ahlmann AL 65 User manual

Ahlmann Baumaschinen GmbH
D-24782 Büdelsdorf Telefon [phone]
Am Friedrichsbrunnen 2 Telefax 04331/351404
Ahlmann Baumaschinen GmbH
D-24782 Büdelsdorf Telefon [phone]
Am Friedrichsbrunnen 2 Telefax 04331/351404
AL 65/75/95
AL 65/75/95
1004319A
OPERATINGINSTRUCTIONS
ARTICULATED-LOADER
GB1004319A GB
OPERATINGINSTRUCTIONS
ARTICULATED-LOADER

K65C/K75C/K95C I K65C/K75C/K95C I
Introduction
Preface
Ahlmann’sswivelshovelloaders,articulatedloadersandloaderexcavators
with backhoe are machines included in Ahlmann’s vast product range
covering a wide variety of working tasks.
Decades of experience in the construction of earth-moving machines, the
widerangeofattachmentsavailableaswellasmodernproductionfacilities,
careful testing and highest quality demands guarantee the highest degree
of reliability of your Ahlmann machine.
The extent of documentation delivered by the manufacturer includes the
following:
- Loader operating instructions
- Engine operating instructions
- Loader spare parts list
- Engine spare parts list
- EC conformity declaration
Operating instructions
The operating instructions contain all the information which the user
requires for operation and maintenance.
Inthe“Maintenance”section,allmaintenanceworkandoperationtestsare
described which can be carried out by trained personnel.
Repairs on a larger scale which may only be carried out by specialised
personnel or by personnel authorised and trained by the manufacturer, in
particularonthoseunitssubjecttotheMotorVehicle ConstructionandUse
Regulations and the Regulations for the Prevention of Accidents, are not
described.
Due to the construction modifications reserved by the manufacturer, there
may be differences in the figures; however, this has no influence on the
technical contents.
Introduction
Preface
Ahlmann’sswivelshovelloaders,articulatedloadersandloaderexcavators
with backhoe are machines included in Ahlmann’s vast product range
covering a wide variety of working tasks.
Decades of experience in the construction of earth-moving machines, the
widerangeofattachmentsavailableaswellasmodernproductionfacilities,
careful testing and highest quality demands guarantee the highest degree
of reliability of your Ahlmann machine.
The extent of documentation delivered by the manufacturer includes the
following:
- Loader operating instructions
- Engine operating instructions
- Loader spare parts list
- Engine spare parts list
- EC conformity declaration
Operating instructions
The operating instructions contain all the information which the user
requires for operation and maintenance.
Inthe“Maintenance”section,allmaintenanceworkandoperationtestsare
described which can be carried out by trained personnel.
Repairs on a larger scale which may only be carried out by specialised
personnel or by personnel authorised and trained by the manufacturer, in
particularonthoseunitssubjecttotheMotorVehicle ConstructionandUse
Regulations and the Regulations for the Prevention of Accidents, are not
described.
Due to the construction modifications reserved by the manufacturer, there
may be differences in the figures; however, this has no influence on the
technical contents.

II K65C/K75C/K95C II K65C/K75C/K95C
How to handle this manual
Explanations
- Thedesignations “left” and“right” are to be seen from thedriver’sseat
in driving direction.
- Optional equipment means: not fitted in series.
Information about illustrations
- (3-35)
means: chapter 3, fig. 35
- (3-35/1)
means: chapter 3, fig. 35, item 1
- (3-35/arrow)
means: chapter 3, fig. 35,
Abbreviations used:
UVV = Unfallverhütungsvorschrift
(Accident Prevention Regulations)
StVZO= Straßenverkehrzulassungsordnung
(German Traffic Regulations)
opt. = optional equipment
Edition: 06.98
Print: 04.99
How to handle this manual
Explanations
- Thedesignations “left” and “right” are tobeseenfromthe driver’s seat
in driving direction.
- Optional equipment means: not fitted in series.
Information about illustrations
- (3-35)
means: chapter 3, fig. 35
- (3-35/1)
means: chapter 3, fig. 35, item 1
- (3-35/arrow)
means: chapter 3, fig. 35,
Abbreviations used:
UVV = Unfallverhütungsvorschrift
(Accident Prevention Regulations)
StVZO= Straßenverkehrzulassungsordnung
(German Traffic Regulations)
opt. = optional equipment
Edition: 06.98
Print: 04.99

