mecalac AS 1600 Bedienungsanleitung
AS 1600
Swing loader
FIN: Valid from W09S15001GBA08812...
Service manual
Status: 28.04.2016
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AS 1600 Service manual 28.04.2016 23133693 0 SERIES GB
Product Swing loader AS 1600
FIN as from W09S15001GBA08812
Publisher MECALAC Baumaschinen GmbH
Am Friedrichsbrunnen 2
D-24782 Büdelsdorf
Tel: +49 (0)4331 351 325
Fax: +49 (0)4331 351 491
E-Mail: [email protected]
www: www.mecalac.com
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 .
Subject to change without notice.
Foreword This service manual contains all the information and instructions required for the
correct execution of service tasks required for the wheel loader. Read this service
manual before commencing the tasks and always keep it to hand for reference.
Validity This Service manual applies together with the operator´s manual of the Swing loader
AS 1600.
Suggestions and
comments ...regarding this documentation or the wheel loader can be sent to the above-
mentioned address.
Most recent amend-
ment 28.04.2016
Contents
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1 Notes for the Reader............................................................................................................. 5
1.1 Validity ........................................................................................................................ 5
1.2 Illustrations ................................................................................................................. 5
1.3 Accentuated text......................................................................................................... 5
1.3.1 Pictograms ............................................................................................... 5
1.3.2 Safety Note............................................................................................... 6
1.3.3 Safety instructions .................................................................................... 6
1.3.4 Warning notes .......................................................................................... 7
1.3.5 Guideline .................................................................................................. 7
2 Description ............................................................................................................................ 9
2.1 Parts of the wheel loader............................................................................................ 9
2.2 Front section............................................................................................................. 10
2.2.1 Overview ................................................................................................ 10
2.2.2 Hydraulic hoses...................................................................................... 10
2.3 Cab - interior............................................................................................................. 11
2.3.1 Multi-function panel ................................................................................ 11
2.3.2 Display.................................................................................................... 11
2.3.3 Central electrical system ........................................................................ 19
2.3.4 Diagnostic unit........................................................................................ 20
2.3.5 Error messages ...................................................................................... 20
3 Service tasks....................................................................................................................... 23
3.1 Checks ..................................................................................................................... 23
3.1.1 Checking the front axle oil level.............................................................. 23
3.1.2 Checking the rear axle oil level .............................................................. 26
3.1.3 Checking the planetary gear oil level ..................................................... 29
3.1.4 Checking the transfer case oil level........................................................ 31
3.1.5 Checking the electrical functions and connections................................. 35
3.1.6 Checking the hydraulic hoses ................................................................ 35
3.2 Repair work .............................................................................................................. 36
3.2.1 Changing a wheel................................................................................... 36
3.2.2 Changing the air-conditioner V-belt........................................................ 40
3.2.3 Changing the alternator/water pump V-belt ........................................... 47
3.2.4 Changing the fuel pre-filter ..................................................................... 55
3.2.5 Changing the fuel filter ........................................................................... 58
3.2.6 Changing the hydraulic fluid filter ........................................................... 60
3.2.7 Changing the engine oil filter.................................................................. 64
3.2.8 Changing the air filter ............................................................................. 66
3.3 Changing the consumables ...................................................................................... 71
3.3.1 Changing the engine oil.......................................................................... 71
3.3.2 Changing the gearbox oil of the front axle.............................................. 74
3.3.3 Changing the gearbox oil of the rear axle .............................................. 79
3.3.4 Changing the gearbox oil of the planetary gear ..................................... 84
3.3.5 Changing the gearbox oil of the reduction gear ..................................... 87
3.3.6 Topping up the hydraulic fluid ................................................................ 90
3.3.7 Refilling with diesel fuel .......................................................................... 91
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AS 1600 Service manual 28.04.2016 23133693 0 SERIES GB
3.4 Lubrication ................................................................................................................93
3.4.1 Lubrication plan ...................................................................................... 93
3.4.2 Lubrication points - front and rear axles .................................................93
3.4.3 Lubrication points - interior of engine compartment ...............................94
3.4.4 Lubricating the turntable chain ..............................................................94
3.4.5 Return ....................................................................................................96
3.4.6 Support valve .........................................................................................96
4 Circuit diagrams..................................................................................................................97
5 Annex ...................................................................................................................................99
5.1 Spare Parts ..............................................................................................................99
5.1.1 Filter .......................................................................................................99
5.1.2 Consumables .......................................................................................101
5.2 Deutz error messages ............................................................................................101
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AS 1600 Service manual 28.04.2016 23133693 0 SERIES GB
Accentuated text
Notes for the Reader
1 Notes for the Reader
In this chapter you will find information regarding the use of the Service manual:
•Validity (Page 5)
•Illustrations (Page 5)
•Accentuated text (Page 5)
1.1 Validity
This service manual contains information and codes of behaviour for service tasks on
the Swing loader AS 1600. Read this service manual carefully before the first service.
