ahlmann AS 210 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 210
OPERATING INSTRUCTIONS
SWING SHOVEL LOADER
GB

S220/S221/S230/S231/Z200 I
Table of Contents
Introduction
Preface
Ahlmann’s swivel shovel loaders, articulated loaders and loader excavators with backhoe are machines included
in Ahlmann’s vast product range covering a wide variety of working tasks.
Decades of experience in the construction of earth-moving machines, the wide range of attachments available as
well as modern production facilities, careful testing and highest quality demands guarantee the highest degree of
reliability of your Ahlmann machine.
The extent of documentation delivered by the manufacturer includes the following:
- Loader operating instructions
- Engine operating instructions
- Loader spare parts list
- Engine spare parts list
- EC conformity declaration
Operating instructions
The operating instructions contain all 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
by trained personnel.
This section does not cover more extensive maintenance work that is reserved to personnel authorized and trained
by the manufacturer. In particular, this applies to facilities governed by Motor Vehicle Construction and Use
Regulations and the Regulations for the Prevention of Accidents.
Due to the construction modifications reserved by the manufacturer, there may be differences in the figures;
however, this has no influence on the technical contents.
How to use this manual
Explanations
- The designations “left” and “right” are to be seen from the driver’s seat in the driving direction.
- Optional equipment
means: not fitted in series.
Information about illustrations
- (3-35)
means: chapter 3, fig. 35
- (3-35/1)
means: chapter 3, fig. 35, item 1
- (3-35/arrow)
means: chapter 3, fig. 35,

S220/S221/S230/S231/Z200II
Table of Contents
Abbreviations used
UVV = Unfallverhütungsvorschrift (Accident Prevention Regulations)
StVZO = Straßenverkehrzulassungsordnung (German Traffic Regulations)
Edition: 09.2006
Printed: 09.2006

S220/S221/S230/S231/Z200 III
Table of Contents
Table of Contents
1 Fundamental safety instructions
1.1 Warnings and symbols ............................................................................................................ 1 - 2
1.2 Proper use of the loader .......................................................................................................... 1 - 2
1.3 Organisational measures ......................................................................................................... 1 - 2
1.4 Selection of personnel and necessary qualifications ............................................................... 1 - 3
1.5 Safety Information for Certain Operating Phases .................................................................... 1 - 4
1.5.1 Normal Operation..................................................................................................................... 1 - 4
1.5.2 Special work regarding the use of the machine and elimination of defects during work; disposal . 1 - 7
1.6 Instructions regarding special categories of danger ................................................................ 1 - 9
1.6.1 Electrical energy ..................................................................................................................... 1 - 9
1.6.2 Hydraulics ............................................................................................................................... 1 - 10
1.6.3 Noise ....................................................................................................................................... 1 - 10
1.6.4 Oil, grease and other chemical substances ............................................................................. 1 - 11
1.6.5 Gas, dust, steam, smoke ......................................................................................................... 1 - 11
1.7 Transport and towing; recommissioning .................................................................................. 1 - 11
1.8 Safety information for the contractor or the contractor’s authorised personnel ....................... 1 - 12
1.8.1 Organizational measures ......................................................................................................... 1 - 12
1.8.2 Selection 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 Floating position ...................................................................................................................... 4 - 3
4.4 Bucket position indicator ......................................................................................................... 4 - 3
4.5 Lifting device suspension(option) ............................................................................................4 - 3
4.6 Fan reversal (option) ............................................................................................................... 4 - 4
4.7 Wheel change ......................................................................................................................... 4 - 4
4.8 Controls ................................................................................................................................... 4 - 6
4.9 Fuses ....................................................................................................................................... 4 - 8
5 Operation
5.1 Checks before start-up ............................................................................................................ 5 - 2
5.2 Commissioning ........................................................................................................................ 5 - 2
5.2.1 Starting the diesel engine ........................................................................................................ 5 - 2
5.2.2 Winter operation ...................................................................................................................... 5 - 3
5.2.2.1 Fuel ......................................................................................................................................... 5 - 3
5.2.2.2 Engine oil change .................................................................................................................... 5 - 4
5.2.2.3 Changing oil in the hydraulic system ....................................................................................... 5 - 4
5.2.2.4 Anti-freezing agent for the windshield washer system ............................................................. 5 - 4
5.2.3 Driving the loader on public roads ........................................................................................... 5 - 4
5.2.3.1 Carrying a bucket .................................................................................................................... 5 - 5
5.2.4 Working with the loader ........................................................................................................... 5 - 6
5.2.5 Heater and ventilation system .................................................................................................. 5 - 7
5.2.5.1 Set the air flow ......................................................................................................................... 5 - 7
5.2.5.2 Switching on the heater ........................................................................................................... 5 - 7
5.3 Decommissioning the loader ...................................................................................................5 - 8
5.3.1 Parking the loader ................................................................................................................... 5 - 8

