ahlmann AS 210 Operating Instructions Manual

ahlmann AS 210 Operating Instructions Manual

Swing shovel loader
Table of Contents

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OPERATING INSTRUCTIONS
SWING SHOVEL LOADER
AS 210
Ahlmann Baumaschinen GmbH Am Friedrichsbrunnen 2 D-24782 Büdelsdorf
Telefon 04331/351-325
Telefax 04331/351404
GB
Internet: www.ahlmann-baumaschinen.de
E-Mail: info@ahlmann-baumaschinen.de

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Summary of Contents for ahlmann AS 210

  • Page 1 OPERATING INSTRUCTIONS SWING SHOVEL LOADER AS 210 Ahlmann Baumaschinen GmbH Am Friedrichsbrunnen 2 D-24782 Büdelsdorf Telefon 04331/351-325 Internet: www.ahlmann-baumaschinen.de Telefax 04331/351404 E-Mail: info@ahlmann-baumaschinen.de...
  • Page 2 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.
  • Page 3 Table of Contents Abbreviations used = Unfallverhütungsvorschrift (Accident Prevention Regulations) StVZO = Straßenverkehrzulassungsordnung (German Traffic Regulations) Edition: 09.2006 Printed: 09.2006 S220/S221/S230/S231/Z200...
  • Page 4: Table Of Contents

    Table of Contents Table of Contents Fundamental safety instructions Warnings and symbols ......................1 - Proper use of the loader ......................1 - Organisational measures ......................1 - Selection of personnel and necessary qualifications ............... 1 - Safety Information for Certain Operating Phases ..............1 - 1.5.1 Normal Operation ........................
  • Page 5 Table of Contents 5.3.2 Switching off the diesel engine ....................5 - 5.3.3 Switching off the heater and ventilation system ............... 5 - 5.3.4 Leaving the loader ........................5 - Adjusting the driver’s seat ......................5 - 5.4.1 Isri seat ........................... 5 - 5.4.2 Grammer seat ..........................
  • Page 6 AS 210 hydraulic diagram (bolt lock), “35 km/h” model ............10 - 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 Technical data (loader) 11.1...
  • Page 7 Safety Regulations...
  • Page 8: Fundamental Safety Instructions

    Safety Regulations Fundamental safety instructions 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 Special information for regulations and prohibitions for avoiding damage. DANGER Information or regulations and prohibitions for prevention of damage to persons or extensive...
  • Page 9: Selection Of Personnel And Necessary Qualifications

    Safety Regulations 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;...
  • Page 10: Safety Information For Certain Operating Phases

    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.
  • Page 11 Safety Regulations 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,...
  • Page 12 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.
  • Page 13: Special Work Regarding The Use Of The Machine And Elimination Of Defects During Work; Disposal

    Safety Regulations 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;...
  • Page 14 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.
  • Page 15: Instructions Regarding Special Categories Of Danger

    Safety Regulations 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.
  • Page 16: Hydraulics

    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...
  • Page 17: Oil, Grease And Other Chemical Substances

    Safety Regulations 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.
  • Page 18: Safety Information For The Contractor Or The Contractor's Authorised Personnel

    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.
  • Page 19: Signs

    Signs...
  • Page 20 Do not switch on the lifting suspension while the fork-lift or lifting hook attachment is fitted. AS 210 2,5 bar 2,5 bar CAUTION! CAUTION! Steering only possible Use only the rear-wheel...
  • Page 21 Signs Symbol: Stay out of the danger zone Symbol: Lashing eyes Symbol: Lifting hook Symbol: Swivelling Sign: » Only for loaders with pipe break protection « CAUTION! The lift cylinders’ pipe break protection is disabled when the lifting suspension is switched on.
  • Page 22: Protection Against Theft

    Protection Against Theft...
  • Page 23: Identifying Features On The Loader

    To make it possible for the police, customs and other authorities to find and identify machines much faster, Ahlmann construction machines are fitted with the following identifying features: Identifying features on the loader (1) Loader type plate (3-1/arrow). Among other details, the loader type plate also gives the 17-digit FIN number (truck identification number) starting with W09.
  • Page 24: Transponder For Drive-Away Interlock

    Protection Against Theft Transponder for drive-away interlock (option) The “transponder for drive-away interlock” is an electronic drive-away interlock that deactivates vital loader functions. If the transponder (e.g. a tag at the ignition key) is taken away from the receiver unit (in the immediate vicinity of the ignition lock), these vital functions are interrupted.
  • Page 25: Description