K65C/K75C/K95C III K65C/K75C/K95C III
Table of contents
1 Fundamental safety instructions 1 - 1
1.1 Warnings and symbols 1 - 1
1.2 Use of the loader as authorized 1 - 1
1.3 Organizational measures 1 - 2
1.4 Selection of personnel and necessary qualification 1 - 4
1.5 Safety information for certain operating phases 1 - 5
1.5.1 Normal operation 1 - 5
1.5.2 Special work within the exploitation of the machine and
elimination of defects during process of work; disposal 1 -10
1.6 Instructions regarding special categories 1 -14
1.6.1 Electrical energy 1 -14
1.6.2 Hydraulic systems 1 -16
1.6.3 Noise 1 -16
1.6.4 Oil, grease and other chemical substances 1 -17
1.6.5 Gas, dust, steam, smoke 1 -17
1.7 Transport and towing; restart 1 -18
1.8 Safety information for the contractor or the contractor’s
authorized personnel 1 -19
1.8.1 Organizational measures 1 -19
1.8.2 Selection of personnel and necessary qualification;
additional duties 1 -19
2 Signs 2 - 1
2.1 Warning and information signs 2 - 1
2.2 Fuses 2 - 2
2.3 Symbols 2 - 3
3 Technical data 3 - 1
3.1 AL 65 3 - 1
3.1.1 Machine 3 - 1
3.1.2 Engine 3 - 1
3.1.3 Starter 3 - 1
3.1.4 Alternator 3 - 1
3.1.5 Hydrostatic traction drive 3 - 1
3.1.6 Axle loads 3 - 2
3.1.7 Tires 3 - 2
3.1.8 Steering system 3 - 2
3.1.9 Brake system 3 - 2
3.1.10 Electrical system 3 - 2
3.1.11 Hydraulic system 3 - 3
3.1.12 Fuel supply system 3 - 3
Table of contents
1 Fundamental safety instructions 1 - 1
1.1 Warnings and symbols 1 - 1
1.2 Use of the loader as authorized 1 - 1
1.3 Organizational measures 1 - 2
1.4 Selection of personnel and necessary qualification 1 - 4
1.5 Safety information for certain operating phases 1 - 5
1.5.1 Normal operation 1 - 5
1.5.2 Special work within the exploitation of the machine and
elimination of defects during process of work; disposal 1 -10
1.6 Instructions regarding special categories 1 -14
1.6.1 Electrical energy 1 -14
1.6.2 Hydraulic systems 1 -16
1.6.3 Noise 1 -16
1.6.4 Oil, grease and other chemical substances 1 -17
1.6.5 Gas, dust, steam, smoke 1 -17
1.7 Transport and towing; restart 1 -18
1.8 Safety information for the contractor or the contractor’s
authorized personnel 1 -19
1.8.1 Organizational measures 1 -19
1.8.2 Selection of personnel and necessary qualification;
additional duties 1 -19
2 Signs 2 - 1
2.1 Warning and information signs 2 - 1
2.2 Fuses 2 - 2
2.3 Symbols 2 - 3
3 Technical data 3 - 1
3.1 AL 65 3 - 1
3.1.1 Machine 3 - 1
3.1.2 Engine 3 - 1
3.1.3 Starter 3 - 1
3.1.4 Alternator 3 - 1
3.1.5 Hydrostatic traction drive 3 - 1
3.1.6 Axle loads 3 - 2
3.1.7 Tires 3 - 2
3.1.8 Steering system 3 - 2
3.1.9 Brake system 3 - 2
3.1.10 Electrical system 3 - 2
3.1.11 Hydraulic system 3 - 3
3.1.12 Fuel supply system 3 - 3

IV K65C/K75C/K95C IV K65C/K75C/K95C
3.1.13 Heating and ventilation system 3 - 3
3.1.14 Return-flow suction filter 3 - 3
3.1.15 Electrical contamination indicator 3 - 3
3.1.16 Oil cooler with temperature-controlled fan 3 - 3
3.2 AL 75 3 - 4
3.2.1 Machine 3 - 4
3.2.2 Engine 3 - 4
3.2.3 Starter 3 - 4
3.2.4 Alternator 3 - 4
3.2.5 Hydrostatic traction drive 3 - 4
3.2.6 Axle loads 3 - 5
3.2.7 Tires 3 - 5
3.2.8 Steering system 3 - 5
3.2.9 Brake system 3 - 5
3.2.10 Electrical system 3 - 5
3.2.11 Hydraulic system 3 - 6
3.2.12 Fuel supply system 3 - 6
3.2.13 Heating and ventilation system 3 - 6
3.2.14 Return-flow suction filter 3 - 6
3.2.15 Electrical contamination indicator 3 - 6
3.2.16 Oil cooler with temperature-controlled fan 3 - 6
3.3 AL 95 3 - 7
3.3.1 Machine 3 - 7
3.3.2 Engine 3 - 7
3.3.3 Starter 3 - 7
3.3.4 Alternator 3 - 7
3.3.5 Hydrostatic traction drive 3 - 7
3.3.6 Axle loads 3 - 8
3.3.7 Tires 3 - 8
3.3.8 Steering system 3 - 8
3.3.9 Brake system 3 - 8
3.3.10 Electrical system 3 - 8
3.3.11 Hydraulic system 3 - 9
3.3.12 Fuel supply system 3 - 9
3.3.13 Heating and ventilation system 3 - 9
3.3.14 Return-flow suction filter 3 - 9
3.3.15 Electrical contamination indicator 3 - 9
3.3.16 Oil cooler with temperature-controlled fan 3 - 9
3.4 Attachments AL 65 3 -10
3.4.1 Buckets 3 -10
3.4.2 Fork-lift attachment 3 -12
3.4.3 Lifting hook 3 -12
3.5 Attachments AL 75 3 -14
3.5.1 Buckets 3 -14
3.1.13 Heating and ventilation system 3 - 3
3.1.14 Return-flow suction filter 3 - 3
3.1.15 Electrical contamination indicator 3 - 3
3.1.16 Oil cooler with temperature-controlled fan 3 - 3
3.2 AL 75 3 - 4
3.2.1 Machine 3 - 4
3.2.2 Engine 3 - 4
3.2.3 Starter 3 - 4
3.2.4 Alternator 3 - 4
3.2.5 Hydrostatic traction drive 3 - 4
3.2.6 Axle loads 3 - 5
3.2.7 Tires 3 - 5
3.2.8 Steering system 3 - 5
3.2.9 Brake system 3 - 5
3.2.10 Electrical system 3 - 5
3.2.11 Hydraulic system 3 - 6
3.2.12 Fuel supply system 3 - 6
3.2.13 Heating and ventilation system 3 - 6
3.2.14 Return-flow suction filter 3 - 6
3.2.15 Electrical contamination indicator 3 - 6
3.2.16 Oil cooler with temperature-controlled fan 3 - 6
3.3 AL 95 3 - 7
3.3.1 Machine 3 - 7
3.3.2 Engine 3 - 7
3.3.3 Starter 3 - 7
3.3.4 Alternator 3 - 7
3.3.5 Hydrostatic traction drive 3 - 7
3.3.6 Axle loads 3 - 8
3.3.7 Tires 3 - 8
3.3.8 Steering system 3 - 8
3.3.9 Brake system 3 - 8
3.3.10 Electrical system 3 - 8
3.3.11 Hydraulic system 3 - 9
3.3.12 Fuel supply system 3 - 9
3.3.13 Heating and ventilation system 3 - 9
3.3.14 Return-flow suction filter 3 - 9
3.3.15 Electrical contamination indicator 3 - 9
3.3.16 Oil cooler with temperature-controlled fan 3 - 9
3.4 Attachments AL 65 3 -10
3.4.1 Buckets 3 -10
3.4.2 Fork-lift attachment 3 -12
3.4.3 Lifting hook 3 -12
3.5 Attachments AL 75 3 -14
3.5.1 Buckets 3 -14

