mecalac AS 150e Guide

Maintenance

7.1 12.2 12.1 11.2 12.1 8.1/8.2/8.3/8.4
3.1/3.2/3.3/3.4/5.1/11.1 6.1 6.2 5.2 10.1 4.1/4.2 5.2 6.1 6.2 2.1/2.2/2.3/2.4/5.1/11.1
1.1/1.2/1.3/1.4/1.5
12.1
GB
Maintenance Points
1
Engine
1.1 Maintenance according to manufacturers specs 1.2 Dry air filter unit: Check service display
Change filter element if display shows red
1.3 Check and clean fuel filter 1.4 Check coolant fill-level 1.5 Check and clean combined cooling unit 2
Rear axle
2.1 Check oil fill-level of transmission unit (inspection screw) 2.2 Oil change transmission unit 2.3 Check oil fill-level of helical planetary gearing (inspection screw) 2.4
Oil change helical planetary gearing
3
Front axle
3.1 Check oil fill-level of transmission unit (inspection screw) 3.2 Oil change transmission unit 3.3 Check oil fill-level of helical planetary gearing (inspection screw) 3.4 Oil change helical planetary gearing 4Transfer Case 4.1 Check oil fill-level of transfer case (inspection screw) 4.2 Oil change transfer case 5
Axles / Articulated Shafts
5.1 Check tightness of axles (500 Nm) 5.2 Check tightness of articulated shafts (65 Nm) 6
Wheels and Tyres
6.1 Check air pressure 6.2 Check tightness of wheel bolts (550 Nm) 7
Swivel Joint
7.1 Check tightness (610 Nm) 8
Hydraulic Unit
8.1 Change suction return line filter insert, check electr. display 8.2 Check oil fill-level (inspection glass) 8.3 Oil change 8.4 Check and clean hydraulic oil cooler 9
Greasing points (marked in red)
10
Battery
10.1 Visual check 11
Brakes
11.1
Perform visual and functional check of brakes and parking brakes before starting work
11.2 Check accumulator valve 12
Lighting unit / Air filter / Air conditioning unit
12.1 Perform functional check before starting work 12.2 Check air filter 12.3 Visual check
air conditioning unit
12.4 Check condensator for contamination 12.5 Check tension of compressor drive belt
Item Name Specification Viscosity Quantity
1Engine Oil MIL-L-2104 C = API-CD SAE 15 W 40 = 10 l with Oil filter
2.2
Transm. Oil with LS Add.
MIL-L-2105 B = API-GL5-6-LS SAE 85 W 90-LS = 12,8 l
2.4
Transm. Oil with LS Add.
MIL-L-2105 B = API-GL5-6-LS SAE 85 W 90-LS = 2 x 1,9 l
3.2
Transm. Oil with LS Add.
MIL-L-2105 B = API-GL5-6-LS SAE 85 W 90-LS = 15,0 l
3.4
Transm. Oil with LS Add.
MIL-L-2105 B = API-GL5-6-LS SAE 85 W 90-LS = 2 x 1,9 l
4.2 Transmission OIl
General Motors ATF Typ DEXRON II
ATF 22 SAE 75 W = 4,7 l (upper oil compartment)
= 3,9 l (lower oil compartment)
8.3 Hydraulic Oil (4.) DIN 51524 - HVLP 46 ISO VG 46, VI > 180 = 160 l
9Grease DIN 51825 - KPF 1/2 N-20 as required
10 Distilled water as required 12 Coolant R 134 a 850 g ± 50 g
Lubrication Points (marked in red) 1. Grease bolts with DIN 51825 - KPF 1/2 N-20
every 10 hours.
2. Grease friction points as required and after
cleaning with DIN 51825 - KPF 1/2 N-20.
Oil Lubrication Points 3. Oil joints and bell cranks every 50 working
hours with engine oil MIL-L-2104 C
Biodegradable Hydraulic Oil 4. Synthetic ester based hydraulic oil viscosity
class ISO VG 46 VI > 180
Intervals in working hours
max. permissible intervals, can be shorter dep. on use
* *
*
*
*
* *
10
100
500
750
1500
Pos.
Legend First oil or filter change or cleaning First service interval, repair any failures noted Service, repair any failures noted Change or cleaning these marks, filling or service points are mandatory: Refer to manual Attention Observe accident prevention measures when performing servicing tasks!
*
AS150e
23116882
a
8-1
S160/S161/S165/Z162
8Maintenance plan AS 150e

