ahlmann AS 90tele User manual

Ahlmann Baumaschinen GmbH Am Friedrichsbrunnen 2 D-24782 Büdelsdorf
Telefon [phone] Internet: www.ahlmann-baumaschinen.de
Telefax +49 4331/351404 E-Mail: [email protected]
OPERATING INSTRUCTIONS
TELESCOPIC LOADERS
GB
AS 90tele

T90C/T90D I
Table of Contents
Introduction
Preface
Ahlmann’s swivel shovel loaders, telescopic loaders, articulated loaders and front loaders are machines
included in the vast product range of Ahlmann’s Baumaschinen covering a wide variety of working tasks.
Decades of experience in the construction of earth-moving machines, the wide range of attachments available
as well as modern production facilities, careful testing and highest quality demands guarantee the highest degree
of reliability of your Ahlmann machine.
The extent of documentation delivered by the manufacturer includes the following:
- Loader operating instructions
- Engine operating instructions
- Loader spare parts list
- Engine spare parts list
- EC conformity declaration
Operating instructions
The operating instructions contain all the information which the user requires for operation and maintenance.
In the “Maintenance” section, all maintenance work and operation tests are described which can be carried out
by trained personnel.
This section does not cover more extensive maintenance work that is reserved to personnel authorized and
trained by the manufacturer. In particular, this applies to facilities governed by Motor Vehicle Construction and
Use Regulations and the Regulations for the Prevention of Accidents.
Due to the construction modifications reserved by the manufacturer, there may be differences in the figures;
however, this has no influence on the technical contents.
How to use this manual
Explanations
- The designations “left”and “right” are to be seen from the driver’s seat in the driving direction.
- Option
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,

T90C/T90DII
Table of Contents
Abbreviations used
UVV = Unfallverhütungsvorschrift(Accident Prevention Regulations)
StVZO = Straßenverkehrzulassungsordnung (German Traffic Regulations)
Edition: 09.2006

T90C/T90D III
Table of Contents
Table of Contents
1 Fundamental safety instruction
1.1 Warnings and symbols............................................................................................................ 1 - 2
1.2 Proper use of the loader.......................................................................................................... 1 - 2
1.3 Organizational measures ........................................................................................................ 1 - 2
1.4 Selection of personnel and necessary qualifications............................................................... 1 - 3
1.5 Safety information for certain operating phases ...................................................................... 1 - 4
1.5.1 Normal operation .................................................................................................................... 1 - 4
1.5.2 Special work regarding the use of the machine and
elimination of defects during work; disposal............................................................................ 1 - 7
1.6 Instructions regarding special categories of danger ................................................................ 1 - 9
1.6.1 Electrical energy ...................................................................................................................... 1 - 9
1.6.2 Hydraulics ............................................................................................................................... 1 - 10
1.6.3 Noise ....................................................................................................................................... 1 - 10
1.6.4 Oil, grease and other chemical substances ............................................................................ 1 - 11
1.6.5 Gas, dust, steam, smoke ........................................................................................................ 1 - 11
1.7 Transport and towing; recommissioning ................................................................................. 1 - 11
1.8 Safety information for the contractor or the contractor’s authorized personnel ....................... 1 - 12
1.8.1 Organizational measures ........................................................................................................ 1 - 12
1.8.2 Selection of personnel and necessary qualifications; basic responsibilities ............................ 1 - 12
2 Signs
3 Protection against theft
3.1 Identifying features on the loader ............................................................................................ 3 - 2
3.2 Parking the loader ................................................................................................................... 3 - 2
3.3 Drive-away interlocks .............................................................................................................. 3 - 3
3.3.1 Transponder for drive-away interlock ...................................................................................... 3- 3
3.3.2 Encodable drive-away interlock............................................................................................... 3 - 3
4 Description
4.1 Overview ................................................................................................................................. 4 - 2
4.2 Loader ..................................................................................................................................... 4 - 3
4.2.1 Undercarriage ......................................................................................................................... 4 - 3
4.2.2 Tyres ....................................................................................................................................... 4 - 3
4.2.3 Steering system ...................................................................................................................... 4 - 3
4.2.4 Brake system .......................................................................................................................... 4 - 4
4.2.5 Battery ..................................................................................................................................... 4 - 4
4.2.6 Fuel supply system ................................................................................................................. 4 - 4
4.2.7 Air filter device ........................................................................................................................ 4 - 4
4.2.8 Lift, tip and telescoping devices .............................................................................................. 4 - 4
4.2.9 Swivel unit and axle support ................................................................................................... 4 - 5
4.2.10 Floating position ...................................................................................................................... 4 - 5
4.2.11 Lifting device suspension ........................................................................................................ 4 - 5
4.2.12 Pipe break safety device ......................................................................................................... 4 - 5
4.2.13 Swivel restriction ..................................................................................................................... 4 - 6
4.2.14 Load indicator.......................................................................................................................... 4 - 6
4.2.15 Overload cut-off ...................................................................................................................... 4 - 7
4.2.16 Equipment ............................................................................................................................... 4 - 7
4.3 Wheel change ......................................................................................................................... 4 - 8
4.4 Controls ................................................................................................................................... 4 - 9
4.5 Instrument panel ..................................................................................................................... 4 - 10