K65C/K75C/K95C V K65C/K75C/K95C V
3.5.2 Fork-lift attachment 3 -16
3.5.3 Lifting hook 3 -16
3.6 Attachments AL 95 3 -18
3.6.1 Buckets 3 -18
3.6.2 Fork-lift attachment 3 -20
3.6.3 Lifting hook 3 -20
4 Description 4 - 1
4.1 Overview 4 - 1
4.2 Loader 4 - 2
4.3 Changing a wheel 4 - 8
4.4 Controls 4 -10
4.5 Instrument panel 4 -11
5 Operation 5 - 1
5.1 Checks before start-up 5 - 1
5.2 Starting up 5 - 1
5.2.1 Starting the diesel engine 5 - 1
5.2.2 Winter operation 5 - 2
5.2.2.1 Fuel 5 - 2
5.2.2.2 Changing the engine oil 5 - 3
5.2.2.3 Changing the oil in the hydraulic system 5 - 3
5.2.2.4 Anti-freezing agent for the windshield washer system 5 - 4
5.2.3 Driving the loader on public roads 5 - 4
5.2.4 Working with the loader 5 - 6
5.2.5 Heating and ventilation system 5 - 8
5.2.5.1 Adjusting the amount of air 5 - 8
5.2.5.2 Switching on the heater 5 - 8
5.3 Stopping loader operation 5 - 9
5.3.1 Parking the loader 5 - 9
5.3.2 Switching off the diesel engine 5 - 9
5.3.3 Switching off the heating and ventilation system 5 -10
5.3.4 Leaving the loader 5 -10
5.4 Adjusting the operator's seat 5 -10
6 Attachments 6 - 1
6.1 Mounting and dismounting attachments
without hydraulic connections 6 - 1
6.1.1 Standard/lightweight bucket 6 - 1
6.1.2 Fork-lift attachment 6 - 2
6.1.3 Lifting hook 6 - 3
6.2 Mounting and dismounting attachments
with a hydraulic connection 6 - 4
6.2.1 Multi-purpose bucket 6 - 4
6.3 Using other attachments 6 - 7
3.5.2 Fork-lift attachment 3 -16
3.5.3 Lifting hook 3 -16
3.6 Attachments AL 95 3 -18
3.6.1 Buckets 3 -18
3.6.2 Fork-lift attachment 3 -20
3.6.3 Lifting hook 3 -20
4 Description 4 - 1
4.1 Overview 4 - 1
4.2 Loader 4 - 2
4.3 Changing a wheel 4 - 8
4.4 Controls 4 -10
4.5 Instrument panel 4 -11
5 Operation 5 - 1
5.1 Checks before start-up 5 - 1
5.2 Starting up 5 - 1
5.2.1 Starting the diesel engine 5 - 1
5.2.2 Winter operation 5 - 2
5.2.2.1 Fuel 5 - 2
5.2.2.2 Changing the engine oil 5 - 3
5.2.2.3 Changing the oil in the hydraulic system 5 - 3
5.2.2.4 Anti-freezing agent for the windshield washer system 5 - 4
5.2.3 Driving the loader on public roads 5 - 4
5.2.4 Working with the loader 5 - 6
5.2.5 Heating and ventilation system 5 - 8
5.2.5.1 Adjusting the amount of air 5 - 8
5.2.5.2 Switching on the heater 5 - 8
5.3 Stopping loader operation 5 - 9
5.3.1 Parking the loader 5 - 9
5.3.2 Switching off the diesel engine 5 - 9
5.3.3 Switching off the heating and ventilation system 5 -10
5.3.4 Leaving the loader 5 -10
5.4 Adjusting the operator's seat 5 -10
6 Attachments 6 - 1
6.1 Mounting and dismounting attachments
without hydraulic connections 6 - 1
6.1.1 Standard/lightweight bucket 6 - 1
6.1.2 Fork-lift attachment 6 - 2
6.1.3 Lifting hook 6 - 3
6.2 Mounting and dismounting attachments
with a hydraulic connection 6 - 4
6.2.1 Multi-purpose bucket 6 - 4
6.3 Using other attachments 6 - 7