S160/S161/S165/Z162 8-3
Maintenance 8
8Maintenance
Figures and descriptions may vary due to modifications in
the construction that become possible and necessary to
improve the loader and to develop it further technically.
These modifications are summarised in section 13.
8.1 Notes regarding maintenance
DANGER
-The engine must be turned off.
-For work to be carried out under the bucket
arm:
-the bucket must be emptied or the
attachment must be relieved,
-the bucket arm must be mechanically
propped up [e.g. by inserting the bucket
arm support (option) (1-2/arrow)],
-the ball block valves for the working and
auxiliary hydraulics (1-2/1 and 1-2/2) must
be closed,
-the swivel mechanism is to be blocked
(1-4/arrow).
-The loader must be secured against rolling by
applying the parking brake (4-7/4) and by
setting the drive direction switch (4-7/3) to
position “0“. In addition, wheel chocks must
be placed on both sides of one of the two
wheels of the front axle.
CAUTION
-Change the oil when the units are lukewarm.
-Perform maintenance work when the loader is
on level ground and the bucket arm is in its
lowest position.
-Replace damaged filter inserts and gaskets
immediately.
-Clean pressure lubrication nipples before
lubricating.
NOTE
-For the maintenance work required, refer to
the maintenance plan (page 8-1).
-Damage which is traceable to non-observance
of the maintenance plan is not covered by the
guarantee.
-The lubricants listed in the maintenance plan
can be used at ambient temperatures ranging
from -15° C to +40° C.
CAUTION
For ambient temperatures below 15° C, refer to
the description in chapter 5.2.2 “Winter operation”.

S160/S161/S165/Z1628-4
8Maintenance
8.2 Maintenance work
8.2.1 Engine oil level check
See the operating instructions for the engine.
8.2.2 Oil level check for axles
8.2.2.1 Rear axle
(1) Unscrew the plugs from the axle arch (8-1/arrow) or
(8-2/arrow).
NOTE
-The oil level must reach the plug bores.
If necessary, top up oil.
-Collect any oil that escapes.
(2) Screw in the plug again.
8.2.2.2 Planetary gear
(1) Move the loader until the marking line ”OIL LEVEL” is
horizontal and the plug is located above the top left of the
marking line (8-3/arrow).
(2) Unscrew the plug.
NOTE
-The oil level must reach the plug bore.
If necessary, top up oil.
-Collect any oil that escapes.
(3) Fit a new gasket and screw the plug back in.
Figure 8-1
Figure 8-3
Figure 8-2

S160/S161/S165/Z162 8-5
Maintenance 8
1
2
3
4
8.2.2.3Front axle
(1) Unscrew the plugs from the axle arch (8-4/arrow) or
(8-5/arrow).
NOTE
-The oil level must reach the plug bore.
If necessary, top up oil.
-Collect any oil that escapes.
(2) Screw in the plug again.
8.2.3 Oil level check (distribution
gear)
8.2.3.1 Oil level check (distribution gear)
Type 1:
(1) Remove the foot mat in the footwell of the operator’s
cabin.
(2) Dismantle the floor plate under the foot mat.
(3) Check the oil level using the check marking of the oil
dipstick(8-6/1) for the upper oil compartment (coupling
space).
(4) Unscrew the plug (8-6/4) from the lower oil compart-
ment (spur gear space).
NOTE
-The loader must have been standing still for
at least 15 minutes before you can check the
oil level.
-The transmission housing temperature must
be at least 60 °C (warm up if necessary).
-The oil level must reach the plug bore (8-6/4).
-If necessary, fill oil into oil filling screw 8-6/2
(upper oil compartment) or 8-6/3 (lower oil
compartment) until the oil reaches the required
level.
The filling bore of the upper oil compartment is
accessible when you have loosened the union
nut of the ventilation hose and pushed the hose
aside.
-Collect any oil that escapes.
(5) Fit a new gasket and screw the plug back in.
Figure 8-4
Figure 8-6
Figure 8-5
Top view Front view