T90C/T90DIV
Table of Contents
5 Operation
5.1 Checks before start-up............................................................................................................ 5 - 2
5.2 Commissioning ....................................................................................................................... 5 - 2
5.2.1 Start the diesel engine ............................................................................................................ 5 - 2
5.2.2 Winter operation...................................................................................................................... 5 - 3
5.2.2.1 Fuel ......................................................................................................................................... 5 - 3
5.2.2.2 Engine oil change .................................................................................................................... 5 - 3
5.2.2.3 Changing the oil in the hydraulic system .................................................................................5 - 3
5.2.2.5 Anti-freezing agent for the windshield washer system ............................................................ 5 - 4
5.2.3 Driving the loader on public roads ........................................................................................... 5 - 4
5.2.3.1 Carrying a bucket .................................................................................................................... 5 - 4
5.2.5 Working with the loader .......................................................................................................... 5 - 5
5.2.5 Heater and ventilation system ................................................................................................. 5 - 7
5.2.5.1 Setting the air flow ................................................................................................................... 5 - 7
5.2.5.2 Switching on the heater ........................................................................................................... 5 - 7
5.3 Decommissioning the loader ...................................................................................................5 - 8
5.3.1 Parking the loader ................................................................................................................... 5 - 8
5.3.2 Switching off the diesel engine ................................................................................................ 5 - 8
5.3.3 Switching off the heater and ventilation system ...................................................................... 5 - 8
5.3.5 Leaving the loader ................................................................................................................... 5 - 8
5.4 Adjusting the driver’s seat ........................................................................................................ 5 - 9
5.4.1 Isri seat ................................................................................................................................... 5 - 9
5.4.2 Grammer seat .......................................................................................................................... 5 - 9
5.5 Switching the steering type...................................................................................................... 5 - 11
6 Attachments
6.1 Mounting and dismounting attachments without hydraulic connections .................................. 6 - 2
6.1.1 Standard/lightweight bucket .................................................................................................... 6 - 2
6.1.2 Fork-lift attachment ................................................................................................................. 6 - 3
6.1.2.1 Picking up an elevated load .................................................................................................... 6 - 3
6.1.3 Lifting hook .............................................................................................................................. 6 - 4
6.2 Mounting and dismounting attachments with hydraulic connections ....................................... 6 - 4
6.2.1 Multi-purpose bucket ............................................................................................................... 6 - 4
6.3 Use of additional attachments ................................................................................................. 6 - 6
7 Rescue, towing, lashing, lifting by crane
7.1 Rescue, towing, lashing .......................................................................................................... 7 - 2
7.1.1 Rescue/towing of the swivel shovel loader if the engine or drive has failed ............................ 7 - 2
7.1.1.1 Towing the swivel shovel loader if the engine has failed ......................................................... 7 - 2
7.1.1.2 Towing the loader if the drive has failed .................................................................................. 7 - 4
7.2 Lifting by crane ........................................................................................................................ 7 - 5
8 Maintenance
8 Maintenance Plan .................................................................................................................... 8 - 1
8.1 Notes regarding maintenance ..................................................................................................8 - 2
8.2 Maintenance work ................................................................................................................... 8 - 3
8.2.1 Engine oil level check .............................................................................................................. 8 - 3
8.2.2 Oil level check for axles ........................................................................................................... 8 - 3
8.2.2.1 Rear axle » slow loader « ......................................................................................................... 8 - 3
8.2.2.2 Rear axle » fast loader « .......................................................................................................... 8 - 3
8.2.2.3 Planetary gear ......................................................................................................................... 8 - 4
8.2.2.4 Front axle................................................................................................................................. 8 - 4
8.2.3 Oil level check in the hydraulic oil reservoir ............................................................................ 8- 5
8.2.4 Oil change, engine .................................................................................................................. 8 - 5
8.2.5 Oil change, axles ..................................................................................................................... 8 - 5
8.2.5.1 Rear axle » slow loader « ......................................................................................................... 8 - 5
8.2.5.2 Rear axle » fast loader « .......................................................................................................... 8 - 6

