Sennebogen 825 M Operating Instruction Manual 825.0.1039 - PDF DOWNLOAD by www.heydownloads.com

Operating Instructions

825 M

04.2007

825.0.1039

Important notes regarding the operating instructions

Notes regarding the instructions

Read through the operating instructions thoroughly, in particular Chapter 1 SAFETY, before starting work 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 Note lifting capacity tables in Section 3.2. 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 machine may be set up, operated and maintained by trained

personnel only. 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. z Maintenance of the machine is described in separate instructions.

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.

Current when going to press

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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.

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

Glossary of terms

Operator The operator (owner of the company/company) is responsible for operating the machine in a correct manner, or for ensuring that the product is being used by suitable and instructed personnel. Operating personnel The operating personnel are the person/s authorized by the operator to use the product. Specialist personnel Trained technicians are those authorized by the operator to fulfill certain obligations such as installation, fitting, repair and maintenance and troubleshooting. z Specialist

Specialists are those who, on the basis of specialist training, knowledge and experience with the product and in the full knowledge of the relevant standards, can appraise the work allocated to them and can recognize potential dangers and avoid them. z Instructed personnel

Instructed personnel are those who have received instruction in the tasks allocated to them and in the potential dangers of misuse and misbehavior, who have been taught about the necessary safety equipment, safety measures, relevant regulations, accident prevention guidelines and operating conditions and who have proved their abilities. z Expert

Experts are those who, on the basis of specialist training and experience have sufficient knowledge in the area of the product and are sufficiently aware of the relevant national occupational safety guidelines, accident prevention guidelines, regulations and generally recognized technical regulations (e.g. EEC-Guidelines, VDE-Regulations, VBG) as to be able to judge the operational safety of the machine. z Authorized expert

Authorized experts are those who are authorized by the technical authorities (TÜV) or by a trade association to check the machinery. Authorization by the trade association takes place in accordance with the “Principles for the authorization of experts for the testing of cranes” (ZH 1/518). It is linked with the issue of an identity number. This is to be stated by the authorized expert in the test report and/or test memo. Authorizations can be limited to parts of tests or specified crane types.

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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. Operation and deployment may only be carried out by trained personnel. Initial operation, maintenance, transportation and assembly/dismantling only by trained specialists. Detailed information on the prior knowledge and qualifications required of the operator can be found in Chapter 1 SAFETY of these instructions.

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Important notes regarding the operating instructions

Which documentation belongs with the machine?

The following documentation belongs to the machine: z These operating instructions z Maintenance instructions z Spare parts catalogue

Note The complete scope of delivery is defined in the order confirmation.

How are the instructions organized?

The instructions are split into 10 chapters: z 1: Safety

The applicable safety information is found here. z 2: Overview

The main components of the machine are shown in Chapter 2. z 3: Technical data

Here, you can find the fundamental machine information, e.g. lifting capacities. z 4: Commissioning

This chapter contains notes on daily machine maintenance and start-up. z 5: Operation

This chapter contains the information on the operational elements and operation of the unit. z 6: Inspecting, maintaining and cleaning

Chapter 6 gives procedures for ensuring the functionality of the machine. z 7: Transportation

Dimensions and weights of the machine are found in Chapter 7. z 8: Troubleshooting

This chapter contains notes on recognizing the causes of faults and how to correct them. z 9: Set-up work

Chapter 9 gives information on optional tools. z 10: Appendix

Here you will find an index of key words and additional info, e.g. about the warranty.

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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 540380

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

CE Conformity Symbol

The CE Stamp indicates that the basic safety requirements have been fulfilled. See separate conformity declaration as well.

EuroTest

EuroTest is a voluntary prototype test that is based on the EC machine guidelines and the respective European standards.

