mecalac AS 1600 User manual

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: [phone]
Fax: [phone]
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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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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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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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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Accentuated text
Notes for the Reader

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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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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)

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Cab - interior
Description
2.3 Cab - interior
2.3.1 Multi-function panel
Multi-function panel
2.3.2 Display
2.3.2.1 Overview
The function of the display is expanded in the new AS 1600 series. In the new compo-
nent, CAN bus messages are displayed in addition to the familiar operating parame-
ters. As a rule, these are error messages from the vehicle control system. The actual
meaning of the error messages is described in Chapter “Error messages“. An error
message appears in the display for only as long as the cause remains active.
Key
No. Designation Function
1Display See Chapter "Display" (Page 11).

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Cab - interior
Description
2.3.2.2 Start
Display – Start
Key
No. Figure Description
1Engine speed control by M-Drive or accelerator.
2Rear window is activated.
3Unlocking of the quick-change device.
4Boom suspension is activated.
5A fault is present on the engine or wheel loader.

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Cab - interior
Description
Display – Main menu
Key
No. Description
1Proceeds to the SETTINGS – DISPLAY (See page 14: Settings - Display) sub-
menu.
2Proceeds to the ENGINE AND VEHICLE MESSAGES (See page 15: Engine and
vehicle messages) sub-menu.
3Proceeds to the INFORMATION (See page 16: Information) sub-menu.
4Proceeds to the SETTINGS – HYDRAULICS (See page 18: Settings - Hydrau-
lics) sub-menu.

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Cab - interior
Description
2.3.2.3 Settings - Display
Settings - Display

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Cab - interior
Description
2.3.2.4 Engine and vehicle messages
Engine and vehicle messages

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Cab - interior
Description
2.3.2.5 Information
Information

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Cab - interior
Description
Figures – Information
Figure Description Unit
Coolant temperature degrees Celsius [°C]
Engine oil pressure bar
Air filter differential pressure bar
Engine revolutions Revolutions per minute [rpm]
On-board voltage Volt [V]
Ash loading - diesel particulate filter Percent [%]
Fuel consumption Litres per hour [i/h

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Cab - interior
Description
2.3.2.6 Settings - Hydraulics
Settings - Hydraulics

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Cab - interior
Description
2.3.3 Central electrical system
With the implementation of the currently required emission directives, a new generation
of vehicle control system has been introduced in the AS 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 develop-
ment to include electronic control of the hydraulic movement function. Furthermore,
communication of the control signals has been optimised by the implementation of a
CAN bus system between the control units in the vehicle.
Diagnosis interface - Overview
Key
No. Designation Function
1Diagnosis interface -
engine control system
The diagnostic unit is connected to the engine
control system diagnosis interface. Further infor-
mation regarding the diagnostic unit can be found
in Section: "Diagnostic unit" (Page 20).
2Diagnosis interface -
vehicle control system
The diagnostic unit is connected to the vehicle
control system diagnosis interface. Further infor-
mation regarding the diagnostic unit can be found
in Section: "Diagnostic unit" (Page 20).

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Cab - interior
Description
2.3.4 Diagnostic unit
2.3.4.1 Overview
The stand-alone diagnostic unit (TKZ 23115585) 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 20).
Active errors are displayed in the display. In addition, this error is stored in the main
memory of the controller. The error memory is read and analysed within the framework
of the recurring service.
Once the error has been processed, the error memory is deleted (reset).
The engine control diagnosis interface and the vehicle control diagnosis interface
permit various diagnostic units to be used.
Diagnostic unit
2.3.5 Error messages
The controller messages that are shown in the display are listed in the following table.
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 tools avail-
able on the wheel-loader.
Errors from the engine control system are based on the mandatory SAE j1939
protocol. This is used internationally by various manufacturers.
The list of all messages from the "U05" engine controller are to be found in the annex
of this service manual (See page 99: Annex).
Messages from the vehicle control system are generated as "M-messages (Mecalac)".
As is the case with engine messages, they are shown in the display (only if active).