ahlmann AS90 Guide

Maintenance

S05E/S06E8-2
8 Maintenance
8 Maintenance
8.1 Maintenance notes
DANGER
- The engine must be turned off.
- For work to be carried out under the bucket arm:
- the bucket must be emptied or the attachment
must be relieved,
- the bucket arm support (1-1/arrow) is to be
inserted,
- the ball block valve for the working and auxiliary
hydraulics (1-2/arrow) must be closed,
- the swivel mechanism is to be blocked (1-4/
arrow).
- The loader is to be secured against rolling by using
the parking brake (4-10/8) and by setting the drive
direction switch (4-10/3) to the “0” position. In
addition, wedges must be placed on both sides of
one of the two wheels of the front axle.
CAUTION
- Change the oil when the units are lukewarm.
- Perform maintenance work when the loader is on
level ground and the bucket arm is in its lowest
position.
- Replace damaged filter inserts and gaskets imme-
diately.
- Clean pressure lubrication fittings before lubrica-
ting.
NOTE
- All necessary maintenance work is to be taken from
the maintenance plan.
- Damage which is traceable to non-observance of
the maintenance plan is not covered by the
guarantee.
- The lubricants mentioned in the maintenance plan
can be used at an ambient temperature from -15° to
+40°C.
CAUTION
For ambient temperatures below -15° C, refer to the
description in chapter 5.2.2 “Winter operation”.
NOTE
If a hose and/or pipe break occurs, the two lids of the
hydraulic oil filter (8-20/arrows) must be loosened because
the loader does not have a shut-off valve that could prevent
large amounts of hydraulic oil from escaping.

S05E/S06E 8-3
Maintenance 8
8.2 Maintenance work
8.2.1 Checking the engine oil level
See Engine Operating Instructions.
8.2.2 Checking the oil level in the axles
8.2.2.1 Rear axle of the slow loader
» 20 km/h «
(1) Unscrew the plugs from the axle arch (8-1/arrow) and
the intermediate gear (8-2/arrow).
NOTE
- The axle arch and the intermediate gear do not have
a common oil reservoir.
- The oil level must reach the plug bores.
- Collect any escaping oil.
(2) Replace the plugs.
8.2.2.2 Rear axle of the » fast loader «
(1) Unscrew the plugs from the axle arch (8-3/arrow) and
the distribution gear (8-4/arrow).
Figure 8-1
Figure 8-3
Figure 8-2

S05E/S06E8-4
8 Maintenance
NOTE
- The axle arch and the distribution gear do not have
a common oil reservoir.
- The oil level must reach the plug bores.
- Collect any escaping oil.
(2) Replace the plugs.
8.2.2.3 Planetary gear
(1) Move the loader until the marking line “OIL LEVEL” is
horizontal and the plug is located above the top left of the
marking line (8-5/arrow).
(2) Unscrew the plug.
NOTE
- The oil level must reach the plug bore.
- Collect any escaping oil.
(3) Fit a new gasket and replace the plug.
8.2.2.4 Front axle
(1) Unscrew the plug (8-6/arrow) from the axle arch.
NOTE
- The oil level must reach the plug bore.
- Collect any escaping oil.
(2) Replace the plug.
Figure 8-4
Figure 8-6
Figure 8-5

S05E/S06E 8-5
Maintenance 8
421 3 1
8.2.3 Checking the oil level in the hydraulic
oil reservoir
(1) Park the loader in a level position.
(2) Move the bucket to its lowest position.
(3) Tilt the quick-change device and move out the locking
bolts using the hand lever for the auxiliary hydraulics (4-9/5).
(4) Open the motor cover.
(5) Check the oil level in the sight glass.
NOTE
The oil level must be visible in the upper quarter of the sight
glass (8-7/arrow). If necessary, fill oil into the filler neck
(8-18/arrow).
8.2.4 Changing the engine oil
(1) Unscrew the maintenance flap from the motor protec-
tion (size 13) (8-8/arrow).
(2) Place a sufficiently large oil drain pan underneath the
motor oil sump.
(3) Open the motor cover.
(4) Unscrew the cover of the oil drain plug on the motor.
(5) Screw the drainage nozzle with hose from the tool box
(4-1/13) to the oil drain plug.
(6) Remove the cover cap from the hose.
(7) Further procedures are to be found in the Engine
Operating Manual.
8.2.5 Changing the oil in the axles
8.2.5.1 Rear axle of the »slow loader
» 20 km/h «
(1) Place a sufficiently large oil drain pan underneath the
axle.
(2) Unscrew the plugs from the axle arch (8-9/1, 8-9/2,
8-9/3 and 8-9/4) and the intermediate gear (8-10/1 and
8-10/2) and let the oil drain out.
CAUTION
Waste oil must be disposed of in such a way that it will not
cause pollution!
Figure 8-7
Figure 8-9
Figure 8-8

