Sennebogen 825 D Maintenance Instruction Manual 825.0.1148 - PDF DOWNLOAD by www.heydownloads.com

MAINTENANCE INSTRUCTIONS

11.2006

825D

Important notes regarding the operating instructions

Target group

The machine has been developed for demanding work. Persons working on or with the machine must be trained or instructed for that purpose. Maintenance must be carried out by trained specialist personnel only.

Notes regarding the operating instructions

Read the instructions, especially Chapter 1 Safety when performing maintenance, carefully before working with the machine. Keep operating instructions in a safe place for future use. WARNING z Only work with the machine once you have read and completely

understood these operating instructions. z Refrain from operating or maintaining the machine in an unsafe manner. z Do not operate machine if a fault has been detected! z The employer is responsible for the qualifications and training of the

personnel. z These operating instructions are a part of the machine. Keep the

operating instructions in the cab at all times. Recommended storage place: Storage compartment behind the driver’s seat. In the event of sale, disposal or loan, the operating instructions must accompany the machine! z Contact SENNEBOGEN immediately if you are unsure about

anything in the instruction manual! Your comments will help us to make the instructions even more user-friendly. For reasons of clarity, the specified safety devices are not shown in some of the illustrations. Operation with safety devices removed is not permitted! DANGER Safety devices must be installed when working with the machine.

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Important notes regarding the operating instructions

Symbols and illustration devices

These operating instructions contain safety notes that highlight dangerous working practices. These safety notes are marked with a warning symbol and a keyword. This warning symbol means: Attention - this concerns your safety and the safety of others. The associated keyword signifies the degree of danger: DANGER Is used for serious, impending danger. If this danger is not averted, serious physical injuries or loss of life will result. WARNING Is used for potentially dangerous situations. If this danger is not averted, serious physical injuries or death may result. CAUTION Is used for potentially dangerous situations. If this danger is not averted, physical injuries or serious material damage may result. Notes which make the work easier or contribute to better understanding when operating the machine are displayed in the following way: Note Indicates notes which draw your attention to unusual features. Note Indicates a cross reference to other documents. Procedures are shown in tabular form as follows: 1

Press switch (1).

Actuate control lever (2).

Unfasten pins (3).

z Listings are marked with bullet points.

– Sub-points in listings or procedures are marked with dashes.

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Important notes regarding the operating instructions

How to contact us

SENNEBOGEN Maschinenfabrik GmbH Hebbelstraße 30 D-94315 Straubing Telephone:

+49 9421 540-0

Internet:

http://www.sennebogen.de

Fax Customer Service Desk:

+49 9421 540279

Fax Spare parts depot:

+49 9421 40811

Technical documentation: E-mail:

doku@sennebogen.de

Fax:

+49 9421 41425

Note The address of the SENNEBOGEN Sales and Service Partners can be found on our homepage on the Internet.

Current when going to press

Ongoing development ensures the advanced technology and the high level of quality in our machines. This may result in deviations between these operating instructions and your machine. Errors can also not be ruled out. Please understand that no legal claims can be derived from the specifications, illustrations and descriptions within these instructions.

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Table of contents

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Safety when performing maintenance . . . . . . . . . . . . 1-1 1.1 Prior to performing maintenance work . . . . . . . . . . 1-1 1.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.3 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1.4 Potential instances of misuse . . . . . . . . . . . . . . . . 1-4 1.5 Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1.6 Other risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1.7 Responsibilities of the operator . . . . . . . . . . . . . . . 1-6 1.8 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 1.9 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 1.10 Entering and exiting safely . . . . . . . . . . . . . . . . . 1-10 1.11 Emergency descent . . . . . . . . . . . . . . . . . . . . . . . 1-10 1.12 Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1.13 Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 1.14 Oils and lubricants . . . . . . . . . . . . . . . . . . . . . . . . 1-12 1.15 Engine coolants . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1.15.1 Coolant for CATERPILLAR engines . . . . . 1-13 1.15.2 Coolant for DEUTZ engines . . . . . . . . . . . 1-14 1.15.3 Coolant for Cummins engines . . . . . . . . . 1-15 1.15.4 Coolants - General . . . . . . . . . . . . . . . . . . 1-16 1.16 Fuel (not for equipment with electric motors) . . . . 1-18 1.17 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 1.18 SENNEBOGEN Diagnostics System (SDS) . . . . 1-20

Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Specifications of 825D with Cummins engine . . . . . . 3-1 3.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 Inspection tools - overview . . . . . . . . . . . . . . . . . . 3-2 3.3 Lubricating the machine . . . . . . . . . . . . . . . . . . . . 3-3 3.4 Tightening torques for bolts . . . . . . . . . . . . . . . . . . 3-5 3.5 Conversion factors . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.2 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.3 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.3.1 Water separator . . . . . . . . . . . . . . . . . . . . . . 4-6 4.4 Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4.5 Belt drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

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Table of contents

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Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1 Cleaning and lubricating . . . . . . . . . . . . . . . . . . . . 5-1 5.2 Tire air pressure (pneumatic tires) . . . . . . . . . . . . . 5-1 5.3 Tightening the wheel nuts . . . . . . . . . . . . . . . . . . . 5-2 5.4 Hub drive train . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.5 Transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.6 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 5.7 Drive shafts/universal joints . . . . . . . . . . . . . . . . . . 5-7

Slewing mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 Lubricating the slewing ring raceway . . . . . . . . . . . 6-2 6.1.1 Central lubrication system . . . . . . . . . . . . . . 6-2 6.2 Lubricating the slewing ring gearing . . . . . . . . . . . 6-3 6.2.1 Checking the grease fill level . . . . . . . . . . . . 6-3 6.3 Tightening the slewing ring bolts . . . . . . . . . . . . . . 6-4

Hydraulic system: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.2.1 Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . 7-2 7.2.2 Threaded fittings . . . . . . . . . . . . . . . . . . . . . 7-2 7.3 Hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 7.4 De-pressurizing the hydraulic system . . . . . . . . . . 7-4 7.5 Checking the oil level. . . . . . . . . . . . . . . . . . . . . . . 7-5 7.6 Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . 7-6 7.7 Replacing return filter elements . . . . . . . . . . . . . . . 7-8 7.8 Replacing the pilot circuit filter element . . . . . . . . . 7-9 7.9 Replacing the leakage oil filter element . . . . . . . . 7-10 7.10 Replacing the ventilation filter . . . . . . . . . . . . . . . 7-11 7.11 Hydro Clean – fine filtration system (optional) . . . 7-12 7.12 Checking the preload pressure of the accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Heating/air-conditioning system . . . . . . . . . . . . . . . . 9-1 9.1 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.2 Air conditioning (optional) . . . . . . . . . . . . . . . . . . . 9-2

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Safety when performing maintenance - Prior to performing maintenance work

Safety when performing maintenance

1.1 Prior to performing maintenance work Prior to starting any maintenance work, park the machine on level ground and prepare as described in the following. DANGER Danger to life! There is a risk of serious injury or even death to persons using the machine or in its vicinity if it moves suddenly or is started unintentionally. Observe the following: z Park the machine on a safe surface (flat, firm, horizontal),

if necessary, set back from the edge of the excavation. z Lower suspended loads and booms to the ground. z Apply the brake. z Pull the safety lever backwards (all hydraulic functions are disabled). z Switch off machine and secure against unauthorized re-starting. z Use a chock to stop the machine from rolling away.

Additional measures: z Allow the machine to cool. If this is not possible, be aware that hot

fluids and components can cause burns. z De-pressurize the hydraulic system to avoid dangers.

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Safety when performing maintenance - General

1.2

General

Failure to observe these instructions can result in accidents, serious injuries or death. Perform the maintenance work described in these maintenance instructions completely and at the specified time intervals. WARNING z Observe all signs and safety stickers on the machine as well as those in the operating instructions. They contain important information about maintenance procedures. z The maintenance work described may only be carried out by trained

and instructed specialist personnel. z Only use genuine Sennebogen replacement parts. z Use only oils and lubricants listed in the lubricant table. z Collect lubricants and other consumables in suitable containers and

dispose of them properly. z Observe statutory accident prevention and safety regulations. z When performing maintenance, attach a warning sign to controls. z Keep the vehicle (e.g. handles, steps, platforms, hand rails etc.) free

from dirt, snow and ice. z Use safety-compliant access ladder aids or operating platforms. z If necessary, switch the battery isolator switch off (or remove the

cable from the battery terminal) to interrupt the current. z When working near batteries these are to be covered with insulating

material; do not place tools onto batteries. z When handling batteries, observe the safety and protective

measures specified by the battery's manufacturer. Fire, sparks, open flames and smoking are prohibited when handling batteries. z When working on air conditioning systems, be aware that

refrigerants and refrigerant vapors are hazardous to health. Wear appropriate safety equipment. z Smoking and handling of open flames is strictly forbidden. z Wear personal protection equipment (e.g. safety helmet, ear protection,

protective gloves, safety boots) where working conditions require. z Wear protective gloves when working with steel wire ropes. z Do not lift heavy objects by hand. Use lifting gear. z Maintain a safe distance from rotating and moving parts.

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825D / 11.2006

Safety when performing maintenance - General

z For pneumatic tires:

When pumping up tires, maintain an adequate safety distance and use a tire cage. z If an accident occurs in spite of all safety and precautionary

measures, e.g. – scalding by hot oil or coolant – contact with strong acid – entry of fuel or hydraulic into the skin – coolant- or hydraulic oil spraying into the eyes etc., apply first aid immediately and contact a doctor. z Replace all safety devices after completing any maintenance work.

Exchange damaged safety devices for new ones. z Only the machine owner or representative may approve the

machine for operation following maintenance work. z After maintenance or repair work, carry out a thorough visual

inspection and function check in accordance with the operating instructions in order to ensure proper and safe operation.

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Safety when performing maintenance - Correct use

1.3

Correct use

The correct use of the machine concerns solely the lifting, transport and loading/unloading of loads. Permitted work tools are: z Grab. z Magnetic equipment.

Specifications according to Chapter 3SPECIFICATIONS OF 825D WITH CUMMINS ENGINE . Observe the performance details of the machine. Other or additional applications are considered as misuse and can endanger persons or machinery. Workplace: The machine operator’s workplace is in the driver's cab of the machine. Target group

The machine has been developed for demanding work. Persons working on or with the machine must be trained or instructed for that purpose. Operation and deployment may only be carried out by trained personnel. Initial operation, maintenance, transportation and assembly/ dismantling only by trained specialists.

