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.