
1
UNIDECK
4560_6018
Fig. 6-19 Refueling
Check the fuel level (1) in the gauge.

In order to prevent the formation of condensation water before the machine
is put into operation the next time, top up fuel through the filler opening (2)
every day after use.

10
6 Maintenance
Draining the fuel filter
2
1
4560_6020
Fig. 6-20 Draining the fuel filter
Open the fuel filter (1) on the water drain (2) until pure fuel escapes.
Close the water drain.
10
Maintenance
6
Replacing fuel filter

Property damage
Machine damage due to air in the filter.
Z Before starting the engine, operate the fuel pump one minute to remove air from the
filter.
Note
Collect the fuel in a suitable container and dispose of according to
regulations!
Note
The high pressure system must not be vented
3 4560_6021
Fig. 6-21 Replacing the fuel filter
Clean the fuel filter (1) and the outside of the fuel pre-cleaner (2).
Open the water drain (3) on the filter bottom to drain fuel from the filter.
Unscrew the filter housing (1+2) using commercially available tools and
remove the filter housing along with the filter element from the filter flange.

10
6 Maintenance
Draining water from the fuel tank
4560_6023
1
Fig. 6-22 Draining water from the fuel tank
Drain water from the fuel tank through the water-drain plug (1).
Clean the filling screen filter (2) and check it for damage, replace if
necessary.
10
Maintenance
6
6.7.6 V-belt
Danger of crushing
Body parts may be crushed by moving parts.
Z Check or replace V-belts only when the engine is turned off.
Z Secure the engine against unauthorized starting.
Checking the V-belt

Check the entire circumference of the V-belt for damage (visual inspection).
Replace worn or damage V-belts immediately.
Checking V-belt tension

We recommend the use of a belt tensioner gauge in order to check the V-belt
tension.
The tension check must be carried out according to the manufacturers manual.
Checking the V-belt tension without belt tensioner gauge

Press the V-belt with your thumb in the middle of the longest free length, and
measure the sagging. Using medium thumb pressure of approx. 45 N/10 lbf
(approx. 4.5 kg/10 lbs), the V-belt sag should equal 10 mm/0.4 in.

10
6 Maintenance
4560_6025
Fig. 6-23 Changing the V-belt
Changing V-belts
Open the engine hood.
Disconnect the battery.
Loosen the screws of the protection grille.
Remove the protection grille.
Place the nut wrench (1) on the tension roll (2) and release the tension roll (2).
Take off the V-belt.
Assemble a new V-belt and tension it with the tension roller.
Assemble the protection grille.
Reconnect the battery.
Perform a test run.
Measure the tension of the new V-belt after 15 minutes.
Note
If V-belts have been replaced, their tension must be checked again after
approx. 20 operating hours.
10
Maintenance
6
6.7.7 Hydraulic oil tank
Checking the hydraulic oil level
I 12 km/h
1
4560_6026
Fig. 6-24 Checking the hydraulic oil level
The hydraulic oil level is monitored automatically.

If the hydraulic oil level is insufficient, the hydraulic oil level indicator appears on
the display as soon as the ignition is switched on (1).
Check the hydraulic oil level every day with the machine standing on level
ground.
Top up hydraulic oil if the hydraulic oil level is insufficient.
The oil level should be in the top third of the sight glass.
Topping up hydraulic oil
1
4560_6027
Fig. 6-25 Topping up hydraulic oil

Read off the hydraulic oil level on the sight glass (1) and, if required, top up
hydraulic oil using the breather (2).
The oil level should be in the top third of the sight glass (1).

10
6 Maintenance
Changing the hydraulic oil

Danger of burning
Z Be careful when draining hot oil.
Retract all hydraulic cylinders.

Stop the engine.
Remove the drain plug on the hydraulic oil tank and drain oil into a clean
receptacle.
Note
Collect the waste oil in a suitable container and dispose of in compliance
with regulations.
Remove ventilation filter (2), return filter (3) with filter head and suction
filter (4).
Clean filter head.
Fit new filter.
Turn the drain plug tightly back in.
Fill up with clean hydraulic oil using the return filter (3); to do so, open the filter
cover.
Replace the cover of the return filter.
3 4
4560_6032
Fig. 6-26 Changing the hydraulic oil
10
Maintenance
6
Replacing the hydraulic oil tank breathing filter

Property damage
Machine damage due to dirt reaching the uncovered hydraulic oil tank.
Z Before starting, clean all parts above the tank.
Note
The breathing filter must be replaced if it is soiled e.g. by oil mist.
3 4
4560_6032
Fig. 6-27 Replacing the hydraulic oil breathing filter
Remove the breathing filter (2) and dispose of according to regulations.
4560_6033
Fig. 6-28 Replacing the breathing filter
Clean the screen (3) and check for damage; replace if required.
Screw in new breather (1) with O-ring (2) and tighten by hand.

10
6 Maintenance
6.7.8 Hydraulic oil suction filter

Property damage
Note
After a larger repair job, renew the filter cartridge following the test run.
Note
Remove the suction filter above a receptacle for the collection of waste oil.
Changing the filter insert
4560_6028
Fig. 6-29 Changing the hydraulic oil suction filter

Open the breathing filter (1).
Loosen the filter cover (2) of the suction filter with the aid of a tool.
10
Maintenance
6
5
6
4
8
7
10
9
12
11
2
4560_6029
Fig. 6-30 Changing the filter insert of the suction filter
Remove the assembly (10) by turning and completely removing the filter
cover, paying attention to the O-ring (3).
Grasp the assembly by the filter cover (1) and unscrew the valve (2).
Remove the filter insert and dispose of according to regulations.
Clean the filter cover with centre rod (8) and the valve with diesel oil or
benzine. While doing so, pay attention to the retaining plate (6) along with the
seals (5), (7) and the compression spring (4).
Check the O-ring (3) and seals (5), (7), (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 (5).
Push the filter insert downward against the springs and tighten the valve (2)
by hand.
Slide the assembly (10) into the enclosure (12) and tighten the filter cover by
hand. Ensure that the O-ring (3) is in exactly the right position.
Screw back on the filter cover (1) and tighten by hand.
Check the tightness of the filter by means of a test run.

10
6 Maintenance
6.7.9 Hydraulic oil return filter

Property damage
Note
After a larger repair job, renew the filter cartridge following the test run.
Changing the filter insert
4560_6030
Fig. 6-31 Changing the hydraulic oil return filter

Open the breathing filter (1).
Remove the cover (2) of the return filter.
10
Maintenance
6
3
2
4560_6031
Fig. 6-32 Changing the filter insert of return filter
Pull out the filter bowl (2) together with the filter insert (3).
Remove the filter insert from the filter bowl by turning and pulling at the same
time.
Clean the filter bowl using appropriate detergents.
Ensure that the O-rings (4-6) are in perfect condition and replace any
damaged part.
Insert the new filter element into the filter bowl.
Re-insert the filter bowl along with the cartridge into the hydraulic oil tank.
Apply some oil to the cover seal.
Install the return filter cover and tighten by hand.
Check the tightness of the filter by means of a test run.

10
6 Maintenance
6.7.10 Axles
Property damage
Machine damage due to insufficient oil in axles.
Z After filling the axles with oil, move the machine for approx. 5 minutes to ensure that
the oil is evenly distributed.
Z After 5 minutes, check the oil level again, and top up if necessary.
Note
Only change the axle oil when it is at operating temperature.
Note
Collect the waste oil in a suitable container and dispose of in compliance
with regulations.
10
Maintenance
6
Front axle differential
1 1
4560_6034
Fig. 6-33 Checking / replacing the front axle oil
Checking the axle oil level

Remove the inspection-filling plugs (1).
Check if the oil is up to the edge of the inspection-filling hole.
Top up oil if required.
Turn the inspection-filling plugs tightly back in.
Changing axle oil

Clean the area around the inspection-filling plugs (1) and drain plugs (2).
Open the inspection-filling plugs (1).
Open the drain plugs (2) on the differential and brake housings and drain oil.
Flush the axle, if necessary.
Turn the drain plugs tightly back in.
Pour in oil using the inspection-filling hole until oil escapes from the other
inspection-filling hole.
Damage to property
Machine damage from incorrect oil.
Z Use transmission oil!
See chapter 6.4.2 "Consumables", page 50.
Turn the inspection-filling plugs (1) tightly back in.

10
6 Maintenance
Change the crawler gear oil
1
2
4560_6036
Fig. 6-34 Changing the crawler gear oil

Clean the area around the checking-filler plug (1) and drain plug (2).
Open the checking-filler plug (1).
Unscrew the drain plug (2) and drain oil.
Carefully seal the drain plug (2).
Pour in oil using the checking-filler plug (1) until it reaches the bottom edge.
Damage to property
Z Use automatic transmission oil!
Carefully seal the checking-filling plug (1).
10
Maintenance
6
Check crawler gear oil
1
2
4560_6036
Fig. 6-35 Changing the crawler gear oil

Remove the checking plug (1).
Check if the oil is up to the edge of the inspection hole.
Carefully seal checking plugs.
Damage to property
Z Use automatic transmission oil!
Carefully seal the checking-filler plug (1).

10
6 Maintenance
Differential of rear axle with transmission
1 1
4560_6034
Fig. 6-36 Checking / replacing the rear axle oil
Checking the axle oil level

Remove the inspection-filling plugs (1).
Check if the oil is up to the edge of the inspection-filling hole.
Turn the inspection-filling plugs tightly back in.
Changing axle oil

Clean the area around the inspection-filling plugs (1) and drain plugs (2).
Open the inspection-filling plugs (1).
Open the drain plugs (2) on the differential and brake housings and drain oil.
Flush the axle, if necessary.
Turn the drain plugs tightly back in.
Pour in oil using the inspection-filling hole until oil escapes from the other
inspection-filling hole.
Damage to property
Turn the inspection-filling plugs (1) tightly back in.
10
Maintenance
6
Wheel hub
Note
The wheel hub has a combined inspection, filling and drain plug!
2 4560_6038
Fig. 6-37 Checking and replacing oil
Checking wheel hub oil level

Turn the wheel to the filling and inspection position; the screw plug must be
horizontal (1).
Remove the screw plug (1).
Check if the oil is up to the edge of the screw plug.
Turn the screw plug tightly back in.
Changing axle oil

Turn the wheel until the screw plug on the hub is at the bottom (drain position
(2)).
Unscrew the screw plug and catch running out oil.
Flush, if necessary.
Turn the wheel to the filling and inspection position; the screw plug must be
horizontal (1).
Fill in oil up to the lower edge of the screw plug.
Damage to property
Turn the screw plug tightly back in.