VI K65C/K75C/K95C VI K65C/K75C/K95C
7 Rescue, towing, lashing, lifting by crane 7 - 1
7.1 Rescue, towing, lashing 7 - 1
7.1.1 Rescue/towing of the articulated loader
if the engine or drive has failed 7 - 1
7.1.1.1 Towing the articulated loader if the engine has failed 7 - 2
7.1.1.2 Towing the articulated loader if the drive has failed 7 - 5
7.2 Lifting by crane 7 - 7
8 Maintenance (maintenance plan) 8 - 1
8.1 Notes regarding maintenance 8 - 1
8.2 Maintenance work 8 - 2
8.2.1 Checking the engine oil level 8 - 2
8.2.2 Changing the engine oil 8 - 2
8.2.3 Replacing the fuel prefilter 8 - 2
8.2.4 Maintaining/replacing the air filter 8 - 3
8.2.5 Replacing the safety cartridge 8 - 5
8.2.6 Checking the oil level in the front axle 8 - 5
8.2.7 Changing the oil in the front axle 8 - 6
8.2.8 Checking the oil level in the rear axle 8 - 7
8.2.8.1 Slow loader » 20 km/h « 8 - 7
8.2.8.2 Fast loader » 30 km/h « 8 - 7
8.2.9 Changing the oil in the rear axle 8 - 8
8.2.9.1 Slow loader » 20 km/h « 8 - 8
8.2.9.2 Rear axle of the fast loader » 30 km/h « 8 - 9
8.2.10 Checking the oil level in the planetary gear 8 -11
8.2.11 Changing the oil in the planetary gear 8 -11
8.2.12 Changing the oil in the hydraulic system 8 -12
8.2.13 Replacing the hydraulic oil filter insert 8 -13
8.2.14 Lubrication points 8 -14
8.2.14.1 Door of the driver's cabin 8 -14
8.2.14.2 Engine hood 8 -14
8.2.14.3 Multi-purpose bucket 8 -14
8.2.15 Replacing the starter battery 8 -15
8.2.16 Checking/adjusting the service/parking brake 8 -16
8.2.17 Maintaining/replacing the fresh air filter 8 -17
9 Malfunctions, causes and remedies 9 - 1
10 Protection against theft 10 - 1
10.1 Identifying features on the loader 10 - 1
10.2 Parking the loader 10 - 1
10.3 Transponder for drive-away interlock 10 - 2
7 Rescue, towing, lashing, lifting by crane 7 - 1
7.1 Rescue, towing, lashing 7 - 1
7.1.1 Rescue/towing of the articulated loader
if the engine or drive has failed 7 - 1
7.1.1.1 Towing the articulated loader if the engine has failed 7 - 2
7.1.1.2 Towing the articulated loader if the drive has failed 7 - 5
7.2 Lifting by crane 7 - 7
8 Maintenance (maintenance plan) 8 - 1
8.1 Notes regarding maintenance 8 - 1
8.2 Maintenance work 8 - 2
8.2.1 Checking the engine oil level 8 - 2
8.2.2 Changing the engine oil 8 - 2
8.2.3 Replacing the fuel prefilter 8 - 2
8.2.4 Maintaining/replacing the air filter 8 - 3
8.2.5 Replacing the safety cartridge 8 - 5
8.2.6 Checking the oil level in the front axle 8 - 5
8.2.7 Changing the oil in the front axle 8 - 6
8.2.8 Checking the oil level in the rear axle 8 - 7
8.2.8.1 Slow loader » 20 km/h « 8 - 7
8.2.8.2 Fast loader » 30 km/h « 8 - 7
8.2.9 Changing the oil in the rear axle 8 - 8
8.2.9.1 Slow loader » 20 km/h « 8 - 8
8.2.9.2 Rear axle of the fast loader » 30 km/h « 8 - 9
8.2.10 Checking the oil level in the planetary gear 8 -11
8.2.11 Changing the oil in the planetary gear 8 -11
8.2.12 Changing the oil in the hydraulic system 8 -12
8.2.13 Replacing the hydraulic oil filter insert 8 -13
8.2.14 Lubrication points 8 -14
8.2.14.1 Door of the driver's cabin 8 -14
8.2.14.2 Engine hood 8 -14
8.2.14.3 Multi-purpose bucket 8 -14
8.2.15 Replacing the starter battery 8 -15
8.2.16 Checking/adjusting the service/parking brake 8 -16
8.2.17 Maintaining/replacing the fresh air filter 8 -17
9 Malfunctions, causes and remedies 9 - 1
10 Protection against theft 10 - 1
10.1 Identifying features on the loader 10 - 1
10.2 Parking the loader 10 - 1
10.3 Transponder for drive-away interlock 10 - 2

Safety regulations

K65C/K75C/K95C 1-1 K65C/K75C/K95C 1-1
1 Fundamental
safety instruction
1.1 Warningsandsymbols
In this operation manual the follo-
wing designations or symbols are
used for important information.
NOTE
Special information for the econo-
mical use of the machine.
CAUTION
Special information for necessities
and prohibitions for avoiding
damages.
DANGER
Information or necessities and pro-
hibitions for prevention of damage
to persons or extensive damage to
goods.
1.2 Use of the loader as
authorized
1.2.1 This machine was designed
according to the state of the art and
recognized safety rules. Never-
theless the use of the machine may
cause danger for the user or third
parties or impairments to the
machine or other real values.
1 Fundamental
safety instruction
1.1 Warningsandsymbols
In this operation manual the follo-
wing designations or symbols are
used for important information.
NOTE
Special information for the econo-
mical use of the machine.
CAUTION
Special information for necessities
and prohibitions for avoiding
damages.
DANGER
Information or necessities and pro-
hibitions for prevention of damage
to persons or extensive damage to
goods.
1.2 Use of the loader as
authorized
1.2.1 This machine was designed
according to the state of the art and
recognized safety rules. Never-
theless the use of the machine may
cause danger for the user or third
parties or impairments to the
machine or other real values.

