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ahlmann AS 150, Operating Instructions Manual

The Ahlmann AS 150 Operating Instructions Manual is a comprehensive guide that provides step-by-step instructions for effectively operating the AS 150 model. This essential manual is available for free download on our website, offering users an easy and convenient way to access the necessary guidance.

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S150/S151/S152/Z152

10-5

1

2

3

4

5

6

7 8

9

37

38

39

46

47

48

49

50

Y6

DS2

DS4

DS3

10

11

12

13

14

15

16

40

41

42

43

44

Y50

17

36

45

Y7

29

30

32

33

34

35

31

DS1

26

27

28

Y2

Y1

Y3

TS1

Y5

Y4

G2

21

22

23

24

25

18

19

20

10.2.2 - 04.2001

Hydraulics Diagram AS 150 (bolt lock) Type "40 km/h"

_ .. _ ..

Gauge part

Optional equipment

X

_

Einschaltdruck120 bar
Abschaltdruck 150 bar

Anschluss an Pilot-
druck Auskippen

Anschluss an
Pilotdruck Senken Anschluss an

Speisedruck

Summary of Contents for AS 150

Page 1: ...mbH Am Friedrichsbrunnen 2 D 24782 Büdelsdorf Telefon 04331 351 325 Internet www ahlmann baumaschinen de Telefax 04331 351404 E Mail info ahlmann baumaschinen de AS 150 OPERATING INSTRUCTIONS SWING SHOVEL LOADER 1000995A GB ...

Page 2: ...ions and maintenance The Maintenance section contains details of all service tasks and functional checks which must be performed by trained staff These do not include major servicing tasks which must be performed by technicians specially trained and authorized by the manufacturer This specifically includes equipment subject to road safety and safety at work regulations Themanufacturerreservestheri...

Page 3: ...S150 S151 S152 Z152 I I Table of Contents Abbreviations used SW Safety at work regulations RS Roadsafetyregulations Version 02 2007 Printed 02 2007 ...

Page 4: ...staff basic requirements 1 12 2 Signs 3 Anti Theft Mechanism 3 1 Identification marks on the equipment 3 2 3 2 Parkingtheequipment 3 2 3 3 Transponderimmobilizer 3 3 4 Description 4 1 Overview 4 2 4 2 Swingdriveandundercarriage 4 3 4 3 Schwimmstellung 4 3 4 4 Bucket position indicator 4 3 4 5 Accoustic warning 4 3 4 6 Air Conditioning 4 4 4 7 Bucket cushioning 4 5 4 8 Transmission type 20 km h and...

Page 5: ...1 Towing the swivel loader in case of engine failure 7 2 7 1 1 2 Towing the swivel loader in case of transmission failure 7 5 7 2 Lifting by crane 7 7 8 Maintenance 8 Maintenance plan type 40 km h 8 1 8 Maintenance plan types 20 km h and 25 km h 8 2 8 1 Maintenancenotes 8 3 8 2 Maintenancetasks 8 4 8 2 1 Checking the engine oil level 8 4 8 2 2 Checking the axle oil level 8 4 8 2 2 1 Rearaxle 8 4 8...

Page 6: ... 11 2 11 4 Alternator 11 2 11 5 Hydrostaticdrive 11 2 11 6 Axle loads 11 3 11 7 Tires 11 3 11 8 Steering 11 3 11 9 Brakes 11 3 11 10 Electricalequipment 11 3 11 11 Hydraulicequipment 11 4 11 11 1 Work hydraulic system 11 4 11 11 2 Loader hydraulic system 11 4 11 11 3 Abstützanlage 11 4 11 12 Fuel supply system 11 4 11 13 Heating and ventilation system driver s cab 11 4 11 14 Suction return filter ...

Page 7: ...Safety regulations ...

Page 8: ...machine or other real values 1 2 2 Themachineandattachmentsmayonlybeused inatechnicalnon objectionablecondition takingallsafety regulationsespeciallywithregardtotheoperatingmanuals machine and engine In particular defects which could have a detrimental effect on the safety of the machine should be eliminated immediately 1 2 3 The machine is determined exclusively for the purposes described in this...

Page 9: ...d in by the machine 1 3 6 Allsafetyanddangerplatesonthemachinemust beobserved 1 3 7 All safety and danger plates must be attached to the machine and must be kept in legible condition 1 3 8 Incaseofmodificationstothemachine especially in case of damages or changes in the operating behavior of the machine which could influence the safety of the machine stop the machine immediately and inform the com...

Page 10: ...her persons must not be transported 1 5 1 2 Startanddrivethemachinefromthedriver sseat only 1 5 1 3 Duringstartingandswitching offoperationobserve the control lamps according to the operation manual machineandengine 1 5 1 4 Before commencing work driving check brakes steering signal lights and lights for their functioning 1 5 1 5 Before moving the machine always check that the attachments are safe...

Page 11: ... engine Report any defects or changes immediately to the person incharge Ifnecessarystopthemachineimmediatelyand safeguardit 1 5 1 15 The driver may only slew the attachments over headdriving operatingandworkingareasiftheseareasare suitablysafeguardedbyprotectiveroofing Theseprotection roofs must offer appropriate safety against loads and goodsfallingdown Incaseofdoubt itshouldbeassumed that they ...

Page 12: ... 5 1 27 Avoid such work which could have detrimental effect on the stability of the machine The stability can be detrimented by overloading too soft ground abruptaccelerationordecelerationofdrivingmovement orworkingmovement reversingoutofhighdrivingspeed working on slopes driving too quickly round sharp bends drivingthemachineonroughterrainwiththebucketarm swung 1 5 1 28 Do not drive along slopes ...