10
6 Maintenance
6.7.11 Wheels
Note
Note that the tightening torque of 610 Nm/450 lbf ft applies to the wheel nuts
M 22 x 1.5.
Checking the tire pressure

Check the air pressure in accordance with the pressure chart. See chapter
9.3.2 "----", page 161.
Checking the tightness of wheel nuts

During the first 50 operating hours, check the tightness of the wheel nuts (M
22 x 1.5) daily and subsequently every week, and tighten to the correct torque
if necessary.
When fitting a wheel, tighten the nuts to the correct torque crosswise in
several stages.
10
Maintenance
6
6.7.12 Electrical equipment
Battery
Danger of explosion
Death, burns or blindness due to explosive gases or contact with corrosive acids.
Z Keep electrical arcs, sparks, open fire and smoldering tobacco away.
Z Wear protective clothing.
Note
Follow the instructions of the battery manufacturer when taking a battery into
service for the first time.
The two batteries are located in the rear-end below the engine hood, behind the
left-hand wheelhouse.
2
1
3 4560_6039
Fig. 6-38 Checking the battery
Checking the battery

Note
For maintenance-free batteries, this check is not necessary.

The acid level should be approximately 10 mm/0.4 in above the plate edges.
If necessary, top up with distilled water.
J For maintenance-free batteries, this check is not necessary.

10
6 Maintenance
Removing batteries
1
6 2
3 4
7
4560_6040
Fig. 6-39 Removing batteries
Turn off the battery main switch (1).
Damage to persons and property

Risk of accident due to incorrect operation.
Z The battery isolator switch must never be pressed when the engine is running.
Z After switching off the engine, wait 2 minutes before pressing the battery isolator
switch because the engine control unit needs this time to store errors.
Non-observance may result in damage to the engine control unit.
First disconnect the ground cable (2) on battery 1 (66), then the positive cable
(3) on battery 2 (7).
Remove the connecting cable (4).
Loosen the clamping angle (5; 2 brackets on each battery side).
Lift out the battery.
10
Maintenance
6
Installing batteries
Property damage
Machine damage caused by reversing the terminals.
Z Connect the minus terminal with the minus pole and the plus terminal with the plus
pole.
Place both batteries into the machine.

Attach the batteries using a clamping bracket (5) for each battery.
Attach the connecting cable (4): Connect the positive terminal (+) of battery
1 (6) with the negative terminal (-) of battery 2 (6).
Connect the positive cable (3) to the positive terminal (+) of battery 2 (7).
Connect the ground cable (2) to the negative terminal (-) of battery 1 (6).
Pay attention to a good charge condition of the battery, especially in winter.
Checking the lighting and warning equipment

Check the function of the lighting equipment.
Check the function of the control lights.
Check the function of the warning equipment.

10
6 Maintenance
6.7.13 Cab ventilation dust filter

The air intake for the heater and fresh air supply of the cab features a dust filter,
optionally a charcoal/ pollen filter.
Removing the dust filter for cab ventilation
4560_6042
1
Fig. 6-40 Removing the dust filter for cab ventilation
Remove the ventilation grate (1).

Remove the angle bracket (2).
Remove the dust filter (3).
Clean the filter or replace it.
Cleaning the dust filter for cab ventilation

Note
Never wash or brush out the filter.
Never continue to use damaged dust filters!
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/73 psi), blow against the direction of
flow.
Check the filter for damage to the paper bellows and seal.
10
Maintenance
6
Installing the dust filter for cab ventilation

Note
Observe the mounting position of the dust filter; the air flow arrows must
point towards the cab.
Insert new or cleaned dust filter until the stop.
Fasten the dust filter with the angle bracket.
Attach the ventilation grate.

10
6 Maintenance
6.7.14 Windshield washer system
4560_6043
1
Fig. 6-41 Top up the windshield washer tank
Fill up the washing water reservoir (1) as required.

Add antifreeze when temperatures are around or below freezing.
10
Maintenance
6
6.8 Taking out of service

6.8.1 Preservation (temporary immobilization )
Property damage
Machine damage caused by bearing defects (e. g. corrosion damage) during
shutdown periods over three months.
Z Preserve the machine.
Preserving the machine

We recommend keeping the machine in a dry, dust-free room during the
storage period.
Thoroughly clean the inside and outside of the machine, including the engine.
Lubricate the machine by following the lubrication plan. See chapter 6.5.1
"Lubrication plan", page 55.
Check and top up all oil levels in components like engine, gearbox, etc.
Check and top up the hydraulic oil level.
Repair paint damage.
Fill the diesel fuel tank completely to avoid wall corrosion.
Check the antifreeze properties of the coolant and adapt these, if necessary.
Apply all preservation measures as specified in the operating instructions for
the engine.
Check the tire pressure according to the prescribed value and protect the
tires from direct sunlight.
Treat bare piston rods with a commercially available corrosion protection
agent.
Remove the battery, clean it and store it properly in a dry and, over winter, in
a frost-free room. Cover the poles with pole grease.
Close the air intake openings of the air filter system and the exhaust outlet on
the exhaust pipe.
Check whether there are special procedures from CUMMINS.

10
6 Maintenance
6.8.2 While being taken out of service
Running the movements

Beforehand, the anti-corrosion coat must be removed from the piston rods,
and the openings of the air filter system and the exhaust pipe freed.
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.
Renew the preservation after the movement test.
6.8.3 After the machine had been taken out of service

Before putting the machine into operation once more, the following measures
must be carried out:
Taking the machine back into service

Clean the piston rods from the corrosion protection coating.
Clear the air intake of the air filter and the exhaust opening.
Check the condition of main air filter element and safety cartridge, replace if
necessary.
Wash the machine with a neutral cleansing agent.
Check the battery, recharge if necessary and install it.
Carry out all measures for putting the diesel engine back into operation listed
in the Engine Operating Manual.
If the machine has been out of use for more than 6 months, the oil in the
assemblies such as engine, gearbox, etc. must be changed.
After a downtime of six month or more replace the hydraulic filters(pressure,
return flow, and breathing filter, if applicable).
Lubricate the machine by following the lubrication plan. See chapter 6.5.1
"Lubrication plan", page 55.
6.8.4 Disposal
If the machine is not correctly disposed of at the end of its working life, accidents
and environmental damage may result.
Z Arrange for the machine to be disposed of by a suitable disposal company only.
Z TEREX recommends returning the machine to a TEREX dealer.
10
Operation
7
7 Operation
Note
See chapter 3.6 "Operation", page 20.
7.1 Before operation

Danger of accident caused by wrong actuation and uncontrolled machine
movements.
Z Become familiar with all display and control elements before starting excavating. See
chapter 5.2.1 "Operating controls", page 35.
Note
Initial inspection must be carried out before commissioning. See chapter 6.6
"Maintenance and Inspection Plan", page 58.
The chapter "Operation" describes all functions for operating the wheel loader.
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.
Become familiar with the display and control elements before driving or
starting work. See chapter 5.2 "Display elements and operating controls in
operator's stand", page 35.
Familiarize yourself with the control levers and pedals. See chapter 5.2
"Display elements and operating controls in operator's stand", page 35.
Thoroughly inspect the wheel loader visually before each start-up. Watch out
for damage, loose or missing screws, oil deposits, oil or fuel leaks.
Any faults must be immediately rectified.
If the operational safety of the wheel loader is at risk, you must only start
operation after the faults have been eliminated.
07_Operation_us.fm - V 0.1 - 4.5.11 TL310 107 / 178

14
7 Operation
7.1.1 Adjustments
Adjusting the driver's seat

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.
1 2
3 4
5
4560_5010
Fig. 7-1 Adjusting the driver's seat
Operate the horizontal adjustment (6) to move the seat to the position most
convenient for you.
The driver's weight can be adjusted for in 9 stages (22.05 lb each).
Swing the weight adjustment handle (7) to the right against the stop. The
weight adjustment automatically changes to pos. 50 kg/110 lbs.
Adjust the backrest with the inclination adjustment (5) to the desired
inclination.
Adjust the backrest with the backrest adjustment (4) to the desired inclination.
Armrest (3) (option)
Vertical adjustment (2):
Raising seat: Raise seat until it clicks audibly into place.
Lowering seat: Raise seat as far as the stop; the seat then sinks to its
lowest position.
Position adjustment (1):
Adjustment to the front: Slide the seat forward.
Adjustment to the back: Slide the seat backward.
108 / 178 TL310 07_Operation_us.fm - V 0.1 - 4.5.11
14
Operation
7
Steering wheel adjustment
1
P
+ -
UNIDECK UNIDECK
HAZARD
AUTO OFF
0
I
4560_7001
Fig. 7-2 Steering wheel adjustment
Tilt adjustment of steering wheel:

Push the locking lever (1) down.
Adjust steering-wheel tilt.
Release the locking lever.
Steering wheel height adjustment:
Pull the locking lever (1) up.
Adjust steering-wheel height.
Release the locking lever.

14
7 Operation
Adjusting heating, ventilation and air-conditioning

The air-conditioning unit should be switched on for approx. 5 minutes at least
once a month to lubricate the compressor seals.
After switching on the air-conditioning system, open the windows 2-3 minutes
to allow the hot air (stored heat) to escape.
Keep windows and doors closed.
Note
It is recommended to cool down the vehicle interior temperature by no more
than 6 C/42.8 F to 8 C/44.6 F below outside temperature.
3 4
2 5
1 6
AUTO OFF
7
11 10 9 8 4560_5006
Fig. 7-3 Button assignment of operator control panel Heating, ventilation and air-conditioning
Cooling (10) If the LED below the button lights up (10), cooling is ON. If the LED does not light
up, cooling is OFF.
Circulating air If the LED under the button lights up (9), recirculation mode is activated. If the
(9) LED does not light up, fresh air mode is activated.
Display (3) The display (3) shows the relevant temperatures or trouble codes in case of
malfunction.
Fan (4) The LEDs in the fan symbol indicate the momentary fan speed.
14
Operation
7
3 4
2 5
1 6
AUTO OFF
7
11 10 9 8 4560_5006
Fig. 7-4 Button assignment of operator control panel Heating, ventilation and air-conditioning
Adjusting the fan speed

Press the button (5).
J The fan speed increases by one step.
The fan speed decreases by one step.

J The type and the version of the air-conditioning unit are displayed on the
screen.
Release the button (11).
Performing automatic diagnosis

To this purpose, the engine cover should be closed and the engine itself be at
operating temperature. The outside temperature should be between 15 C/59 F
and 30 C/86 F. The air-conditioning system should be ON.
Hold the button (11) depressed.
J The air-conditioning unit performs an automatic diagnosis.
Displaying interior/exterior temperature

J The cab temperature is measured by the interior temperature sensor (8).
J The inside temperature is shown on the display (3) for approx. 6 sec.
J If the air-conditioning unit is in cooling-air mode, the outside temperature is
shown on the display (3) for approx. 6 sec by pressing the button (7).
Setting the temperature

J The temperature increases by 1 C/33.8 F.
J The temperature decreases by 1 C/33.8 F.