1.4

Potential instances of misuse

z Exceeding admissible overall loads (see Section 3.2). z Using non-Sennebogen parts z Use in inadmissible ambient conditions. z Misuse by untrained and uninstructed personnel. z Inadequate equipment for the application (e.g. protection of cab

against falling objects with guard grill). z Operating on insufficiently firm base. z Neglect of necessary inspection and maintenance work.

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Safety when performing maintenance - Misuse

1.5

Misuse

Incorrect use (Misuse) applies in particular to: z hoisting, driving and transporting of persons z hoisting loads at an angle. z dragging loads. z pulling free jammed loads. z operation of the machine in an explosive environment.

WARNING Misuse excludes all liability of the manufacturer! The risk is borne solely by the operator.

1.6 Other risks The safety notes in these operating instructions are guidelines for the safe use of the machine by qualified machine operators. However, SENNEBOGEN cannot anticipate every situation in practice which may result in danger. Therefore, the safety notes and warnings on the machine and in the operating instructions cannot be all inclusive. The owner and machine operator still remain responsible for safety.

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Safety when performing maintenance - Responsibilities of the operator

1.7

Responsibilities of the operator

ATTENTION The operator is obliged to supply operating instructions when working with hazardous machines or materials. The necessary information is contained in z EC directives on safety at work z National laws on safety at work z Accident prevention regulations and z these operating instructions.

Specialist check

Have a specialist check the machine thoroughly, z before initial operation z before putting the machine back into operation after significant

modifications z at least once yearly z and in between according to operating conditions and conditions of use.

A specialist in this context is a person, who z has extensive knowledge of this machine and the corresponding

regulations and guidelines due to specialist training and z through special instructions of Co. Sennebogen

and can assess the safe working condition of the machine. Specialist testing

Specialist testing, only required for crane operation The following cranes must be tested by a specialist every 4 years: – Fuel driven mobile crane – Location changing fuel driven derrick crane – Vehicle attachment crane The specialist inspection is to be performed in the 13th year of operation and annually thereafter. Faults that are determined in recurring inspections must be eliminated according to the safety-relevance and within a suitable time-frame.

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Safety when performing maintenance - Responsibilities of the operator

Personnel selection and qualifications

z Employ only trained and instructed personnel. z Define responsibility for operation and maintenance. z Observe the permitted minimum age.

ATTENTION z Personnel under training or instruction must remain under constant supervision while working on the machine. z Work on the machine's electrical equipment may only be carried out

by a qualified electrician. z Work on running gear, braking and steering systems may only be

carried out by specifically trained technicians! z Work on hydraulic systems may only be carried out by personnel

with specific knowledge of and experience with hydraulics! Technical condition of the machine

Noise protection

Independent conversion and replacement parts

The operator has an ongoing responsibility to monitor the overall technical condition (obvious external faults and damage as well as changes to operational behavior) of the machine. Do not operate the machine if a fault has been detected! Observe mandatory time limits for routine checks. The operator is to ensure that appropriate ear protection is available and used by the operating personnel. For safety reasons the machine may not be modified or altered in any way. This applies also to the installation and use of safety devices and valves as well as welding on load carrying parts. Genuine Sennebogen replacement parts and accessories ensure the safety of personnel. Parts and fittings from other manufacturers are not tested by Sennebogen and are therefore not approved. The use of other components can alter the machine's characteristics and present a safety hazard. If other components are used, Sennebogen will not be considered liable for any resulting consequences.

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Safety when performing maintenance - Safety devices

Fire extinguisher and first aid box (optional)

The machine is provided with spaces for a fire extinguisher and first aid box. The operator is obliged to equip the machine with these items. If necessary, purchase a fire extinguisher (1) and first air box (2) from Sennebogen.

1 Warranty conditions

The warranty conditions of SENNEBOGEN Maschinenfabrik GmbH are summarized in the warranty manual. You will also find an extract from the warranty conditions in the operating instructions (chapter 10).

1.8

Safety devices

DANGER z Do not remove safety devices or covers. z Always check that safety devices are complete and correctly

secured before starting the machine. z Replace all safety devices and covers correctly on completion of

assembly or maintenance work. z Exchange damaged safety devices for new ones.

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Safety when performing maintenance - Disposal

1.9

Disposal

Lubricants and Consumables ATTENTION Observe environmental guidelines! Handle and dispose of used items and materials correctly, especially z when working on lubrication systems and devices and z when working with solvents.

Extract from the Disposal of Waste Oils Directive 75/439/EEC: z "It is prohibited to mix waste oil with other waste." z "Waste oils must not be mixed together." z "Used oil filters must be collected, stored, transported and disposed

of separately from other waste." Notes z Lubricants and other consumables must be disposed of at suitable collection points. z National environmental conditions valid in the country of use also apply.

Batteries

Observe safety and protective measures when handling batteries. Notes z Do not throw batteries out with the rubbish! Dispose of defective batteries at a recycling point for spent batteries. z National environmental conditions valid in the country of use also apply.

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Safety when performing maintenance - Entering and exiting safely

1.10 Entering and exiting safely Enter and exit machine only when stationary.and after the cab has been lowered completely - never - during any motion. Use the appropriate steps and ladders: 1. Open the sliding door while standing on the ground 2. Grab a handhold and step onto the ladder 3. Enter the cab from the rear via the platform

z If necessary, clean steps and ladders prior to use. z Do not carry any items when climbing up or down. z Lift items of equipment onto machine using a rope or lifting gear. z Do not use operating elements as handholds in driver’s cab.

1.11 Emergency descent Note Enter and exit the cab via the wheel hub and tire only in extreme emergencies and with extreme caution.

1.12 Emergency exit A safety hammer that can be used to knock out the rear window is located in the cab. Exit the cab via the rear structure with extreme caution and climb down from the vehicle.

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Safety when performing maintenance - Cleaning work

1.13 Cleaning work Notes z Clean machine daily. z When the machine is especially dirty, especially when being used

in recycling applications, it may have to be cleaned more than once per day. z Ensure that the cleaning agents used do not damage the seals and

components of the machine. z Do not use aggressive cleaning agents. z Only use lint-free cleaning cloths. z Only use dry, filtered compressed air up to max. 29 PSI (2 bar). z On completion of cleaning work, carry out a visual and functional

check of the machine acc. to section 4.3 (in the machine operating instructions). z Lubricate the lubrication points after every cleaning. z Replace protective caps on the grease nipples. z After cleaning the engine compartment, check all lines for leaks,

loosening or damage and correct any problems. z Risk of condensation

After a wet cleaning, check that there is no moisture in the electrical control cabinet. WARNING Electrical and electronic components such as the alternator, control cabinet etc. as well as the bearings of the elevating cab D270 (may cause damage to the bearing surfaces and result in sudden, uncontrolled motion when positioning the cab), must never be subjected to a direct stream of water! Wet cleaning of these components is prohibited! When wet cleaning the machine, always make sure that no water/ moisture comes into contact with electrical or electronic components. The ingress of water can otherwise damage or destroy the electrical system of the machine. This can result in sudden, uncontrolled motion when working.

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Safety when performing maintenance - Oils and lubricants

1.14 Oils and lubricants Only use oils and lubricants approved by Sennebogen. These are listed in the LUBRICANTS TABLE. The ambient temperature for operating the machine must be between -20 °C (- 4 °F) and + 40 °C (+ 104 °F). If the temperature at the site lies outside these values, discuss this with Sennebogen Customer Service before starting operation. WARNING Mixing oils, lubricants or operational fluids of different types is not permitted! Filling or mixing oils, lubricants or operating fluids (e.g. hydraulic oil, gear oil, motor oil, coolant, etc.) of different types can, for instance, lead to damage to machine components caused by chemical reactions. This damage can in turn result in severe damage to property and to personal injuries. Use oils, lubricants and operational fluids that are approved by SENNEBOGEN only. Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer! Oil diagnosis

A regular oil diagnosis helps to avoid unnecessary costs. A series of tests will determine: z the condition of the oil z the amount of worn metal in the sample z the wear rate of components

Recommended for hydraulic system. Further information is available from Sennebogen Customer Service. Biodegradable oils and lubricants

The use of such substances is expressly required where the leakage of mineral-based oils and lubricants presents a danger to the environment. The use of environmental-friendly lubricants is mandatory, particularly in water or nature conservation areas. Only synthetic, ester-based bio-oils may be used. WARNING Switching to bio-oils and bio-lubricants is only permitted subject to agreement and written confirmation of Sennebogen Customer Service.

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Safety when performing maintenance - Engine coolants

1.15 Engine coolants 1.15.1 Coolant for CATERPILLAR engines The Caterpillar engines can be recognized by the 17-digit PIN (Product Identification Number) and the rating plate. Example: *CAT 0789BG 6SL12345* Note The Caterpillar engines are filled with the coolant z Caterpillar CAT ELCTM (Extended Life Coolant)

in the factory. Use only this coolant for the Caterpillar engines! SENNEBOGEN will accept no responsibility and will provide no warranty or make any guarantees for the use of any other coolants. Note Observe the coolant label in the cooler area.

ATTENTION! Observe the notes in the operating instructions of the motor manufacturer as well as the special additional documentation on the Caterpillar CAT ELCTM- Coolant. These are for the operational safety of the machine. Note SENNEBOGEN recommends using the pre-mixed coolant from Caterpillar CAT ELCTM, which is available in two different concentrations.

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Safety when performing maintenance - Engine coolants

1.15.2 Coolant for DEUTZ engines The DEUTZ engines can be recognized by the ratings plate. Note The DEUTZ engines are filled with the coolant z Hunold Coolant ANF based on monoethyleneglycol in the factory.

Use this coolant only for the DEUTZ engines! SENNEBOGEN will accept no responsibility and will provide no warranty or make any guarantees for the use of any other coolants. Note Observe the coolant label in the cooler area.

ATTENTION! Also observe the notes in the operating instructions of the engine manufacturer. These are for the operational safety of the machine.