1-2 K65C/K75C/K95C 1-2 K65C/K75C/K95C
1.2.2 The machine and attach-
mentsmayonlybeusedinatechnical
non-objectionable condition, taking
all safety regulations especially with
regard to the operating manuals
(machine and engine). In particular
defects which could have a
detrimentaleffectonthesafetyofthe
machine should be eliminated
immediately.
1.2.3 The machine is determined
exclusively for the purposes
described in this operating manual.
Any other utilization is not permitted.
The manufacturer is not liable for
any damage caused in this
connection. The user solely carries
the risk.
The authorized use of the machine
also requires the observation of the
operating manual (machine and
engine) as well as the observation of
the inspection and maintenance
conditions.
1.3 Organizational measures
1.3.1 The operating manual
(machine and engine) must be
available at all times and at the site
where the machine is in operating
condition.
1.3.2 In addition to the operating
manual (machine and engine) the
generalapplicable and other binding
regulations for the prevention of
accidents (especially the safety
regulations of the German Trade
Association - VBG 40) as well as the
regulations for environment
protectionmustbeobserved and the
personnel must be accordingly.
Traffic regulations must also be
observed.
1.2.2 The machine and attach-
mentsmayonlybeusedinatechnical
non-objectionable condition, taking
all safety regulations especially with
regard to the operating manuals
(machine and engine). In particular
defects which could have a
detrimentaleffectonthesafetyofthe
machine should be eliminated
immediately.
1.2.3 The machine is determined
exclusively for the purposes
described in this operating manual.
Any other utilization is not permitted.
The manufacturer is not liable for
any damage caused in this
connection. The user solely carries
the risk.
The authorized use of the machine
also requires the observation of the
operating manual (machine and
engine) as well as the observation of
the inspection and maintenance
conditions.
1.3 Organizational measures
1.3.1 The operating manual
(machine and engine) must be
available at all times and at the site
where the machine is in operating
condition.
1.3.2 In addition to the operating
manual (machine and engine) the
generalapplicable and other binding
regulations for the prevention of
accidents (especially the safety
regulations of the German Trade
Association - VBG 40) as well as the
regulations for environment
protectionmustbeobserved and the
personnel must be accordingly.
Traffic regulations must also be
observed.

K65C/K75C/K95C 1-3 K65C/K75C/K95C 1-3
1.3.3 The personnel in charge of
workingwiththemachinemustread
theoperatingmanual(machineand
engine) before start of work,
especially the chapter concerning
safety precautions.
This also applies to personnel
working occasionally with the
machine, e.g. during maintenance
work.
1.3.4 The driver must wear a seat
belt during operation.
1.3.5 Personnel working with the
machine must not wear long
flowing hair, loose clothing or
jewelryincluding rings asthiscould
cause injuries by getting caught up
or pulled in by the machine.
1.3.6 All safety and danger plates
on the machine must be observed.
1.3.7 All safety and danger plates
must be attached to the machine
and must be kept in legible
condition.
1.3.8 In case of modifications to
the machine, especially in case of
damages or changes in the
operating behavior of the machine
which could influence the safety of
the machine, stop the machine
immediately and inform the
competent person in charge about
the incident.
1.3.3 The personnel in charge of
workingwiththemachinemustread
theoperatingmanual(machineand
engine) before start of work,
especially the chapter concerning
safety precautions.
This also applies to personnel
working occasionally with the
machine, e.g. during maintenance
work.
1.3.4 The driver must wear a seat
belt during operation.
1.3.5 Personnel working with the
machine must not wear long
flowing hair, loose clothing or
jewelryincluding rings asthiscould
cause injuries by getting caught up
or pulled in by the machine.
1.3.6 All safety and danger plates
on the machine must be observed.
1.3.7 All safety and danger plates
must be attached to the machine
and must be kept in legible
condition.
1.3.8 In case of modifications to
the machine, especially in case of
damages or changes in the
operating behavior of the machine
which could influence the safety of
the machine, stop the machine
immediately and inform the
competent person in charge about
the incident.

1-4 K65C/K75C/K95C 1-4 K65C/K75C/K95C
1.3.9 Without the manufacturer’s
consent, do not make any
modifications or conversions to the
machine which could affect safety.
This also applies to the installation
and adjustment of safety devices,
valves and welding work to
supporting parts.
1.3.10 Check hydraulic system,
especially hydraulic pipes, at
regular intervals for defects.
Immediately eliminate any defects
found.
1.3.11 The prescribed inspection
periods set down in the operating
manual (machine and engine) and
the maintenance plan must be
observed.
1.4 Selection of personnel
and necessary qualifications
Fundamental obligations
1.4.1 The machine may only be
drivenandmaintainedbypersonnel
selected by the employer for this
purpose.
These persons must:
- haveattainedtheageof18years,
- be physically and intellectually
suitable,
- have been instructed in the
operation or maintenance of the
machine and must have demon-
strated their ability to their em-
ployer,
- mustbeexpectedtocarryoutthe
workconveyedtothemindiligent
manner.
1.3.9 Without the manufacturer’s
consent, do not make any
modifications or conversions to the
machine which could affect safety.
This also applies to the installation
and adjustment of safety devices,
valves and welding work to
supporting parts.
1.3.10 Check hydraulic system,
especially hydraulic pipes, at
regular intervals for defects.
Immediately eliminate any defects
found.
1.3.11 The prescribed inspection
periods set down in the operating
manual (machine and engine) and
the maintenance plan must be
observed.
1.4 Selection of personnel
and necessary qualifications
Fundamental obligations
1.4.1 The machine may only be
drivenandmaintainedbypersonnel
selected by the employer for this
purpose.
These persons must:
- haveattainedtheageof18years,
- be physically and intellectually
suitable,
- have been instructed in the
operation or maintenance of the
machine and must have demon-
strated their ability to their em-
ployer,
- mustbeexpectedtocarryoutthe
workconveyedtothemindiligent
manner.

