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ahlmann AL 150 Use And Maintenance Manual

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  • Page 3 Ahlmann Baumaschinen GmbH Am Friedrichsbrunnen 2 THE DESCRIPTIONS AND DIAGRAMS IN THIS PUBLICATION ARE INDI- D-24782 Büdelsdorf CATIVE. AHLMANN BAUMASCHINEN GMBH FOLLOWS A POLICY OF Telefon +49 4331/351-01 CONSTANT PRODUCT IMPROVEMENT AND THEREFORE RESERVES THE Telefax +49 4331/351404 RIGHT TO MODIFY THIS PUBLICATION WITHOUT PRIOR NOTICE.
  • Page 4 It is absolutely forbidden to transport or lift on the vehicle passengers (either sitting or standing) Should you need to use it for work that requires special equipment we advise you to get in touch with your Ahlmann Distributor to ensure that modifications comply with machine technical specifications and safety standards.

  • Page 5: Table Of Contents

    PRESENTATION SUMMARY The AL 150 model is a hydraulic machine. It is made up of loader parts, an SAFETY STANDARDS................Page 4 engine, hydraulic systems and a driver cab. When the driver operates the controls the engine-driven pump sends hydraulic fluid towards the distributor which, in CONTROLS ....................

  • Page 6: The Al 150 Model Is A Hydraulic Machine. It Is Made Up Of Loader Parts, An Engine, Hydraulic Systems And A Driver Cab. When The Driver Operates The Controls Safety Standards

    Should you have any doubts whatsoever please get in touch with your Ahlmann Distributor. The safety information contained in this manual refers to situations which may occur during normal machine use and maintenance work, and gives various ways of dealing with such situations.
  • Page 7 Before using the machine Check that all controls and safety devices are working properly and that you are in a safe, obstacle-free area before starting work. Do not drive the vehicle until the instructions and warnings contained in this manual have been read and fully understood. Keep well away from danger zones such as ditches, overhangs, subsidence- prone areas etc.
  • Page 8 Machine use Use the controls in sequence to ensure proper machine operation. Vehicle must be driven only by expert and authorised personnel. For on- road transfers the drivers must have a regular driving licence (“B” or upper category); the use of a pivotable headlight is compulsory. When transporting the machine on a trailer position the speed selector at on-site speed.
  • Page 9 Unauthorised machine modifications could cause serious injury. Never carry properly bolted and the driver cab doors locked. out modifications without obtaining prior authorisation from your Ahlmann Distributor. All modifications must be compatible with machine technical 9. Make sure that no vehicle parts protrude into a traffic lane. If this is features and comply with the safety standards in force.
  • Page 10 A spark or naked flame could cause the hydrogen in one of the batteries to When checking tire pressure or inflating the tire always position yourself in line with tire tread, not in front of the tire wall. When removing a wheel explode.
  • Page 11 Preventing burns Declared performances Working conditions Battery electrolyte can cause serious burns. The battery contains sulphuric Standard use (continuous running), working temperature: acid. Avoid contact with skin, eyes and clothing. - Max 48° C Treatment: - Min -15° C (standard vehicle) EXTERNAL: rinse with water.
  • Page 12 Hand signals Lift the load or loader equipment Lower the load or loader equipment Should the machine be used in precision manoeuvres or for jobs with restricted visibility it is advisable to have the driver guided by a ground-based assistant using hand signals. Make sure that both driver and assistant understand the signals to be used.

  • Page 13: The Engine-Driven Pump Sends Hydraulic Fluid Towards The Distributor Which, In Turn, Directs It Towards The Various Components. A Cooler, Installed Next To The Controls

    CONTROLS - INSTRUMENTS - ACCESSORIES CONTROLS Cab door controls Open door release Opening from the outside To open the emergency door (right) To release the left door from its open The left door is opened from the from the inside rotate the knob position pull the handle indicated in the outside by pressing the push-button clockwise as shown in the picture.
  • Page 14 Driver cab controls Ignition Located on the Abs vehicle dashboard on the right of the driver seat. Key positions: 1. Stop 2. Contact and pre-heating 3. Start Note: The “Start” position is only enabled if the speed selector switch is in the neutral position.
  • Page 15 Light control Located on the dahboard to the right of the driver seat, this control has 3 positions: Pos. 1: Stop. Pos. 2: Side lights always on. Pos. 3: Dipped headlights enabled only when the ignition contact is on. Directional indicator control Located on the right-hand side of the steering column, this control has three positions: Front windshield wiper/washer control Pos.
  • Page 16 Loader control lever Switches on right-hand side-dashboard Located to the right of the seat, this lever 1. This switch disables hydraulic system has 6 positions: of the manipulator. SENSO DI 0. Neutral 2. General lighting switch MARCIA 1. Loader equipment down 3.
  • Page 17 Loader control locking switch Quick hydraulic coupling control Located on the dashboard, on the right switches (on request) side. To couple or disconnect the equipment This switch disables the loader control. from the quick coupling operate simultaneously on the “F”-button positioned on the speed direction selector When the machine is stopped it and on the “E”-buttons on the loader...
  • Page 18 Engine hood release handle Adjusting the driver seat Located inside the cab Distance control through flex cable for the lock located under the engine hood. Proper machine use with maximum efficiency and comfort also depends on careful seat adjustment to suit the driver’s build.