14
7 Operation
Adjusting the lighting in compliance with German Road Traffic

Regulations (StVZO)
2
P
+ -
UNIDECK UNIDECK
HAZARD
AUTO OFF
0
I
4560_7002
Fig. 7-5 Adjusting the lighting
The lighting of the loader is switched on and off by turning the steering-
column switch (1).
J Setting 0: Light Off.
J Setting 1: Parking light.
J Setting 2: Driving light (low beam / high beam).
Switching high beam on

Raise the steering column switch (1).
J Blue indicator lamp for high-beam (2) lights up.
14
Operation
7
7.2 Operation
Danger to life
Physical injury caused by machine movements.
Z Before starting the engine, take care to ensure that no one is in the immediate vicinity
of the wheel loader or in the danger zone.

Danger of accident caused by wrong actuation and uncontrolled machine
movements.
Z Start at low engine speed when familiarizing yourself with the controls.
Immobilizer Note
(option)
The immobilizer is self-activating; that is, without additional activation
or divergent actions.
If the mechanical start switch is in position "0" (terminal 15 off), the
immobilizer is generally activated.
Set the start switch key to position "0."
J The immobilizer is automatically activated after 5 sec.
J The immobilizer becomes and remains activated if the key remains inserted
in position 0.
Deactivating the immobilizer

Note
The immobilizer is deactivated if a valid mechanical key and a valid
electronic key (transponder) are present.
Set the start switch key to position 1.
J The transponder is not read until the mechanical key in the start switch has
activated terminal 15. This makes it necessary to first open the mechanical
locking system before the electronic key is inspected. A manipulation of the
immobilizer with the ignition deactivated is thereby impossible.
Learning a new key

Learning a new key takes place with a master key that is identified with a red key
pommel.
The master key must be stored carefully; only one master key is available for
each immobilizer.
This master key can only be used to learn new keys; it cannot be used to
deactivate the immobilizer. This prevents the master key from being used to
operate the vehicle.
Insert the master key into the ignition lock.
Set the master key in position "1" (terminal 15 on) for max. 5 sec.
Set the master key in position 0 (terminal 15 off).

14
7 Operation
Pull out the master key.

J The immobilizer electronics expects the key that is to be learned in the next
15 sec.
Insert the key to be learned into the ignition lock.
Turn the key to be learned to position 1.
J The learned key is registered as a valid key.
If no key is recognized for learning in 15 sec, the learning procedure ends
automatically.
Learning multiple new keys

Insert the keys to be learned into the ignition lock one after the other.
Turn the key to be learned to position 1.
Leave the individual keys in the position "1" for at least 1 sec.
Up to 10 keys can be learned.

With this technique, it is possible to learn one key on several immobilizers, such
as for a general fleet key.
Note
This function is only available if the control unit relay is additionally
connected to terminal 30.
Clearing learned keys

Clearing learned keys is necessary if a learned key has been lost.
All learned keys are cleared during the deletion process. After clearing, all
available keys can be relearned.
Insert the master key into the ignition lock.
Set the master key in position 1 (terminal 15 on) for minimum 20 sec.
J All learned keys are cleared and all available keys can be relearned.
J The master key code is not deleted during the clearing process.
Note
This function is only available if the control unit relay is additionally
connected to terminal 30.
14
Operation
7
Security functions
If more than 5 keys are activated in the ignition lock within 1 minute with different
invalid codes, the immobilizer remains active for 15 minutes and accepts no
valid keys during this time.
This procedure prevents the "testing" of different keys and the coincidental
locating of the correct key.
If different invalid keys are recognized without the ignition lock being brought to
position "0," the immobilizer remains activated for 15 minutes and accepts no
valid keys.
Valid keys are only accepted after the 15 minutes and recognition of the start
switch in the "0" position. This prevents the key from being tested without the
mechanical ignition lock being activated, such as if the ignition lock is forcibly
brought to the "1" position.
Malfunctions
Note
Fault causes and their resolution See chapter 10.3.1 "Immobilizer
faults", page 170.

14
7 Operation
Staring and shutting down the engine

Property damage
Engine damage caused by improper operation.
Z Do not drive the engine at full throttle straight away.
Z Drive with restraint until the operating temperature of the engine has been reached.
Starting the engine
+ -
2
3
1
P
+ -
UNIDECK UNIDECK
8 4
P
HAZARD
AUTO OFF
7
0
I
4560_7003
Fig. 7-6 Starting the engine
Set all control levers to neutral position.

Set the parking brake (6) switch to forward position and the travel direction
preselection switches (8) and (5) to the center position.
Insert the ignition key into the preheating/start switch (7).
14
Operation
7
+ -
2
3
1
P
+ -
UNIDECK UNIDECK
8 4
P
HAZARD
AUTO OFF
0
I
4560_7003
Switch on ignition and wait for approx. 5 sec.

Note
The display establishes the internal readiness for operation. As a result, all
indicator lamps are briefly activated for a functional check.
J The control lights for Pre-heating monitor (1), Charge Control (2) and
Engine Oil Pressure (3) light up.
Once the Preheating (1) control light has gone out, turn the ignition key to
START. As soon as the engine is running, turn the ignition key back to
Position "1" and decrease the revs to low idle speed. The indicator lamps
should go out.
If the engine does not start after max. 20 seconds, return the ignition key to
position "1" or "0".
Repeat the starting procedure at the earliest after 1 minute.
If the engine does not start after 2 attempts, perform trouble shooting.

14
7 Operation
Shutting down the engine

Note
Do not shut down the engine all of a sudden from full load, but let it idle
without load for a while.
Turn the ignition key to position "0".
J The engine stops automatically.
14
Operation
7
7.2.1 Monitoring the machine during operation

Property damage
Engine damage due to fault which has not been remedied.
Z The fault must be remedied before restarting the engine and operating the machine
again.
Action to be taken if the control lights for charge control or engine oil
pressure light up
Shut down the engine immediately and perform trouble shooting.
Call for service personnel, if necessary.
Action to be taken if the control light for air filter contamination lights up
Perform the necessary air filter maintenance.
Action to be taken if the permitted coolant temperature is exceeded

Stop work.
Open the engine hood and run the engine with idle speed to cool it down.
Shut down the engine after it has cooled down and perform trouble shooting.
Call for service personnel, if necessary.

14
7 Operation
7.2.2 Driving, steering and braking

Danger to life
Physical injury due to incorrect operation.
Z The multi-function switch is only to be pressed if the machine is at a standstill and
both travel direction preselection switches are in the center position. If the two
direction-of-travel preselection switches are pressed in a contradictory manner, the
machine stops.
Z When driving on roads, the joystick for the work equipment must be deactivated by
operating the multi-function switch. By doing so, the travel direction preselection
switch on the joystick is without function, too.
Danger to life
Z When travelling downhill, proceed carefully and at moderate speed. Do not press
accelerator pedal fully down.
Z Before switching out of hydraulic fast gear "rabbit" into the hydraulic slow gear, the
travel speed must be reduced.
14
Operation
7
Driving
2
1
P
+ -
UNIDECK UNIDECK
HAZARD
AUTO OFF
0
I
4560_7004
Fig. 7-7 Driving and steering
The machine has two preselection switches for travel direction (2) and (3) which
are alternately active. One preselection switch for travel direction (2) is located
on the control console at the front and another such switch on the joystick (3)
controlling the working hydraulics.
Adjusting the travel direction with working hydraulics activated

Set the multi-function switch (1) to the front position.
J The "travel direction preselection" (2) switch is deactivated.
J The "travel direction preselection" (3) switch is activated.
Set the travel direction on the travel direction preselection (3) switch.
Adjusting the travel direction with working hydraulics disabled

Set the multi-function switch (1) to the rear position.
J The "travel direction preselection" (3) switch is deactivated.
J The "travel direction preselection" (2) switch is activated.
Set the travel direction on the travel direction preselection (2) switch.

14
7 Operation
Driving off
2 3
8
9 I 12 km/h
7
P
+ -
UNIDECK UNIDECK
00014,0 h
1 4
10 II
I 21 km/h
00014,0 h
HAZARD
6
P
11
AUTO OFF
0
I
4560_7005
Fig. 7-8 Driving off
Put the travel direction preselection switches (8) and (5) to the center
position.
J The indicator lamps (2) and (3) must not light up.
Start the engine. See chapter "Starting the engine", page 116.
Raise lift frame as far as the Travel height mark (11).
Select speed range FAST (forward switch position) or SLOW (rear switch
position) on the switch (7) as required.
J Observe the indicator lamps (9) and (10).
Release the parking brake (6) (forward switch position).
Set the required travel direction on the travel direction preselection switches
(8) and (5).
J The indicator light (2) or (3) lights up.
Press accelerator pedal (4).
J The machine only drives off once a certain engine speed is reached.
J Travel speed is increased and decreased using the accelerator pedal. Travel
speed directly depends on engine speed.
Change the travel direction by operating the travel direction preselection
switches (8) and (5).
14
Operation
7
Coming to a halt
+ -
UNIDECK UNIDECK
1 2
HAZARD
AUTO OFF
0
I
4560_7006
Fig. 7-9 Coming to a halt
Reduce the travel speed by releasing the accelerator pedal (2).

J The hydrostatic travel drive acts as a non-wearing auxiliary brake.
Operate the brake-inching pedal (1) as required.
J See chapter "Brakes", page 127.

14
7 Operation
Steering
Property damage
Machine damage due to fault which has not been remedied.
Z In the event of steering malfunctions, determine the cause immediately (see Trouble-
Shooting Table) and call for service personnel if necessary.
Danger of accident
Versa steering changes the steering speed.
Z Once mode 2 of the Versa steering is activated, turn the steering wheel slowly and
carefully as the steering response is now faster.
Danger of accident
The vehicle is only approved for mode 1, conventional steering, on public roads.
Z Use mode 1 only when driving on public roads.
Z Only use mode 2 for loading operations.
Steering
Mode 1 Conventional steering
0 The wheel loader features a fully hydraulic, proportionally acting

articulated steering.
Priority supply of hydraulic oil to steering through load-sensing system.
360 The steering angle depends on how many times the steering wheel is turned.
Mode 2 - Versa steering - fast steering function
R HAZARD
lubrication
Intermediate
schmierung
Zwischen-
15
AUTO OFF
0
I
Mode 2 is activated via the flip switch (15) next to the driver's seat.
With Versa steering, the operator has to move the steering wheel in the
desired direction (right or left) and the wheel loader continues to steer as far
as it can go.
The maximum angle of rotation for the steering wheel is 50 in either
direction. At 50, the wheel loader steers as far as it can go at maximum
speed. If the steering wheel only moves 10, for example, the wheel loader
14
Operation
7
steers as far as it can go, but at a slower speed.

