ahlmann AS 150 User manual

Ahlmann Baumaschinen GmbH Am Friedrichsbrunnen 2 D-24782 Büdelsdorf
Telefon [phone] Internet: www.ahlmann-baumaschinen.de
Telefax 04331/351404 E-Mail: [email protected]
AS 150
OPERATING INSTRUCTIONS
SWING SHOVEL LOADER
1000995A GB

S150/S151/S152/Z152 I
Table of Contents
Introduction
Preface
Ahlmann swing loaders, articulated loaders and front loaders are part of Ahlmann selection of heavy construction
equipment, and design for a wide range of uses.
Years of experience in manufacturing earth-moving equipment and various auxilliary tools, modern construction
and manufacturing approaches, careful testing and an stringent quality control assure the reliability of your
Ahlmann wheel loader.
Scope of documentation supplied by manufacturer:
- Equipment Operating Manual
- Engine Operating Manual
- Parts List Equipment
- Parts List Engine
- EU Statement of Conformity
Operating Manual
The operating manual contains information required for safe operations 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.
The manufacturer reserves the right to alter construction details, which may lead to some deviations between your
actual equipment and the figures shown in this manual, but will not affect the accuracy of the contents.
Using the Manual
Terminology
- The terms "left" or "right" refer to the equipment as viewed from the driver´s cab facing in direction of travel.
- Optional
means: Not included as standard equipment.
Note on Figures
- (3-35)
means: Chapter 3, Fig. 35
- (3-35/1)
means: Chapter 3, Fig. 35, Position 1
- (3-35/arrow)
means: Chapter 3, Fig. 35,

S150/S151/S152/Z152II
Table of Contents
Abbreviations used
SW = Safety at work regulations
RS = Road safety regulations
Version: 02.2007
Printed: 02.2007

S150/S151/S152/Z152 III
Table of Contents
Table of Contents
1 Basic Safety Notes
1.1 Warnings and symbols ............................................................................................................ 1 - 2
1.2 Appropriate use ....................................................................................................................... 1 - 2
1.3 Administrative tasks ................................................................................................................ 1 - 2
1.4 Selecting and training staff ...................................................................................................... 1 - 3
1.5 Safety notes in various operating modes.................................................................................. 1 - 4
1.5.1 Normal operations .................................................................................................................... 1 - 4
1.5.2 Special tasks applicable to using the equipment
and troubleshooting; waste disposal ........................................................................................ 1 - 7
1.6 Note on specific dangers ......................................................................................................... 1 - 9
1.6.1 Electrical power ....................................................................................................................... 1 - 9
1.6.2 Hydraulics ............................................................................................................................... 1 - 10
1.6.3 Noise levels ............................................................................................................................. 1 - 10
1.6.4 Oils, greases and other chemical substances ......................................................................... 1 - 11
1.6.5 Gas, dust, steam, smoke ........................................................................................................ 1- 11
1.7 Transporting and towing; re-commissioning ............................................................................. 1 - 11
1.8 Safety notes for the owner or responsible persons................................................................... 1 - 12
1.8.1 Administrative tasks ................................................................................................................ 1 - 12
1.8.2 Selecting and training staff; basic requirements....................................................................... 1 - 12
2 Signs
3 Anti-Theft Mechanism
3.1 Identification marks on the equipment...................................................................................... 3 -2
3.2 Parking the equipment ............................................................................................................. 3 - 2
3.3 Transponder immobilizer .......................................................................................................... 3 - 3
4 Description
4.1 Overview ................................................................................................................................... 4 - 2
4.2 Swing drive and undercarriage ................................................................................................. 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 "25 km/h" ........................................................................... 4 - 5
4.9 Changing wheels ..................................................................................................................... 4 - 5
4.10 Control elements ..................................................................................................................... 4 - 7
4.11 Dashboard ............................................................................................................................... 4- 8
5 Operations
5.1 Checks before you start ........................................................................................................... 5 - 2
5.2 Getting started ......................................................................................................................... 5 - 2
5.2.1 Starting the diesel engine ........................................................................................................ 5 - 2
5.2.2 Winter running ......................................................................................................................... 5 - 3
5.2.2.1 Fuel ......................................................................................................................................... 5 - 3
5.2.2.2 Engine oil change .................................................................................................................... 5 - 4
5.2.2.3 Hydraulic oil change ................................................................................................................ 5 - 4
5.2.2.4 Anti-frost for screen washer system......................................................................................... 5 - 4
5.2.3 Driving on public roads ............................................................................................................. 5 - 4
5.2.3.1 Transporting an excavator ........................................................................................................ 5 - 5
5.2.4 Working with the equipment .................................................................................................... 5 -6
5.2.4.1 Slow-runner type "20 km/h" and "25 km/h" .............................................................................. 5 - 6
5.2.4.2 Fast-runner type "40 km/h" ......................................................................................................5 - 6