Page 13: ... the attachments must be guaranteed at all times during maintenance and repairwork 1 5 2 5 Maintenanceandrepairworkmayonlybecarried out when the attachment is set down on the ground or supported or when equivalent measures against un intentionalmovementweretaken Duringmaintenanceandrepairworkunderthebucketarm the bucket arm must be mechanically propped up e g by inserting the bucket arm support op...

Page 14: ... at very great heights All handles steps railings podests platforms ladders must be kept free from dirt and ice 1 5 2 16 Clean the machine especially connections and screwconnectionsbeforecommencementofmaintenance work and make sure that the machine is free from oil fuel oil or dirt Do not use aggressive detergents Use lintless cleaningrags 1 5 2 17 Beforecleaningthemachinewithwaterorsteam jet hig...

Page 15: ... 2 Whenworkingnearoverheadlinesandoverhead wires a safety clearance must be kept between the machine and its working equipment in order to prevent sparkingover Thesafetyclearancedependsonthenominal voltage of the overhead wire line This also applies to the distance between the lines and to the attachments and slung loads Thefollowingsafetyclearancemustbeobserved tomeet theabovementionedrequirement...

Page 16: ...mediately 1 6 1 6 Always de energise machine or system parts to beinspected maintainedorrepairedbydisconnectingthe battery main switch 1 6 1 7 Always disconnect the battery main switch be fore starting any electrical welding on the machine 1 6 2 Hydraulic systems 1 6 2 1 Onlyexpertsmaycarryoutworkonthehydraulic system 1 6 2 2 Allpipelines hosesandscrewconnectionsmust be checked regularly for leaka...

Page 17: ...free of fuel oil and grease 1 6 5 Gas dust steam smoke 1 6 5 1 The machine may only be started and run in closedoperatingareaswherethereissufficientventilation The regulations for the respective working site must be strictlyobserved 1 6 5 2 Onlycarryoutwelding burningandgrindingwork onthemachinewhenthisisexplicitlyapproved Otherwise danger of fire and explosion 1 6 5 3 Beforecarryingoutwelding bur...

Page 18: ...heldrespon sible for damage that results from the use of non original parts and accessories 1 8 1 2 Informaboutthelocation useoffireextinguishers 1 5 arrow and first aid kit on the maintenance plate behindthedriver sseat 1 8 2 Selectionofpersonnel qualifications additional duties 1 8 2 1 Onlyreliablepersonsareallowedtoworkon with the machine The minimum legal age must be observed 1 8 2 2 Only empl...

Page 19: ...Signs ...

Page 20: ... 5 25 17 5 R 25 550 65 R 25 2 2 2 2 bar 3 0 3 0 bar 9b 23 Bau Bau jahr jahr kW kW Fahrzeug Identifi Fahrzeug Identifi zierungs Nr FIN zierungs Nr FIN Motor Motor leistung leistung Typ Typ Ausf Ausf zul Achslast hinten zul Achslast hinten zul Achslast vorn zul Achslast vorn zul Gesamtgewicht zul Gesamtgewicht Betriebserlaubnis Nr Betriebserlaubnis Nr 2 2 1 1 Baumaschinen GmbH Baumaschinen GmbH D 24...

Page 21: ... Four wheel 8 Symbol Hydraulic oil tank 9a Sign Noise level Chp 11 17 9b Sign Accoustic pressure Chp 11 17 10 Symbol Lifting hook 11 Symbol Lashing points 12 Sign Low noise emission equipment 13 Sign Max speed 14 Sign Maintenance plan 15 Sign Tire pressure 16 Symbol Manual lever for main hydraulics 4 7 2 17 Symbol for slow runners Type 20 km h and 25 km h Hydraulic gear shift 4 7 1 Hare symbol roa...

Page 22: ...Anti TheftProtection ...

Page 23: ...rrow This includes the name of the manufacturer details of the ROPS type vehicle type and max permitted weight 3 2 Parking the vehicle 1 Turn the steering to the left or right till it locks in place 2 Put the parking brake on 4 7 4 3 Lower the quick change mechanism to allow the lip of the bucket the forks of the fork loader the lifting hook boom to touch the ground 4 Close both stop valves 1 2 1 ...

Page 24: ...3 Transponder Immobilizer Optional The TransponderImmoblizer isanelectronicimmobilizer that disables critical features of the vehicle Ifthetransponder whichcanbeattachedtothekey fobfor theignitionkey isremovedfromthevicinityofthereceiver i e the vicinity of the ignition lock these functions are interrupted Insurance Benefits The transponder immobilizer is in line with the latest stringentrequireme...

Page 25: ...Description ...

Page 26: ...ontent in this manual These changes are summarized in Chapter 13 Please refer to Chapter 13 for details 4 1 Overview 1 Bucket protector 2 Bucket Attachment 3 Trunnionballs 4 Push cylinder 5 Boom 6 Lift cylinder 7 Cabin 8 Hydraulic oil tank Filler cap 9 Engine 10 Rear axle 11 Battery case 12 Tool case 13 Swivelassembly 14 Front axle 15 Quick coupling mechanism 16 Fuel tank access ladder on right si...

Page 27: ... 3 Float Feature The assembly is equipped with a float feature that allows the operator to perform tasks such as leveling on uneven terrains To enable the float feature push the hydraulics control lever 4 7 2 forwards through its pressure point Theleverwillremaininthispositionuntilyoudisengagethe float feature by pulling it in the opposite direction DANGER Ensure that the bucket is grounded before...

Page 28: ... once a week for a short period in order to lubricate the internal gaskets If the ambient temperature is low the compressor should not be switched on until the engine has reached running temperature The coolant which in fluid state tends to collect at the lowest point in the compressor circuit assumes its gaseous form due to engine heat Fluid coolant can cause damage to the compressor DANGER Due n...