S05E/S06E8-6
8 Maintenance
1 2
421 3 1
1 2
(3) Replace the plugs for the axle arch (8-9/1 and 8-9/2)
and the intermediate gear (8-10/2).
(4) Fill oil into the plug bore of the axle arch (8-9/3) and of
the intermediate gear (8-10/1) until the oil reaches the
opening (8-9/4 or 8-10/1).
NOTE
- The axle arch and the intermediate gear do not have
a common oil reservoir.
- Information about the quantity of oil is given in the
maintenance plan (chapter 8.4).
- After a few minutes, when the oil level has lowered,
top up the oil until the oil level reaches the marked
level and remains stable.
(5) Replace the plugs for the axle arch (8-9/3 and 8-9/4)
and the intermediate gear (8-10/1).
8.2.5.2 Rear axle of the » fast loader «
(1) Place a sufficiently large oil drain pan underneath the
axle.
(2) Remove the plugs from the axle arch (8-11/1, 8-11/2,
8-11/3 and 8-11/4) and the distribution gear (8-12/1 and
8-12/2) and drain the oil.
CAUTION
Waste oil must be disposed of in such a way that it will not
cause pollution.
(3) Replace the plugs for the axle arch (8-11/1 and
8-11/2) and the distribution gear (8-12/2).
(4) Fill in oil via the plug hole in the axle arch (8-11/3) and
the distribution gear (8-12/1) until the oil reaches the
opening (8-11/4 or 8-12/1).
NOTE
- The axle arch and the distribution gear do not have
a common oil reservoir.
- Information about the quantity of oil is given in the
maintenance plan (chapter 8.4).
- After a few minutes, when the oil level has lowered,
top up the oil until the oil level reaches the marked
level and remains stable.
(5) Replace the plugs for the axle arch (8-11/3 and
8-11/4) and the distribution gear (8-12/1).
Figure 8-10
Figure 8-12
Figure 8-11

S05E/S06E 8-7
Maintenance 8
213
8.2.5.3 Planetary gear
(1) Move the loader so that the plug (8-13/arrow) is
positioned at 6 o'clock.
(2) Place an oil drain vessel with a drain channel under-
neath the gear.
(3) Unscrew the drain plug and let the oil drain out.
CAUTION
Waste oil must be disposed of in such a way that it will not
cause pollution.
(4) Move the loader until the marking line “OIL LEVEL” is
horizontal and the plug is located above the top left of the
marking line (8-14/arrow).
(5) Fill in oil via the plug bore until the oil level reaches the
opening.
(6) Use a new gasket when replacing the plug.
8.2.5.4 Front axle
(1) Place a sufficiently large oil drain pan underneath the
axle.
(2) Unscrew the plugs from the axle arch (8-15/1, 8-15/2,
8-15/3, 8-16/1 and 8-16/2) and drain the oil.
CAUTION
Waste oil must be disposed of in such a way that it will not
cause pollution.
Figure 8-13
Figure 8-15
Figure 8-14

