OPERATING INSTRUCTIONS SWING SHOVEL LOADER A GB AS 150

Transcription

1 OPERATING INSTRUCTIONS SWING SHOVEL LOADER A GB AS 150 Ahlmann Baumaschnen GmbH Telefon 04331/ Telefax 04331/ Am Fredrchsbrunnen 2 D Büdelsdorf Internet: E-Mal: nfo@ahlmann-baumaschnen.de

2 Table of Contents Introducton Preface Ahlmann swng loaders, artculated loaders and front loaders are part of Ahlmann selecton of heavy constructon equpment, and desgn for a wde range of uses. Years of experence n manufacturng earth-movng equpment and varous auxllary tools, modern constructon and manufacturng approaches, careful testng and an strngent qualty control assure the relablty of your Ahlmann wheel loader. Scope of documentaton suppled by manufacturer: - Equpment Operatng Manual - Engne Operatng Manual - Parts Lst Equpment - Parts Lst Engne - EU Statement of Conformty Operatng Manual The operatng manual contans nformaton requred for safe operatons and mantenance. The "Mantenance" secton contans detals of all servce tasks and functonal checks, whch must be performed by traned staff. These do not nclude major servcng tasks whch must be performed by techncans specally traned and authorzed by the manufacturer. Ths specfcally ncludes equpment subject to road safety, and safety at work regulatons. The manufacturer reserves the rght to alter constructon detals, whch may lead to some devatons between your actual equpment and the fgures shown n ths manual, but wll not affect the accuracy of the contents. Usng the Manual Termnology - The terms "left" or "rght" refer to the equpment as vewed from the drver s cab facng n drecton of travel. - Optonal means: Not ncluded as standard equpment. Note on Fgures - (3-35) means: Chapter 3, Fg (3-35/1) means: Chapter 3, Fg. 35, Poston 1 - (3-35/arrow) means: Chapter 3, Fg. 35, S150/S151/S152/Z152 I

3 Table of Contents Abbrevatons used SW = Safety at work regulatons RS = Road safety regulatons Verson: Prnted: II S150/S151/S152/Z152

4 Table of Contents 1 Basc Safety Notes Table of Contents 1.1 Warnngs and symbols Approprate use Admnstratve tasks Selectng and tranng staff Safety notes n varous operatng modes Normal operatons Specal tasks applcable to usng the equpment and troubleshootng; waste dsposal Note on specfc dangers Electrcal power Hydraulcs Nose levels Ols, greases and other chemcal substances Gas, dust, steam, smoke Transportng and towng; re-commssonng Safety notes for the owner or responsble persons Admnstratve tasks Selectng and tranng staff; basc requrements Sgns 3 Ant-Theft Mechansm 3.1 Identfcaton marks on the equpment Parkng the equpment Transponder mmoblzer Descrpton 4.1 Overvew Swng drve and undercarrage Schwmmstellung Bucket poston ndcator Accoustc warnng Ar-Condtonng Bucket cushonng Transmsson type "20 km/h" and "25 km/h" Changng wheels Control elements Dashboard Operatons 5.1 Checks before you start Gettng started Startng the desel engne Wnter runnng Fuel Engne ol change Hydraulc ol change Ant-frost for screen washer system Drvng on publc roads Transportng an excavator Workng wth the equpment Slow-runner type "20 km/h" and "25 km/h" Fast-runner type "40 km/h" S150/S151/S152/Z152 III

5 Table of Contents Heatng and ventlaton system/ar condtonng unt(sa) Blower output Turnng on the heatng Turnng on the ar condtonng unt (SA) Settng the temperature De-commssonng Swtchng off the equpment Swtchng off the desel engne Swtchng of the Heatng and ventlaton system/ar condtonng unt(sa) Leavng the vehcle Adjustng the drver seat Isr seat Grammer seat Changng the steerng mode Auxllary Attachments 6.1 Attachng and detachng auxllary devces wthout hydraulcs Standard/Lghtwork bucket Fork-lft attachment Lftng hook Attachng and detachng auxllary devces wth hydraulcs Mult-purpose bucket Front-end excavator Changng the backhoe Usng other attachments Rescue, Towng, Lashng, Lftng by crane 7.1 Rescue, towng, lashng Rescue/towng the swvel loader n case of engne or transmsson falure Towng the swvel loader n case of engne falure Towng the swvel loader n case of transmsson falure Lftng by crane Mantenance 8 Mantenance plan type 40 km/h Mantenance plan types 20 km/h and 25 km/h Mantenance notes Mantenance tasks Checkng the engne ol level Checkng the axle ol level Rear axle Planetary gear Front axle Checkng ol level n power take-off drve» slow-runners 20 km/h and 25 km/h « Checkng ol level n power take-off drve» fast-runners 40 km/h « Checkng ol level hydraulc ol contaner Changng the engne ol Changng the axle ol Rear axle Planetary gear Front axle Ol change power take-off drve» slow-runners 20 km/h and 25 km/h « Ol change power take-off drve» fast-runners 40 km/h « Ol change hydraulcs system Changng sucton return flter meda Changng/Mantanng the ar flter Changng the safety cartrdge Changng the fuel flter Changng the starter battery Changng/Mantanng the fresh ar flter Checkng/adjustng the servce brake Greasng ponts IV S150/S151/S152/Z152

6 Table of Contents Rear axle clevs pn Rear axle Front axle Swng roller bearng Bucket motor Cab doors Engne hood Olng ponts Support valve swtchgear Malfunctons, Causes and Troubleshootng 10 Wrng dagrams 10.1 Elektrcal wrng dagram Hydraulc dagram Hydraulk-Schaltplan AS 150 (Bolzenverregelung) Ausführung "20 km/h" und "25 km/h" Hydraulk-Schaltplan AS 150 (Bolzenverregelung) Ausführung "40 km/h" Hydraulk-Schaltplan AS 150 (Klauenverregelung) Ausführung "20 km/h" Hydraulk-Schaltplan AS 150 (Klauenverregelung) Ausführung "40 km/h" Techncal Specfcatons (Equpment) 11.1 Equpment Engne Starter Alternator Hydrostatc drve Axle loads Tres Steerng Brakes Electrcal equpment Hydraulc equpment Work hydraulc system Loader hydraulc system Abstützanlage Fuel supply system Heatng and ventlaton system (drver s cab) Sucton return flter (hydraulcs) Elektrcal contamnaton dsplay Ol cooler (comb cooler) wth thermostatc valve control Nose levels Optons Ar condtonng (drver s cab) Techncal Specfcatons (Attachments) 12.1 Buckets Fork-lft attachment Front loader Lftng hook Addtonal Equpment, Changes, Sample "Notes on Testng Wheel Loaders" 13.1 Addtonal equpment Descrpton Ppe burst protecton Lft range lmter Servce nterval warnng dsplay Changes S150/S151/S152/Z152 V

7 Safety regulatons

8 1 Safety regulatons 1 Fundamental safety nstructon 1.1 Warnngs and symbols In ths operaton manual the followng desgnatons or symbols are used for mportant nformaton. Specal nformaton for the economcal use of the machne. CAUTION Specal nformaton for necesstes and prohbtons for avodng damages. DANGER Informaton or necesstes and prohbtons for preventon of damage to persons or extensve damage to goods. 1.2 Use of the loader as authorzed Ths machne was desgned accordng to the state of the art and recognzed safety rules. Nevertheless the use of the machne may cause danger for the user or thrd partes or mparments to the machne or other real values The machne and attachments may only be used n a techncal non-objectonable condton, takng all safety regulatons especally wth regard to the operatng manuals (machne and engne). In partcular defects whch could have a detrmental effect on the safety of the machne should be elmnated mmedately The machne s determned exclusvely for the purposes descrbed n ths operatng manual. Any other utlzaton s not permtted. The manufacturer s not lable for any damage caused n ths connecton. The user solely carres the rsk. The authorzed use of the machne also requres the observaton of the operatng manual (machne and engne) as well as the observaton of the nspecton and mantenance condtons. 1.3 Organzatonal measures The operatng manual (machne and engne) must be avalable at all tmes and at the ste where the machne s n operatng condton. 1-2 S150/S151/S152/Z152

9 Safety regulatons In addton to the operatng manual (machne and engne) the general applcable and other bndng regulatons for the preventon of accdents (especally the safety regulatons of the German Trade Assocaton - VBG 40) as well as the regulatons for envronment protecton must be observed and the personnel must be accordngly nstructed. Traffc regulatons must also be observed The personnel n charge of workng wth the machne must read the operatng manual (machne and engne) before start of work, especally the chapter concernng safety precautons. Ths also apples to personnel workng occasonally wth the machne, e.g. durng mantenance work The drver must wear a seat belt durng operaton Personnel workng wth the machne must not wear long flowng har, loose clothng or jewelry ncludng rngs as ths could cause njures by gettng caught up or pulled n by the machne All safety and danger plates on the machne must be observed All safety and danger plates must be attached to the machne and must be kept n legble condton In case of modfcatons to the machne, especally n case of damages or changes n the operatng behavor of the machne whch could nfluence the safety of the machne, stop the machne mmedately and nform the competent person n charge about the ncdent Wthout the manufacturer s consent, do not make any modfcatons or conversons to the machne whch could affect safety. Ths also apples to the nstallaton and adjustment of safety devces, valves and weldng work to supportng parts Check hydraulc system, especally hydraulc ppes, at regular ntervals for defects. Immedately elmnate any defects found The prescrbed nspecton perods set down n the operatng manual (machne and engne) and the mantenance plan must be observed. 1.4 Selecton of personnel and necessary qualfcatons Fundamental oblgatons The machne may only be drven and mantaned by personnel selected by the employer for ths purpose. S150/S151/S152/Z

10 1 Safety regulatons These persons must: - have attaned the age of 18 years, - be physcally and ntellectually sutable, - have been nstructed n the operaton or mantenance of the machne and must have demonstrated ther ablty to ther employer, - must be expected to carry out the work conveyed to them n dlgent manner Electrcal work on the machne may only be carred out by a qualfed electrcan or persons supervsed by a qualfed electrcan accordng to the electrotechncal regulatons Only qualfed specalsts may carry out work on the transmsson mechansm and to the hydraulc system Only personnel wth specal experence and the necessary know-how are permtted to carry out work on the hydraulc system. 1.5 Safety Informaton for Certan Operatng Phases Normal Operaton Other persons must not be transported! Start and drve the machne from the drver s seat only! Durng startng and swtchng-off operaton observe the control lamps accordng to the operaton manual (machne and engne)! Before commencng work/drvng check brakes, steerng, sgnal lghts and lghts for ther functonng! Before movng the machne always check that the attachments are safely stowed so that no accdent may occur! Before commencng work make yourself famlar wth the workng envronment. Ths means observng obstacles on the workng ste, qualty and resstance of the sol ground, undertakng the necessary protecton precautons between the buldng ste and the publc traffc Before startng the machne make sure that no person s endangered by the machne! Take measures so that the machne can be operated n a safe and functonal manner. The machne may only be operated when all safety devces, e. g. detachable safety devces, sound-absorpton, exst and functon. 1-4 S150/S151/S152/Z152

11 Safety regulatons Avod any work operaton whch appears to be dangerous! Persons must not be carred n the workng equpment, e.g.n the attachments! The operator may only carry out work wth the machne when no persons are n the danger zone. The danger zone means that area near the machne where persons may be njured - by work-nduced movements of the machne, - by work attachments and devces, - by loads swvelng out, - by loads fallng down, - by attachments fallng down from the machne In case of danger to persons the operator must gve approprate warnng sgns. It may be necessary to stop work In case of functonal defects stop machne mmedately and safeguard t. Elmnate defects mmedately! Check machne at least once every shft for external vsble damage and defects wth regard to any changes and to the operatng behavor of the engne. Report any defects or changes mmedately to the person n charge. If necessary stop the machne mmedately and safeguard t The drver may only slew the attachments overhead drvng, operatng and workng areas f these areas are sutably safeguarded by protectve roofng. These protecton roofs must offer approprate safety aganst loads and goods fallng down. In case of doubt, t should be assumed that they are not protectve roofs When drvng, the attachment s to be kept as close to the ground as possble Please observe the applcable traffc regulatons when drvng on publc roads, paths or open spaces. The machne must be brought nto road-worthy condton n beforehand In general, swtch on lghts n poor vsblty and durng darkness If lghts of the machne are not adequate for the safe executon of certan work, addtonal lghtng must be provded on the workng ste, especally at dumpng ponts Should the drver s sght of hs drvng and workng area be restrcted due to work-nduced nfluences, he must be gven gudance or he must safeguard the workng area by a frm barrer. S150/S151/S152/Z

12 1 Safety regulatons The person gvng gudance must be a relable person and must be nformed about hs tasks before commencement of the work The drver and gude must agree on sgnals for communcaton. These sgnals may only be gven by the drver and gude The gude must be easly recognzable e.g. by wearng warnng clothng and must always be n the drver s feld of vson When passng subways, brdges, tunnels, electrcal over-head lnes make sure that there s adequate clearance! Keep good clearance when workng at the edge of quarres, pts, rubbsh dumps and embankments to elmnate any danger of the machne plungng down. The contractor or hs deputy must stpulate the dstance from the edge takng the sol bearng capacty nto consderaton The machne may only be used at statonary dumpng areas when frmly ntegrated nstallaton are provded to prevent the machne from runnng or sldng down Avod such work whch could have detrmental effect on the stablty of the machne. The stablty can be detrmented by: - overloadng, - too soft ground, - abrupt acceleraton or deceleraton of drvng movement or workng movement, - reversng out of hgh drvng speed, - workng on slopes, - drvng too quckly round sharp bends, - drvng the machne on rough terran wth the bucket arm swung Do not drve along slopes n traverse drecton. Always carry workng equpment and loads near the ground, especally when drvng down slopes. Sudden cornerng s forbdden! On steep nclnes and gradents, the load s to be carred on the uphll sde Before the slope, reduce the speed and always adapt to the local condtons! Always adapt the speed of the machne to the envronmental condtons when drvng down slopes! Never change nto low gear when drvng on slopes but before enterng the slope! Reversng over a longer perod must be avoded! When leavng the machne always safeguard the machne to prevent t from unntentonally rollng away or prevent non-authorzed persons from usng t! The drver must not leave the machne f the attachments are not lowered or safeguarded. 1-6 S150/S151/S152/Z152

13 Safety regulatons Durng work-brakes and after work hours the drver should endeavor to leave the machne on good bearng sol and f possble on level ground and safeguard the machne to prevent t from unntentonally rollng away Specal work wthn the explotaton of the machne and elmnaton of defects durng process or work; dsposal The prescrbed dates for adjustment work, mantenance work and nspectons lad down n the operatng manual (machne and engne) must be strctly observed. Ths also apples to detals regardng the nterchangng of parts/ part equpment. Ths work may only be executed by sklled personnel. Fgure For all work concernng the operaton, converson or adjustment of the machne and ts safety devces as well as nspecton, mantenance and repar work please observe the swtchng and stoppng operaton n accordance wth the operatng manual (machne and engne) as well as the related nstructons for mantenance work The engne must be swtched off before mantenance or repar work s carred out The stablty of the machne or the attachments must be guaranteed at all tmes durng mantenance and repar work Mantenance and repar work may only be carred out when the attachment s set down on the ground or supported or when equvalent measures aganst unntentonal movement were taken. Durng mantenance and repar work under the bucket arm: the bucket arm must be mechancally propped up, e.g. by nsertng the bucket arm support (opton) (1-1/ arrow). - the hand levers for the hydraulc loader (1-2/1) and auxlary functons (1-2/2) must be secured. - the swng mechansm must be blocked. Remove the blockng wedge (1-3/arrow) out of the mountng, swtch to swng blockng (1-4/arrow), and secure wth sprng pn. Fgure If necessary, protect the mantenance area on a large scale The machne must be protected from unntentonally startng after t was swtched off for mantenance and repar work: - remove the gnton key - attach warnng sgn at battery man swtch. Ths apples especally to works to the electrcal equpment Indvdual peces and large assembles must be carefully secured to hostng equpment when beng substtuted to avod any damage. Only sutable and techncal sound hostng equpment may be used as well as crane equpment wth adequate payload. Do not stand or work underneath suspended loads! Fgure 1-3 S150/S151/S152/Z

14 1 Safety regulatons Only experenced personnel should be entrusted wth the securng of loads! Loads must be secured so that they cannot slp or fall down Attached loads may only be moved wth the machne when the road s graded When workng wth hostng equpment/elevators the slngers may only work wth the approval of the drver and from the sde of the boom. The drver may only gve hs consent f the machne s standng stll and the workng attachment s not beng moved. Fgure Persons assstng wth the gudance of loads and slngers may only stay n vsual or communcaton reach of the drver The operator must move the load as close to the ground as possble and avod to swvel the load The operator may not move the load over the heads of persons In the case of erecton work havng to be carred out above normal human heght, sutable safety ascent devces and workng platforms must be used. Do not use engne parts as clmbng and descendng facltes. Use safety harnesses when workng at very great heghts. All handles, steps, ralngs, podests, platforms, ladders must be kept free from drt and ce Clean the machne, especally connectons and screw connectons before commencement of mantenance work and make sure that the machne s free from ol, fuel ol or drt. Do not use aggressve detergents. Use lntless cleanng rags! Before cleanng the machne wth water or steam jet (hgh pressure cleanng unt) or wth detergent protect all areas where water/ steam/ detergent may penetrate and affect the functons or safety of the machne by a sutable cover or by applyng tape. In partcular, such parts as engne components, e.g. njecton pump, generator governor, starter are very delcate After cleanng completely remove all protecton coverng and tape After cleanng check all ppelnes for fuel, engne ol and hydraulc ol for leakages, loose connectons, abrased parts and damages. Elmnate defects mmedately Always fasten screw connectons after completon of mantenance and repar work Should t be necessary to dsmantle safety devces durng mountng, mantenance or repar work, these safety devces must be re-nstalled and checked carefully after completed mantenance and repar work. 1-8 S150/S151/S152/Z152

