mecalac AS Series Service Manual
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mecalac AS Series Service Manual

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Serie AS / AF / AT / AS tele
Serie AS / AF / AT / AS tele
Service manual
Status: 14.10.2015

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  • Page 1 Serie AS / AF / AT / AS tele Serie AS / AF / AT / AS tele Service manual Status: 14.10.2015...
  • Page 2 This document is protected by copyright. All rights reserved. The document may not, in whole or in part, be copied, reproduced, translated or reduced to an electronic medium of machine-readable form without the express permission of MECALAC Baumaschinen GmbH .
  • Page 3 14.10.2015 Most recent amend- ment Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...

  • Page 4: Table Of Contents

    Contents 1 Notes for the Reader......................6 1.1 Validity ........................1.2 Illustrations ......................... 1.3 Accentuated text......................1.3.1 Pictograms ....................1.3.2 Safety Note....................1.3.3 Safety instructions ..................1.3.4 Warning notes ..................1.3.5 Guideline ....................2 Description ..........................9 2.1 Front section - overview ..................... 2.2 Cab - interior......................
  • Page 5 4 Circuit diagrams........................115 5 Annex ..........................117 5.1 Spare Parts ......................117 5.1.1 Filter .....................117 5.1.2 Consumables ..................120 5.2 Deutz error messages ....................120 Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...

  • Page 6: Notes For The Reader

    Accentuated text Notes for the Reader Notes for the Reader In this chapter you will find information regarding the use of the Service manual: • Validity (Page 6) • Illustrations (Page 6) • Accentuated text (Page 6) Validity This service manual contains information and rules of conduct for service work on the Serie AS / AF / AT / AS tele.

  • Page 7: Safety Note

    Accentuated text Notes for the Reader 1.3.2 Safety Note Safety instruction: Special note for an informatory section Explanation of the note. • The dot identifies measures that relate to the note. 1.3.3 Safety instructions Safety Instruction To ensure the safe implementation, ensure compliance with the following steps: First step of a safety instruction Important note regarding a safety instruction Second step of a safety instruction.

  • Page 8: Warning Notes

    Accentuated text Notes for the Reader 1.3.4 Warning notes DANGER Warning of injuries leading to fatality Failure to observe the safety instruction will result in serious damage to health, including death.  The arrow identifies a precautionary measure you have to take to avoid the hazard. WARNING Warning: Serious Injuries.

  • Page 9: Description

    Front section - overview Description Description In this chapter you will find additional information regarding the parts of the wheel loader that are not described in the operating manual. • Front section - overview (Page 9) • Cab - interior (Page 10) •...

  • Page 10: Cab - Interior

    Cab - interior Description Cab - interior 2.2.1 Multi-function panel Multi-function panel Designation Function Display See Chapter "Display" (Page 10). 2.2.2 Display 2.2.2.1 Overview The functioning of the display has been enhanced. In the new component, CAN bus messages are displayed in addition to the familiar operating parameters. As a rule, these are error messages from the vehicle control system.
  • Page 11 Cab - interior Description 2.2.2.2 Settings in the display The following flowchart shows how the various display modes and settings are imple- mented directly in the component. The operation of the display is described in the operating manual. Display – settings Serie AS / AF / AT / AS tele ...
  • Page 12 Cab - interior Description Display – Engine messages Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...

  • Page 13: Central Electrical System

    Cab - interior Description 2.2.3 Central electrical system With the implementation of the required emission directives of the Tier standard, a new generation of vehicle control system has been introduced in this product segment. Electronic control of the power unit that is taken for granted in today's automotive industry in order to achieve the required emission values, has been enhanced in this stage of development to include electronic control of the hydraulic movement function.
  • Page 14 Cab - interior Description 2.2.3.2 Location of the control unit The control unit is located below the glove box on the left-hand side of the wheel loader. The interior of the glove box must be removed in order to gain access to the control unit.

  • Page 15: Diagnostic Unit

    Diagnostic unit Description Diagnostic unit 2.3.1 Overview The diagnostic unit serves as a reader to read and display engine and vehicle data from the CANbus system. In addition, stored error messages can be read and reset. The list of the error messages are to be found in Section Error messages (Page 16). Active errors are displayed in the display.