The steering speed is determined by the steering wheel angle.
Note
The working hydraulics have to be switched on for Versa steering.

14
7 Operation
Brake accumulator pressure fill
max.
0 1
+50 P
max. + -
-50 UNIDECK UNIDECK
HAZARD
AUTO OFF
0
I
4560_7006a
Fig. 7-10 a Accumulator pressure fill
Brake accumulator pressure fill

If the brake accumulator pressure indicator (1) lights up, stop the machine
and determine the cause.
Danger to life
Physical injury caused by machine movements.
Z The machine may not be operated with insufficient brake accumulator pressure.
Z Danger of accident!
Z No braking power.
14
Operation
7
Brakes
+ -
UNIDECK UNIDECK
1 2
HAZARD
3
P
AUTO OFF
0
I
4560_7007
Fig. 7-11 Brakes
Operating service and auxiliary brake

To bring the machine to a halt, release the accelerator pedal (2). The
hydrostatic travel drive then acts as an auxiliary brake.
Operate the brake-inching pedal (1) as required.
Operating the parking brake

Only apply the parking brake (3) if the machine is stationary (rear switch
position).
Note
Once the parking brake is applied (3), the travel drive is deactivated.

14
7 Operation
Brake-inching The machine features a brake-inching mechanism altering the relationship

mechanism between travel speed and engine speed.
Operating the brake-inching mechanism

Operate the brake-inching pedal (1).
J Travel speed is reduced - irrespective of engine speed - until the machine
comes to a stop.
J This mechanism permits sensitive driving at maximum engine speed, e.g.
when loading a truck, where fast working cycles are required.
Danger to life
Z Continually braking on downhill sections will overheat and damage the service brake.
Z Travel downhill with care!
Note
You can avoid this by travelling downhill in a lower speed range and using
the engine as a brake.
14
Operation
7
Driving on roads
Danger to life
Physical injury due to rigid forks.
Z Rigid forks must be dismounted before driving on public roads!
Property damage
Endangerment of road-traffic due to missing equipment.
Z 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.
Danger to life
Physical injury from tires overheating.
Z If travelling long journeys, schedule in breaks to allow the tires and components to
cool down.
Z Switch off machine for at least 30 minutes every 30 km/18,6 mi or every hour of
travel.
Note
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).
Before driving on open roads, the following points have to be observed:

Empty the bucket and fully tilt it in.
Attach the guard on the front bucket edge.
Secure the side-dump bucket with socket pins.
Completely retract the high-tip bucket.
Fold up the forks of the fork lift attachment, lock in place and secure against
lateral shifting.

14
7 Operation
Driving on public roads
2
1
P
+ -
UNIDECK UNIDECK
HAZARD
4
AUTO OFF
0
I
4560_7008
Fig. 7-12 Driving on public roads
Raise the lift frame as far as the height color mark (4) until sufficient ground
clearance is secured.
Put the "travel direction preselection" switches in the joystick (3) and in the
control console (2) to the center position.
Switch off the working hydraulics (1) (forward switch position).
Note
Only switch off working hydraulics when stationary.
Versa steering, if switched on, is automatically deactivated.
Check the function of the direction indicators, hazard warning lights, horn,
low/high beam.
Close the cab door.
Drive ahead. See chapter "Driving off", page 122.
14
Operation
7
Switching off the machine (parking)

Danger to life
Physical injury due to rolling away of machine.
Z If necessary, secure the machine with chocks to prevent it from rolling away.
+ -
1 UNIDECK UNIDECK
2 3
HAZARD
4
P
AUTO OFF
0
I
4560_7009
Fig. 7-13 Parking
Parking the wheel loader

Put the travel direction preselection switches (2) and (3) to the center
position.
Set the multi-function switch (1) to rear switch position.
J The working hydraulics will be switched off.
Set the parking brake switch (4) to front position.
J The parking brake is applied.
Lock the cab after finishing work to keep unauthorized persons from getting
in.

14
7 Operation
7.2.3 Working operation

Danger to life
Physical injury due to incorrectly fastened work attachments.
Z 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-attach system
is properly locked.
Z The bucket must be moved carefully at a low height.
Before commencing loading work, memorize the lever controls well.

During loading operations, driving and work movements should flow in
smooth succession.
Drive slowly when familiarizing yourself with the controls.
Danger to life
Z Do not raise bucket higher than necessary (30-40 cm/1-1.3 ft above the ground!)
Travel on uphill inclines

The bucket must be facing uphill.
Travel on downhill inclines

The bucket must be facing uphill.
14
Operation
7
Operation of work equipment
+ -
UNIDECK UNIDECK
1
3
HAZARD
AUTO OFF
0
I
5
4560_7010
Fig. 7-14 Operating the loader
Operating the loader

Set the multi-function switch (1) to the forward switch position.
J The working hydraulics will be switched on.
Operating the loading bucket

Operate the loading bucket with the joystick (3).
Operation of additional control circuit (adjustable)

Impulse mode = press button (4) 1x
Continuous mode = press button (4) 2x
Press button (2) for up and down (e.g., open/ close multi-purpose bucket).
Additional control circuit only active as long as the button is pressed
(pulse-mode).
Note
The additional control circuit must always be switched off unless additional
equipment is operated. The hydraulic power of a number of attachments
must be adjusted, e.g. rotational speed of sweepers, etc.
Move the attachment to operating position.

Operate the turning knob (5) to adjust hydraulic power (e.g. rotational speed).

14
7 Operation
Continuous operation additional control circuit (adjustable)

Danger to life
Z Observe the function of the attachment (e.g. rotating direction of attachment).
+ -
UNIDECK UNIDECK
1
3
HAZARD
AUTO OFF
0
I
5
4560_7010
Fig. 7-15 Continuous operation
Activating the continuous operation

Continuous mode = press button (4) 2x
Press button (2) for up and down (button featuring stay-down function).
Operate the turning knob (5) to adjust hydraulic power (e.g. rotational speed).
Deactivating the continuous operation

Press a push-button switch (2).
Note
The additional control circuit must always be switched off unless additional
equipment is operated.
14
Operation
7
Float position of lift frame
+ -
UNIDECK UNIDECK
HAZARD
AUTO OFF
0
I
4560_7011_a
1
Fig. 7-16 Float position
Adjusting the impulse mode

Place the loading bucket on the floor.
Push joystick forwards beyond the pressure point.
J The float position is activated for as long as the joystick is held in the pressed
position.
Adjusting the continuous operation

Place the loading bucket on the floor.
Move the switch (2) to the rear switch position.
J The green indicator lamp lights up.
Push joystick forwards beyond the pressure point.
Joystick is automatically engaged in this position.
Exiting continuous operation

Exit continuous operation by returning the joystick to neutral or moving the
switch (2).
Note
The float position must always be disengaged unless operated. Move the
switch (2) to position "1".

14
7 Operation
7.2.4 Changing work attachments

Various work attachments are available to achieve maximum utilization of the
machine for a variety of applications.
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.
Danger to life
Physical injury due to incorrectly fastened work attachment.
Z Perform a visual check to ensure that the quick-attach system is correctly locked.

Danger of injury due to unsecured work attachments.
Z Secure unused working attachments with wedges or similar.
Property damage
Machine damage due to additional control circuit which has not been switched
off.
Z The additional control circuit must be switched off unless a hydraulically operated
additional attachment is connected.
Note
Under certain circumstances, it is possible to use the work attachments of
predecessor models on our machines. When mounting work attachments of
predecessor models, however, these may have to be adjusted and/or are
subject to utilization restrictions. The installation of work attachments which
are not included in our product range requires our written approval. It is
essential to consult your dealer before mounting such a work attachment.
Note
The bearings on the quick-attach system and work attachment must be free
of dirt.
Changing directly mounted work attachments

Note
Before disconnecting hydraulic connections, the system must be released
from pressure.
Note
In the event of a hydraulically operated attachment, first of all the hydraulic
connection must be disconnected (system must be without pressure).
Place the work attachment on the ground so that it cannot tip or turn over.
Remove the pin of the linkage and the pin of the lift frame.
Remove the lift frame from the work attachment and mount the new work
attachment.
14
Operation
7
Mounting and changing work attachments with hydraulic quick-attach

system (option)
+ -
UNIDECK UNIDECK
1 1
HAZARD
AUTO OFF
0
I
2 3
4560_7012
Fig. 7-17 Operating the quick-attach system
Place the work attachment on the ground so that it cannot tip or turn over.
Shut down the diesel engine.
Operate the push-button switches (1) for pressure relief.
In case of hydraulically controlled additional tools: Release the hydraulic
connections on both distributor blocks.
Set the ball valve to position "Quick-attach system unlocked" (2).
Start the diesel engine.
Unlock the quick-attach system (1) and remove it from the work attachment.
Take up new work attachment and lock by pressing the push-button switch
(1).
Shut down the diesel engine.
Operate the push-button switches (1) for pressure relief.
Set the ball valve to position "Quick-attach system locked" (3).
Connect the hydraulically operated work attachment to the connection of the
additional control circuit.

14
7 Operation
7.2.5 Loading, grading, excavating

During transport, the bucket - either filled or empty - must be kept as close to the
ground as possible.
If possible, avoid long transport distances!
+ -
UNIDECK UNIDECK
HAZARD
AUTO OFF
0
I
4560_7013
Fig. 7-18 Loading, grading
Loading
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.
Slightly raise the lift frame as soon as the bucket is filling, and tilt back the
bucket.
For dumping, raise the bucket until it is above the point of dumping and dump
the material.
Scraping and grading

Lower the lift frame and move the cutting edge into the ground keeping a flat
angle of inclination.
Do not penetrate too deeply to ensure smooth removal of earth.
During this operation, the depth is only to be leveled by moving the bucket in and
out.
14
Operation
7
Excavating
To dig out an excavation, strip layers which are as regular as possible.
Plan the excavating work in such a way as to enable the wheel loader to drive
forward with full bucket out of the excavation.
Keep the outward run of the excavation as flat as possible.

14
7 Operation
7.2.6 Ride control system (RCS) (option)

Depending on the machine's operating weight, road conditions, and speed,
there may be pitching oscillations when driving wheel loaders.
The ride control system reduces pitching oscillation, which results in the
following advantages:
higher transport speed
improved material-handling performance
more stable steering performance
shorter braking distance
increased ride comfort
Note
Load-retaining valves (option) are without function as long as the ride control
system is activated (at more than 6 km/h/3.7 mph)!
Switching on the ride control system

Set the ride control system to the forward switch position.
J The green indicator lamp lights up.
The ride control system is automatically activated as soon as the travel speed is
more than 6 km/h/3.7 mph.
Note
The bucket tilt cylinder must not be at a cylinder stop (bucket not completely
tilted back) as otherwise free oscillation is not possible.
14
Operation
7
Reducing the accumulator pressure

Danger to life
Physical injury due to pressure in the hydraulic system.
Z Before working on the loader hydraulic system, the accumulator pressure of the ride
control system must be let off.
2
1
4560_7014
Fig. 7-19 RCS pressure reduction
Switch off the machine according to regulations.