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825D / 11.2006

Safety when performing maintenance - Engine coolants

1.15.3 Coolant for Cummins engines The Cummins engines can be recognized by the ratings plate. Note The Cummins engines are filled with the coolant z ES COMPLEATTM

in the factory. Use only this coolant for the Cummins engines! SENNEBOGEN will accept no responsibility and will provide no warranty or make any guarantees for the use of any other coolants. Note Observe the coolant label in the cooler area.

ATTENTION! Also observe the notes in the operating instructions of the engine manufacturer. These are for the operational safety of the machine.

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Safety when performing maintenance - Engine coolants

1.15.4 Coolants - General WARNING Mixing coolants and adding cooling system sealing agents or antifreeze that contains sealing agents is not permitted. By filling or mixing different types of coolant or cooling agent additives, the mixture can gel or build up to plug the cooler, resulting in the engine overheating or the cooling system failing and therefore causing damage to the engine. WARNING Mixing of nitrite-based cooling agents with amine-based agents produces health-hazardous nitrosamines. Use the coolant indicated and described in chapter 3.3.1 and 3.3.2 depending on the motor that is installed. The antifreeze is sufficient to -37 °C (-34 °F). Note Observe the coolant label in the cooler area. If the ambient temperature at the work-site is under this value (-37 °C (-34 °F)), observe the operating instructions of the motor manufacturer or contact SENNEBOGEN - customer service before starting operation. Note If only a small amount (up to max. 5 l) is required to fill the water-coolant circuit and no suitable coolant is available, you can top up with clean water for the time being. We recommend that you test the concentration at the next possible opportunity before freezing temperatures however. In some cases, you must refill with the respective coolant so that the required mixture is achieved again to prevent freezing. The coolant is not only required to guarantee the protection against freezing, it also performs the very important task of protecting against corrosion. This also requires checking for the correct concentration and adding when necessary.

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Safety when performing maintenance - Engine coolants

Water: Note z Use clean, neutral, filtered, fairly soft fresh tap water. Sennebogen recommends distilled water as the best variant. z Please note that Caterpillar specifies using distilled water! z Do not use ditch water, industrial drain water, salt water, sea water

or rain water. z Always fill using a water-coolant mixture. Observe mixing ratios.

Mix before filling! Ensure that the water has the following characteristics: pH value

7-8

Chloride content

max. 100 ppm

Sulphate content

max. 100 ppm

Water hardness

3-12 °dGH

Note Observe the recommended mixing ratio (see manufacturer's specifications). If the coolant concentration is too high, the cooling and antifreeze behavior will deteriorate. ATTENTION! Follow the instructions of the coolant manufacturer. WARNING Never fill with coolant when the motor is overheated. This will cause damage to the motor. Allow the motor to cool first. WARNING Regarding possible danger to health or environmental dangers, observe the instructions for using the coolant manufacturer as well.

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Safety when performing maintenance - Fuel (not for equipment with electric motors)

Using other coolants

If you should ever use a coolant other than that specified, the following must be considered or expressly observed. SENNEBOGEN will accept no responsibility and will provide no warranty or make any guarantees for the use of any coolants other than those previously indicated. WARNING Scalding hazard! Be careful when draining hot coolant! First allow the engine to cool down. Catch the coolant in a suitable container when draining and dispose of according to the respective regulations.

Changing coolant

– The cooling system is to be emptied completely before filling again. – Rinse the cooling system several times with clear water to rid it of any residue. – Fill the cooling system and check the level after a short waiting period. – Start the motor and check the coolant levels ATTENTION Adjusting to the correct coolant level must sometimes be checked more than once. Check the following states when inspecting the coolant levels regularly, e.g. – lubricant incursion, – obvious opacity caused by corrosion residue or other particulate matter, in which case, the coolant must be replaced as indicated above.

Coolant change intervals

Information on changing the coolant and the changing intervals is provided in the operating instructions of the engine manufacturer.

1.16 Fuel (not for equipment with electric motors) Fill the tank with the specified grade of fuel. Clean fuel is essential for trouble-free operation of the diesel engine. Note regarding fuel grade and selection Please observe the notes and recommendations in the operating instructions of the engine manufacturer.

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Safety when performing maintenance - Welding work

1.17 Welding work WARNING z Welding work must only be carried out by an authorized and qualified welding specialist. z It is forbidden to carry out drilling or welding on

– boom sections – load-bearing frame parts – the engine – the hydraulic tank – the fuel tank – parts feeding fuel and oil z Cover vulnerable components with fireproof material.

Preliminary work

825D / 11.2006

Before starting welding work, carry out the following preliminary tasks. 1

If necessary, switch off the optional battery isolator switch in order to interrupt the current.

Disconnect battery.

The battery must be switched off (no current flowing) when attaching or removing the battery cables.

Secure the ground clamp of the welding unit directly to the component to be welded.

Prior to any welding, remove the paint from a generous area round the point to be welded. Hazardous gases can form and cause irritation.

1 - 19

Safety when performing maintenance - SENNEBOGEN Diagnostics System (SDS)

1.18 SENNEBOGEN Diagnostics System (SDS) Note Sensors monitor the current operating state of the machine and transmit the information to the SDS. The measured data are evaluated in the SDS and displayed automatically or at the push of a button on the unit. If irregularities occur on the machine, the indicator and warning lights are activated. After the ignition is switched on, the SDS performs a self-check. If the SDS detects a fault condition, it is displayed on the screen and by means of LEDs. Correct a minor fault condition (clogged air filter, empty fuel tank or the like) by yourself without delay. Contact SENNEBOGEN Customer Service to correct a more serious irregularity (one that you cannot correct yourself). SENNEBOGEN Diagnostics System

Note Further information on the SDS is contained in the operating instructions. ATTENTION! The SENNEBOGEN Diagnostics System must never be cleaned with cleaning agents containing alcohol or solvents. Failure to observe the above could result in damage to the plastic surface.

1 - 20

825D / 11.2006

Maintenance schedule

2 Safety instructions

Maintenance schedule

Read the safety instructions before starting work. WARNING z The maintenance work described may only be carried out by trained and instructed specialist personnel. z Wear personal safety equipment (e.g. safety helmet, ear protection,

protective gloves, safety boots). Shorter intervals may be necessary when operating in extreme conditions, e.g. high ambient temperatures. Note Shorter intervals may be necessary when operating in extreme conditions, e.g. high ambient temperatures.

825D / 11.2006

2-1

Maintenance schedule daily/weekly General

Steps to take

Are the danger areas (overhead lines, ditches, etc.) marked and secured in the operating area? Do you know the operating and environmental conditions (soil strength etc.)? Is an experienced signaler available, if required?

Is there anyone in the danger area?

Do you know the weight of the load?

Are the machine and load securing devices appropriate for the loads to be suspended?

Mark and secure as necessary If necessary, obtain information If necessary, arrange for a signaler If so, advise them to leave the danger area Refer to the operating instructions as necessary. Refer to the operating instructions as necessary.

A1 A2

Functional check F1

Is the limit sensor on the arm set correctly?

If necessary, adjust

Is the hoisting limit sensor set correctly?

If necessary, adjust

Is the overload warning device activated?

If necessary, activate

Is the machine positioned horizontally?

Is the stability of the machine assured?

F10

Are all safety features (brakes, monitoring/warning indicators, signal and lighting devices) working correctly? Are any warning or fault messages displayed on the SDS? Are electrical devices such as the windshield wipers, heating, air conditioning working correctly? Is the emergency lowering feature of the elevating/maneuverable cab functioning? Check steering for correct adjustment and operation.

If necessary, position correctly If necessary, support properly If necessary, replace bulbs, locate and correct faults

F11

Is the central lubrication unit functioning?

F7 F8 F9

If necessary, locate and correct faults, read fault log If necessary, locate and correct faults If necessary, locate and correct faults If necessary, readjust. Grease must appear at all connected lubrication points.

Visual checks S1 S2

Are all protective covers, insulating materials and warning signs in place on the machine and intact? Are all steps/ladders, handles/handholds and antislip surfaces in place and intact (e.g. cracks)? Is the machine clean enough to ensure no danger areas exist due to dirt (danger of slipping, falling, poor visibility)?

If necessary, replace

Are the windows clean and free of ice and snow?

If necessary, repair or replace If necessary, clean using a high-pressure cleaner. Be careful around sensitive or electrical components! If necessary, clean

Is the undercarriage/running gear (tires, axles, drive shafts/universal joints) intact? Are the wheel nuts tight and the intermediate ring firmly seated? Is the tire pressure correct (machines with pneumatic tires)?

If necessary, repair or replace If necessary, retighten to the specified torque. If necessary, pump up tires (using a tire cage).

S6 S7

2-2

Chapter

; ; ;

825D / 11.2006

Maintenance schedule Is the hydraulic system (lines, hoses etc.) free of leaks and intact? Are the hydraulic cylinders (e.g. support, arm, floating axle cylinders, steering cylinders) free of leaks and intact? Inspect piston rods for cracks. Is the shutoff on the hydraulic tank open?

If necessary, tighten connections or replace seals If necessary, tighten connections or replace seals

If necessary, open

S11

Are the oil and fluid reservoirs sufficiently full (hydraulic system, fuel tank, engine oil, cooling system, windshield washer etc.)?

S11

Is the fan wheel intact?

If necessary, top up hydraulic oil, fuel, engine oil and windshield washer fluid. Follow manufacturer’s instructions! If necessary, replace

S11

Are the cooler and cooling system free of leaks?

If necessary, replace

S14

Are all hose clamps tight and the hose connections free of leaks? Is there enough grease in the central lubrication system? Has the water separator on the fuel system been drained? Are the V-belts intact and tensioned?

If necessary, retighten

S8 S9 S10

S12 S13 S14

If necessary, refill If necessary, drain

S16

Are the cooling fins on the combination cooler soiled or damaged? Are the electrical lines damaged?

If necessary, retension or replace If necessary, clean by reversing the fan or replace If necessary, replace

S16

Are the batteries held in place securely?

If necessary, resecure

S16

Are the cable connections (terminals) on the battery corroded?

S17

Are all service access doors closed?

If necessary, clean and grease, Cover terminals with protective caps If necessary, close

S18

Are all bolted connections – especially on the elevating cab – intact and tight? Have any cable connections to external power sources been disconnected? Is the correct counterweight (ballast) installed and secured in place? Are the boom components intact? Inspect for corrosion and cracks. Are any bolts cracked or damaged?