  • Page 16: Error Messages

    Diagnostic unit Description 2.3.2 Error messages The messages from the controller are shown on the display. By using this information and a standard multimeter, the causes of the error can be identified and the function of the electrical components can be checked with on-board resources. Errors from the engine control system are based on the mandatory SAE j1939 protocol.

  • Page 17: Service Tasks

    Checks Service tasks Service tasks In this chapter you will find information regarding service tasks for technical personnel: • Checks (Page 17) • Repair work (Page 36) • Changing the consumables (Page 81) • Lubrication (Page 108) Checks 3.1.1 Checking the front axle oil level Location of the bolts on the front axle No.
  • Page 18 Checks Service tasks Requirement  The wheel loader is warmed up.  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The parking brake is applied.  The ignition key has been removed. ...
  • Page 19 Checks Service tasks Using a ratchet and extension, unscrew both inspection and filler plugs. Catch any escaping gearbox oil in the oil drip tray immediately. Check the oil level of the front axle. The oil level must reach precisely below the lower edge of the inspection port . If required, top up with fresh gearbox oil up to the lower edge of the inspection port Using a ratchet and extension, tighten the inspection and filler plugs.

  • Page 20: Checking The Rear Axle Oil Level

    Checks Service tasks 3.1.2 Checking the rear axle oil level Requirement  The wheel loader is warmed up.  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The parking brake is applied. ...
  • Page 21 Checks Service tasks Using a square socket wrench unscrew the inspection and oil filler plug. Catch any escaping gearbox oil in the oil drip tray immediately. Check the oil level of the rear axle. The oil level must reach precisely below the lower edge of the inspection port . If required, top up with fresh gearbox oil up to the lower edge of the inspection port Using a square socket wrench tighten inspection and oil filler plug.

  • Page 22: Checking The Planetary Gear Oil Level

    Checks Service tasks 3.1.3 Checking the planetary gear oil level Requirement  The wheel loader is warmed up.  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The parking brake is applied. ...
  • Page 23 Checks Service tasks Move the wheel loader so that the fill level line of the planetary gear is Oil Level horizontal. Place an oil drip tray in the tyre rim.  The oil drip tray prevents the gearbox oil from penetrating the subsoil. Using a ratchet and extension, tighten the inspection and filler plugs.
  • Page 24 Checks Service tasks Check the oil level of the planetary gear. The oil level must reach precisely below the lower edge of the inspection port . If required, top up with fresh gearbox oil up to the lower edge of the inspection port Using a ratchet and extension, tighten the inspection and filler plug.

  • Page 25: Checking The Transfer Case Oil Level

    Checks Service tasks 3.1.4 Checking the transfer case oil level There are fast and slow runners - each with different transfer cases. 3.1.4.1 Checking the oil level of the fast runner transfer case Location of the bolts on the transfer case No.
  • Page 26 Checks Service tasks Requirement  The wheel loader is warmed up.  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The parking brake is applied.  The ignition key has been removed. Tools required: ...
  • Page 27 Checks Service tasks Catch any escaping gearbox oil in the oil drip tray immediately. Check the oil level of the transfer case. The oil level must reach precisely below the lower edge of the inspection port . If required, top up with fresh gearbox oil up to the lower edge of the inspection port Using a ratchet and extension, tighten the inspection and filler plug.
  • Page 28 Checks Service tasks Requirement  The wheel loader is warmed up.  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The parking brake is applied.  The ignition key has been removed. Tools required: ...

  • Page 29: Checking The Electrical Functions And Connections

    Checks Service tasks Catch any escaping gearbox oil in the oil drip tray immediately. Check the oil level of the transfer case. The oil level must reach precisely below the lower edge of the inspection port . If required, top up with fresh gearbox oil up to the lower edge of the inspection port Using a ratchet and extension, tighten the inspection and filler plug.
  • Page 30 Checks Service tasks Description of the replacement intervals of the hydraulic hoses Demands on the hydraulic hose Recommended replacement interval Normal use 6 years (operating life, including a maximum of 2 years' storage) Enhanced demands: 2 years (operating life) Increased time in use; for example •...