T90C/T90D V
Table of Contents
8.2.5.3 Planetary gear ......................................................................................................................... 8 - 7
8.2.5.4 Front axle................................................................................................................................. 8 - 7
8.2.6 Oil change, hydraulic system .................................................................................................. 8 - 8
8.2.7 Changing the hydraulic oil filter cartridges .............................................................................. 8- 9
8.2.8 Maintaining/replacing the air filter ........................................................................................... 8 - 9
8.2.9 Replacing the safety cartridge ................................................................................................. 8 - 10
8.2.10 Replacing the fuel filter ............................................................................................................ 8 - 11
8.2.11 Replacing the starter battery .................................................................................................... 8 - 11
8.2.12 Maintaining/replacing the fresh air filter .................................................................................. 8 - 11
8.2.13 Checking/adjusting the parking brake play .............................................................................. 8 - 12
8.3 Grease/oil lubrication points .................................................................................................... 8 - 13
8.3.1 Rear axle pivot bolts ................................................................................................................. 8 - 13
8.3.2 Rear axle ................................................................................................................................. 8 - 13
8.3.3 Front axle................................................................................................................................. 8 - 13
8.3.4 Ball bearing ring ...................................................................................................................... 8 - 14
8.3.5 Wear liners on the telescope arm ...........................................................................................8 - 14
8.3.6 Telescope arm ......................................................................................................................... 8 - 14
8.3.7 Driver’s cabin door .................................................................................................................. 8 - 18
8.3.8 Multi-purpose bucket ............................................................................................................... 8 - 18
8.3.9 Oil lubrication points ................................................................................................................ 8 - 19
8.3.9.1 Parking brake .......................................................................................................................... 8 - 19
8.3.9.2 Supporting valve actuator ........................................................................................................ 8 - 19
9 Faults, causes and remedies
10 Wiring diagrams
10.1 Electric wiring diagram ........................................................................................................... 10 - 1
10.2 Hydraulic circuit diagram .......................................................................................................10 - 4
11 Technical data (loader)
11.1 Loader ................................................................................................................................... 11 - 2
11.2 Engine ................................................................................................................................... 11 - 2
11.3 Starter ................................................................................................................................... 11 - 2
11.4 Alternator .............................................................................................................................. 11 - 2
11.5 Hydrostatic drive motor ......................................................................................................... 11 - 2
11.6 Axle loads ............................................................................................................................. 11 - 3
11.7 Tyres ..................................................................................................................................... 11 - 3
11.8 Steering system .................................................................................................................... 11 - 3
11.9 Brake system ........................................................................................................................ 11 - 3
11.10 Electrical system ................................................................................................................... 11 - 3
11.11 Hydraulic system ................................................................................................................... 11 - 3
11.11.1 Swivel unit ............................................................................................................................. 11 - 4
11.11.2 Support system ..................................................................................................................... 11 - 4
11.12 Fuel supply system ............................................................................................................... 11 - 4
11.13 Heater and ventilation system ............................................................................................... 11 - 4
11.14 Full flow suction filter ............................................................................................................. 11 - 4
11.15 Electric contamination indicator ............................................................................................ 11 - 4
11.16 Oil cooler with temperature-controlled fan ............................................................................ 11 - 4
11.17 Noise emission ...................................................................................................................... 11 - 4
12 Technical data (attachments)
12.1 Buckets ................................................................................................................................. 12 - 2
12.2 Fork-lift attachment ............................................................................................................... 12 - 3
12.3 Lifting hook ............................................................................................................................ 12 - 4