    Description...
  • Page 26: Overview

    Description Description Figures and descriptions may vary due to modifications in the construction that become possible and necessary to improve the loader and to develop it further technically. These modifications are summarised in section 13. Overview Figure 4-1 1 - Bucket protection 2 - Bucket/attachment 3 - Deflection lever 4 - Tip cylinder...
  • Page 27: Swivel Unit And Axle Support

    Description Swivel unit and axle support Two swivel cylinders are fed by a separate gear-type pump via a servo valve. The revolving seat is connected to the cylinders by a chain drive and is thus completely free of play. Swivelling can be carried out simultaneously with lifting of the bucket arm without mutual interference.
  • Page 28: Fan Reversal (Option)

    Description - Do not switch on the lifting suspension while the fork-lift or lifting hook attachment is fitted. - The pipe break protection is disabled when the lifting suspension is switched on. Fan reversal (option) The loader is equipped with a fan reversal unit, permitting the radiator to be cleaned quickly and easily.
  • Page 29 Description (9) Fit a suitable jack (minimum capacity 6.0 tons) from the side under the axle bridge in the vicinity of the axle fixture so that it is centred and cannot slip (4-3). Lift the front/rear axle until the wheel does not have any contact to the ground.
  • Page 30: Controls

    Description Controls 1 - Lock lever for steering column adjustment - to the front/rear - in axial steering column direction 2 - Steering column switch - to the front: turn signal, right - to the rear: turn signal, left - up: Dipped beam - down: High beam - Pushbutton:...
  • Page 31 Description 1 - Air outlet nozzle (heater) 2 - Ball block valve for working and auxiliary hydraulics 3 - Switching lever for steering - to the left four-wheel steering - to the right: rear-axle steering 4 - Suction flap for recirculation mode (air-conditioning system –...
  • Page 32: Fuses

    Description Pilot valve for auxiliary hydraulics (2nd auxiliary hydraulic circuit) » Optional equipment « NOTE If the loader has a 2nd auxiliary hydraulic circuit, the two buttons (4-9/3) have no function or are missing. The working movements of the two buttons (4-9/3) (e.g. opening/closing the multi-purpose bucket –...
  • Page 33: Operation

    Operation...
  • Page 34: Checks Before Start-Up

    Operation Operation Figures and descriptions may vary due to modifications in the construction that become possible and necessary to improve the loader and to develop it further technically. These modifications are summarised in section 13. Checks before start-up - Engine oil level (see the operating instructions for the engine) - Hydraulic oil level - Fuel level...
  • Page 35: Winter Operation

    Operation NOTE If the engine has not started after two attempts, determine the cause using the troubleshooting table in the operating instructions for the engine. For operation at extremely low temperatures, see the operating instructions for the engine. The clogging indicator (4-6/15) may light up prematurely after a cold start.
  • Page 36: Engine Oil Change

    Operation 5.2.2.2 Engine oil change See the operating instructions for the engine and for the machine (section 8.2.6). 5.2.2.3 Changing oil in the hydraulic system CAUTION The viscosity of the hydraulic oil changes according to the temperature; therefore, the ambient temperature in the location where the machine will be used determines what viscosity class (SAE class) must be chosen.
  • Page 37: Carrying A Bucket

    Operation Before driving on public roads, the following road safety measures must be taken: 5.2.3.1 Carrying a bucket (1) Lower the bucket arm until the lowest point of the bucket arm or the bucket is at least 30 cm above the road (5-4).
  • Page 38: Working With The Loader

    Operation 5.2.4 Working with the loader DANGER Always use seat belts when working with the swivel shovel loader. Generally, all work is carried out in gear stage “I” (4-9/1). For special tasks which ask for a more sensitive control of the speed or a higher engine speed at reduced travel speed, gear stage “Alpha max.”...
  • Page 39: Heater And Ventilation System

    Operation DANGER If driving with the bucket arm swivelled is required in special cases, the bucket/attachment must be positioned close over the wheel and the travel distance must be kept as short as possible. If unevenness of the ground causes the support system to lift a wheel off the ground, the bucket arm must be briefly swivelled in the direction of travel so that the axle block can be cancelled.
  • Page 40: Decommissioning The Loader

