mecalac AS50 Service Manual
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mecalac AS50 Service Manual

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AS50
FIN: Valid from W09S45E01DBA08797...
Service manual
Status: 26.10.2015

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Summary of Contents for mecalac AS50

  • Page 1 AS50 FIN: Valid from W09S45E01DBA08797... Service manual Status: 26.10.2015...
  • Page 2 This Service manual applies togther with the operating manual of the Mecalac AS50. Validity Suggestions and ...regarding this documentation or the wheel loader can be sent to the above- comments mentioned address. 26.10.2015 Most recent amend- ment AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 3: Table Of Contents

    Contents 1 Notes for the Reader......................5 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....................... 2.1.1 Overview ....................
  • Page 4 5 Annex ........................... 83 5.1 Spare Parts ......................83 5.1.1 Filter .......................83 5.1.2 Consumables ..................84 AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 5: Notes For The Reader

    Pictogram Meaning Further useful information. Conditions that must be fulfilled in order to perform an action Tools or material required in order to perform an action. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 6: Safety Note

    Second step of a safety instruction.  The result of this step.  The safety instruction is complete, the goal of the of a safety instruction has been achieved. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 7: Warning Notes

    Required settings ..Setting values Second step in a sequence of operations.  The result of this step.  The operation is complete, the goal has been achieved. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 8 Accentuated text Notes for the Reader AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 9: Description

    See Chapter "Hydraulic hoses" (Page 21). Bucket valve block Valves for control units for lifting, lowering, tipping and dumping the bucket Extract See "Extract" (Page 10) AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 10: Extract

    The solenoid valve is shut in the event of over- pressure. Nitrogen accumulator Provides suspension for the hydraulic system. Solenoid valve Serves to control the lifting unit suspension. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 11: Service Tasks

    Checking the front axle oil level Location of the bolts on the front axle No. Designation Inspection and filler plug Axle vent valve Inspection and filler plug Drain plug AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 12 Carry out the following steps: Place an oil drip tray beneath the front axle.  The oil drip tray prevents the gearbox oil from penetrating the subsoil. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 13 Dispose of the gearbox oil that has been collected, according to the local statutory provisions,  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 14: Checking The Rear Axle Oil Level

    Checking the rear axle oil level Location of the bolts on the rear axle No. Designation Axle vent valve Inspection and filler plug Inspection and filler plug Drain plug AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 15  The oil drip tray prevents the gearbox oil from penetrating the subsoil. Unscrew the inspection and oil filler plug by means of an Allen key. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 16 Dispose of the gearbox oil that has been collected, according to the local statutory provisions,  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 17: Checking The Planetary Gear Oil Level

    Dispose of the used gearbox oil according to the local statutory provisions,  Catch the draining gearbox oil in a suitable container.  Prevent the gearbox oil from entering the soil. Carry out the following steps: AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 18  The oil drip tray prevents the gearbox oil from penetrating the subsoil. Unscrew the inspection and oil filler plug by means of an Allen key. Catch any escaping gearbox oil in the oil drip tray immediately. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 19: Checking The Transfer Case Oil Level

    Checking the transfer case oil level Location of the bolts on the transfer case No. Designation Inspection and filler plug Inspection and filler plug Drain plug AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 20 Place an oil drip tray beneath the transfer case.  The oil drip tray prevents the gearbox oil from penetrating the subsoil. Using a square socket wrench unscrew the inspection and oil filler plug. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 21: Checking The Electrical Functions And Connections

    DIN 20066. Depending on the demands made on the hoses, the specified replacement intervals can be extended. The replacement interval remains the responsibility of the operator. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 22 Exchange damaged hydraulic hoses immediately.  Done. Info The recommended replacement intervals for the hydraulic hoses to be found in Chapter: “Service tasks“ > “Hydraulic hoses“ (Page 21). AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 23: Disc Brakes - Checking The Pad Thickness

     The parking brake tell-tale should light up at the 3rd detent of the ratchet. Adjust the parking brake if necessary (See page 46: Setting the parking brake).  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 24: Repair Work

    Always carry out a wheel change with two persons! Carry out the following steps: Using the wheel-brace loosen all eight wheel nuts by approximately half a turn. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 25 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. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 26 Screw in the eight wheel nuts on the wheel loader. Only fasten the wheel nuts finger-tight. Loosen the jack. Remove the jack, the base and the safety blocks. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 27: Changing The V-Belt

    Info After approximately ten hours of operation, re-tighten the wheel nuts of the wheel that has been changed. 3.2.2 Changing the V-belt Location of the v-belt AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 28  Always wear protective gloves!  Always work carefully! Carry out the following steps: Open the two locking mechanisms of the air filter lid. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 29 Remove the ‹V- ›. BELT The V-belt has been removed. Installing the V-belt Carry out the following steps: Put the new ‹V- › in place. BELT AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 30  The V-belt must be tensioned to the extent that it can only be twisted once through 90 degrees. Fasten the mounting bolts with the aid of a socket wrench. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 31 Repair work Service tasks Re-install the lid. The new V-belt has been installed.  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 32: Changing The Fuel Filter