Set the ride control system to the rear switch position.
J The green indicator lamp goes out.
Remove the front-end cover.
Carefully release the nut (1).
Unscrew the setscrew (2) by 2 turns.
J Pressure is reduced.

14
7 Operation
7.2.7 Notes for winter operation

The following points and the relevant notes in the engine instruction manual
should be observed during winter operation.
Hydraulic oil If the machine has not been used for long periods of time and temperatures
are around or below freezing, warm up the engine by running at medium revs
for approx. 3-5 min.
Engine oil The oil viscosity (SAE class) should be selected according to the ambient
temperature at the machine's place of operation.
Condition of the A good cold start performance requires a well-charged battery.

battery
Warm up the battery to approx. +20 C/68 F (remove the battery after
shutting down the engine and store it in a warm room). This can help to lower
the start limit temperatures by 4 C/39.2 F-5 C/41 F.
Ensure good contact of the terminal connections when installing the battery.
Only tighten terminal screws "hand-tight", to prevent deformation of the
terminal cones!
Coolant Check the antifreeze setting before the beginning of the cold season.
Match the antifreeze to the ambient temperature, as required. At the factory,
the antifreeze protection is set to approx. -25 C/-13 F.
Fuel Use only standard commercial brand diesel fuel with a sulfur content lower
than 0.5%.
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.
14
Transportation
8
8 Transportation
Note
See chapter 3.20 "Recovery, loading and transporting", page 29.
8.1 Recovering the wheel loader

Danger to life
Physical injury due to rolling away of machine.
Z Always secure the machine with chocks and relieve the hydraulic system of pressure
before carrying out maintenance and repair work.
Property damage
Machine damage due to excessively fast towing.
Z Tow the machine at walking speed.
Z Tow the machine to a maximum distance of 50 m/164 ft.
Property damage
Machine damage due to hydraulic system contamination.
Z Absolute cleanliness is essential when working on the hydraulic system.
08_Transportation_us.fm - V 0.1 - 4.5.11 TL310 143 / 178

14
8 Transportation
Whenever the wheel loader has to be towed, for whatever reason, the "Travel"
oil circuit must be opened so that the hydrostatic transmission no longer acts as
an auxiliary brake.
4560_8001
Fig. 8-1 Hydraulic pump
At the two high-pressure relief valves (1) with bypass located on top and
bottom, loosen the screw (1) by no more than 3 turns.
After towing, screw back in screw (1) until the stop.
144 / 178 TL310 08_Transportation_us.fm - V 0.1 - 4.5.11
14
Transportation
8
Recovering the wheel loader

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.
Towing lugs For towing the wheel loader the following towing lugs are available:
4560_8004
1
Fig. 8-2 Towing lugs
1 right and left on the axle plates

2 bottom right and left on the side plates of the rear end
Note
Max. load suspension of towing lugs approx. 14,500 kg/31,973 lbs.

14
8 Transportation
Releasing the spring-loaded brake
+ -
UNIDECK UNIDECK
HAZARD
P
P
AUTO OFF
3
2
0
I
4560_8002
Fig. 8-3 Releasing the spring-loaded brake
Switch on the ignition (2).

Release the spring-loaded brake by operating the switch (1).
If the spring-loaded brake cannot be released, release it in both axles by
screwing in the adjusting screws (3) by 30 mm/1 ft (4).
Note
After towing, re-adjust the spring-loaded brake.
14
Transportation
8
8.2 Lifting with a crane

Danger to life
Danger to life when exceeding the maximum weight-lifting capacity.
Z Ensure that the maximum lifting capacity of the crane and the crane harness is not
exceeded.
1 2 4560_8003
Fig. 8-4 Lifting positions
Lifting the wheel loader

Empty the bucket and tip back.
Move the lift frame to travel position.
Apply the pin of the articulation lock (2) on the articulation.
Leave the machine and close the door.
Attach the loader to the hoisting appliance at the specified, marked points (1)
in the correct manner.

14
8 Transportation
8.3 Transport
Danger to life
Danger to life due to disregarding the total transport height.
Z It is essential to observe the clearance heights of tunnels, bridges, etc.
To transport the machine onto a flat bed trailer, railway goods wagon, etc. the
following measures must be taken:
Securing the wheel loader

Empty the bucket and tilt it in.
Drive the machine onto the flat bed trailer, goods wagon, etc., or lift by crane
if required.
Apply the pin of the articulation lock (2) on the articulation.
Leave the machine and close the door.
Lash the machine to the hoisting appliance at the specified, marked points
(1) in the correct manner.
1 1
1 1
2
1 1
4560_8005
Fig. 8-5 Lashing points
14
Specifications
9
9 Specifications
9.1 Views
9.1.1 Dimensioned drawing with bucket, directly mounted
is being created
Fig. 9-1 Dimensioned drawing with bucket and tires 23,5 R 25
09_Specifications_us.fm - V 0.1 - 4.5.11 TL310 149 / 178

16
9 Specifications
9.1.2 Dimensioned drawing with bucket and quick-attach system
is being created
Fig. 9-2 Dimensioned drawing with loading bucket and quick-attach system and tires 23,5 R 25
150 / 178 TL310 09_Specifications_us.fm - V 0.1 - 4.5.11
16
Specifications
9
9.1.3 Dimensioned drawing with light-material bucket and quick-

attach system
is being created
Fig. 9-3 Dimensioned drawing with light-material bucket and quick-attach system and tires 23,5 R 25

16
9 Specifications
9.2 Technical data

9.2.1 Engine
Engine
Manufacturer Cummins
Type Diesel
Design 6 cylinders in line
Four-stroke diesel engine
with turbocharger and
charge-air cooler,
exhaust-gas optimized
(EPA III, EG-Stufe III)
Displacement 6700 cm3/409 in3
Power output according to DIN 70020 149 kW/200 HP at 2200
rpm
Cooling Water-antifreeze mixture

for all-year operation
Heating Cab hot water heating with
three-speed heater fan
Max. inclined position 30 in all directions
Engine lubricating-oil supply Observe the overturning
limit angle of the machine!
Tab. 9-1 Engine
9.2.2 Electrical system

Electrical system
Nominal voltage 24 V
Battery 2 x 12 V 100Ah / 900A
(EN) / 510 A (DIN)
Generator 24 V 70A
Starter 24 V / 3.7 kW/5HP
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
Tab. 9-2 Electrical system
16
Specifications
9
9.2.3 Travel drive

Two-stage hydrostatic travel system with variable displacement axial piston
motor and reduction gear
Automatic changeover between low and high speed range
Travel drive
Travel drive Variable displacement pump,
flange-mounted directly onto diesel
engine, two-stage variable
displacement motor with power shift
on rear axle reduction gear.
Suction and return filter in the
form of a tank insert filter.
Travel speed Forward - Reverse
Travel range "Work" 0 - 6.0 km/h/
0 - 3.7 mph
Travel range "Road" 0 - 40 km/h/
0 - 25 mph
Power transmission Hydrostatic travel drive with
advanced driving automatics.
Automatic adjustment of propulsive
force and speed. Continuous speed
regulation forward and in reverse.
Four-wheel drive via propeller shaft
connection.
Max. operating pressure - max. 420 bar/6,090 psi
driving
Tab. 9-3 Travel drive
9.2.4 Brakes
Brakes
Service brake Hydraulic two-circuit power brake. Wet discs in both axles
acting on all 4 wheels via four-wheel drive.
Parking brake Spring-loaded brake acting on the discs of the rear axle.
Additional brake Hydrostatic through closed-circuit travel drive.
Tab. 9-4 Brakes

16
9 Specifications
9.2.5 Hydraulics
Hydraulic system
Hydraulic pump Variable displacement piston pump with pressure-flow rate
governor
Pump capacity: max. 220 l/min/58 gal/min.
Working pressure, steering: 215 bar/3,117.5 psi
Working pressure, loading: 350 bar/5,075.0 psi
Priority valve Priority supply of hydraulic oil to steering through load-sensing
system, ensuring that all the available oil can be provided if
necessary. Rapid steering movements even at low engine
revs.
Steering Fully hydraulic, proportionally acting articulated steering. Two
double-acting steering cylinders.
Total steering 80
angle
Loader frame Double-acting work cylinders, two lift cylinders and one tilt
cylinder.
Control block with load-sensing flow distribution.
Control circuits "Lift / Lower" and "Dump / Tilt-back" pilot-
operated.
Float position if "lowering" pressure point on joystick exceeded.
Single, four-way control lever (joystick) with integrated
direction-of-travel switch and switch for additional control
circuit.
Additional control Max. oil flow 180 l/min/47.6 gal/min
circuit Max. operating pressure 230 bar/3,335.0 psi
Hydraulic oil cooler Thermostatically controlled, hydrostatic fan drive
16
Specifications
9
9.2.6 Permissible loads in compliance with German Road Traffic

Regulations (StVZO)
Permissible loads in compliance with German Road Traffic Regulations

(StVZO)
Permitted overall weight see type label, or
General Certification
Permissible axle load, front
Permissible axle load, rear
Tab. 9-5 Permissible loads in compliance with German Road Traffic Regulations (StVZO)
9.2.7 Sound level values, vibration

Sound level values in compliance with directive 2000/14/EC and EN 474
Guaranteed sound power level LWA = 106 dB (A)
Sound pressure level (at driver's ear) LPA = 79 dB (A)
Tab. 9-6 Sound level values
Vibration values in compliance with directive 2002/44/EC and EN 474

Effective values of acceleration below 0.5 m/s/20 in/s for entire body
and 2.5 m/s/98 in/s for upper limbs.
Tab. 9-7 Vibration values
Equivalent vibration values for entire body vibration emission according

to ISO/TR 25398
Type of machine Typical operating Average value Standard deviation
condition
1.4*w,eqx 1.4*w,eqy w,eqz 1.4*Sx 1.4*Sy Sz
m/s/in/s
Compact wheeled Load & carry 0.94/37.0 0.86/33.9 0.65/25.6 0.27/10.6 0.29/11.4 0.13/5.1
loader
<4500kg
Wheel loader Load & carry 0.84/33.1 0.81/31.9 0.52/20.5 0.23/9.1 0.20/7.9 0.14/5.5
4500kg>
Use in quarrying 1.27/50.0 0.97/38.2 0.81/31.9 0.47/18.5 0.31/12.2 0.47/18.5
Transition travel 0.76/29.9 0.91/35.8 0.49/19.3 0.33/13.0 0.35/13.8 0.17/6.7
V-shaped motion 0.99/39.0 0.84/33.1 0.54/21.3 0.29/11.4 0.32/12.6 0.14/5.5
Tab. 9-8 Equivalent vibration values