S220/S221/S230/S231/Z200IV
Table of Contents
5.3.2 Switching off the diesel engine ................................................................................................ 5 - 8
5.3.3 Switching off the heater and ventilation system ....................................................................... 5 - 8
5.3.4 Leaving the loader ................................................................................................................... 5 - 8
5.4 Adjusting the driver’s seat ........................................................................................................ 5 - 9
5.4.1 Isri seat ................................................................................................................................... 5 - 9
5.4.2 Grammer seat .......................................................................................................................... 5 - 9
5.5 Switching the steering type...................................................................................................... 5 - 11
6 Attachments
6.1 Mounting and dismounting attachments without hydraulic connections to loaders
with bolt locks (standard equipment) ........................................................................................ 6 - 2
6.1.1 Standard/lightweight bucket ..................................................................................................... 6 - 2
6.2 Mounting and dismounting attachments without hydraulic connections to loaders
with claw locks (optional equipment) ........................................................................................ 6 - 3
6.2.1 Standard/lightweight bucket ..................................................................................................... 6 - 3
6.2.2 Fork-lift attachment .................................................................................................................. 6 - 4
6.3 Mounting and dismounting attachments with hydraulic connections to loaders
with claw locks (optional equipment) ........................................................................................ 6 - 4
6.3.1 Multi-purpose bucket ............................................................................................................... 6 - 4
6.3.2 Front-end excavator ................................................................................................................ 6 - 7
6.3.2.1 Shovel replacement ................................................................................................................. 6 - 7
6.3.3 Grab bucket ............................................................................................................................. 6 - 8
6.4 Use of additional attachments .................................................................................................. 6 - 9
7 Rescue, towing, lashing, lifting by crane
7.1 Rescue, towing, lashing ........................................................................................................... 7 - 2
7.1.1 Rescue/towing of the swivel shovel loader if the engine or drive has failed ............................. 7 - 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 Notes regarding maintenance ..................................................................................................8 - 3
8.2 Maintenance work ................................................................................................................... 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 Rear axle ................................................................................................................................. 8 - 4
8.2.3.2 Planetary gear ......................................................................................................................... 8 - 5
8.2.3.3 Front axle................................................................................................................................. 8 - 5
8.2.4 Oil level check (distribution gear) ............................................................................................ 8 - 5
8.2.5 Oil level check of the hydraulic oil reservoir ............................................................................ 8- 6
8.2.6 Oil change, engine .................................................................................................................. 8 - 6
8.2.7 Oil change, axles ..................................................................................................................... 8 - 6
8.2.7.1 Rear axle ................................................................................................................................. 8 - 6
8.2.7.2 Planetary gear ......................................................................................................................... 8 - 7
8.2.7.3 Front axle................................................................................................................................. 8 - 7
8.2.8 Oil change, distribution gear.................................................................................................... 8 - 8
8.2.9 Oil change, hydraulic system .................................................................................................. 8 - 8
8.2.10 Replacing the suction / return flow filter cartridge ................................................................... 8 - 9
8.2.11 Maintaining/replacing the air filter ........................................................................................... 8 - 10
8.2.12 Replacing the safety cartridge ................................................................................................. 8 - 11
8.2.13 Replacing the fuel filter ............................................................................................................ 8 - 11
8.2.14 Replacing the starter batteries ................................................................................................. 8 - 11
8.2.15 Cleaning the cooler ................................................................................................................. 8 - 12
8.2.16 Maintaining/replacing the fresh air filter .................................................................................. 8 - 12
8.2.17 Checking/adjusting the service/spring parking brake .............................................................. 8 - 12
8.2.18 Lubrication points .................................................................................................................... 8 - 13
8.2.18.1 Rear axle ................................................................................................................................. 8 - 13
8.2.18.2 Rear axle pivot bolts ................................................................................................................. 8 - 13
8.2.18.3 Front axle................................................................................................................................. 8 - 14
8.2.18.4 Rear cardan shaft .................................................................................................................... 8 - 14
8.2.18.5 Front cardan shaft ................................................................................................................... 8 - 15

