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ahlmann AS 210, Operating Instructions Manual

The Ahlmann AS 210 Operating Instructions Manual is essential for efficiently operating this powerful machinery. Easily download the comprehensive manual for free from our website, where you can find a vast collection of user manuals. Personalize your AS 210 experience with clear, concise instructions easily accessible at manualshive.com.

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S220/S221/S230/S231/Z200

8-16

8

Maintenance

2

1

2

2

4

3

1

2

1

Figure 8-35

Figure 8-36

8.2.18.7

Bucket assembly

CAUTION

The support bolts/lubrication points of the bucket

assembly must be lubricated 

every 10  operating

hours

.

2x item 8-34/1

Tip lever / pivot arm

2x item 8-34/2

Pivot arm / reversing rod

2x item 8-34/3

Tip lever / quick-change device

2x item 8-34/4

Bucket assembly / quick-change device

2x Item 8-35/1

Pivot arm / bucket assembly

2x Item 8-35/2

Reversing lever / reversing rod

2x item 8-36/1

Bucket assembly / swivel unit

4x item 8-36/2

Lift cylinder

Figure 8-34

Summary of Contents for AS 210

Page 1: ...nen GmbH 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 210 OPERATING INSTRUCTIONS SWING SHOVEL LOADER GB ...

Page 2: ...ll the information which the user requires for operation and maintenance In the Maintenance section all maintenance work and operation tests are described which can be carried out bytrainedpersonnel Thissectiondoesnotcovermoreextensivemaintenanceworkthatisreservedtopersonnelauthorizedandtrained by the manufacturer In particular this applies to facilities governed by Motor Vehicle Construction and ...

Page 3: ...S230 S231 Z200 I I Table of Contents Abbreviations used UVV Unfallverhütungsvorschrift AccidentPreventionRegulations StVZO Straßenverkehrzulassungsordnung GermanTrafficRegulations Edition 09 2006 Printed 09 2006 ...

Page 4: ... of personnel and necessary qualifications basic responsibilities 1 12 2 Signs 3 Protection against theft 3 1 Identifying features on the loader 3 2 3 2 Parking the loader 3 2 3 3 Transponder for drive away interlock 3 3 4 Description 4 1 Overview 4 2 4 2 Swivel unit and axle support 4 3 4 3 Floatingposition 4 3 4 4 Bucket position indicator 4 3 4 5 Lifting device suspension option 4 3 4 6 Fan rev...

Page 5: ... 2 7 1 1 1 Towing the swivel shovel loader if the engine has failed 7 2 7 1 1 2 Towing the swivel shovel loader if the drive has failed 7 5 7 2 Lifting by crane 7 7 8 Maintenance 8 1 Notesregardingmaintenance 8 3 8 2 Maintenancework 8 4 8 2 1 Engine oil level check 8 4 8 2 2 Coolant level check 8 4 8 2 3 Oil level check for axles 8 4 8 2 3 1 Rearaxle 8 4 8 2 3 2 Planetary gear 8 5 8 2 3 3 Frontaxl...

Page 6: ...11 9 Brake system 11 3 11 10 Electricalsystem 11 3 11 11 Hydraulic system 11 3 11 11 1 Working hydraulics 11 3 11 11 2 Swivel unit hydraulics 11 3 11 11 3 Supportsystem 11 4 11 12 Fuel supply system 11 4 11 13 Heater and ventilation system driver s cabin 11 4 11 14 Suction return flow filter hydraulics 11 4 11 15 Electric contamination indicator 11 4 11 16 Oil cooler hydrostatic 11 4 11 17 Noiseem...

Page 7: ...Safety Regulations ...

Page 8: ... 2 Themachineandmanufacturer approvedattach ments may only be used in a technical non objectionable condition taking all safety regulations into account especially with regard to the operating manuals machine and engine In particular defects which could have a detrimental effect on the safety of the machine should be eliminatedimmediately 1 2 3 The machine is designed exclusively for the purposes ...

Page 9: ...ting caught or being pulled in 1 3 6 Allsafetyanddangerplatesonthemachinemust beobserved 1 3 7 All safety and danger plates must be attached to the machine and must be kept legible 1 3 8 Incaseofmodificationstothemachine especially in case of damage or changes in the operating behaviour of the machine which could influence its safety stop the machineimmediatelyandinformtheresponsiblepersonin charg...

Page 10: ...ns must not be transported 1 5 1 2 Startanddrivethemachinefromthedriver sseat only 1 5 1 3 Observe the control lamps according to the ope ration manual machine and engine during starting and switching offoperation 1 5 1 4 Before commencing work driving make sure thatthebrakes steering signalbeaconsandlightsfunction 1 5 1 5 Before moving the machine always check that the attachments are safely stow...

Page 11: ... behaviour imme diately to the person in charge If necessary stop the machine immediately and secure it 1 5 1 15 Thedrivermayslewtheattachmentsinoverhead driving operatingandworkingareasonlyiftheseareasare suitablysafeguardedbyprotectiveroofing Theseprotec tion roofs must offer appropriate safety against loads and falling goods If you are in doubt assume no protection roofsarepresent 1 5 1 16 When...

Page 12: ...ided to prevent the machine from running or sliding down 1 5 1 27 Avoid such work which could have a detrimental effect on the stability of the machine The following may affect the stability overloading ground that is too soft abruptaccelerationordecelerationofdrivingorworking movement reversing out of a high driving speed working on slopes driving too quickly round sharp bends drivingthemachineon...