S150/S151/S152/Z152IV
Table of Contents
5.2.5 Heating and ventilation system/Air conditioning unit(SA)......................................................... 5 - 8
5.2.5.1 Blower output ........................................................................................................................... 5 - 8
5.2.5.2 Turning on the heating ............................................................................................................. 5 - 8
5.2.5.3 Turning on the air conditioning unit (SA) ................................................................................. 5 - 8
5.2.5.4 Setting the temperature ........................................................................................................... 5 - 8
5.3 De-commissioning ................................................................................................................... 5 - 9
5.3.1 Switching off the equipment .................................................................................................... 5 - 9
5.3.2 Switching off the diesel engine ................................................................................................ 5 - 9
5.3.3 Switching of the Heating and ventilation system/Air conditioning unit(SA) .............................. 5 - 9
5.3.4 Leaving the vehicle .................................................................................................................. 5 - 9
5.4 Adjusting the driver seat .......................................................................................................... 5 - 10
5.4.1 Isri seat ................................................................................................................................... 5 - 10
5.4.2 Grammer seat .......................................................................................................................... 5 - 10
5.5 Changing the steering mode .................................................................................................... 5 - 12
6 Auxilliary Attachments
6.1 Attaching and detaching auxilliary devices without hydraulics ................................................. 6 - 2
6.1.1 Standard/Lightwork bucket ...................................................................................................... 6 - 2
6.1.2 Fork-lift attachment .................................................................................................................. 6 - 3
6.1.3 Lifting hook .............................................................................................................................. 6 - 4
6.2 Attaching and detaching auxilliary devices with hydraulics...................................................... 6 - 4
6.2.1 Multi-purpose bucket ............................................................................................................... 6 - 4
6.2.2 Front-end excavator ................................................................................................................ 6 - 7
6.2.2.1 Changing the backhoe ............................................................................................................ 6 - 8
6.3 Using other attachments .......................................................................................................... 6 - 8
7 Rescue, Towing, Lashing, Lifting by crane
7.1 Rescue, towing, lashing ........................................................................................................... 7 - 2
7.1.1 Rescue/towing the swivel loader in case of engine or transmission failure .............................. 7 - 2
7.1.1.1 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 Maintenance notes .................................................................................................................. 8 - 3
8.2 Maintenance tasks ................................................................................................................... 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 Rear axle ................................................................................................................................. 8 - 4
8.2.2.2 Planetary gear ......................................................................................................................... 8 - 4
8.2.2.3 Front axle................................................................................................................................. 8 - 5
8.2.3 Checking oil level in power take-off drive » slow-runners 20 km/h and 25 km/h « ................... 8 - 5
8.2.4 Checking oil level in power take-off drive » fast-runners 40 km/h « ....................................... 8 - 6
8.2.5 Checking oil level hydraulic oil container .................................................................................8 - 6
8.2.6 Changing the engine oil ........................................................................................................... 8 - 7
8.2.7 Changing the axle oil ............................................................................................................... 8 - 7
8.2.7.1 Rear axle ................................................................................................................................. 8 - 7
8.2.7.2 Planetary gear ......................................................................................................................... 8 - 8
8.2.7.3 Front axle................................................................................................................................. 8 - 9
8.2.8 Oil change power take-off drive » slow-runners 20 km/h and 25 km/h « ................................. 8 - 10
8.2.9 Oil change power take-off drive » fast-runners 40 km/h « ...................................................... 8 - 10
8.2.10 Oil change hydraulics system .................................................................................................. 8 - 11
8.2.11 Changing suction return filter media ........................................................................................ 8 - 12
8.2.12 Changing/Maintaining the air filter ........................................................................................... 8 - 13
8.2.13 Changing the safety cartridge ................................................................................................. 8 - 13
8.2.14 Changing the fuel filter ............................................................................................................ 8 - 14
8.2.15 Changing the starter battery .................................................................................................... 8 - 14
8.2.16 Changing/Maintaining the fresh air filter .................................................................................. 8 - 15
8.2.17 Checking/adjusting the service brake ......................................................................................8 - 15
8.3 Greasing points ....................................................................................................................... 8 - 16