S220/S221/S230/S231/Z200 V
Table of Contents
8.2.18.6 Ball bearing ring ...................................................................................................................... 8 - 15
8.2.18.7 Bucket assembly ..................................................................................................................... 8 - 16
8.2.18.8 Engine flaps ............................................................................................................................ 8 - 17
8.2.18.9 Multi-purpose bucket ............................................................................................................... 8 - 17
9 Faults, causes and remedies
10 Diagrams
10.1 Electric wiring diagram .......................................................................................................... 10 - 3
10.2 Hydraulic diagram ................................................................................................................. 10 - 7
10.2.1 AS 210 hydraulic diagram (bolt lock), “20 km/h” model ......................................................... 10 - 7
10.2.2 AS 210 hydraulic diagram (bolt lock), “35 km/h” model ......................................................... 10 - 9
10.2.3 AS 210 hydraulic diagram (claw lock), “20 km/h” model ....................................................... 10 - 11
10.2.4 AS 210 hydraulic diagram (claw lock), “35 km/h” model ....................................................... 10 - 13
11 Technical data (loader)
11.1 Loader ................................................................................................................................... 11 - 2
11.2 Engine ................................................................................................................................... 11 - 2
11.3 Starter ................................................................................................................................... 11 - 2
11.4 Alternator ............................................................................................................................... 11 - 2
11.5 Hydrostatic drive motor.......................................................................................................... 11 - 2
11.6 Axle loads .............................................................................................................................. 11- 3
11.7 Tyres ..................................................................................................................................... 11 - 3
11.8 Steering system ..................................................................................................................... 11 - 3
11.9 Brake system......................................................................................................................... 11 - 3
11.10 Electrical system ................................................................................................................... 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 Support system...................................................................................................................... 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 Noise emission ...................................................................................................................... 11 - 4
12 Technical data (attachments)
12.1 Loaders with bolt locks (Kat. V) ............................................................................................. 12 -2
12.1.1 Buckets ................................................................................................................................. 12 - 2
12.1.2 Fork-lift attachment ................................................................................................................ 12 - 4
12.1.3 Lifting hook ............................................................................................................................ 12 - 4
12.1.4 Front-end excavator .............................................................................................................. 12 - 6
12.1.5 Grab bucket ........................................................................................................................... 12 - 6
12.2 Loaders with claw locks (Kat. IV) .......................................................................................... 12 - 8
12.2.1 Buckets ................................................................................................................................. 12 - 8
12.2.2 Fork-lift attachment ................................................................................................................ 12 - 10
12.2.3 Lifting hook ............................................................................................................................ 12 - 10
12.2.4 Front-end excavator .............................................................................................................. 12 - 12
12.2.5 Grab bucket ........................................................................................................................... 12 - 12
13 Additional options, modifications, notes on inspection for loaders
13.1 Additional options .................................................................................................................. 13 - 2
13.2 Modifications ......................................................................................................................... 13 - 2

Safety Regulations

S220/S221/S230/S231/Z2001-2
1 Safety Regulations
1 Fundamental safety
instructions
1.1 Warnings and symbols
In this operation manual, the following designations or
symbols are used for important information.
NOTE
Extra information about the economical use of
the loader.
CAUTION
Specialinformation forregulations and prohibitions
for avoiding damage.
DANGER
Information or regulations and prohibitions for
prevention of damage to persons or extensive
damage to goods.
1.2 Proper use of the loader
1.2.1 This machine was designed according to the
state of the art and recognised safety rules. Nevertheless,
use of the machine may cause danger for the user or third
parties or impairments to the machine or other objects.
1.2.2 The machine and manufacturer-approved attach-
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
eliminated immediately.
1.2.3 The machine is designed exclusively for the
purposes described in this operating manual. Any other
use beyond these purposes is regarded as being improper
use. The manufacturer is not liable for any damage caused
in this connection. The risk is solely that of the user.
Authorised use of the machine also requires that the
operating manual (machine and engine) be heeded and the
inspection and maintenance conditions are complied with.
1.3 Organisational measures
1.3.1 The operating manuals (machine and engine)
must be available at all times and at the site where the
machine is in operation.
i