  • Page 19: Instruments

    INSTRUMENTS Heating and ventilation controls Central dashboard Heating and ventilation controls are located on the right-hand side of the cab. Heating Rotate the heating faucet (2) until the 2 3 4 desired position is obtained. The lower (3), front and rear vents establish airflow direction.
  • Page 20 Switches on side-dashboard Wiring scheme of the panel on the side dashboard LIVELLO TERMOMETRO CONTAGIRI MOTORE CARBURANTE ACQUA TACHOMETER FUEL LEVEL W ATER TEMPERATURE GAUGE GAUGE CONTAORE HOURMETER +ILL CONNECTOR: AMP 070 Multilock 20 ways POS. FUNZIONE CONNESSA SEGNALE COLORE FILO POS.
  • Page 21 Steering column 1. Steering wheel adjustment lever Located on the left side of the steering wheel. Loosen the lever indicated in the picture, adjust the steering wheel in a suitable position, then lock the lever again. 2. Warning lights switch Located on the right side of the steering wheel.

  • Page 22: Accessories

    ACCESSORIES First Aid Box (To be installed on the vehicle before driving) Always keep a first aid box handy. Make sure that it is complete and ready to be COD. 826.C.591 used: If not replace it immediately. 1. Windshield washer tank Positioned to the right of the driver seat under the inspection cover plate.
  • Page 23 Inspection light socket (on request) Keil (Spezialkeil für einige Länder) Located to the left of the front dashboard, this socket provides a connection point for an inspection light or any other 12 V electrical accessory. Fire Extinguisher (To be installed on the vehicle before driving) To be positioned in the rear-right part of the driver seat.

  • Page 24: Start-Up And Work

    Bleeding air trapped in the fuel line START- UP AND WORK Air bubbles may form in the fuel supply system after prolonged engine idleness, after TOWING - TRANSPORT - LIFT work on the fuel filter and fuel feed lines, or if the fuel tank is allowed to run dry. Air ON-ROAD TRANSFER may be present in the fuel feed pipes causing feeding difficulties.

  • Page 25: Towing

    Machine use: basic rules TOWING Ensure that all machine parts and equipment work properly during machine use. Towing pin Remember: the majority of inconveniences and breakdowns that occur during machine use are caused by loosening of machine components and leaks that have not been dealt with quickly enough.

  • Page 26: Vehicle Recovery

    VEHICLE RECOVERY TRANSPORT Loading onto a railway wagon Tow flaps Rail transport is governed by specific standards. Consult the relevant authorities. Loading onto a trailer bed This vehicle could slip and fall off a trailer bed or ramp, causing serious injury.

  • Page 27: Lift

    LIFT Stage 4 Insert the central articulated joint locking Stage 1 pin (located on the right-hand side of Lower the loader bucket onto the ground and lock the loader controls inside the driver’s the joint). Then stop the engine and cab by using the lock pin.

  • Page 28: On-Road Transfer

    Stage 3 ON-ROAD TRANSFER Lock the loader controls by using the special lever. Observe the machine user standards described in this chapter, any other use must be considered forbidden unless you have prior authorisation from the manufacturer. Before driving the vehicle on the road lock the loader gear into place by means of the special lever and ensure that all regulation-required safety devices are operative.

  • Page 29: Rops/Fops Protection Structure

    The structure is fastened to the frame as shown in the assembly drawing below: 1.General Features The structure is suited to installation only on the vehicle AL 150. It has been sized for a maximum weight of 11,300 kg. The structure is composed of COPPIA DI SERRAGGIO 550 Nm P/N 000.8.218...
  • Page 30 2. Safety standards Use only the bolts supplied by the Manufacturer together with the The operator must observe the following rules of general safety. The structure guarantees structure. The Manufacturer declines all liability for the damages caused the protection of the operator against the risk of overturning and falling objects: by the use of non-original bolts.