  • Page 31: Disc Brakes - Checking The Pad Thickness

    Checks Service tasks 3.1.7 Disc brakes - checking the pad thickness Location of the bolts on the front axle No. Designation Front axle inspection and filler plug Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...
  • Page 32 Checks Service tasks Requirement  The wheel loader is warmed up.  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The parking brake is applied.  The ignition key has been removed. ...
  • Page 33 Checks Service tasks Using a ratchet and extension, unscrew the inspection and filler plugs. Catch any escaping gearbox oil in the oil drip tray immediately. Using a feeler gauge or test-pin (check gauge 4,08mm). check the distance between the two thrust plates at both inspection ports. ...

  • Page 34: Inspecting The Wearing Rails

    Checks Service tasks 3.1.8 Inspecting the wearing rails The wearing rails are only installed on a telescopic loader. The wearing rails may not be worn down so far that the lug bolts rub on the boom. The state of wear must there- fore be checked regularly.
  • Page 35 Checks Service tasks Requirement  The wheel loader is standing on a horizontal surface.  The parking brake is applied.  The wheel loader is switched off.  The parking brake is applied.  The ignition key has been removed. Tools required: ...

  • Page 36: Repair Work

    Repair work Service tasks Repair work 3.2.1 Changing a wheel Requirement  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The parking brake is applied.  The direction of travel toggle switch must be in the neutral position. ...
  • Page 37 Repair work Service tasks Carry out the following steps: Using the wheel-brace loosen all eight wheel nuts by approximately half a turn. Position a suitable base beneath the jack below the jacking points of the axle of the wheel to be changed. Place the safety blocks centrally on the upper end of the jack.
  • Page 38 Repair work Service tasks Using the jack lift up the wheel loader. The wheel must be lifted approximately one centimetre off the ground.  The wheel has been lifted. Using the wheel-brace remove all eight wheel nuts. With two persons, carefully lift the wheel off the axle . The wheel has been dismounted.

  • Page 39: Changing The V-Belt

    Repair work Service tasks Tighten all eight wheel nuts to 500 Nm . For fastening, use a suitable torque wrench. The wheel has been mounted.  Done. Info After approximately ten hours of operation, re-tighten the wheel nuts of the wheel that has been changed.
  • Page 40 Repair work Service tasks Requirement  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The diesel engine must be cold.  The parking brake is applied.  The ignition key has been removed. Tools required: ...
  • Page 41 Repair work Service tasks Turn the ‹ › of the ‹V- › to one side with the aid of a ratchet and TENSION PULLEY BELT a short extension.  The ‹V- › is loosened. BELT Secure the ‹ › with a suitable mandrel. TENSION PULLEY Slide the mandrel into the opening provided so that the ‹...
  • Page 42 Repair work Service tasks Remove the ‹V- ›. BELT Install the new ‹V- ›. BELT Carefully withdraw the mandrel.  Carefully allow the ‹ › to swing back slowly. TENSION PULLEY  The ‹V- › is tensioned. BELT Press the guard plate into the four retaining points. ...
  • Page 43 Repair work Service tasks 3.2.2.2 Changing V-belts - Cummins engine Location of the v-belt Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...
  • Page 44 Repair work Service tasks Requirement  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The diesel engine must be cold.  The parking brake is applied.  The ignition key has been removed. Tools required: ...
  • Page 45 Repair work Service tasks Carefully withdraw the ‹ › from the ‹ › . INDICATOR CHASSIS Separate the electrical ‹ › of the ‹ ›. PLUG CONNECTION INDICATOR The indicator is dismounted. Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...
  • Page 46 Repair work Service tasks Removing the Carry out the following steps: protective cover of the V-belt Loosen the three mounting bolts of the protective cover of the V-belt. Using a ratchet, loosen the three mounting bolts of the protective cover. ...
  • Page 47 Repair work Service tasks Change the V-belt Carry out the following steps: Loosen the set screws on the ‹ › of the ‹V- ›. TENSIONING DEVICE BELT Push the ‹ › in the direction of the ‹ ›. ALTERNATOR ENGINE ...
  • Page 48 Repair work Service tasks Tension the V-belt with the aid of the tensioning device. The sag of the longest straight length of the V-belt may, under light thumb-pres- sure, reach a maximum of millimetres. five eight Re-tighten the screw on the ‹ ›...
  • Page 49 Repair work Service tasks Install the protec- Carry out the following steps: tive cover Insert the three mounting bolts of the protective cover from outside into the mounting holes. Place the protective cover onto the three bolts. Tighten the three bolts of the protective cover by using a ratchet. When tightening, counter the respective bolts with the Allen key, The protective cover has been installed.
  • Page 50 Repair work Service tasks Re-installing the Carry out the following steps: indicator Reconnect the electrical plug connection of the ‹ › to the wheel loader. INDICATOR  The electrical supply to the indicator is reconnected. Carefully insert the ‹ › into the ‹ ›.
  • Page 51 Repair work Service tasks Using the ratchet tighten both mounting bolts for the indicator in the interior of the engine compartment. The indicator has been re-installed.  Done. Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...