Page 29: ... 8 19 to the 0 position will automatically disengage the bucket cushioning mechanism Re engage the the mechanism if required 4 8 Gear Selection Type 20 km h and 25 km h ATTENTION The gears of the transfer gear shift can only be selected when the vehicle is stationary the servicebrakeshavebeenappliedandthedirection selector 4 7 3 is in neutral position 0 Toselectagear pressthepush button 4 8 4 onth...

Page 30: ...ack is centered under the axle and cannot slip Then raise the jack until the wheel is clear of the road DANGER Ensure that the jack does not sink into soft ground by using an appropriate base Ensure that the jack is properly seated 10 Completely loosen and remove the wheel nuts 11 Lower the vehicle by lowering the jack slightly to a point where the wheel bolts are freely accessible 12 Rotate the w...

Page 31: ...ot used 3 Inspectionflap 4 Steeringselectionlever outwards four wheel drive inwards rear wheel drive 5 Control lever auxiliary hydraulics front boom 6 Switch for auxiliary hydraulics front boom opt 7 Push button dump lock opt 8 Manualconsoleadjustmentwheel valvecontrolfor auxiliaryhydraulics Right of driver s seat 1 Fast runners Gears left 2ndgear center 1st gear right Alpha max Turtle symbol Slow...

Page 32: ... Rocker switch for road lights Position I Rear lights side lights Stellung II Drivinglights 14 Push button Release quick coupling mechanism 15 Push button for bucket cushioning 16 Socket 17 Fusebox 18 not used 19 Starter switch 20 Rocker switch for heated rear screen rear view mirror opt 21 Rocker switch for screen wash rear screen wash 22 Rocker switch for windscreen wipers front continuous 23 Ro...

Page 33: ... 10 0 A 5 Heatedrearscreen 15 0 A 6 Headlightbeam 7 5 A 7 Headlightdip 7 5 A 8 Tail light left Sidelight left 5 0 A 9 Tail light right Sidelight right 5 0 A 10 Hazardwarning 7 5 A 11 Wipers Washer 15 0 A 12 Enginecut off 5 0 A 13 Working floodlights Panel display lighting Brake lights 25 0 A 14 360 light opt Signal horn Socket Interior light 20 0 A opt optional feature ...

Page 34: ...Operations ...

Page 35: ...upport option 1 1 arrow ifnecessary Stop valves for main and auxiliary hydraulics 1 2 1 and 1 2 2 may need to be removed prior to commencing work only Generalconditionofequipment checkforleakages for example Checkwhether a first aid kit awarningtriangle a hazard warning light areavailable 5 2 Getting started 5 2 1 Starting the diesel engine 1 Apply the parking brakes 4 7 4 2 Insert the main batter...

Page 36: ...llthecylinders lifting tipping andswivelcylinder forsometime dependingon theambienttemperature The following tasks must be fulfilled to ensure trouble free operations at low temperatures 5 2 2 1 Fuel At low temperatures paraffin precipitation can cause blockages of the fuel system Use winter diesel fuel suitable down to 15 C at temperatures below 0 C NOTE Winter diesel fuel is normally available f...

Page 37: ...TION Ifthetemperatureisexpectedtodropbelow0 C add a sufficient amount of anti freezing agent to the water in the windshield washer system 5 3 arrow to prevent it from icing up Follow the manufacturer s instructions for the mixing ratio 5 2 3 Driving the loader on public roads ATTENTION Driving on public roads is allowed only when an empty standard or multi purpose isattachedandonlythenifabucketpro...

Page 38: ...sing the spring pin 4 Cover the bucket cutting edge and teeth with the bucketprotector 5 4 arrow 5 Insert the plug of the bucket protector into the socket 5 5 arrow 6 Check the lights 7 Close both doors 8 Put on your seat belt 9 Switch the steering system selection lever to rear axlesteering 4 9 4 DANGER Theworkinglightsmustbeswitchedoff 4 8 24 10 Release the parking brake 4 7 4 11 Applies to slow...

Page 39: ...switchfromhydraulicdrivestepItoII or vice versa whiletraveling However shiftingfrom hydraulicdrivelevelIIdowntoIisnotrecommended at higher speeds as it will cause the vehicle to brakesuddenly 5 2 4 2 Fast runners Type 40 km h DANGER Alwaysfastenyourseatbeltwhileworkingwitha swivelloader Normally all work is executed in hydraulic drive stage II 4 7 1 In special cases where more granular speed contr...

Page 40: ...er even if the drive pedal is fully depressed Power and travel speed are equal both in forwardandreversedirections ATTENTION If the warning indicator for hydraulic oil temperature 4 8 31 lightsup oranaccoustic signal is given stop the vehicle immediately and call in an expert to troubleshoot the hydraulics and remedy the issue Do not attempt to lock the hydraulic quick coupling assembly unless an ...

Page 41: ... 5 6 2 clockwise hot or anticlockwise cold 5 2 5 3 Switching on the air conditioning unit opt 1 Use the ON OFF switch 5 6 3 to switch the air conditioning unit on or off as required Press top of switch Air conditioning ON Press bottom of switch Air conditioning OFF 5 2 5 4 Selecting a temperature 1 Use the dial 5 6 1 to set the cab temperature Turn dial clockwise colder Turn dial anticlockwise wär...

Page 42: ... idea to lettheengineidleforashorttimebeforeswitching it off Turn the ignition key to the left to the 0 position 5 1 and remove the key NOTE In the P position the parking light and the dashboard illumination remain switched on 5 3 3 Switching off the heating and ventilation unit air conditioning opt 1 Shut off the warm air supply 5 6 2 2 Turn the dial for the fan 5 6 4 to the 0 position 3 Switch o...