  • Page 31: Rating Plates And Adhesive Stickers

    RATING PLATES AND ADHESIVE STICKERS FOR INFORMATION AND WARNING The rating plates and adhesive stickers on the vehicle provide information or warnings in the form of texts or drawings that the operator must learn and respect. Whenever they are no longer legible, damaged, or covered by paint, they must be replaced.
  • Page 32 826.B.231 OLIO IDRAULICO HYDRAULIC OIL ATTENZIONE NON APRIRE HYDRAULIKFLÜSSIGKEIT Ferm are il m otore prim a di scendere dalla m acchina. Non azionare i com andi della m acchina e i suoi accessori QUANDO IL MOTORE finché non si è posizionat i sul sedile. HUILE HYDRAULIQUE Prim a di s cendere dalla m acchina abbassare l’attrezzatura SERBATOIO OLIO FRENI...

  • Page 33: Periodic Maintenance

    The hour counter lets you know when its is risk of serious personnel injury. If you have any doubts regarding time to carry out maintenance. With the engine maintenance procedures contact your Ahlmann distributor. running the counter works as a clock. Maintenance schedules are clearly stated in...
  • Page 34 RUNNING-IN PERIOD INTERVALLI DI MANUTENZIONE Good engine care during the first 20 working hours will give longer-lasting top level performance and more economic running. During this period you must: · · · · · Monitor the dashboard instruments carefully. · · · · · Check oil and coolant levels frequently Use the vehicle at low engine r.p.m.
  • Page 35 every working hours 1. Check diesel engine oil level 3. Check hydraulic oil The level should be checked with the Check the level with the engine OFF engine OFF and must be between the and cold. The level must be between min and max notches.
  • Page 36 every working hours 8. Check dry air filter 6. Lubricate central joint Main Filter Inject grease (via the special pump) until Dismantle the cartridge and clean with the old grease flows out. dry air at a maximum pressure of 7 kg/ Note: Greasing points are highlighted cm2.
  • Page 37 every working hours 10. Battery 9. Check tire pressure Check that the battery is clean and that the terminals are properly insulated. These must always be covered with grease. Check electrolyte (distilled water) level and top up if necessary; the electrolyte should just cover the electrodes.
  • Page 38 every working hours 14. Check differential oil 12. Replace hydraulic oil filter cartridge. Check that the level reaches the plug as shown in the picture. If necessary top up via the same. Change after the first 200 working hours Note: The level must be checked with the vehicle perfectly horizontal. and then every 1,000 hours.
  • Page 39 Screw on the new filters. This operation should be carried out by your AHLMANN distributor. e) Start the engine and check for oil leaks. Start the engine only when the hood is closed. Drain plug...
  • Page 40 21. Replace the transfer box oil 24. Replace differential oil - Remove the plug indicated in the picture to aid oil outflow and ensure complete - Remove the drain plug “1”. emptying. - Remove the level-filler cap “2” to ease - Pour oil into the plug hole until it flows out.
  • Page 41 2000 every working hours 26. Multistage centrifugal blower cleaning The compressor rotor, its volute and the oil return pipe from the multistage centrifugal blower to the oil sump must be cleaned every 2,000 working hours by a Perkins authorised workshop.

  • Page 42: Designazione Dei Principali Componenti Supply Tables

    P t r P t r P t r P t r . l. l. l. l. l - f l - f l ° ° °...
  • Page 43 c i r i t a P t r P t r P t r P t r P IP IP IP IP I A P I A P I A P I A P I l l l l l f l e f l e °...

  • Page 44: Cab/Driver's Seat Summary Tables

    Tightening torque table SUMMARY TABLES Valve setting summary table ABBREVIATION NAME PRESSURE kg/cmq S I O S I O S I O S I O - V.G.C. GENERAL LOADER VALVE (on distributor) - V.A.B.C.F. LOADER BUCKET ANTI-SHOCK VALVE (end-plate side) 300 * - V.A.B.C.A.

  • Page 45: Radiator Hydraulic System Scheme

    Hydraulic system scheme Entrata A1 B1 IMPIANTO FRENANTE BREAKING SYSTEM Front Axle SERBATOIO Assale Anteriore TANK Attrezzatu ra Sollevamento Ben n a A ttac hm en t B u c ket L ift R T1 Rear Axle Assale Posteriore AVANTI FRONT INDIETRO REAR...
  • Page 46 Hydraulic system scheme Max capacity 108 (59.5 + 48.5) litres/m 2200 rpm - LOADER Loader pressure setting 230 bar Pressure setting of hydraulic power steering: 175 bar POS. DESCRIPTION HYDROSTATIC PUMP (A4VG 90DA) HYDROSTATIC ENGINE (A6VM 80EZ) HYDROSTATIC ENGINE (A6VM 107HA) COMPLETE RADIATOR UNIDIRECTIONAL VALVE HYDRAULIC OIL FILTER...