    Operation Decommissioning the loader 5.3.1 Parking the loader (1) Stop the loader on solid ground; if possible, not on a slope. (2) Apply the parking brake (4-9/7). (3) Place the bucket or the attachment on the ground. (4) Set the drive switch (4-9/5) to “0”. DANGER If parking on a gradient cannot be avoided, wheel chocks must be used and placed on the sloping...
  • Page 41: Adjusting The Driver's Seat

    Operation Adjusting the driver’s seat 5.4.1 Isri seat (1) Adjust or swing forward the backrest using the hand lever (5-9/1). (2) Adjust the seat height and rear inclination by pulling the hand lever (5-9/3) upwards. (3) Adjust the seat height and front inclination by pulling the hand lever (5-9/4) upwards.
  • Page 42 Operation (2) Height adjustment: The height can be adjusted in several steps. Lift the driver’s seat to the desired height until it can be heard to engage. The seat returns to the lowest position when it is lifted over the topmost position (stop) (5-12). Figure 5-12 (3) Armrest inclination: Turn the handwheel (5-13/arrow) to adjust the armrest in...
  • Page 43: Switching The Steering Type

    Operation (5) Adjusting the backrest: Use the locking lever (5-15/arrow) to adjust the backrest. NOTE The locking lever must engage in the desired position. It must be impossible to move the backrest to another position when the lever has engaged. Figure 5-15 (6) Longitudinal adjustment: You can adjust the seat in longitudinal direction when you...
  • Page 44: Attachments

    Attachments...
  • Page 45: Mounting And Dismounting Attachments Without Hydraulic Connections To Loaders With Bolt Locks (Standard Equipment)

    Attachments Attachments Mounting and dismounting attach- ments without hydraulic connections to loaders with bolt locks (standard equipment) 6.1.1 Standard/lightweight bucket Mounting (1) Bring the bucket arm to its lowest position and tip the quick-change device. (2) Drive the loader up to the bucket (6-1). (3) Pick up the bucket using the quick-change device Figure 6-1 and, by simultaneously tilting the quick-change device,...
  • Page 46: Mounting And Dismounting Attachments Without Hydraulic Connections To Loaders With Claw Locks (Optional Equipment)

    Attachments Mounting and dismounting attach- ments without hydraulic connections to loaders with claw locks (optional equipment) 6.2.1 Standard/lightweight bucket Mounting (1) Bring the bucket arm to its lowest position and tip the quick-change device. (2) Drive the loader up to the bucket (6-4). (3) Press and hold the release button for the quick- change device (4-7/1).
  • Page 47: Fork-Lift Attachment

    Attachments 6.2.2 Fork-lift attachment NOTE Mounting and dismounting are carried out in the same way as for the standard/lightweight bucket (section 6.2.1). DANGER The fork-lift attachment is mounted and locked correctly when it is located next to the quick- change device and the piston rods of the quick-change device cylinder can be plainly seen (6-7/arrow).
  • Page 48 Attachments (4) Pick up the bucket using the quick-change device and, by simultaneously tilting the quick-change device, raise the bucket until the quick-change device is next to it (6-10). (5) Release the release button for the quick-change device (4-7/1). NOTE When the release button for the quick-change device is pressed, the claws release as long as the button is pressed.
  • Page 49 Attachments Notes on the application of the multipurpose bucket The multi-purpose bucket can be used for: - peeling (6-13) Figure 6-13 - scraping (6-14) Figure 6-14 - grabbing (6-15) and - in bucket operation. Figure 6-15 S220/S221/S230/S231/Z200...
  • Page 50: Front-End Excavator

    Attachments 6.3.2 Front-end excavator Mounting The front-end excavator is mounted in a manner similar to the multi-purpose bucket (section 6.3.1), except that all four hydraulic hoses of the front-end excavator must be connected to the four quick-change couplings of the quick- change device (6-16).
  • Page 51: Grab Bucket

    Attachments (5) Remove the spring locking lever of the bolt locks (6-18/ arrows). Figure 6-18 (6) Knock out the bearing bolts (6-19/arrows) and remove the shovel. (7) Mounting is in the reverse order. NOTE The type plate of the shovel is on the left outer side.
  • Page 52: Use Of Additional Attachments