T90C/T90DVI
Table of Contents
13 Additional options, modifications, notes on inspection for loaders
13.1 Additional options .................................................................................................................. 13 - 2
13.2 Modifications ......................................................................................................................... 13 - 2

Safety regulations

T90C/T90D1-2
1 Safety regulations
1 Fundamental safety instructions
1.1 Warnings and symbols
In this operation manual, the following designations or
symbols are used for important information.
NOTE
Extra information about the economical use of the loader.
CAUTION
Special information for regulations and prohibitions for
avoiding damage.
DANGER
Information or regulations and prohibitions for prevention
of damage to persons or extensive damage to goods.
1.2 Proper use of the loader
1.2.1 This machine was designed according to the
state of the art and recognised safety rules. Nevertheless,
use of the machine may cause danger for the user or third
parties or impairments to the machine or other objects.
1.2.2 The machine and manufacturer-approved at-
tachments may only be used in a technical non-objection-
able condition, taking all safety regulations into account,
especially with regard to the operating manuals (machine
and engine). In particular, defects which could have a
detrimental effect on the safety of the machine should be
eliminated immediately.
1.2.3 The machine is designed exclusively for the
purposes described in this operating manual. Any other
use beyond these purposes is regarded as being improper
use. The manufacturer is not liable for any damage caused
in this connection. The risk is solely that of the user.
Authorised use of the machine also requires that the
operating manual (machine and engine) be heeded and
the inspection and maintenance conditions are complied
with.
1.3 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.

T90C/T90D 1-3
Safety regulations 1
1.3.2 In addition to the operating manuals (machine
and engine), the general applicable and other binding
regulations for the prevention of accidents (especially the
safety regulations of the German Trade Association -
VBG 40) as well as the regulations for environmental
protection must be observed; personnel must be instructed
accordingly.
Also heed all regulations governing public traffic.
1.3.3 The personnel who are to work with the machine
must read the operating manuals (machine and engine)
before starting work, especially the chapter concerning
safety precautions.
This also applies to personnel working occasionally with
the machine, e.g. during maintenance work.
1.3.4 The driver must wear a seat belt during opera-
tion.
1.3.5 Personnel working with the machine must not
wear long flowing hair, loose clothing or jewellery, including
rings. Danger of injuries, e.g. by getting caught or being
pulled in.
1.3.6 All safety and danger plates on the machine
must be observed!
1.3.7 All safety and danger plates must be attached to
the machine and must be kept legible.
1.3.8 In case of modifications to the machine, espe-
cially in case of damage or changes in the operating
behaviour of the machine which could influence its safety,
stop the machine immediately and inform the responsible
person in charge about the incident.
1.3.9 Do not make any modifications or conversions to
the machine which could affect safety without the manu-
facturer’s consent. This also applies to the installation and
adjustment of safety devices, valves and welding of
supporting parts.
1.3.10 Check the hydraulic system, especially hydrau-
lic pipes, at regular intervals for defects and immediately
eliminate any defects found.
1.3.11 The inspection periods specified in the operating
manual (machine and engine) and the maintenance plan
must be observed.
1.4 Selection of personnel and necessary
qualifications
Basic responsibilities
1.4.1 The machine may be driven and maintained only
by personnel selected by the employer for this purpose.

