mecalac AS 50 User manual

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

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AS50 Service manual 26.10.2015 23133562 0 SERIES GB
Product SERIES AS50
FIN as from W09S45E01DBA08797
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 operating 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 togther with the operating manual of the Mecalac AS50.
Suggestions and
comments ...regarding this documentation or the wheel loader can be sent to the above-
mentioned address.
Most recent amend-
ment 26.10.2015

Contents
3
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 Front section............................................................................................................... 9
2.1.1 Overview ................................................................................................. 9
2.1.2 Extract ................................................................................................... 10
3 Service tasks ....................................................................................................................... 11
3.1 Checks ..................................................................................................................... 11
3.1.1 Checking the front axle oil level.............................................................. 11
3.1.2 Checking the rear axle oil level .............................................................. 14
3.1.3 Checking the planetary gear oil level ..................................................... 17
3.1.4 Checking the transfer case oil level........................................................ 19
3.1.5 Checking the electrical functions and connections................................. 21
3.1.6 Hydraulic hoses...................................................................................... 21
3.1.7 Disc brakes - checking the pad thickness .............................................. 23
3.1.8 Checking the parking brake.................................................................... 23
3.2 Repair work .............................................................................................................. 24
3.2.1 Changing a wheel................................................................................... 24
3.2.2 Changing the V-belt ............................................................................... 27
3.2.3 Changing the fuel filter .......................................................................... 32
3.2.4 Changing the fresh air filter .................................................................... 35
3.2.5 Changing the hydraulic fluid filter ........................................................... 37
3.2.6 Changing the engine oil filter.................................................................. 40
3.2.7 Changing the air filter ............................................................................. 42
3.2.8 Setting the parking brake ....................................................................... 46
3.2.9 Cleaning the radiator.............................................................................. 48
3.2.10 Cleaning the hydraulic fluid cooler ......................................................... 50
3.2.11 Setting the gas pedal (accelerator) ........................................................ 52
3.3 Changing the consumables ...................................................................................... 54
3.3.1 Changing the engine oil.......................................................................... 54
3.3.2 Changing the gearbox oil of the front axle.............................................. 56
3.3.3 Changing the gearbox oil of the rear axle .............................................. 60
3.3.4 Changing the gearbox oil of the planetary gear ..................................... 64
3.3.5 Changing the gearbox oil ...................................................................... 67
3.3.6 Refilling with diesel fuel .......................................................................... 71
3.3.7 Changing the hydraulic fluid ................................................................... 73
3.4 Lubrication ................................................................................................................ 75
3.4.1 Lubrication plan ...................................................................................... 75
3.4.2 Lubricating the turntable chain .............................................................. 76
3.4.3 Oiling the check valve ............................................................................ 78
4 Circuit diagrams.................................................................................................................. 81

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5 Annex ...................................................................................................................................83
5.1 Spare Parts ..............................................................................................................83
5.1.1 Filter .......................................................................................................83
5.1.2 Consumables .........................................................................................84

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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 rules of conduct for service work on the
AS50. 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, in conjunction with the operating manual, to the respec-
tive wheel loader of the AS50 SERIES.
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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Front section
Description
2 Description
2.1 Front section
The bucket arm and the valves required for the control of the hydraulic cylinders are
located on the front section. The valves are controlled hydraulically or electrically. Due
to the mechanical design of the wheel loader, the supply and control lines are
subjected to high mechanical loading. Care must be taken that the lines are always
fixed to the front and rear sections of the vehicle. The lines must be able to move freely
without touching other components between the attachment points.
All valves and hydraulic hoses must be checked for leaks at regular intervals, see
"Checking hydraulic hose lines" (page 31).
2.1.1 Overview
The valve block is located behind a protective plate.
Overview - Front section | Hydraulic hoses and valves
Key
No. Designation Function
1Hydraulic hose See Chapter "Hydraulic hoses" (Page 21).
2Bucket valve block Valves for control units for lifting, lowering, tipping
and dumping the bucket
3Extract See "Extract" (Page 10)

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Front section
Description
2.1.2 Extract
Overview - Front section | Hydraulic hoses and valves
Key
No. Designation Function
1Solenoid valve Serves to control the lifting unit suspension.
2Switch Tests the pressure of the nitrogen accumulator.
The solenoid valve is shut in the event of over-
pressure.
3Nitrogen accumulator Provides suspension for the hydraulic system.
4Solenoid valve Serves to control the lifting unit suspension.