    Place the strap of the strap wrench around the ‹ ›. FUEL FILTER Loosen the ‹ › with the aid of the strap wrench. FUEL FILTER AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 33 Operate the manual fuel pump (10 - 20 times) until you detect a marked resistance. Start the ‹ › DIESEL ENGINE Check the fuel filter for leaks while the diesel engine is running. The fuel pre-filter has been changed. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 34 › with the aid of a Torx key. FUEL SIEVE FILTER Operate the manual fuel pump. You must detect a marked resistance. The fuel sieve filter has been cleaned.  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 35: Changing The Fresh Air Filter

     The second person must hold the protective plate on the other side. Together, lift off the protective plate of the ‹ › . FRESH AIR FILTER AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 36 Using the wrench, refasten the two mounting screws on the left- and right-hand sides of the ‹ › protective plate. FRESH AIR FILTER Fasten the four protective caps of the screws.  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 37: Changing The Hydraulic Fluid Filter

    Prevent the hydraulic fluid from entering the soil. Carry out the following steps: Place an oil drip tray in the cab. Remove the rubber mat beneath the driver's seat. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 38 › into the ‹ › . HYDRAULIC FLUID FILTER HYDRAULIC FLUID RESERVOIR Screw the lid back onto the ‹ ›. HYDRAULIC FLUID RESERVOIR Tip the driver's seat back. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 39 The hydraulic fluid filter is installed.  Done. Info The clogging indicator can light up prematurely after a cold start. It does, however, go out as the hydraulic fluid warms up. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 40: Changing The Engine Oil Filter

     The oil drip tray prevents the engine oil from penetrating the subsoil or entering the interior of the engine bay. Place the strap of the strap wrench around the engine oil filter. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 41 Check the oil level of the engine. Dispose of the engine oil that has been collected according to the local statutory provisions. The new engine oil filter has been installed.  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 42: Changing The Air Filter

     A new safety cartridge Dismounting the Carry out the following steps: air filter cartridge Open the three locking mechanisms of the lid. Remove the lid. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 43 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. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 44 Slide the new safety cartridge carefully into the filter housing. The safety cartridge has been exchanged. Re-install the air Carry out the following steps: filter cartridge Slide the inspected filter cartridge back into the holder. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 45 When remounting the lid, take care that the TOP marking faces upwards Secure the three locking mechanisms of the lid. The air filter cartridge has been installed.  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 46: Setting The Parking Brake

    Slide the rubber sleeve up the handbrake lever. Unscrew the four mounting bolts with the aid of the wrench (SW 10). Pull out the handbrake lever with the linkage and Bowden cable. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 47 Slide the rubber sleeve back down. Perform a function check of the parking brake (See page 23: Checking the parking brake). The parking brake has been installed.  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 48: Cleaning The Radiator

    Loosen the two mounting bolts with the aid of a ratchet. Place the guard plate in a suitable location. Inspect the area behind the protective plate for leaks. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 49 Clean the radiator with the aid of a compressed air cleaner. Blow the dust from the top to the bottom. Fasten the protective plate with the two mounting bolts.  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 50: Cleaning The Hydraulic Fluid Cooler

    Protective gloves Carry out the following steps: Loosen the two mounting bolts with the aid of the Allen key. Place the protective plate in a suitable location. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 51 Clean the radiator with the aid of a compressed air cleaner. Blow the dust from the opening in the direction of the engine bay. Fasten the protective plate with the two mounting bolts.  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 52: Setting The Gas Pedal (Accelerator)

    Carry out the following steps: Loosen the lock nut on the set screw below the gas pedal by using a wrench (SW 13). The engine must be switched off. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 53 When the gas pedal is fully depressed, the accelerator lever in the engine bay must be at the limit. Tighten the lock nut with a wrench.  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 54: Changing The Consumables

    Prevent the engine oil from entering the soil. Carry out the following steps: Place an oil collection container beneath the sump. Unscrew the protective cap of the oil drain plug. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 55 Dispose of the engine oil that has been collected according to the local statutory provisions. Check the oil level using the dipstick. The check is complete.  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 56: Changing The Gearbox Oil Of The Front Axle