  • Page 52: Changing The Fuel Pre-Filter

    Repair work Service tasks 3.2.3 Changing the fuel pre-filter There are various models that can be described as follows: 3.2.3.1 Changing the fuel pre-filter –Deutz engine Requirement  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off. ...
  • Page 53 Repair work Service tasks Carry out the following steps: Carefully detach the connection cable for the ‹ › . WATER LEVEL SENSOR Place the strap of the strap wrench around the ‹ ›. FUEL PRE FILTER Loosen the ‹ › with the aid of the strap wrench. FUEL PRE FILTER Carefully pull the ‹...
  • Page 54 Repair work Service tasks Unscrew the water separator valve from the ‹ › . FUEL PRE FILTER Secure the ‹ › onto the new ‹ ›. WATER SEPARATOR VALVE FUEL PRE FILTER Slide the ‹ › back into the mounting. FUEL PRE FILTER Install the connection cable for the ‹...
  • Page 55 Repair work Service tasks 3.2.3.2 Changing the fuel pre-filter – Cummins engine Requirement  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The diesel engine must be cold.  The parking brake is applied. ...
  • Page 56 Repair work Service tasks Carry out the following steps: Carefully unscrew the banjo bolt from the ‹ › . FUEL FILTER Using a suitable screwdriver, unscrew the ‹ › located in the ‹ FUEL PRE FILTER BANJO › . BOLT Clean it using a ‹...
  • Page 57 Repair work Service tasks Repeat the last two steps for the other end of the ‹ ›. FUEL PRE FILTER Carefully pull the ‹ › from both the hose ends. FUEL PRE FILTER The fuel pre-filter has been removed. Installing the fuel Carry out the following steps: pre-filter Connect the new ‹...
  • Page 58 Repair work Service tasks Using the vice-grip pliers push the opened hose clamp back onto the ‹ FUEL PRE › . FILTER Repeat the last two steps for the other end of the ‹ ›. FUEL PRE FILTER Remove the cloth from the interior of the engine compartment. Dispose of the captured diesel fuel and the dirty cloth according to the locally ap- plicable provisions.

  • Page 59: Changing The Fuel Filter

    Repair work Service tasks 3.2.4 Changing the fuel filter There are various models that can be described as follows: 3.2.4.1 Changing the fuel filter - Deutz engine Requirement  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off. ...
  • Page 60 Repair work Service tasks Carry out the following steps: Place the strap of the strap wrench around the ‹ ›. FUEL FILTER Loosen the ‹ › with the aid of the strap wrench. FUEL FILTER Carefully pull the ‹ › from both the hose ends . FUEL PRE FILTER Screw the new ‹...
  • Page 61 Repair work Service tasks 3.2.4.2 Changing the fuel filter - Cummins engine Requirement  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The diesel engine must be cold.  The parking brake is applied. ...
  • Page 62 Repair work Service tasks Loosen the ‹ › with the aid of the strap wrench. FUEL FILTER Carefully pull the ‹ › from both the hose ends . FUEL PRE FILTER Unscrew the ‹ › from the ‹ › . WATER SEPARATOR VALVE FUEL FILTER The fuel filter has been removed.
  • Page 63 Repair work Service tasks Install the new fuel Carry out the following steps: filter Screw the new ‹ › onto the ‹ ›. FUEL FILTER WATER SEPARATOR VALVE Screw the new ‹ › onto the mounting. FUEL FILTER Operate the ‹ ›...