Page 13: ... 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 uninten tional movement were taken Duringmaintenanceandrepairworkunderthebucketarm the bucket arm must be mechanically supported e g insert the bucket arm support option 1 1 arrows the hand lever for working and auxil...

Page 14: ... Use safety harnesses when working at very great heights All handles steps railings platforms scaffolds and ladders must be kept free from dirt and ice 1 5 2 16 Clean the machine especially connections and screw connections before commencement of mainte nanceworkandmakesurethatthemachineisfreefromoil fuel oil or dirt Do not use aggressive detergents Use lintless cleaning rags 1 5 2 17 Beforecleani...

Page 15: ...eadlinesandoverhead wires a safety clearance must be kept between the machine and its working equipment in order to prevent sparkingover Thesafetyclearancedependsonthenomi nal voltage of the overhead wire line This also applies to thedistancebetweenthelinesandtotheattachmentsand slung loads Thefollowingsafetyclearancesmustbeobservedtomeet theabovementionedrequirement Nominalvoltage Safetyclearance...

Page 16: ...in battery switch must be disconnected beforeinspection maintenanceorrepairofmachineparts and components so that they are not under power 1 6 1 7 Electric welding operations may only be per formed if the main battery switch has been removed 1 6 2 Hydraulics 1 6 2 1 Only experts with special expertise and expe rience may carry out work on the hydraulic system 1 6 2 2 Allpipelines hosesandscrewconne...

Page 17: ...ease 1 6 5 Gas dust steam smoke 1 6 5 1 The machine may be operated in closed rooms only if sufficient ventilation is ensured Ensure sufficient ventilation prior to starting the machine The regulations for the respective working site must be strictlyobserved 1 6 5 2 Carry out welding burning and grinding work on the machine only when this is explicitly approved Other wise there is the danger of fi...

Page 18: ...2 Inform yourself of the location use of fire extin guishers 1 5 arrow andfirst aidkit 1 6 arrow 1 8 1 3 When travelling on public roads a first aid kit a warning triangle and a warning lamp must be available on thevehicle 1 8 2 Selectionofpersonnelandnecessary qualifications basic responsibilities 1 8 2 1 Onlyreliablepersonsareallowedtoworkon with the machine The minimum legal age must be observe...

Page 19: ...Signs ...

Page 20: ...riving on public roads AS 210 AS 210 11 20 12 2 1 9 15 16 18 19 20 21 1 2 4 5 6 7a 9 10 11 20 1 1 2 14 12 13 2 5 bar 2 5 bar 23 24 7b 22 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 Betriebserl...

Page 21: ...ow noise construction machine 10 Symbol Hydraulic oil tank 11 Sign Maximum speed 12 Symbol Open only when the engine is not running 13 Sign Tyre pressure 14 Sign Maintenance schedule 15 Sign CAUTION Steering only possible when engine is running 16 Sign CAUTION Use only rear wheel steering when driving on public roads 17 Symbol Gear shift 2nd gear 1st gear Alpha max 18 Symbol Hand lever for working...

Page 22: ...ProtectionAgainstTheft ...

Page 23: ... type and the per missibleoverallweight 3 2 Parking the loader 1 Turn the steering wheel fully to the left or the right 2 Apply the parking brake 4 9 7 3 Tip the quick change device until the tines of the bucket the tines of the fork lift attachment or the boom of the lifting hook etc is placed on the ground 4 Closetheballblockvalvefortheworkingandauxiliary hydraulics 4 8 2 5 Set the drive switch ...

Page 24: ...ivatesvitalloaderfunctions If the transponder e g a tag at the ignition key is taken awayfromthereceiverunit intheimmediatevicinityofthe ignition lock these vital functions are interrupted Advantages in case of an insured event The transponder for drive away interlock meets the new stricter requirements of the insurance companies Ask your insurance company for the appropriate details ...

Page 25: ...Description ...

Page 26: ...ader and to develop it further technically These modifications are summarised in section 13 4 1 Overview 1 Bucket protection 2 Bucket attachment 3 Deflectionlever 4 Tip cylinder 5 Bucket arm 6 Lift cylinder 7 Driver scab 8 Drivemotor 9 Hydraulic oil reservoir filler neck 10 Rear axle 11 Batterycompartment 12 Toolbox 13 Revolvingseat 14 Front axle 15 Quick changedevice 16 Fuel tank right loader sid...

Page 27: ...as levelling grading on uneven ground to be performed To do this move the hand lever for the working hydraulics 4 9 6 forwards beyond its pressure point Thehandleverremainsinthispositionuntilthebucketarm is to be raised again by moving the hand lever in the oppositedirection DANGER Thefloatingpositionmayonlybeactivatedwhen the bucket arm is in the lowermost position 4 4 Bucket position indicator T...

Page 28: ...must be properly marked 1 Park the loader on a hard surface 2 Set the drive switch 4 9 5 to 0 3 Apply the parking brake 4 9 7 4 When changing a wheel on the front axle Lift and mechanically prop up the bucket arm e g by inserting the bucket arm support option 1 1 arrows and lower the bucket arm until it rests on the bucket arm support Block the swivel unit To do this remove the blocking wedge 1 3 ...

Page 29: ...wheel from the wheel hub by moving it back and forth Remove the wheel and roll it aside 13 Mount the new wheel onto the planetary axle NOTE Onlythetyresthatarelistedinsection11 7are permitted Pay attention to the profile position If the profile position of the spare tyre does not fit thesparetyremayonlybeusedtemporarily until a suitable tyre can be fitted All four tires must be the same size and h...