If necessary, tighten or replace

Are the pipe rupture safeties (restraints) tight and intact? Are the lubrication lines intact and all lubrication points being greased? Are the hydraulic lines and hoses secured in place?

If necessary, replace

S28

Are the quick-connect couplings free of leaks and the protective caps in place? Is the slewing mechanism intact and lubricated sufficiently? Is the slewing ring filling cover (internal gearing) in place and is there enough grease. Inspect the positive stops for the steering for wear.

If necessary, replace couplings and attach protective caps If necessary replace and lubricate gearing If necessary, re-install and refill grease If necessary, replace

S28

Inspect the power cable track for wear.

If necessary, replace

S15

S19 S20 S21 S22 S23 S24 S25 S26 S27 S27

825D / 11.2006

If necessary, disconnect If necessary, replace or resecure with specified torque If necessary, replace If so, replace

If necessary, replace, clean and lubricate If necessary, tighten fasteners

2-3

Maintenance schedule after 250 hours of operation

Component / activity

Material needed

Section

Transfer case

Check oil level

2 ea. O-ring

Steering axle: Hub

Check oil level

1 ea. O-ring Axle/differential

Check oil level

1 ea. O-ring Steering

Check positive stops for steering Check steering cylinder for leaks and proper operation

Rigid axle:

Hub

Check oil level

1 ea. O-ring Axle/differential

Check oil level

1 ea. O-ring

Drive shafts/universal joints

Lubricate joints via the grease nipples (3 each)

Undercarriage – steel components

Inspect for structural damage (e.g. deformation, defects, corrosion, cracks) using appropriate means

Slewing ring:

Visually inspect of all connecting elements for damage and corrosion

Cab:

Air conditioning system

Visually inspect the entire system for dirt, secure mounting, absence of leaks, hoses and electrical cables Switch on at least once a month

Hydraulics:

Return filter – replace filter element Leakage oil filter – replace filter element * Pilot control filter – replace filter element Hydro Clean – replace filter element (optional)

SE: 027417 2 ea.

7.1

SE: 027376

7.2

SE: 054520

7.2

SE: 054523

7.2

Engine:

Check coolant level, antifreeze concentration

: There is no pilot control filter when Hydro-Clean is installed! **: Filters in the hydraulic system should be changed initially after 250 hours of operation. Thereafter, change at the specified intervals.

2-4

825D / 11.2006

after 500 hours of operation

Components / activities

Maintenance schedule

Material needed

Section

SE: 057228

8.1

Steering axle:

Steering Check for secure installation of assemblies and steering components; if necessary, retighten with specified torque

Check positive stops for steering Check steering cylinders for leaks and proper operation Slewing ring:

Gearing/raceway Check for secure installation of slewing ring bolts; if necessary, retighten with specified torque Upper structure: Gallery Inspect for structural damage (e.g. deformation, defects, corrosion, cracks) using appropriate means Body hardware Check hinges, quick-latch catches, gas-filled struts for proper operation

Cab:

Air conditioning system

Have the air conditioning system inspected by an authorized inspection facility

Working tools:

Check load-carrying capacity with 1 t Hydraulics: the accumulator preload pressure checked by a company Have specializing in hydraulics ventilation filter on hydraulic tank for dirt and damage; Inspect if necessary, replace

Engine: maintenance intervals (see engine manufacturer’s Engine instructions) Inspect mounting and V-belts of the air conditioning compressor SE: 087040 Water separator – replace filter insert Check coolant level, antifreeze concentration Charge-air cooler – drain condensation

825D / 11.2006

9.1.3

2-5

Maintenance schedule after 1000/3000/5000 hours of operation

Components / activities

Material needed

Section

2 ea. O-ring 3 L transmission fluid

4.5

2 ea. O-ring 5 L oil

4.6

2 ea. O-ring

4.7

Transfer case

Check for secure installation of transmission and drive shafts / universal joints; if necessary, retighten with specified torque Oil change

Steering axle:

Hub

Oil change Brake

Brake wear measurement Axle/differential Check for secure installation of drive shafts / universal joints; if necessary, retighten with specified torque Steering Check for secure installation of assemblies and steering components; if necessary, retighten with specified torque Check positive stops for steering Check steering cylinders for leaks and proper operation

Rigid axle:

2 ea. O-ring 11 L oil

Oil change

Hub 2 ea. O-ring 5 L oil

Oil change Brake

Brake wear measurement

2 ea. O-ring

Axle/differential Check for secure installation of drive shafts / universal joints; if necessary, retighten with specified torque 2 ea. O-ring 15 L oil

Oil change

Floating axle cylinder

Check for secure installation; if necessary retighten with specified torque

Undercarriage – steel components

Check engagement / teeth of the slewing mechanism pinion gear slewing ring bolts inspected by an engineering company * Have and replace, if necessary Slewing ring play

2-6

Measure wear and inspect the bearing surfaces/bearing play

825D / 11.2006

Maintenance schedule

Components / activities

Material needed

Section

Slewing mechanism

Check for secure installation of slewing ring bolts using appropriate means; if necessary retighten with specified torque Upper structure: Steel components Inspect for structural damage (e.g. deformation, defects, corrosion, cracks) using appropriate means Gallery Inspect for structural damage (e.g. deformation, defects, corrosion, cracks) using appropriate means Body hardware Check hinges, quick-latch catches, gas-filled struts for proper operation Ballast Check for secure installation of ballast; if necessary, retighten with specified torque Fuel / hydraulic tank Check for secure installation; if necessary, retighten with specified torque Cab: Air conditioning system Have the air conditioning system inspected by an authorized inspection facility

Working tools:

Inspect for structural damage (e.g. deformation, defects, corrosion, cracks) using appropriate means Inspect bolts for cracks or defects Check load-carrying capacity with 1 t Check limit sensor settings for arm and boom

7.8

Check pipe rupture safeties (restraints)

Hydraulics:

Have the accumulator preload pressure checked by a company specializing in hydraulics Replace ventilation filter on hydraulic tank

SE: 057228

8.1

SE: 087040

9.1.3

Motor:

Engine maintenance intervals (see engine manufacturer’s instructions) Inspect mounting and V-belts of the air conditioning compressor Water separator – replace filter insert Check coolant level, antifreeze (concentration) Charge-air cooler – drain condensation Safety cartridge – change air filter

SE: 072385

Replaceable cartridge – change air filter

SE: 072386

*: every 5000 hours of operation or every 5 years 825D / 11.2006

2-7

Maintenance schedule after 2000/4000/6000 hours or operation

Components / activities

Material needed

Section

2 ea. O-ring 3 L transmission fluid

4.5

2 ea. O-ring 5 l oil

4.6

2 ea. O-ring

4.7

Transfer case

Check for secure installation of transmission and drive shafts / universal joints; if necessary, retighten with specified torque Oil change

Steering axle:

Hub

Oil change Brake

Brake wear measurement and functional check Axle/differential Check for secure installation of drive shafts / universal joints; if necessary, retighten with specified torque Steering Check for secure installation of assemblies and steering components; if necessary, retighten with specified torque Check positive stops for steering Check steering cylinders for leaks and proper operation

Rigid axle:

2 ea. O-ring 11 L oil

Oil change

Hub 2 ea. O-ring 5 L oil

Oil change Brake

Brake wear measurement

2 ea. O-ring

Axle/differential Check for secure installation of drive shafts / universal joints; if necessary, retighten with specified torque Oil change

2 ea. O-ring 15 L oil

Floating axle cylinder

Check for secure installation of assemblies and steering components; if necessary, retighten with specified torque

Undercarriage – steel components

2-8

Inspect for structural damage (e.g. deformation, defects, corrosion, cracks) using appropriate means Slewing ring: Gearing/raceway Check for secure installation of slewing ring bolts using appropriate means; if necessary retighten with specified torque Check engagement / teeth of the slewing mechanism pinion gear Slewing ring play Measure wear and inspect the bearing surfaces/bearing play

825D / 11.2006

Maintenance schedule

Components / activities

Material needed

Section

Slewing mechanism

Check for secure installation of slewing ring bolts using appropriate means; if necessary retighten with specified torque

Upper structure:

steel components

Inspect for structural damage (e.g. deformation, defects, corrosion, cracks) using appropriate means Gallery Inspect for structural damage (e.g. deformation, defects, corrosion, cracks) using appropriate means Body hardware Check hinges, quick-latch catches, gas-filled struts for proper operation Ballast Check for secure installation of ballast; if necessary, retighten with specified torque Fuel / hydraulic tank Check for secure installation; if necessary, retighten with specified torque Cab: Air conditioning system Have the air conditioning system inspected by an authorized inspection facility

Working tools:

7.8

Check pipe rupture safeties (restraints)

Hydraulics: Have the accumulator preload pressure checked by a company specializing in hydraulics Return filter – replace filter element Leakage oil filter – replace filter element * Pilot control filter – replace filter element Hydro Clean – replace filter element (optional) ** Change hydraulic oil ** Inspect hydraulic hoses for damage *** Replace hydraulic hoses Replace ventilation filter on hydraulic tank

825D / 11.2006

SE: 027417 2 St.

7.1

SE: 027376

7.2

SE: 054520

7.2

SE: 054523

7.2

SE: 057228

8.1

2-9

Maintenance schedule

Engine:

*: **:

***:

2 - 10

Engine maintenance intervals (see engine manufacturer’s instructions) Inspect mounting and V-belts of the air conditioning compressor Water separator – replace filter insert

SE: 087040

9.1.3

Change coolant Charge-air cooler – drain condensation Safety cartridge – change air filter

SE: 072385

Replaceable cartridge – change air filter

SE: 072386

There is no pilot control filter when Hydro-Clean is installed! Necessary only every 4000 hours of operation, provided that: the machine is equipped with a SENNEBOGEN Hydro-Clean System and an oil analysis is performed yearly/every 2000 hours of operation by a SENNEBOGEN-authorized laboratory and determined to be acceptable Change every 12000 hours of operation or 6 years

825D / 11.2006

Specifications of 825D with Cummins engine - Capacities

Specifications of 825D with Cummins engine

3.1 Capacities The following values are guidelines. The level specified on the corresponding components is authoritative. (upper mark on dipstick).