  • Page 64: Changing The Fresh Air Filter

    Repair work Service tasks 3.2.5 Changing the fresh air filter The installation and removal of the fresh air filter is the same throughout the Serie AS / AF / AT / AS tele . In the case of the AS700, the process of changing is different. Both versions are described in this chapter.
  • Page 65 Repair work Service tasks Using the Allen key unscrew the two mounting screws on the left- and right-hand sides of the ‹ › cover. FRESH AIR FILTER Lift off the cover of the ‹ › . FRESH AIR FILTER Carefully withdraw the old ‹ ›...
  • Page 66 Repair work Service tasks Replace the protective pad on the floor of the ‹ ›  Done. 3.2.5.2 Changing the fresh air filter - AS700 Requirement  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off. ...
  • Page 67 Repair work Service tasks Install the new fresh air filter.V-belt. Carefully lift the driver's seat together with the base plate into the cab. Using the wrench, fasten the four mounting bolts of the driver's seat baseplate.  Done. Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...

  • Page 68: Changing The Hydraulic Fluid Filter

    Repair work Service tasks 3.2.6 Changing the hydraulic fluid filter Requirement  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The diesel engine must be cold.  The parking brake is applied. ...
  • Page 69 Repair work Service tasks  The oil-absorbent mat protect the interior of the engine bay from contamination. Hold a suitable oil drip tray beneath the ‹ ›. OIL DRAIN PLUG Using an Allen key, unscrew the ‹ › from the ‹ OIL DRAIN PLUG HYDRAULIC FLUID ›...
  • Page 70 Repair work Service tasks Using the open-end spanner loosen the lid of the ‹ ›. HYDRAULIC FLUID RESERVOIR Unscrew the lid by hand. Withdraw the ‹ › by the handle . HYDRAULIC FLUID FILTER Allow the surplus hydraulic fluid to run into the ‹ ›...
  • Page 71 Repair work Service tasks Place the ‹ › in the oil drip tray. HYDRAULIC FLUID FILTER The oil drip tray must be held by a second person. The hydraulic fluid filter is dismounted. Install the Carry out the following steps: hydraulic fluid filter Insert the new ‹...

  • Page 72: Changing The Engine Oil Filter

    Repair work Service tasks Dispose of the gearbox oil that has been collected, according to the local statutory provisions, The hydraulic fluid filter is installed.  Done. 3.2.7 Changing the engine oil filter There are various models that can be described as follows: 3.2.7.1 Changing the engine oil filter - Deutz engine Requirement...
  • Page 73 Repair work Service tasks Place the strap of the strap wrench around the engine oil filter. Loosen the engine oil filter with the aid of the strap wrench. Carefully pull the engine oil filter from the mounting . The engine oil filter has been removed. Install the new Carry out the following steps: engine oil filter...
  • Page 74 Repair work Service tasks 3.2.7.2 Changing the engine oil filter - Cummins engine Requirement  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The diesel engine must be cold.  The parking brake is applied. ...
  • Page 75 Repair work Service tasks Loosen the ‹ › with the aid of the strap wrench. ENGINE OIL FILTER Carefully pull the ‹ › from both the hose ends . ENGINE OIL FILTER The engine oil filter has been removed. Install the new Carry out the following steps: engine oil filter Coat the surfaces of the new ‹...