S220/S221/S230/S231/Z200 1-3
Safety Regulations 1
1.3.2 In addition to the operating manuals (machine
and engine), the general applicable and other binding
regulations for the prevention of accidents (especially the
safety regulations of the German Trade Association - VBG
40) as well as the regulations for environmental protection
must be observed; personnel must be instructed
accordingly.
Also heed all regulations governing public traffic.
1.3.3 The personnel who are to work with the machine
must read the operating manuals (machine and engine)
before starting 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 jewellery, including
rings. Danger of injuries, e.g. by getting caught or being
pulled in.
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 legible.
1.3.8 In case of modifications to the machine, especially
in case of damage or changes in the operating behaviour
of the machine which could influence its safety, stop the
machine immediately and inform the responsible person in
charge about the incident.
1.3.9 Do not make any modifications or conversions to
the machine which could affect safety without the
manufacturer’s consent. This also applies to the installa-
tion and adjustment of safety devices, valves and welding
of supporting parts.
1.3.10 Check the hydraulic system, especially hydrau-
lic pipes, at regular intervals for defects and immediately
eliminate any defects found.
1.3.11 The inspection periods specified in the operating
manual (machine and engine) and the maintenance plan
must be observed.
1.4 Selection of personnel and
necessary qualifications
Basic responsibilities
1.4.1 The machine may be driven and maintained only
by personnel selected by the employer for this purpose.

S220/S221/S230/S231/Z2001-4
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 a diligent manner.
1.4.2 Electrical work on the machine may be carried
out only by a qualified electrician or persons supervised by
a qualified electrician according to the electrical regula-
tions.
1.4.3 Only qualified specialists may carry out work on
the chassis, the brake and steering 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 Observe the control lamps according to the ope-
ration manual (machine and engine) during starting and
switching-off operation!
1.5.1.4 Before commencing work / driving, make sure
that the brakes, steering, signal beacons and lights function!
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, undertaking the necessary protection precautions
between the building site and public traffic.
1.5.1.7 Before starting the machine, make sure that no
person is endangered by the moving machine!
1.5.1.8 Take measures so that the machine can be
operated only in a safe and functional manner. The
machine may only be operated when all safety devices,
e.g. detachable safety devices and sound absorption,
exist and function.

S220/S221/S230/S231/Z200 1-5
Safety Regulations 1
1.5.1.9 Avoid any action which appears to be dangerous!
1.5.1.10 Persons must not be carried in the working
equipment, e.g. in the attachments!
1.5.1.11 The operator may carry out work with the machine
only if no persons are in the danger zone.
The danger zone is the area near the machine where
persons may be injured
- by work-induced movements of the machine,
- by work attachments and devices,
- by loads swinging out,
- by dropping loads,
- by attachments falling from the machine.
1.5.1.12 In case of danger to persons, the operator must
give appropriate warning signs. It may be necessary to
stop work.
1.5.1.13 In case of functional defects, stop the machine
immediately and secure it. Eliminate defects imme-
diately!
1.5.1.14 Check the machine at least once every shift for
external visible damage and defects. Report any defects
(including changes in the operational behaviour) imme-
diately to the person in charge. If necessary, stop the
machine immediately and secure it.
1.5.1.15 The driver may slew the attachments in overhead
driving, operating and working areas only if these areas are
suitably safeguarded by protective roofing. These protec-
tion roofs must offer appropriate safety against loads and
falling goods. If you are in doubt, assume no protection
roofs are present.
1.5.1.16 When driving, the attachment is to be kept as
close to the ground as possible.
1.5.1.17 Please observe the applicable traffic regulations
when driving on public roads, paths or open spaces. The
machine must be brought into road-worthy condition be-
forehand.
1.5.1.18 Make sure to always switch on the lights in the
dark and when visibility is poor.
1.5.1.19 If the lights of the machine are not adequate for
the safe execution of certain work, additional lighting must
be provided on the working site, especially at dumping
points.
1.5.1.20 Should the driver’s sight of his driving and working
area be restricted due to work-induced influences, he must
be given guidance or he must safeguard the working area
by a firm barrier.