T90C/T90D1-4
1 Safety regulations
These persons must:
- have attained the age of 18 years,
- be physically and intellectually suitable,
- have been instructed in the operation or maintenance of
the machine and must have demonstrated their ability to
their employer,
- must be expected to carry out the work conveyed to
them in a diligent manner.
1.4.2 Electrical work on the machine may be carried
out only by a qualified electrician or persons supervised
by a qualified electrician according to the electrical regu-
lations.
1.4.3 Only qualified specialists may carry out work on
the chassis, the brake and steering system.
1.4.4 Only personnel with special experience and the
necessary know-how are permitted to carry out work on
the hydraulic system.
1.5 Safety information for certain operat-
ing phases
1.5.1 Normal operation
1.5.1.1 Always fasten seat belts prior to starting the
machine.
1.5.1.2 A passenger may only be transported if an
appropriate seat is available (option)!
1.5.1.3 Start and drive the machine from the driver’s
seat only!
1.5.1.4 Observe the control lamps according to the
operation manual (machine and engine) during starting
and switching-off operation!
1.5.1.5 Before commencing work / driving, make sure
that the brakes, steering, signal beacons and lights func-
tion!
1.5.1.6 Before moving the machine, always check that
the attachments are safely stowed so that no accident
may occur!
1.5.1.7 Before commencing work, make yourself familiar
with the working environment. This means observing ob-
stacles on the working site, quality and resistance of the
soil ground, undertaking the necessary protection precau-
tions between the building site and the public traffic.
1.5.1.8 Before starting the machine, make sure that no
person is endangered by the moving machine!
1.5.1.9 Take measures so that the machine can be
operated only in a safe and functional manner. The
machine may only be operated when all safety devices,
e.g. detachable safety devices and sound absorption,
exist and function.

T90C/T90D 1-5
Safety regulations 1
1.5.1.10 Avoid any action which appears to be dangerous!
1.5.1.11 Persons must not be carried in the working
equipment, e.g. in the attachments!
1.5.1.12 The operator may carry out work with the machine
only if no persons are in the danger zone.
The danger zone is the area near the machine where
persons may be injured
- by work-induced movements of the machine,
- by work attachments and devices,
- by loads swinging out,
- by dropping loads,
- by attachments falling from the machine.
1.5.1.13 In case of danger to persons, the operator must
give appropriate warning signs. It may be necessary to
stop work.
1.5.1.14 In case of functional defects, stop the machine
immediately and secure it. Eliminate defects immediately!
1.5.1.15 Check the machine at least once every shift for
external visible damage and defects. Report any defects
(including changes in the operational behavior) immediate-
ly to the person in charge. If necessary stop the machine
immediately and safeguard it.
1.5.1.16 The driver may slew the attachments in over-
head driving, operating and working areas only if these
areas are suitably safeguarded by protective roofing.
These protection roofs must offer appropriate safety
against loads and falling goods. If you are in doubt,
assume no protection roofs are present.
1.5.1.17 When driving, the attachment is to be kept as
close to the ground as possible.
1.5.1.18 Driving with the extended telescope is permit-
ted in exceptional cases only, and even then with extreme
care, drastically reduced speed and careful braking only.
1.5.1.19 Please observe the applicable traffic regulations
when driving on public roads, paths or open spaces. The
machine must be brought into road-worthy condition
beforehand.
1.5.1.20 Make sure to always switch on lights in poor
visibility and during darkness.
1.5.1.21 If the lights of the machine are not adequate for
the safe execution of certain work, additional lighting must
be provided on the working site, especially at dumping
points.
1.5.1.22 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.