  • Page 76: Changing The Air Filter

    Repair work Service tasks 3.2.8 Changing the air filter Requirement  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The diesel engine must be cold.  The engine hood of the wheel loader is open. ...
  • Page 77 Repair work Service tasks Remove the filter cartridge. Loosen the filter cartridge with gentle rotating movements left and right. The air filter cartridge has been dismounted. Exchanging the Carry out the following steps: safety cartridge. Remove the safety cartridge. Loosen the safety cartridge with gentle rotating movements left and right. Serie AS / AF / AT / AS tele ...
  • Page 78 Repair work Service tasks Check the interior of the filter housing for dust and dirt. If necessary, carefully clean the interior of the filter housing with a cloth. Slide the new safety cartridge carefully into the filter housing. The safety cartridge has been exchanged. Serie AS / AF / AT / AS tele ...
  • Page 79 Repair work Service tasks Re-install the air Carry out the following steps: filter cartridge Slide the inspected filter cartridge back into the holder. Re-install the lid. When remounting the lid, take care that the TOP marking faces upwards Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...
  • Page 80 Repair work Service tasks Secure the three locking mechanisms of the lid. The air filter cartridge has been installed.  Done. Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...

  • Page 81: Changing The Consumables

    Changing the consumables Service tasks Changing the consumables 3.3.1 Changing the engine oil There are various models that can be described as follows: 3.3.1.1 Changing the engine oil - Deutz engine Requirement  The wheel loader is standing on a horizontal surface. ...
  • Page 82 Changing the consumables Service tasks  Alternatively, the laser pre-cut plate can be pushed inwards and a Bochum plug can be installed on the oil drain plug in the resulting hole. Carefully remove the sump guard. Place an oil collection container beneath the sump. Unscrew the protective cap of the oil drain plug.
  • Page 83 Changing the consumables Service tasks Performing the Carry out the following steps: check Switch on the diesel engine. Allow the diesel engine to idle for a short while. Switch off the diesel engine. Inspect the sump and the oil drain plug for leaks. Remove the oil collection container.
  • Page 84 Changing the consumables Service tasks 3.3.1.2 Changing the engine oil - Cummins engine Requirement  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The ignition key has been removed.  The engine must be warm. Tools required: ...
  • Page 85 Changing the consumables Service tasks  The engine oil begins draining. Wait until the engine oil has drained completely. Screw the ‹ › into the ‹ › completely. OIL DRAIN BOLT SUMP Using a cloth clean any places that may have been contaminated with oil on the ‹...

  • Page 86: Changing The Gearbox Oil Of The Front Axle

    Changing the consumables Service tasks Performing the Carry out the following steps: check Switch on the diesel engine. Allow the diesel engine to idle for a short while. Switch off the diesel engine. Inspect the sump and the oil drain plug for leaks. Remove the oil collection container.
  • Page 87 Changing the consumables Service tasks Requirement  The wheel loader is warmed up.  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The parking brake is applied.  The ignition key has been removed. ...
  • Page 88 Changing the consumables Service tasks Using a ratchet and extension, unscrew the oil drain plug.  The gearbox oil drains immediately. Wait until the gearbox oil has drained completely. Using a ratchet and extension, unscrew the oil drain plug. The gearbox oil has been drained. Refilling the Carry out the following steps: gearbox oil...
  • Page 89 Changing the consumables Service tasks Refill with fresh gearbox oil up to the lower edge of both inspection ports.  Check the level at both inspection ports. Using a ratchet and extension, tighten both the inspection and filler plugs. Dispose of the gearbox oil that has been collected, according to the local statutory provisions, The gearbox oil has been refilled.

  • Page 90: Changing The Gearbox Oil Of The Rear Axle

    Changing the consumables Service tasks 3.3.3 Changing the gearbox oil of the rear axle Requirement  The wheel loader is warmed up.  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The parking brake is applied.
  • Page 91 Changing the consumables Service tasks Using a square socket wrench remove the drain plug.  The gearbox oil drains immediately. Wait until the gearbox oil has drained completely. Using a square socket wrench re-install the drain plug in the rear axle. The gearbox oil has been drained.
  • Page 92 Changing the consumables Service tasks Refill with fresh gearbox oil up to the lower edge of the inspection port . Using a square socket wrench tighten the inspection and oil filler plug. Dispose of the gearbox oil that has been collected, according to the local statutory provisions, The gearbox oil has been refilled.