Page 30: ...ndicator lamp assembly 2 Fuelgauge 3 Coolanttemperaturegauge 4 Operatinghoursmeter 5 Tachometer 6 Engine oil pressure indicator lamp 7 free 8 Parking brake indicator lamp 9 Hydraulic oil temperature indicator lamp 10 Turn signal indicator lamp 11 free 12 High beam indicator lamp 13 free 14 free 15 Hydraulic oil filter clogging indicator 16 Service brake failure indicator lamp andwarningbuzzer 17 G...

Page 31: ...shbuttons not pressed Differentiallockdisabled 3 Actuator for auxiliary hydraulics forloaderswithboltlock standardequipment upperpushbutton Lock attachment Closemultipurposebucket bottompushbutton Unlock attachment only in conjunction with 4 7 1 Openmultipurposebucket 3 Actuator for auxiliary hydraulics forloaderswithclawlock optionalequipment upperpushbutton Closemultipurposebucket bottompushbutt...

Page 32: ...Rocker switch for working floodlights step 1 front step 2 front and rear 8 Rocker switch for heated rear screen 9 Rocker switch for 360 light opt 10 Rocker switch for bucket cushioning opt 11 not used 12 Push button for fan reversal opt 13 not used 4 9 Fuses NOTE Fuses relays the turn signal relay the interval timer etc arelocatedattherightbehindthedriver s seat 4 13 To access them push the seat t...

Page 33: ...Operation ...

Page 34: ... block valve for the working and auxiliary hydraulics 1 2 arrow openifnecessary only if work is to be commenced General state of the loader e g check for leaks Thepresenceof a fist aid kit awarningtriangle a signal lamp mustbeverified 5 2 Commissioning 5 2 1 Starting the diesel engine 1 Engagetheparkingbrakelever 4 9 7 2 Insert the battery main switch 8 21 2 NOTE The vehicle is ready for operation...

Page 35: ...ent temperature with the machine idling Proper operation of the machine even for subzero temperatures can only be guaranteed if the following measures have been taken 5 2 2 1 Fuel Atlowtemperatures paraffinprecipitatingfromthefuelcan cause the fuel system to clog up For this reason always use winter diesel fuel suitable for temperatures down to 15 C when the outside temperature is below 0 C NOTE T...

Page 36: ...eisexpectedtodropbelow0 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 Heedtheinstructionsprovidedbythemanufacturer for the mixture ratio 5 2 3 Driving the loader on public roads CAUTION Drivingonpublicroadsisonlypermittedwith an empty standard or multi purpose bucket and only with bucket protection When the road ...

Page 37: ...ith the bucketprotector 5 4 arrow 5 Insert the plug of the bucket protector into the socket 5 5 arrow option 6 Perform a function check 7 Lock both doors 8 Put on the safety belt 9 Switchtheswitchingleverforthesteeringtothe rear wheelsteering position 4 8 3 DANGER Theworkinglights 4 12 7 mustbeswitchedoff 10 Release the parking brake 4 9 7 11 Switch to gear stage II 4 9 1 12 Select the travel dire...

Page 38: ...4 Select the travel direction 4 9 5 5 Press the accelerator pedal 4 7 3 NOTE To attain full performance the combined action of propulsion and of the working hydraulicsisnecessary Itisuptotheoperator to control the available power using the accelerator the inching function and the hand lever for the working hydraulics The travel speed and the thrust force are altered exclusively by depressing the a...

Page 39: ...st be briefly swivelled in the direction of travel so that the axle block can be cancelled 5 2 5 Heater and ventilation system 5 2 5 1 Set the air flow 1 Turntherotaryswitch 5 6 2 fortheblowertoposition 0 1 2 or 3 depending on the air flow desired 2 Adjust the air flow direction with the nozzles at the windshield 5 7 arrows orinthefloorarea 5 8 arrows 5 2 5 2 Switching on the heater 1 Turn the kno...

Page 40: ...ry hot or has been subjected to heavy loads let the engine idle for a short time before switching it off Turn the ignition key to the left to position 0 5 1 and remove the key NOTE Inposition P theparkinglightandthedashboard illumination remain switched on 5 3 3 Switching off the heater and ventilation system 1 Shut off the hot air supply 5 6 1 2 Turntherotaryswitch 5 6 2 fortheblowertoposition 0 ...

Page 41: ...r s weight 40 130 kg with the handwheel 5 10 1 5 Adjust the height of the arm rest by turning the knob 5 9 2 6 Readjustthepositionofthepilotvalvefortheworking and auxiliary hydraulics 4 9 4 if necessary 7 The operator s seat can be adjusted in the horizontal direction to suit the driver s requirements by pulling the handle 5 10 2 upwards and moving the seat forward or backward 5 4 2 Grammer seat 1...

Page 42: ...ed 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 Pushtheremovedcap onto the nut ag...

Page 43: ...ction 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 type CAUTION The wheels of the rear axle must be straight before the switching lever 5 17 arrow can be applied Enable the steering switch only when the loaderisatastandstill Toswitcht...

Page 44: ...Attachments ...

Page 45: ...idling speed so that the retraction speed of the locking bolts does not become too high 5 Checkthatthedeviceismountedandlockedcorrectly on both sides DANGER Thetwoboltsofthequick changedevicemustbe in the bore holes of the bucket suspension and must be clearly visible 6 3 arrow Dismounting 1 Place the bucket firmly on the ground 2 Press the release button for the quick change device 4 7 1 and whil...