S160/S161/S165/Z1628-6
8Maintenance
1
2
Figure 8-9
Figure 8-8
Figure 8-7
Top view Front view
8.2.3.2 Oil level check distribution gear
Type 2:
(1) Open battery and tool compartment on the left side of
the loader.
(2) Move the bucket arm all the way to the left or right and
remove the front cover plate below the driver’s cabin in the
swivel unit area.
(3) Unscrew check plug (8-7/arrow) and sealing plug
(8-8/arrow) from the upper oil compartment (clutch
compartment).
(4) Unscrew the plug (8-9/1 and 8-9/2) from the lower oil
compartment (spur gear compartment).
NOTE
-The loader must have been standing still for at
least 15 minutes before you can check the oil
level.
-The transmission housing temperature must
be at least 60 °C (warm up if necessary).
-The oil level must reach the check hole (8-7/
arrow) of the upper oil compartment or the
sealing plug hole (8-9/2) of the lower oil
compartment.
-If necessary, fill oil into oil filling hole 8-8/arrow
(upper oil compartment) or 8-9/1 (lower oil
compartment) until the oil reaches the required
level.
-Collect any oil that escapes.
(5) Screw check plug (8-7/arrow) and sealing plugs
(8-8/arrow, 8-9/1 and 8-9/2) back in with new sealing
washers.

S160/S161/S165/Z162 8-7
Maintenance 8
8.2.4 Oil level check of the hydraulic oil
reservoir
(1) Park the loader in a level position.
(2) Move the bucket to its lowest position.
(3) Tilt the quick-change device and move out the locking
bolts using the hand lever for the auxiliary hydraulics
(4-6/5).
(4) Open the motor hood.
(5) Check the oil level in the view glass (8-10/arrow).
NOTE
-The oil level must be visible in the upper
quarter of the view glass.
-If necessary, top up hydraulic oil via the filler
neck (8-11/arrow). Use the special tool (flat
open-ended spanner) to undo the lid of the
hydraulic oil tank.
8.2.5 Oil change, engine
(1) Unscrew the maintenance flap from the motor protec-
tion (8-12/arrow).
(2) Place a sufficiently large oil drain pan underneath the
axle.
(3) Open the motor hood.
(4) Unscrew the cover of the oil drain plug on the motor.
(5) Screw the drainage nozzle with hose from the tool box
(4-1/13) to the oil drain plug.
(6) Remove the cover cap from the hose.
(7) Further procedures are to be found in the Engine
Operating Manual.
Figure 8-11
Figure 8-10
Figure 8-12

S160/S161/S165/Z1628-8
8Maintenance
1 2 3 4
8.2.6 Oil change, axles
8.2.6.1 Rear axle
(1) Place a sufficiently large oil drain pan underneath.
(2) Unscrew the plugs from the axle arch (8-13/1,
8-13/2, 8-13/3, 8-13/4 and 8-14/arrow) and drain the oil.
CAUTION
Waste oil must be disposed of in such a way that
it will not cause pollution!
(3) Replace the plugs for the axle arch (8-13/1, 8-13/2 and
8-13/3).
(4) Fill oil into the plug bore of the axle arch (8-13/4 or
8-14/arrow) until the oil level reaches the opening.
NOTE
-Details regarding the amount of oil required
are given in the maintenance plan (page 8-1).
-After a few minutes, when the oil level has
lowered, top up the oil until the oil level
reaches the marked level and remains stable.
-The vent valve of the axle (8-15/arrow) must be
free from dirt.
(5) Screw in the plugs of the axle arch (8-13/4 and 8-14/
arrow) again.
Figure 8-14
Figure 8-13
Figure 8-15