K65C/K75C/K95C 1-5 K65C/K75C/K95C 1-5
1.4.2 Electrical work on the
machinemayonlybecarriedoutby
a qualified electrician or persons
supervisedbyaqualifiedelectrician
according to the electrotechnical
regulations.
1.4.3 Only qualified specialists
may carry out work on the trans-
mission mechanism and to the
hydraulic system.
1.4.4 Only personnel with special
experience and the necessary
know-how are permitted to carry
out work on the hydraulic system.
1.5 Safety Information for
Certain Operating Phases
1.5.1 Normal Operation
1.5.1.1 Other persons must not
be transported!
1.5.1.2 Start and drive the
machinefromthedriver’sseatonly!
1.5.1.3 During starting and
switching-offoperationobservethe
control lamps according to the
operation manual (machine and
engine)!
1.5.1.4 Before commencing
work/drivingcheckbrakes,steering,
signal lights and lights for their
functioning!
1.5.1.5 Before moving the
machine always check that the
attachments are safely stowed so
that no accident may occur!
1.4.2 Electrical work on the
machinemayonlybecarriedoutby
a qualified electrician or persons
supervisedbyaqualifiedelectrician
according to the electrotechnical
regulations.
1.4.3 Only qualified specialists
may carry out work on the trans-
mission mechanism and to the
hydraulic system.
1.4.4 Only personnel with special
experience and the necessary
know-how are permitted to carry
out work on the hydraulic system.
1.5 Safety Information for
Certain Operating Phases
1.5.1 Normal Operation
1.5.1.1 Other persons must not
be transported!
1.5.1.2 Start and drive the
machinefromthedriver’sseatonly!
1.5.1.3 During starting and
switching-offoperationobservethe
control lamps according to the
operation manual (machine and
engine)!
1.5.1.4 Before commencing
work/drivingcheckbrakes,steering,
signal lights and lights for their
functioning!
1.5.1.5 Before moving the
machine always check that the
attachments are safely stowed so
that no accident may occur!

1-6 K65C/K75C/K95C 1-6 K65C/K75C/K95C
1.5.1.6 Beforecommencingwork
make yourself familiar with the
working environment. This means
observingobstaclesontheworking
site, quality and resistance of the
soil ground, undertaking the
necessary protection precautions
between the building site and the
public traffic.
1.5.1.7 Before starting the
machine make sure that no person
is endangered by the machine!
1.5.1.8 Take measures so that
the machine can be operated in a
safe and functional manner. The
machine may only be operated
when all safety devices, e. g.
detachable safety devices, sound-
absorption, exist and function.
1.5.1.9 Avoidanyworkoperation
which appears to be dangerous!
1.5.1.10 Persons must not be
carried in the working equipment,
e.g.in the attachments!
1.5.1.11 The operator may only
carry out work with the machine
when no persons are in the danger
zone. The danger zone means that
area near the machine where
persons may be injured
- by work-induced movements of
the machine,
- byworkattachmentsanddevices,
- by loads swiveling out,
- by loads falling down,
- byattachments falling downfrom
the machine.
1.5.1.6 Beforecommencingwork
make yourself familiar with the
working environment. This means
observingobstaclesontheworking
site, quality and resistance of the
soil ground, undertaking the
necessary protection precautions
between the building site and the
public traffic.
1.5.1.7 Before starting the
machine make sure that no person
is endangered by the machine!
1.5.1.8 Take measures so that
the machine can be operated in a
safe and functional manner. The
machine may only be operated
when all safety devices, e. g.
detachable safety devices, sound-
absorption, exist and function.
1.5.1.9 Avoidanyworkoperation
which appears to be dangerous!
1.5.1.10 Persons must not be
carried in the working equipment,
e.g.in the attachments!
1.5.1.11 The operator may only
carry out work with the machine
when no persons are in the danger
zone. The danger zone means that
area near the machine where
persons may be injured
- by work-induced movements of
the machine,
- byworkattachmentsanddevices,
- by loads swiveling out,
- by loads falling down,
- byattachments falling downfrom
the machine.

K65C/K75C/K95C 1-7 K65C/K75C/K95C 1-7
1.5.1.12 In case of danger to
persons the operator must give
appropriate warning signs. It may
be necessary to stop work.
1.5.1.13 In case of functional
defects stop machine immediately
and safeguard it. Eliminate defects
immediately!
1.5.1.14 Check machine at least
once every shift for external visible
damage and defects with regard to
any changes and to the operating
behavior of the engine. Report any
defects or changes immediately to
the person in charge. If necessary
stop the machine immediately and
safeguard it.
1.5.1.15 The driver may only slew
the attachments overhead driving,
operatingandworkingareasifthese
areas are suitably safeguarded by
protectiveroofing.Theseprotection
roofs must offer appropriate safety
against loads and goods falling
down.
1.5.1.16 Whendriving, the attach-
ment is to be kept as close to the
ground as possible.
1.5.1.17 Please observe the
applicable traffic regulations when
driving on public roads, paths or
open spaces. The machine must
be brought into road-worthy
condition in beforehand.
1.5.1.18 In general, switch on
lights in poor visibility and during
darkness.
1.5.1.19 If lights of the machine
are not adequate for the safe
execution of certain work, additio-
nal lighting must be provided on
the working site, especially at
dumping points.
1.5.1.12 In case of danger to
persons the operator must give
appropriate warning signs. It may
be necessary to stop work.
1.5.1.13 In case of functional
defects stop machine immediately
and safeguard it. Eliminate defects
immediately!
1.5.1.14 Check machine at least
once every shift for external visible
damage and defects with regard to
any changes and to the operating
behavior of the engine. Report any
defects or changes immediately to
the person in charge. If necessary
stop the machine immediately and
safeguard it.
1.5.1.15 The driver may only slew
the attachments overhead driving,
operatingandworkingareasifthese
areas are suitably safeguarded by
protectiveroofing.Theseprotection
roofs must offer appropriate safety
against loads and goods falling
down.
1.5.1.16 Whendriving, the attach-
ment is to be kept as close to the
ground as possible.
1.5.1.17 Please observe the
applicable traffic regulations when
driving on public roads, paths or
open spaces. The machine must
be brought into road-worthy
condition in beforehand.
1.5.1.18 In general, switch on
lights in poor visibility and during
darkness.
1.5.1.19 If lights of the machine
are not adequate for the safe
execution of certain work, additio-
nal lighting must be provided on
the working site, especially at
dumping points.