Page 46: ... quick change device 4 7 1 NOTE Whenthereleasebuttonforthequick change device is pressed the claws release as long as the button is pressed The bucket claws engage again when the button is released 6 Checkthatthedeviceismountedandlockedcorrectly on both sides DANGER The bucket is mounted and locked correctly when the bucket is located next to the quick change device and the piston rods of the quic...

Page 47: ...l distance fromthecentre 6 8 arrows andsecurethem with socket pins Distribute the load equally on both fork tines and secure it against moving and falling off Let the load rest against the rear of the fork and tilt the fork lift attachment NOTE The type plate is on the rear of the upper fork carrier 6 3 Mounting and dismounting attach ments with hydraulic connections to loaders with claw locks opt...

Page 48: ...emovethepressurefromthehydrauliclines Forthis purpose press both pushbuttons for the auxiliary hy draulics 4 9 3 alternatingly several times 9 Unscrew the protective caps 6 12 1 of the hoses of the multi purpose bucket 10 Unscrew the protective caps 6 12 2 of the quick change couplings on the bucket arm and connect the hoses of the multi purpose bucket 6 12 3 to those in the bucket arm CAUTION Whe...

Page 49: ...31 Z200 6 6 6 Attachments Figure 6 13 Figure 6 14 Figure 6 15 Notes on the application of the multipurpose bucket The multi purpose bucket can be used for peeling 6 13 scraping 6 14 grabbing 6 15 and in bucket operation ...

Page 50: ...is mounted and locked correctly when it is located next to the quick change device and the piston rods of the quick changedevicecylindercanbeplainlyseen 6 17 arrow Dismounting Thefront endexcavatorisdismountedinamannersimilar tothemulti purposebucket section6 3 1 exceptthatthe four hydraulic hoses of the front end excavator must be disconnected from the four quick change couplings of the quick cha...

Page 51: ...OTE The movements of the grab bucket can be seen in the symbols of the sign for the auxiliary hydraulic system The grab bucket can be turned to the left or right around its vertical axis without limits Mounting The grab bucket is mounted in a manner similar to the multi purpose bucket section 6 3 1 except that all four hydraulic hoses of the grab bucket must be connected to thefourquick changecoup...

Page 52: ... correspond to the symbols in the sign for the auxiliary hydraulic system DANGER Thegrabbucketismountedandlockedcorrectly whenitislocatednexttothequick changedevice and the piston rods of the quick change device cylinder can be plainly seen 6 22 arrow Dismounting Dismountingiscarriedoutinthesamewayasforthemulti purpose bucket section 6 3 1 NOTE Thetypeplateisonthetopsideoftheboom near the support ...

Page 53: ...Rescue Towing Lashing Lifting by Crane ...

Page 54: ...r the engine has failed thus causing a failure of the entire hydraulic system or if only the drive has failed and the engine can drive the rest of the hydraulic system 7 1 1 1 Towing the swivel shovel loader if the engine has failed 1 Actuate the toggle switch for the hazard flasher 4 5 6 2 Secure both wheels of the front axle against rolling away in both directions 3 Set the drive switch 4 9 5 to...

Page 55: ...ing the lifting gear Collect the escapinghydraulicoilinasufficientlylargeoil pan After towing has been completed fill the liftingcylinderswithhydraulicoilanddeaerate them by raising and lowering the bucket arm severaltimes 10 Mechanicallypropupthebucketarm e g byinserting the bucket arm supports option 1 2 arrows and lower the bucket arm until it rests on the bucket arm support 11 Closetheballbloc...

Page 56: ...ick release hex screws 7 5 arrow within the caps and screw them into the spring cylinder 7 6 arrow until a definite stop can be felt This tensions the spring package 17 Screw both caps on again and tighten manually NOTE After towing is completed unscrew the caps 7 4 arrows again removethequick releasehex screws 7 6 arrow insert them in the caps 7 5 arrow and tighten the caps again by hand i ...

Page 57: ...points see 7 2 1 and 7 2 2 or 7 3 1 and7 3 2 Themax permissibleloadoftheshunting and towing coupling 7 2 1 is 8 0 t horizontally in the longitudinal direction Themax permissibleloadoftherearshunting and towing coupling 7 3 1 is 12 0 t horizontally in the longitudinal direction The max permissible load of the lashing points loadbearingpoints 7 2 2and7 3 2 is 4 0 t at an assumed bracing angle of 45 ...

Page 58: ...lock 1 4 arrow 10 Attach the tow rod to the loader to be towed 7 2 1 forwardstowing or7 3 1 rearwardstowing and to the towing vehicle CAUTION If the front of the loader does not have a shunting and towing coupling the loader may only be towedrearwards 11 Switch the hydrostatic drive motor to free oil flow before towing For this purpose screw in the setscrews at both high pressure relief valves 7 7...

Page 59: ... the parking brake 4 9 7 2 Set the drive switch 4 9 5 to 0 3 Switch to gear stage Alpha max 4 9 1 4 Liftorlowerthebucketarmuntilthelowestpointofthe bucketarmorofthebucketisatleast30 cmabovetheroad 5 2 5 Closetheballblockvalvefortheworkingandauxiliary hydraulics 4 8 2 6 Block the swivel unit by inserting the blocking wedge 1 3 arrow intotheswivelblock 1 4 arrow 7 Lock both doors 8 Fold the outside ...

Page 60: ...Maintenance ...

Page 61: ...ry gear oil 4 2 gear distribution gear 4 1 Check distribution gear oil level check plug 4 2 Change distribution gear oil 5 Wheels and tyres 5 1 Check air pressure 5 2 Check fastening of wheel nuts 550 Nm 6 Cardan shafts ball bearing ring axes 6 1 Check fastening of cardan shafts 115 Nm 6 2 Check fastening of ball bearing rings 610 Nm 6 3 Check fastening of axles 385 Nm 7 Hydraulic systems 7 1 Repl...