S05E/S06E8-8
8 Maintenance
21
(3) Replace the plugs (8-15/1 and 8-16/1).
(4) Fill in oil via the plug bore (8-15/3) until the oil level
reaches the opening (8-15/2 or 8-16/2).
NOTE
- Information about the quantity of oil is given in the
maintenance plan (chapter 8.4).
- After a few minutes, when the oil level has lowered,
top up the oil until the oil level reaches the marked
level and remains stable.
(5) Replace the plugs (8-15/2 and 8-15/3 and 8-16/2).
8.2.6 Changing the oil in the hydraulic
system
(1) Have an oil pan ready (at least 130 l).
(2) Unscrew the cap of the oil drain (8-17/arrow).
(3) Screw the drainage nozzle with hose from the tool box
(4-1/13) to the oil drain plug.
(4) Remove the cover cap from the hose.
(5) Drain the oil into the drain pan.
CAUTION
Waste oil must be disposed of in such a way that it will not
cause pollution!
(6) Remove the nozzle with the hose and replace the
cover cap on the hose.
(7) Replace the cap on the oil drain.
(8) Change the hydraulic oil filter inserts (section 8.2.7).
(9) Fill in oil into the filler neck (8-18/arrow).
CAUTION
For those loaders which are fitted to run with biodegradable
hydraulic oil (synthetic hydraulic oil on ester basis -
viscosity class ISO VG 46 VI > 180) (designation can be
found on the hydraulic oil tank and on the dashboard), only
this type of oil may be used for oil changes.
Mineral and biodegradable oils must never be mixed.
Biodegradable hydraulic oil must be changed every 1000
operating hours.
Changing the oil type from mineral oil to biodegradable oil
must be performed according to the VDMA 24 569
conversion guidelines!
CAUTION
The service brake must only be operated with mineral oil!
(10) Check the oil level at the sight glass (8-7/arrow).
(11) Close the filling nozzle.
Figure 8-16
Figure 8-18
Figure 8-17

S05E/S06E 8-9
Maintenance 8
2
1
8.2.7 Changing the hydraulic oil filter inserts
CAUTION
Change the filter inserts according to the maintenance plan
or when the clogging indicator lamp (4-11/23) lights up.
NOTE
The clogging indicator lamp may light up briefly after a cold
start but will go out when the hydraulic oil has reached its
operating temperature.
(1) Move the seat to the frontmost position (5-12/2).
(2) Tilt the backrest of the seat completely forward
(5-11/2).
(3) Fold back the insulation mats to the left and the right
of the driver's seat, unscrew the four screws
(size 13) (8-19/arrows) that fix the maintenance plate and
remove the plate.
(4) Loosen the lids of the hydraulic oil filters (8-20/arrows)
and replace the filter inserts by new ones.
CAUTION
Waste hydraulic oil filter inserts must be disposed of in
such a way that they will not cause pollution.
(5) Lock the lids of the hydraulic oil filters.
(6) Fasten the maintenance plate.
(7) Restore the individual seat position.
8.2.8 Maintaining/replacing the air filter
NOTE
Maintenance of the filter cartridge is necessary when either
the red range is visible in the maintenance indicator
(8-21/1) or after 12 months, whichever is sooner.
(1) Open the engine cover.
(2) Loosen the three spring-loaded catches on the air filter
lid (8-21/2) and remove the air filter lid.
Figure 8-19
Figure 8-21
Figure 8-20

S05E/S06E8-10
8 Maintenance
(3) Pull out the filter cartridge (8-22/arrow) by carefully
turning it back and forth.
(4) Clean the filter cartridge.
CAUTION
- For cleaning, use a compressed air gun to which a
pipe (angled at 90°) has been attached. The pipe
must be sufficiently long to reach the cartridge
bottom. Use dry compressed air of no more than
5 bar to blow out the cartridge by moving the pipe
back and forth in the interior of the cartridge.
Cleaning can be stopped when dust formation cea-
ses.
- Do not use petrol or hot liquid for cleaning.
(5) Use a hand-held lamp to check the filter cartridge for
damage to the cartridge paper or the rubber gasket. If the
cartridge or seals are damaged, replace the cartridge.
(6) Carefully insert the filter cartridge.
(7) Install the air filter lid on the filter housing in such a way
that the direction arrow in the marking “OBEN-TOP”
points towards half past one.
NOTE
The dust removal valve must be checked from time to time
and cleaned if necessary.
(8) When the indicator field becomes red (8-21/1), push
the reset button. The field becomes clear.
CAUTION
Check all connection pipes and hoses of the air filter
system for damage before starting the engine.
8.2.9 Changing the safety cartridge
CAUTION
- The safety cartridge must not be cleaned.
- The safety cartridge must be replaced after the filter
cartridge has been maintained/cleaned 5 times, at
the latest after two years.
- Make sure that no dirt or dust can enter the filter
housing during replacement of the safety cartridge.
(1) Remove the filter cartridge (section 8.2.8).
(2) Pierce the seal of the safety cartridge (8-23/arrow)
from the inside by using a screwdriver or similar tool and
pull up both strips.
(3) Hold the safety cartridge by both strips and pull it out
by carefully turning it back and forth. Replace the safety
cartridge and the filter cartridge by new ones.
(4) The remaining installation is performed as described
in section 8.2.8 (6)-(8).
Figure 8-22
Figure 8-23