    Attachments CAUTION When making connections, make sure that the hydraulic connections are clean and completely connected and that the colour codings coincide. The grab bucket must be set down with the grab scoops open. The spacing plate (6-21/1) welded onto the boom must be inserted between the two grab scoops.
  • Page 53 Rescue, Towing, Lashing, Lifting by Crane...
  • Page 54: Rescue, Towing, Lashing, Lifting By Crane Rescue, Towing, Lashing

    Rescue, Towing, Lashing, Lifting by Crane Rescue, towing, lashing, lifting by crane Rescue, towing, lashing 7.1.1 Rescue/towing of the swivel shovel loader if the engine or drive has failed DANGER Secure the rescue location if it is on a public road. CAUTION The swivel shovel loader must not be tow- started.
  • Page 55 Recue, Towing, Lashing, Lifting by Crane (6) Cover the bucket cutting edge and teeth with the bucket protector (5-4/arrow). (7) Insert the plug of the bucket protector into the socket (5-5/arrow, option). (8) Push the valve lever for the working hydraulics (4-9/6) beyond its pressure point into the forward position.
  • Page 56 Rescue, Towing, Lashing, Lifting by Crane (15) Loosen the spring. To do this, loosen and remove the two caps (7-4/arrows). Figure 7-4 (16) Remove the quick-release hex screws (7-5/arrow) within the caps and screw them into the spring cylinder (7-6/arrow) until a definite stop can be felt. This tensions the spring package.
  • Page 57: Towing The Swivel Shovel Loader If The Drive Has Failed

    Recue, Towing, Lashing, Lifting by Crane (18) Switch the hydrostatic drive motor to free oil flow before towing. For this purpose, screw in the setscrews at both high-pressure relief valves (7-7/arrows) of the drive pump until they are level with the hexagon nuts (size 13) loosened beforehand.
  • Page 58 Rescue, Towing, Lashing, Lifting by Crane (4) After the front-axle wheels have been straightened, switch the switching lever for the steering (4-8/3) to the „rear-axle steering“ position. (5) Cover the bucket cutting edge and teeth with the bucket protector (5-4/arrow). (6) Insert the plug of the bucket protector into the socket (5-5/arrow, option).
  • Page 59: Lifting By Crane

    Recue, Towing, Lashing, Lifting by Crane For a longer towing distance, the defective loader must be loaded onto a truck (for the lashing points, see 7-2/1 and 7-2/2 or 7-3/1 and 7-3/2). - The max. permissible load of the shunting and towing coupling (7-2/1) is 8.0 t horizontally in the longitudinal direction.
  • Page 60: Maintenance

    Maintenance...
  • Page 61 Maintenance (Maintenance Plan) 11.1 11.2 11.1 1.4 1.2/1.3 1.5/1.6 Every x operating hours Max. permissible intervals or shorter (depending on use) Maintenance points E n g i n e 7.1/7.2/7.3 1.1 Maintenance acc. to manufacturer’s regulations (open left and right engine flaps) Dry air filter system: 1.2 Check maintenance display (open left engine flap) 1.3 Maintain/replace filter element / safety cartridge...
  • Page 62: Notes Regarding Maintenance

    Maintenance Maintenance Figures and descriptions may vary due to modifications in the construction that become possible and necessary to improve the loader and to develop it further technically. These modifications are summarised in section 13. Notes regarding maintenance DANGER The engine must be turned off. For work to be carried out under the bucket arm: - the bucket must be emptied or the...
  • Page 63: Maintenance Work

    Maintenance Maintenance work 8.2.1 Engine oil level check See the operating instructions for the engine. 8.2.2 Coolant level check The coolant level of the engine is to be checked each time that the loader is started or at least once per day. The compensation tank (8-1/arrow) in the motor compartment is located on the right side of the loader;...
  • Page 64: Planetary Gear

    Maintenance Maintenance 8.2.3.2 Planetary gear (1) Move the loader so that the plug (8-4/2) is positioned at 3 o’clock. (2) Unscrew the plug. NOTE Collect any oil that escapes. The oil level must reach the plug bore. If necessary, fill oil into the plug bore (8-4/1) until the oil reaches the required level.
  • Page 65: Oil Level Check Of The Hydraulic Oil Reservoir

    Maintenance 8.2.5 Oil level check of the hydraulic oil reservoir (1) Park the loader in a level position. (2) Bring the bucket arm to its lowest position and tip the quick-change device. (3) Open the engine flap on the right side of the loader. (4) Check the oil level in the sight glass.
  • Page 66: Planetary Gear