16
9 Specifications
9.3 Dimensions and weights
J Specifications refer to general-purpose bucket and 23,5 R 25 tires

Dimensions and weights
Operating weight, standard equipment1) 17,600 kg/38,808 lbs
Total length, standard bucket on ground (quick- approx 7,600 mm/
attach system / directly mounted) 299.3 in (direct)
Total width 2,950 mm/116.2 in
Total height (cab roof) 3,400 mm/133.9 in
Wheel base 3,250 mm/128.0 in

Track width FR / RR 2,141 mm/84.3 in
Rear overhang angle 33
Ground clearance below propeller shaft 675 mm/26.6 in
Turning radius at outside edge of bucket in transport 6,475 mm/255.0 in
position (quick-attach system/ directly mounted) (direct)
Turning radius at inside edge of tires 3,065 mm/120.7 in
1)
according to ISO 6016
Tab. 9-9 Dimensions and weights
J Specifications refer to general-purpose bucket and 20.5 R 25 tires

J Stability conforms to DIN 24094
Front loader installation Quick-attach Direct
system mounting
Width of bucket 2,950 mm/ 2,950 mm/
116.2 in 116.2 in
Capacity to DIN/ISO 7546 (max. density = 1.8 t/m/ approx. 3.0 m/ approx. 3.1 m/
112.4 lb/ft) 183.1 in 189.2 in
Payload in bucket 5,400 kg/ 5,580 kg/
11,907 lbs 12,304 lbs
Dump height at 43 dump angle 3,065 mm/ 3,065 mm/
120.7 in 120.7 in
Dump reach at max. dump height 1,180 mm/ 1,165 mm/
46.5 in 45.9 in
Max. bucket hinge pin height 4,260 mm/ 4,260 mm/
167.8 in 167.8 in
Reset angle 41 41
Dump angle at max. dump height 43 43
Digging depth, horizontal bucket 100 mm/3.9 in 70 mm/2.8 in
16
Specifications
9
Front loader installation Quick-attach Direct

system mounting
Lift capacity at ground level according to ISO 14397-2 232,0 kN/ 232,0 kN/
52,153.6 lbf 52,153.6 lbf
Ripping force at cutting edge of bucket1) 128,9 kN/ 153,6 kN/
28,976.7 lbf 34,529.3 lbf
Tipping load, straight 12,700 kg/ 13,250 kg/
28,004 lbs 29,216 lbs
Tipping load, articulated 11,200 kg/ 11,700 kg/
24,696 lbs 25,799 lbs
Work cycle time, "Lift" 6.5 s 6.5 s
Work cycle time Lower 4.0 s 4.0 s
Work cycle time Dumping in uppermost position 2.8 s 2.8 s
IN
Work cycle time Dumping in upper position 2.5 s 2.5 s
OUT
1)according to ISO 8313
Tab. 9-10 Dimensions and weights
Bucket Width Capacity, Max. density ()

mm/in heaped 1) t/m3/lb/ft3
m3/in3
General-purp. bucket 2,950/116.2 3.0/183.1 / 1.8/112
3.1/189.2
Bucket 2,950/116.2 3.0/183.1 / 1.8/112
3.1/189.2
Earth bucket 2,950/116.2 3.2/195.3 / 1.6/100
3.3/201.4
Light-material 2,950/116.2 -/- / 1.2/75
bucket, bolt-on 4.0/244.1
cutting edge
Light-material 2,950/116.2 -/- / 0.8/50
bucket, bolt-on 5.0/305.1
cutting edge
High-tip bucket Bolt- 2,950/116.2 -/- / 0.8/50
on cutting edge 4.5/274.6
1)
Quick-attach system / directly mounted
Tab. 9-11 Bucket dimensions
J Fork-arm connection in compliance with ISO/FEM Class 3 Form B, DIN 15

16
9 Specifications
173 / ISO 2328 respectively, forks according to ISO 2330

Fork lift attachment mm/in
Width of fork carrier 1,900/74.8
Length of forks 1,500/59.1
Fork cross section 150 x 70/ 5.9 x 2.8
Max. stacking height 3,940/155.2
Tab. 9-12 Dimensions of fork lift attachment
The payloads are determined in compliance with ISO 14397-1 respectively with a
stability factor of 1.25 or 80 % of the tipping load and the machine moving over level
ground.
The payloads are valid for the machine fitted with 23,5 R25 tires and the equipment
condition as described in compliance with ISO 6016.
Total lift range
600 S=2.0 S=1.25

23,6
kg 4800 7800
lbs 10580 17200
kg
kg 4800 7800
lbs
kg
lbs 10580 17200
lbs
Tab. 9-13 Total lift range of fork attachment
16
Specifications
9
Transport position
S=1.67 S=1.25
6
23,6
kg 6800 9000
lbs 14990 19840
kg
kg 6800 9000
lbs
kg
lbs 14990 19840
lbs
Tab. 9-14 Transport position of fork lift attachment
If rear tires with hydroinflation are used.

kg
lbs Note
During fork lift operations, the tire pressure of the front wheels must be
increased by at least 0.5 bar/7.3 psi.

16
9 Specifications
9.3.1 Cab
Spacious, sound-insulated full-vision steel cab, FOPS (acc. to ISO 3449) and
ROPS (according to EN ISO 3471) certified
Door with large access on left hand side
Sliding window on left-hand side
Safety glass
Thermal windows tinted green
Rear panorama window
Windscreen washing system
Storage rack
Preparation for radio installation
Outside rear-view mirrors on both sides
Heating/ Automatic climate control

ventilation
Driver's seat Comfort seat with fabric lining, weight, longitudinal and inclination adjustment
Lap seat belt
Armrest right
Operating Control console to the right of the driver's seat

controls Visual and audible warning systems
Operating-hour meter
Instrument cluster with large tank display
Working flood lights Halogen H-3 FR / RR
Options Rotating beacon

Radio
Immobilizer
Vandalism guard only for canopy version
2. Additional control circuit
Additional front and rear lighting
16
Specifications
9
9.3.2 ----

16
9 Specifications
9.3.3 Optional accessories

Property damage
Machine damagecaused by unauthorized alterations to the design, additional
equipment and work attachments of Terex products.
Z Alterations must be approved by the manufacturer in writing. If our approval is not
sought, our warranty expires, as does our product liability for any resulting
consequential damage.
Orthopedic air-cushioned driver's seat

Fire extinguisher
Pressurized cab
Independent diesel heating with timer
Diverse electrical accessories such as working floodlights, rotating beacon,
radio, etc.
Sliding window, door
Diesel exhaust cleaner
Catalyst
Ride control system
Anti-theft device
Back-up alarm system
Electrical tank refilling pump
Quick-attach system, hydraulically operated
Load hook for attaching to forks
Filling with biodegradable hydraulic oil (ester-based "BIO-E-HYD-HEES")
Pilot-controlled pipe rupture valve for lift and tilt cylinders
StVZO package
Note
Additional accessories available from the manufacturer.
16
Troubleshooting
10
10 Troubleshooting
Malfunctions are frequently caused by:

incorrect handling of the machine.
use of unsuitable fuels and lubricants.
irregular maintenance.
10.1 Who is allowed to rectify malfunctions?

During the warranty period, malfunctions must be dealt with by your
responsible Service Agent or a specialist workshop.
If a problem can only be eliminated through repair, then your responsible
Service Agent must be called in.
Engine faults All defects and faults in the diesel engine must be examined as described in
the separate engine instruction book.
During the warranty period, malfunctions must be dealt with by the
responsible SERVICE Agent or a specialist workshop.
10.2 Before trouble shooting and fault rectification

Park the wheel loader on a solid and level base.
The wheel loader is only to be parked in places where it does not obstruct
e. g. the public or the construction site traffic.
Close or lock windows and doors.
Secure the wheel loader with wheel chocks against rolling.
10_Troubleshooting_us.fm - V 0.1 - 4.5.11 TL310 163 / 178

17
10 Troubleshooting
10.3 Trouble shooting and fault rectification

Malfunction No steering movement
Cause Oil supply to pump interrupted

Hydraulic pump damaged
Priority valve damaged
Hand metering unit damaged
Steering cylinder damaged
Mechanical fault
Remedy Only Terex-customer service personnel are permitted to undertake the following
type of work.
Check and repair suction line
Repair or replace the hydraulic pump
Remedy damage to priority valve
Remedy damage to hand metering unit
Repair steering cylinder
Remedy mechanical fault
Malfunction Insufficient performance of service brake
Cause Wear in brake discs

Brake control system damaged
Mechanical fault
Remedy Adjust or repair brake discs (call Service Agent)

Repair or replace brake control system (call Service Agent)
Remedy mechanical fault (call Service Agent)
Malfunction Insufficient performance of parking brake
Cause Wear in brake discs

Hydraulic fault in brake actuation
type of work.
Re-adjust or repair brake discs
Replace and/or re-adjust brake actuation
164 / 178 TL310 10_Troubleshooting_us.fm - V 0.1 - 4.5.11
17
Troubleshooting
10
Malfunction Hydrostatic travel drive without neutral position
Cause Switch for travel direction damaged

Solenoids of valve damaged
Neutral position incorrectly adjusted
Internal damage to travel pump
Excessive engine idling
type of work.
Replace or repair direction switch
Check / re-calibrate solenoids of valve (call Service Agent)
Replace travel pump
Re-adjust engine idling
Malfunction Hydraulic oil exceeds max. admissible temperature
Cause Thermo switch damaged

Oil level too low
Oil cooler dirty or damaged
Suction filter clogged
High-pressure valves do not respond all the time or too early
Flushing circulation not functioning
Travel pump or travel motor damaged (wear)
Loader pump worn
Main pressure relief valve damaged
Remedy Replace suction filter

Top up oil to mark on dipstick
Clean, check and, if necessary, replace oil cooler
Only Terex-customer service personnel are permitted to undertake the following
type of work.
Replace thermo switch
Check high-pressure valves, re-adjust or replace if necessary
Check pressure of flushing and charge pump, possible back pressure in
cooling circuit, check housing pressure
Replace travel pump or travel motor
Replace working pump
Replace main pressure relief valve

17
10 Troubleshooting
Malfunction Sluggish acceleration and deceleration, too little propulsive power
Cause Insufficient engine power

Brake has got stuck
No tank pressurization
FAST-SLOW-gear not functioning due to electric or mechanical fault
Fault in operation of brake-inching pedal
Charge pump sucking up air
Travel pump incorrectly adjusted
Insufficient charge or supply pressure
Pressure relief valve of charge circuit dirty or damaged
Insufficient high-pressure
Travel pump does not open fully, pilot pressure too low
Internal damage to travel pump or travel motor
Travel motor mis-adjusted
Remedy Check ventilation filters and breathers, replace