S160/S161/S165/Z162 8-9
Maintenance 8
1 2 3 4
8.2.6.2Planetary gear
(1) Move the loader so that the plug (8-16/arrow) is
positioned at 6 o’clock.
(2) Place an oil drain vessel with a drain channel under-
neath the gear.
(3) Unscrew the drain plug and let the oil drain out.
CAUTION
Waste oil must be disposed of in such a way that
it will not cause pollution!
(4) Move the loader until the marking line ”OIL LEVEL” is
horizontal and the plug is located above the top left of the
marking line (8-17/arrow).
(5) Fill in oil via the plug bore until the oil level reaches the
opening.
(6) Use a new gasket when screwing the plug back in.
8.2.6.3 Front axle
(1) Place a sufficiently large oil drain pan underneath.
(2) Remove the plugs from the axle arch (8-18/1, 8-18/2,
8-18/3, 8-18/4 and 8-19/Pfeil) and drain the oil.
CAUTION
Waste oil must be disposed of in such a way that
it will not cause pollution!
(3) Screw the plugs (8-18/1, 8-18/2 and 8-18/3) back in.
Figure 8-17
Figure 8-16
Figure 8-18

S160/S161/S165/Z1628-10
8Maintenance
2
1
(4) Fill oil into the plug bore (8-18/4 or 8-19/arrow) until
the oil level reaches the opening.
NOTE
-Details regarding the amount of oil required
are given in the maintenance plan (page 8-1).
-After a few minutes, when the oil level has
lowered, top up the oil until the oil level
reaches the marked level and remains stable.
-The vent valve of the axle (8-20/arrow) must be
free from dirt.
(5) Screw the plugs (8-18/4 and 8-19/arrow) back in.
8.2.7 Oil change, distribution gear
8.2.7.1 Oil change, distribution gear
Type 1:
(1) Remove the foot mat in the footwell of the operator’s
cabin.
(2) Dismantle the floor plate under the foot mat.
(3) Place a sufficiently large oil drain pan with a drain
channel underneath.
(4) Unscrew the filling (8-21/1 and 8-21/2) and drain
plugs(8-22/2) andlet oildrain fromthe upperoil compartment
through the drain channel.
Figure 8-20
Figure 8-19
Figure 8-21
Top view

S160/S161/S165/Z162 8-11
Maintenance 8
1
3
2
2
3
4
1
Figure 8-22
(5) Unscrew the drain (8-22/3) and inspection plugs
(8-22/4) and drain the oil from the lower oil compartment.
CAUTION
Waste oil must be disposed of in such a way that
it will not cause pollution!
(6) Screw the plugs (8-22/2 and 8-22/3) back in with new
gaskets.
(7) Fill in oil through the filling plug bore of the upper oil
compartment (8-21/1) until the oil reaches the mark on the
dipstick (8-22/1).
(8) Fill in oil through the filling plug bore of the lower oil
compartment (8-21/2) until the oil reaches the lower edge
of the oil inspection bore (8-22/4).
NOTE
-The transmission housing temperature must
be at least 60 °C (warm up if necessary).
-Details regarding the amount of oil required
are given in the maintenance plan (page 8-1).
-When the oil level has lowered – not earlier than
after 15 minutes - top up the oil until the oil
reaches the marked level and remains stable.
(9) Screw the filling (8-21/1 and 8-21/2) and inspection
plugs (8-22/4) back in with new gaskets.
8.2.7.2 Oil change distribution gear
Type 2:
(1) Open battery and tool compartment on the left side of
the loader.
(2) Move the bucket arm all the way to the left or right and
remove the front cover plate below the driver’s cabin in the
swivel unit area.
(3) Place a sufficiently large oil drain pan with a drain
channel underneath.
(4) Unscrew check plug (8-7/arrow), filling plug (8-8/arrow)
and drain plug (8-24/1) of the upper oil compartment
(clutch compartment) and let the oil drain off via a drain
channel.
(5) Unscrew check plug (8-24/3), filling plug (8-23/arrow)
and drain plug (8-24/2) of the lower oil compartment (spur
gear compartment) and let the oil drain off via a drain
channel.
CAUTION
Waste oil must be disposed of in such a way that
it will not cause pollution!
(6) Screw the plugs (8-24/1 and 8-24/2) back in with new
gaskets.
(7) Fill in oil through the filling of the upper oil compartment
(8-8/arrow) until the oil reaches the lower edge of the oil
check hole (8-7/arrow).
(8) Fill in oil through the filling plug bore of the lower oil
compartment (8-23/arrow) until the oil reaches the lower
edge of the oil inspection bore (8-24/3).
Figure 8-23
Figure 8-24
Rear view Front view
Top view
Rear view Front view