    Maintenance Maintenance 8.2.7.2 Planetary gear (1) Move the loader so that the plug (8-10/arrow) is positioned at 6 o’clock. (2) Place an oil drain vessel with a drain channel under- neath the gear. (3) Unscrew the drain plug and let the oil drain out. CAUTION Waste oil must be disposed of in such a way that it will not cause pollution!
  • Page 67: Oil Change, Distribution Gear

    Maintenance Plan view 8.2.8 Oil change, distribution gear (1) Remove the foot mat in the footwell of the operator’s cabin. (2) Dismantle the floor plate under the foot mat. (3) Place a sufficiently large oil drain pan with a drain channel underneath.
  • Page 68: Replacing The Suction / Return Flow Filter Cartridge

    Maintenance (10) Fill oil into the filler neck (8-14/arrow). CAUTION For those loaders which are fitted to run with biodegradable hydraulic oil (ester-based synthetic hydraulic oil of viscosity class ISO VG 46 VI > 180 – designation can be found on the hydraulic oil reservoir and on the dashboard), only this type of oil may be used for oil changes.
  • Page 69: Maintaining/Replacing The Air Filter

    Maintenance 8.2.11 Maintaining/replacing the air filter NOTE Maintenance of the filter cartridge is necessary when either the red range is visible in the maintenance indicator (8-17/1 on the right side of the loader) or after 12 months, whichever is sooner. (1) Open the engine flap on the left side of the loader.
  • Page 70: Replacing The Safety Cartridge

    Maintenance 8.2.12 Replacing the safety cartridge CAUTION The safety cartridge must not be cleaned. The safety cartridge must be replaced after the filter cartridge has been maintained/ cleaned 5 times, but no later than two years. Make sure that no dirt or dust can enter the filter housing during replacement of the safety cartridge.
  • Page 71: Cleaning The Cooler

    Maintenance 8.2.15 Cleaning the cooler NOTE The cooler must be checked every 50 operating hours and cleaned when necessary. To do this, flip back the lamella plate (8-23/arrow) on the engine hood. 8.2.16 Maintaining/replacing the fresh air filter NOTE The fresh air filter is located at the right loader side in the vicinity of the front side window.
  • Page 72: Lubrication Points

    Maintenance 8.2.18 Lubrication points NOTE The lubrication points are marked in red on the loader. 8.2.18.1 Rear axle CAUTION The spindle bolts (8-25/1), the track rod bearings (8-25/2), and the steering cylinder bearings (8-25/3) must all be lubricated every 50 operating hours.
  • Page 73: Front Axle

    Maintenance 8.2.18.3 Front axle CAUTION The spindle bolts (8-28/1), the track rod bearings (8-28/2), and the steering cylinder bearings (8-28/3) must all be lubricated every 50 operating hours. NOTE Lubricate the axle spindle bolts (top and bottom), the track rod bearings and the steering cylinder bearings on both sides of the axle.
  • Page 74: Front Cardan Shaft

    Maintenance 8.2.18.5 Front cardan shaft CAUTION The cardan shaft must be lubricated every 50 operating hours (8-31/arrow and 8-32/arrow). Figure 8-31 Figure 8-32 8.2.18.6 Ball bearing ring The grease filling is to avoid friction and to provide sealing and protection against corrosion. Therefore, the ring must be lubricated every 10 operating hours until grease becomes visible on the outside.
  • Page 75: Bucket Assembly

    Maintenance 8.2.18.7 Bucket assembly CAUTION The support bolts/lubrication points of the bucket assembly must be lubricated every 10 operating hours. 2x item 8-34/1 Tip lever / pivot arm 2x item 8-34/2 Pivot arm / reversing rod 2x item 8-34/3 Tip lever / quick-change device 2x item 8-34/4 Bucket assembly / quick-change device Figure 8-34...
  • Page 76: Engine Flaps

    Maintenance 4x item 8-37/arrows Tip cylinder Figure 8-37 8.2.18.8 Engine flaps CAUTION The hinges of the engine flaps (8-28/arrows) must be lubricated every 50 operating hours. Figure 8-38 8.2.18.9 Multi-purpose bucket CAUTION The bearing bolts of the multi-purpose bucket must be lubricated every 10 operating hours. NOTE The bolt (8-39/arrow) must be lubricated on both sides of the multi-purpose bucket.
  • Page 77 Maintenance NOTE The bolts (8-40/arrows) must be lubricated on both sides of the multi-purpose bucket. Figure 8-40 8-18 S220/S221/S230/S231/Z200...
  • Page 78: Faults, Causes And Remedies