Page 43: ...1 to adjust the seat cushioning to the weight of the driver 40 130 kg 5 You can use the wheel 5 9 1 to adjust the height of the armrests 6 Ifrequired adjustthepositionsofthevalvecontrolsfor the main 4 7 8 and auxiliary hydraulics 4 6 8 7 Pullupthebar 5 10 2 andatthesametimemovethe seat forwards or back to adjust the horizontal position to thedriver srequirements 5 4 2 Grammer seat 1 Weight adjustm...

Page 44: ...west position when it is lifted over the topmost position stop 5 12 3 Armrestinclination Turn the handwheel 5 13 arrow to adjust the armrest in longitudinal direction 4 Armrests Ifdesired youcanswingthearmreststotherearandadjust their height Toadjustthearmrestheight removetheroundcap 5 14 arrow in the covering Loosen the hex nut wrench size 13 mm set the armrest asdesiredandtightenthenutagain Push...

Page 45: ...ust the seat in longitudinal direction when you pull the lever 5 16 upwards NOTE The locking lever must engage in the desired position Itmustbeimpossibletomovethedriver s seat to another position when the lever has engaged 5 5 Switching the steering ATTENTION The wheels of the rear axle must be straight before operating the steering toggle switch 5 17 arrow The steering mode may only be changed wh...

Page 46: ...Attachments ...

Page 47: ... thus prevent leakages 5 Checkseatingandensurethatthepinsarelockedleft and right DANGER The lock pins of the quick coupler must be insertedintheliftingholesonbothsidesofbucket and must protude visibly when viewed from the side 6 3 arrow Uncoupling 1 Place the bucket firmly on the ground 2 Hold down the quick coupler release button 4 8 14 and at the same time unlock the bucket using the auxiliary h...

Page 48: ...tinesmustbeequidistant fromthecenter 6 6 arrows andlockthemin place Whenmovingloadsensurethatthefork liftis raised only slightly above the ground Whenmovingloads avoidquickacceleration braking andsteeringmaneovres ATTENTION Incaseofequipmentwithpipeburstprotection opt engaging the fork lift cushioning 4 8 15 willdeactivatethepipeburstprotection mechanism Thedrivermaynotleavethevehiclewhilethe fork...

Page 49: ...on mechanism Ensure that the engine is idling while locking orunlockingtheliftinghookinordertoreduce theinsertion retractionspeedofthelockpins and thus prevent leakages Ensure that an attachment is fitted before engaging the hydraulic quick coupler 6 2 Coupling and uncoupling attach ments with hydraulics 6 2 1 Multi purpose bucket Coupling 1 Lower the loader arms as far and possible and tilt the q...

Page 50: ...c hoses pay attention to cleanlinessofthejointandensurethatconnectors areseatedproperly Uncoupling 1 Place the bucket firmly on the ground 2 Stop the engine 3 Release the pressure on the hydraulic hoses by movingtheauxiliaryhydraulicslever 4 6 5 backandforth 4 Follow the coupling procedure in reverse order the exception being that you need to press the quick coupler releasebutton 4 8 14 toreleaset...

Page 51: ...152 Z152 6 6 6 Attachments Fig 6 13 Fig 6 15 Fig 6 14 Notes on using the multi purpose bucket The multi purpose bucket can be used for blading 6 13 clamming 6 14 grappling 6 15 andfor digging like a normal bucket ...

Page 52: ...NGER The lock pins of the quick coupler must be inserted in the lifting holes on both sides of the front endexcavatorattachmentandmustprotude visibly when viewed from the side ATTENTION Ensure that the engine is idling while locking thefront endexcavatorinordertoreducethe insertion speed of the lock pins and thus preventleakages Whenattachinghydraulichosespayattention to cleanliness of the joint a...

Page 53: ...ndforth 5 Close both stop valves 1 2 1 and 1 2 2 6 Unscrew the safeguards for the bolts size 19 6 17 arrows 7 Knock out the bearing pin 6 18 arrows and remove the bucket 8 Followthesestepsinreverseordertoattachabucket NOTE Thetypeplateforthebucketisontheoutsideleft 6 3 Using other attachments DANGER 1 Useonlythoseattachmentsdescribedinthis manul 2 Beawarethatwecannotapproveattachments we have not ...

Page 54: ...Rescue Towing Lashing Crane Lifting ...

Page 55: ...ystem is inoperable or only the transmission has failed and the engine can still power the hydraulic subsystem 7 1 1 1 Towing the swing loader in case of engine failure ATTENTION When the engine has failed towing is only permitted to rescue the machine out of the dangerarea Remove both cardan shafts prior to towing if the machine must be towed over a longer distance and cannot be loaded 1 Press th...

Page 56: ...ulic hoses are disconnected from the lift cylinder before attaching the lifting equipment Use an oil tray with appropriate dimensions to catch any hydraulic oil that seeps out After completing towing remember to fill the lift cylinder with hydraulic oil and vent the cylinder by repeatedly raising and dropping the loader arm 10 Lift and mechanically prop up bucket arm e g by insertingthebucketarmsu...

Page 57: ...separately Adjustment after manual slackening Remove the set screws 7 4 1 and 7 4 3 counter nuts 7 4 2 and 7 4 4 and gaskets Lubricate the set screws with silicon grease TECNO LUBE 101 Refit the set screws counter nuts and gaskets 16 Tighten the set screws to a point where the measure ment between the screw head and the axle assembly is 32 1 mm 17 Use counter nuts to fix the set screws in position...

Page 58: ... vehicle does not roll 3 Put the gear selector 4 7 3 in neutral position 0 NOTES Preparatory tasks 4 6 7 and 10 are only required if the rescue area is not in a publicly accessible area 4 Align the wheels on the front axle and then use the steering selector lever 4 6 4 to set the steering mode to rear wheel steering 5 Apply the bucket protector to protect the lip and teeth of the bucket 5 4 arrow ...