S220/S221/S230/S231/Z2001-6
1 Safety Regulations
1.5.1.21 The person giving guidance must be a reliable
person and must be informed about his tasks before
commencement of the work.
1.5.1.22The driver and guide must agree on signals for
communication. These signals may only be given by the
driver and guide.
1.5.1.23 The guide must be easily recognizable – e.g. by
wearing warning clothing – and must always be in the
driver’s field of vision.
1.5.1.24 When passing under subways, bridges, tunnels,
electrical overhead lines, etc., make sure that there is
adequate clearance!
1.5.1.25 Maintain adequate clearance when working at
the edge of quarries, pits, rubbish dumps and embank-
ments to eliminate any danger of the machine plunging
down. The contractor or his deputy must stipulate the
distance from the edge, taking the soil bearing capacity
into consideration.
1.5.1.26 The machine may only be used at stationary
dumping areas when firmly integrated installations are
provided 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,
- abrupt acceleration or deceleration of driving or working
movement,
- reversing out of a high driving speed,
- working on slopes,
- driving too quickly round sharp bends,
- driving the machine on rough terrain when the bucket arm
is swivelled.
1.5.1.28 Do not traverse across slopes. Always carry
working equipment and loads near the ground, especially
when driving down slopes. Sudden cornering is forbidden!
1.5.1.29 On steep inclines and gradients, the load is to be
carried on the uphill side.
1.5.1.30 Reduce speed before inclines; always adapt the
speed of the machine to the local conditions!
Never change into low gear when driving on slopes, but
rather before the slope!
1.5.1.31 Reversing over a longer period must be avoided!
1.5.1.32 When leaving the machine, always safeguard the
machine to prevent it from unintentionally rolling away;
prevent non-authorised persons from using it!
1.5.1.33 The driver must not leave the machine if the
attachments are not lowered or safeguarded.

S220/S221/S230/S231/Z200 1-7
Safety Regulations 1
1.5.1.34 During breaks and after work hours, the driver
must park the machine on solid and, if possible, level
ground and safeguard it against unintentionally rolling
away.
1.5.2 Special work regarding the use of the
machine and elimination of defects during
work; disposal
1.5.2.1 The dates for adjustment work, maintenance
work and inspections laid down in the operating manual
(machine and engine) must be strictly observed. This also
applies to information regarding the replacement of parts/
part equipment. This work may only be executed by skilled
personnel.
1.5.2.2 For all work involving the operation, conversion or
adjustment of the machine and its safety devices as well
as inspection, maintenance and repair work, please observe
the switch-on and switch-off procedures in accordance
with the operating manual (machine and engine) as well as
the related instructions for maintenance work.
1.5.2.3 The engine must be switched off before mainte-
nance or repair work is carried out.
1.5.2.4 The stability of the machine or the attachments
must be guaranteed at all times during maintenance and
repair work.
1.5.2.5 Maintenance and repair work may only be carried
out when the attachment is set down on the ground or
supported or when equivalent measures against uninten-
tional movement were taken.
During maintenance and repair work under the bucket arm:
- the bucket arm must be mechanically supported,e.g.
insert the bucket arm support (option) (1-1/arrows)
- the hand lever for working and auxiliary hydraulics (1-2/
arrow) must be secured (horizontal position).
- the swivel unit must be blocked. To do this, remove the
blocking chock from the tool box (1-3), insert it in the
swivel block (1-4/arrow) and secure it with the spring
locking lever.
1.5.2.6 If necessary, secure the maintenance area on a
large scale.
1.5.2.7 The machine must be protected from unintentio-
nally starting after it has been switched off for maintenance
and repair work:
- remove the ignition key and
- attach a warning sign to the main battery switch.
This applies especially to works on the electrical equipment.
1.5.2.8 Individual pieces and large assemblies must be
carefully secured to hoisting equipment when being re-
placed to avoid any damage. Only suitable and technically
sound hoisting equipment may be used as well as crane
equipment with adequate payload. Do not stand or work
underneath suspended loads!
Figure 1-1
Figure 1-3
Figure 1-2