  • Page 93: Changing The Gearbox Oil Of The Planetary Gear

    Changing the consumables Service tasks 3.3.4 Changing the gearbox oil of the planetary gear Requirement  The wheel loader is warmed up.  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The parking brake is applied.
  • Page 94 Changing the consumables Service tasks Place an oil drip tray in the tyre rim.  The oil drip tray prevents the gearbox oil from penetrating the subsoil. Using a ratchet and extension, unscrew the inspection and filler plug.  The gearbox oil drains immediately. Wait until the gearbox oil has drained completely.
  • Page 95 Changing the consumables Service tasks Using a ratchet and extension, unscrew the inspection and filler plugs. Fill with fresh gearbox oil in the inspection port. The oil level must reach precisely below the lower edge of the inspection port . Using a ratchet and extension, tighten the inspection and filler plug.

  • Page 96: Changing The Gearbox Oil Of The Transfer Box

    Changing the consumables Service tasks 3.3.5 Changing the gearbox oil of the transfer box There are fast and slow runners - each with different transfer cases. 3.3.5.1 Changing the oil of the fast runner transfer case Location of the bolts on the transfer case No.
  • Page 97 Changing the consumables Service tasks Requirement  The wheel loader is warmed up.  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The parking brake is applied.  The ignition key has been removed. Tools required: ...
  • Page 98 Changing the consumables Service tasks Using a ratchet and extension, unscrew the oil drain plug.  The gearbox oil drains immediately. Wait until the gearbox oil has drained completely. Using a ratchet and extension, tighten the drain plug. The gearbox oil has been drained. Refilling the Carry out the following steps: gearbox oil...
  • Page 99 Changing the consumables Service tasks Dispose of the gearbox oil that has been collected, according to the local statutory provisions, The gearbox oil has been refilled.  Done. 3.3.5.2 Changing the oil of the slow runner transfer case Location of the bolts on the transfer case No.
  • Page 100 Changing the consumables Service tasks Requirement  The wheel loader is warmed up.  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The parking brake is applied.  The ignition key has been removed. Tools required: ...
  • Page 101 Changing the consumables Service tasks Using a ratchet and extension, unscrew the oil drain plug.  The gearbox oil drains immediately. Wait until the gearbox oil has drained completely. Using a ratchet and extension, tighten the drain plug. The gearbox oil has been drained. Refilling the Carry out the following steps: gearbox oil...
  • Page 102 Changing the consumables Service tasks Dispose of the gearbox oil that has been collected, according to the local statutory provisions, The gearbox oil has been refilled.  Done. Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...

  • Page 103: Refilling With Diesel Fuel

    Changing the consumables Service tasks 3.3.6 Refilling with diesel fuel There is no diesel tank drain plug in this series. Requirement  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The ignition key has been removed. ...
  • Page 104 Changing the consumables Service tasks Use a diesel fuel catchment receptacle of adequate capacity.  The diesel fuel collection container prevents the diesel fuel from penetrating the subsoil. Guide the scavenge pump into the diesel fuel filler nozzle. Operate the scavenge pump Wait until the diesel fuel oil has been pumped out completely.

  • Page 105: Changing The Hydraulic Fluid

    Changing the consumables Service tasks 3.3.7 Changing the hydraulic fluid Location of the hydraulic fluid reservoir. Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...
  • Page 106 Changing the consumables Service tasks Requirement  The wheel loader is standing on a horizontal surface.  The wheel loader is switched off.  The bucket arm is lowered.  If a bucket is mounted, this must be tilted.  The engine hood of the wheel loader is open.
  • Page 107 Changing the consumables Service tasks Unscrew the protective cap of the oil drain plug. Screw the oil drainage hose onto the oil drain plug.  The hydraulic fluid begins draining. Wait until the hydraulic fluid has drained completely. Unscrew the oil drainage hose from the oil drain plug. Screw the protective cap back onto the oil drain plug.