Engine

Machine

Cummins QSB6.7-C173 Output (in acc. with ISO14396)

129 kW (171.6 HP) at rated speed of 2200 min -1

Displacement

6700 cm3

Cylinders

Oil capacity with filter

approx. 18,5 L / approx. 4.88 gal. (US)

Engine, general

see manufacturer's instructions

Subassembly

Capacity

Fuel tank

approx. 480 L / approx. 127 gal. (US)

Hydraulic tank

approx. 300 L / approx. 79 gal. (US)

Hydraulic system, overall

approx. 370 l / approx. 98 gal. (US)

Transfer case

approx. 3.0 L / approx. 0.8 gal. (US)

Differential z front

approx. 11.0 L / approx. 2.9 gal. (US)

z rear

approx. 15.0 l / approx. 4 gal. (US)

Hub drive train

825D /11.2006

z front

each approx. 2.5 l / approx. 0.7 gal. (US)

z rear

each approx. 2.5 l / approx. 0.7 gal. (US)

Slewing ring lubrication reservoir

approx. 3 kg / approx. 6.615 lb

Central lubrication system reservoir (optional)

approx. 5.0 L / approx. 1.4 gal. (US)

3-1

Specifications of 825D with Cummins engine - Inspection tools - overview

3.2 Inspection tools - overview The following items are needed to inspect the machine at the specified maintenance intervals. Detailed information can be found at the corresponding inspection intervals. Machine

Item

Quantity

SE Number

O-ring for hydraulic tank

028627

Return filter:

027417

Leakage oil filter

027376

Ventilation filter

057228

Pilot control filter *)

054520

Hydro-Clean (optional)

054523

Recirculated air filter

??????

Outside air filter

??????

Drier bottle

??????

*) The pilot control filter is not needed if Hydro-Clean is used!

Engine

Item

Quantity

SE Number

Oil filter

027026

Fuel filter

089014

Water separator

087040

Safety cartridge-air filter

072385

Replacement cartridge-air filter

072386

V-belt - alternator

076901

V-belt - water pump

076902

V-belt - air conditioner

059077

V-belt - magnetic equipment (optional)

072950

Valve cover gasket

038926

Note If the machine is equipped with electric drive, only the ventilation air filter set (094559) is required.

3-2

825D / 11.2006

Specifications of 825D with Cummins engine - Lubricating the machine

3.3

Lubricating the machine

Note The machine comes with a central lubrication system for the slewing mechanism and attachments as well as the optional cab positioning mechanism. ATTENTION! The reservoir for the central lubrication system must always be adequately filled in order to prevent damaging the bearings. Central lubricationoverview

= bearings supplied with grease by the central lubrication system

825D /11.2006

3-3

Specifications of 825D with Cummins engine - Lubricating the machine

Clean lubricating nipple before lubricating. Lubricate with grease in accordance with chapter 5 of the maintenance instructions. Remove excess grease (see also chapter 1.7). Lubrication nipples - overview

a Centralized lubrication, front: Steering knuckle (2 per side) Support cylinder, inner (2) Floating axle (1)

Note.: 4 grease nipples per drive shaft/ universal joint

b Centralized lubrication, rear: Support cylinder, inner (2)

= grease manually

3-4

825D / 11.2006

Specifications of 825D with Cummins engine - Tightening torques for bolts

3.4

Tightening torques for bolts

Note For certain assembly bolts on the undercarriage, values differing from those listed in this table may apply. Please observe the notes in the respective sections. Strength class 8.8

825D /11.2006

Coarse thread

Fine thread

Bolt

Tightening torque MA [Nm]

Bolt

Tightening torque MA [Nm]

2.7

M8x1

5.4

M10x1

9.3

M10x1.25

M12x1.25

M10

M12x1.5

M12

M14x1.5

135

M14

125

M16x1.5

205

M16

190

M18x1.5

305

M18

275

M20x1.5

430

M20

385

M22x1.5

580

M22

530

M24x2

720

M24

660

M27x2

1050

M27

980

M30x2

1450

M30

1350

M33

1850

M36

2350

3-5

Specifications of 825D with Cummins engine - Tightening torques for bolts

Strength class 10.9

3-6

Coarse thread

Fine thread

Bolt

Tightening torque MA [Nm]

Bolt

Tightening torque MA [Nm]

4.0

M8x1

7.9

M10x1

M10x1.25

M12x1.25

125

M10

M12x1.5

120

M12

115

M14x1.5

195

M14

180

M16x1.5

300

M16

280

M18x1.5

435

M18

390

M20x1.5

610

M20

550

M22x1.5

830

M22

750

M24x2

1050

M24

950

M27x2

1500

M27

1400

M30x2

2100

M30

1900

M33

2600

M36

3300

825D / 11.2006

Specifications of 825D with Cummins engine - Tightening torques for bolts

Strength class 12.9

825D /11.2006

Coarse thread

Fine thread

Bolt

Tightening torque MA [Nm]

Bolt

Tightening torque MA [Nm]

4.7

M8x1

9.2

M10x1

M10x1.25

M12x1.25

145

M10

M12x1.5

140

M12

135

M14x1.5

230

M14

210

M16x1.5

350

M16

330

M18x1.5

510

M18

455

M20x1.5

710

M20

640

M22x1.5

960

M22

880

M24x2

1200

M24

1100

M27x2

1750

M27

1650

M30x2

2450

M30

2200

M33

3000

M36

3900

3-7

Specifications of 825D with Cummins engine - Conversion factors

3.5 Pressure

1 bar

100 Kpa

14.5 psi

10 psi

68.95 Kpa

0.6895 bar

1 L/min

0.0353 cfm

1 gal. (Brit.) / min

0.1605 cfm

1 km

39340 in

3280.8 ft

1 km

1093.6 yd

0.62137 mile

Weight

1 kg

2.205 lb

35.27 Oz

Power

= HP x 0.746

= kW x 1.341

°C

= (°F -32) x 5/9

°F

= (°C x 9/5) + 32

Flow rate

Distance

Temperature

Volume

3-8

Conversion factors

1 m3

1000 L

35.31 ft3

61020 inch3

1 ft3

28.32 L

0.02832 m3

1728 inch3

0.2642 gal. (US)

0.2201 gal (Brit.)

1 gal. (US)

3.785 L

231 inch3

1 gal. (Brit.)

4.544 L

277 inch3

825D / 11.2006

Engine -

4 Safety instructions

Engine

Read the safety instructions before starting work. WARNING! z Only carry out maintenance or repair work with engine shut off and cooled down. z Secure machine against unauthorized re-starting before starting

with maintenance work. z Waste oil must not be allowed to seep into the ground or waterways.

Dispose of oil and oil filters in accordance with statutory regulations. z Coolant must not be allowed to seep into the ground or waterways.

Dispose of coolant in accordance with statutory regulations. z After maintenance work on the engine, check that all safety devices

have been installed and all tools are removed from the engine. Note Please also observe the instructions and recommendations in the engine manufacturer's operating instructions.

825D / 11.2006

4-1

Engine - Engine oil

4.1

Engine oil

WARNING! z Scalding hazard! Proceed with utmost caution when draining hot oil. z Waste oil must not be allowed to seep into the ground or waterways.

Dispose of oil and oil filters in accordance with statutory regulations. CAUTION! Mixing oils, lubricants or operational fluids of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer! Note Also comply with the notes in the operating instructions of the engine manufacturer. Detailed view of engine

1 Oil dipstick handle 2 Oil filler strainer

4-2

825D / 11.2006

Engine - Engine oil

Checking engine oil level

Changing the engine oil and oil filter

825D / 11.2006

Position machine horizontally.

Run engine for approx. 2 minutes until the system is filled with oil.

Shut off engine.

Open the service access door on the right.

Pull out oil dipstick (1) and wipe off using a clean, lint-free cloth.

Insert oil dipstick (1) up to stop and pull out again.

Check the oil level (with handle pointing upward!): The oil level must lie between the lower marking (MIN) and the upper marking (MAX).

If necessary top up with oil of the specified grade.

Insert oil dipstick (1) up to stop and pull out again.

Close the service access door on the right.

Warm up engine.

Position machine horizontally.

Switch off engine.

Open service access doors on the right.

Change engine oil and oil filter in accordance with the engine manufacturer's instructions.

Check the oil level (with handle pointing upward!): The oil level must lie between the lower marking (MIN) and the upper marking (MAX).

If necessary top up with oil of the specified grade.

Close the service access doors on the right.

4-3

Engine - Air filter

4.2 Safety instructions

Air filter

Read the safety instructions before starting work. CAUTION! z Never use gasoline, soap or hot liquids to clean the air filter. z Never use compressed air to clean the interior of the housing,

as dust and contamination can enter the engine. Air filter indicator lamp

The condition of the air filter is monitored by a sensor. The degree of clogging is determined by measuring the resistance to air flow through the filter. Once the maximum permissible resistance is reached, the air filter indicator light on the right side of the control panel lights up. A warning tone also sounds. Inspect and clean the air filter without delay. Note The air filter is located behind the left rear service access door service access door.

1 Air filter 2 Service access door

4-4

825D / 11.2006

Engine - Air filter

Air filter maintenance

Open the left rear service access door.

Open the locking clamps (2) of the air filter cover (1) and remove the air filter cover.

Remove replacement cartridge (3).

Clean the replaceable cartridge: – Blow out from inside to outside using dry compressed air (max. 29 PSI (2 bar)). – Only knock out if unavoidable!

Check replaceable cartridge for damage to the filter paper and the seals. Exchange if necessary.

Exchange safety cartridge (6) after 5 filter service intervals (at least every 2 years): – Remove the safety cartridge by pulling on the handle (4) . Never clean the safety cartridge! – Insert new safety carriage.

Insert new or cleaned replaceable cartridge (3).

Replace the air filter cover (1) so that the nose (6) faces downwards or the word "TOP" faces upwards.

Reattach the air filter cover (1) using the locking clamps (2).

Close the service access door.

6 1 Air filter cover 2 Locking clamps (3 each) 3 Replaceable cartridge 4 Handle 5 Safety cartridge 6 Nose

825D / 11.2006

4-5

Engine - Fuel system

4.3 Safety instructions

Fuel system

Read the safety instructions before starting work. WARNING! z Danger of injury from rotating parts! Only carry out maintenance work with the engine shut off and the cooling system cooled down. z Do not handle open flames when working on the fuel system!