Page 59: ...nuts 7 4 2 and 7 4 4 and gaskets Lubricate the set screws with silicon grease TECNO LUBE 101 Refit the set screws counter nuts and gaskets 14 Tighten the set screws to a point where the measure ment between the screw head and the axle assembly is 32 1 mm 15 Use counter nuts to fix the set screws in position ATTENTION The screws must protrude by exactly 32 1 mm 7 4 Applies to slow runners Type 20 k...

Page 60: ...ect first gear 4 8 4 Select hydraulic gear I 4 7 1 Applies to fast runners only Type 40 km h Select Alpha max Turtle symbol 4 7 1 4 Raise or lower the loader arm to a position where the bucket heel is at least 30 cm above the ground 5 2 5 Close stop valves for main and auxiliary hydraulics 1 2 1and1 2 2 6 Blocktheswivelmechanismbyinsertingtheblocking wedge 1 3 arrow in the swivel blocking mechanis...

Page 61: ...Maintenance ...

Page 62: ...d functional check of brakes and parking brakes before starting work 11 2 Checkaccumulatorvalve 12 Lighting unit Air filter Air conditioning unit 12 1 Perform functional check before starting work 12 2 Check air filter 12 3 Check condensator for contamination 12 4 Check tension of compressor drive belt Item Name Specification Viscosity Quantity 1 Engine Oil MIL L 2104C API CD SAE 15 W 40 10 l with...

Page 63: ... work 11 2 Checkaccumulatorvalve 12 Lightingunit Airfilter Airconditioningunit 12 1 Performfunctionalcheckbeforestartingwork 12 2 Checkairfilter 12 3 Checkcondensatorforcontamination 12 4 Checktensionofcompressordrivebelt Lubrication Points marked in red 1 Greaseboltswith DIN51825 KPF1 2N 20every10hours 2 Greasefirctionpointsasrequiredandaftercleaningwith DIN51825 KPF1 2N 20 Oil Lubrication Points...

Page 64: ...e vehicle cannot roll away by applyingtheparkingbrake 4 7 4 andplacing the travel direction selector 4 7 3 in neutral position 0 Additionallychockbothwheels on the front axle ATTENTION Ensure that units are warm but not hot before carry out oil changes Performmaintenanceworkwhenthevehicle is on level ground and the loader arm has beengrounded Immediately replace damaged filter media and gaskets Cl...

Page 65: ...le arches 8 1 arrow and or 8 2 arrow NOTE The oil level must reach the plug bore Collect any escaping oil 2 Replace the plugs 8 2 2 2 Planetary Gear 1 Movetheloaderuntilthe OILLEVEL markishorizontal and the plug is located at the top right of the mark 8 3 arrow 2 Removetheplug NOTE The oil level must reach the plug bore Collect any escaping oil 3 Fit a new gasket and re insert the plug Fig 8 1 Fig...

Page 66: ...r 8 5 arrow NOTE The oil level must reach the plug bore Collect any escaping oil 2 Re insert the plug 8 2 3 Check oil fill level transfer gearbox Slow runner 20 km h and 25 km h 1 Removeplug 8 6 arrow NOTE The oil level must reach the plug bore Collect any escaping oil 2 Re insertplug Fig 8 4 Fig 8 6 Fig 8 5 i i ...

Page 67: ...ping oil 8 2 5 Check oil fill level in hydraulic oil reservoir 1 Park the vehicle on level ground 2 Lower the loader arm to the ground 3 Tilt the quick coupler assembly and use the auxiliary hydraulics lever 4 6 5 to retract the locking bolts 4 Open the engine hood 5 Checktheoillevelintheinspectionglass 8 8 arrow NOTE The oil level must be visible in the upper quarteroftheinspectionglass Ifrequire...

Page 68: ... to the oil drain plug 6 Remove the cover cap from the hose 7 For further instructions see the engine operating manual 8 2 7 Oil change axles 8 2 7 1 Rear axle 1 Placeasufficientlylargeoilspilltrayunderthevehicle 2 Remove the plugs from the axle arches 8 11 1 8 11 2 8 11 3 8 11 4 and 8 12 arrow and drain oil ATTENTION Disposeofwasteoilinanenvironmentallyfriendly way 3 Re insertaxlearchplugs 8 11 1...

Page 69: ...4 and 8 12 arrow 8 2 7 2 Planetary gear 1 Position the vehicle so that the plug 8 14 arrow is at 6 o clock 2 Place a sufficiently large oil spill tray with a drainage chuteunderneach 3 Remove the plug and drain the oil ATTENTION Disposeofwasteoilinanenvironmentallyfriendly way 4 Position the vehicle to allow the OIL LEVEL to be horizontal so that the plug is to the top left of the mark 8 15 arrow ...

Page 70: ... way 3 Re insert plugs 8 16 1 8 16 2 and 8 16 3 4 Top up with oil via axle arch plug bore 8 16 4 or 8 17 arrow until oil fill level reaches plug bore NOTE Refertothemaintenanceplan pages8 1and 8 2 for details on required amounts The oil fill level will drop after a few minutes Top up with oil until the required level has been reached and remains constant Theaxleventvalve 8 18 arrow mustbefree ofco...

Page 71: ...red level has been reached and remains constant 5 Re insert the plugs 8 19 2 8 2 9 Oil change transfer gear gox fast runners 40 km h 1 Placeasufficientlylargeoilspilltrayunderthetransfer case 2 Remove plugs 8 20 2 and 8 20 3 and allow oil to drain 3 Changethefiltercartridge microfilter 8 21 1 4 Clean the suction filter macrofilter 8 21 2 ATTENTION Disposeofwasteoilinanenvironmentallyfriendly way 5...