S160/S161/S165/Z1628-12
8Maintenance
Figure 8-25
Figure 8-26
Figure 8-27
NOTE
-The transmission housing temperature must
be at least 60 °C (warm up if necessary).
-Details regarding the amount of oil required
are given in the maintenance plan (page 8-1).
-When the oil level has lowered – not earlier
than after 15 minutes - top up the oil until the
oil reaches the marked level.
(9) Screw filling plug (8-8/arrow) and check plug (8-7/
arrow) of the upper oil compartment back in with new
sealing washers.
(10) Screw filling plug (8-23/arrow) and check plug
(8-24/3) of the lower oil compartment back in with new
sealing washers.
(11) Move the loader for a short period of time (approx. 10
to 15 minutes) and then check the oil level (see chapter
8.2.3).
8.2.8 Oil change, hydraulic system
(1) Open the motor hood.
(2) Have an oil drain pan ready (for the minimum size,
refer to section 11.11).
(3) Unscrew the covering flap of the oil drain plug (8-25/
arrow).
(4) Screw the drainage nozzle with hose from the tool box
(4-1/13) to the oil drain plug.
(5) Remove the cover cap from the hose.
(6) Drain the oil into the oil vessel.
CAUTION
Waste oil must be disposed of in such a way that
it will not cause pollution!
(7) Fit the cover cap on the hose and unscrew the
drainage nozzle with the hose.
(8) Screw the covering plate onto the oil drain plug.
(9) Change the hydraulic oil filter cartridge (section
8.2.9).
(10) Fill oil into the filler neck (8-26/arrow).
CAUTION
For loaders which are fitted to run with
biodegradable hydraulic oil (ester-based synthetic
hydraulic oil of viscosity class ISO VG 46 VI
> 180) - (designation can be found on the
hydraulic oil reservoir and on the dashboard),
only this type of oil may be used for oil changes.
Mineral and biodegradable hydraulic oils must
never be mixed!
Biodegradable hydraulic oil must be changed
every 1000 operating hours.
Changing the oil type from mineral oil to
biodegradable oil must be performed according
to the VDMA 24 569 conversion guidelines.
(11) Check the oil level at the sight glass (8-27/arrow).

S160/S161/S165/Z162 8-13
Maintenance 8
2
3
4
1
2
1
1
3
Figure 8-28
NOTE
-The bucket arm must be in the lowest position.
-The quick-change device must be tipped and
the locking bolts extended with the hand lever
for the auxiliary hydraulics (4-6/5).
-The oil level must be visible in the upper
quarter of the view glass.
(12) Close the filler neck with the special tool (flat open-
ended spanner).
8.2.9 Replacing the suction return flow filter
cartridge
CAUTION
Replace the filter insert according to the
maintenance plan or when the clogging indicator
lamp (4-10/13) lights up.
NOTE
The clogging indicator may light up prematurely
after a cold start. It will go out when the hydraulic
oil warms up.
(1) Unscrew the maintenance plate (8-28/arrow).
(2) Undo the hose clamp on the rubber bellows (8-29/3)
and pull of the bellows.
(3) Loosen but do not unscrew both screws of the
hydraulic oil filter lid (8-29/1).
(4) Lift out the hydraulic oil filter lid with the magnetic tube
(8-30/2).
(5) Swing up the handle (8-30/3), pull out the filter
cartridge (8-30/4) and replace it with a new one.
CAUTION
The used hydraulic oil filter cartridge must be
disposed of in such a way that it does not cause
pollution.
(6) Use a clean cloth to wipe the magnet tube (8-30/2)
before fitting it back in.
(7) Refit the hydraulic oil filter lid with magnet tube and
fasten it again.
(8) Connect the ventilation hose to the ventilation valve
(8-29/2 or 8-30/1).
(9) Start the engine.
(10) Have an oil drain pan ready and open the ventilation
valve.
NOTE
Keep the ventilation valve open until there are no
more bubbles in the escaping oil.
(11) Close the ventilation valve.
(12) Push the rubber bellows (8-29/3) on the air filter hose
and fasten it with the hose clamp.
(13) Screw the maintenance plate (8-28/arrow) back on.
Figure 8-29
Figure 8-30

