mecalac AS 150e Guida
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
Indice
Altri manuali mecalac Trattore