No smoking! z Also comply with the notes in the operating instructions of the

engine manufacturer.

4.3.1 Water separator 1

2 4

6 7

1 Hand pump 2 Filter cartridge 3 Shutoff valve 4 Bleed screw 5 Sensor connector 6 Drain valve 7 Water reservoir

4-6

825D / 11.2006

Engine - Fuel system

Draining off water

Changing the filter cartridge

*Tightening torque 18 Nm!

825D / 11.2006

Place a suitable collection vessel under the water reservoir (7).

Open the drain valve (6).

Allow water and dirt to drain out of the water reservoir.

Close the drain valve again.

The filter element must be changed after draining the water five times. 1

Close the shutoff valve (3).

Press the knob on the hand pump (1) in while turning to the left. -> The spring-loaded knob pops out.

Remove the sensor connector (5).

Unscrew the filter cartridge (2) from the upper part of the housing.

Unscrew the water reservoir (7) from the cartridge.

Dispose of the cartridge and O-rings.

Wet new O-rings with diesel fuel.

Screw the water reservoir* with new O-ring onto the cartridge.

Screw the filter cartridge* with new O-ring onto the upper part of the housing.

Reattach the sensor connector.

Open the shutoff valve.

Unscrew the bleed screw (4) slightly.

Using the hand pump, pump fuel into the water separator until it comes out through the bleed screw.

Screw in the bleed screw.

Press the knob on the hand pump (1) in while turning to the right. -> The spring-loaded knob is now secured in the upper part of the housing once again.

4-7

Engine - Cooler

4.4 Safety instructions

Cooler

Read the safety instructions before starting work. WARNING! z Danger of injury from rotating parts and scalding! Only carry out maintenance work with the engine shut off and the cooling systemcooled down. z Coolant must not be allowed to seep into the ground or waterways.

Dispose of coolant in accordance with statutory regulations. CAUTION! Mixing oils, lubricants or operational fluids of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

Coolant level indicator lamp

The coolant level is monitored by a sensor. If the coolant drops below a certain level, a warning tone is sounded. Top up coolant. If the coolant level is too low, check the fittings and lines for leaks. The machine is equipped with a combination cooler for coolant, hydraulic oil and charge air. 1 Combination 2 Service acce

Fig. Cooler grille

1 2

4-8

825D / 11.2006

Engine - Cooler

Cleaning the cooler.

Allow the engine and combination cooler (1) to cool down.

Open the service access door (2).

Small amounts of dirt can be blown out by reversing the fan. To do so: Actuate the fan reversal switch in the driver's cab.

Otherwise, blow off cooling fins from the outlet side with dry, filtered compressed air (max. 29 PSI (2 bar)). If contaminated with grease and oil, clean the cooling ribs with detergent.

Check cooler for leaks and damaged cooling fins.

Close the service access door.

Check coolant level and/or antifreeze

3 4

5 3 Hand screws 4 Handle 5 Service panel 6 Cap

825D / 11.2006

Allow engine and cooler to cool down.

Unscrew the two hand screws (3).

Grab the service panel (5) by the handle (4) and remove.

Pace large, thick cloths on the cap (6) of the coolant expansion tank and open it carefully in order to equalize the pressure.

Check antifreeze and coolant level, top up if necessary. Mixing ratio: 50% antifreeze, 50% water. This mixture withstands temperatures down to -40 °F (-40 °C).

Close the cap on the expansion tank.

Replace the service panel and secure using the hand screws.

4-9

Engine - Cooler

Additional information is contained in the separate maintenance instructions.

Coolant change intervals

SENNEBOGEN recommends a change interval of 2000 hours of operation or max. 24 months, whichever comes first.

Note To exchange the coolant, refer to the directions in the operating instructions of the engine manufacturer.

4 - 10

825D / 11.2006

Engine - Belt drives

4.5 Safety instructions

Belt drives

Read the safety instructions before starting work. DANGER! z Only carry out maintenance work with engine shut down and stationary. z Shut down machine and secure against unauthorized re-starting

before starting with maintenance work. z Where applicable, replace protective covers after maintenance work. z Make sure that the V-belts run in parallel.

Note To check, tension and change the belt drives,refer to the directions in the operating instructions of the engine manufacturer.

Fig. Belt drives

Drive belts 1 Alternator 2 Generator for magnet attachment (optional) 3 Air conditioner (optional) 4 Diesel fuel injection pump

825D / 11.2006

4 - 11

Engine - Belt drives

4 - 12

825D / 11.2006

Undercarriage - Cleaning and lubricating

Undercarriage

WARNING! z Danger of injury from rotating parts! Only carry out maintenance work when the engine is switched off. z Maintenance and repair work must only be carried out by trained

specialist personnel. z Oil must not be allowed to seep into the ground or waterways.

Dispose of waste oil in accordance with the statutory regulations.

5.1 Cleaning and lubricating 1

Position machine horizontally.

Shut down engine.

Clean tires and running gear using a steam cleaner. Attention! Hold the steam cleaner lance at least 20 cm (7.9 inch) from the surface to be cleaned.

Lightly grease guides and bolts.

Lubricate all lubrication points (see Section 3.3).

5.2 Tire air pressure (pneumatic tires) DANGER! When pumping up tires, maintain adequate safety distance and use tire cage. Tire size

825D /11.2006

Air pressure bar

psi

10.00-20

7.5

108.78

12.00-20

130.53

12.00-24

145.04

395/85

8.5

123.28

5-1

Undercarriage - Tightening the wheel nuts

5.3

Tightening the wheel nuts

Check tightness of all wheel nuts. The tightening torque is 650 Nm. Use a torque wrench. Fig. Twin tires, solid rubber

5.4 Hub drive train

1 2

1 Oil filler/drain screw 2 Oil level marking

ATTENTION! Mixing oils, lubricants or operational fluids of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

5-2

825D / 11.2006

Undercarriage - Hub drive train

Checking the oil level

Changing the oil

825D /11.2006

Position machine horizontally.

Turn hub until the marking (2) is horizontal and the lettering can be read.

Shut down engine and secure against re-starting.

Unscrew oil filler/drain screw (1). The oil level must reach up to the marking (2), top up if necessary.

Clean components, check seal and replace if necessary.

Re-tighten the oil filler/drain screw (1).

Repeat procedure on the three remaining hubs.

Position machine horizontally.

Turn hub until the oil filler/drain screw (1) is at the bottom.

Shut down engine and secure against re-starting.

Place a suitable collecting vessel under the oil filler/drain screw (1). For capacity, see Section 3.1.

Unscrew the oil filler/drain screw (1) and collect the waste oil in the container.

Clean components, check seals and replace if necessary.

Turn hub until the marking (2) is horizontal and the lettering can be read.

Fill with new oil up to the marking (2).

Re-tighten the oil filler/drain screw (1).

Repeat procedure on the three remaining hubs.

Operate for 2 hours, then re-check the oil level.

5-3

Undercarriage - Transfer case

5.5

Transfer case

1 2 1 Oil filler screw 2 Oil drain screw

Changing the oil

5-4

Bring machine up to operating temperature.

Position machine horizontally.

Switch off engine. Wait approx. 10 minutes for the oil to collect in transfer case.

Clean exterior of the transfer case using a cloth.

Unscrew oil filler screw (1). The oil level must reach up to lower edge of filler opening, top up if necessary.

Clean components, check seal and replace if necessary.

Re-tighten oil filler screw (1).

Bring machine up to operating temperature.

Position machine horizontally.

Switch off engine. Wait approx. 10 minutes for the oil to collect in transfer case.

Clean exterior of the transfer case using a cloth.

Loosen oil filler screw (1) to relieve the pressure.

825D / 11.2006

Undercarriage - Differential

Place a suitable container under the oil drain screw (2). For capacity, see Section 3.1.

Unscrew oil drain screw (2) and collect the waste oil in the container.

Clean components, check seals and replace if necessary.

Re-tighten oil drain screw (2).

Unscrew oil filler screw (1).

Fill with new oil up to lower edge of filler opening.

Re-tighten oil filler screw (1).

Operate for 2 hours, then re-check the oil level.

5.6 Differential

1 2 1 Oil filler screw 2 Oil drain screw ATTENTION! Mixing oils, lubricants or operational fluids of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

825D /11.2006

5-5

Undercarriage - Differential

Checking the oil level

Changing the oil

5-6

Bring machine up to operating temperature.

Position machine horizontally.

Switch off engine. Wait approx. 10 minutes for the oil to collect in the differential.

Clean exterior of differential using a cloth.

Unscrew oil filler screw (1). The oil level must reach up to the lower edge of filler opening, top up if necessary.

Clean components, check seal and replace if necessary.

Re-tighten oil filler screw (1).

Bring machine up to operating temperature.

Position machine horizontally.

Switch off engine. Wait approx. 10 minutes for the oil to collect in the differential.

Clean exterior of differential using a cloth.

Loosen oil filler screw (1) to relieve the pressure.

Place a suitable container under the oil drain screw (2). For capacity, see Section 3.1.

Unscrew oil drain screw (2) and collect the waste oil in the container.

Clean components, check seals and replace if necessary.

Re-tighten oil drain screw (2).

Unscrew oil filler screw (1).

Fill with new oil up to lower edge of filler opening.

Re-tighten oil filler screw (1).

Operate for 2 hours, then re-check the oil level.

825D / 11.2006

Undercarriage - Drive shafts/universal joints

5.7 Drive shafts/universal joints Note The two drive shafts/universal joints have three grease nipples each. Each joint is lubricated via one grease nipple; the third nipple is used to lubricate the telescopic profile. ATTENTION! To avoid damaging the seals and prevent the ingress of water and dirt, high-pressure cleaning must not be used to clean the drive shafts/ universal joints. Note Check the following items regularly: z Fittings and connecting flanges z Drive shaft/universal joints for unusual noises and vibration

during operation z Drive shaft/universal joints for play in the bearings and length

compensation prior to lubricating

1 2

1 Grease nipple for cross joint (shown here with protective cap) 2 Grease nipple for telescopic profile (shown here without protective cap) Lubricating the drive shafts/universal joints

825D /11.2006

Lift the machine using all four supports.

Shut off engine and secure against re-starting.

Turn the wheels until the grease nipples on the universal joints are in an accessible position.

5-7

Undercarriage - Drive shafts/universal joints

5-8

Remove the protective caps from the grease nipples.