1-8 K65C/K75C/K95C 1-8 K65C/K75C/K95C
1.5.1.20 Should the driver’s sight
of his driving and working area be
restricted due to work-induced
influences, he must be given
guidance or he must safeguard the
working area by a firm barrier.
1.5.1.21 The person giving
guidancemust be a reliable person
and must be informed about his
tasks before commencement of
the work.
1.5.1.22 Thedriverandguidemust
agree on signals for commu-
nication. These signals may only
be given by the driver and guide.
1.5.1.23 The guide must be easily
recognizable e.g. by wearing
warning clothing and must always
be in the driver’s field of vision.
1.5.1.24 When passing subways,
bridges, tunnels, electrical over-
head lines make sure that there is
adequate clearance!
1.5.1.25 Keep good clearance
when working at the edge of
quarries, pits, rubbish dumps and
embankments to eliminate any
danger of the machine plunging
down. The contractor or his deputy
must stipulate the distance from
the edge taking the soil bearing
capacity into consideration.
1.5.1.26 The machine may only
beusedatstationarydumpingareas
when firmly integrated installation
areprovidedtopreventthemachine
from running or sliding down.
1.5.1.20 Should the driver’s sight
of his driving and working area be
restricted due to work-induced
influences, he must be given
guidance or he must safeguard the
working area by a firm barrier.
1.5.1.21 The person giving
guidancemust be a reliable person
and must be informed about his
tasks before commencement of
the work.
1.5.1.22 Thedriverandguidemust
agree on signals for commu-
nication. These signals may only
be given by the driver and guide.
1.5.1.23 The guide must be easily
recognizable e.g. by wearing
warning clothing and must always
be in the driver’s field of vision.
1.5.1.24 When passing subways,
bridges, tunnels, electrical over-
head lines make sure that there is
adequate clearance!
1.5.1.25 Keep good clearance
when working at the edge of
quarries, pits, rubbish dumps and
embankments to eliminate any
danger of the machine plunging
down. The contractor or his deputy
must stipulate the distance from
the edge taking the soil bearing
capacity into consideration.
1.5.1.26 The machine may only
beusedatstationarydumpingareas
when firmly integrated installation
areprovidedtopreventthemachine
from running or sliding down.

K65C/K75C/K95C 1-9 K65C/K75C/K95C 1-9
1.5.1.27 Avoid such work which
could have detrimental effect on
the stability of the machine.
The stability can be detrimented
by:
- overloading,
- too soft ground,
- abrupt acceleration or decelera-
tion of driving movement or
working movement,
- reversing out of high driving
speed,
- working on slopes,
- driving too quickly round sharp
bends,
- driving the machine on rough
terrain.
1.5.1.28 Donotdrivealongslopes
in traverse direction. Always carry
working equipment and loads near
theground,especiallywhendriving
down slopes. Sudden cornering is
forbidden!
1.5.1.29 On steep inclines and
gradients, the load is to be carried
on the uphill side.
1.5.1.30 Always adapt the speed
ofthemachinetotheenvironmental
conditions when driving down
slopes!Neverchangeintolowgear
when driving on slopes but before
entering the slope!
1.5.1.31 Reversing over a longer
period must be avoided!
1.5.1.32 When leaving the
machine always safeguard the
machine to prevent it from
unintentionally rolling away or
prevent non-authorized persons
from using it!
1.5.1.33 Thedrivermustnotleave
the machine if the attachments are
not lowered or safeguarded.
1.5.1.27 Avoid such work which
could have detrimental effect on
the stability of the machine.
The stability can be detrimented
by:
- overloading,
- too soft ground,
- abrupt acceleration or decelera-
tion of driving movement or
working movement,
- reversing out of high driving
speed,
- working on slopes,
- driving too quickly round sharp
bends,
- driving the machine on rough
terrain.
1.5.1.28 Donotdrivealongslopes
in traverse direction. Always carry
working equipment and loads near
theground,especiallywhendriving
down slopes. Sudden cornering is
forbidden!
1.5.1.29 On steep inclines and
gradients, the load is to be carried
on the uphill side.
1.5.1.30 Always adapt the speed
ofthemachinetotheenvironmental
conditions when driving down
slopes!Neverchangeintolowgear
when driving on slopes but before
entering the slope!
1.5.1.31 Reversing over a longer
period must be avoided!
1.5.1.32 When leaving the
machine always safeguard the
machine to prevent it from
unintentionally rolling away or
prevent non-authorized persons
from using it!
1.5.1.33 Thedrivermustnotleave
the machine if the attachments are
not lowered or safeguarded.

1-10 K65C/K75C/K95C 1-10 K65C/K75C/K95C
1.5.1.34 During work-brakes and
after work hours the driver should
endeavor to leave the machine on
good bearing soil and if possible on
level ground and safeguard the
machine to prevent it from
unintentionally rolling away.
1.5.2 Special work within
the exploitation of the
machine and elimination of
defects during process or
work; disposal
1.5.2.1 The prescribed dates for
adjustmentwork,maintenancework
and inspections laid down in the
operating manual (machine and
engine) must be strictly observed.
Thisalsoappliestodetailsregarding
the interchanging of parts/ part
equipment. This work may only be
executed by skilled personnel.
1.5.2.2 Forallworkconcerningthe
operation,conversionor adjustment
ofthemachineanditssafetydevices
as well as inspection, maintenance
and repair work please observe the
switching and stopping operation in
accordance with the operating
manual (machine and engine) as
well as the related instructions for
maintenance work.
1.5.2.3 The engine must be
switched off before maintenance or
repair work is carried out.
1.5.2.4 The stability of the
machineortheattachmentsmustbe
guaranteed at all times during
maintenance and repair work.
1.5.2.5 Maintenance and repair
work may only be carried out when
the attachment is set down on the
ground or supported or when
equivalent measures against un-
intentional movement were taken.
1.5.1.34 During work-brakes and
after work hours the driver should
endeavor to leave the machine on
good bearing soil and if possible on
level ground and safeguard the
machine to prevent it from
unintentionally rolling away.
1.5.2 Special work within
the exploitation of the
machine and elimination of
defects during process or
work; disposal
1.5.2.1 The prescribed dates for
adjustmentwork,maintenancework
and inspections laid down in the
operating manual (machine and
engine) must be strictly observed.
Thisalsoappliestodetailsregarding
the interchanging of parts/ part
equipment. This work may only be
executed by skilled personnel.
1.5.2.2 Forallworkconcerningthe
operation,conversionor adjustment
ofthemachineanditssafetydevices
as well as inspection, maintenance
and repair work please observe the
switching and stopping operation in
accordance with the operating
manual (machine and engine) as
well as the related instructions for
maintenance work.
1.5.2.3 The engine must be
switched off before maintenance or
repair work is carried out.
1.5.2.4 The stability of the
machineortheattachmentsmustbe
guaranteed at all times during
maintenance and repair work.
1.5.2.5 Maintenance and repair
work may only be carried out when
the attachment is set down on the
ground or supported or when
equivalent measures against un-
intentional movement were taken.