S160/S161/S165/Z1628-14
8Maintenance
11 2
Figure 8-31
8.2.10 Maintaining/replacing the air filter
NOTE
Maintenance of the filter cartridge is necessary
when either the red range is visible in the mainte-
nance indicator (8-31/arrow) or after 12 months,
whichever is sooner.
(1) Open the motor hood.
(2) Unscrew the two upper wing nuts on the maintenance
grille (8-32/arrows). Push the grille outward at the upper
section and lift it out.
(3) Loosen the two retaining clamps of the air filter lid
(8-33/1) and remove the air filter lid.
(4) Pull out the filter cartridge (8-33/2) by carefully turning
it back and forth.
(5) Clean the filter cartridge.
CAUTION
-Forcleaning, use a compressed airgun to which
a pipe (angled at 90°) has been attached. The
pipe must be sufficiently long to reach the
bottom of the cartridge. Use dry compressed air
of no more than 5 bar to blow out the car
tridge by moving the pipe back and forth in the
interior of the cartridge. Cleaning can be
stopped when dust formation ceases.
-Do not use petrol or hot liquids for cleaning.
(6) Use a hand-held lamp to check the cartridge paper
and the rubber gasket of the filter cartridge for damage.
If the cartridge or the gasket is damaged, replace the
cartridge.
(7) Carefully insert the filter cartridge.
(8) Install the air filter lid on the filter housing in such a way
that the direction arrow in the marking “OBEN-TOP” points
upwards. This ensures that the dust removal valve faces
downwards.
(9) When the indicator field becomes red (8-31/arrow),
push the reset button. The field becomes clear.
(10) Screw the maintenance plate (8-32/arrows) back on.
CAUTION
Checkall connection pipes and hoses of the air filter
system for damage before starting the engine.
Figure 8-32
Figure 8-33

S160/S161/S165/Z162 8-15
Maintenance 8
1
2
1 2 1
8.2.11 Replacing the safety cartridge
CAUTION
-The safety cartridge must not be cleaned.
-The safety cartridge must be replaced after
the filter cartridge has been maintained/
cleaned 5 times, but no later than after two
years.
-Make sure that no dirt or dust can enter the
filter housing during replacement of the safety
cartridge.
(1) Remove the filter cartridge (section 08/02/2010).
(2) Pierce the seal of the safety cartridge (8-34/arrow)
from the inside by using a screwdriver or similar tool and
pull up both strips.
(3) Hold the safety cartridge by both strips and pull it out
by carefully turning it back and forth. Replace the safety
cartridge and the filter cartridge by new ones.
(4) The remaining installation is performed as described
in section 8.2.10 (7)...(10).
8.2.12 Replacing the fuel filter
See the operating instructions for the engine.
8.2.13 Replacing the starter batteries
NOTE
-The starter batteries are maintenance-free
according to DIN 72311, section 7. They are
located on the left side of the cabin access
area.
-The batteries are to be kept clean and dry.
(1) Remove the main battery switch (8-35/2).
(2) Use a square spanner to open the maintenance flap.
(3) Unscrew both securing screws (size 19) (8-35/1) of
the battery drawer.
(4) Pull out the drawer with the batteries until it stops.
(5) Loosen and remove the fastening screws (size 17)
(8-36/1) of the battery holders.
(6) Loosen and remove the connecting cables (8-36/2)
from the batteries (size 13).
DANGER
Always remove the negative terminal first and
then the positive terminal. Installation is in reverse
order.
(7) Remove the batteries and replace them.
(8) Lightly grease the terminals and battery poles with
acid-free and acid-resistant grease before fastening.
(9) Installation is in reverse order.
DANGER
Make sure the fastenings are secure.
(10) Close the maintenance flap again.
Figure 8-34
Figure 8-36
Figure 8-35