Replace suction filter
type of work.
Check diesel engine
Check and repair brake
Check power supply and solenoid valve, repair and replace if necessary
Check, adjust, replace brake-inching device
Check charge pump, eliminate leaks
Re-adjust travel pump
Check and adjust charge or supply pressure
Check, re-adjust or replace pressure relief valve of charge circuit
Check high-pressure; re-adjust or replace pressure cut-off and high-pressure
valves if required.
Nozzles clogged, check, repair
Replace travel pump or travel motor
Re-adjust travel motor
17
Troubleshooting
10
Malfunction Transmission works in one direction only
Cause Switch for travel direction damaged

Solenoid valve gets stuck or is damaged
Power supply towards switch for travel direction or solenoid valve interrupted
Pilot pressure too low on one side
High-pressure relief valve is faulty or incorrectly adjusted
type of work.
Repair or, if necessary, replace direction switch
Repair or, if necessary, replace solenoid
Check and repair power supply towards switch for travel direction (incl.
ground connection)
Nozzles clogged, check, repair
Swap valves around. If machine now travels in the other direction, examine
valve, clean and replace if necessary
Malfunction Transmission works in neither direction
Cause Too little hydraulic oil in tank

Mechanical connection to diesel engine faulty
Charge pump damaged, no charge pressure
Switch for travel direction damaged
Solenoid valve for travel direction damaged
Suction line between tank and pump kinked
Power supply towards switch for travel direction and solenoid valve interrupted
Internal damage to travel pump or travel motor
Mechanical connection between travel motor and axle interrupted
type of work.
Top up hydraulic oil to mark on dipstick
Check and repair mechanical connection to diesel engine
Remove charge pump and examine, install new pump if necessary
Repair or, if necessary, replace direction switch
Repair or, if necessary, replace solenoid valve for travel direction
Replace suction filter
Check and eliminate kink in suction line between tank and pump
Remedy interruption of power supply towards switch for travel direction
Replace travel pump or travel motor completely
Check and repair mechanical connection between travel motor and axle

17
10 Troubleshooting
Malfunction Loader installation is not working
Cause Oil supply to pump interrupted

Main pressure relief valve damaged
Hydraulic pump damaged
Hydraulic pump drive mechanically interrupted
Remedy Check suction line

type of work.
Check and replace main pressure relief valve if necessary
Check, repair or replace the hydraulic pump
Check and repair hydraulic pump drive
Malfunction Decrease in machine's performance (loader installation)
Cause Insufficient engine power

Hydraulic oil level too low
Pump is sucking up air
Insufficient operating pressure
Pump worn
Incorrect hydraulic oil
Remedy Check diesel engine

Top up hydraulic oil to mark on dipstick
Quality of hydraulic oil must conform to our recommendation
type of work.
Re-tighten hose connections. Replace O-ring or seals
Re-adjust main pressure relief valve, replace if necessary
Replace pump
Malfunction Working cylinders are not working satisfactorily
Cause Seals in cylinders worn

Secondary valves defective
type of work.
Re-seal cylinders
Check secondary valves and replace completely if necessary
17
Troubleshooting
10
Malfunction Faults in the electrical system
Cause Outside and/or internal lighting damaged

Windshield wiper not working
Horn not responding
Control organs are imprecise
Starting system does not work satisfactorily
Remedy Check cables, connections, bulbs and fuses of outside and/or internal lighting
Check cables, connections, and fuses of windshield wipers
Examine windshield wiper for mechanical damage, replace if necessary
Check cables, connections, and fuses of horn
Replace complete horn if required
Determine the fault or source of the control organ problems, call Service
Agent if necessary
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

17
10 Troubleshooting
10.3.1 Immobilizer faults
Malfunction Immobilizer has no function
Remedy Inspect voltage supply on plug contacts.

Check antenna plug-in connection.
Check antenna cable.
Use key with learned transponder.
Malfunction Key learning not possible
Remedy Terminal 30 not connected to control unit.

No or incorrect master key used previously (red grip).
Time for master key in ignition too short or too long.
Key to be learned does not have transponder.
Defective antenna.
Learning time for key in ignition too short.
Malfunction Clearing of learned keys not possible
Remedy No or incorrect master key used (red grip).

Time for master key in ignition lock too short.
Defective antenna.
17
Service and spare parts information
11
11_Service_us.fm - V 0.1 - 4.5.11 TL310 171 / 178

17
11 Service and spare parts information
172 / 178 TL310 11_Service_us.fm - V 0.1 - 4.5.11
17
Index
12
12 Index
A
Accumulator pressure . . . . . . . . . . . . . . . . 141
Additional control circuit . . . . . . . . . . . 37, 133
Adjusting heating, ventilation and air-conditioning 110
Adjusting the driver's seat . . . . . . . . . . . . . 108
Adjusting the fan speed . . . . . . . . . . . . . . 111
Adjusting the lighting in compliance with German Road Traffic Regulations (StV-
ZO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Adjusting the travel direction . . . . . . . . . . . 121
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air filter control . . . . . . . . . . . . . . . . . . . . . . 36
Air filter main cartridge . . . . . . . . . . . . . . . . 74
Air filter safety cartridge . . . . . . . . . . . . . . . 74
Air intake system . . . . . . . . . . . . . . . . . . . . 73
Air pressure . . . . . . . . . . . . . . . . . . . . . . . . 97
B
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Battery charge indicator . . . . . . . . . . . . . . . 14
Brake accumulator pressure . . . . . . . . . 14, 36
Brake-inching mechanism . . . . . . . . . . . . 128
Brakes . . . . . . . . . . . . . . . . . . . . . . . . 127, 153
Bucket return positioner . . . . . . . . . . . . 15, 36
C
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Cab ventilation dust filter . . . . . . . . . . . . . 101
Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Carbon filter contamination . . . . . . . . . . . . . 15
Cartridge maintenance intervals . . . . . . . . . 74
Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Changeover fan/engine cooling . . . . . . . . . 15
Changing coolant . . . . . . . . . . . . . . . . . . . . 69
Changing the engine oil . . . . . . . . . . . . . . . 65
Changing the engine oil filter . . . . . . . . . . . 66
Changing the filter insert . . . . . . . . . . . . 87, 89
Changing the hydraulic oil . . . . . . . . . . . . . 85
Changing the main cartridge . . . . . . . . . . . . 75
Changing the V-belt . . . . . . . . . . . . . . . . . . 83
Changing work attachments . . . . . . . . . . . 136
Charge control lamp . . . . . . . . . . . . . . . . . . 36
Checking antifreeze . . . . . . . . . . . . . . . . . . 68
Checking the air intake . . . . . . . . . . . . . . . . 73
Checking the battery . . . . . . . . . . . . . . . . . . 98
Checking the coolant level . . . . . . . . . . . . . 67
Index_enSIX.fm - V 0.1 - 4.5.11 TL310 173 / 178

17
12 Index
Checking the engine oil level . . . . . . . . . . . 64

Checking the hydraulic oil level . . . . . . 84, 87
Checking the lighting and warning equipment 100
Checking the V-belt . . . . . . . . . . . . . . . . . . 82
Checking V-belt tension . . . . . . . . . . . . . . . 82
Circulating air . . . . . . . . . . . . . . . . . . . 15, 110
Cleaning cooling fins . . . . . . . . . . . . . . . . . 70
Cleaning the dust ejection valve . . . . . . . . 73
Cleaning the dust filter for cab ventilation 101
Cleaning the water separator . . . . . . . . . . . 82
Coming to a halt . . . . . . . . . . . . . . . . . . . . 123
Condition of the battery . . . . . . . . . . . . . . 142
Consumables . . . . . . . . . . . . . . . . . . . . 50, 52
Continuous operation - Additional control circuit 134
Conversions . . . . . . . . . . . . . . . . . . . . . . . . 27
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Coolant level . . . . . . . . . . . . . . . . . . . . . . . 15
Coolant temperature . . . . . . . . . . . . . . 14, 36
Cooling . . . . . . . . . . . . . . . . . . . . . . . . 15, 110
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Customer service . . . . . . . . . . . . . . . . . . . 171
D
Daily tasks . . . . . . . . . . . . . . . . . . . . . . . . . 57
Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Danger zone . . . . . . . . . . . . . . . . . . . . . . . . 20
Declaration of Conformity . . . . . . . . . . . . . . . 8
Deployment location . . . . . . . . . . . . . . . . . . . 5
Differential of rear axle with transmission . 95
Dimensions and weights . . . . . . . . . . . . . 156
Direction indicator . . . . . . . . . . . . . . . . 14, 36
Display . . . . . . . . . . . . . . . . . . . . . 36, 39, 110
Display elements and operating controls . . 35
Displaying interior/exterior temperature . . 111
Draining the fuel filter . . . . . . . . . . . . . . . . . 79
Draining water from the fuel tank . . . . . . . . 81
Driver's seat . . . . . . . . . . . . . . . . . . . . . . . 160
Driving . . . . . . . . . . . . . . . . . . . . 22, 120, 121
Driving off . . . . . . . . . . . . . . . . . . . . . . . . . 122
Driving on public roads . . . . . . . . . . . . . . . 130
Driving on roads . . . . . . . . . . . . . . . . . . . . 129
E
Economical operation . . . . . . . . . . . . . . . . . . 5
Electrical equipment . . . . . . . . . . . . . . . . . . 98
Electrical system . . . . . . . . . . . . . . . . . . . 152
Emergency exit . . . . . . . . . . . . . . . . . . . . . 30
Emergency steering . . . . . . . . . . . . . . . . . . 15
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
174 / 178 TL310 Index_enSIX.fm - V 0.1 - 4.5.11
17
Index
12
Engine cooler fan changeover switch . . . . . 36