15 Safety regulatons Make sure that fuel, accessory materal and nterchanged parts are safely dsposed of wth no danger to the envronment The machne should be checked by a specalst before commssonng. In addton, t should be checked after essental modfcatons before t returns to servce The machne must be checked by a specalst once a year. Furthermore, a specalst must check the machne whenever necessary because of operatng condtons The test results must be recorded and kept n the archves at least untl the followng control date. 1.6 Instructons regardng specal categores of danger Electrcal energy Only use orgnal fuses (mandatory current). Immedately swtch off machne n case of breakdown of electrcal supply When workng near overhead lnes and overhead wres, a safety clearance must be kept between the machne and ts workng equpment n order to prevent sparkng over. The safety clearance depends on the nomnal voltage of the overhead/wre lne. Ths also apples to the dstance between the lnes and to the attachments and slung loads. The followng safety clearance must be observed, to meet the above mentoned requrement: Nomnal voltage (klovolt) Safety clearance (meter) up 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 nomnal voltage 5,0 m When approachng overhead lnes all workng movements of the machne must be taken nto consderaton, e.g. the poston of jbs, the swngng of ropes and the dmensons of slung loads. In addton, attenton must be pad to any roughness of sol whch could cause an nclned poston of the machne thus gettng t closer to the overhead lne. The fact that overhead lnes may swng out durng wndy weather and may reduce the dstance must also be taken nto consderaton. S150/S151/S152/Z

16 1 Safety regulatons In the case of sparkng over any work or movement must stop. Instructons to be followed: brng the machne out of the danger area by lftng or lowerng the attachments or by swvelng away or drvng the machne out of the area. If ths s not possble then the followng rules must be observed: - do not leave the drver s cabn! - Warn persons standng near the machne not to approach or touch the machne! - Gve mmedate nstructons to have the power cut off! - Leave the machne only when t s sure that the electrcty n the damaged/contacted power lne s swtched off so that the lne s dead! Work on the electrcal system or on the operatng system may only be carred out by a sklled electrcan or by personnel nstructed or supervsed by such traned electrcan accordng to electrotechncal regulatons The electrcal nstallaton of a machne must be revewed/nspected at regular ntervals. Any defects, e.g. loose connectons or scorched cablng, must be elmnated mmedately Always de-energse machne or system parts to be nspected, mantaned or repared by dsconnectng the battery man swtch Always dsconnect the battery man swtch before startng any electrcal weldng on the machne Hydraulc systems Only experts may carry out work on the hydraulc system All ppelnes, hoses and screw connectons must be checked regularly for leakages and vsble damages. Immedately elmnate such defects. Spurtng hydraulc ol may cause njures and fre Those hydraulc system segments whch are to be opened must be made free of pressure before commencement of the repar work accordng to the assembly group descrpton The hydraulc ppelnes must be correctly lad and connected. Do not get the connectons mxed up. The spare parts must be n an accordance wth the techncal requrements stpulated by the manufacturer. Ths s, of course, guaranteed when orgnal spare parts are ordered Never change factory settngs for hydraulc components (such as the maxmum permssble speed for the axal pston engne). Changng such settngs wll cause the warranty to become vod Nose Sound protecton equpment must be n protectve poston durng operaton of the machne S150/S151/S152/Z152

17 Safety regulatons Ol, grease and other chemcal substances The relevant safety regulatons must be observed when usng ol, grease or other chemcal substances Cauton when workng wth hot fuel and other accessory materal (danger of burnng and scaldng) Cauton when workng wth brake flud and battery acd. TOXIC AND CAUSTIC! Be careful when workng wth fuel. FIRE HAZARD! - Before refuel, swtch off engne and remove gnton key. - Do not refuel n a closed operatng area. - Never refuel near open fre or sparks. - Do not smoke durng refuelng. - Immedately wpe up splled fuel. - Keep machne free of fuel, ol and grease Gas, dust, steam, smoke The machne may only be started and run n closed operatng areas where there s suffcent ventlaton. The regulatons for the respectve workng ste must be strctly observed Only carry out weldng, burnng and grndng work on the machne when ths s explctly approved. Otherwse danger of fre and exploson! Before carryng out weldng, burnng and grndng work clean the machne and ts vcnty from combustbles and make sure that the room s adequately ventlated. Exploson hazard! 1.7 Transport and towng, restart The machne may only be towed f the brakes and steerng functon Towng may be carred out only by means of an adequately dmensoned towng bar n connecton wth towng devces When towng drve slowly. Persons must not reman near the towng bar. S150/S151/S152/Z

18 1 Safety regulatons When the machne s loaded and transported the necessary auxlary equpment must be ftted to prevent any unntended movement. The tres must be kept clean of mud, snow and ce so that the machne can drve on the ramp wthout danger of sldng Restart the machne strctly observng the regulatons of the operatng manual. 1.8 Safety nformaton for the contractor or the contractor s authorzed personnel Organzatonal measures We would lke to emphasze that parts and accessores that are not suppled by us are also not tested and approved by us. Installaton and/or use of such products can thus negatvely affect the constructonal qualtes of your loader and thereby reduce the actve and passve drvng stablty. The manufacturer cannot be held responsble for damage that results from the use of non-orgnal parts and accessores Inform about the locaton/use of fre extngushers (1-5/arrow) and frst-ad kt (on the mantenance plate behnd the drver's seat)! Selecton of personnel, qualfcatons; addtonal dutes Only relable persons are allowed to work on/wth the machne. The mnmum legal age must be observed. Fgure Only employ traned or nstructed personnel. Clearly defne the competences of the personnel regardng operaton, nstallaton, mantenance and repar work. Ensure that only authorzed personnel may work on/ wth the machne Determne the drver s responsblty regardng traffc regulatons. Authorze hm to refuse nstructons gven by thrd partes when these nstructons are detrmental to the safety of the drver and the machne Personnel that are beng traned are permtted to operate the loader only f they are under constant supervson of an experenced person authorzed by the employer! 1-12 S150/S151/S152/Z152

19 Sgns

20 2 Sgns a ATTENTION! ACHTUNG! Be Only Fahrten the rear-wheel auf öffentlchen steerng Straßen may be used st nur for de drvng Hnterradlenkung publc roads! zu on benutzen! 1 ATTENTION! ACHTUNG! Lenkung Steerng s nur only be avalable laufendem whle Motor the engne betrebsfähg! s runnng! ATTENTION! ACHTUNG! Das The transfer Vertelergetrebe gear shft darf can only nur m be Stllstand operated geschaltet whle the vehcle werden. s Bem Gangwechsel de Betrebsbremse betätgen und statonary. When changng gear, den apply Fahrtrchtungsschalter the brakes and put the gear n "0"-Stellung selector n neutral, schalten. "0". ATTENTION! ACHTUNG! Bem The burst Betreb ppe der Hubwerksfederung mechansm st de for Rohrbruch- the lftng protecton scherung cylnder s der dsabled Hubzylnder when außer bucket Funkton. cushonng s enabled. Be You angebautem must dsengage Staplervorsatket cushonng oder Lasthaken mechansm darf de the buk- Hubwerksfederung before fttng a fork-lft ncht engeschaltet lftng hook. or werden. 9b AS ,0 3,0 bar 17.5 R /65 R bar Baumaschnen GmbH D Büdelsdorf 24 Betrebserlaubns Nr. Fahrzeug Identf- zerungs Nr. (FIN) zul. Gesamtgewcht kg 27 zul. Achslast vorn zul. Achslast hnten Typ/ Ausf Bau- jahr kg kg Motor- lestung: kw AS AHLMANN-Baumaschnen GmbH ROPS-Typ: Fzg.-Typ: zul. Ges. Gew.: ROPS-Prüfung nach DIN so 3471 TIM SA B.P. No BERGUES FRANCE S150/S151/S152/Z152

21 Sgns 2 1 Symbol: Dangerous area, keep clear 2 Sgn: ATTENTION! Only the rear-wheel steerng may be used for drvng on publc roads!! 3 Sgn: ATTENTION! - Steerng s only avalable whle the engne s runnng! 4 Sgn:» for slow-runners only «ATTENTION! The transfergear shft can only be operated whle the vehcle s statonary. When changng gear, apply the servce brakes and select neutral gear ("0"). 5 Sgn:» only for machnes wth ppe burst protecton «ATTENTION! The burst ppe protecton mechansm for the lftng cylnder s dsabled when bucket cushonng s enabled. You must dsable the bucket cushonng mechansm before fttng a fork-lft or lftng hook. 6 Symbol: Manual lever for hydraulcs (4-6/5)» left of seat «7 Symbol: Swtch steerng type (4-6/4) Rear wheel /Four wheel 8 Symbol: Hydraulc ol tank 9a Sgn: Nose level (Chp ) 9b Sgn: Accoustc pressure (Chp ) 10 Symbol: Lftng hook 11 Symbol: Lashng ponts 12 Sgn: Low nose emsson equpment 13 Sgn: Max. speed 14 Sgn: Mantenance plan 15 Sgn: Tre pressure 16 Symbol: Manual lever for man hydraulcs (4-7/2) 17 Symbol:» for slow-runners (Type 20 km/h and 25 km/h) «Hydraulc gear shft (4-7/1) Hare symbol - road Snal symbol - feld Drecton - forwards reverse 18 Symbol:» for quck-runners (Type 40 km/h) «Gear lever - 2nd gear - 1st gear - Alpha max. (Turtle symbol) 19 Symbol: Stop valve for man/auxllary hydraulcs - closed 20 Symbol: Read and mplement nstructons n manual before commssonng. Ensure that all other users are aware of safety precautons! 21 Symbol: Swvel jont 22 Symbol: Fuel tank 23 Type plate: Machne (ncludes vehcle ID number) 24 Sgn: Annual nspecton to TC standards 25 Sgn: TC plaque 26 Type plate: Operator s cabn 27 Sgn: Do not open whle engne s runnng S150/S151/S152/Z

22 Ant-Theft Protecton

23 3 Ant-Theft Protecton 3 Ant-Theft Protecton Recent years have seen a sharp ncrease n the number of thefts of constructon machnery. To allow the authortes (such as the polce, or customs and excse) to dscover and dentfy stolen vehcles more quckly, Ahlmann constructon machnes are ftted wth the followng dentfcaton marks: Fg Equpment ID marks (1) The machne type plaque (3-1/arrow). Amongst other detals ths ncludes the 17 dgt FIN number (vehcle dentfcaton number) whch starts wth W09. (2) The FIN number s also punched nto the front of the vehcle (3-2/arrow). (3) The ROPS plaque (3-3/arrow). Ths ncludes the name of the manufacturer, detals of the ROPS type, vehcle type, and max. permtted weght. W09S150011BA Parkng the vehcle (1) Turn the steerng to the left or rght tll t locks n place. (2) Put the parkng brake on (4-7/4). (3) Lower the quck change mechansm to allow - the lp of the bucket, - the forks of the fork loader, - the lftng hook boom to touch the ground. Fg. 3-2 (4) Close both stop valves (1-2/1 and 1-2/2). (5) Place gear lever (4-7/3) n "forward" or "reverse". (6) - Slow-runners: - Use gear selecton swtch to select gear "I" (4-8/4). - Select hydraulc drve level "I" (4-7/1). - Fast-runners: Use work hydraulcs valvecontrol lever (4-7/1) for to select gear "Alpha max. (Turtle symbol)". (7) Remove gnton key. (8) Remove man battery key (4-7/5). (9) Swtch on workng lghts (4-8/24). * (10) Swtch on 360 degree lght (SA) (4-8/12). * (11) Swtch on hazard-warnng lghts (4-8/11). * Fg S150/S151/S152/Z152

24 Ant-Theft Protecton 3 (12) Push steerng column headlamp swtch to select "beam" (4-5/5). * (13) Lock both doors. (14) Lock engne hood. (15) Lock fuel tank fller cap. * If the vehcle s short-crcuted, bystanders wll be alerted by the unusual lghtng dsplayed. 3.3 Transponder Immoblzer (Optonal) The "Transponder Immoblzer" s an electronc mmoblzer that dsables crtcal features of the vehcle. If the transponder (whch can be attached to the key-fob for the gnton key) s removed from the vcnty of the recever (.e. the vcnty of the gnton lock), these functons are nterrupted. Insurance Benefts: The transponder mmoblzer s n lne wth the latest strngent requrements mposed by nsurance companes. Ask your nsurance broker for detals! S150/S151/S152/Z

25 Descrpton

26 4 Descrpton 4 Descrpton Constructonal and desgn enhancements are mportant for the techncal development of ths equpment and may lead to devatons between fgures and content n ths manual. These changes are summarzed n Chapter 13. Please refer to Chapter 13 for detals. 4.1 Overvew AS 150 Fg Bucket protector 2 - Bucket/Attachment 3 - Trunnon balls 4 - Push cylnder 5 - Boom 6 - Lft cylnder 7 - Cabn 8 - Hydraulc ol tank/fller cap 9 - Engne 10 - Rear axle 11 - Battery case 12 - Tool case 13 - Swvel assembly 14 - Front axle 15 - Quck couplng mechansm 16 - Fuel tank, access ladder on rght sde of vehcle (not shown) 4-2 S150/S151/S152/Z152

27 Descrpton Swvel assembly and Axle support The twn rotatonal cylnders are drven by a separate gear ol pump va a control valve. The swvel assembly s attached to the cylnders va drve chans, and thus totally free of play. Rotaton can occur smutaneously whle lftng the boom wthout any nterference between the two components. The loader assembly can be rotated through 90 left or rght. When the loader assembly s rotated through more than approxmately 30, the axle support mechansm automatcally engages. Hydraulc pressure s bult up n the rear axle support cylnder on the load-bearng sde va the support valve and uses the actual load pressure to counteract the effect of the rotated load. Axle support s dsengaged when the swvel assembly s centered. 4.3 Float Feature The assembly s equpped wth a float feature that allows the operator to perform tasks such as levelng on uneven terrans. To enable the float feature, push the hydraulcs control lever (4-7/2) forwards through ts pressure pont. The lever wll reman n ths poston untl you dsengage the float feature by pullng t n the opposte drecton. DANGER Ensure that the bucket s grounded before engagng the float feature. Fg Bucket Poston Dsplay The drver can determne the bucket poston by checkng the colored marks on the tlt cylnder. If the mark on the tlt cylnder algns wth the end of the montorng rod (4-2/ arrow), the bucket heel s parallel to the ground. 4.5 Accoustc Warnng System The machne s ftted wth an accoustc warnng system that provdes three functons: 1. Show gear shft falure.» In combnaton wth sgnal lamp (4-8/10). «2. Show hydraulc ol temperature over 100 C (+/- 3 C).» In combnaton wth sgnal lamp (4-8/36). «3. Show ndcator use.» In combnaton wth sgnal lamp(4-8/26). «S150/S151/S152/Z

28 4 Descrpton 4.6 Ar Condtonng (optonal) The loader s equpped wth an ar condtonng unt that allows the drver to set the desred temperature, thus guaranteeng mproved operator response and consderably enhancng operator concentraton. At the same tme, the ar condtonng unt dehydrates the ar enterng the cab, preventng condensaton and steamed up wndows, and allowng for better vsblty. Addtonally, the ar condtonng unt uses dust flters to flter the ar, at the same tme preventng dust and other unpleasant or harmful substances from enterng the cab by permanently generatng slghtly rased cab pressure. To ensure perfect workng order and full performance, the compressor must be engaged once a week for a short perod, n order to lubrcate the nternal gaskets. If the ambent temperature s low, the compressor should not be swtched on untl the engne has reached runnng temperature. The coolant, whch n flud state tends to collect at the lowest pont n the compressor crcut, assumes ts gaseous form due to engne heat. Flud coolant can cause damage to the compressor. DANGER - Due not attempt to open the ar condtonng crcut, as ths wll cause coolant loss. - The coolant crcut contans gas whch can be dangerous n certan crcumstances. ATTENTION - The ar condtonng unt should be mantaned by traned and authorzed staff only. - The compressor has an ol fll-level gage. Do not remove the gage, as ths wll empty the unt. The ol fll-level does not need to be checked, except when emptyng the ar condtonng crcut. If the crcut develops a leak, the ar condtonng unt wll become neffectve. 4-4 S150/S151/S152/Z152

29 Descrpton Bucket Cushonng When drvng the loader over a longer dstance, partcularly f the bucket s loaded, t makes sense to engange the bucket cushonng feature (4-8/15) to prevent the loader from seesawng. Ths partcularly apples on uneven terran and f the loader s drven at hgher speeds. ATTENTION - Bucket cushonng can only be actvated whle movng the loader, but not for normal operatons. - The ppe burst protecton system s deactvated when bucket cushonng s engaged. - Bucket cushonng cannot be actvated when a fork-lft attachment or lftng hook s ftted. - Bucket cushonng s actvated by pressng a button (4-8/15). - Returnng the starter swtch (4-8/19) to the "0" poston wll automatcally dsengage the bucket cushonng mechansm. Re-engage the the mechansm, f requred. 4.8 Gear Selecton Type "20 km/h" and "25 km/h" ATTENTION The gears of the transfer gear shft can only be selected when the vehcle s statonary, the servce brakes have been appled and the drecton selector (4-7/3) s n neutral ( poston "0"). To select a gear, press the push-button (4-8/4) on the dash board. - Press the button once to engage frst gear (the pushbutton lghts up). - Press the button agan to engage second gear (the pushbutton s unlt). Second gear s automatcally selected when you restart the vehcle, that s after the devce has been powered off. 4.9 Changng Wheels DANGER Before changng a wheel on a publc road, ensure that the danger area has been secured. (1) Park the vehcle on level ground. (2) Put the drve selector (4-7/3) n neutral (poston "0". (3) Apply the parkng brakes (4-7/4). S150/S151/S152/Z