K65C/K75C/K95C 1-11 K65C/K75C/K95C 1-11
During maintenance and repair
work under the bucket arm:
- the bucket arm support must be
removedafterloosingofthefixing
bolt (1-1/arrows)
- the bucket arm must be suppor-
ted (1-2/arrow) and
- the ball block valve for working
and additional hydraulic (1-3/
arrow) must be closed.
1.5.2.6 Fix the articulated link
form-locking during maintenance
and repair work. Remove the bend
in protection after loosing of the
fixing screw, insert the bend in
protection into the articulated link
and fasten it (1-4/arrow).
1.5.2.7 If necessary, protect the
maintenanceareaonalargescale.
1.5.2.8 The machine must be
protected from unintentionally
starting after it was switched off for
maintenance and repair work:
- remove the ignition key
- attach warning sign at battery
main switch, if installed.
This applies especially to works to
the electrical equipment.
1.5.2.9 Individual pieces and
large assemblies must be carefully
securedtohoistingequipmentwhen
being substituted to avoid any
damage. Only suitable and tech-
nicalsoundhoistingequipmentmay
beusedaswellascraneequipment
withadequatepayload.Donotstand
or work underneath suspended
loads!
1.5.2.10 Only experienced per-
sonnelshouldbeentrustedwiththe
securing of loads!
Loadsmustbesecuredsothatthey
cannot slip or fall down.
During maintenance and repair
work under the bucket arm:
- the bucket arm support must be
removedafterloosingofthefixing
bolt (1-1/arrows)
- the bucket arm must be suppor-
ted (1-2/arrow) and
- the ball block valve for working
and additional hydraulic (1-3/
arrow) must be closed.
1.5.2.6 Fix the articulated link
form-locking during maintenance
and repair work. Remove the bend
in protection after loosing of the
fixing screw, insert the bend in
protection into the articulated link
and fasten it (1-4/arrow).
1.5.2.7 If necessary, protect the
maintenanceareaonalargescale.
1.5.2.8 The machine must be
protected from unintentionally
starting after it was switched off for
maintenance and repair work:
- remove the ignition key
- attach warning sign at battery
main switch, if installed.
This applies especially to works to
the electrical equipment.
1.5.2.9 Individual pieces and
large assemblies must be carefully
securedtohoistingequipmentwhen
being substituted to avoid any
damage. Only suitable and tech-
nicalsoundhoistingequipmentmay
beusedaswellascraneequipment
withadequatepayload.Donotstand
or work underneath suspended
loads!
1.5.2.10 Only experienced per-
sonnelshouldbeentrustedwiththe
securing of loads!
Loadsmustbesecuredsothatthey
cannot slip or fall down.

1-12 K65C/K75C/K95C 1-12 K65C/K75C/K95C
1.5.2.11 Attached loads may only
be moved with the machine when
the road is graded.
1.5.2.12 When working with
hoisting equipment / elevators the
slingers may only work with the
approval of the driver and from the
side of the boom. The driver may
onlygive his consent if themachine
is standing still and the working
attachment is not being moved.
1.5.2.13 Personsassistingwiththe
guidance of loads and slingers may
onlystayinvisualorcommunication
reach of the driver.
1.5.2.14 The operator must move
the load as close to the ground as
possible and avoid to swivel the
load.
1.5.2.15 The operator may not
move the load over the heads of
persons.
1.5.2.16 In the case of erection
workhavingtobe carried out above
normal human height, suitable
safety ascent devices and working
platformsmust be used. Do not use
engine parts as climbing and
descending facilities. Use safety
harnesses when working at very
great heights.
Allhandles,steps,railings,podests,
platforms,laddersmustbekeptfree
from dirt and ice.
1.5.2.17 Clean the machine,
especially connections and screw
connections before commence-
ment of maintenance work and
make sure that the machine is free
from oil, fuel oil or dirt. Do not use
aggressive detergents. Use lintless
cleaning rags!
1.5.2.11 Attached loads may only
be moved with the machine when
the road is graded.
1.5.2.12 When working with
hoisting equipment / elevators the
slingers may only work with the
approval of the driver and from the
side of the boom. The driver may
onlygive his consent if themachine
is standing still and the working
attachment is not being moved.
1.5.2.13 Personsassistingwiththe
guidance of loads and slingers may
onlystayinvisualorcommunication
reach of the driver.
1.5.2.14 The operator must move
the load as close to the ground as
possible and avoid to swivel the
load.
1.5.2.15 The operator may not
move the load over the heads of
persons.
1.5.2.16 In the case of erection
workhavingtobe carried out above
normal human height, suitable
safety ascent devices and working
platformsmust be used. Do not use
engine parts as climbing and
descending facilities. Use safety
harnesses when working at very
great heights.
Allhandles,steps,railings,podests,
platforms,laddersmustbekeptfree
from dirt and ice.
1.5.2.17 Clean the machine,
especially connections and screw
connections before commence-
ment of maintenance work and
make sure that the machine is free
from oil, fuel oil or dirt. Do not use
aggressive detergents. Use lintless
cleaning rags!