Press the fill valve on the grease gun onto the grease nipple until it snaps into place.

Grease the joint by pumping the grease gun with a smooth motion. Note.: Grease must exit from the seals of the cross joints visibly. But: When lubricating the telescopic profile, pump the grease gun only a few times (not until grease appears, as otherwise excessive axial forces and damage to the seals will result!).

Repeat these steps with the remaining grease nipples.

Wipe off excess grease with a cloth.

Replace all protective caps on the grease nipples.

Retract the supports completely.

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Slewing mechanism -

Slewing mechanism

Ensure that the slewing mechanism is lubricated generously. z Raceway (1):

– via central lubrication. z Gearing (2):

– via grease filling

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1 Raceway 2 Gearing

6-1

Slewing mechanism - Lubricating the slewing ring raceway

6.1

Lubricating the slewing ring raceway

6.1.1 Central lubrication system The central lubrication system automatically lubricates the slewing ring raceway. The lubrication cycle is preset at the factory. Note The preset lubrication cycle can be shortened. In this regard, see the documentation on the CENTRAL LUBRICATION SYSTEM in Chapter 10 of the operating instructions. Shorter intervals between lubrication are needed, z in the tropics, z in regions with high humidity/moisture levels, z in areas with high levels of dust and dirt, z in regions with severe temperature variations, z when operating the slewing mechanism continuously.

1 Threaded cover - for refilling with grease 2 Grease reservoir - note MIN/MAX markings 3 Grease nipple - for refilling with grease

Initiating raceway lubrication manually

Lubrication can be initiated manually prior to the preset lubrication cycle. 1

6-2

Actuate the switch on the control panel:

825D / 11.2006

Slewing mechanism - Lubricating the slewing ring gearing

6.2

Lubricating the slewing ring gearing

6.2.1 Checking the grease fill level

CAUTION! Mixing oils, lubricants or operational fluids of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

825D / 11.2006

Rotate the upper structure counterclockwise away from the direction of travel by 360°.

Continue rotating the upper structure counterclockwise until the boom is oriented transverse to the undercarriage (90° with respect to the direction of travel).

Rotate the upper structure clockwise by 90° (boom in the direction of travel).

Remove cover plate (1).

A mound of grease must be visible (at least 0.79 inch (20mm)). If necessary, refill with grease.

Replace cover plate (1).

6-3

Slewing mechanism - Tightening the slewing ring bolts

6.3

Tightening the slewing ring bolts

DANGER! Danger to life! Defective slewing ring bolts can result in the upper structure tipping. For this reason, always observe the maintenance intervals! z Tighten slewing ring bolts using a torque wrench.

Observe the tightening torque specified in Section 3.4! z Inspect and, if necessary, replace the slewing ring bolts after

5000 hours of operation / every 5 years. Note The inspection must be performed by a specialist from an independent engineering company/independent institute. Unrestricted continued use of the slewing ring bolts must be documented by a certificate. Otherwise, replace the slewing ring bolts! Corroded or damaged bolts can fail and result in the upper structure tipping. z Do not tighten corroded or damaged bolts; instead, replace with new

bolts immediately. z Always use the correct number of bolts and the specified bolt diameter. z Use only original SENNEBOGEN replacement parts. z Should you have any further questions, contact SENNEBOGEN-

Customer Service. z If you suspect that any of the bolt connections are damaged,

have SENNEBOGEN-Customer Service perform an inspection! Fig.: Tightening with a torque wrench

6-4

825D / 11.2006

Slewing mechanism - Tightening the slewing ring bolts

Shut down engine.

Tighten the slewing ring bolts with a torque wrench, following an alternating pattern.

Note The tension on the initially tightened bolt is affected as the remaining bolts are tightened. It is thus necessary to make at least two passes. Use of a hydraulic bolt-tensioning cylinder is recommended when tightening bolts larger than M30 in size.

825D / 11.2006

6-5

Slewing mechanism - Tightening the slewing ring bolts

6-6

825D / 11.2006

Hydraulic system: - Safety instructions

Hydraulic system:

7.1 Safety instructions Read the safety instructions before starting work on the hydraulic system. DANGER! z Warning - high oil pressure! The hydraulic system is subject to high pressure. Serious injuries can be caused by escaping hydraulic oil when loosening a hydraulic connection or if a leak should occur. Only carry out work on a de-pressurized hydraulic system! z Work on the hydraulic system may only be carried out by trained

personnel with specialist knowledge of and experience with hydraulics. z Wear personal safety equipment (e.g. safety helmet, ear protection,

protective gloves, safety boots). z De-pressurize the hydraulic system before starting maintenance

work (see Section 7.4). z The pilot control is equipped with a pressure accumulator, which

remains under high pressure even after the engine is shut down. The pressure accumulator must therefore be de-pressurized. z Danger of injury!

If leaks are present, hydraulic oil will escape under high pressure. Hydraulic oil escaping under high pressure will penetrate the skin and cause severe damage to health. Danger of infection. In the case of injury contact a doctor immediately! z Danger of injury from scalding

The hydraulic oil can reach temperatures of 158°F (70°C) and above. Only carry out maintenance work once the hydraulic oil system has cooled down. z Danger of injury from rotating parts.

Only carry out maintenance work when the engine is switched off, and then only if you are sure that the fan wheel has come to a stop and there is no risk of automatic start-up. Before starting up again, ensure that: – No items (e.g. tools) are in the vicinity of the fan wheels or could fall into this area as a result of vibrations, for example – The protective features have been installed.

825D / 11.2006

7-1

Hydraulic system: - General

7.2

General

7.2.1 Hydraulic cylinder Pressure cylinders are subject to slight leakage. Remove excess leakage residue with a cloth. Dispose of oil-soaked cloth as hazardous waste. The sliding surfaces of the piston rods are chrome-plated. Heavier leakage indicates damaged sliding surfaces or defective seals. Cleaning hydraulic cylinders z Do not use sharp edged tools, caustic fluids or abrasives. z Wash down piston rods regularly using a steam cleaner.

Do not direct the jet straight at the sealing elements. z Apply preservative to extended piston rods after cleaning. This protects

the surface from the effects of the environment and weather. Fig.: Hydraulic cylinder on boom

7.2.2 Threaded fittings Check hydraulic fittings and connections regularly for leaks. Seal points of leakage and remove oil residue. Leaking hydraulic oil endangers the environment and presents a hazard due to danger of slipping. Always seal opened connections immediately at both sides with plugs.

7-2

825D / 11.2006

Hydraulic system: - Hydraulic hoses

7.3 Storage and service life

Hydraulic hoses

Even when used correctly at permissible loads, hoses and hose lines are subject to natural wear and tear. Their service life is therefore limited. The operator is responsible for ensuring that hose lines are replaced at suitable intervals, even when there are no obvious defects to be seen in the hose line. Hose lines must be replaced at least every six years, including a maximum of two years storage time, where applicable.

Inspection

Hose lines should be inspected by a specialist technician at least once a year to ensure that they are safe for further use. Remedy any defects discovered immediately.

Defects

Replace hose lines in the following cases (see also DIN 20066): z Outer layer damaged as far as reinforcement (e.g. abrasion points,

cuts, cracks); z Outer layer brittle (cracks appearing in hose material); z Deformation, which does not conform to the natural shape of the

hose or hose line, both when under and not under pressure, or when bent (e.g. layer separation, bubbles forming); z Leaks; z Hose fittings damaged or deformed (sealing function affected); z Hose has separated from fittings; z Corrosion of fittings which reduces function and strength; z Installation requirements ignored; z Storage times and/or service life exceeded.

825D / 11.2006

7-3

Hydraulic system: - De-pressurizing the hydraulic system

7.4

De-pressurizing the hydraulic system

Lower suspended loads and boom to the ground.

Shut down engine, move ignition key immediately back to position "1".

Move the control levers in the driver's cab in all directions several times. This relieves the pressure in the main hydraulic circuit and the accumulator for pilot control.

Open the cover plate.

Unscrew the threaded cap (1) on the hydraulic tank. This releases the residual pressure in the tank.

Connect the pressure gauge (reading up to max. 600 bar (8700 PSI)) to the measurement ports (P1, P2, P3, P4, PV9).

Note The pressure gauge must indicate 0 bar (0 PSI). If the pressure is not completely released, repeat points 2 to 6.

7-4

825D / 11.2006

Hydraulic system: - Checking the oil level.

7.5

Checking the oil level.

Lower suspended loads and boom to the ground.

Position machine horizontally.

Fully retract all hydraulic cylinders.

Shut down engine.

Open the service access door on the right.

825D / 11.2006

Check oil level on the oil level indicator (1): the oil level must reach the upper marking (MAX).

Top up hydraulic oil, if required: – Open the cover plate. – Unscrew the threaded cap (1) on oil filler neck. – Top up hydraulic oil and re-check. – Replace threaded cap. Close the cover plate.

7-5

Hydraulic system: - Changing the hydraulic oil

7.6 Safety instructions

Changing the hydraulic oil

Read the safety instructions before starting work on the hydraulic system. DANGER! z Warning - high oil pressure! The hydraulic system is subject to high pressure. Serious injuries can be caused by escaping hydraulic oil when loosening a hydraulic connection or if a leak should occur. Only carry out work on a de-pressurized hydraulic system! z Work on the hydraulic system may only be carried out by trained

personnel with specialist knowledge of and experience with hydraulics. CAUTION! Mixing oils, lubricants or operational fluids of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer! Note The task can be made easier by pumping out as much oil as possible. Use the opening of the return filter for this. Procedure

Lower suspended loads and boom to the ground.

Position machine horizontally.

Fully retract all hydraulic cylinders.

De-pressurize the hydraulic system as described in Section 7.4.

Remove filter element of return filter acc. to Section 7.7.

Place a suitable container under the drain opening of the tank. For the capacity, see Section 3.1.

CAUTION Ensure that the container is large enough to hold the relevant quantity of oil. Hydraulic oil must not be allowed to seep into the ground or water. Dispose of waste oil and oil filters in accordance with statutory regulations.

7-6

825D / 11.2006

Hydraulic system: - Changing the hydraulic oil

Unscrew cover nut (1).

2 3

Screw in drain plug until the waste oil emerges via the plastic hose. Collect waste oil in a suitable container.