Page 72: ...8 23 arrow ATTENTION Equipmentusingbiodegradablehydraulicoil ester based synthetic hydraulic oil viscosity class ISO VG 46 VI 180 refer to the label on the hydraulicoilreservoirandonthedashboard need to use the same replacement oil type Donotmixmineralandbiodegradablehydraulic oils Biodegradablehydraulicoilmustbechangeevery 1000 operating hours Follow the migration guidelines VDMA 24 569 whenmovin...

Page 73: ...ehydraulicoilfiltercoverandthemagnetic tube attached to it 8 27 2 5 Lift up the handle 8 27 3 remove the filter insert 8 27 4 and replace it with a new insert ATTENTION Dispose of used hydraulic oil filter inserts in an environ mentallyfriendlyway 6 Wipe the magnetic tube 8 27 2 clean before re fitting 7 Re fit and tighten the hydraulic oil filter cover and magnetic tube 8 Attach the vent tube to ...

Page 74: ...dwhendustformationceases Do not use petrol or hot liquid for cleaning 6 Use a hand held inspection lamp to check the filter cartridge for damage to the cartridge paper or the rubber gasket If the cartridge or seals are damaged replace the cartridge 7 Re insert the filter cartridge carefully 8 Installtheairfilterlidonthefilterhousinginsuchaway that the direction arrow in the OBEN TOP mark points up...

Page 75: ...side of the machine Alwaysstorebatteriesinacleananddryplace 1 Disconnect the battery master switch 4 7 5 2 Use a square wrench to open the access panel 3 Removeboth securingboltsSW19 8 31 arrows for the battery holder 4 Pull out the battery holder and the batteries to the extent the retainer allows 5 Loosen and remove the securing bolts SW 17 8 32 1 for the battery holder 6 Loosen and disconnect t...

Page 76: ...e filter elements 8 34 arrows and blow them clean with air ATTENTION Donotusepetrol hotfluidsorcompressedairfor cleaning 4 Check the filter elements for signs of damage NOTE Change the filter elements in case of damage or every 1500operatinghours 5 Re fit the filter elements and the heating unit cover 8 2 17 Checking brake play 1 Apply the parking brake 4 7 4 2 Remove the axle arch plugs 8 12 arro...

Page 77: ... operating hours 8 3 2 Rear axle 8 37 arrows ATTENTION Therearaxlespindleboltsmustbegreasedevery 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 38 arrows ATTENTION The front axle spindle bolts must be greased every 50 operating hours NOTE Lubricate the top and the bottom of the axle spindle bolts on both sides of the ...

Page 78: ...er periods of inactivity DANGER Before greasing mechanically prop up the bucket arm e g by inserting the bucket arm support option 1 1 arrow applytheparking brake 4 7 4 andsetthedrivedirectionswitch 4 7 3 to 0 Makes sure that nobody is in the working areaoftheloaderarmwhilerotatingthearm 8 3 5 Loader assembly ATTENTION The bolts greasing points 8 40 arrows of the loader quickcouplerassembly mustbe...

Page 79: ... valve control mechanism ATTENTION The support valve control mechanism must be oiled with engine oil every 50 operating hours 1 Raise the loader arm insert the loader arm support and swivel the arm out fully to the left or right 2 Loosen and remove the four holding screws on the accesspanel 8 43 arrows NOTE Oil only the visible area of the piston rod on the suspensioncasing 8 44 arrow Fig 8 44 i ...

Page 80: ...Troubleshooting ...

Page 81: ... after engine failure Moreforcerequiredforsteering Pressure valve in steering unit Removepressurevalve cleanand may be open re calibrate Slidevalveinpriorityvalve Replacepriorityvalve blocked Swivelassembly 1 4 arrow fails Swivel mechanism may be Removeswivelassembly blockand to rotate blocked storeinholder Pressurevalveincontrolvalve Removepressurevalve cleanand may be open re calibrate Supportfa...

Page 82: ...breaker circuit is attached to brake lever Alternatornotcharging Looseconnector Replace and fasten connector Alternatorbeltsnapped Relace belt Alternator revs too low Check tension of alternator belt and re tension if needed Heating Ventilationunitfailure Fuse blown Replacefuse Hose connectors for attachments Increased pressure due to effect Carefully remove screw joint will not attach of heat on ...

Page 83: ...Wiring and Hydraulics ...

Page 84: ...ramm Elektrisch schakelschema Elektrisk kopplingsschema 1 3 1 2 3 4 5 6 7 8 11 12 14 19 20 9 10 13 15 16 17 18 22 57 58 23 28 25 29 31 32 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 51 52 53 S150 S151 S152 Z152 24 26 30 50 54 55 56 10 1 TS1 DS2 DS1 DS3 Y6 Y50 Y7 DS6 33 27 53S T 53M 15 31 ...

Page 85: ...héma électrique Wiring diagramm Elektrisch schakelschema Elektrisk kopplingsschema 59 60 61 62 63 64 65 68 69 71 74 66 67 70 72 73 2 3 75 88 89 90 76 80 S150 S151 S152 Z152 10 2 Y8 77 Y9 79 DS4 81 Y1 82 Y4 83 Y2 84 Y3 85 Y5 86 G2 78 DS7 ...

Page 86: ...plan Schéma électrique Wiring diagramm Elektrisch schakelschema Elektrisk kopplingsschema 91 92 93 94 95 97 99 96 98 100 101 102 3 3 113 103 107 108 114 115 116 117 118 119 120 S150 S151 S152 Z152 105 10 3 112 106 104 109 110 111 ...