30 4 Descrpton (4) Changng a front wheel: - Lft and mechancally prop up bucket arm [e.g. by nsertng the bucket arm support (opton) (1-1/arrow)] and lower bucket arm untl t rests on the bucket arm support. - Block the swvel assembly. To do so remove the wedge (1-3/arrow) from the holder, nsert t n the swvel retaner (1-4/arrow) and use a sprng-pn to lock t n ths poston. (4) Changng a rear wheel: Drop and uncouple attachment. Fg. 4-3 (5) Turn the gnton key (4-8/19) left to poston "0". (6) Lock the levers for man and auxlary hydraulcs (1-2/1 and 1-2/2). (7) Chock one wheel on the rear axle n both drectons to prevent the vehcle from rollng. Choose the wheel that does not need to be changed. (8) Loosen the wheel nuts on the wheel you are changng to a pont where they can be removed wthout needng to apply force. (9) Place a sutable jack (mnmum load 6 tons) at the jackng pont under the rear axle as ndcated n (4-3) ensurng that the jack s centered under the axle and cannot slp. Then rase the jack untl the wheel s clear of the road. DANGER - Ensure that the jack does not snk nto soft ground by usng an approprate base. - Ensure that the jack s properly seated. <<<<<< <<<<<< (10) Completely loosen and remove the wheel nuts. (11) Lower the vehcle by lowerng the jack slghtly to a pont where the wheel bolts are freely accessble. (12) Rotate the wheel clockwse and antclockwse whle pullng the wheel off the wheel hub, and then roll the wheel to one sde. (13) Ft the new wheel on the hub. - Use only tres specfed n Chapter Pay attenton to the profle drecton. - If the profle drecton of your spare tre s napproprate, the spare wheel must be replaced by a wheel wth the approprate tre profle as soon as possble. - All four wheels must be of the same sze and have the same PR (ply ratng) number. Refer to Fg. 4-4 for the runnng drecton. (14) Replace wheel nuts manually. <<<<<< <<<<<< (15) Lower the jack to lower the front/rear axle. (16) Use a torque wrench (600 Nm) to tghten the wheel nuts. Fg. 4-4 ATTENTION Re-tghten the wheel nuts after 8-10 operatng hours. 4-6 S150/S151/S152/Z152

31 Descrpton Operatng elements 1 - Lockng devce for steerng column adjustment - forwards/backwards - axally parallel to steerng column 2 - Throttle 3 - Double pedal for servce brakes/nchng 4 - Foot pedal for swvel 5 - Steerng column swtch - forwards: rght ndcator - backwards: left ndcator - up - drvng lghts - down - drvng lghts beam - push-button - sgnal-horn 6 - Heatng and ventlaton unt /ar condtonng (opt.) Fg. 4-5 Left of drver s seat: 1 - Door handle 2- not used 3 - Inspecton flap 4 - Steerng selecton lever - outwards : four-wheel-drve - nwards: rear-wheel-drve 5 - Control lever auxlary hydraulcs front boom 6 - Swtch for auxlary hydraulcs front boom (opt.) 7 - Push-button dump lock (opt.) 8 - Manual console adjustment wheel (valve control for auxlary hydraulcs) Fg Rght of drver s seat: 1- Fast-runners - Gears: - left: 2nd gear - center: 1st gear - rght: Alpha max. (Turtle symbol) - Slow-runners - Hydraulc drve levels: - rght - speed I: slow - left - speed II: fast 2 - Valve control for man hydraulcs 3 - Drve selector: forward/0/reverse 4 - Lever for parkng brake 5 - Man battery swtch 6 - Inspecton flap 7 - Holder 8 - Manual console adjustment wheel (valve control for man hydraulcs) 9 - Door handle Fg S150/S151/S152/Z

32 4 Descrpton 4.11 Dashboard Fg Rocker swtch for permanently engagng auxlary hydraulcs (opt.) 2 - not used 3 - not used 4 - Push-button for speed select (nur für Langsamläufer) 5 - Rocker swtch for dfferental lock (opt.) 6 - Fuel ndcator 7 - Coolng water temperature dsplay/ Warnng lght coolng water temperature 8 - Tachometer 9 - Operatng hour counter 10 - Indcators for gear select from left to rght: 2nd gear, 1st gear, Alpha max. (Turtle symbol), malfuncton (red) wth accoustc warnng (see secton 4.5) 11 - Rocker swtch for hazard warnng lghts 12 - Rocker swtch for 360 lght (opt.) 13 - Rocker swtch for road lghts - Poston I: Rear lghts, sde lghts - Stellung II: Drvng lghts 14 - Push-button Release quck couplng mechansm 15 - Push-button for bucket cushonng 16 - Socket 17 - Fusebox 18 - not used 19 - Starter swtch 20 - Rocker swtch for heated rear screen, rear vew mrror (opt.) 21 - Rocker swtch for screen wash / rear screen wash 22 - Rocker swtch for wndscreen wpers front (contnuous) 23 - Rocker swtch for wndscreen wpers front (nterval) 24 - Rocker swtch for workng floodlghts 25 - Warnng ndcator engne ol pressure 26 - Warnng ndcator coolng water low 27 - Warnng ndcator parkng brake 28 - Warnng ndcator hydraulc ol temperature 29 - Indcator travel drecton 30 - Indcator servce nterval (opt) Warnng Indcator Unt: 25 Servce 31 - Warnng ndcator drvng lghts beam 32 - not used 33 - not used 34 - Warnng ndcator hydraulc ol flter blocked 35 - Warnng ndcator servce brake malfuncton 36 - not used 37 - Indcator loadng opt. = optonal feature! S150/S151/S152/Z152

33 Descrpton 4 Fuse box (Item 17): Drvng operatons 7,5 A 2 Indcators 7,5 A 3 Hydraulcs 10,0 A 4 Heatng/Ar cond. 10,0 A 5 Heated rear screen 15,0 A 6 Headlght beam 7,5 A 7 Headlght dp 7,5 A 8 Tal lght left, Sdelght left 5,0 A 9 Tal lght rght, Sdelght rght 5,0 A 10 Hazard warnng 7,5 A 11 Wpers/Washer 15,0 A 12 Engne cut-off 5,0 A 13 Workng floodlghts, Panel dsplay lghtng, Brake lghts 25,0 A lght (opt.), Sgnal-horn, Socket, Interor lght 20,0 A opt. = optonal feature S150/S151/S152/Z

34 Operatons

35 5 Operatons 5 Operatons The manufacturer reserves the rght to alter constructon detals, whch may lead to some devatons between your actual equpment and the fgures shown n ths manual, but wll not affect the accuracy of the contents. Changes have been collated and documented n Chapter Checks before you start - Engne ol fll-level (refer to engne manual) - Hydraulc ol fll-level - Fuel reserves - Tre pressure - Tre tread - Battery flud fll-level - Lghtng unt - Mrrors - Seat poston - Swvel assembly lock (1-4/arrow) may need to be removed» pror to commencng work only«- Remove bucket arm prop [(e.g. bucket arm support (opton) (1-1/arrow)] f necessary - Stop valves for man and auxlary hydraulcs (1-2/1 and 1-2/2) may need to be removed» pror to commencng work only «- General condton of equpment, check for leakages, for example - Check whether - a frst ad kt - a warnng trangle - a hazard warnng lght are avalable. 5.2 Gettng started Startng the desel engne (1) Apply the parkng brakes(4-7/4). (2) Insert the man battery key (4-7/5). (3) Put the gear selector (4-7/3) n neutral (poston "0") (mmoblzer!). (4) Insert the gnton key n the gnton (4-8/19) and turn rght to the "I" (5-1) poston. The charge ndcator, and the ndcators for the parkng brake and engne ol pressure wll lght up. The fuel and coolng water temperature dsplays wll show readngs. Fg. 5-1 (5) Now turn the gnton key to the rght to poston "III". Let go of the key as soon as the engne fres. 5-2 S150/S151/S152/Z152

36 Operatons 5 - If the engne fals to fre after two attempts, follow the troubleshootng procedures outlned n the engne manual. - In case of extremely low ambent temperature, follow the procedures outlned n the engne manual. - After cold startng the blockwage warnng ndcator may lght up, however, the ndcator wll be swtched off as the hydraulc ol reaches normal temperature. Run the equpment at low revs, and never at full power untl the ndcator s swtched off (4-8/36) Wnter operatons ATTENTION If the ambent temperature s below 0 C, the equpment must be "warmed up" to avod damage to specfc components. Whle the engne s dlng, accentuate all the cylnders (lftng, tppng and swvel cylnder) for some tme (dependng on the ambent temperature). The followng tasks must be fulflled to ensure trouble free operatons at low temperatures: Fuel At low temperatures paraffn precptaton can cause blockages of the fuel system. Use wnter desel fuel (sutable down to -15 C) at temperatures below 0 C. Wnter desel fuel s normally avalable from refuellng statons n tme for the cold season. Often desel fuels wth addtves are avalable for use n ambent temperatures down to -20 C (super-grade desel fuel). Add paraffn addtves for temperatures below -15 C or -20 C. Dagram (5-2) shows the requred quanttes. I = Summer desel fuel II = Wnter desel fuel III = Super-grade desel fuel ATTENTION Use only the fuel tank for mxng fuel! Frst fll n the requred amount of paraffn ol and then add desel. Fg. 5-2 S150/S151/S152/Z

37 5 Operatons Ol Change Engne Refer to the operatng manual for the engne and the operatng manual for the equpment (secton 8.2.6) Ol Change Hydraulc System ATTENTION The vscosty of the hydraulc ol changes accordng to the temperature; therefore, the ambent temperature n the place where the machne wll be used determnes what vscosty class (SAE class) must be chosen. If the hydraulc ol used matches the expected ambent temperature, optmum operatng condtons can be attaned. Therefore, use hydraulc ol of an approprate grade f requred. See secton for the ol change procedure requred for the hydraulc system Ant-Freeze for the Screen Washer ATTENTION If the temperature s expected to drop below 0 C, add a suffcent amount of ant-freezng agent to the water n the wndsheld washer system (5-3/ arrow) to prevent t from cng up. Follow the manufacturer s nstructons for the mxng rato. Fg Drvng the loader on publc roads ATTENTION - Drvng on publc roads s allowed only when an empty standard or mult-purpose s attached and only then f a bucket protector has been ftted. - The maxmum permssble speed s 30 km/h wth the drvng lght swtched on. The drvng lght only serves to llumnate the road. - The 360 lght (optonal feature) may not be permtted by local traffc codes unless the vehcle s marked wth red and whte hazard markngs. - Ensure that a warnng trangle and frst ad kt are avalable at all tmes. The drver must possess an approprate drver s lcense - European class "C". The drver must carry a drvng lcense (orgnal) and operatng permt at all tmes. 5-4 S150/S151/S152/Z152

38 Operatons 5 Before enterng a publc road ensure that the followng safety checks have been performed: Transportng a bucket (1) Lower the bucket arm untl the lowest pont of the bucket arm or the bucket heel s at least 30 cm above the road (5-4). (2) Close both stop valves (1-2/1 and 1-2/2). CAUTION When closed, the hand levers for the stop valves are perpendcular to the drecton of flow. Ths prevents the bucket arm from beng lowered and the bucket from tppng whle drvng. Fg. 5-4 (3) Block the swvel mechansm by nsertng the blockng wedge (1-3/arrow) n the swvel blockng devce (1-4/arrow) and secure t usng the sprng pn. (4) Cover the bucket cuttng edge and teeth wth the bucket protector (5-4/arrow). (5) Insert the plug of the bucket protector nto the socket (5-5/arrow). (6) Check the lghts. (7) Close both doors. (8) Put on your seat belt. (9) Swtch the steerng system selecton lever to rear axle steerng (4-9/4). DANGER The workng lghts must be swtched off (4-8/24). Fg. 5-5 (10) Release the parkng brake (4-7/4). (11) - Apples to slow-runners only» Type 20 km/h and 25 km/h «Select speed II (4-8/4). - Apples to fast-runners only» Type 40 km/h «Select "2" (4-7/1). (12) Pre-select hydraulc drve speed II (4-7/1) - apples to slow-runners only» Type 20 km/h and 25 km/h «. (13) Select the travel drecton (4-7/3). (14) Depress the drve pedal (4-5/2). DANGER Do not change the travel drecton whle the vehcle s n moton to avod endangerng other road users. S150/S151/S152/Z

39 5 Operatons Workng wth the loader Slow-runner type "20 km/h" and "25 km/h" DANGER Always fasten your seat belt whle workng wth a swvel loader. Normally, all work s executed n hydraulc drve stage "II" (4-7/1) and a transmsson step (4-8/4) that matches the workng condtons. ATTENTION Ensure that the vehcle s statonary, the parkng brake s on and the travel drecton selector (4-7/3) s n neutral (poston "0") before selectng a gear va the transfer gearbox. In specal cases where more granular speed control, or hgher revs at lower speeds are requred, you can select hydraulc drve step "I" (4-7/1) and thus reduce the speed to 6 km/h (for slow-runners rated "20 km/h") or 7 km/h (for slow-runners rated "25 km/h"). You can swtch from hydraulc drve step I to II, or vce-versa, whle travelng. However, shftng from hydraulc drve level II down to I s not recommended at hgher speeds as t wll cause the vehcle to brake suddenly Fast-runners Type "40 km/h" DANGER Always fasten your seat belt whle workng wth a swvel loader. Normally, all work s executed n hydraulc drve stage "II" (4-7/1). In specal cases where more granular speed control, or hgher revs at lower speeds are requred, you can select hydraulc drve step "I" and thus reduce the speed to 5 km/h. Speed ranges per gear Alpha max. (Turtle symbol) from 0 to 5 km/h 1st from 0 to 11.5 km/h 2nd from 0 to 40 km/h When you swtch from 3rd to 2nd gear - the dsplay for the selected gear (4-8/10) starts to flash (the gear you selected wll not be avalable untl the dsplay stops flashng). - f the permssble speed range has been reached the gear wll not be selected untl you press the drve pedal (4-5/2) down hard for a short whle. 5-6 S150/S151/S152/Z152

40 Operatons 5 (1) Close both doors. (2) Release the parkng brake (4-7/4). (3) Pre-select a gear [(4-8/4)» apples to slow-runners type "20 km/h" and "25 km/h" «] or [(4-7/1)» apples to fastrunners type "40 km/h" «]. (4) Pre-select a hydraulc drve step [(4-7/1)» apples to slow-runners type "20 km/h" and "25 km/h" «]. (5) Select a travel drecton (4-7/3). (6) Depress the drve pedal (4-5/2). - To acheve maxmum performance the combned acton of propulson unt and man hydraulcs s requred. It s up to the operator to to control the avalable power usng the drve pedal, nchng and the manual hydraulc controls to assgn power as requred for the job n hand. - Travel speed and power are controlled by depressng the drve pedal only. - Whle the vehcle s travelng up a slope, travel speed s reduced to provde more power, even f the drve pedal s fully depressed. - Power and travel speed are equal both n forward and reverse drectons. ATTENTION - If the warnng ndcator for hydraulc ol temperature (4-8/31) lghts up, or an accoustc sgnal s gven, stop the vehcle mmedately and call n an expert to troubleshoot the hydraulcs and remedy the ssue. - Do not attempt to lock the hydraulc quck couplng assembly unless an attachment s ftted. - Ensure that the engne s dlng whle couplng or decouplng an attachment. Ths ensures that the nserton or retracton speed of the lockng bolts stays reasonably low thus preventng leaks. DANGER If specal tasks necesstate drvng wth the bucket arm swveled, the bucket or the attachment must be kept close above the wheel and the travel dstance must be kept as short as possble. If because of rough terran a wheel s rased off the ground by the stablzer equpment, the bucket arm must be brefly swveled n the drecton of travel n order to dsengage the axle lock. S150/S151/S152/Z

41 5 Operatons Heatng and Ventlaton Unt / Ar- Condtonng (opt.) Adjustng the arflow (1) Turn the rotary swtch (5-6/4) for the fan to poston 0, 1 or 2, dependng on the amount of ar desred. (2) Adjust the drecton of the ar flow by means of the lateral nozzles on the left and rght sdes (5-7/1 and 5-8/1). Fg Swtchng on the heater (1) Dependng on the heatng requrement, turn the dal (5-6/2) clockwse (hot) or antclockwse (cold) Swtchng on the ar-condtonng unt (opt.) (1) Use the "ON/OFF" swtch (5-6/3) to swtch the arcondtonng unt on or off, as requred. Press top of swtch - Ar-condtonng "ON" Press bottom of swtch - Ar-condtonng "OFF" Fg Selectng a temperature (1) Use the dal (5-6/1) to set the cab temperature. 1 2 Turn dal clockwse Turn dal antclockwse - colder - wärmer The ar-condtonng unt draws ar n through four vents (5-7/2 and 5-8/2). ATTENTION For safety recommendatons, dsposal notes, and mantenance tasks, plese refer to the manual suppled wth the ar-condtonng unt. Fg S150/S151/S152/Z152