T90C/T90D1-6
1 Safety regulations
1.5.1.23 Only reliable persons may act as guides. They
must be informed of their duties prior to commencing
work.
1.5.1.24 The driver and guide must agree on signals for
communication. These signals may only be given by the
driver and guide.
1.5.1.25 The guide must be easily recognizable – e.g. by
wearing warning clothing – and must always be in the
driver’s field of vision.
1.5.1.26 When passing under subways, bridges, tunnels,
electrical overhead lines, etc., make sure that there is
adequate clearance!
1.5.1.27 Maintain adequate clearance when working at
the edge of quarries, pits, rubbish dumps and embank-
ments 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.
1.5.1.28 The machine may only be used at stationary
dumping areas when firmly integrated installations are
provided to prevent the machine from running or sliding
down.
1.5.1.29 Avoid such work which could have a detrimental
effect on the stability of the machine.
The following may affect the stability:
- overloading,
- ground that is too soft,
- abrupt acceleration or deceleration of driving or working
movement,
- reversing out of a high driving speed,
- working on slopes,
- driving too quickly round sharp bends,
- driving the machine on rough terrain when the bucket
arm is swivelled.
1.5.1.30 Donottraverseacross slopes.Alwayscarryworking
equipmentandloadsnear the ground,especiallywhendriving
down slopes. Sudden cornering is forbidden!
1.5.1.31 On steep inclines and gradients, the load is to be
carried on the uphill side.
1.5.1.32 Reduce speed before inclines; always adapt the
speed of the machine to the local conditions!
Never change into low gear when driving on slopes, but
rather before the slope!
1.5.1.33 When leaving the machine, always safeguard
the machine to prevent it from unintentionally rolling
away; prevent non-authorised persons from using it!
1.5.1.34 The driver must not leave the machine if the
attachments are not lowered or safeguarded.
1.5.1.35 During breaks and after work hours, the driver
must park the machine on solid and, if possible, level
ground and safeguard it against unintentionally rolling
away.

T90C/T90D 1-7
Safety regulations 1
Figure 1-1
Figure 1-3
Figure 1-2
1.5.2 Special work regarding the use of the
machine and elimination of defects during
work; disposal
1.5.2.1 The dates for adjustment work, maintenance
work and inspections laid down in the operating manual
(machine and engine) must be strictly observed. This also
applies to information regarding the replacement of parts/
part equipment. This work may only be executed by
skilled personnel.
1.5.2.2 For all work involving the operation, conversion or
adjustment of the machine and its safety devices as well as
inspection, maintenance and repair work, please observe
the switch-on and switch-off procedures 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 mainte-
nance or repair work is carried out.
1.5.2.4 The stability of the machine or the attachments
must be guaranteed at all times during maintenance and
repair work.
1.5.2.5 Maintenance and repair work may only be car-
ried out when the attachment is set down on the ground
or supported or when equivalent measures against unin-
tentional movement were taken.
During maintenance and repair work under the telescope
arm:
- the telescope arm must be mechanically supported,
e.g. insert the bucket arm support (option)
(1-1/arrow).
- secure the hand lever for the working and auxiliary
hydraulics (1-2/arrow).
- the swivel unit must be blocked. To do this, remove the
blocking wedge (1-3/arrow) from the holder, insert it into
the swivel block (1-4/arrow) and secure it with the spring
locking lever.
1.5.2.6 If necessary, secure the maintenance area on a
large scale.
1.5.2.7 The machine must be protected from uninten-
tionally starting after it has been switched off for mainte-
nance and repair work:
- remove the ignition key and
- attach a warning sign to the main battery switch.
This applies especially to works on the electrical equip-
ment.
1.5.2.8 Individual pieces and large assemblies must be
carefully secured to hoisting equipment when being re-
placed to avoid any damage. Only suitable and technical-
ly sound hoisting equipment may be used as well as crane
equipment with adequate payload. Do not stand or work
underneath suspended loads!