S150/S151/S152/Z152 V
Table of Contents
8.3.1 Rear axle clevis pin .................................................................................................................. 8 - 16
8.3.2 Rear axle ................................................................................................................................. 8 - 16
8.3.3 Front axle ................................................................................................................................ 8 - 16
8.3.4 Swing roller bearing ................................................................................................................. 8 - 17
8.3.5 Bucket motor ........................................................................................................................... 8 - 17
8.3.6 Cab doors ................................................................................................................................ 8 - 17
8.3.7 Engine hood ............................................................................................................................ 8 - 18
8.4 Oiling points ............................................................................................................................ 8 - 18
8.4.1 Support valve switchgear .......................................................................................................... 8 - 18
9 Malfunctions, Causes and Troubleshooting
10 Wiring diagrams
10.1 Elektrical wiring diagram ........................................................................................................ 10 - 1
10.2 Hydraulic diagram .................................................................................................................. 10 - 4
10.2.1 Hydraulik-Schaltplan AS 150 (Bolzenverriegelung) Ausführung "20 km/h" und "25 km/h" ...... 10 - 4
10.2.2 Hydraulik-Schaltplan AS 150 (Bolzenverriegelung) Ausführung "40 km/h" ............................. 10 - 5
10.2.3 Hydraulik-Schaltplan AS 150 (Klauenverriegelung) Ausführung "20 km/h" ............................. 10 - 6
10.2.4 Hydraulik-Schaltplan AS 150 (Klauenverriegelung) Ausführung "40 km/h" ............................. 10 - 7
11 Technical Specifications (Equipment)
11.1 Equipment ............................................................................................................................. 11 - 2
11.2 Engine ................................................................................................................................... 11 - 2
11.3 Starter.................................................................................................................................... 11 - 2
11.4 Alternator ............................................................................................................................... 11 - 2
11.5 Hydrostatic drive .................................................................................................................... 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 Electrical equipment .............................................................................................................. 11 - 3
11.11 Hydraulic equipment .............................................................................................................. 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 (hydraulics) ............................................................................................. 11 - 4
11.15 Elektrical contamination display ............................................................................................ 11 - 4
11.16 Oil cooler (combi cooler) with thermostatic valve control ........................................................ 11 - 5
11.17 Noise levels ........................................................................................................................... 11 - 5
11.18 Options .................................................................................................................................. 11 - 5
11.18.1 Air conditioning (driver´s cab) .................................................................................................11 - 5
12 Technical Specifications (Attachments)
12.1 Buckets ................................................................................................................................. 12 - 2
12.2 Fork-lift attachment ................................................................................................................ 12 - 4
12.3 Front loader ........................................................................................................................... 12 - 6
12.4 Lifting hook ............................................................................................................................ 12 - 8
13 Additional Equipment, Changes ,
Sample "Notes on Testing Wheel Loaders"
13.1 Additional equipment ............................................................................................................. 13 - 2
13.1.1 Description ............................................................................................................................ 13 - 2
13.1.1.1 Pipe burst protection.............................................................................................................. 13 - 2
13.1.1.2 Lift range limiter ..................................................................................................................... 13 - 2
13.1.1.3 Service interval warning display ............................................................................................. 13 -2
13.2 Changes ................................................................................................................................13 - 3