    Faults, Causes and Remedies...
  • Page 79 Faults, Causes and Remedies Faults, causes and remedies NOTE *) Faults may be eliminated only by authorised personnel Fault Probable cause Remedy Engine See the operating instructions for the engine Engine does not start. Drive switch (4-9/5) is not in neutral Set the drive switch to the neutral position position...
  • Page 80 Faults, Causes and Remedies Fault Probable cause Remedy Faults in the driving and working Clogged filter Replace filter cartridge (section hydraulics 8.2.10). Lack of oil in hydraulic oil reservoir Top off oil Electrical connection at axial Connect or clean electrical piston pump are not tight, are not connection according to electrical connected or are oxidised...
  • Page 81: Diagrams

    Diagrams...
  • Page 82 1 - 4 10.1 - 06.2005 Elektrik-Schaltplan/Schéma électrique/Wiring diagramm/Elektrisch schakelschema 10-1 S220/S221/S230/S231/Z200...
  • Page 83 2 - 4 10.1 - 06.2005 Elektrik-Schaltplan/Schéma électrique/Wiring diagramm/Elektrisch schakelschema 14 15 16 17 18 19 20 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 4 - 4 S220/S221/S230/S231/Z200 10-2...
  • Page 84 3 - 4 10.1 - 06.2005 Elektrik-Schaltplan/Schéma électrique/Wiring diagramm/Elektrisch schakelschema 10-3 S220/S221/S230/S231/Z200...
  • Page 85 2 - 4 4 - 4 10.1 - 06.2005 Elektrik-Schaltplan/Schéma électrique/Wiring diagramm/Elektrisch schakelschema 93 94 95 96 97 S220/S221/S230/S231/Z200 10-4...
  • Page 86: Electric Wiring Diagram

    Diagrams 10 10.1 Electric wiring diagram Item Designation Indicator lamp assembly Fuel gauge Coolant temperature gauge Tachometer Operating hours meter Actuator: release of quick-change device Actuator: rear window wiper/washer Actuator: road lights Actuator: hazard flasher Start switch Indicator lamp assembly for gear shift Steering column switch S200/S201/S210/S211/Z200 10-1...
  • Page 87 10 Diagrams Item Designation Fuse (chapter 4.9/A1) Hydraulics Fuse (chapter 4.9/A2) Heater Fuse (free) free Fuse (chapter 4.9/A4) Engine shut-off Fuse (chapter 4.9/A5) Fuse (chapter 4.9/A6) Brake lights Fuse (chapter 4.9/A7) Rear window heater Fuse (chapter 4.9/A8) Traction drive Fuse (chapter 4.9/B1) Turn indicator Fuse (chapter 4.9/B2) Windshield wiper/washer...
  • Page 88 Diagrams 10 Item Designation Actuator: working lights Actuator: rear window heater Actuator: warning beacon (opt.) Actuator: lifting device suspension (option) Actuator: four-wheel drive shutdown Actuator: fan/blower Actuator: fan reversal unit (option) Voltage transformer Radio (option) Fuse: air-conditioning system (4-13/arrows) Fuse: air-conditioning system (4-13/arrows) Fuse: air-conditioning system (4-13/arrows) Relay for air-conditioning system Relay for air-conditioning system...
  • Page 89 10 Diagrams Item Designation Starter Alternator Battery main switch Batteries Engine shut-off valve Start fuel allowance valve Coolant temperature switch Coolant temperature sensor Oil pressure switch Fan valve Temperature sensors Temperature sensors Fan reversal valve Brake light switch Air condition compressor Reversing buzzer Synchronisation valve Valve, reverse drive direction...
  • Page 90: Hydraulic Diagram