T90C/T90D1-8
1 Safety regulations
Figure 1-4
1.5.2.9 Only experienced personnel should be entrusted
with the securing of loads! Loads must be secured so that
they cannot slip or fall down.
1.5.2.10 Attached loads may only be moved with the
machine when the road is graded.
1.5.2.11 When working with hoisting equipment / eleva-
tors the slingers may only work with the approval of the
driver and from the side of the boom. The driver may only
give his consent if the machine is standing still and the
working attachment is not being moved.
1.5.2.12 Persons assisting with the guidance of loads
and slingers may only stay in visual or communication
reach of the driver.
1.5.2.13 The operator must move the load as close to the
ground as possible and avoid swivelling the load.
1.5.2.14 The operator may not move the load over the
heads of persons.
1.5.2.15 In the case of erection work that must be carried
out above normal human height, suitable safety ascent
devices and working platforms must be used. Do not use
engine parts, especially attachments such as buckets, as
climbing and descending facilities. Use safety harnesses
when working at very great heights. All handles, steps,
railings, platforms, scaffolds, and ladders must be kept
free from dirt and ice.
1.5.2.16 Clean the machine, especially connections and
screw connections, before commencement of mainte-
nance work and make sure that the machine is free from
oil, fuel oil or dirt. Do not use aggressive detergents. Use
lintless cleaning rags!
1.5.2.17 Before cleaning the machine with water or steam
jet (high pressure cleaning unit) or with detergent, protect
all areas where water/steam/detergent may penetrate
and affect the functions or safety of the machine by a
suitable cover or by applying tape. In particular, engine
components such as the injection pump, generator,
generator governor and starter are very delicate.
1.5.2.18 After cleaning, completely remove all protective
covering and tape.
1.5.2.19 After cleaning, check all fuel, engine oil and
hydraulic oil pipelines for leakages, loose connections,
abraded parts and damage. Eliminate defects immediate-
ly!
1.5.2.20 Always fasten screw connections after comple-
tion of maintenance and repair work.
1.5.2.21 Should it be necessary to dismantle safety de-
vices during mounting, maintenance or repair work, these
safety devices must be re-installed and checked carefully
after completed maintenance and repair work.

T90C/T90D 1-9
Safety regulations 1
1.5.2.22 Make sure that fuel, accessory material and
interchanged parts are safely disposed of with no danger
to the environment.
1.5.2.23 The machine should be checked by a specialist
before commissioning and after essential modifications
before it returns to service.
1.5.2.24 The machine must be checked by a specialist
once a year. Furthermore, a specialist must check the
machine whenever necessary according to operating
conditions.
1.5.2.25 The test results must be recorded and kept in the
archives at least until the following inspection date.
1.6 Instructions regarding special catego-
ries of danger
1.6.1 Electrical energy
1.6.1.1 Only use original fuses with stipulated ratings.
Immediately switch off the machine if the electrical supply
fails.
1.6.1.2 When working near overhead lines and over-
head wires, a safety clearance must be kept between the
machine and its working equipment in order to prevent
sparking over. The safety clearance depends on the
nominal voltage of the overhead/wire line. This also
applies to the distance between the lines and to the
attachments and slung loads.
The following safety clearance must be observed to meet
the above mentioned requirement:
Nominal voltage Safety clearance
(kilovolts) (meters)
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 nominal voltage 5.0 m
When approaching overhead lines, all working move-
ments of the machine must be taken into consideration,
e.g. the position of jibs, the swinging of ropes and the
dimensions of attached loads.
In addition, attention must be paid to any roughness of soil
which could cause an inclined position of the machine,
thus getting it closer to the overhead line.
The fact that overhead lines may swing out during windy
weather and may reduce the distance must also be taken
into consideration.

T90C/T90D1-10
1 Safety regulations
1.6.1.3 In the case of sparking over, the driver must
bring the machine out of the danger area by lifting or
lowering the attachments or by swivelling away or driving
the machine out of the danger area. If this is not possible
then the following rules must be observed:
- Do not leave the driver’s cabin!
- Warn persons standing near the machine not to approach
or touch the machine!
- Give immediate instructions to have the power cut off!
- Leave the machine only when it is sure that the electricity
in the damaged / contacted power line is switched off so
that the line is dead!
1.6.1.4 Work on the electrical system or on the operating
system may only be carried out by a skilled electrician or
by personnel instructed or supervised by such a trained
electrician according to electrotechnical regulations.
1.6.1.5 The electrical installation of a machine must be
reviewed/inspected at regular intervals. Any defects, e.g.
loose connections or scorched cabling, must be eliminated
immediately.
1.6.1.6 The main battery switch must be disconnected
before inspection, maintenance or repair of machine parts
and components so that they are not under power.
1.6.1.7 Electric welding operations may only be performed
if the main battery switch has been removed.
1.6.2 Hydraulics
1.6.2.1 Only experts with special expertise and experi-
ence may carry out work on the hydraulic system!
1.6.2.2 All pipelines, hoses and screw connections must
be checked regularly for leakages and visible damage!
Immediately repair such defects! Spurting hydraulic oil
may cause injuries and fire.
1.6.2.3 Those hydraulic system segments which are to
be opened must be depressurised before commence-
ment of the repair work according to the assembly group
description!
1.6.2.4 The hydraulic pipelines must be correctly laid
and connected! Do not mix up the connections. Spare
parts must meet the technical requirements of the manu-
facturer. Original spare parts ensure the fulfilment of
these requirements.
1.6.2.5 The factory settings of hydraulic components
(e.g. the maximum permissible speed of the axial piston
engine) must not be altered. Any adjustment will render
the warranty invalid.
1.6.3 Noise
Sound protection equipment must be in the protective
position during operation of the machine.