S05E/S06E 8-11
Maintenance 8
2
1
8.2.10 Replacing the fuel filter
See the Engine Operating Instructions.
8.2.11 Exchanging the starter battery
NOTE
The starter battery is a maintenance-free part according to
DIN 72311, section 7. It is located to the right in the motor
compartment.
(1) Pull off the battery main switch (4-10/5).
(2) Open the motor hood.
(3) Remove the fastening screw (size 17) (8-24/1) of the
battery holder.
(4) Loosen and remove the connecting cables (8-24/2)
from the battery (size 13).
DANGER
Always remove the negative pole cable first and then the
positive cable. Installation is in the reverse order.
(5) Remove the battery and replace it.
(6) Apply grease to the connecting cables before faste-
ning them.
(7) Installation is in the reverse order.
DANGER
Make sure the fastenings are secure.
(8) Close the motor hood.
8.2.12 Maintaining/replacing the fresh air
filter
(1) Lift the bucket arm, insert the bucket arm support and
swivel the bucket arm all the way to the right or to the left.
(2) Loosen the four fastening screws (size 10) (8-25/
arrows) of the heater cover and remove the cover.
(3) Remove the filter elements (8-26/arrows) and clean
them with compressed air.
CAUTION
Do not use any petrol, hot fluids or compressed air for
cleaning.
(4) Check the filter elements for damage.
NOTE
The filter elements must be replaced when they are
damaged or every 1500 operating hours.
(5) Insert the filter elements and install the heater cover.
Figure 8-24
Figure 8-26
Figure 8-25

S05E/S06E8-12
8 Maintenance
1 3 42
8.2.13 Checking/adjusting the parking brake
play
DANGER
- All work on the brake system must only be carried
out by authorized personnel.
- Oil loss (leaks) in the brake system must be imme-
diately reported to authorized personnel.
(1) Check the brake's hydraulic oil level (4-10/4) and top
up if necessary.
(2) Pull the parking brake lever (8-27/arrow) and release it
again (lowest position).
CAUTION
The parking brake should become effective on the third
catch.
If the path the parking brake lever must travel before the
parking brake becomes effective is significantly longer, the
following work must be carried out:
NOTE
Figure 8-28 shows a top view of the front axle/chassis area.
1st possibility of an adjustment:
(3) Loosen the adjusting screw on the cable (8-28/3) from
the holder and turn it until the visible end of the thread is
reached.
(4) Tighten the adjusting screw (8-28/4) until it touches
the holder.
2nd possibility of an adjustment:
(5) Loosen the counter nut (8-28/2) at the steering head
(8-28/1).
(6) Unhook the steering head and turn it in clockwise
direction.
(7) Hook the steering head in again.
(8) Tighten the counter nut again.
CAUTION
- While adjusting the leverage, make sure to check
from time to time whether or not the parking brake
becomes effective on the 3rd catch.
- The parallel leverage must make contact with the
abutments (8-29/arrows) when the parking brake is
released.
(9) Perform a functional check.
Figure 8-27
Figure 8-29
Figure 8-28