Page 62: ...ked 1 4 arrow Theloadermustbesecuredagainstrollingby applying the parking brake 4 9 7 and by setting the drive direction switch 4 9 5 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...

Page 63: ...he compensationtank 8 1 arrow inthemotorcompartment is located on the right side of the loader the filling hole is locatedattheenginehood 8 2 arrow Thelevelofcoolant must be between the Minimum and Maximum marks CAUTION Ifcoolantneedstobeadded notethatthewater anti freeze mixing ratio is 2 1 8 2 3 Oil level check for axles 8 2 3 1 Rear axle 1 Unscrew the plug from the axle arch 8 3 arrow NOTE The ...

Page 64: ... fill oil into the plug bore until the oil reaches the required level 2 Fit a new gasket and screw the plug back in 8 2 4 Oil level check distribution gear 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...

Page 65: ...left side of the loader 8 8 arrow 3 Unscrew the covering plate of the oil drain plug 4 Screwthedrainagenozzlewithhosefromthetoolbox 4 1 12 to the oil drain plug 5 Remove the cover cap from the hose 6 Further procedures are to be found in the Engine OperatingManual 8 2 7 Oil change axles 8 2 7 1 Rear axle 1 Place a sufficiently large oil drain pan underneath 2 Unscrew the plugs from the axle arch 8...

Page 66: ...chapter 8 After a few minutes when the oil level has lowered topuptheoiluntiltheoilreachesthe marked level and remains stable 6 Use new gaskets when screwing the plug back in 8 2 7 3 Front axle 1 Place a sufficiently large oil drain pan underneath 2 Unscrew the plugs from the axle arch 8 11 1 and 8 11 2 and drain the oil CAUTION Waste oil must be disposed of in such a way that it will not cause po...

Page 67: ...tick 8 12a 1 8 Fill in oil through the filling plug bore of the lower oil compartment 82 3 until the oil reaches the lower edge of the oil inspection bore 8 12 4 NOTE Information about the quantities of oil is given in the maintenance plan chapter 8 9 Screw the filling 8 12 1 and 8 12 2 and inspection plugs 8 12a 4 back in with new gaskets 8 2 9 Oil change hydraulic system 1 Have an oil pan ready ...

Page 68: ...NOTE The clogging indicator may light up prematurely after a cold start It will go out when the hydraulic oil warms up 1 Open the maintenance flap of the hydraulic oil reser voir 8 15 1 2 Loosen but do not unscrew both screws of the hy draulic oil filter lid 8 15 2 or 8 16 1 3 Turn the hydraulic oil filter lid with the magnetic tube 8 15 4 or 8 16 2 to the left and lift it out Collect hydraulic oi...

Page 69: ... attached The pipe must be sufficiently long to reach the bottom of the cartridge Use dry compressedairofnomorethan5 bartoblow outthecartridgebymovingthepipebackand forth in the interior of the cartridge Cleaning canbestoppedwhendustformationceases Do not use petrol or hot liquids for cleaning 5 Useahand heldlamptocheckthecartridgepaperand the rubber gasket of the filter cartridge for damage If th...

Page 70: ...ew ones 4 The remaining installation is performed as described in section 8 2 11 6 8 8 2 13 Replacing the fuel filter See the operating instructions for the engine 8 2 14 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 1 Dismount the maintenance flap 8 22 2 Remove the main ba...

Page 71: ...r cleaning 4 Check the filter element for damage NOTE The filter element must be replaced when it is damaged butatleastevery1500operatinghours 5 Insertthefilterelementandreinstallthefiltercartridge andcompensatorcovers 8 2 17 Checking adjusting the service spring parking brake DANGER Thecombinedservice parkingbrakemustbe checked and if necessary adjusted every 500 operating hours All work on the b...

Page 72: ...25 2 and the steering cylinder bearings 8 25 3 must all be lubricated every 50 operating hours NOTE Lubricatetheaxlespindlebolts topandbottom the track rod bearings and the steering cylinder bearings on both sides of the axle 8 2 18 2 Rear axle pivot bolts CAUTION Therearaxlepivotbolts 8 26 arrowand8 27 arrow mustbelubricatedevery10operating hours Release the rear axle from load before lubricating...

Page 73: ... 8 28 2 and the steering cylinder bearings 8 28 3 mustallbelubricatedevery50operatinghours NOTE Lubricatetheaxlespindlebolts topandbottom the track rod bearings and the steering cylinder bearings on both sides of the axle 8 2 18 4 Rear cardan shaft CAUTION The cardan shaft must be lubricated every 50 operatinghours 8 29 arrowand8 30 arrow Figure 8 28 i ...

Page 74: ...rease becomes visible on the outside When lubricating the ball bearing ring swivel the bucket arm by 20 at a time Then lubricate all four grease nipples 8 33 arrows at each stage 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 bucketarmsupport optional 1 1...

Page 75: ...ymustbelubricatedevery10 operating hours 2x item 8 34 1 Tip lever pivot arm 2x item 8 34 2 Pivot arm reversing rod 2x item 8 34 3 Tiplever quick changedevice 2x item 8 34 4 Bucketassembly quick changedevice 2x Item8 35 1 Pivot arm bucket assembly 2x Item8 35 2 Reversinglever reversingrod 2x item 8 36 1 Bucket assembly swivel unit 4x item 8 36 2 Lift cylinder Figure 8 34 ...