  • Page 47: Loader Equipment Wiring Scheme

    Wiring scheme impianto colonnetta...
  • Page 48 Wiring scheme - side dashboard line...
  • Page 49 Wiring scheme - central unit (X9) (X3) (X7) (X5) 20Amp 1 2 3 4 5 6 7 8 9 10 11 12 20Amp F10B 20Amp 20Amp K10B F10A 20Amp F10C 20Amp 20Amp (X6) 20Amp 20Amp Check timer K12B 20Amp (X4) (X1) 20Amp 20Amp...
  • Page 50 Wiring scheme - front light line...
  • Page 51 Wiring scheme - cab . f e...
  • Page 52 Schema impianto elettrico - engine rear line...
  • Page 53 Wiring scheme - fuse carrier line...
  • Page 54 Wiring scheme - relay diagram...
  • Page 55 Wiring scheme - description 1 N A M E N A M E D E S C R IP T IO N D E SC R IP T IO N SYSTEM CONNECTION 9 WA Y F CONNECTOR RELA Y UNIT FIRST GEA R WA RNING LIGHT FRONT LIGHTS LINE CONNECTION 1 2 WA Y CONNECTOR SECOND GEAR WARNING LIGHT...
  • Page 56 Wiring scheme - description 2 NAME DESCRIPTION FUSE CARRIER BOX FUSE CARRIER BOX CONNECTION 5 WAY F CONNECTOR FUEL LEVEL FLOATER BOOM SENSOR ANTI – PITCH DEVICE SOLENOID VALVE HYDRAULIC CYLINDER BLOCK SOLENOID VALVE BUZZER FRONT LEFT LIGHT FRONT RIGHT LIGHT CENTRAL UNIT (X10) CONNECTION 9 WAY M CONNECTOR...
  • Page 57 Wiring scheme - connectors 5 PARKING BRAKE 21-WAY-X1 CONNECTOR 20 FORWARD GEAR 1 ON REQUEST 6 RIGHT REAR SIDE LIGHT 21 BRAKE LIQUID LEVEL SENSOR 2 GENERATOR WARNING LIGHT 7 STOPLIGHTS 13-way-X3 Connector 3 EQUIPMENT LIGHTING 11-way-X7 Connector 1 SOLENOID VALVE FOR REVERSE GEAR 4 PIVOTABLE HEADLIGHT PUSH SWITCH FEED 9 ON REQUEST 5 SIDE LIGHTS SWITCH FEED...

  • Page 58: Technical Specifications

    ENGINE TECHNICAL SPECIFICATIONS Make and type ............... Perkins 1004-40T Number of cylinders ................4 in line Tread width ................. mm. 1760 Cycle ..................4 stroke Diesel Diameter and stroke in mm..............100 x 127 Maximum width without bucket ..........mm.

  • Page 59: Troubleshooting

    Possible cause Solution Hydrostatic motor ............... Double displacement Not enough water in radiato Top up AXLES Contact your Ahlmann Distributor Front ......................Rigid Limescale deposits in radiator Rear ....................Oscillating Total oscillation ..................... 25° Alternator belt loose Set correct belt tension The engine Total reduction ..................
  • Page 60 The vehicle moves pressure neither forwards Elastic diesel engine - pump nor backwards, or coupling faulty Hydrostatic motor faulty: check oil Contact your Ahlmann Distributor it moves with a draw flow-rate Contact your Ahlmann Distributor Supercharger faulty certain delay Inefficient oil-water exchanger...
  • Page 61 Problem Possible cause Solution Oil leakage at O-Ring seals worn Contact your Ahlmann Distributor cylinders between rod and piston...
  • Page 62 UNIVERSAL FORKS OVERALL DIMENSIONS WITH FORKS (without quick coupling) Load with forks - Load centre at 500 mm The universal forks are fitted on the front part. The coupling may be of the pin type with quick mechanical coupling or with a quick hydraulic coupling.
  • Page 63 NOTES THIS MANUAL IS THE PROPERTY OF AHLMANN BAUMASCHINEN GMBH COPYING OF THE TEXT AND ILLUSTRATIONS, EITHER IN WHOLE OR IN PART, IS FORBIDDEN Technical office, July 2002...

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