Page 87: ...switch Overload loader arm cushioning 25 Accumulatorvalve Loaderarmcushioning 26 Valve Pipe burst protection Loader arm cushioning opt 27 Combi valve 28 Socket 7 pin front 29 Valve Quick coupler release 30 Adapter for socket 7 pin rear 31 Numberplatelighting 32 Marker lamp right 33 Marker lamp left 34 Tail light unit right 35 Tail light unit left 36 Indicator markerlightright 37 Indicator markerli...

Page 88: ...trolforwards 70 Relaypowercontrolreverse 71 Relaydrivebreaker 72 Indicator light unit gear selector 73 Fuse Chapter 4 9 Pos 17 1 74 Push button gear shift selector slow fast only slow runners 75 SchrittschaltRelay onlyslow runners 76 Valve1stgear onlyslow runners 77 Valve2ndgear onlyslow runners 78 Switch Relase gear selector only slow runners 79 Switch Parking brake 80 Reversewarningpick up 81 Va...

Page 89: ...ing 108 Radio opt 109 Pressureswitch filterair conditioning 110 compressor air conditioning 111 Fanmotor air conditioning 112 Air conditioning opt 113 Transformerradio 114 Heated mirror right opt 115 Heated mirror left opt 116 Rearscreenheating 117 Motor wiper back 118 Motor washer back 119 Motorwasherfront 120 Motorwiperfront Opt Optionalequipment NOTE The item nos printed in bold type in the wir...

Page 90: ...DS2 Y4 DS4 DS3 Y7 G2 Y8 Y9 DS7 20 bar Anschluss an Pilot druck Auskippen Anschluss an Pilotdruck Senken Anschluss an Speisedruck Einschaltdruck120 bar Abschaltdruck 150 bar Fahrtrichtung X2 A1 weiß X2 B1 gelb Y1 B4 rot X1 A4 blau X2 A3 grün X2 B3 grau Y1 B2 braun X1 A2 schwarz 10 2 1 04 2001 Hydraulics Diagram AS 150 bolt lock Type 20 km h and 25 km h _ _ Gauge part Optional equipment X _ ...

Page 91: ... 36 45 Y7 29 30 32 33 34 35 31 DS1 26 27 28 Y2 Y1 Y3 TS1 Y5 Y4 G2 21 22 23 24 25 18 19 20 10 2 2 04 2001 Hydraulics Diagram AS 150 bolt lock Type 40 km h _ _ Gauge part Optional equipment X _ Einschaltdruck120 bar Abschaltdruck 150 bar Anschluss an Pilot druck Auskippen Anschluss an Pilotdruck Senken Anschluss an Speisedruck ...

Page 92: ...G3 8 P T A B G3 8 G3 8 G3 8 G3 8 DS1 10 muem M10x1 5 10 muem A 5500 qcm G1 1 4 G 3 4 Ent und Belüftung Befüllung 100 muem 3 0 bar 0 04 bar 0 5 bar 2 5 bar E1 S2 S1 J2 G 1 130 muem G 1 G 1 LLK KWK TS1 100 C F X1 Y1 X2 Y2 Y2 X2 Y1 X1 P T G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 P T G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 Y6 Anschluß an Pilotdruck Auskippen G1 2 G1 2 G1 2 G1 2 3 4 16UNF Y55 Y54 NS53 NS54 NS55 NS52 G1 2 G...

Page 93: ...G3 8 G3 8 G3 8 DS1 10 muem M10x1 5 10 muem A 5500 qcm G1 1 4 G 3 4 Ent und Belüftung Befüllung 100 muem 3 0 bar 0 04 bar 0 5 bar 2 5 bar E1 S2 S1 J2 G 1 130 muem G1 G1 LLK KWK G1 100 C F X1 Y1 X2 Y2 Y2 X2 Y1 X1 P T G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 P T G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 i 1 189 11 ccm U S P Anschluß an Pilotdruck Auskippen G1 2 G1 2 G1 2 G1 2 3 4 16UNF Y55 Y54 NS53 NS54 NS55 NS52 G1 2 G1 2...

Page 94: ...DW100 50 180 18 SteeringcylinderfrontGDW100 50 180 19 Steeringmodeswitchvalve 20 Blockingvalve opt 21 Steering unit 240 100 cm U 22 Combi cooler oilside 23 Priorityvalve 24 Temperaturecontrol 55 C opt 25 Drive motor A6VM 107 HA1R2 26 Idlegear 27 Cam pump 16 cm U 28 Cam pump 38 cm U 29 Drive pump A4VG 90 DA2D8 30 Drivemotor 31 Suction filter 32 Combined suction return filter 33 Electrical contamina...

Page 95: ...ylinderfrontGDW100 50 180 19 Steeringmodeswitchvalve 20 Blockingvalve opt 21 Steering unit 240 100 cm U 22 Combi cooler oilside 23 Priorityvalve 24 Temperaturecontrol 55 C opt 25 Drive motor A6VM 107 HA1R2 26 Loadswitchgear 27 Cam pump 16 cm U 28 Cam pump 38 cm U 29 Drive pump A4VG 90 DA2D8 30 Drivemotor 31 Cam pump11 cm U 32 Suction filter 33 Combined suction return filter 34 Elektrical contamina...

Page 96: ...ngcylinderfrontGDW100 50 180 19 Steeringmodeswitchvalve 20 Blockingvalve opt 21 Steering unit 240 100 cm U 22 Combi cooler oilside 23 Priorityvalve 24 Temperaturecontrol 55 C opt 25 Drive motor A6VM 107 HA1R2 26 Idlegear 27 Cam pump 16 cm U 28 Cam pump 38 cm U 29 Drive pump A4VG 90 DA2D8 30 Drivemotor 31 Suction filter 32 Combined suction return filter 33 Elektrical contamination display 34 Hydrau...