    Diagrams 10 10.2 Hydraulic diagram 10.2.1 AS 210 hydraulic diagram (bolt lock), “20 km/h” model Item Designation 01 Swivel cylinder DW 110/45/910/1287 02 Supporting valve 03 Supporting cylinder EW 70/210/470 04 Reservoir system, pipe break protection (option) 05 Auxiliary hydraulics, external circuit...
  • Page 91 10.2.1 - 04.2004 Hydraulic diagram AS 210 (bolt lock) "20 km/h" variant G3/4 G3/4 G3/4 G3/4 G3/8 G3/8 G3/4 G3/4 G3/4 G3/4 G1/2 G1/2 G1/2 G1/2 G1/2 G1/2 G3/8 G3/8 A2 B2 A1 B1 3 5 b G1/2 G1/2 G3/4...
  • Page 92 10.2.2 - 07.2004 Hydraulic diagram AS 210 (bolt lock) "35 km/h" variant G3/4 G3/4 G3/4 G3/4 G3/8 G3/8 G3/4 G3/4 G3/4 G3/4 G1/2 G1/2 G1/2 G1/2 G1/2 G1/2 G3/8 G3/8 A2 B2 A1 B1 3 5 b G1/2 G1/2 G3/4...
  • Page 93 10.2.3 - 07.2004 Hydraulic diagram AS 210 (claw lock) "20 km/h" variant 10 11 G3/4 G3/4 G3/4 G3/4 G3/8 G3/8 G3/4 G3/4 G3/4 G3/4 G1/2 G1/2 G1/2 G1/2 G1/2 G1/2 G3/8 G3/8 A2 B2 A1 B1 G1/2 G1/2 3 5 b...
  • Page 94 10.2.4 - 07.2004 Hydraulic diagram AS 210 (claw lock) "35 km/h" variant 10 11 G3/4 G3/4 G3/4 G3/4 G3/8 G3/8 G3/4 G3/4 G3/4 G3/4 G1/2 G1/2 G1/2 G1/2 G1/2 G1/2 G3/8 G3/8 A2 B2 A1 B1 G1/2 G1/2 3 5 b...
  • Page 95: As 210 Hydraulic Diagram (Bolt Lock), "35 Km/H" Model

    Diagrams 10 10.2.2 AS 210 hydraulic diagram (bolt lock), “35 km/h” model Item Designation 01 Swivel cylinder DW 110/45/910/1287 02 Supporting valve 03 Supporting cylinder EW 70/210/470 04 Reservoir system, pipe break protection (option) 05 Auxiliary hydraulics, external circuit 06 Locking cylinder DW 40/63/70/397...
  • Page 96: As 210 Hydraulic Diagram (Claw Lock), "20 Km/H" Model

    Diagrams 10 10.2.3 AS 210 hydraulic diagram (claw lock), “20 km/h” model Item Designation 01 Swivel cylinder DW 110/45/910/1287 02 Supporting valve 03 Supporting cylinder EW 70/210/470 04 Reservoir system, pipe break protection (option) 05 Auxiliary hydraulics, external circuit 06 Lift cylinder DW 110/70/908/1317...
  • Page 97: As 210 Hydraulic Diagram (Claw Lock), "35 Km/H" Model

    Diagrams 10 10.2.4 AS 210 hydraulic diagram (claw lock), “35 km/h” model Item Designation 01 Swivel cylinder DW 110/45/910/1287 02 Supporting valve 03 Supporting cylinder EW 70/210/470 04 Reservoir system, pipe break protection (option) 05 Auxiliary hydraulics, external circuit 06 Lift cylinder DW 110/70/908/1317...
  • Page 98: Technical Data (Loader)

    Technical Data (Loader)
  • Page 99: Loader

    11 Technical Data (Loader) Technical data (loader) NOTE The technical data refer to 20.5 -25 tyres. 11.1 Loader - Height 3.155 mm - Width 2.660 mm - Wheelbase 2.400 mm - Track width 2.080 mm - Operating weight w/o attachment 13.800 kg - Ground clearance - Distribution gear...
  • Page 100: Axle Loads

    Technical Data (Loader) 11 11.6 Axle loads - Perm. axle loads front 9.500 kg rear 9.500 kg - Perm. total weight 16.500 kg 11.7 Tyres The following tyres are permitted: - Size 20.5 - 25 - Tyre pressure front 3.0 bar rear 3.0 bar - Size...
  • Page 101: Support System

    11 Technical Data (Loader) 11.11.3 Support system - Operating pressure depending on load - 2 support cylinders Plunger diameter 70 mm 11.12 Fuel supply system - Contents Fuel tank 250 l 11.13 Heater and ventilation system (driver’s cabin) - Water heat exchanger - Type Gallay PVH 2505 - Heating capacity, continuously adjustable...
  • Page 102: Technical Data (Attachments)

