mecalac AS Series User manual

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

2
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 0 SERIES GB
Product Serie AS / AF / AT / AS tele
FIN Chassis number AS700 T3A: as from Chassis number W09S70001BBA08778
Chassis number AS700 T3B: as from Chassis number W09S70101FBA08810
Chassis number AS900 T3A: as from Chassis number W09S90001BBA08778
Chassis number AS900 T3B: as from Chassis number W09S90101FBA08810
Chassis number AF1050 T3A: as from Chassis number W09F10501ABA08779
Chassis number AF1050 T3B: as from Chassis number - no details at present
Chassis number AF1200 T3A: as from Chassis number W09F12001ABA08779
Chassis number AF1200 T3B: as from Chassis number - no details at present
Chassis number AT900 T3A: as from Chassis number W09FT0901DBA08799
Chassis number AT900 T3B: as from Chassis number - no details at present
Chassis number AT1050 T3A: as from Chassis number W09FT1001DBA08799
Chassis number AT1050 T3B: as from Chassis number - no details at present
Chassis number AS900tele T3A: as from Chassis number W09ST0801CBA08792
Chassis number AS900tele T3B: as from Chassis number W09ST0901CBA08808
Publisher MECALAC Baumaschinen GmbH
Am Friedrichsbrunnen 2
D-24782 Büdelsdorf
Tel: [phone]
Fax: [phone]
E-Mail: [e-mail]
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 only in conjunction with the operating manual, to the Serie
AS / AF / AT / AS tele.
Suggestions and
comments ...regarding this documentation or the wheel loader can be sent to the above-
mentioned address.

3
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 0 SERIES GB
Most recent amend-
ment 14.10.2015

Contents
4
1 Notes for the Reader............................................................................................................. 6
1.1 Validity ........................................................................................................................ 6
1.2 Illustrations ................................................................................................................. 6
1.3 Accentuated text......................................................................................................... 6
1.3.1 Pictograms ............................................................................................... 6
1.3.2 Safety Note............................................................................................... 7
1.3.3 Safety instructions .................................................................................... 7
1.3.4 Warning notes .......................................................................................... 8
1.3.5 Guideline .................................................................................................. 8
2 Description ............................................................................................................................ 9
2.1 Front section - overview ............................................................................................. 9
2.2 Cab - interior............................................................................................................. 10
2.2.1 Multi-function panel ................................................................................ 10
2.2.2 Display.................................................................................................... 10
2.2.3 Central electrical system ........................................................................ 13
2.3 Diagnostic unit .......................................................................................................... 15
2.3.1 Overview ................................................................................................ 15
2.3.2 Error messages ...................................................................................... 16
3 Service tasks ....................................................................................................................... 17
3.1 Checks ..................................................................................................................... 17
3.1.1 Checking the front axle oil level.............................................................. 17
3.1.2 Checking the rear axle oil level .............................................................. 20
3.1.3 Checking the planetary gear oil level ..................................................... 22
3.1.4 Checking the transfer case oil level........................................................ 25
3.1.5 Checking the electrical functions and connections................................. 29
3.1.6 Hydraulic hoses...................................................................................... 29
3.1.7 Disc brakes - checking the pad thickness .............................................. 31
3.1.8 Inspecting the wearing rails ................................................................... 34
3.2 Repair work .............................................................................................................. 36
3.2.1 Changing a wheel................................................................................... 36
3.2.2 Changing the V-belt................................................................................ 39
3.2.3 Changing the fuel pre-filter ..................................................................... 52
3.2.4 Changing the fuel filter ........................................................................... 59
3.2.5 Changing the fresh air filter .................................................................... 64
3.2.6 Changing the hydraulic fluid filter ........................................................... 68
3.2.7 Changing the engine oil filter.................................................................. 72
3.2.8 Changing the air filter ............................................................................. 76
3.3 Changing the consumables ...................................................................................... 81
3.3.1 Changing the engine oil.......................................................................... 81
3.3.2 Changing the gearbox oil of the front axle.............................................. 86
3.3.3 Changing the gearbox oil of the rear axle .............................................. 90
3.3.4 Changing the gearbox oil of the planetary gear ..................................... 93
3.3.5 Changing the gearbox oil of the transfer box ......................................... 96
3.3.6 Refilling with diesel fuel ........................................................................ 103
3.3.7 Changing the hydraulic fluid ................................................................. 105
3.4 Lubrication .............................................................................................................. 108
3.4.1 Lubrication plan .................................................................................... 108
3.4.2 Lubricating the turntable chain ............................................................ 109
3.4.3 Oiling the check valve .......................................................................... 111

5
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 0 SERIES GB
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

6
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 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 6)
•Illustrations (Page 6)
•Accentuated text (Page 6)
1.1 Validity
This service manual contains information and rules of conduct for service work on the
Serie AS / AF / AT / AS tele. 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 Serie AS / AF / AT / AS tele.
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.

7
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 0 SERIES GB
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.

8
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 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.

9
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 0 SERIES GB
Front section - overview
Description
2 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)
•Diagnostic unit (Page 15)
2.1 Front section - overview
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 the hydraulic hoses" (Page 30).
Overview - Front section | Hydraulic hoses and valves
Key
No. Designation Function
1Hydraulic hose See Chapter "Hydraulic hoses" (Page 29).
2Solenoid valve Serves to control the lifting unit suspension.
3Switch Tests the pressure of the nitrogen accumulator.
The solenoid valve is shut in the event of over-
pressure.
4Bottom end of lifting
cylinder
Responsible for the control of the lifting unit
suspension.
5Nitrogen accumulator Provides suspension for the hydraulic system.

10
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 0 SERIES GB
Cab - interior
Description
2.2 Cab - interior
2.2.1 Multi-function panel
Multi-function panel
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. The actual meaning of the
error messages is described in Chapter "Error messages" (Page 16) . 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 10).

11
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 0 SERIES GB
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

12
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 0 SERIES GB
Cab - interior
Description
Display – Engine messages

13
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 0 SERIES GB
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.
Furthermore, communication of the control signals has been optimised by the imple-
mentation of a CAN bus system between the control units in the vehicle.
2.2.3.1 Diagnosis interface - engine control system
Location - diagnosis interface - engine control system
The diagnostic unit is connected to the engine control system diagnosis interface.
Further information regarding the diagnostic unit can be found in Section: Diagnostic
unit (Page 15).
Diagnosis interface - engine control system

14
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 0 SERIES GB
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.
Location of the control systems

15
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 0 SERIES GB
Diagnostic unit
Description
2.3 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. 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 system diagnosis interface allows various diagnostic units to be
used.
Diagnostic unit

16
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 0 SERIES GB
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. 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 117: Annex).

17
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 0 SERIES GB
Checks
Service tasks
3 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)
3.1 Checks
3.1.1 Checking the front axle oil level
Location of the bolts on the front axle
Key
No. Designation
1Axle vent valve
2Inspection and filler plug
3Drain plug

18
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 0 SERIES GB
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:
Ratchet with 1/2“ extension
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.

19
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 0 SERIES GB
Checks
Service tasks
2. Using a ratchet and extension, unscrew both inspection and filler plugs.
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. Using a ratchet and extension, tighten the inspection and filler plugs.
7. Dispose of the gearbox oil that has been collected, according to the local statutory
provisions,
Done.

20
Serie AS / AF / AT / AS tele Service manual 14.10.2015 23133561 0 SERIES GB
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.
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 rear axle.
The oil drip tray prevents the gearbox oil from penetrating the subsoil.