T90C/T90D 1-11
Safety regulations 1
1.6.4 Oil, grease and other chemical sub-
stances
1.6.4.1 The relevant safety regulations must be ob-
served when handling oil, grease or other chemical sub-
stances.
1.6.4.2 Caution when working with hot fuel and other
accessory materials (danger of burning and scalding).
1.6.4.3 Caution when working with brake fluid and bat-
tery acid.
TOXIC AND CAUSTIC!
1.6.4.4 Be careful when working with fuel.
FIRE HAZARD!
- Before refuelling, switch off the engine and remove the
ignition key.
- Do not refuel in an enclosed area.
- Never refuel near open fires or sparks.
- Do not smoke during refuelling.
- Immediately wipe up spilled fuel.
- Keep the machine free of fuel, oil and grease.
1.6.5 Gas, dust, steam, smoke
1.6.5.1 The machine may be operated in closed rooms
only if sufficient ventilation is ensured! Ensure sufficient
ventilation prior to starting the machine!
The regulations for the respective working site must be
strictly observed.
1.6.5.2 Carry out welding, burning and grinding work on
the machine only when this is explicitly approved. Other-
wise, there is the danger of fire and explosion!
1.6.5.3 Before carrying out welding, burning and grinding
work, clean the machine and its vicinity of combustibles
and make sure that the room is adequately ventilated.
Explosion hazard!
1.7 Transport and towing;
recommissioning
1.7.1 The machine may only be towed if the brakes
and steering function.
1.7.2 Towing may be carried out only by means of an
adequately dimensioned towing bar in connection with
towing devices.
1.7.3 Start towing at a low speed. Persons must not be
near the towing bar.

T90C/T90D1-12
1 Safety regulations
Figure 1-5
1.7.4 When the machine is loaded and transported,
the necessary auxiliary equipment must be fitted to pre-
vent any unintended movement. The tyres must be kept
clean of mud, snow and ice so that the machine can drive
on ramps without danger of sliding.
1.7.5 Strictly observe the operating manual during
recommissioning.
1.8 Safety information for the contractor
or the contractor’s authorized personnel
1.8.1 Organizational measures
1.8.1.1 We emphasise that attachments that are not
supplied by us are also not tested and approved by us.
Use of such products can under certain conditions ad-
versely affect the present constructional qualities of your
loader and thus limit the active and passive driving safety.
The manufacturer cannot be held responsible for damage
that occurs through the use of such products.
1.8.1.2 Inform yourself of the location/use of fire extin-
guishers (1-5/arrow) and first-aid kit (on the maintenance
plate behind the driver’s seat)!
1.8.1.3 When travelling on public roads, a first-aid kit, a
warning triangle and a warning lamp must be available on
the vehicle.
1.8.2 Selection of personnel and necessary
qualifications; basic responsibilities
1.8.2.1 Only reliable persons are allowed to work on/
with the machine. The minimum legal age must be ob-
served.
1.8.2.2 Employ trained or instructed personnel only.
Clearly define the competencies of the personnel regarding
operation, installation, maintenance and repair work.
Ensure that only authorised personnel may work on/with
the machine!
1.8.2.3 Authorize the drive to refuse instructions given
by third parties when these instructions are detrimental to
the safety of the driver and the machine.
1.8.2.4 Personnel who are to be trained, instructed or
working on/with the machine in the scope of professional
training must not work on/with the machine unless they
are supervised by an experienced person who has been
authorised by the employer.

Signs