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Important notes regarding the operating instructions

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Contents

825 M / 04.2007

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.3 Potential instances of misuse . . . . . . . . . . . . . . . . 1-2 1.4 Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.5 Other risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.6 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1.6.2 Starting operation . . . . . . . . . . . . . . . . . . 1-10 1.6.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 1.6.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . 1-12 1.6.5 Transportation . . . . . . . . . . . . . . . . . . . . . 1-14 1.7 Responsibilities of the operator . . . . . . . . . . . . . . 1-15 1.8 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 1.9 Machine Labeling . . . . . . . . . . . . . . . . . . . . . . . . 1-20 1.9.1 Type plate . . . . . . . . . . . . . . . . . . . . . . . . 1-20 1.9.2 CE stamp of conformity . . . . . . . . . . . . . . 1-20 1.9.3 Warning and Notice Signs . . . . . . . . . . . . 1-21 1.9.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 1.10 Hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1 Complete machine . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.2 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.3 Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.4 Upper structure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.5 Central electrical system . . . . . . . . . . . . . . . . . . . . 2-5 2.6 Driver's cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.7 Pipe rupture safety . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1 Basic machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 Lifting capacities . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.3 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.4 Conversion factors . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Starting operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 Initial commissioning . . . . . . . . . . . . . . . . . . . . . . . 4-2

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Contents

4.3 Checks before daily start-up . . . . . . . . . . . . . . . . . 4-2 4.4 Switching on the machine . . . . . . . . . . . . . . . . . . . 4-6 4.4.1 Restraint belt (optional) . . . . . . . . . . . . . . . 4-6 4.4.2 Start engine . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.4.3 Bring machine up to operating temperature 4-8 4.4.4 Jump start . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 4.5 Switching off the machine . . . . . . . . . . . . . . . . . . 4-10 4.5.1 Shutting down the engine. . . . . . . . . . . . . 4-10 4.6 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . 4-11 5

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Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.2 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.2.1 Positioning the cab . . . . . . . . . . . . . . . . . . 5-4 5.2.2 Cab Emergency lowering . . . . . . . . . . . . . . 5-7 5.3 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5.3.2 Control panel, left-hand . . . . . . . . . . . . . . 5-10 5.3.3 Control lever, left-hand . . . . . . . . . . . . . . 5-11 5.3.4 Control lever, right-hand . . . . . . . . . . . . . 5-12 5.3.5 Safety lever . . . . . . . . . . . . . . . . . . . . . . . 5-13 5.3.6 Console to the right of the driver's seat . . 5-14 5.3.7 Control panels, lower right . . . . . . . . . . . . 5-15 5.3.8 Control panel, upper right . . . . . . . . . . . . 5-18 5.3.9 Radio (optional) . . . . . . . . . . . . . . . . . . . . 5-20 5.3.10 Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 5.3.11 SENNEBOGEN-Diagnostic-System (SDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 5.3.12 Central lubrication system . . . . . . . . . . . . 5-37 5.4 Automatic climate control . . . . . . . . . . . . . . . . . . . 5-38 5.4.1 Safety instructions - climate control system . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 5.5 Starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 5.5.1 Safety instructions . . . . . . . . . . . . . . . . . . 5-40 5.5.2 Driving the machine . . . . . . . . . . . . . . . . . 5-41 5.5.3 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 5.5.4 Supporting the machine . . . . . . . . . . . . . . 5-45 5.5.5 Rotating/braking the upper structure . . . . 5-48 5.5.6 Lifting/lowering loads . . . . . . . . . . . . . . . . 5-50 5.5.7 Limit position sensors . . . . . . . . . . . . . . . 5-51 5.5.8 Bypassing the safety limit position sensor 5-53

825 M / 04.2007

Contents

5.5.9 Grab operation . . . . . . . . . . . . . . . . . . . . . 5-54 5.5.10 Generator and magnet system (optional) 5-55 5.5.11 Refueling the machine . . . . . . . . . . . . . . . 5-57 5.6 Actions to take if the electronics fail . . . . . . . . . . 5-60 5.6.1 Reverse airflow -insufficient cooling capacity- . . . . . . . . . . . . . . . . . . . . . . . . . 5-60 5.6.2 Steering failure (optional with joystick steering) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61