42 Operatons Stoppng loader operatons Parkng the loader (1) Stop the vehcle on frm and preferably level ground. (2) Apply the parkng brake (4-7/4). (3) Lower the bucket or front-loaded attachment to the ground. (4) Set the drve swtch (4-7/3) to 0. DANGER If parkng on a slope or gradent cannot be avoded, wheel chocks must be used and placed on the slopng sde of the front axle wheels n addton to applyng the parkng brake Swtchng off the desel engne ATTENTION If the desel engne s very hot, t s a good dea to let the engne dle for a short tme before swtchng t off. Turn the gnton key to the left to the 0 poston (5-1) and remove the key. In the P poston, the parkng lght and the dashboard llumnaton reman swtched on Swtchng off the heatng and ventlaton unt / ar-condtonng (opt.) (1) Shut off the warm ar supply (5-6/2). (2) Turn the dal for the fan (5-6/4) to the "0" poston. (3) Swtch off the ar-condtonng unt (opt.) (5-6/3) Leavng the loader (1) Lock the hand levers for the workng and auxlary hydraulcs (1-2/1 and 1-2/2). (2) Remove the man battery swtch (4-7/5). If you wll not be usng the vehcle for a whle, follow the steps outlned n Chapter 3 (Ant-Theft Protecton). (3) Remove the gnton key and lock the doors. S150/S151/S152/Z

43 5 Operatons 5.4 Adjustng the drver s seat Isr seat (1) Use the lever (5-9/2) to adjust the nclnaton of the backrest or fold the backrest. (2) Pull the lever (5-9/3) up to adjust the heght and tlt for the rear of the seat. (3) Pull (5-9/4) up adjust the heght and tlt for the front of the seat. (4) You can use the wheel (5-10/1) to adjust the seat cushonng to the weght of the drver ( kg). Fg. 5-9 (5) You can use the wheel (5-9/1) to adjust the heght of the armrests. (6) If requred, adjust the postons of the valve controls for the man (4-7/8) and auxlary hydraulcs (4-6/8). 1 (7) Pull up the bar (5-10/2) and at the same tme move the seat forwards or back to adjust the horzontal poston to the drver s requrements. 2 Fg Grammer seat (1) Weght adjustment: Adjust the seat to the drver s weght by actuatng the weght adjustment lever. The set drver s weght s vsble n the specton wndow (5-11). Fg S150/S151/S152/Z152

44 Operatons 5 (2) Heght adjustment: The heght can be adjusted n several steps. Lft the drver s seat to the desred heght untl t can be heard to engage. The seat returns to the lowest poston when t s lfted over the topmost poston (stop) (5-12). Fg (3) Armrest nclnaton: Turn the handwheel (5-13/arrow) to adjust the armrest n longtudnal drecton. Fg (4) Armrests: If desred, you can swng the armrests to the rear and adjust ther heght. To adjust the armrest heght, remove the round cap (5-14/ arrow) n the coverng. Loosen the hex nut (wrench sze 13 mm), set the armrest as desred and tghten the nut agan. Push the removed cap onto the nut agan. Fg S150/S151/S152/Z

45 5 Operatons (5) Adjustng the backrest: Use the lockng lever (5-15/arrow) to adjust the backrest. The lockng lever must engage n the desred poston. It must be mpossble to move the backrest to another poston when the lever has engaged. Fg (6) Longtudnal adjustment: You can adjust the seat n longtudnal drecton when you pull the lever (5-16) upwards. The lockng lever must engage n the desred poston. It must be mpossble to move the drver s seat to another poston when the lever has engaged. Fg Swtchng the steerng ATTENTION - The wheels of the rear axle must be straght before operatng the steerng toggle swtch (5-17/arrow). - The steerng mode may only be changed when the machne s statonary. To toggle the steerng mode, move the lever forward (rear-wheel steerng) or backward (four-wheel steerng). Fg S150/S151/S152/Z152

46 Attachments

47 6 Attachments 6 Attachments 6.1 Couplng and uncouplng attachments wthout hydraulcs Standard/Lght Materal Bucket Couplng (1) Lower the loader arms as far and possble and tlt the quck coupler. (2) Drve the loader up to the bucket (6-1). Fg. 6-1 (3) Pck up the bucket usng the quck coupler frame and, by smultaneously tltng the quck coupler, rase the bucket untl the quck coupler s n lne wth t (6-2). (4) Use the auxlary hydraulc system lever (4-6/5) to lock the bucket (6-3). ATTENTION Ensure that the engne s dlng whle lockng the bucket n order to reduce the nserton speed of the lock pns and thus prevent leakages. (5) Check seatng and ensure that the pns are locked left and rght. DANGER The lock pns of the quck coupler must be nserted n the lftng holes on both sdes of bucket and must protude vsbly when vewed from the sde (6-3/arrow). Fg. 6-2 Uncouplng (1) Place the bucket frmly on the ground. (2) Hold down the quck coupler release button (4-8/14) and at the same tme unlock the bucket usng the auxlary hydraulcs lever (4-6/5). ATTENTION - Ensure that the engne s dlng whle lockng the bucket n order to reduce the retracton speed of the lock pns and thus prevent leakages. - Ensure that an attachment s ftted before engagng the hydraulc quck coupler. (3) Roll the quck coupler off and reverse away from t. Fg. 6-3 The type plate s on the back of the bucket on the rght-hand sde of the box beam. 6-2 S150/S151/S152/Z152

48 Attachments Fork-lft attachment - Fg. 6-4 shows the vehcle wth wth the forklft attachment at full stretch. - For couplng and uncouplng procedures please refer to the descrpton of the standard/ lght materal bucket n secton DANGER - The lock pns of the quck coupler must be nserted n the lftng holes on both sdes of fork-lft attachment and must protude vsbly when vewed from the sde (6-5/arrow). Fg Spread the load evenly across both fork tnes and ensure that the load cannot slde or fall off. - Algn the load wth the heel of the fork and tlt the fork-lft attachment slghtly up. - Ensure that the fork tnes must be equdstant from the center (6-6/arrows) and lock them n place. - When movng loads ensure that the fork-lft s rased only slghtly above the ground! - When movng loads, avod quck acceleraton, brakng, and steerng maneovres. ATTENTION - In case of equpment wth ppe burst protecton (opt.), engagng the fork-lft cushonng (4-8/15) wll deactvate the ppe burst protecton mechansm. Fg The drver may not leave the vehcle whle the fork-lft s attached. - Ensure that the engne s dlng whle lockng or unlockng the fork-lft attachment n order to reduce the nserton/retracton speed of the lock pns and thus prevent leakages. - Ensure that an attachment s ftted before engagng the hydraulc quck coupler. - To ensure that the fork tnes are properly locked, both lockng levers must be flush wth the fork-lft coupler frame. - The type plate s on the back of the top forklft coupler frame. Fg. 6-6 S150/S151/S152/Z

49 6 Attachments Lftng Hook - For couplng and uncouplng procedures please refer to the descrpton of the standard/ lght materal bucket n secton The type plate s on the top rght of the lftng hook coupler frame. Fg. 6-7 DANGER - The lock pns of the quck coupler must be nserted n the lftng holes on both sdes of fork-lft attachment and must protude vsbly when vewed from the sde. - Ensure that the safety lock on the lftng hook s workng. ATTENTION - In case of equpment wth ppe burst protecton (opt.), engagng lftng hook cushonng (4-8/15) wll deactvate the ppe burst protecton mechansm. - Ensure that the engne s dlng whle lockng or unlockng the lftng hook n order to reduce the nserton/retracton speed of the lock pns and thus prevent leakages. - Ensure that an attachment s ftted before engagng the hydraulc quck coupler. Fg Couplng and uncouplng attachments wth hydraulcs Mult-purpose bucket Couplng (1) Lower the loader arms as far and possble and tlt the quck coupler. (2) Drve the loader up to the bucket (6-7). (3) Pck up the bucket usng the quck coupler frame and, by smultaneously tltng the quck coupler, rase the bucket untl the quck coupler s n lne wth (6-8). (4) Use the auxlary hydraulc system lever (4-6/5) to lock the bucket (6-9). Fg. 6-9 ATTENTION Ensure that the engne s dlng whle lockng the bucket n order to reduce the nserton speed of the lock pns and thus prevent leakages. 6-4 S150/S151/S152/Z152

50 Attachments 6 (5) Check seatng and ensure that the pns are locked left and rght. DANGER The lock pns of the quck coupler must be nserted n the lftng holes on both sdes of bucket and must protude vsbly when vewed from the sde (6-9/arrow). (6) Stop the engne. (7) Release the pressure on the hydraulc hoses by movng the auxlary hydraulcs lever (4-6/5) back and forth. (8) Unscrew and remove the protectve sheld on the rghthand connector of the quck coupler (6-10/arrow). (9) Attach the protectve sheld to the box beam of the quck coupler (6-11/2). Fg (10) Flp up the protectve lds on the quck ft couplng sleeves of the mult-purpose bucket (6-11/1) and frmly press onto the quck coupler hose (6-11). ATTENTION When attachng hydraulc hoses pay attenton to cleanlness of the jont and ensure that connectors are seated properly. 1 Uncouplng (1) Place the bucket frmly on the ground. (2) Stop the engne. (3) Release the pressure on the hydraulc hoses by movng the auxlary hydraulcs lever (4-6/5) back and forth. 2 Fg (4) Follow the couplng procedure n reverse order, the excepton beng that you need to press the quck coupler release button (4-8/14) to release the mult-purpose bucket. ATTENTION - Ensure that the engne s dlng whle unlockng the mult-purpose bucket n order to reduce the nserton/retracton speed of the lock pns and thus prevent leakages. - To release a connector from the correspondng coupler lne up the grooves n the grp rng (6-12/arrows) wth the cams on the couplng sleeve (you wll feel t snap nto place), and then pull frmly upward. - Ensure that an attachment s ftted before engagng the hydraulc quck coupler. The type plate s on the back rght of the bucket underneath the box beam. Fg S150/S151/S152/Z

51 6 Attachments Notes on usng the mult-purpose bucket The mult-purpose bucket can be used for: - bladng (6-13) Fg clammng (6-14) Fg grapplng (6-15) and for Fg dggng lke a normal bucket. 6-6 S150/S151/S152/Z152

52 Attachments Front-end excavator Couplng For couplng and uncouplng procedures please refer to the descrpton of the mult-purpose bucket n secton (1)...(10), except that all four hydraulc hose sleeves on the front-end excavator need to be attached to the connectors on the quck coupler assembly. Ensure that the hoses on the rght of the front-end excavator are attached to the connectors on the rght of the quck coupler assembly and that that both hoses on the left of the front-end excavator are attached to the connectors on the left of the quck coupler assembly. Make sure that the hoses do not cross. If you cross attach the hydraulc hoses, the moton of the front-end excavator boom and bucket wll not correspond to the descrpton on plate (2-1/5). DANGER The lock pns of the quck coupler must be nserted n the lftng holes on both sdes of the front-end excavator attachment and must protude vsbly when vewed from the sde. ATTENTION - Ensure that the engne s dlng whle lockng the front-end excavator n order to reduce the nserton speed of the lock pns and thus prevent leakages. - When attachng hydraulc hoses pay attenton to cleanlness of the jont and ensure that connectors are seated properly. Fg Uncouplng For uncouplng procedures see the descrpton of the multpurpose bucket (secton 6.2.1), however, ensure that all four hydraulc hoses of the front-end excavator are dsconnected from the four connectors on the quck coupler. ACHTUNG - Ensure that the engne s dlng whle unlockng the front-end excavator n order to reduce the retracton speed of the lock pns and thus prevent leakages. - Ensure that an attachment s ftted before engagng the hydraulc quck coupler. The type plate s on the rght of the arm near the coupler frame. S150/S151/S152/Z

53 6 Attachments Changng a bucket (1) Lft and mechancally prop up bucket arm [e.g. by nsertng the bucket arm support (opton) (1-1/arrow)] and lower bucket arm untl t rests on the bucket arm support. (2) Move the front-end loader nto a poston where the bucket heel s flush wth the ground. (3) Swtch off the engne. (4) Release the pressure on the hydraulc hoses by movng the auxlary hydraulcs lever (4-6/5) back and forth. (5) Close both stop valves (1-2/1 and 1-2/2). Fg (6) Unscrew the safeguards for the bolts (sze 19) (6-17/ arrows). (7) Knock out the bearng pn (6-18/arrows) and remove the bucket. (8) Follow these steps n reverse order to attach a bucket. The type plate for the bucket s on the outsde left. Fg Usng other attachments DANGER 1. Use only those attachments descrbed n ths manul. 2. Be aware that we cannot approve attachments we have not suppled ourselves. Usng nonapproved products may adversely affect the constructonal and actve or passve safety features of your equpment. We accept no responsblty for damage caused by usng non-approved products. 6-8 S150/S151/S152/Z152

54 Rescue, Towng, Lashng, Crane-Lftng

55 7 Rescue, Towng, Lashng, Crane-Lftng 7 Rescue, Towng, Lashng, Crane-Lftng 7.1 Rescue, Towng, Lashng Rescue/Towng of the swng loader n case of engne or transmsson falure DANGER On publc roads, frst secure the rescue area. ATTENTION - Do not attempt to tow-start the swvel loader. Any attempt to do so wll cause damage. - Towng s permtted to remove the loader from hazardous areas only, and when loadng onto a low-loader. Preparatory steps before towng depend on whether the engne has faled, and thus the hydraulc system s noperable, or only the transmsson has faled and the engne can stll power the hydraulc subsystem Towng the swng loader n case of engne falure ATTENTION - When the engne has faled, towng s only permtted to rescue the machne out of the danger area. - Remove both cardan shafts pror to towng f the machne must be towed over a longer dstance and cannot be loaded. (1) Press the rocker swtch for the hazard warnng lghts (4-8/11). (2) Chock both front wheels n both drectons to prevent the vehcle from to ensure that the vehcle does not roll. (3) Put the gear selector (4-7/3) n neutral (poston "0"). The preparaton n ponts (4), (6), (7) and (13) s only to be carred out f the rescue locaton s not on a publc road. 7-2 S150/S151/S152/Z152

56 Rescue, Towng, 7 Lashng, Crane-Lftng (4) Algn the wheels on the front axle and then use the steerng selector lever (4-6/4) to set the steerng mode to "rear-wheel-steerng". (5) Release the parkng brake (4-7/4). (6) Apply the bucket protector to protect the lp and teeth of the bucket (5-4/arrow). (7) Insert the bucket protector plug n the socket (5-5/arrow). (8) Push the valve control lever for man hydraulcs (4-7/2) forwards through ts pressure pont to the front poston. (9) Usng a sutable lftng devce, e.g. a second loader wth an attached bucket, lft the bucket arm of the loader to be towed untl the mechancal bucket arm support can be nserted at the loader to be towed (7-1). Fg If the vehcle breakdown occurred some tme ago, ensure that the hydraulc hoses are dsconnected from the lft cylnder before attachng the lftng equpment. Use an ol tray wth approprate dmensons to catch any hydraulc ol that seeps out. - After completng towng, remember to fll the lft cylnder wth hydraulc ol and vent the cylnder by repeatedly rasng and droppng the loader arm. (10) Lft and mechancally prop up bucket arm [e.g. by nsertng the bucket arm support (opton) (1-1/arrow)] and lower bucket arm untl t rests on the bucket arm support. (11) Close both stop valves (1-2/1 and 1-2/2). (12) Return the valve control for man hydraulcs (4-7/2) to ts orgnal poston. (13) Block the swvel mechansm by nsertng the blockng wedge (1-3/arrow) n the swvel blockng mechansm (1-4/arrow). (14) Attach the towng rod to the loader to be towed [(7-2/1 - for towng forwards) or (7-4/1 - for towng backwards)] and to the towng vehcle. Fg ATTENTION If the loader does not have a forward shuntng and towng couplng, the loader can only be towed backwards Fg. 7-3 S150/S151/S152/Z

57 7 Rescue, Towng, Lashng, Crane-Lftng mm 1 2 Fg mm 3 4 (15) Detach the sprng brake. To do so, loosen the counter nuts (7-4/2 and 7-4/4) and set screws (7-4/1 and 7-4/3) a quarter turn n sequence. One turn s requred to slacken the sprng brake. ATTENTION - Do not exceed one turn! - Tghten the set screws n sequence. That s, when you tghten the screws, you must tghten each screw a quarter turn n sequence to prevent jammng or cantng. - Detach the sprng brakes to the left and rght of the axle assembly separately. Adjustment after manual slackenng - Remove the set screws (7-4/1 and 7-4/3), counter nuts (7-4/2 and 7-4/4) and gaskets. - Lubrcate the set screws wth slcon grease TECNO LUBE Reft the set screws, counter nuts and gaskets. (16) Tghten the set screws to a pont where the measurement between the screw head and the axle assembly s mm. (17) Use counter nuts to fx the set screws n poston. ATTENTION The screws must protrude by exactly mm (7-4). Fg. 7-5 Apples to slow-runners» Type "20 km/h" and "25 km/h" «(18) Put the gear lever (7-5/arrow and 7-6/arrow) nto neutral. - The gear lever wll snap notcably nto place. The correct poston s between frst gear (pressed n) and second gear (pulled out). - The measurement wll be 123,5 mm (7-6). 123,5 mm (19) Remove chocks. Fg S150/S151/S152/Z152