    Changing the gearbox oil of the front axle Location of the bolts on the front axle No. Designation Inspection and filler plug Axle vent valve Inspection and filler plug Drain plug AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 57 Carry out the following steps: Place an oil drip tray beneath the front axle.  The oil drip tray prevents the gearbox oil from penetrating the subsoil. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 58 The gearbox oil has been drained. Refilling the Carry out the following steps: gearbox oil Unscrew the two inspection and oil filler plugs by means of an Allen key. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 59 AXLE VENT VALVE If necessary, clean the axle vent valve . Inspect the rear axle and the oil drain bolt for leaks. The check is complete.  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 60: Changing The Gearbox Oil Of The Rear Axle

    Changing the gearbox oil of the rear axle Location of the bolts on the front axle No. Designation Axle vent valve Inspection and filler plug Inspection and filler plug Drain plug AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 61 Carry out the following steps: Place an oil drip tray beneath the rear axle.  The oil drip tray prevents the gearbox oil from penetrating the subsoil. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 62 The gearbox oil has been drained. Refilling the Carry out the following steps: gearbox oil Unscrew the inspection and oil filler plug by means of an Allen key. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 63 AXLE VENT VALVE If necessary, clean the axle vent valve . Inspect the rear axle and the oil drain bolt for leaks. The check is complete.  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 64: Changing The Gearbox Oil Of The Planetary Gear

    Carry out the following steps: Move the wheel loader so that the inspection and oil filler plug of the planetary gearbox is at the lowest position. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 65 Refilling the Carry out the following steps: gearbox oil Move the wheel loader so that the fill level line of the planetary gearbox OIL LEVEL is horizontal. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 66 Wipe off any escaping gearbox oil with a cloth . Dispose of the gearbox oil that has been collected, according to the local statutory provisions, The gearbox oil has been refilled.  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 67: Changing The Gearbox Oil

    Service tasks 3.3.5 Changing the gearbox oil Location of the bolts on the transfer case No. Designation Inspection and filler plug Inspection and filler plug Drain plug AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 68 Carry out the following steps: Place an oil drip tray beneath the transfer case.  The oil drip tray prevents the gearbox oil from penetrating the subsoil. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 69 The oil level must reach precisely below the lower edge of the inspection port . Using a square socket wrench tighten the inspection and oil filler plug. Remove the oil collection container. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 70 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. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 71: Refilling With Diesel Fuel

    Catch the draining diesel fuel in a suitable container. Prevent the diesel fuel from entering the soil.  Carry out the following steps: Using the ignition key, open the tank cap. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 72 Wipe off any spilled diesel fuel with a cloth . Dispose of the collected diesel fuel according to the local statutory provisions, The diesel fuel has been topped up.  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 73: Changing The Hydraulic Fluid

    Carry out the following steps: Place an hydraulic fluid drip tray beneath the hydraulic fluid drain plug.  The hydraulic fluid drip prevents the hydraulic fluid from penetrating the subsoil. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 74 HYDRAULIC FLUID FILLING NOZZLE Wipe off any spilled ‹ › with a ‹ › . HYDRAULIC FLUID CLOTH The hydraulic fluid has been topped up.  Done. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 75: Lubrication

    500 hours of opera- Turntable chain See "Lubricating the turntable tion chain" (Page 76) after 500 hours of opera- Support valve See "Oiling the check valve" tion (Page 78) AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 76: Lubricating The Turntable Chain

    Catch the draining lubricant in a suitable container.  Prevent the lubricant from entering the soil. Carry out the following steps: Lift the bucket arm Secure the bucket arm support. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 77 Slowly move the bucket arm completely to the right and to the left once. While moving, lubricate the chain by means of the brush. Install the protective plate.  The turntable chain has been lubricated. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 78: Oiling The Check Valve

    Catch the draining maintenance oil in a suitable container.  Prevent the maintenance oil from entering the soil. Carry out the following steps: Check the areas for leaks. Oil the check valve. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 79 Lubrication Service tasks  The check valve has been oiled. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 80 Lubrication Service tasks AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...

  • Page 81: Circuit Diagrams

    Circuit diagrams Circuit diagrams Circuit diagrams can be obtained from Mecalac on request. AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 82 Circuit diagrams AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 83 Filter set 4180710A Engine oil filter 4109834A Fuel filter 4195730A Fuel pre-filter 4110672A Air filter insert 4108914A Safety cartridge 4108913A Hydraulic fluid filter 4104787A O-ring 4197692A AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 84 Spare Parts Annex 5.1.2 Consumables Designation Quantity Mecalac TKZ Engine oil 23106886 Gearbox oil 23104578 Hydraulic fluid 23107305 Lubricating grease cartridge 4117807A AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 85 Spare Parts Annex AS50  Service manual  26.10.2015  23133562  0  SERIES  GB...
  • Page 86 MECALAC Baumaschinen GmbH Am Friedrichsbrunnen 2 D-24782 Büdelsdorf Tel: +49 (0)4331 351 325 Fax: +49 (0)4331 351 491 E-Mail: Web: www.mecalac.com...

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