Page 76: ...aps CAUTION Thehingesoftheengineflaps 8 28 arrows must be lubricated every 50 operating hours 8 2 18 9 Multi purpose bucket CAUTION The bearing bolts of the multi purpose bucket must be lubricated every 10 operating hours NOTE The bolt 8 39 arrow must be lubricated on both sides of the multi purpose bucket Figure 8 37 i ...

Page 77: ...S220 S221 S230 S231 Z200 8 18 8 Maintenance Figure 8 40 NOTE The bolts 8 40 arrows must be lubricated on both sides of the multi purpose bucket i ...

Page 78: ...Faults Causes and Remedies ...

Page 79: ...ck Swivel block blocks swivelling 1 4 arrow Pressure reliefvalveinservovalveis open Switchingofstopvalveinframeunder revolvingseatstuck Non returnvalveinpressureline stuck in open position Remedy Seetheoperatinginstructionsforthe engine Set the drive switch to the neutral position Remove and clean pressure relief valvecoupling readjust Unlockpilotvalve 4 8 2 Open clean and readjust pressure relief...

Page 80: ...heatingof the attachment Remedy Replace filter cartridge section 8 2 10 Top off oil Connect or clean electrical connection according to electrical plan clean Check setting adjust if necessary Check whether electrical traction drive break is connected to brake lever Press in and lock connection ReplaceV belt Check V belt tension tighten if necessary Replacefuse Carefully loosen the screwed connecti...

Page 81: ...Diagrams ...

Page 82: ...2 4 1 4 10 1 10 1 06 2005 Elektrik Schaltplan Schéma électrique Wiring diagramm Elektrisch schakelschema 1 2 3 4 5 6 7 8 9 10 12 S220 S221 S230 S231 Z200 IA IB IC 11 ...

Page 83: ...2005 Elektrik Schaltplan Schéma électrique Wiring diagramm Elektrisch schakelschema 13 21 37 2 4 45 S220 S221 S230 S231 Z200 48 14 15 16 17 18 19 20 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 38 39 40 41 42 43 44 47 46 A B C ...

Page 84: ...5 Elektrik Schaltplan Schéma électrique Wiring diagramm Elektrisch schakelschema 49 50 51 52 54 53 55 56 57 61 S220 S221 S230 S231 Z200 74 68 69 70 71 72 73 75 76 77 78 79 80 81 82 83 84 85 86 87 62 67 63 64 65 66 58 60 59 88 ...

Page 85: ...kelschema 4 4 S220 S221 S230 S231 Z200 89 90 103 104 105 106 107 108 109 110 111 113 114 115 116 117 118 119 120 121 122 124 125 126 127 128 129 130 131 98 Y1 Y2 DS1 DS4 DS2 Y14 Y3 Y63 Y64 Y11 Y50 Y10 Y7 G2 Y12 112 Y5 91 92 93 94 95 96 97 101 99 100 102 123 132 133 134 135 Y15 Y13 Y6 TS1 DS3 ...

Page 86: ...lamp assembly 02 Fuelgauge 03 Coolanttemperaturegauge 04 Tachometer 05 Operatinghoursmeter 06 Actuator release of quick change device 07 Actuator rearwindowwiper washer 08 Actuator road lights 09 Actuator hazardflasher 10 Start switch 11 Indicator lamp assembly for gear shift 12 Steering column switch ...

Page 87: ...de light 28 Light indicator diode chapter 4 9 B8 Diode light 29 Fuse chapter4 9 C1 Hazardflasher 30 Fuse chapter4 9 C2 Warningbeacon opt headlampflasher 31 Fuse chapter4 9 C3 2 pole socket 32 Fuse chapter4 9 C4 Cigarettelighter 33 Fuse chapter4 9 C5 Interiorlighting 34 Fuse chapter4 9 C6 Working lights 35 Fuse chapter4 9 C7 Dippedbeam 36 Fuse chapter4 9 C8 Highbeam 37 Relay for auxiliary hydraulic...

Page 88: ... system 63 Air condition on off switch 64 Pressure switch air conditioning system 65 Pressure switch air conditioning system 66 Pressure switch air conditioning system 67 Air condition fan switch 68 Ventilation motor for air conditioning system 69 Air condition condenser fan 70 Air condition condenser fan 71 License plate illumination 72 License plate illumination 73 Interiorlighting 74 Interiorli...

Page 89: ... brake failure 115 Auxiliary hydraulics valve open bucket 116 Auxiliary hydraulics valve close bucket 117 Alphamax valve 118 Gear switch valve only for fast loaders 119 Differentiallockvalve 120 Combination valve pipe break protection lifting device suspension option 121 Reservoirvalve liftingdevicesuspension option 122 Memoryvalve liftingdevicesuspension option 123 Pressure switch lifting device ...

Page 90: ...ringcylinder80 40 152 472 5 15 Doubleshockvalve 16 Steeringswitchingvalve 17 Blockingvalve 18 Steering unit 300 100 cm rev 19 Priorityvalve 20 Drive motor A6VM 160 EP2D 21 Gear typepump 51 27 cm rev 22 Drive pump A4VG 125 DA 23 Drivemotor 24 Gear typepump14cm rev 25 Suction strainer 26 Electric contamination indicator 27 Combined suction and return flow filter 28 Hydraulic oil tank 29 Hydraulic oi...