58 Rescue, Towng, 7 Lashng, Crane-Lftng DANGER - In case of engne falure consderably more force s requred to steer the vehcle. - Tow the vehcle at slow speed (2 km/h). - For longer towng dstances, the defectve vehcle should be loaded (see 7-2/1 and 7-2/2, 7-3/1 and 7-3/2) for lashng ponts. - The max. permssble load of the front towng and shuntng couplng (7-2/1) s 8.0 t horzontally and axally. - The max. permssble load of the rear towng and shuntng couplng (7-3/1) s 8.0 t horzontally and axally. - The max. permssble load of the lashng ponts/ loadng ponts (7-2/2, and 7-3/2) s x t assumng an angle of Note maxmum heght restrctons! Towng the swng loader n case of transmsson falure (1) Press the rocker swtch for the hazard warnng lghts (4-8/11). (2) Chock both front wheels n both drectons to prevent the vehcle from to ensure that the vehcle does not roll. (3) Put the gear selector (4-7/3) n neutral (poston "0"). S Preparatory tasks (4), (6), (7), and (10) are only requred f the rescue area s not n a publcly accessble area: (4) Algn the wheels on the front axle and then use the steerng selector lever (4-6/4) to set the steerng mode to "rear-wheel-steerng". (5) Apply the bucket protector to protect the lp and teeth of the bucket (5-4/arrow). (6) Insert the bucket protector plug n the socket (5-5/ arrow). (7) Lft and mechancally prop up bucket arm [e.g. by nsertng the bucket arm support (opton) (1-1/arrow)] and lower bucket arm untl t rests on the bucket arm support. (8) Close both stop valves (1-2/1 and 1-2/2). (9) Block the swvel mechansm by nsertng the blockng wedge (1-3/arrow) n the swvel blockng mechansm (1-4/arrow). (10) Attach the towng rod to the loader to be towed [(7-2/1 - for towng forwards) or (7-4/1 - for towng backwards)] and to the towng vehcle. ATTENTION If the loader does not have a forward shuntng and towng couplng, the loader can only be towed backwards. (11) Swtch off the engne. (12) Release the parkng brake (4-7/4). S150/S151/S152/Z

59 7 Rescue, Towng, Lashng, Crane-Lftng (13) Detach the sprng brake. To do so, loosen the counter nuts (7-4/2 and 7-4/4) and set screws (7-4/1 and 7-4/3) a quarter turn n sequence. One turn s requred to slacken the sprng brake. ATTENTION - Do not exceed one turn! - Tghten the set screws n sequence. That s, when you tghten the screws, you must tghten each screw a quarter turn n sequence to prevent jammng or cantng. - Detach the sprng brakes to the left and rght of the axle assembly separately. Adjustment after manual slackenng - Remove the set screws (7-4/1 and 7-4/3), counter nuts (7-4/2 and 7-4/4) and gaskets. - Lubrcate the set screws wth slcon grease TECNO LUBE Reft the set screws, counter nuts and gaskets. (14) Tghten the set screws to a pont where the measurement between the screw head and the axle assembly s mm. (15) Use counter nuts to fx the set screws n poston. ATTENTION The screws must protrude by exactly mm (7-4). Apples to slow-runners» Type "20 km/h" and "25 km/h" «(16) Put the gear lever (7-5/arrow and 7-6/arrow) nto neutral. - The gear lever wll snap notcably nto place. The correct poston s between frst gear (pressed n) and second gear (pulled out). - The measurement wll be 123,5 mm (7-6). (17) Remove chocks. DANGER - In case of engne falure consderably more force s requred to steer the vehcle. - Tow the vehcle at slow speed (2 km/h). 7-6 S150/S151/S152/Z152

60 Rescue, Towng, 7 Lashng, Crane-Lftng - For longer towng dstances, the defectve vehcle should be loaded (see 7-2/1 and 7-2/2, 7-3/1 and 7-3/2) for lashng ponts. - The max. permssble load of the front towng and shuntng couplng (7-2/1) s 8.0 t horzontally and axally. - The max. permssble load of the rear towng and shuntng couplng (7-3/1) s 8.0 t horzontally and axally. - The max. permssble load of the lashng ponts/ loadng ponts (7-2/2, and 7-3/2) s? t assumng an angle of Note maxmum heght restrctons! B D A 2 A 1 C 2 C 1 D 7.2 Crane Lftng The followng steps are requred to prepare the vehcle for crane lftng: (1) Apply the parkng brake (4-7/4). (2) Put the gear selector (4-7/3) n neutral (poston "0"). (3) - Apples to slow-runners only» Type 20 km/h and 25 km/h «- Select frst gear (4-8/4). - Select hydraulc gear I (4-7/1). - Apples to fast-runners only» Type 40 km/h «Select "Alpha max. (Turtle symbol)" (4-7/1). (4) Rase or lower the loader arm to a poston where the bucket heel s at least 30 cm above the ground (5-2). (5) Close stop valves for man and auxlary hydraulcs (1-2/1 and 1-2/2). (6) Block the swvel mechansm by nsertng the blockng wedge (1-3/arrow) n the swvel blockng mechansm (1-4/arrow). (7) Lock the doors. (8) Fold the outsde mrrors n. Fg. 7-7 Fg. 7-8 ATTENTION Pay partcular attenton to the followng ponts when crane lftng a loader, see fgure 7-7: - The lftng pont (A 1 - vehcles wthout standard bucket or A 2 - vehcles wth standards bucket) of the lftng equpment (B) must be exactly vertcally above the center of gravty (C 1 bzw. C 2 ) of the vehcle, to allow the lftng devce to be placed horzontally above the longtudnal axs of the loader. - The lftng gear (D) must lead vertcally upwards from the lftng ponts of the loader (7-8/ arrows and 7-9/arrows). DANGER The lftng gear must have a lftng capacty of at least 6.5 t. Fg. 7-9 S150/S151/S152/Z

61 Mantenance

62 8 Mantenance (Mantenance Plan AS 150 Type 40 km/h) A GB /8.2/8.3/ /1.2/1.3/1.4/ /3.2/3.3/3.4/5.1/ / /2.2/2.3/2.4/5.1/11.1 * * * * Item Name Specfcaton Vscosty Quantty 1 Engne Ol MIL-L-2104 C = API-CD SAE 15 W 40 = 10 l wth Ol flter 2.2 Transm. Ol wth LS Add. MIL-L-2105 B = API-GL5-6-LS SAE 85 W 90-LS = 12,8 l 2.4 Transm. Ol wth LS Add. MIL-L-2105 B = API-GL5-6-LS SAE 85 W 90-LS = 2 x 1,9 l 3.2 Transm. Ol wth LS Add. MIL-L-2105 B = API-GL5-6-LS SAE 85 W 90-LS = 15,0 l 3.4 Transm. Ol wth LS Add. MIL-L-2105 B = API-GL5-6-LS SAE 85 W 90-LS = 2 x 1,9 l 4.2 Transmsson OIl General Motors ATF Typ DEXRON II ATF 22 SAE 75 W = 6,0 l 8.3 Hydraulc Ol (4.) DIN HVLP 46 ISO VG 46, VI > 180 = 160 l 9 Grease DIN KPF 1/2 N-20 as requred 10 Dstlled water as requred 12 Coolant R 134 a 850 g ± 50 g Legend Frst ol or flter change Frst servce nterval, repar any falures noted Servce, repar any falures noted Change these marks, fllng or servce ponts are mandatory: Refer to manual Attenton Observe accdent preventon measures when performng servcng tasks! 12.1 Lubrcaton Ponts (marked n red) 1. Grease bolts wth DIN KPF 1/2 N-20 every 10 hours. 2. Grease frcton ponts as requred and after cleanng wth DIN KPF 1/2 N-20. Ol Lubrcaton Ponts 3. Ol jonts and bell cranks every 50 workng hours wth engne ol MIL-L-2104 C Bodegradable Hydraulc Ol 4. Synthetc ester based hydraulc ol vscosty class ISO VG 46 VI > 180 Intervals n workng hours Pos. max. permssble ntervals, can be shorter dep. on use Mantenance Ponts 1 Engne 1.1 Mantenance accordng to manufacturers specs 1.2 Dry ar flter unt: Check servce dsplay Change flter element f dsplay shows red 1.3 Check and clean fuel flter 1.4 Check coolant fll-level 1.5 Check and clean combned coolng unt 2 Rear axle 2.1 Check ol fll-level of transmsson unt (nspecton screw) 2.2 Ol change transmsson unt 2.3 Check ol fll-level of helcal planetary gearng (nspecton screw) 2.4 Ol change helcal planetary gearng 3 Front axle 3.1 Check ol fll-level of transmsson unt (nspecton screw) 3.2 Ol change transmsson unt 3.3 Check ol fll-level of helcal planetary gearng (nspecton screw) 3.4 Ol change helcal planetary gearng 4 Transfer Case 4.1 Check ol fll-level of transfer case (nspecton screw) 4.2 Ol change transfer case 4.3 Change transfer case ol flter nsert (fne flter) 4.4 Clean transfer case sucton flter (pre-flter) 5 Axles / Artculated Shafts 5.1 Check tghtness of axles (500 Nm) 5.2 Check tghtness of artculated shafts (65 Nm) 6 Wheels and Tyres 6.1 Check ar pressure 6.2 Check tghtness of wheel bolts (600 Nm) 7 Swvel Jont 7.1 Check tghtness (610 Nm) 8 Hydraulc Unt 8.1 Change sucton return lne flter nsert, check electr. dsplay 8.2 Check ol fll-level (nspecton glass) 8.3 Ol change 8.4 Check and clean hydraulc ol cooler 9 Greasng ponts (marked n red) 10 Battery 10.1 Vsual check 11 Brakes 11.1 Perform vsual and functonal check of brakes and parkng brakes before startng work 11.2 Check accumulator valve 12 Lghtng unt / Ar flter / Ar condtonng unt 12.1 Perform functonal check before startng work 12.2 Check ar flter 12.3 Check condensator for contamnaton 12.4 Check tenson of compressor drve belt 8-1 S152/Z152

63 8 Mantenance (Mantenance Plan AS 150 Type 20 km/h und 25 km/h) A GB /8.2/8.3/8.4 AS /1.2/1.3/1.4/ /3.2/3.3/3.4/5.1/ / /2.2/2.3/2.4/5.1/11.1 * * * * Item Name Specfcaton Vscosty Quantty 1 Motor Ol MIL-L-2104 C = API-CD SAE 15 W 40 = 10 l wth Ol flter 2.2 Transm. Ol wth LS Add. MIL-L-2105 B = API-GL5-6-LS SAE 85 W 90-LS = 12,8 l 2.4 Transm. Ol wth LS Add. MIL-L-2105 B = API-GL5-6-LS SAE 85 W 90-LS = 2 x 1,9 l 3.2 Transm. Ol wth LS Add. MIL-L-2105 B = API-GL5-6-LS SAE 85 W 90-LS = 15,0 l 3.4 Transm. Ol wth LS Add. MIL-L-2105 B = API-GL5-6-LS SAE 85 W 90-LS = 2 x 1,9 l 4.2 Transm. Ol MIL-L-2105 D = API-GL5-6 SAE 85 W 90 = 3,2 l 8.3 Hydraulc Ol (4.) DIN HVLP 46 ISO VG 46, VI > 180 = 160 l 9 Lubrcant DIN KPF 1/2 N-20 as requred 10 Dstlled Water as requred 12 Coolant R 134 a 850 g ± 50 g Legend Frst ol or flter change Frst servce nterval, repar any falures noted Servce, repar any falures noted Change these marks, fllng or servce ponts are mandatory: Refer to manual Attenton Observe accdent preventon measures when performng servcng tasks! 12.1 Lubrcaton Ponts (marked n red) 1. Grease bolts wth DIN KPF 1/2 N-20 every 10 hours. 2. Grease frcton ponts as requred and after cleanng wth DIN KPF 1/2 N-20. Ol Lubrcaton Ponts 3. Ol jonts and bell cranks every 50 workng hours wth engne ol MIL-L-2104 C. Bodegradable Hydraulc Ol 4. Synthetc ester based hydraulc ol vscosty class ISO VG 46 VI > 180 Intervals n workng hours Pos. max. permssble ntervals, can be shorter dep. on use Mantenance Ponts 1 Motor 1.1 Mantenance accordng to manufacturers specs 1.2 Dry ar flter unt: Check servce dsplay Change flter element f dsplay shows red 1.3 Check and clean fuel flter 1.4 Check coolant fll-level 1.5 Check and clean combned coolng unt 2 Rear axle 2.1 Check ol fll-level of transmsson unt (nspecton screw) 2.2 Ol change transmsson unt 2.3 Check ol fll-level of helcal planetary gearng (nspecton screw) 2.4 Ol change helcal planetary gearng 3 Front axle 3.1 Check ol fll-level of transmsson unt (nspecton screw) 3.2 Ol change transmsson unt 3.3 Check ol fll-level of helcal planetary gearng (nspecton screw) 3.4 Ol change helcal planetary gearng 4 Transfer Case 4.1 Check ol fll-level of transfer case (nspecton screw) 4.2 Ol change transfer case 5 Axles / Artculated Shafts 5.1 Check tghtness of axles (500 Nm) 5.2 Check tghtness of artculated shafts (65 Nm) 6 Wheels and Tyres 6.1 Check ar pressure 6.2 Check tghtness of wheel bolts (600 Nm) 7 Swvel Jont 7.1 Check tghtness (610 Nm) 8 Hydraulc Unt 8.1 Change sucton return lne flter meda, check electr. dsplay 8.2 Check ol fll-level (nspecton glass) 8.3 Ol change 8.4 Check and clean hydraulc ol cooler 9 Greasng ponts (marked n red) 10 Battery 10.1 Vsual check 11 Brakes 11.1 Perform vsual and functonal check of brakes and parkng brakes before startng work 11.2 Check accumulator valve 12 Lghtng unt / Ar flter / Ar condtonng unt 12.1 Perform functonal check before startng work 12.2 Check ar flter 12.3 Check condensator for contamnaton 12.4 Check tenson of compressor drve belt 8-2 S150/S151

64 Mantenance 8 8 Mantenance Constructonal and desgn enhancements are mportant for the techncal development of ths equpment and may lead to devatons between fgures and content n ths manual. These changes are summarzed n Chapter 13. Please refer to Chapter 13 for detals.n. 8.1 Mantenance Notes DANGER - Ensure that the engne has stopped. - When workng under the loader arm, - unload the bucket and/or support the attachment, - the bucket arm must be mechancally propped up [e.g. by nsertng the bucket arm support (opton) (1-1/arrow)], - close the stop valves for man (1-2/1) and auxlary hydraulcs (1-2/2), - block the swvel assembly(1-4/arrow). - Ensure that the vehcle cannot roll away by applyng the parkng brake (4-7/4) and placng the travel drecton selector (4-7/3) n neutral (poston "0"). Addtonally chock both wheels on the front axle. ATTENTION - Ensure that unts are warm, but not hot, before carry out ol changes. - Perform mantenance work when the vehcle s on level ground and the loader arm has been grounded. - Immedately replace damaged flter meda and gaskets. - Clean pressure lubrcaton fttngs before lubr catng. - Refer to the mantenance schedule (on pages 8-1 and 8-2) for a lst of mantenance tasks. - Damage that occurs due to falure to comply wth the mantenance plan s not covered by warranty. - The materals mentoned n the mantenance plan are desgned for use n ambent temperatures between -15 C and +40 C. ATTENTION In case of ambent temperatures below -15 C refer to the descrpton of wnter operatons n secton S150/S151/S152/Z

65 8 Mantenance 8.2 Mantenance Tasks Check engne ol fll-level See the operatng manual for the engne. Fg Check axle ol fll-level Rear axle (1) Remove the plugs from the axle arches (8-1/arrow) and/or (8-2/arrow). - The ol level must reach the plug bore. - Collect any escapng ol. (2) Replace the plugs. Fg Planetary Gear (1) Move the loader untl the OIL LEVEL mark s horzontal and the plug s located at the top rght of the mark (8-3/arrow). (2) Remove the plug. - The ol level must reach the plug bore. - Collect any escapng ol. (3) Ft a new gasket and re-nsert the plug. Fg S150/S151/S152/Z152

66 Mantenance Front axle (1) Remove the plugs from the axle arches (8-4/arrow) and/or (8-5/arrow). - The ol level must reach the plug bore. - Collect any escapng ol. (2) Re-nsert the plug. Fg. 8-4 Fg Check ol fll-level transfer gearbox» Slow-runner 20 km/h and 25 km/h «(1) Remove plug (8-6/arrow). - The ol level must reach the plug bore. - Collect any escapng ol. (2) Re-nsert plug. Fg. 8-6 S150/S151/S152/Z

67 8 Mantenance Check ol fll-level transfer gearbox» Fast-runner 40 km/h «(1) Check ol-level n nspecton glass (8-7/1). - The ol level must be vsble n the upper quarter of the nspecton glass. If requred use the plug bore to top up wth transmsson ol (8-7/2) Collect any escapng ol. Fg Check ol fll-level n hydraulc ol reservor (1) Park the vehcle on level ground. (2) Lower the loader arm to the ground. (3) Tlt the quck coupler assembly and use the auxlary hydraulcs lever (4-6/5) to retract the lockng bolts. (4) Open the engne hood. (5) Check the ol level n the nspecton glass (8-8/arrow). Fg The ol level must be vsble n the upper quarter of the nspecton glass. If requred use the plug bore to top up wth transmsson ol (8-7/2). - Collect any escapng ol. Fg S150/S151/S152/Z152