S160/S161/S165/Z1628-16
8Maintenance
Figure 8-37
Figure 8-38
8.2.14 Maintaining/replacing the fresh air
filter
(1) Lift and mechanically prop up the bucket arm [e.g. by
inserting the bucket arm support (option) (1-1/arrows)],
lower the bucket arm until it rests on the bucket arm support
and swivel it all the way to right or left.
(2) Loosen the four fastening screws (8-37/arrows) of the
heater cover and remove the cover.
(3) Remove the filter elements (8-38/arrows) and clean
them with compressed air.
CAUTION
Do not use any petrol, hot fluids or industrial
compressed air for cleaning.
(4) Check the filter elements for damage.
NOTE
The filter elements must be replaced when they
are damaged or every 1500 operating hours.
(5) Insert the filter elements and install the heater cover.
8.2.15 Checking the lining play
(1) Apply the parking brake (4-7/4).
(2) Unscrew the plugs (8-14/arrow and 8-19/arrow) from
the axle arch.
(3) Use the special tool (feeler gauge) to check the
dimension “S” between the center brake discs (8-39).
CAUTION
-“S” minimum: 5 mm.
-If necessary, replace the centre brake discs
on both sides.
(4) Screw the plugs (8-14/arrow and 8-19/arrow) back in.
Figure 8-39

S160/S161/S165/Z162 8-17
Maintenance 8
Figure 8-40
Figure 8-41
8.3 Lubrication points
NOTE
The grease points are marked in red on the
loader.
8.3.1 Rear axle pivot bolt (8-40/arrows)
CAUTION
-The rear axle pivot bolt must be lubricated
every 10 operating hours.
-Release the rear axle from load before
lubricating the rear axle pivot bolts.
8.3.2 Rear axle (8-41/arrows)
CAUTION
The spindle bolts must be lubricated every 50
operating hours.
NOTE
Lubricate the top and the bottom of the axle
spindle bolts on both sides of the axle.
8.3.3 Front axle (8-42/arrows)
CAUTION
The spindle bolts must be lubricated every 50
operating hours.
NOTE
Lubricate the top and the bottom of the axle
spindle bolts on both sides of the axle.
Figure 8-42

S160/S161/S165/Z1628-18
8Maintenance
8.3.4 Ball bearing ring (8-43/arrows)
The grease filling is to avoid friction, and to provide sealing
and protection against corrosion. Therefore, the bearing
must be lubricated every 10 operating hours until grease
becomes visible on the outside. When lubricating the ball
bearing ring, swivel the bucket arm by 20° at a time. Grease
all four grease nipples in each position. It is absolutely
necessary to lubricate the machine before and after a
longer period of inactivity.
DANGER
-Before you start lubricating, mechanically
support the bucket arm [e.g. by inserting the
bucket arm support (optional ) (1-1/arrow)],
apply the parking brake (4-7/4) and set the
drive direction switch (4-7/3) to the “0” position.
-During swivelling, no-one may be present in
the swivel area of the bucket arm.
8.3.5 Bucket assembly
CAUTION
The bolts/lubrication points of the bucket assembly
must be lubricated every 10 operating hours.
8.3.6 Driver’s cabin doors (8-45/arrows)
CAUTION
The hinges of the driver’s cabin doors must be
lubricated every 50 operating hours.
NOTE
Lubricate the hinges on both doors of the driver’s
cabin.
Figure 8-43
Figure 8-44
Figure 8-45

S160/S161/S165/Z162 8-19
Maintenance 8
Figure 8-47
8.3.7 Engine hood
CAUTION
The hinges of the engine hood (8-46/arrows)
must be lubricated every 50 operating hours.
8.4 Oil lubrication points
8.4.1 Supporting valve actuator
CAUTION
The leverage of the supporting valve actuator
must be lubricated with engine oil every 50
operating hours.
(1) Lift the bucket arm, insert the bucket arm support and
swivel the bucket arm all the way to the right or to the left.
(2) Unscrew the four screws (8-47/arrows) that fix the
maintenance plate and remove the plate.
NOTE
Lubricate only the visible surface of the spring
housing piston rod (8-48/arrow).
Figure 8-46
Figure 8-48