S05E/S06E 8-13
8.3 Grease/oil lubrication points
- Item 8 of the maintenance plan.
- Marked in red on the loader.
8.3.1 Rear axle pivot bolt (8-30/arrows)
CAUTION
The rear axle pivot bolt must be lubricated every
50 operating hours.
8.3.2 Rear axle (8-31/arrows)
CAUTION
The spindle bolts must be lubricated every 50 operating
hours.
NOTE
Lubricate the top and the bottom of the axle spindle bolts
on both sides of the axle.
8.3.3 Front axle (8-32/arrows)
CAUTION
The spindle bolts must be lubricated every 50 operating
hours.
NOTE
Lubricate the top and the bottom of the axle spindle bolts
on both sides of the axle.
Figure 8-30
Figure 8-31
Figure 8-32

S05E/S06E8-14
8 Maintenance
1/2
3
4/5
8
6/7
9
10
11
8.3.4 Bucket motor (8-33 and 8-34)
CAUTION
The support bolts of the bucket motor must be lubricated
every 10 operating hours.
Items 1 + 2 Swivel unit/bucket motor
Item 3 Toggle lever
Items 4 + 5 Bucket motor/quick-change device
Items 6 + 7 Tip rod bolt
Item 8 Tip lever
Item 9 Tip lever
Item 10 Deflection lever
Item 11 Deflection lever
8.3.5 Ball bearing ring
The grease filling is to avoid friction, and to provide sealing
and protection against corrosion. Therefore, the ring must
be lubricated every 10 operating hours until grease
becomes visible on the outside. Swivel the bucket arm in
steps of 20° while lubricating the ball bearing ring and make
sure to inject grease in each of the four grease nipples
(8-35/arrows). It is absolutely necessary to lubricate the
machine before and after a longer period of inactivity.
DANGER
- Before you start lubricating, insert the bucket arm
support (1-1/arrow), apply the parking brake
(4-10/8) and set the drive direction switch (4-10/3)
to the "0" position.
-During swiveling, no-one may be present in the
swivel area of the bucket arm.
Figure 8-33
Figure 8-35
Figure 8-34

S05E/S06E 8-15
Maintenance 8
8.3.6 Driver's cabin doors (8-36/arrows)
CAUTION
The hinges of the driver's cabin doors must be lubricated
every 50 operating hours.
NOTE
Lubricate the hinges on both doors of the driver's cabin.
8.3.7 Multi-purpose bucket
CAUTION
The bearing bolts of the multi-purpose bucket must be
lubricated every 10 operating hours.
NOTE
- The bolt (8-37/arrow) must be lubricated on both
sides of the multi-purpose bucket.
- The bolts (8-38/arrows) must be lubricated on both
sides of the multi-purpose bucket.
Figure 8-36
Figure 8-37
Figure 8-38

S05E/S06E8-16
8 Maintenance
4
1
2
1
2
3
5 6
7
8.3.8 Front-end excavator
CAUTION
The bearing bolts of the front-end excavator must be
lubricated every 10 operating hours.
NOTE
- Lubricate the bolts (8-39/1, 8-39/2, 8-39/3, 8-39/5
and 8-39/7) at both ends.
- Item 8-39/4 shows the lubricating point of the shaft
cylinder.
- Item 8-39/6 shows the lubricating point of the bucket
cylinder.
- Item 8-40/1 shows the lubricating point of the shaft
cylinder.
- Item 8-40/2 shows the lubricating point of the bucket
cylinder.
8.3.9 Oil lubrication points
8.3.9.1 Parking brake
CAUTION
Use engine oil to lubricate the joints and deflection levers
every 50 operating hours (8-41/arrows).
NOTE
Figure 8-41 shows a top view of the front axle/chassis area.
Figure 8-39
Figure 8-41
Figure 8-40

S05E/S06E 8-17
Maintenance 8
8.3.9.2 Supporting valve activation (8-42/
arrow)
CAUTION
The leverage of the supporting valve activation must be
lubricated with engine oil every 50 operating hours.
NOTE
Lubricate only the visible surface of the spring housing
piston rod.
Figure 8-42