68 Mantenance Change the engne ol (1) Remove the nspecton plate from the engne trough (8-10/Pfel). (2) Place a suffcently large ol spll tray under the motor ol sump. (3) Open the engne hood. (4) Remove the nspecton plate for the engne ol dran plug. (5) Attach the dranage nozzle wth hose from the tool case (4-1/13) to the ol dran plug. (6) Remove the cover cap from the hose. Fg (7) For further nstructons see the engne operatng manual Ol change axles Rear axle (1) Place a suffcently large ol spll tray under the vehcle. (2) Remove the plugs from the axle arches (8-11/1, 8-11/2, 8-11/3, 8-11/4, and 8-12/arrow) and dran ol. ATTENTION Dspose of waste ol n an envronmentally frendly way! (3) Re-nsert axle arch plugs (8-11/1, 8-11/2, and 8-11/3). Fg (4) Top up wth ol va axle arch plug bore (8-11/4 or 8-12/arrow) untl the ol fll-level reaches the bore openng. Fg S150/S151/S152/Z

69 8 Mantenance - Refer to the mantenance plan (pages 8-1and 8-2) for detals on requred amounts. - The ol fll-level wll drop after a few mnutes. Top up wth ol, untl the requred level has been reached and remans constant. - The axle vent valve (8-13/arrow) must be free of contamnaton. (5) Re-nsert the axle arch bore plugs (8-11/4 and 8-12/ arrow). Fg Planetary gear (1) Poston the vehcle so that the plug (8-14/arrow) s at 6 o clock. (2) Place a suffcently large ol spll tray wth a dranage chute underneach. (3) Remove the plug and dran the ol. ATTENTION Dspose of waste ol n an envronmentally frendly way! Fg (4) Poston the vehcle to allow the "OIL LEVEL" to be horzontal so that the plug s to the top left of the mark (8-15/arrow). (5) Add ol va the plug bore untl the ol fll level reaches the bore openng. (6) Re-nsert the plug wth a new gasket. Fg S150/S151/S152/Z152

70 Mantenance Front axle (1) Place a suffcently large ol spll tray underneath the vehcle. (2) Remove plugs from axle arches (8-16/1, 8-16/2, 8-16/3, 8-16/4, and 8-17/Pfel) and dran ol. ATTENTION Dspose of waste ol n an envronmentally frendly way! (3) Re-nsert plugs (8-16/1, 8-16/2, and 8-16/3). Fg (4) Top up wth ol va axle arch plug bore (8-16/4 or 8-17/arrow) untl ol fll-level reaches plug bore. Fg Refer to the mantenance plan (pages 8-1and 8-2) for detals on requred amounts. - The ol fll-level wll drop after a few mnutes. Top up wth ol, untl the requred level has been reached and remans constant. - The axle vent valve (8-18/arrow) must be free of contamnaton. (5) Re-nsert plugs (8-16/4 and 8-17/arrow). Fg S150/S151/S152/Z

71 8 Mantenance Ol change transfer gear gox» slow-runners 20 km/h and 25 km/h «(1) Place a suffcently large ol spll tray under the transfer case. (2) Remove plugs (8-19/1 and 8-19/2) and allow ol to dran. Fg ATTENTION Dspose of waste ol n an envronmentally frendly way! (3) Re-nsert plugs (8-19/1). (4) Top up wth ol va plug bore (8-19/2) untl the ol flllevel reaches the bore openng. - Refer to the mantenance plan (pages 8-1and 8-2) for detals on requred amounts. - The ol fll-level wll drop after a few mnutes. Top up wth ol, untl the requred level has been reached and remans constant. (5) Re-nsert the plugs (8-19/2). Fg Ol change transfer gear gox» fast-runners 40 km/h «(1) Place a suffcently large ol spll tray under the transfer case. (2) Remove plugs (8-20/2 and 8-20/3)and allow ol to dran. (3) Change the flter cartrdge (mcroflter) (8-21/1). (4) Clean the sucton flter (macroflter) (8-21/2). ATTENTION Dspose of waste ol n an envronmentally frendly way! (5) Re-nsert plugs (8-20/2). (6) Top up wth ol va plug bore (8-20/3). Fg Refer to the mantenance plan (pages 8-1and 8-2) for detals on requred amounts. - The ol level must be vsble n the upper quarter of the nspecton glass (8-20/1). - The ol fll-level wll drop after a few mnutes. Top up wth ol, untl the requred level has been reached and remans constant. (7) Re-nsert plug (8-20/3). S150/S151/S152/Z152

72 Mantenance Ol change hydraulcs (1) Open the engne hood. (2) Ensure that an ol spll tray s avalable (for sze refer to secton Kaptel 11.11). (3) Remove the nspecton plate for the ol dran plug (8-22/arrow). (4) Attach the dranage nozzle wth hose from the tool case (4-1/13) to the ol dran plug. (5) Remove the cover cap from the hose. (6) Allow the ol to dran nto the spll tray. ATTENTION Dspose of waste ol n an envronmentally frendly way! Fg (7) Screw the cap back on the hose and remove the dranage nozzle wth hose. (8) Replace the nspecton plate and tghten the ol dran plug. (9) Change the hydraulc ol flter meda (secton ). (10) Top wth ol va plug bore (8-23/arrow). ATTENTION Equpment usng bodegradable hydraulc ol (ester based synthetc hydraulc ol - vscosty class ISO VG 46 VI > 180) - (refer to the label on the hydraulc ol reservor and on the dashboard) need to use the same replacement ol type. Do not mx mneral and bodegradable hydraulc ols! Bodegradable hydraulc ol must be change every 1000 operatng hours. Follow the mgraton gudelnes VDMA when movng from mneral based to bodegradable hydraulc ol grade! Fg (11) Check the ol fll-level n the ol fll-level nspecton glass (8-24/Pfel). - Ensure that the loader arm has been lowered to the ground. - Ensure that the quck coupler assembly has been tpped, and that the lockng bolts have been moved to lock poston usng the auxlary hydraulcs lever (4-6/5). - The ol fll-level must be n the top quarter of the nspecton glass. (12) Use specalzed tool (hook wrench) to move the fllng nozzle. Fg S150/S151/S152/Z

73 8 Mantenance Changng the sucton return flter nsert ATTENTION Change the flter nsert at the ntervals ndcated n the mantenance plan or when cloggng s ndcated (4-8/34). When cold startng the vehcle the cloggng ndcator may lght up prematurely. The ndcator wll go off as soon as the hydraulc ol warms up. Fg (1) Remove the access cover (8-25/cover) (2) Loose the hose band clp of the rubber collar (8-26/3) and pull off the collar. (3) Remove both screws on the hydraulc ol flter cover (8-26/1) (4) Remove the hydraulc ol flter cover and the magnetc tube attached to t (8-27/2). (5) Lft up the handle (8-27/3), remove the flter nsert (8-27/4) and replace t wth a new nsert. ATTENTION Dspose of used hydraulc ol flter nserts n an envron-mentally frendly way! Fg (6) Wpe the magnetc tube (8-27/2) clean before refttng. (7) Re-ft and tghten the hydraulc ol flter cover and magnetc tube. (8) Attach the vent tube to the vent outlet (8-26/2 or 8-27/1). (9) Start the engne (10) Make sure you have an ol spll tray avalable and open the vent valve. Keep the vent valve open untl the ol that emerges s bubble free. (11) Close the vent valve. (12) Slp the rubber collar (8-26/3) on the ar flter tube and fasten t wth the hose band clp. Fg (13) Re-ft the access cover (8-25/arrow) S150/S151/S152/Z152

74 Mantenance Servcng/Changng the arflter The flter nsert requres attenton when the mantenance ndcator (8-28/1) shows red, or after 12 months, whch ever s sooner. (1) Open the engne hood. (2) Unscrew both wng screws on the top of the mantenance grd (8-28/2). Push the grd outsde n the upper part and lft t. (3) Loosen the two fastenng clamps on the ar flter ld (8-29/1) and remove the ar flter ld. (4) Pull out the flter cartrdge (8-29/2) by carefully turnng t back and forth. (5) Clean the flter cartrdge. ATTENTION - For cleanng, use a compressed ar gun to whch a ppe (angled at 90 ) has been attached. The ppe must be suffcently long to reach the cartrdge bottom. Use dry compressed ar of no more than 5 bar to blow out the cartrdge by movng the ppe back and forth n the nteror of the cartrdge. Cleanng may be stopped when dust formaton ceases. - Do not use petrol or hot lqud for cleanng. Fg (6) Use a hand-held nspecton lamp to check the flter cartrdge for damage to the cartrdge paper or the rubber gasket. If the cartrdge or seals are damaged, replace the cartrdge. (7) Re-nsert the flter cartrdge carefully. (8) Install the ar flter ld on the flter housng n such a way that the drecton arrow n the OBEN-TOP mark ponts upward. Ths ensures that the dust removal valve s pontng down. (9) If the servce ndcator (8-28/1) prevously showed red, press the reset button. The ndcator should now be clear. (10) Re-nstall the mantenance grd (8-28/2) Fg ATTENTION Before startng the engne, check the connectng ppes and hose on the arflter unt for sgns of damage Changng the safety cartrdge ATTENTION - The safety cartrdge must not be cleaned. - The safety cartrdge must be replaced after the flter cartrdge has been mantaned/ cleaned 5 tmes, or every two years at the latest. - Make sure that no drt or dust can enter the flter housng durng replacement of the safety cartrdge. S150/S151/S152/Z

75 8 Mantenance (1) Remove the flter cartrdge (secton ). (2) Perce the seal of the safety cartrdge (8-30/arrow) from the nsde by usng a screwdrver or smlar tool and pull up both strps. (3) Hold the flter cartrdge by both strps and pull t out by carefully turnng t back and forth. Replace the safety cartrdge and the flter cartrdge by new ones. (4) The remanng nstallaton s performed as descrbed n secton (7)...(10). Fg Changng the fuel flter See the engne operatng manual Changng the starter batteres - The starter battery s a low mantenance part accordng to DIN 72311, secton 7. It s located n the engne compartment, on the rght-hand sde of the machne. - Always store batteres n a clean and dry place. (1) Dsconnect the battery master swtch (4-7/5). (2) Use a square wrench to open the access panel. (3) Remove both securng bolts SW 19) (8-31/arrows) for the battery holder. (4) Pull out the battery holder and the batteres to the extent the retaner allows. Fg (5) Loosen and remove the securng bolts (SW 17) (8-32/1) for the battery holder. 1 Fg (6) Loosen and dsconnect the battery cable clamps (8-32/2) from the battery termnals (SW 13). DANGER Always remove the negatve cable clamp frst, before removng the postve clamp. When reattachng, use the reverse order. (7) Remove and replace the batteres. (8) Lghtly lubrcate the termnals and clamps before reattachng them wth acd-free and acd-resstant grease. (9) To ft a new battery perform these steps n reverse order. DANGER Make sure the fastenngs are secure. (10) Close the access cover agan S150/S151/S152/Z152

76 Mantenance Servcng/Changng the fresh ar flter (1) Lft and mechancally prop up bucket arm [e.g. by nsertng the bucket arm support (opton) (1-1/arrow)], Lower bucket arm untl t rests on the bucket arm support and swvel all the way to the rght or left. (2) Loosen and remove the four holdng screws (8-33/ arrows) of the heatng unt cover, and then remove the cover. (3) Remove the flter elements (8-34/arrows) and blow them clean wth ar. ATTENTION Do not use petrol, hot fluds or compressed ar for cleanng. Fg (4) Check the flter elements for sgns of damage. Change the flter elements n case of damage or every 1500 operatng hours. (5) Re-ft the flter elements and the heatng unt cover. Fg Checkng brake play (1) Apply the parkng brake (4-7/4). (2) Remove the axle arch plugs (8-12/arrow and 8-17/ arrow). (3) Use a specal feeler gage to measure the gap between the center brake dsks. ATTENTION - "S" mnmum: 5 mm. - If necessary, change the center brake dsks on both sdes. (4) Re-ft the plugs (8-12/arrow and 8-17/arrow) weder. Fg S150/S151/S152/Z

77 8 Mantenance 8.3 Greasng ponts Greasng ponts are panted red on the vehcle Rear axle pvot bolt (8-36/arrows) ATTENTION The rear axle pvot bolt must be greased every 10 operatng hours. Fg Rear axle (8-37/arrows) ATTENTION The rear axle spndle bolts must be greased every 50 operatng hours. Lubrcate the top and the bottom of the axle spndle bolts on both sdes of the axle. Fg Front axle (8-38/arrows) ATTENTION The front axle spndle bolts must be greased every 50 operatng hours. Lubrcate the top and the bottom of the axle spndle bolts on both sdes of the axle. Fg S150/S151/S152/Z152

78 Mantenance Swvel assembly (8-39/arrows) The grease pack s desgned to avod frcton, to seal the unt and protect t from corroson. For ths reason, the bearngs should be greased lberally every 10 operatng hours untl grease emerges. When greasng the swvel assembly rotate the loader arm n 20 steps. Ensure that all four grease ponts are greased at every step. Addtonally grease the assembly before and after longer perods of nactvty. DANGER - Before greasng, mechancally prop up the bucket arm [e.g. by nsertng the bucket arm support (opton) (1-1/arrow)], apply the parkng brake (4-7/4) and set the drve drecton swtch (4-7/3) to 0. - Makes sure that nobody s n the workng area of the loader arm whle rotatng the arm. Fg Loader assembly ATTENTION The bolts/greasng ponts (8-40/arrows of the loader/quck coupler assembly) must be greased every 10 operatng hours. Fg Drver cab doors (8-41/arrows) ATTENTION Ensure that the hnges of the drver cab doors are greased every 50 operatng hours. Ensure that the hnges on both drver cab doors are greased. Fg S150/S151/S152/Z

79 8 Mantenance Engne hood ATTENTION The hnges of the engne hood (8-42/arrows) must be lubrcated every 50 operatng hours. Fg Olng ponts Support valve control mechansm ATTENTION The support valve control mechansm must be oled wth engne ol every 50 operatng hours. (1) Rase the loader arm, nsert the loader arm support and swvel the arm out fully to the left or rght. Fg (2) Loosen and remove the four holdng screws on the access panel (8-43/arrows). Ol only the vsble area of the pston rod on the suspenson casng (8-44/arrow). Fg S150/S151/S152/Z152

80 Troubleshootng

81 9 Troubleshootng 9 Troubleshootng *) These tasks to be performed by authorzed staff only Malfuncton Probable Cause Remedy Engne Refer to engne manual Engne wll not start Drve selector (4-7/3) not n Put drve selector n neutral neutral Loader arm cannot be lfted or Pressure valve n n control valve Remove pressure valve, clean and dropped may be open re-calbrate* Control valve for man hydraulcs Unlock control valve (1-2/1) (4-7/2) locked No plot pressure or pressure too low Open pressure valve n control crcut, clean and re-calbrate* Desel engne falure Use resdual pressure to lower the loader arm to the ground mmedately after engne falure More force requred for steerng Pressure valve n steerng unt Remove pressure valve, clean and may be open re-calbrate* Slde valve n prorty valve blocked Replace prorty valve Swvel assembly (1-4/arrow) fals Swvel mechansm may be Remove swvel assembly block and to rotate blocked store n holder Pressure valve n control valve may be open Remove pressure valve, clean and re-calbrate* Support falure Cut-off valve swtch n frame under Rotate loader arm n drecton of swvel assembly jammed travel; free arm Support falure when loader arm s Non-return valve n pressure hose Rotate loader arm n drecton of lowered n swvelled state open travel, remove non-return valve clean and reft or replace* 9-2 S150/S151/S152/Z152

82 Malfuncton Probable Cause Remedy Troubleshootng 9 Malfuncton n travel and man Flter clogged Change flter nserts hydraulcs Low ol fll-level n hydraulc ol reservor Top up wth ol Electrcal connecton of axal pston pump not tght, separated or corroded Connect accordng to wrng dagram or clean Hgh pressure valves contamnated Clean Brake malfuncton Parkng brake cannot hold vehcle Check adjustment and possbly readjust* Check whether breaker crcut s attached to brake lever Alternator not chargng Loose connector Replace and fasten connector Alternator belt snapped Relace belt Alternator revs too low Check tenson of alternator belt. and re-tenson, f needed Heatng/Ventlaton unt falure Fuse blown Replace fuse Hose connectors for attachments Increased pressure due to effect Carefully remove screw jont wll not attach of heat on attachment above the quck couplng, to bleed ol and reduce the ncreased pressure. Re-tghten the screw jont Dspose of waste ol n an envronmentally frendly way! Increased pressure n unt Swtch engne off, release pressure n plot valve (4-9/5) through crcular moton of lever S150/S151/S152/Z

83 Wrng and Hydraulcs

84 Elektrk-Schaltplan/Schéma électrque/wrng dagramm/elektrsch schakelschema/elektrsk kopplngsschema S T 53M 15/ /16 23/17 23/6 23/11 23/ DS TS1 DS2 DS1 DS3 Y6 Y50 Y S150/S151/S152/Z152

85 Elektrk-Schaltplan/Schéma électrque/wrng dagramm/elektrsch schakelschema/elektrsk kopplngsschema G2 85 Y5 84 Y3 83 Y2 82 Y4 81 Y DS4 78 DS7 77 Y9 76 Y8 S150/S151/S152/Z