Safety regulations

S150/S151/S152/Z1521-2
1 Safety regulations
1 Fundamental safety
instruction
1.1 Warnings and symbols
In this operation manual the following designations or
symbols are used for important information.
NOTE
Special information for the economical use of the
machine.
CAUTION
Special information for necessities and prohibi-
tions for avoiding damages.
DANGER
Information or necessities and prohibitions for
prevention of damage to persons or extensive
damage to goods.
1.2 Use of the loader as authorized
1.2.1 This machine was designed according to the
state of the art and recognized safety rules. Nevertheless
the use of the machine may cause danger for the user or
third parties or impairments to the machine or other real
values.
1.2.2 The machine and attachments may only be used
in a technical non-objectionable condition, taking all safety
regulations 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 eliminated immediately.
1.2.3 The machine is determined exclusively for the
purposes described in this operating manual. Any other
utilization is not permitted. The manufacturer is not liable
for any damage caused in this connection. The user solely
carries the risk.
The authorized use of the machine also requires the
observation of the operating manual (machine and engine)
as well as the observation of the inspection and mainte-
nance conditions.
1.3 Organizational measures
1.3.1 The operating manual (machine and engine) must
be available at all times and at the site where the machine
is in operating condition.
i

S150/S151/S152/Z152 1-3
Safety regulations 1
1.3.2 In addition to the operating manual (machine and
engine) the general applicable and other binding regula-
tions for the prevention of accidents (especially the safety
regulations of the German Trade Association - VBG 40) as
well as the regulations for environment protection must be
observed and the personnel must be accordingly instructed.
Traffic regulations must also be observed.
1.3.3 The personnel in charge of working with the
machine must read the operating manual (machine and
engine) before start of work, especially the chapter
concerning safety precautions.
This also applies to personnel working occasionally with
the machine, e.g. during maintenance work.
1.3.4 The driver must wear a seat belt during operation.
1.3.5 Personnel working with the machine must not
wear long flowing hair, loose clothing or jewelry including
rings as this could cause injuries by getting caught up or
pulled in by the machine.
1.3.6 All safety and danger plates on the machine must
be observed.
1.3.7 All safety and danger plates must be attached to
the machine and must be kept in legible condition.
1.3.8 In case of modifications to the machine, 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
competent person in charge about the incident.
1.3.9 Without the manufacturer’s consent, do not make
any modifications or conversions to the machine which
could affect safety. This also applies to the installation and
adjustment of safety devices, valves and welding work to
supporting parts.
1.3.10 Check hydraulic system, especially hydraulic
pipes, at regular intervals for defects. Immediately eliminate
any defects found.
1.3.11 The prescribed inspection periods set down in the
operating manual (machine and engine) and the mainte-
nance plan must be observed.
1.4 Selection of personnel and necessary
qualifications
Fundamental obligations
1.4.1 The machine may only be driven and maintained
by personnel selected by the employer for this purpose.

S150/S151/S152/Z1521-4
1 Safety regulations
These persons must:
- have attained the age of 18 years,
- be physically and intellectually suitable,
- have been instructed in the operation or maintenance of
the machine and must have demonstrated their ability to
their employer,
- must be expected to carry out the work conveyed to them
in diligent manner.
1.4.2 Electrical work on the machine may only be
carried out by a qualified electrician or persons supervised
by a qualified electrician according to the electrotechnical
regulations.
1.4.3 Only qualified specialists may carry out work on
the transmission mechanism and to the hydraulic system.
1.4.4 Only personnel with special experience and the
necessary know-how are permitted to carry out work on the
hydraulic system.
1.5 Safety Information for Certain
Operating Phases
1.5.1 Normal Operation
1.5.1.1 Other persons must not be transported!
1.5.1.2 Start and drive the machine from the driver’s seat
only!
1.5.1.3 Duringstarting andswitching-off operation observe
the control lamps according to the operation manual
(machine and engine)!
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 safely stowed so that no accident
may occur!
1.5.1.6 Before commencing work make yourself familiar
with the working environment. This means observing
obstacles on the working site, quality and resistance of the
soil ground, undertaking the necessary protection precau-
tions between the building site and the public traffic.
1.5.1.7 Before starting the machine make sure that no
person is endangered by the machine!
1.5.1.8 Take measures so that the machine can be
operated in a safe and functional manner. The machine
may only be operated when all safety devices, e. g.
detachable safety devices, sound-absorption, exist and
function.