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Checks
Service tasks
3 Service tasks
In this chapter you will find information regarding service tasks for technical personnel:
•Checks (Page 11)
•Repair work (Page 24)
•Changing the consumables (Page 54)
•Lubrication (Page 75)
3.1 Checks
3.1.1 Checking the front axle oil level
Location of the bolts on the front axle
Key
No. Designation
1Inspection and filler plug
2Axle vent valve
3Inspection and filler plug
4Drain plug

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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.
The bucket arm is raised.
The bucket arm support is installed.
Tools required:
Allen key, SW 12
a sufficiently large oil drip tray
Protective gloves
Suitable, fresh gearbox oil, if necessary
WARNING
Health hazard posed by gearbox oil!
The gearbox oil is hazardous to health. Frequent skin contact can be carcinogenic.
Avoid continuous skin contact with the gearbox oil.
Always wear gloves when carrying out this job.
NOTICE
Environmental hazard posed by gearbox oil!
The used gearbox oil of the wheel loader is hazardous to the environment!
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:
1. Place an oil drip tray beneath the front axle.
The oil drip tray prevents the gearbox oil from penetrating the subsoil.

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Checks
Service tasks
2. Unscrew the inspection and oil filler plug by means of an Allen key.
3. Catch any escaping gearbox oil in the oil drip tray immediately.
4. Check the oil level of the front axle.
!The oil level must reach precisely below the lower edge of the inspection port .
5. If required, top up with fresh gearbox oil up to the lower edge of the inspection port
.
6. Tighten the inspection and oil filler plug by using an Allen key.
7. Repeat steps one to six on the second inspection and oil filler plug, on the other
side of the axle.
8. Dispose of the gearbox oil that has been collected, according to the local statutory
provisions,
Done.

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Checks
Service tasks
3.1.2 Checking the rear axle oil level
Location of the bolts on the rear axle
Key
No. Designation
2Axle vent valve
1Inspection and filler plug
3Inspection and filler plug
4Drain plug

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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:
Allen key, SW 12
a sufficiently large oil drip tray
Protective gloves
Suitable, fresh gearbox oil, if necessary
WARNING
Health hazard posed by gearbox oil!
The gearbox oil is hazardous to health. Frequent skin contact can be carcinogenic.
Avoid continuous skin contact with the gearbox oil.
Always wear gloves when carrying out this job.
NOTICE
Environmental hazard posed by gearbox oil!
The used gearbox oil of the wheel loader is hazardous to the environment!
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:
1. Place an oil drip tray beneath the rear axle.
The oil drip tray prevents the gearbox oil from penetrating the subsoil.
2. Unscrew the inspection and oil filler plug by means of an Allen key.

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Checks
Service tasks
3. Catch any escaping gearbox oil in the oil drip tray immediately.
4. Check the oil level of the rear axle.
!The oil level must reach precisely below the lower edge of the inspection port .
5. If required, top up with fresh gearbox oil up to the lower edge of the inspection port
.
6. Using an Allen key, tighten the inspection and oil filler plug.
7. Repeat steps one to six on the second inspection and oil filler plug, on the other
side of the axle.
8. Dispose of the gearbox oil that has been collected, according to the local statutory
provisions,
Done.

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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.
The ignition key has been removed.
Tools required:
Allen key, SW 12
a sufficiently large oil drip tray
Protective gloves
Suitable, fresh gearbox oil, if necessary
WARNING
Health hazard posed by gearbox oil!
The gearbox oil is hazardous to health. Frequent skin contact can be carcinogenic.
Avoid continuous skin contact with the gearbox oil.
Always wear gloves when carrying out this job.
NOTICE
Environmental hazard posed by gearbox oil!
The used gearbox oil of the wheel loader is hazardous to the environment!
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:

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Checks
Service tasks
1. Move the wheel loader so that the Oil Level fill level line of the planetary gear is
horizontal.
2. Place an oil drip tray in the tyre rim.
The oil drip tray prevents the gearbox oil from penetrating the subsoil.
3. Unscrew the inspection and oil filler plug by means of an Allen key.
4. Catch any escaping gearbox oil in the oil drip tray immediately.

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Checks
Service tasks
5. Check the oil level of the planetary gear.
!The oil level must reach precisely below the lower edge of the inspection port .
6. If required, top up with fresh gearbox oil up to the lower edge of the inspection port
.
7. Using an Allen key, tighten the inspection and oil filler plug.
8. Dispose of the gearbox oil that has been collected, according to the local statutory
provisions,
Done.
3.1.4 Checking the transfer case oil level
Location of the bolts on the transfer case
Key
No. Designation
1Inspection and filler plug
2Inspection and filler plug
3Drain plug

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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:
Wrench SW 17
a sufficiently large oil drip tray
Protective gloves
Suitable, fresh gearbox oil, if necessary
WARNING
Health hazard posed by gearbox oil!
The gearbox oil is hazardous to health. Frequent skin contact can be carcinogenic.
Avoid continuous skin contact with the gearbox oil.
Always wear gloves when carrying out this job.
NOTICE
Environmental hazard posed by gearbox oil!
The used gearbox oil of the wheel loader is hazardous to the environment!
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:
1. Place an oil drip tray beneath the transfer case.
The oil drip tray prevents the gearbox oil from penetrating the subsoil.
2. Using a square socket wrench unscrew the inspection and oil filler plug.