  • Page 108: Lubrication

    Lubrication Service tasks Using a suitable funnel pour the hydraulic fluid into the open hydraulic fluid filler nozzle. The sight glass must be at least half full with hydraulic fluid. Close the cap of the hydraulic fluid reservoir manually. Wipe off any spilled hydraulic fluid with a cloth . Dispose of the hydraulic fluid that has been collected, according to the local statu- tory provisions, The hydraulic fluid has been refilled.

  • Page 109: Lubricating The Turntable Chain

    Lubrication Service tasks 3.4.2 Lubricating the turntable chain A turntable chain is only installed on a swing loader. Requirement  The wheel loader is standing on a horizontal surface.  The parking brake is applied. Tools required:  A second person who operates the wheel loader. ...
  • Page 110 Lubrication Service tasks Slowly move the bucket arm completely to the right and to the left once. While moving, a second person smears the chain with a paintbrush.  The turntable chain has been lubricated. Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...

  • Page 111: Oiling The Check Valve

    Lubrication Service tasks 3.4.3 Oiling the check valve Requirement  The wheel loader is standing on a horizontal surface.  The parking brake is applied.  The wheel loader is switched off.  The bucket arm is raised.  The bucket arm support is installed. ...
  • Page 112 Lubrication Service tasks Carry out the following steps: Unscrew the four mounting screws of the protective cover. Loosen the hose from the protective cover with the aid of a screwdriver. Remove the protective cover. Check the interior for leaks. Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...
  • Page 113 Lubrication Service tasks Oil the check valve. Secure the hose to the protective cover. Refasten the four mounting screws of the protective cover.  The check valve has been oiled. Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...
  • Page 114 Lubrication Service tasks Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...

  • Page 115: Circuit Diagrams

    Circuit diagrams Circuit diagrams Circuit diagrams can be obtained from Mecalac on request. Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...
  • Page 116 Circuit diagrams Serie AS / AF / AT / AS tele  Service manual  14.10.2015  23133561  0  SERIES  GB...

  • Page 117: Annex

    Spare Parts Annex Annex Spare Parts 5.1.1 Filter Cummins engine filter – overview No. Designation Mecalac TKZ Filter set 23122185 Fuel pre-filter 23128661 Engine oil filter 23121921 Fuel filter 23121920 Safety cartridge 4198304A Air filter insert 4198305A O-ring 110,72x3,53 4185042A...
  • Page 118 Spare Parts Annex Deutz engine filter 500 operating hours – overview No. Designation Mecalac TKZ Filter set 23133440 Engine oil filter 23110650 Fuel filter 23133339 Air filter insert 4198305A Safety cartridge 4198304A Hydraulic fluid filter 23122182 O-ring 110,72x3,53 4185042A Seal ring A 18X 24 CU 7426631A Deutz engine filter 1000 operating hours –...
  • Page 119 Spare Parts Annex Key (Cont.) No. Designation Mecalac TKZ Engine oil filter 23110650 Fuel filter 23133339 Fuel pre-filter 23133338 Circular gasket 23124774 Air filter insert 4198305A Safety cartridge 4198304A Hydraulic fluid filter 23122182 O-ring 110,72x3,53 4185042A Seal ring A 18X 24 CU 7426631A Serie AS / AF / AT / AS tele ...

  • Page 120: Consumables

    Deutz error messages Annex 5.1.2 Consumables Slow-runner, Cummins engine, consumables Designation Quantity Mecalac TKZ Engine oil 23106886 Gearbox oil 23104578 Hydraulic fluid 23107305 Lubricating grease cartridge 4117807A Coolant 23129554 Fast runner, Cummins engine, consumables Designation Quantity Mecalac TKZ Engine oil...
  • Page 188 MECALAC Baumaschinen GmbH Am Friedrichsbrunnen 2 D-24782 Büdelsdorf Tel: +49 (0)4331 351 325 Fax: +49 (0)4331 351 491 E-Mail: info@mecalac.com Web: www.mecalac.com...

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