S220/S221/S230/S231/Z2001-8
1 Safety Regulations
1.5.2.9 Only experienced personnel should be entrusted
with the securing of loads! Loads must be secured so that
they cannot slip or fall down.
1.5.2.10 Attached loads may only be moved with the
machine when the road is graded.
1.5.2.11 When working with hoisting equipment / eleva-
tors the slingers may only work with the approval of the
driver and from the side of the boom. The driver may only
give his consent if the machine is standing still and the
working attachment is not being moved.
1.5.2.12 Persons assisting with the guidance of loads and
slingers may only stay in visual or communication reach of
the driver.
1.5.2.13 The operator must move the load as close to the
ground as possible and avoid swivelling the load.
1.5.2.14 The operator may not move the load over the
heads of persons.
1.5.2.15 In the case of erection work that must be carried
out above normal human height, suitable safety ascent
devices and working platforms must be used. Do not use
engine parts, especially attachments such as buckets, as
climbing and descending facilities. 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-
nance work and make sure that the machine is free from oil,
fuel oil or dirt. Do not use aggressive detergents. Use
lintless cleaning rags!
1.5.2.17 Before cleaning the machine with water or steam
jet (high pressure cleaning unit) or with detergent, protect
all areas where water/steam/detergent may penetrate and
affect the functions or safety of the machine by a suitable
cover or by applying tape. In particular, engine components
such as the injection pump, generator, generator governor
and starter are very delicate.
1.5.2.18 After cleaning, completely remove all protective
covering and tape.
1.5.2.19 After cleaning, check all fuel, engine oil and
hydraulic oil pipelines for leakages, loose connections,
abraded parts and damage. Eliminate defects imme-
diately!
1.5.2.20 Always fasten screw connections after comple-
tion of maintenance and repair work.
1.5.2.21 Should it be necessary to dismantle safety de-
vices during mounting, maintenance or repair work, these
safety devices must be re-installed and checked carefully
after completed maintenance and repair work.
Figure 1-4

S220/S221/S230/S231/Z200 1-9
Safety Regulations 1
1.5.2.22 Make sure that fuel, accessory materials and
exchanged parts are safely disposed of with no danger to
the environment.
1.5.2.23 The machine should be checked by a specialist
before commissioning and after essential modifications
before it returns to service.
1.5.2.24 The machine must be checked by a specialist
once a year. Furthermore, a specialist must check the
machine whenever necessary according to operating con-
ditions.
1.5.2.25 The test results must be recorded and kept in the
archives at least until the following inspection date.
1.6 Instructions regarding special
categories of danger
1.6.1 Electrical energy
1.6.1.1 Only use original fuses with stipulated ratings.
Immediately switch off the machine if the electrical supply
fails.
1.6.1.2 When working near overhead lines and overhead
wires, a safety clearance must be kept between the
machine and its working equipment in order to prevent
sparking over. The safety clearance depends on the nomi-
nal voltage of the overhead/wire line. This also applies to
the distance between the lines and to the attachments and
slung loads.
The following safety clearances must be observed to meet
the above mentioned requirement:
Nominal voltage Safety clearance
(kilovolts) (meters)
to 1 kV 1.0 m
above 1 kV up to 110 kV 3.0 m
above 110 kV up to 220 kV 4.0 m
above 220 kV up to 380 kV 5.0 m
unknown nominal voltage 5.0 m
When approaching overhead lines, all working movements
of the machine must be taken into consideration, e.g. the
position of jibs, the swinging of ropes and the dimensions
of attached loads.
In addition, attention must be paid to any roughness of soil
which could cause an inclined position of the machine,
thus getting it closer to the overhead line.
The fact that overhead lines may swing out during windy
weather and may reduce the distance must also be taken
into consideration.

S220/S221/S230/S231/Z2001-10
1 Safety Regulations
1.6.1.3 In the case of sparking over, the driver must bring
the machine out of the danger area by lifting or lowering the
attachments or by swivelling away or driving the machine
out of the danger area. If this is not possible then the
following rules must be observed:
- Do not leave the driver’s cabin!
- Warn persons standing near the machine not to approach
or touch the machine!
- Give immediate instructions to have the power cut off!
- Leave the machine only when it is sure that the electricity
in the damaged / contacted power line is switched off so
that the line is dead!
1.6.1.4 Work on the electrical system or on the operating
system may only be carried out by a skilled electrician or
by personnel instructed or supervised by such a trained
electrician according to electrotechnical regulations.
1.6.1.5 The electrical system of the machine must be
checked/inspected at regular intervals. Any defects, e.g.
loose connections or scorched cabling, must be elimina-
ted immediately.
1.6.1.6 The main battery switch must be disconnected
before inspection, maintenance or repair of machine parts
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 All pipelines, hoses and screw connections must
be checked regularly for leakages and visible damage!
Immediately repair such defects! Spurting hydraulic oil
may cause injuries and fire.
1.6.2.3 Those hydraulic system segments which are to
be opened must be depressurised before commencement
of the repair work according to the assembly group descrip-
tion!
1.6.2.4 The hydraulic pipelines must be correctly laid and
connected! Do not mix up the connections. Spare parts
must meet the technical requirements of the manufacturer.
Original spare parts ensure the fulfilment of these require-
ments.
1.6.2.5 The factory settings of hydraulic components
(e.g. the maximum permissible speed of the axial piston
engine) must not be altered. Any adjustment will render the
warranty invalid.
1.6.3 Noise
Sound protection equipment must be in the protective
position during operation of the machine.