86 Elektrk-Schaltplan/Schéma électrque/wrng dagramm/elektrsch schakelschema/elektrsk kopplngsschema S150/S151/S152/Z152

87 Wrng and Hydraulcs Wrng Dagram Pos. Name 01 Starter button 02 Relay: Starter cut-out 03 Fuel fll-level dsplay 04 Coolng water temperature dsplay 05 Tachometer 06 Operatng hour counter 07 Actuator: Workng floodlghts 08 Fuse (Chapter 4.9 Pos. 17/13) 09 Fuse (Chapter 4.9 Pos. 17/6) 10 Fuse (Chapter 4.9 Pos. 17/7) 11 Actuator: StVZO-Beleuchtung 12 Indcator pck-up 13 Actuator: Hazard Warnng Lghts 14 Fuse (Chapter 4.9 Pos. 17/10) 15 Fuse (Chapter 4.9 Pos. 17/2) 16 Fuse (Chapter 4.9 Pos. 17/9) 17 Fuse (Chapter 4.9 Pos. 17/8) 18 Fuse (Chapter 4.9 Pos. 17/3) 19 Actuator: Quck coupler release 20 Actuator: Loader arm cushonng 21 not used 22 Relay: Loader arm cushonng 23 Relay: Accoustc warnng 24 Pressure swtch: Overload loader arm cushonng 25 Accumulator valve: Loader arm cushonng 26 Valve: Ppe burst protecton/loader arm cushonng (opt.) 27 Comb-valve 28 Socket 7-pn front 29 Valve: Quck coupler release 30 Adapter for socket 7-pn rear 31 Number plate lghtng 32 Marker lamp rght 33 Marker lamp left 34 Tal lght unt rght 35 Tal lght unt left 36 Indcator/marker lght rght 37 Indcator/marker lght left 38 Drvng lght left 39 Drvng lght rght 40 Addtonal brake lght 41 Brake lght swtch 42 Sgnal horn 43 Workng floodlght back 44 Workng floodlght front 45 Swtch: Hydraulc ol flter 46 Swtch: Coolng water temperature 47 Swtch: Ol pressure 48 Swtch: Coolng water fll-level 49 Swtch: Servce brake malfuncton 50 Swtch: Hydraulc ol temperature 51 Coolng water temperature pck-up 52 Plunge tube pck-up 53 Alternator 54 Starter motor 55 Battery man swtch 56 Batteres 57 Servce nterval pck-up (opt.) 58 Warnng ndcators S150/S151/S152/S153/S154/Z

88 10 Wrng and Hydraulcs Pos. Name 59 Dode combnaton (only fast-runners) 60 Pulse generator ndcator lght unt gear selector 61 Relay gear selector (only fast-runners) 62 Relay gear selector (only fast-runners) 63 Brücke gear selector (only Langsamläufer) 64 Relay gear selector (only fast-runners) 65 Relay gear selector (only fast-runners) 66 Relay gear selector (only fast-runners) 67 Relay gear shft swtch 68 Relay 1st gear 69 Relay power control forwards 70 Relay power control reverse 71 Relay drve breaker 72 Indcator lght unt gear selector 73 Fuse (Chapter 4.9 Pos. 17/1) 74 Push-button gear shft selector slow/fast (only slow-runners) 75 SchrttschaltRelay (only slow-runners) 76 Valve 1st gear (only slow-runners) 77 Valve 2nd gear (only slow-runners) 78 Swtch: Relase gear selector (only slow-runners) 79 Swtch: Parkng brake 80 Reverse warnng pck-up 81 Valve reverse travel drecton 82 Valve travel drecton recognton 83 Valve forward travel drecton 84 Valve 1st gear 85 Valve gear shft swtch 86 Rev pck-up 87 not used 88 Rev evaluator 89 Mult-purpose lever rght (Valve pck-up for man hydraulcs) 90 Accoustc warnng 10-2 S150/S151/S152/Z152

89 Wrng and Hydraulcs 10 Pos. Name 91 Interval pck-up 92 Fuse (Chapter 4.9 Pos. 17/11) 93 Acuator nterval wpers front 94 Acuator screen washer front 95 Acuator wper/washer back 96 Acuator rear screen heatng 97 Fuse (Chapter 4.9 Pos. 17/5) 98 MaxFuse (40 A) 99 Fuse (Chapter 4.9 Pos. 17/4) 100 Socket dashboard 2 pn 101 Fuse (Chapter 4.9 Pos. 17/14) 102 Acuator 360 lamp (opt.) 103 Fuse (Chapter 4.9 Pos. 17/12) 104 Valve engne cut-out lamp (opt.) 106 Swtch nteror lghtng 107 Interor lghtng 108 Rado (opt.) 109 Pressure swtch (flter ar-condtonng) 110 compressor (ar-condtonng) 111 Fan motor (ar-condtonng) 112 Ar-condtonng (opt.) 113 Transformer rado 114 Heated mrror rght (opt.) 115 Heated mrror left (opt.) 116 Rear screen heatng 117 Motor wper back 118 Motor washer back 119 Motor washer front 120 Motor wper front Opt. =Optonal equpment The tem nos. prnted n bold type n the wrng dagram are cross-references to the nterface n the hydraulcs plan. MaxFuse wechseln (Pos. 98): Should t be necessary to change the fuse for the ar-condtonng system, the dash board cover must be removed frst. After removng the dash board cover, the fuse s accessble n the front area near the front screen. S150/S151/S152/Z

90 Hydraulcs Dagram AS 150 (bolt lock) Type "20 km/h" and "25 km/h" Y Y6 Anschluss an Plotdruck Auskppen Anschluss an Plotdruck Senken Anschluss an Spesedruck Y DS DS2 Enschaltdruck120 bar Abschaltdruck 150 bar DS7 DS3 20 bar Fahrtrchtung Y1/B4/rot X2/B3/grauX2/A3/grün X1/A4/blau X1/A2/schwarz X2/A1/weß X2/B1/gelb Y1/B2/braun Y8 Y Y1 Y2 TS1 24 DS1 Y4 25 G2 Y3 X _.. _.. _ Gauge part Optonal equpment S150/S151/S152/Z152

91 Hydraulcs Dagram AS 150 (bolt lock) Type "40 km/h" Y Y6 Anschluss an Plotdruck Auskppen Anschluss an Plotdruck Senken Anschluss an Spesedruck Y DS DS2 DS Enschaltdruck120 bar Abschaltdruck 150 bar Y1 Y2 TS1 24 DS1 Y4 25 Y5 Y3 G2 X _.. _.. _ Gauge part Optonal equpment S150/S151/S152/Z152

92 M14x1, Hydraulcs Dagram AS 150 (claw lock) Type "20 km/h" NS55 NS G3/8" G3/8" G1/ NS58 NS G1/2 G1/2 G1/ G1/2 G1/2 Y52 Y53 3/4"-16UNF 3/4"-16UNF NS53 NS54 G3/8 P bar G1/2 Y54 G1/2 Y55 G3/8 G3/8 B1 A T1 HPCO G3/8 G1/2 T3 G3/8" B P G3/8" G3/8" A T G3/8" G 3/4 G 3/4 G 3/4 G 3/4 G 3/4 G 3/4 A4 B4 A3 B3 A2 B2 G1" T3 270 bar 270 bar G1/4" G1/4" B P A T Y6 G1/2 G 3/4 B1 G 3/4 Y50 Anschluß an Spesedruck 300 bar 270 bar 300 bar 270 bar P1 G 3/4 A1 G1/2 Anschluß an Plotdruck Auskppen G1/2 Anschluß an Plotdruck Senken bar G1/4" G1/4" Y bar G1/2 DS6 39 P P B A 0,7 l 30 b 30 b 0,7 l M10x1 S M10x1 M18x1,5 T ZL M16x1,5 A 240 P M16x1,5 M16x1,5 B T 240 M16x1,5 M18x1,5 ZR DS2 100±10 bar 10 muem. M22x1,5 P B M22x1,5 0,7 l 50 b 0,7 l M14x1,5 50 b 50 b R F R2 M10x1 M14x1,5 R1 Enschaltdruck 120 bar Abschaltdruck 150 bar Ent- und Belüftung Befüllung 0,7 l DS4 N M18x1,5 DS1 2,5 bar 20 bar DS7 3-6 bar X DS3 M10x1 T T1 M14x1,5 M10x bar F1 T2 M14x1,5 J2 M10x1,5 M12x1,5 M3 M14x1,5 F3 G 3/4" S2 0,5 bar 20 bar G1 1/4" E1 10 muem. A=5500 qcm 0,04 bar T M14x1,5 P M14x1,5 100 muem. G 1" S1 3,0 bar 130 muem KHD BF4M 2012 EC 98 KW G1" T /mn 3 bar G1/4" X1 Y1 X2 Y2 G1/4" G1/4" G1/4" G1/4" G1/4" P T G1/4" R 90 ccm/u M16x1,5 T2 M26x1,5 X2/A1/weß M26x1,5 T1 Y56 X G1/4" Y1 b Y1/B4/rot X1/A4/blau X1 M16x1,5 Y2/B1/gelb a X G1/4" Fahrtrchtung Y2 X2/A3/grün P=480±10 bar P=480±10 bar X2 M16x1,5 F/ohne Y1/B2/braun X1/A2/schwarz Y2/B3/grau Z M10x1 P=27±2 bar G1/4" PS M14x1,5 F Y2 X2 Y1 X1 G1/4" G1/4" G1/4" G1/4" G1/4" P 1,0mm X G A/X1/Y1/b=Rückwärts B/X2/Y2/a=Vorwärts M18x1,5 P=450 bar M42x2 S 10 b 0,7 l M12x1,5 MB 18,7 ccm/u MA X X T G1/4" B Y8 G1/4 T P G1/4 (SAE 1") A Y57 (SAE 1") M12x1,5 P S Y9 G1/4 B A G1/4 X 38 ccm/u P S 40 Y X 16 ccm/u VA G2 HA KWK LLK G 1" SAE 1" 100 C B A SAE 1" Y3 G 1" TS1 Y4 3 2 G 1" U G T M18x1,5 M18x1,5 Y4 bestromt be vorwärts/neutral b a M14x1,5 L M18x1,5 1 t=55 C G1/2 LS G1/4 L G1/4 LS M18x1,5 T 10 L/mn p=16 bar R M18x1,5 240 G1/2 P T G1/2 G1/2 CF P G3/4 EF G3/4 X _.. _.. _ G1/2 R Messanschluss Sonderausstattung S150/S151/S152/S153/S154/Z152

93 Hydraulcs Dagram AS 150 (claw lock) Type "40 km/h" NS55 NS G3/8" G3/8" G1/ NS58 NS G1/2 G1/2 G1/ G1/2 G1/2 Y52 Y53 3/4"-16UNF 3/4"-16UNF NS53 NS54 G3/8 P bar G1/2 Y54 G1/2 Y55 G3/8 G3/8 B1 A T1 HPCO G3/8 G1/2 T3 G3/8" B P G3/8" G3/8" A T G3/8" bar 270 bar G1" T3 G1/4" G1/4" B P A T Y6 G1/2 G 3/4 G 3/4 G 3/4 G 3/4 G 3/4 G 3/4 A4 B4 A3 B3 A2 B2 300 bar 270 bar 300 bar 270 bar G 3/4 A1 G1/2 Anschluß an Plotdruck Auskppen Anschluß an Plotdruck Senken B1 G 3/4 G1/2 Y50 Anschluß an Spesedruck bar P1 G 3/4 G1/4" G1/4" Y58 G1/2 180 bar DS6 40 P P B A 0,7 l 30 b 30 b 0,7 l M10x1 S M10x1 M18x1,5 T ZL M16x1,5 A P M16x1,5 240 M16x1,5 B 240 T M16x1,5 M18x1,5 ZR DS2 100±10 bar M14x1,5 0,7 l 50 b 0,7 l M14x1,5 50 b 50 b 0,7 l DS4 20 bar M12x1,5 M3 M14x1,5 F3 T M14x1,5 P M14x1, G1" T1 G1/4" X1 Y1 X2 Y2 G1/4" G1/4" G1/4" G1/4" Y56 G1/4" Y1/B4/rot G1/4" Fahrtrchtung F/ohne Y1/B2/braun G1/4" Y57 F Y2 X2 Y1 X1 G1/4" G1/4" G1/4" G1/4" 41 Y51 42 L M18x1,5 G1/2 L R M18x1,5 240 G1/2 R M22x1,5 P B M22x1,5 R F R2 M10x1 M14x1,5 R1 Enschaltdruck 120 bar Abschaltdruck 150 bar N M18x1,5 M10x1 T T1 X DS3 3-6 bar M14x1,5 M10x bar F1 T2 M14x1, G1/4" P T G1/4" X2/A1/weß X1/A4/blau Y2/B1/gelb X2/A3/grün X1/A2/schwarz Y2/B3/grau G1/4" P T G1/4" G1/4 LS 175 G1/2 P T G1/2 G1/2 G3/4 CF EF b KWK G1/4 LS 10 muem. Ent- und Belüftung Befüllung DS1 2,5 bar J2 M10x1,5 G 3/4" S2 0,5 bar G1 1/4" E1 10 muem. A=5500 qcm 0,04 bar 100 muem. G 1" S1 3,0 bar 130 muem. 11 ccm/u S P =1,189 KHD BF4M 2012 EC 98 KW /mn X 3 bar T2 M26x1,5 90 ccm/u R M26x1,5 M16x1,5 T1 Y1 b X1 M16x1,5 X a Y2 P=480±10 bar P=480±10 bar X2 M16x1,5 X Z M10x1 P=27±2 bar M14x1,5 PS 1,0mm X G A/X1/Y1/b=Rückwärts B/X2/Y2/a=Vorwärts M18x1,5 P=450 bar M42x2 S 0,7 l M12x1,5 MB 18,7 ccm/u MA X X B (SAE 1") A (SAE 1") M12x1,5 X P S 38 ccm/u P S 16 ccm/u X VA Y5 G2 HA LLK G1" SAE 1" 100 C B A SAE 1" Y3 G1" G1 Y4 3 2 Y4 bestromt be vorwärts/neutral G1" U G T M14x1,5 M18x1,5 M18x1,5 b a 1 t=55 C M18x1,5 T 10 L/mn p=16 bar P G3/4 X _.. _.. _ Messanschluss Sonderausstattung S150/S151/S152/S153/S154/Z152

94 Wrng and Hydraulcs Hydraulcs Dagram Hydraulcs Dagram AS 150 (bolt lock) Type "20 km/h" and "25 km/h" Pos. Name 01 Swvel cylnder DW 100/45/785/ Actuator support 03 Leak free lock 04 Support cylnder EW 60/210/ Storage faclty ppe burst protecton (opt.) 06 Lockng cylnder DW 80/60/ Auxlary hydraulcs rght crcut 08 Electro-hydraulc lock quck coupler 09 Tlt cylnder DW 90/55/540/ Ppe burst protecton tlt cylnder (opt.) 11 Combnaton valve RBS/HWF (SA) 12 Lft cylnder DW 100/60/704/ Drop lmter valve (AKE) (opt.) 14 Ppe burst protecton lft cylnder (SA) 15 Loader arm cushonng (SA) 16 Auxlary hydraulcs left crcut 17 Steerng cylnder back GDW100/50/ Steerng cylnder front GDW100/50/ Steerng mode swtch valve 20 Blockng valve (opt.) 21 Steerng unt 240/100 cm³/u 22 Comb-cooler/ol sde 23 Prorty valve 24 Temperature control (55 C) (opt.) 25 Drve motor A6VM 107 HA1R2 26 Idle gear 27 Cam pump 16 cm³/u 28 Cam pump 38 cm³/u 29 Drve pump A4VG 90 DA2D8 30 Drve motor 31 Sucton flter 32 Combned sucton return flter 33 Electrcal contamnaton dsplay 34 Hydraulc ol reservor 35 Central brakng unt (opt.) 36 Multple dsk brake 37 Drectonal control valve 1-way 38 Hydraulc swvel lmter (opt.) 39 Drectonal control valve 4-way 40 Lft heght lmter (opt.) 41 Hydraulc tlt nhbtor (opt.) 42 Plot pressure ntator man hydraulcs 43 Stop valve man hydraulcs 44 Hydraulc gear change 45 Stop valve auxlary hydraulcs 46 Plot pressure ntator auxlary hydraulcs 47 Hydraulc tlt nhbtor (opt.) 48 Parkng brake valve 49 Pressure cross over 50 Pressureless return crcut (opt.) S150/S151/S152/S153/S154/Z