    Technical Data (Attachments)
  • Page 103: Loaders With Bolt Locks (Kat. V)

    12 Technical Data (Attachments) Attachments 12.1 Loaders with bolt locks (Kat. V) NOTE The technical data refer to 20.5 -25 tyres. 12.1.1 Buckets Dimensions acc. to ISO 7131/35 12-2 S200/S201/Z200...
  • Page 104 Technical Data (Attachments) 12 12.1.1 Buckets Bucket type Standard Lightweight Multi-purpose bucket bucket bucket Bucket volume m³ Bucket width 2.700 2.700 2.700 Dead weight Loads acc. to ISO 14397 Bulk density t/m³ Dump load - frontal 7.800 7.750 7.600 - swivelled 7.450 7.350 7.200...
  • Page 105: Fork-Lift Attachment

    12 Technical Data (Attachments) 12.1.2 Fork-lift attachment Dimensions acc. to ISO 7131/35 12.1.3 Lifting hook Dimensions acc. to ISO 7131/35 12-4 S200/S201/Z200...
  • Page 106 Technical Data (Attachments) 12 12.1.2 Fork-lift attachment Tine length 1.600 mm Tine height 70 mm Dead weight 340 kg Perm. payload N acc. to EN 474-3 frontal - level ground (stability factor 1.25) 5.300 kg - uneven ground (stability factor 1.67) 3.975 kg swivelled - level ground (stability factor 1.25)
  • Page 107: Front-End Excavator

    12 Technical Data (Attachments) 12.1.4 Front-end excavator Dimensions acc. to ISO 7131/35 12.1.5 Grab bucket Dimensions acc. to ISO 7131/35 12-6 S200/S201/Z200...
  • Page 108 Technical Data (Attachments) 12 12.1.4 Front-end excavator Max. breakout force at the shovel cutting edge 6.200 daN Max. tear-out force at the shovel cutting edge 3.100 daN Shovel volume Shovel width Dead weight acc. to DIN ISO 7451 acc. to DIN ISO 7451 0,129 m³...
  • Page 109: Loaders With Claw Locks (Kat. Iv)

    12 Technical Data (Attachments) 12.2 Loaders with claw locks (Kat. IV) NOTE The technical data refer to 20.5 -25 tyres. 12.2.1 Buckets Dimensions acc. to ISO 7131/35 12-8 S200/S201/Z200...
  • Page 110 Technical Data (Attachments) 12 12.2.1 Buckets Bucket type Standard Lightweight Multi-purpose bucket bucket bucket Bucket volume m³ Bucket width 2.700 2.700 2.700 Dead weight Loads acc. to ISO 14397 Bulk density t/m³ Dump load - frontal 7.650 7.600 7.550 - swivelled 7.500 7.400 7.300...
  • Page 111: Fork-Lift Attachment

    12 Technical Data (Attachments) 12.2.2 Fork-lift attachment Dimensions acc. to ISO 7131/35 12.2.3 Lifting hook Dimensions acc. to ISO 7131/35 12-10 S200/S201/Z200...
  • Page 112 Technical Data (Attachments) 12 12.2.2 Fork-lift attachment Tine length 1.600 mm Tine height 70 mm Dead weight 340 kg Perm. payload N acc. to EN 474-3 frontal - level ground (stability factor 1.25) 5450 kg - uneven ground (stability factor 1.67) 4100 kg swivelled - level ground (stability factor 1.25)
  • Page 113: Front-End Excavator

    12 Technical Data (Attachments) 12.2.4 Front-end excavator Dimensions acc. to ISO 7131/35 12.2.5 Grab bucket Dimensions acc. to ISO 7131/35 12-12 S200/S201/Z200...
  • Page 114 Technical Data (Attachments) 12 12.2.4 Front-end excavator Max. breakout force at the shovel cutting edge 6.200 daN Max. tear-out force at the shovel cutting edge 3.100 daN Shovel volume Shovel width Dead weight acc. to DIN ISO 7451 acc. to DIN ISO 7451 0,129 m³...
  • Page 115 Additional Options, Modifications, Notes on Inspection for Loaders...
  • Page 116: Additional Options, Modifications, Notes On Inspection For Loaders Additional Options

    13 Additional Options, Modifications Additional options, modifications, notes on inspection for loaders 13.1 Additional options none 13.2 Modifications none 13-2 S200/S201/Z200...

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