Page 91: ...3 4 T1 G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 3 5 b 3 5 b 150 bar P P A B G1 2 G1 2 G1 2 G1 2 A2 B2 A1 B1 240 B P A T G3 8 G3 8 G3 8 G3 8 T ZL ZR S L R 240 240 G1 2 G1 2 200 L R G1 2 G1 2 P T L S G1 4 140 G1 2 G3 4 G1 4 LS P G3 4 CF E F X G1 4G1 4 G1 4G1 4 G1 4 G1 4 P T A B T P G1 4 G1 4 G1 4 G1 4 S 100 bar MA 1 4 A P A B R G3 4 G3 4 2 bar 2 5 bar S2 S1 E1 J1 3 bar 0 04 bar 0 5 bar 100 muem 10 muem 40 muem...

Page 92: ... L 1 G3 4 T1 G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 3 5 b 3 5 b 150 bar P P A B G1 2 G1 2 A1 B1 240 B P A T G3 8 G3 8 G3 8 G3 8 T ZL ZR S L R 240 240 G1 2 G1 2 200 L R G1 2 G1 2 P T L S G1 4 140 G1 2 G3 4 G1 4 LS P G3 4 CF E F X G1 4G1 4 G1 4G1 4 G1 4 G1 4 P T A B T P G1 4 G1 4 G1 4 G1 4 S 100 bar MA 1 4 A P A B R G3 4 G3 4 2 bar 2 5 bar S2 S1 E1 J1 3 bar 0 04 bar 0 5 bar 100 muem 10 muem 40 muem 130 muem ...

Page 93: ...T1 G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 3 5 b 3 5 b 150 bar P P A B G1 2 G1 2 G1 2 G1 2 A2 B2 A1 B1 240 B P A T G3 8 G3 8 G3 8 G3 8 T ZL ZR S L R 240 240 G1 2 G1 2 200 L R G1 2 G1 2 P T L S G1 4 140 G1 2 G3 4 G1 4 LS P G3 4 CF E F X G1 4G1 4 G1 4G1 4 G1 4 G1 4 P T A B T P G1 4 G1 4 G1 4 G1 4 S 100 bar MA 1 4 A P A B R G3 4 G3 4 2 bar 2 5 bar S2 S1 E1 J1 3 bar 0 04 bar 0 5 bar 100 muem 10 muem 40 muem 130...

Page 94: ...L 1 G3 4 T1 G1 4 G1 4 G1 4 G1 4 G1 4 G1 4 3 5 b 3 5 b 150 bar P P A B G1 2 G1 2 G1 2 G1 2 A2 B2 A1 B1 240 B P A T G3 8 G3 8 G3 8 G3 8 T ZL ZR S L R 240 240 G1 2 G1 2 200 L R G1 2 G1 2 P T L S G1 4 140 G1 2 G3 4 G1 4 LS P G3 4 CF E F X G1 4G1 4 G1 4G1 4 G1 4 G1 4 P T A B T P G1 4 G1 4 G1 4 G1 4 S 100 bar MA 1 4 A P A B R G3 4 G3 4 2 bar 2 5 bar S2 S1 E1 J1 3 bar 0 04 bar 0 5 bar 100 muem 10 muem 40...

Page 95: ...80 40 152 472 5 15 Doubleshockvalve 16 Steeringswitchingvalve 17 Blockingvalve 18 Steering unit 300 100 cm rev 19 Priorityvalve 20 Drive motor A6VM 160 EP2D 21 Gear typepump 51 27 cm rev 22 Drive pump A4VG 125 DA 23 Drivemotor 24 Gear typepump14cm rev 25 Suction strainer 26 Electric contamination indicator 27 Combined suction and return flow filter 28 Hydraulic oil tank 29 Hydraulic oil cooler 30 ...

Page 96: ...der80 40 152 472 5 15 Doubleshockvalve 16 Steeringswitchingvalve 17 Blockingvalve 18 Steering unit 300 100 cm rev 19 Priorityvalve 20 Drive motor A6VM 160 EP2D 21 Gear typepump 51 27 cm rev 22 Drive pump A4VG 125 DA 23 Drivemotor 24 Gear typepump14cm rev 25 Suction strainer 26 Electric contamination indicator 27 Combined suction and return flow filter 28 Hydraulic oil tank 29 Hydraulic oil cooler ...

Page 97: ...80 40 152 472 5 15 Doubleshockvalve 16 Steeringswitchingvalve 17 Blockingvalve 18 Steering unit 300 100 cm rev 19 Priorityvalve 20 Drive motor A6VM 160 EP2D 21 Gear typepump 51 27 cm rev 22 Drive pump A4VG 125 DA 23 Drivemotor 24 Gear typepump14cm rev 25 Suction strainer 26 Electric contamination indicator 27 Combined suction and return flow filter 28 Hydraulic oil tank 29 Hydraulic oil cooler 30 ...

Page 98: ...Technical Data Loader ...

Page 99: ...e to the permitted slanting of the engine limited to 60 Max lifting capacity 106 kN Max thrust force 113 kN Tear out force 130 kN 11 2 Engine Type BF6M 2012C Water cooled turbodiesel engine with charge air cooling 6 cylinders 4 stroke direct injection Displacement 6 057 cm3 Performance acc to ISO 9249 128 kW at 2 200 rpm Cooling system Water Total coolant approx 16 l Anti freeze 8 l Exhaust gas em...

Page 100: ...n all four wheels Parking brake Spring loaded wet lamella brake in the rear axle Flow rate pump III 36 l min 11 10 Electrical system Battery 2 x 88 Ah 11 11 Hydraulic system Contents 230 l Hydraulic oil reservoir 180 l 11 11 1 Working hydraulics Flow rate pump I via priority valve 114 l min Flow rate pump II via swivel unit 60 l min Total flow rate 174 l min Operating pressure max 220 bar 2 lift c...

