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.