Engine faults . . . . . . . . . . . . . . . . . . . . . . . 163
Engine oil . . . . . . . . . . . . . . . . . . . . . . 53, 142
Engine oil pressure . . . . . . . . . . . . . . . . 14, 36
Environmental protection . . . . . . . . . . . . . . 19
Excavating . . . . . . . . . . . . . . . . . . . . 138, 139
F
Falling objects . . . . . . . . . . . . . . . . . . . . . . . 23
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Fan levels . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fire extinguisher . . . . . . . . . . . . . . . . . . 16, 30
Fire prevention . . . . . . . . . . . . . . . . . . . . . . 30
First-aid kit . . . . . . . . . . . . . . . . . . . . . . . . . 16
Float position . . . . . . . . . . . . . . . . . . . . . . . 15
Fluid capacities . . . . . . . . . . . . . . . . . . . . . . 54
Front control console . . . . . . . . . . . . . . . . . 36
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 142
Fuel specification . . . . . . . . . . . . . . . . . . . . 51
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . 78
Fuel-level indicator . . . . . . . . . . . . . . . . . . . 36
Fuse and relay box . . . . . . . . . . . . . . . . . . . 40
G
General safety notes . . . . . . . . . . . . . . . . . . 19
Grading . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Grease gun . . . . . . . . . . . . . . . . . . . . . . . . . 15
Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
H
Hazard Classification . . . . . . . . . . . . . . . . . 11
Hazard warning system . . . . . . . . . . . . . . . 15
Hearing protection . . . . . . . . . . . . . . . . . . . 17
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
High beam light . . . . . . . . . . . . . . . . . . . . . . 36
High gear . . . . . . . . . . . . . . . . . . . . . . . . . . 14
High-beam indicator . . . . . . . . . . . . . . . . . . 14
High-gear changeover switch . . . . . . . . . . . 36
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . 15, 35
Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Hydraulic oil . . . . . . . . . . . . . . . . . 15, 53, 142
Hydraulic oil level . . . . . . . . . . . . . . . . . . . . 15
Hydraulic oil return filter . . . . . . . . . . . . . . . 89
Hydraulic oil suction filter . . . . . . . . . . . . . . 87
Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . 84
Hydraulic system . . . . . . . . . . . . . . . . . . . . 30
Hydraulics . . . . . . . . . . . . . . . . . . . . . 154, 155

17
12 Index
I
Initial familiarization . . . . . . . . . . . . . . . . . . 31
Inspection intervals . . . . . . . . . . . . . . . . . . 46
Inspection plan machine . . . . . . . . . . . . . . 59
Installing batteries . . . . . . . . . . . . . . . . . . 100
Installing the dust filter for cab ventilation 102
Intended use . . . . . . . . . . . . . . . . . . . . . . . . 7
Intermediate lubrication . . . . . . . . . . . . . . . 16
L
Lashing points . . . . . . . . . . . . . . . . . . . . . . 16
Lateral control console . . . . . . . . . . . . . . . . 37
Lifting with a crane . . . . . . . . . . . . . . . . . . 147
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Loading . . . . . . . . . . . . . . . . . . . . . . . 29, 138
Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Low-high beam . . . . . . . . . . . . . . . . . . . . . . 35
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 54
Lubrication plan . . . . . . . . . . . . . . . . . . . . . 55
M
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 27
Maintenance and Inspection Plan . . . . . . . 57
Maximum inclination . . . . . . . . . . . . . . . . . . 21
Modifications . . . . . . . . . . . . . . . . . . . . . . . . 5
Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . 29
Multi-function switch . . . . . . . . . . . . . . . . . . 36
N
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
O
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . 47
Oil analysis intervals . . . . . . . . . . . . . . . . . 47
Operating controls . . . . . . . . . . . . . . . 35, 160
Operating hour meter . . . . . . . . . . . . . . . . . 36
Operating Instructions . . . . . . . . . . . . . . . . . 5
Operating instructions . . . . . . . . . . . . . . . . 31
Operating the loader . . . . . . . . . . . . . . . . 133
Operating the loading bucket . . . . . . . . . . 133
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Operation of work equipment . . . . . . . . . . 133
Optional accessories . . . . . . . . . . . . . . . . 162
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Overhead power lines . . . . . . . . . . . . . . . . 24
Overview filters . . . . . . . . . . . . . . . . . . . . . . 34
Overview of lubrication points on machine . 55
Overview of lubrication points on working attachment 56
17
Index
12
Overview of wheel loader . . . . . . . . . . . . . . 33
P
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Parking brake . . . . . . . . . . . . . . . . 14, 36, 127
Performing automatic diagnosis . . . . . . . . 111
Personal safety gear . . . . . . . . . . . . . . . . . . 17
Pictograms . . . . . . . . . . . . . . . . . . . . . . . . . 14
Preheating . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pre-heating monitor . . . . . . . . . . . . . . . . . . 36
Preservation for temporary taking out of service 104
Preserving the machine . . . . . . . . . . . . . . 104
Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Product Identifikation Number (PIN) plate . 10
Protective clothing . . . . . . . . . . . . . . . . . . . 17
Protective gloves . . . . . . . . . . . . . . . . . . . . 17
Protective goggles . . . . . . . . . . . . . . . . . . . 17
Purchasing spare parts . . . . . . . . . . . . . . . 171
Q
Quick-attach system . . . . . . . . . . . . . . . . . 137
R
RCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Recovery . . . . . . . . . . . . . . . . . . . . . . . 29, 143
Refilling with coolant . . . . . . . . . . . . . . . . . . 68
Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Removing batteries . . . . . . . . . . . . . . . . . . . 99
Removing the dust filter for cab ventilation 101
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Replacing the breathing filter . . . . . . . . . . . 86
Replacing the fuel filter . . . . . . . . . . . . . 79, 80
Residual dangers . . . . . . . . . . . . . . . . . . . . 30
Respiratory protection . . . . . . . . . . . . . . . . . 17
Ride control system . . . . . . . . . . . . . . 15, 140
Rooms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Running the movements . . . . . . . . . . . . . . 105
S
Safety distance . . . . . . . . . . . . . . . . . . . . . . 24
Safety signs . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety symbol . . . . . . . . . . . . . . . . . . . . . . . 11
Scraping . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Service parts . . . . . . . . . . . . . . . . . . . . . . . . 49
Servicing safety signs . . . . . . . . . . . . . . . . . 14
Setting the temperature . . . . . . . . . . . . . . 111
Shutting down the engine . . . . . . . . . . . . . 118
Sound level values . . . . . . . . . . . . . . . . . . 155

17
12 Index
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . 171

Spare parts list . . . . . . . . . . . . . . . . . . . . . . 31
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Starting the engine . . . . . . . . . . . . . . . . . . 116
Steering . . . . . . . . . . . . . . . . . . . . . . 120, 124
Steering wheel adjustment . . . . . . . . . . . . 109
Suspension points for loading by crane . . . 16
Switching high beam on . . . . . . . . . . . . . . 112
T
Taking out of service . . . . . . . . . . . . . . . . 104
Target groups . . . . . . . . . . . . . . . . . . . . . . . . 6
Tasks to be performed weekly . . . . . . . . . . 58
Temperature . . . . . . . . . . . . . . . . . . . . . . . . 15
Topping up hydraulic oil . . . . . . . . . . . . . . . 84
Transportation . . . . . . . . . . . . . . . . . . 29, 148
Transporting persons . . . . . . . . . . . . . . . . . 20
Travel direction . . . . . . . . . . . . . . . . . . . 14, 36
Travel drive . . . . . . . . . . . . . . . . . . . . . . . 153
Travel speed switch . . . . . . . . . . . . . . . . . . 36
Travel speed, FAST . . . . . . . . . . . . . . . . . . 14
U
Underground power lines . . . . . . . . . . . . . . 23
Unlocked . . . . . . . . . . . . . . . . . . . . . . . . . . 15
V
V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . 160
W
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Warranty . . . . . . . . . . . . . . . . . . . . . . 7, 31, 48
Wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . 97
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Windshield washer system . . . . . . . . . . . . 103
Windshield washing function . . . . . . . . 15, 36
Windshield wiper . . . . . . . . . . . . . . . . . 15, 36
Windshield wiper, rear . . . . . . . . . . . . . . . . 36
Winter operation . . . . . . . . . . . . . . . . . . . . 142
Work stoppages . . . . . . . . . . . . . . . . . . . . . 25
Work zone safety . . . . . . . . . . . . . . . . . . . . 18
Working floodlights . . . . . . . . . . . . . . . . . . . 15
Working hydraulics . . . . . . . . . . . . . . . . . . 155
Working hydraulics shut-off . . . . . . . . . . . . 14
Working operation . . . . . . . . . . . . . . . . . . . 22
17

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Terex TL310 Manual

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tl310

Order number: 5780200604

From vehicle ID No: TL03100100>

Original operating instructions

Please complete before commissioning the wheel loader:

Vehicle model: .........................................................................................

Vehicle ID-No: .........................................................................................

Year of construction: .........................................................................................

Commissioned on: .........................................................................................

This Operating Manual is protected by limited copyright. It may be reproduced

01_Table of Contents_enIVZ.fm - V 0.1 - 4.5.11 TL310 1 / 178

3.16 Operation in closed spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

2 / 178 TL310 01_Table of Contents_enIVZ.fm - V 0.1 - 4.5.11

6.6.3 Inspection plan machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

01_Table of Contents_enIVZ.fm - V 0.1 - 4.5.11 TL310 3 / 178

9.1.1 Dimensioned drawing with bucket, directly mounted . . . . . . . . .149

4 / 178 TL310 01_Table of Contents_enIVZ.fm - V 0.1 - 4.5.11

2.1 Concerning these operating instructions

Deployment These operating instructions must always be available at the deployment

Copyright This operating manual is copyrighted. It must not be copied, disseminated or

02_Introduction_us.fm - V 0.1 - 4.5.11 TL310 5 / 178

6 / 178 TL310 02_Introduction_us.fm - V 0.1 - 4.5.11

2.2 Notes on using the operating manual

2.3 Intended use

2.4 Unintended use

02_Introduction_us.fm - V 0.1 - 4.5.11 TL310 7 / 178

2.6 Declaration of Conformity

5. Guaranteed sound power level:

6. Applied harmonized standards:

7. Document editor, who is authorized to compile technical documentation:

8. Voluntary type examination performed as well as certification in accordance with

Replaceable attachments manufactured by Terex or third party manufacturers may only be

Date of the declaration of conformity 08.04.2010.

Terex GmbH Schaeffstrasse 8

8 / 178 TL310 02_Introduction_us.fm - V 0.1 - 4.5.11

02_Introduction_us.fm - V 0.1 - 4.5.11 TL310 9 / 178

2.7 Product Identifikation Number (PIN) plate

Fig. 2-1 Type label

10 / 178 TL310 02_Introduction_us.fm - V 0.1 - 4.5.11

3.1 General safety notes

3.1.2 Hazard Classification

WARNING indicates a potentially hazardous

CAUTION indicates a potentially hazardous

NOTICE indicates a potentially hazardous

03_Safety_us.fm - V 0.1 - 4.5.11 TL310 11 / 178

3.1.3 Descriptions of hazard pictorials

Warning of explosion / burn hazard

Warning of injection hazard

Warning of burn hazard

Warning of entanglement hazard

Warning of entanglement hazard

Warning of crush hazard

Warning of crush hazard

Warning of crush hazard

12 / 178 TL310 03_Safety_us.fm - V 0.1 - 4.5.11

3.2 Location of safety signs

Frame - engine hood Guard

Fig. 3-1 Locations of safety signs

03_Safety_us.fm - V 0.1 - 4.5.11 TL310 13 / 178

Servicing and replacing safety signs

Symbols/ Description Symbols/ Description

Battery charge Parking brake

Coolant Travel direction

Engine oil Air filter