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.