Unscrew drain plug (2).

Screw cover nut (1) back on.

Fill with new hydraulic oil via the filler neck (2) on top of the tank.

Bleed the hydraulic pumps: – Clean the housing. – Loosen the bleed screw on the pump. Do not unscrew completely; hold in place by applying slight pressure with your thumb. – Wait several seconds until the air has escaped. – Re-tighten the bleed screw.

ATTENTION! Bleed pumps after every hydraulic oil change before re-commissioning to prevent damage.

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7-7

Hydraulic system: - Replacing return filter elements

7.7

Replacing return filter elements

A 1 2 3 B

7-8

Open screw cap (2) of hydraulic tank. This releases the residual pressure in the tank.

There are two return filters (A, B). Both filter elements must be replaced! Unscrew the four socket head bolts (1).

Remove cover (3).

Remove filter element and dispose of as hazardous waste.

Clean components, check seal and replace if necessary.

Insert new filter element.

Secure cover (3) with the four socket head bolts (2).

Tighten screw cap (2).

825D / 11.2006

Hydraulic system: - Replacing the pilot circuit filter element

7.8

Replacing the pilot circuit filter element

Note If the machine is equipped with the optional "Hydro Clean" filtering system, there is no pilot circuit filter!.

825D / 11.2006

Unscrew the filter housing (1).

Dispose of filter element (2) as hazardous waste.

Clean components, check seals and replace if necessary.

Insert new filter element (2) in filter housing (1).

Screw filter housing in by hand.

Check filter (1) for leaks.

7-9

Hydraulic system: - Replacing the leakage oil filter element

7.9

Replacing the leakage oil filter element

1 2

Loosen hexagon nuts (1).

Remove cover (2).

7 - 10

Unscrew filter element (3) from return line.

Screw new filter element onto the return line.

Re-attach cover with return line to tank.

Tighten hexagon nuts (1).

825D / 11.2006

Hydraulic system: - Replacing the ventilation filter

7.10 Replacing the ventilation filter Note The ventilation filter is integrated in the threaded cap (2) on the filler neck. The ventilation filter limits over-pressure and under-pressure in the hydraulic system during operation of the hydraulics. CAUTION Dirty ventilation filters let dust and dirt unfiltered into the hydraulic system. This can cause damage to the hydraulic system (e.g. to the pumps) and increased hydraulic oil wear.

825D / 11.2006

Lift cover.

Unscrew threaded cap (1) from the hydraulic tank.

Remove filter element (2) from the threaded cap (2).

Dispose of filter element (3) as hazardous waste.

Place new filter element on the threaded cap.

Replace threaded cap with ventilation filter.

Lower cover back into place.

7 - 11

Hydraulic system: - Hydro Clean – fine filtration system (optional)

7.11 Hydro Clean – fine filtration system (optional) Note The condition of the Hydro Clean filter element is monitored by the SDS. The filter element must be replaced when the associated warning lamp lights up. Changing the filter element

3 4 5

7 - 12

Remove both screws (2) and lift off perforated cover plate (1).

De-pressurize the hydraulic system as described in Section 7.4.

Unscrew cover (5) with integral hex nut (4).

Withdraw filter element.

Dispose of filter element (3) as hazardous waste.

Clean components, check seal and replace if necessary.

Insert new filter element.

Re-attach cover (5).

Start engine.

Unscrew socket head bolt (3) slightly until the bleed opening is exposed.

As soon as oil appears, screw the socket heat bolt back in.

Shut off engine and check filter for leaks.

Replace perforated cover plate (1) and tighten screws (2) again.

825D / 11.2006

Hydraulic system: - Checking the preload pressure of the accumulator

7.12 Checking the preload pressure of the accumulator Note The preload pressure is checked with the aid of the accumulator for the pilot control circuit. 1

Lower suspended loads and boom to the ground.

Connect pressure gauge to the measurement port.

Shut down engine, move ignition key immediately back to position "1".

Move both control levers in the driver's cab in all directions several times.

Observe the pressure gauge. As soon as the preload pressure is reached, the valve in the pressure accumulator closes. The needle in the pressure gauge to "0" immediately. The value displayed just prior to the pressure drop corresponds to the preload pressure of the accumulator.

Compare the displayed value with the tolerance specification on the accumulator. If the preload pressure lies outside the tolerances, replace the accumulator or re-charge with nitrogen.

Disconnect pressure gauge.

ATTENTION! Every 10 years/20,000 operating hours, arrange for a pressure test and an internal inspection by a specialist.

825D / 11.2006

7 - 13

Hydraulic system: - Checking the preload pressure of the accumulator

7 - 14

825D / 11.2006

Electrical system - Batteries

Electrical system

DANGER! Work on electrical system must be carried out by trained specialist electrical engineers.

8.1 Batteries Note The batteries are maintenance-free. Special conditions of use (climatic conditions, high operating hours) as well as older batteries may require regular monitoring of the acid level in the battery. DANGER! z Explosion hazard! No smoking or open flames. Avoid sparks in the vicinity of the battery. z Danger of acid burns!

Wear eye protection and gloves. Do not tilt the battery. Battery electrolyte is caustic and must not come into contact with eyes or skin. z Do not lay tools down on the battery. z Disconnect battery before starting welding work. z Do not interchange battery connections. z Dispose of old batteries as hazardous waste.

825D / 11.2006

8-1

Electrical system - Batteries

: Inspect terminals and cable connections

8-2

Open left rear maintenance panel.

Remove battery terminal covers (1). Ensure that no metal parts come into contact with both the positive and negative terminals of the battery (2) (risk of short circuit!)

Clean the terminals and cable connections on the batteries (2). Check for firm seating and grease with terminal grease.

Replace battery terminal covers.

Close maintenance panel again.

825D / 11.2006

Electrical system - Fuses

8.2

Fuses

WARNING! Fire hazard! Do not repair fuses. Always insert new fuses with the same amperage rating, never higher. If a newly inserted fuse blows again after only a short period of time, the electrical system must be inspected by a professional electrician.

Replacing fuses

Shut down engine and switch off ignition.

Open left rear maintenance panel (1).

Remove fuse box (2) cover (2).

Replace defective fuse.

Check contacts, clean oxidized contacts.

Replace cover of fuse box (1).

Close maintenance panel again.

Note Wiring, see inside of cover and electrical diagram.

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8-3

Electrical system - Fuses

8-4

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Heating/air-conditioning system - Heating

Heating/air-conditioning system

Note The machine is equipped with an active charcoal filter for the air in the cab.

9.1 Heating Cleaning the filter element

Note The filter element is located behind the driver's seat.

825D / 11.2006

Grasp the filter element (2) by the handle (1) and pull out.

Tap the filter element or carefully blow out with compressed air.

Insert the filter element. Ensure correct positioning. Clean air must exit in direction of travel.

9-1

Heating/air-conditioning system - Air conditioning (optional)

9.2

Air conditioning (optional)

WARNING When working on air conditioning systems, be aware that refrigerants and refrigerant vapors are hazardous to health. Wear appropriate safety equipment. z Maintenance and repair work must only be carried out by trained

specialist personnel. z Do not reach inside the unit and do not insert any objects. z Only carry out maintenance work with the engine shut down and fan

disconnected. z Allow the equipment and the components inside the equipment

(heat exchanger, resistors) to cool down completely; start maintenance work only then. z Freezing hazard, Wear protective gloves! Do not allow the

refrigerant to come into contact with bare skin. z Wear eye protection. If refrigerant comes into contact with the eyes

in spite of precautions, contact a doctor immediately. z Danger of injury! Avoid contact with the sharp-edged fins on the

condenser and heat exchanger. z Welding and soldering work on components of the air conditioning

system is prohibited! The pressure increase resulting from the higher temperature could cause an explosion. z Only refrigerant R134a in accordance with DIN 8960 may be used. z No fluorescent additives (tracer-agents, sticks)!

9-2

825D / 11.2006

Index

A Air filter 4-4 Antifreeze 4-9 B Belt drives 4-11 Bio-oils 1-12 C Central lubrication system 6-2 Checking the hydraulic oil level 7-5 Chloride 1-17 Cleaning hydraulic cylinders 7-2 Conversion of the machine 1-7 Coolant 4-8 Coolant level 4-8, 4-9 Cooler 4-9 Cooling system 4-8 Correct use 1-4 Customer Service Desk W-4 D Disposal 1-9 Batteries 1-9 Consumables 1-9 Lubricants 1-9 Driving earth-moving machinery 1-10 E Ear protection 1-7 Engine 3-1 Changing the oil 4-3 Changing the oil filter 4-3 Checking oil level 4-3 Environmental guidelines 1-9 Environmental protection 1-9 F Fire extinguisher 1-8 First aid box 1-8 Fuel system 4-6 G Gearing 6-1

825D / 11.2006

H Hydraulic fittings 7-2 I Initiating raceway lubrication manually 6-2 K Keyword W-3 L Lubricating the machine. 3-4 Lubricating the raceway 6-2 Lubricating the slewing ring gearing 6-3 Lubricating the slewing ring raceway 6-2 Lubrication cycle 6-2 Lubrication intervals 6-2 Lubrication nipple 3-4 M Maintenance schedule 2-1, 3-1 Misuse 1-4, 1-5 N Noise protection 1-7 O Oil diagnosis 1-12 Oil filler pipe 7-5 operation of the machine in an explosive environment. 1-5 Other risks 1-5 P Personal safety equipment 1-2 Personnel qualifications 1-7 Personnel selection 1-7 pH value, water 1-17 Potential instances of misuse 1-4 Pressure cylinders 7-2 Pressure gauge connections 7-4

R Raceway 6-1 Responsibilities of the operator 1-4 Reverse fan 4-9 S Safety instructions 1-1, 1-5 Sales and Service Partners W-4 Service Partners W-4 Slewing mechanism 6-1 Spare parts depot W-4 Spare parts manufacture 1-7 Specialist check 1-6 Strength classes for bolts 3-5 Symbols and illustration devices W-3 T Target group 1-4 Technical condition 1-7 Telephone W-4 Tightening torque 3-5 Topping up hydraulic oil 7-5 U use contrary to regulations 1-5 V V-belt 4-11 W Warning symbol W-3 Warranty conditions 1-8 Warranty manual 1-8 Water separator 4-6 Workplace of machine operator 1-4

S-1