6.1 11.2 11.1 10.2 11.1 7,4 7.1/7.2/7.3
3.1/3.2/3.3/3.4/4.1/10.1 5.1 5.2 4.2 5.1 5.2 2.1/2.2/2.3/2.4/2.5/2.6/4.1
1.1/1.2/1.3
11.1
9.1
Item Designation Specification Viscosity Filling amount
1 Motor oil MIL-L-2104 C = API-CD acc. to manufacturer ca. 10 l with oil filter
2.2 Transmission oil MIL-L-2105 D = API-GL5-6 SAE 85 W 90 ca. 6,25 l
2.4 Transmission oil MIL-L-2105 D = API-GL5-6 SAE 85 W 90 ca. 2 x 0,75 l
2.6 Transmission oil MIL-L-2105 D = API-GL5-6 SAE 85 W 90 ca. 1,9 l (20 km/h)
ca. 1,6 l (30 km/h)
3.2 Transmission oil MIL-L-2105 D = API-GL5-6-LS SAE 85 W 90-LS ca. 6,25 l
with LS additive
3.4 Transmission oil MIL-L-2105 D = API-GL5-6 SAE 85 W 90 ca. 2 x 0,75 l
7.3 Hydraulic oil (4) DIN 51524, HVLP 46 ISO VG 46, VI > 180 ca. 120 l
8 Grease DIN 51825 - KPF 1/2 N-20 as required
9 Distilled water as required
10 Mineral oil DIN 51524, HVLP 46 ISO VG 46, VI > 180 as required
GB
10 50
500
1500
Item
Every x operating hours max. permitted intervals or
shorter (depending on use)
*
Maintenance points
1. Engine
1.1 Maintenance according to manufacturer's regulations
1.2 Dry air filter system
Activate dust removal valve
Check maintenance display
1.3
Replace filter element if maintenance display is red
2 Rear axle with axle power shift gear or gear shift
2.1 Check oil level in axle gear (control screw)
2.2 Change oil in axle gear
2.3 Check oil level in planetary gear (control screw)
2.4 Change oil in planetary gear
2.5 Check oil level in power shift gear (control screw)
2.6 Change oil in power shift gear
3 Front axle
3.1 Check oil level in axle gear (control screw)
3.2 Change oil in axle gear
3.3 Check oil level in planetary gear (control screw)
3.4 Change oil in planetary gear
4 Axles / cardan shaft(s)
4.1 Check fastening of axles (720 Nm)
4.2 Check fastening of cardan shaft(s) (32 Nm)
5 Wheels and tyres
5.1 Check air pressure
5.2 Check fastening of wheel nuts (500 Nm)
6 Ballbearingslewingring(swivelloaderonly)
6.1 Check fastening (300 Nm)
7 Hydraulic system
7.1 Replace filter inserts, observe electric control lamp
7.2 Oil level check (view glass)
7.3 Oil change
7.4 Check and clean hydraulic oil cooler
8 Lubrication points (indicated in red)
9 Battery
9.1 Visual check
10 Brake system
10.1 Service and parking brake: Take function and visual check before starting work
10.2 Service brake: visually check compensation tank
10.3 Parking brake: check and adjust if required
11 Lighting system / fresh air filter
11.1 Take function test before starting work
11.2 Check fresh air filter
Lubrication points (indicated in red)
1. Lubricate bolts every 10 operating hours with grease
DIN 51825 - KPF 1/2 N-20.
2. Lubricate glide points as required and always after
cleaning, using grease DIN 51825 - KPF 1/2 N-20.
Oil lubrication points
3. Lubricate joints and toggle levers every 50 ope-
rating hours wih engine oil MIL-L-2104 C.
Optional features: Biodegradable hydraulic oil
4. Ester-based synthetic hydraulic oil. Viscosity class
ISO VG 46 VI > 180
CAUTION
Use only mineral oil for the
service brake!
Key to symbols
First oil change / first filter replacement
first check; eliminate any determined problems
Check; eliminate any determined problems
Change
The markings, filling and check plugs
are binding
Refer to operating instructions
Caution
When carrying out maintenance work, heed
the accident prevention regulations!
*
*
*
*
*
*
*
*
4182633A
8.4 Maintenance Plan
8-21
S05E/S06E