S220/S221/S230/S231/Z200 1-11
Safety Regulations 1
1.6.4 Oil, grease and other chemical
substances
1.6.4.1 The relevant safety regulations must be observed
when handling oil, grease or other chemical substances.
1.6.4.2 Caution when working with hot fuel and other
accessory materials (danger of burning and scalding).
1.6.4.3 Caution when working with brake fluid and battery
acid.
TOXIC AND CAUSTIC!
1.6.4.4 Be careful when working with fuel.
FIRE HAZARD!
- Before refuelling, switch off the engine and remove the
ignition key.
- Do not refuel in an enclosed area.
- Never refuel near open fires or sparks.
- Do not smoke during refuelling.
- Immediately wipe up spilled fuel.
- Keep the machine free of fuel, oil and grease.
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
strictly observed.
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 fire and explosion!
1.6.5.3 Before carrying out welding, burning and grinding
work, clean the machine and its vicinity of combustibles
and make sure that the room is adequately ventilated.
Explosion hazard!
1.7 Transport and towing;
recommissioning
1.7.1 The machine may only be towed if the brakes and
steering function.
1.7.2 Towing may be carried out only by means of an
adequately dimensioned towing bar in connection with
towing devices.
1.7.3 Start towing at a low speed. Persons must not be
near the towing bar.

S220/S221/S230/S231/Z2001-12
1 Safety Regulations
1.7.4 When the machine is loaded and transported, the
necessary auxiliary equipment must be fitted to prevent
any unintended movement. The tyres must be kept clean
of mud, snow and ice so that the machine can drive on
ramps without danger of sliding.
1.7.5 Strictly observe the operating manual during
recommissioning.
1.8 Safety information for the contractor
or the contractor’s authorised personnel
1.8.1 Organizational measures
1.8.1.1 We emphasise that attachments that are not
supplied by us are also not tested and approved by us. Use
of such products can under certain conditions adversely
affect the present constructional qualities of your loader
and thus limit the active and passive driving safety. The
manufacturer cannot be held responsible for damage that
occurs through the use of such products.
1.8.1.2 Inform yourself of the location/use of fire extin-
guishers (1-5/arrow) and first-aid kit (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
the vehicle.
1.8.2 Selection of personnel and necessary
qualifications; basic responsibilities
1.8.2.1 Only reliable persons are allowed to work on/with
the machine. The minimum legal age must be observed.
1.8.2.2 Employ trained or instructed personnel only.
Clearly define the competencies of the personnel regarding
operation, installation, maintenance and repair work.
Ensure that only authorised personnel may work on/with
the machine!
1.8.2.3 Authorise the driver to refuse instructions given
by third parties when these instructions are detrimental to
the safety of the driver and the machine.
1.8.2.4 Personnel who are to be trained, instructed or
working on/with the machine in the scope of professional
training must not work on/with the machine unless they are
supervised by an experienced person who has been
authorised by the employer.
Figure 1-5
Figure 1-6

Signs

2 Signs
S220/S221/S230/S231/Z2002-2
CAUTION!
The lift cylinders’ pipe break
protection is disabled when
the lifting suspension is swit-
ched on.
Do not switch on the lifting
suspension while the fork-lift
or lifting hook attachment is
fitted.
CAUTION!
Steering only possible
when engine is running!
CAUTION!
Use only the rear-wheel
steering when driving on
public roads.
AS 210
AS 210
11
20
12
2
1
915 16 18 19 20 21
1
2
4 5 6 7a 910
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
Betriebserlaubnis Nr.
Betriebserlaubnis Nr.
2-
2-
1-
1-
Baumaschinen GmbH
Baumaschinen GmbH
D-24782 B
D-24782 B
üdelsdorf
delsdorf
kg
kg
kg
kg
kg
kg
17
3
3
3
3