Page 101: ...2505 Heating capacity continuously adjustable 6 4 kW Air conditioning system capacity 5 5 kW Throughput 400 m h 11 14 Suction return flow filter hydraulics Filter mesh acc to ISO 4572 10 µm abs Bypass response pressure p 3 0 bar 11 15 Electric contamination indicator Switch on pressure p 2 5 bar 11 16 Oil cooler hydrostatic Performance max 35 kW Flow rate 56 l min 11 17 Noise emission Sound power ...

Page 102: ...Technical Data Attachments ...

Page 103: ...S200 S201 Z200 12 2 12 Technical Data Attachments L6 12 Attachments 12 1 Loaders with bolt locks Kat V NOTE The technical data refer to 20 5 25 tyres 12 1 1 Buckets Dimensions acc to ISO 7131 35 i ...

Page 104: ... mm 2 190 2 270 2 360 G Dumping height at max dumping distance and dumping angle 45 mm 1 350 1 290 1 285 H6 Depth of feed in mm 90 90 90 H8 Dumping height at max lifting height and dumping angle 45 mm 3 420 3 360 3 355 H10 Max working height mm 5 600 5 680 5 575 J Free lift height mm 3 660 3 660 3 660 LL Dumping distance at max lifting height and dumping angle 45 mm 890 970 985 L6 Dumping distance...

Page 105: ...S200 S201 Z200 12 4 12 Technical Data Attachments 12 1 2 Fork lift attachment Dimensions acc to ISO 7131 35 12 1 3 Lifting hook Dimensions acc to ISO 7131 35 ...

Page 106: ... uneven ground stability factor 1 67 4 800 kg A Total length 7 950 mm A5 Tilt angle 25 B Min reach 1 095 mm C Max reach 1 810 mm D Reach at max lifting height 950 mm G Free lift height at max reach 2 000 mm H6 Depth of feed in 100 mm HH15 Free lift height at max reach upper tine edge 4 100 mm KK Max reach 1 390 mm LL Distance between tyre and payload 1 750 mm MM Reach at max lifting height 500 mm ...

Page 107: ...S200 S201 Z200 12 6 12 Technical Data Attachments 12 1 4 Front end excavator Dimensions acc to ISO 7131 35 12 1 5 Grab bucket Dimensions acc to ISO 7131 35 ...

Page 108: ... of feed in 100 mm H22 Max dumping height acc to DIN ISO 7135 3 900 mm H24 Max digging depth over cutting edge acc to DIN ISO 7135 3 420 mm H25 Depth of feed in 1 420 mm Working times at nengine max Stalk extension 0 8 s Stalk retraction 1 6 s Opening shovel 0 8 s Closing shovel 1 6 s 12 1 5 Grab bucket Grab bucket type Grab bucket volume Scoop width Dead weight 0 245 m3 600 mm 510 kg C Max dumpin...

Page 109: ...S200 S201 Z200 12 8 12 Technical Data Attachments L6 12 2 Loaders with claw locks Kat IV NOTE The technical data refer to 20 5 25 tyres 12 2 1 Buckets Dimensions acc to ISO 7131 35 i ...

Page 110: ...m 2 100 2 170 2 170 G Dumping height at max dumping distance and dumping angle 45 mm 1 200 1 140 1 135 H6 Depth of feed in mm 70 70 70 H8 Dumping height at max lifting height and dumping angle 45 mm 3 120 3 060 3 055 H10 Max working height mm 5 450 5 530 5 425 J Free lift height mm 3 660 3 660 3 660 LL Dumping distance at max lifting height and dumping angle 45 mm 1 010 1 090 1 100 L6 Dumping dist...

Page 111: ...S200 S201 Z200 12 10 12 Technical Data Attachments 12 2 2 Fork lift attachment Dimensions acc to ISO 7131 35 12 2 3 Lifting hook Dimensions acc to ISO 7131 35 ...

Page 112: ...uneven ground stability factor 1 67 4 950 kg A Total length 7 600 mm A5 Tilt angle 25 B Min reach 900 mm C Max reach 1 560 mm D Reach at max lifting height 820 mm G Free lift height at max reach 1855 mm H6 Depth of feed in 110 mm HH15 Free lift height at max reach upper tine edge 3 830 mm KK Max reach 1 110 mm LL Distance between tyre and payload 1 500 mm MM Reach at max lifting height 370 mm PP M...

Page 113: ...S200 S201 Z200 12 12 12 Technical Data Attachments 12 2 4 Front end excavator Dimensions acc to ISO 7131 35 12 2 5 Grab bucket Dimensions acc to ISO 7131 35 ...

Page 114: ...h of feed in 100 mm H22 Max dumping height acc to DIN ISO 7135 3 640 mm H24 Max digging depth over cutting edge acc to DIN ISO 7135 3 520 mm H25 Depth of feed in 1 450 mm Working times at nengine max Stalk extension 0 8 s Stalk retraction 1 6 s Opening shovel 0 8 s Closing shovel 1 6 s 12 2 5 Grab bucket Grab bucket type Grab bucket volume Scoop width Dead weight 0 245 m3 600 mm 510 kg C Max dumpi...

Page 115: ...AdditionalOptions Modifications Notes on Inspection for Loaders ...

Page 116: ...S200 S201 Z200 13 2 13 AdditionalOptions Modifications 13 Additional options modifications notes on inspection for loaders 13 1 Additional options none 13 2 Modifications none ...

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