95 Wrng and Hydraulcs Hydraulcs Dagram AS 150 (bolt lock) Type "40 km/h" Pos. Name 01 Swvel cylnder DW 100/45/785/ Actuator support 03 Leak free lock 04 Support cylnder EW 60/210/ Storage faclty ppe burst protecton (opt.) 06 Lockng cylnder DW 80/60/ Auxlary hydraulcs rght crcut 08 Electro-hydraulc lock quck coupler 09 Tlt cylnder DW 90/55/540/ Ppe burst protecton tlt cylnder (SA) 11 Combnaton valve RBS/HWF (SA) 12 Lft cylnder DW 100/60/704/ Drop lmter valve (AKE) (SA) 14 Ppe burst protecton lft cylnder (SA) 15 Loader arm cushonng (SA) 16 Auxlary hydraulcs left crcut 17 Steerng cylnder back GDW100/50/ Steerng cylnder front GDW100/50/ Steerng mode swtch valve 20 Blockng valve (opt.) 21 Steerng unt 240/100 cm³/u 22 Comb-cooler/ol sde 23 Prorty valve 24 Temperature control (55 C) (opt.) 25 Drve motor A6VM 107 HA1R2 26 Load swtchgear 27 Cam pump 16 cm³/u 28 Cam pump 38 cm³/u 29 Drve pump A4VG 90 DA2D8 30 Drve motor 31 Cam pump11 cm³/u 32 Sucton flter 33 Combned sucton return flter 34 Elektrcal contamnaton dsplay 35 Hydraulc ol reservor 36 Central brakng unt (opt.) 37 Multple dsk brake 38 Drectonal control valve 1-way 39 Hydraulc swvel lmter (opt.) 40 Drectonal control valve 4-way 41 Lft heght lmter (opt.) 42 Hydraulc tlt lmter (opt.) 43 Plot pressure ntator man hydraulcs 44 Stop valve man hydraulcs 45 Stop valve auxlary hydraulcs 46 Plot pressure ntator auxlary hydraulcs 47 Hydraulc tlt lmter (SA) 48 Parkng brake valve 49 Hgh pressure crossover crcut 50 Pressureless return crcut (opt.) S150/S151/S152/S153/S154/Z

96 Wrng and Hydraulcs Hydraulcs Dagram AS 150 (claw lock) Type "20 km/h" Pos. Name 01 Swvel cylnder DW 100/45/785/ Actuator support 03 Leak free lock 04 Support cylnder EW 60/210/ Storage faclty ppe burst protecton (opt.) 06 Auxlary hydraulcs rght crcut 07 Lockng cylnder GDW 63/40/70/ Electro-hydraulc lock quck coupler 09 Tlt cylnder DW 90/55/540/ Ppe burst protecton tlt cylnder (SA) 11 Combnaton valve RBS/HWF (SA) 12 Lft cylnder DW 100/60/704/ Drop lmter valve (AKE) (SA) 14 Ppe burst protecton lft cylnder (SA) 15 Loader arm cushonng (SA) 16 Auxlary hydraulcs left crcut 17 Steerng cylnder back GDW100/50/ Steerng cylnder front GDW100/50/ Steerng mode swtch valve 20 Blockng valve (opt.) 21 Steerng unt 240/100 cm³/u 22 Comb-cooler/ol sde 23 Prorty valve 24 Temperature control (55 C) (opt.) 25 Drve motor A6VM 107 HA1R2 26 Idle gear 27 Cam pump 16 cm³/u 28 Cam pump 38 cm³/u 29 Drve pump A4VG 90 DA2D8 30 Drve motor 31 Sucton flter 32 Combned sucton return flter 33 Elektrcal contamnaton dsplay 34 Hydraulc ol reservor 35 Central brakng unt (opt.) 36 Multple dsk brake 37 Drectonal control valve 1-way 38 Hydraulc swvel lmter (opt.) 39 Drectonal control valve 4-way 40 Lft heght lmter (opt.) 41 Hydraulc tlt lmter (opt.) 42 Plot pressure ntator man hydraulcs 43 Stop valve man hydraulcs 44 Hydraulc gear shft 45 Stop valve auxlary hydraulcs 46 Plot pressure ntator auxlary hydraulcs 47 Hydraulc tlt lmter (SA) 48 Parkng brake valve 49 Hgh pressure crossover crcut 50 Pressureless return crcut (opt.) S150/S151/S152/S153/S154/Z

97 Wrng and Hydraulcs Hydraulcs Dagram AS 150 (claw lock) Type "40 km/h" Pos. Name 01 Swvel cylnder DW 100/45/785/ Actuator support 03 Leak free lock 04 Support cylnder EW 60/210/ Storage faclty ppe burst protecton (opt.) 06 Auxlary hydraulcs rght crcut 07 Lockng cylnder GDW 63/40/70/ Electro-hydraulc lock quck coupler 09 Tlt cylnder DW 90/55/540/ Ppe burst protecton tlt cylnder (SA) 11 Combnaton valve RBS/HWF (SA) 12 Lft cylnder DW 100/60/704/ Drop lmter valve (AKE) (SA) 14 Ppe burst protecton lft cylnder (SA) 15 Loader arm cushonng (SA) 16 Auxlary hydraulcs left crcut 17 Steerng cylnder back GDW100/50/ Steerng cylnder front GDW100/50/ Steerng mode swtch valve 20 Blockng valve (opt.) 21 Steerng unt 240/100 cm³/u 22 Comb-cooler/ol sde 23 Prorty valve 24 Temperature control (55 C) (opt.) 25 Drve motor A6VM 107 HA1R2 26 Load swtchgear 27 Cam pump 16 cm³/u 28 Cam pump 38 cm³/u 29 Drve pump A4VG 90 DA2D8 30 Drve motor 31 Cam pump11 cm³/u 32 Sucton flter 33 Combned sucton return flter 34 Elektrcal contamnaton dsplay 35 Hydraulc ol reservor 36 Central brakng unt (opt.) 37 Multple dsk brake 38 Drectonal control valve 1-way 39 Hydraulc swvel lmter (opt.) 40 Drectonal control valve 4-way 41 Lft heght lmter (opt.) 42 Hydraulc tlt lmter (opt.) 43 Plot pressure ntator man hydraulcs 44 Stop valve man hydraulcs 45 Stop valve auxlary hydraulcs 46 Plot pressure ntator auxlary hydraulcs 47 Hydraulc tlt lmter (SA) 48 Parkng brake valve 49 Hgh pressure crossover crcut 50 Pressureless return crcut (opt.) S150/S151/S152/S153/S154/Z

98 Techncal Data (Equpment)

99 11 Techncal Data (Equpment) 11 Techncal Data (Equpment) The techncal data assume PR tre specs Equpment - Heght 3100 mm - Wdth 2460 mm - Wheelbase 2200 mm - Track 1980 mm - Operatng weght wthout attachments kg - Clearance - Dfferental 440 mm - Turnng crcle (va rear wth four-wheel-drve) 4300 mm - Turnng angle 35 +/- - Swng angle 10 +/- - Gradent 33 - Clmbng capacty wth workng load restrcted to 60 % due to maxmum permssble tlt of engne - Max. traler load wth max. vertcal load on couplng pont 250 kg - braked 3500 kg - unbraked 750 kg - Max. lftng force 69 kn - Max. thrust 81 kn 11.2 Engne - Lqud cooled desel engne - 4 cylnder, 4 stroke, drect fuel njecton - Capacty 4038 cm 3 - Power correspondng to ISO kw be 2300 mn -1 - Exhaust gas emsson correspondng to RL 97/68 EC Step 1 + EPA 11.3 Starter - 4,0 kw, 24 V 11.4 Alternator - 55 A, 28 V 11.5 Hydrostatc transmsson Type "20 km/h" 1st gear - Step I km/h - Step II 0...8,5 km/h 2nd gear - Step I ,5 km/h - Step II km/h 11-2 S150/S151/S152/Z152

100 Techncal Data (Equpment) 11 Type " 25 km/h" 1st gear - Step I km/h - Step II ,5 km/h 2nd gear - Step I ,5 km/h - Step II km/h Type " 40 km/h" Alpha max. (Turtle symbol) 1st gear 2nd gear km/h ,5 km/h km/h 11.6 Axle loads - max road legal axle load - front 7000 kg - back 7500 kg - max. road legal gross weght kg 11.7 Tres The followng tres are permtted: - Sze Pressure - front 3,0 bar - back 3,0 bar - Sze 17.5 R 25 - Pressure - front 3,0 bar - back 3,0 bar - Sze 455/70 R 24 - Pressure - front 4,5 bar - back 3,0 bar - Sze 550/65 R 25 - Pressure - front 2,2 bar - back 2,2 bar 11.8 Steerng - Four-wheel (swtchable to rear-wheel mode) - hydrostatc va prorty valve - Max. pressure 175 bar 11.9 Brakes - Servce brakes: Hydraulc pump servo brake system (wet multple dsk brake on front and rear axle). Inchng avalable on ntal pedal depress. - Parkng brake: wet sprng loaded multple dsk brake on rear axle Electrcal subsystem - Battery 2 x 88 Ah S150/S151/S152/Z

101 11 Techncal Data (Equpment) Hydraulc subsystem - Volume 160 l - Hydraulc ol reservor 115 l Man hydraulcs - Output flow pump I (prorty valve controlled) 87 l/mn - Output flow pump II (va swvel assembly and accumulator valve) 38 l/mn - Total flow output 125 l/mn - Operatng pressure max. 230 bar - 2 lft cylnders Ø 100/70 mm - 2 tlt cylnders Ø 90/55 mm - Tmng correspondng to DIN ISO 7131 Lftng (wth load) 5,6 s Lowerng (wthout load) 3,0 s Tppng 90 1,5 s Tltng 45 1,0 s Swvel assembly hydraulcs - Output flow pump II (va accumulator valve) 38 l/mn - Operatng pressure max. 210 bar - 2 swvel cylnders Ø 100/45 mm - Swvel tme 180 7,0 s Support assembly - Operatng pressure lastabhängg - 2 support cylnders Plunger damter 60 mm Fuel supply system - Volume Fuel tank 170 l Heatng and Ventlaton System (Drver Cab) - Water heater - Type - Heatng capacty 3 levels - Fan capacty 3 levels Sucton-Return Flter (Hydraulcs) - Flter granularty correspondng to ISO µm abs. - By-pass-Ansprechdruck p = 3,0 bar Electrcal Contamnaton Dsplay - Acuatng pressure p = 2,5 bar 11-4 S150/S151/S152/Z152

102 Techncal Data (Equpment) Ol Cooler (Comb-Cooler) wth Thermostatcally Controlled Valve - Capacty max. 30 kw - Throughflow 43 l/mn Nose Emsson Type "20 km/h" Nose level (LWA) Nose external: In-band accoustc level (LpA) Nose level n cab: Type "25 km/h" Nose level (LWA) Nose external: In-band accoustc level (LpA) Nose level n cab: Type "40 km/h" Nose level (LWA) Nose external: In-band accoustc level (LpA) Nose level n cab: 106 db(a) 81 db(a) db(a) db(a) 106 db(a) 83 db(a) Optons Ar-Condtonng Unt (Drver Cab) S150/S151/S152/Z

103 Techncal Data (Attachments)

104 12 Techncal Data (Attachments) 12 Attachments Notes The techncal data assume PR tres 12.1 Buckets Dmensons correspondng to ISO 7131/ S150/S151/S152/Z152

105 12.1 Buckets Techncal Data (Attachments) 12 Bucket type Bucket I Bucket II Bucket III Mult-purpose wth teeth no teeth no teeth bucket Bucket volume to DIN/ISO 7546 m³ 1,45 2,00 2,40 1,30 - heaped m³ 1,60 2,20 2,65 1,45 Bucket wdth mm Net weght kg Loads to DIN Aggregate densty t/m³ 1,9 1,4 1,1 2,0 Dumpng load - n-lne kg swveled kg Lftng load - n-lne kg lateral kg Loads accordng to ISO 8313 Aggregate densty t/m³ 1,7 1,12 1,0 1,75 Dumpng load - n-lne kg swveled kg Workload - n-lne kg swveled kg Breakout force accordng to ISO 8313 kn A Total length mm AA4 max. dump n angle A2 max. dump n angle B max. dump out range at dump out angle 45 mm G Dump out heght at max. dump out range. and dump out angle 45 mm H6 Penetraton mm H7 Clearance to center lug (Quck coupler) mm H8 Dump out heght at max lftng heght and dump out angle 45 mm H9 Clearance to center lug (Quck coupler) mm H10 max. workng heght mm J Heaped heght mm LL Dump out range at max. lftng heght L6 and dump out angle 45 mm Dump out range at max. lftng heght and dump out angle 45 mm L7 Overall length mm L9 Shuntng and towng couplng mm RR Max. dump out range. at dump out angle 45 mm Mult-purpose bucket open: D Dump out range at max. lftng heght and tlted bucket mm HH13 max. dump out heght wth tlted bucket mm MM Dump out range at max. lftng heght and tlted bucket mm Permssble loads correspondng to DIN are ncluded for purpose of comparson only. - Permssble loads correspondng to ISO 8313 are the actual loads. S150/S151/S152/Z

106 12 Techncal Data (Attachments) 12.2 Fork-lft attachment Measurements correspondng to ISO 7131/ S150/S151/S152/Z152

107 Techncal Data (Attachments) Fork-lft Attachment Tne lenght 1200 mm Tne heght 50 mm Dstance between tnes (from center) - mn. 340 mm - max mm Weght 310 kg Max. permssble load N accordng to DIN frontal - even ground (stablty factor 1,25) 4025 kg - uneven groung (stablty factor 1,67) 3020 kg swveled - even ground (stablty factor 1,25) 3945 kg - uneven ground (stablty factor 1,67) 2960 kg Max. permssble load N accordng to ISO 8313 frontal - even ground (stablty factor 1,25) 3750 kg - uneven ground (stablty factor 1,67) 2810 kg swveled - even ground (stablty factor 1,25) 3460 kg - uneven ground (stablty factor 1,67) 2595 kg Max. permssble load N accordng to ISO 8313, wth fork-lft 300 mm over ground frontal - even ground (stablty factor 1,25) 4460 kg - uneven ground (stablty factor 1,67) 3345 kg A2 Dump out angle 50 A5 Tlt n angle 25 B Mn. range 1020 mm C Max. range 1615 mm D Range at max. lftng heght 760 mm G Heaped heght at max. range 1750 mm H6 Cuttng depth 60 mm H7 Clearance to center lug (quck coupler) 765 mm H9 Clearance to center lug (quck coupler 3995 mm HH15 Heaped heght at max. range (top of fork tnes) 3735 mm KK Max. range 1110 mm LL Clearance between tres and load 1415 mm L1 Length 4615 mm L8 Overall length 7015 mm L9 Shuntng and towng couplng 125 mm L10 Clearance from tres to top of fork tnes (heght at top of fork tnes 300 mm) 2400 mm M Range (heght at top of fork tnes 300 mm) 1195 mm MM Range at max. lftng heght 305 mm PP Heaped heght mn. 780 mm - Permssble loads correspondng to DIN are ncluded for purpose of comparson only. - Permssble loads correspondng to ISO 8313 are the actual loads. S150/S151/S152/Z

108 12 Techncal Data (Attachments) 12.3 Front-end Loader Measurements accordng to ISO 7131/ S150/S151/S152/Z152

109 Techncal Data (Attachments) Front-end loader Breakout force at cuttng edge of bucket max. Curlng force at cuttng edge of bucket max dan 2830 dan Bucket volume Bucket wdth Net weght to DIN ISO 7451 to DIN ISO ,06 m³ 300 mm 65 kg 0,09 m³ 400 mm 75 kg 0,12 m³ 500 mm 90 kg 0,14 m³ 600 mm 95 kg 0,17 m³ 700 mm 105 kg Net weght - Front-end loader wthout bucket 435 kg D Max. dggng depth above cuttng edge accordng to DIN ISO mm E Penetraton./. mm HH22 Max. dump out heght accordng to DIN ISO mm HH24 Max. dggng depth above cuttng edge accordng to DIN ISO mm HH25 Penetraton 1170 mm Tmng values n engne max. : - Extend boom 0,9 s - Retract boom 1,8 s - Open bucket 0,9 s - Close bucket 1,8 s S150/S151/S152/Z

110 12 Techncal Data (Attachments) 12.4 Lftng Hook Dmensons accordng to ISO 7131/ S150/S151/S152/Z152

111 Techncal Data (Attachments) Lftng Hook Max. permssble load accordng to DIN EN (measurement analgous to ISO 8313) at maxmum reach (stablty factor 2) - frontal 1660 kg - swveled 1320 kg Net weght 230 kg A Total length 6515 mm CC Mn. reach 1895 mm DD Max. reach 3335 mm EE Max. reach at maxmum lftng heght 1785 mm FF Mn. lftng heght wth tlted quck coupler 1380 mm GG Lftng heght at max. reach 1670 mm HH Max. lftng heght 5145 mm KK Max. reach 2845 mm LL Mn. reach 2010 mm MM Max. reach at maxmum lftng 1260 mm PP Lftng heght at mn. reach 2515 mm S150/S151/S152/Z

112 Optonal Extras, Changes

113 13 Optonal Extras, Changes 13 Optonal extras, changes, certfcatons for wheel loader 13.1 Optonal extras Descrpton (Chapter 4) Ppe Burst Protecton A ppe burst protecton valve s ftted at the ground sde of lftng and tltng cylnders. In case of rod or ppe burst n the lftng or lftng/tltng subsystem, any movement of the loader arm or tltng mechansm s nterrupted untl the problem s solved. ATTENTION Actvatng loader arm cushonng dsables the ppe burst protecton mechansm Lft Lmter A devce mounted at the jont between the bucket assembly and the swvel assembly allows you to lmt the maxmum lftng heght. Setup: (1) Lft the loader arm to the requred heght. (2) Swtch off the engne and close the stop valves for man and auxlary hydraulcs (1-2/arrows). (3) Loosen the hexagonal bolts (SW 10) (13-1/3) on the gear gate assembly and rotate the gate (13-1/2) aganst the roller gage (13-1/1) untl you hear the gate shft. Fg (4) Re-tghten the hexagonal bolts on the gear gate assembly. DANGER Perform a functonal check before startng a job that requres the lft lmter, and whle workng perform a vsual check whle seated n the drver s seat Servce Interval Dsplay (4-8/30) The servce nterval dsplay lghts up : ntally after then every 50 hours 500 hours 13.2 Changes 13-2 S150/S151/S152/Z152