Page 97: ...gcylinderfrontGDW100 50 180 19 Steeringmodeswitchvalve 20 Blockingvalve opt 21 Steering unit 240 100 cm U 22 Combi cooler oilside 23 Priorityvalve 24 Temperaturecontrol 55 C opt 25 Drive motor A6VM 107 HA1R2 26 Loadswitchgear 27 Cam pump 16 cm U 28 Cam pump 38 cm U 29 Drive pump A4VG 90 DA2D8 30 Drivemotor 31 Cam pump11 cm U 32 Suction filter 33 Combined suction return filter 34 Elektrical contami...

Page 98: ...Technical Data Equipment ...

Page 99: ...h working load restricted to 60 due to maximum permissible tilt of engine Max trailer load with max vertical load on coupling point 250 kg braked 3500 kg unbraked 750 kg Max lifting force 69 kN Max thrust 81 kN 11 2 Engine Liquid cooled diesel engine 4 cylinder 4 stroke direct fuel injection Capacity 4038 cm3 Power corresponding to ISO 1585 98 kW bei 2300 min 1 Exhaust gas emission corresponding t...

Page 100: ...e permitted Size 17 5 25 Pressure front 3 0 bar back 3 0 bar Size 17 5 R 25 Pressure front 3 0 bar back 3 0 bar Size 455 70 R 24 Pressure front 4 5 bar back 3 0 bar Size 550 65 R 25 Pressure front 2 2 bar back 2 2 bar 11 8 Steering Four wheel switchable to rear wheel mode hydrostaticviapriorityvalve Max pressure 175 bar 11 9 Brakes Service brakes Hydraulic pump servo brake system wet multiple disk...

Page 101: ...oad 3 0 s Tipping 90 1 5 s Tilting 45 1 0 s 11 11 2 Swivel assembly hydraulics Output flow pump II via accumulator valve 38 l min Operating pressure max 210 bar 2 swivel cylinders Ø 100 45 mm Swivel time 180 7 0 s 11 11 3 Support assembly Operating pressure lastabhängig 2 support cylinders Plunger diamter 60 mm 11 12 Fuel supply system Volume Fuel tank 170 l 11 13 Heating and Ventilation System Dr...

Page 102: ...ission Type 20 km h Noise level LWA Noise external 106 dB A In band accoustic level LpA Noise level in cab 81 dB A Type 25 km h Noise level LWA Noise external dB A In band accoustic level LpA Noise level in cab dB A Type 40 km h Noise level LWA Noise external 106 dB A In band accoustic level LpA Noise level in cab 83 dB A 11 18 Options 11 18 1 Air Conditioning Unit Driver Cab ...

Page 103: ...Technical Data Attachments ...

Page 104: ...S150 S151 S152 Z152 12 2 12 Technical Data Attachments 12 Attachments Notes The technical data assume 17 5 25 12 PR tires 12 1 Buckets DimensionscorrespondingtoISO7131 35 i ...

Page 105: ...e 45 mm 1920 2055 2145 1990 G Dump out height at max dump out range and dump out angle 45 mm 1100 960 870 1035 H6 Penetration mm 110 110 110 110 H7 Clearance to center lug Quickcoupler mm 565 565 565 565 H8 Dump out height at max lifting height and dump out angle 45 mm 3075 2935 2845 3010 H9 Clearance to center lug Quickcoupler mm 3985 3985 3985 3985 H10 max working height mm 4975 5165 5290 4950 J...

Page 106: ...S150 S151 S152 Z152 12 4 12 Technical Data Attachments 300 12 2 Fork lift attachment MeasurementscorrespondingtoISO7131 35 ...

Page 107: ...frontal even ground stability factor 1 25 4460 kg uneven ground stability factor 1 67 3345 kg A2 Dump out angle 50 A5 Tilt in angle 25 B Min range 1020 mm C Max range 1615 mm D Range at max lifting height 760 mm G Heaped height at max range 1750 mm H6 Cutting depth 60 mm H7 Clearance to center lug quick coupler 765 mm H9 Clearance to center lug quick coupler 3995 mm HH15 Heaped height at max range...

Page 108: ...S150 S151 S152 Z152 12 6 12 Technical Data Attachments 12 3 Front end Loader Measurements according to ISO 7131 35 ...

Page 109: ...09 m 400 mm 75 kg 0 12 m 500 mm 90 kg 0 14 m 600 mm 95 kg 0 17 m 700 mm 105 kg Net weight Front end loader without bucket 435 kg D Max digging depth above cutting edge according to DIN ISO 7135 2090 mm E Penetration mm HH22 Max dump out height according to DIN ISO 7135 2920 mm HH24 Max digging depth above cutting edge according to DIN ISO 7135 2890 mm HH25 Penetration 1170 mm Timing values nengine...

Page 110: ...S150 S151 S152 Z152 12 8 12 Technical Data Attachments 12 4 Lifting Hook Dimensions according to ISO 7131 35 ...

Page 111: ...ontal 1660kg swiveled 1320kg Net weight 230 kg A Totallength 6515mm CC Min reach 1895mm DD Max reach 3335mm EE Max reach at maximum lifting height 1785mm FF Min lifting height with tilted quick coupler 1380mm GG Lifting height at max reach 1670mm HH Max lifting height 5145mm KK Max reach 2845mm LL Min reach 2010mm MM Max reach at maximum lifting 1260mm PP Lifting height at min reach 2515mm ...

Page 112: ...Optional Extras Changes ...

Page 113: ...tedatthejointbetweenthebucketassembly and the swivel assembly allows you to limit the maximum lifting height Setup 1 Lift the loader arm to the required height 2 Switch off the engine and close the stop valves for main and auxiliary hydraulics 1 2 arrows 3 Loosen the hexagonal bolts SW 10 13 1 3 on the gear gate assembly and rotate the gate 13 1 2 against the roller gage 13 1 1 until you hear the ...

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