Always use the service manual when performing service tasks. Store the service
manual at a central point and to hand for the responsible technical personnel. In
accordance with current usage in the industry, the term wheel loader is used in this
service manual.
This Service manual applies togther with the operator´s manual of the Swing loader AS
1600. This service manual applies to technical personnel.
1.2 Illustrations
The illustrations in this service manual show the wheel loader in partially simplified
form.
1.3 Accentuated text
In this service manual, important information is highlighted by symbols or special
formatting. The following examples illustrate the most important types of highlighting.
1.3.1 Pictograms
Pictograms used
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.
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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:
1. First step of a safety instruction
!Important note regarding a safety instruction
2. 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.
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AS 1600 Service manual 28.04.2016 23133693 0 SERIES GB
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.
Failure to observe the warning can cause serious damage to health, or even death.
The arrow identifies a precautionary measure you have to take to avoid the hazard.
CAUTION
Warning: Injuries.
Failure to observe the warning can result in serious damage to health.
The arrow identifies a precautionary measure you have to take to avoid the hazard.
NOTICE
Warning: Damage to property.
Ignoring the warning instructions can result in serious damage to the wheel loader or in
its surroundings
The arrow identifies a precautionary measure you have to take to avoid the hazard.
1.3.5 Guideline
Carry out the following steps: = Start of a set of instructions.
1. First step in a sequence of operations.
Required settings . . . . . . . . Setting values
2. Second step in a sequence of operations.
The result of this step.
The operation is complete, the goal has been achieved.
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AS 1600 Service manual 28.04.2016 23133693 0 SERIES GB
Accentuated text
Notes for the Reader
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AS 1600 Service manual 28.04.2016 23133693 0 SERIES GB
Parts of the wheel loader
Description
2 Description
In this chapter you will find additional information regarding the parts of the wheel
loader that are not described in the operator´s manual.
•Parts of the wheel loader (Page 9)
•Front section (Page 10)
•Cab - interior (Page 11)
2.1 Parts of the wheel loader
Overview - Parts of the wheel loader
Key
No. Designation Function
1 Front section See Chapter "Front section" (Page 10).
2Cab - interior See Chapter "Cab - interior" (Page 11).
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AS 1600 Service manual 28.04.2016 23133693 0 SERIES GB
Front section
Description
2.2 Front section
2.2.1 Overview
Overview - Front section | Hydraulic hoses
2.2.2 Hydraulic hoses
Hydraulic lines must be checked within the framework of the service intervals. Detailed
instructions in this regard are to be found in BGR 237.
A recommendation as to the replacement intervals has been compiled on the basis of
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.
Key
No. Designation Function
1Hydraulic hoses See section "Hydraulic hoses" (Page 10).
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:
•Increased time in use; for example
multi-shift operation or brief cycle times
of the machine or pressure impulses
•Severe external and internal influences
(via the medium) that markedly reduce
the period of use of the hydraulic hose.
•manually-operated hydraulic tools, for
example portable shears in scrap
yards.
2 years (operating life)
Dieses Handbuch passt für folgende Modelle
1
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