825 M / 04.2007

Inspecting, maintaining and cleaning . . . . . . . . . . . . 6-1 6.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2 Daily/weekly checks . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.2.1 Check engine oil level . . . . . . . . . . . . . . . . 6-7 6.2.2 Check coolant level and antifreeze . . . . . . 6-8 6.2.3 Check hydraulic oil level . . . . . . . . . . . . . . 6-9 6.2.4 Check fuel level . . . . . . . . . . . . . . . . . . . . 6-10 6.2.5 Check windshield washer fluid level . . . . 6-10 6.2.6 Drain off water - fuel system . . . . . . . . . . 6-11 6.2.7 Check belt drives . . . . . . . . . . . . . . . . . . . 6-12 6.2.8 Check and clean airfilter cartridges . . . . . 6-13 6.2.9 Check grease fill level - slewing ring . . . . 6-14 6.2.10 Check fill level - central lubrication . . . . . 6-15 6.2.11 Check tire air pressure (pneumatic tires) . 6-16 6.2.12 Check tightness of wheel nuts . . . . . . . . . 6-16 6.3 Maintaining and cleaning . . . . . . . . . . . . . . . . . . . 6-17

Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.2 Dimensions and weight . . . . . . . . . . . . . . . . . . . . . 7-2 7.2.1 Transportation dimensions . . . . . . . . . . . . 7-2 7.2.2 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.3 Securing the upper structure . . . . . . . . . . . . . . . . . 7-3 7.4 Disconnect electrical system from battery . . . . . . . 7-4 7.5 Lifting machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 7.6 Tie down the machine . . . . . . . . . . . . . . . . . . . . . . 7-6

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.2 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8.3 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

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Contents

8.4 Tires and undercarriage . . . . . . . . . . . . . . . . . . . . . 8-5 8.5 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 8.6 SDS fault indicators . . . . . . . . . . . . . . . . . . . . . . . . 8-6 9

Set-up work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.1 Installing/dismantling the counterweight . . . . . . . . 9-2 9.1.1 Dismantling the counterweight . . . . . . . . . . 9-3 9.1.2 Installing the counterweight . . . . . . . . . . . . 9-4

10 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.1 List of abbreviations . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.2 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.3 Driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.4 Cleaning the cooling system . . . . . . . . . . . . . . . . 10-2 10.5 Quick-connect couplings . . . . . . . . . . . . . . . . . . . 10-2 10.6 Installing large roller bearings, gearing and flange connections . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.7 Magnet system . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.8 Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.9 Lubricants table . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

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825 M / 04.2007

Safety - General

Safety

1.1 General The machine is built in accordance with the current state of the art. Nevertheless, there may be dangers during its use to persons, machines and other property, if z the machine is not utilized as intended. z the machine is not operated or maintained by trained personnel. z the safety instructions are not observed. z the machine is found to be defective. z the operating tools attached do not comply with the relevant safety

regulations. z the operating tools attached are found to be defective.

National and international regulations apply in addition to the safety notes in these operating instructions. In the Federal Republic of Germany e.g.: z Winches, Lifting and Pulling Devices (VBG 8) z Cranes (BGV D6) z Hoisting equipment in Lifting Appliance Operation (VBG 9a) z EU Machinery Directive 98/37/EG z EMC Directive 89/336/EWG z Electrical Equipment of Machines (EN 60204-1) z Safety Requirements for Fluid Power Systems and their

Components - Hydraulic (EN 982) z Earth-moving Machinery – Safety (EN 474-1/-5) z Safety of Machinery (DIN EN 12100-1 and DIN EN 12100-2) z “Outdoor” Directive 2000/14/EC

Note If the national regulations deviate from our recommendations, the more stringent procedure should be followed.

825 M / 04.2007

1-1

Safety - Correct use

1.2

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 3 SPECIFICATIONS. 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

1.3 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 grille). z Operating on insufficiently firm base. z Neglect of necessary inspection and maintenance work.

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825 M / 04.2007

Safety - Misuse

1.4

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.

1.5 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.

825 M / 04.2007

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Safety - Safety instructions

1.6

Safety instructions

1.6.1 General Danger area

The danger area is the area around the machine where persons may come into contact with: z machine movements while in operation z working equipment and its attachments z swinging or falling loads z falling working equipment.

DANGER! There must be no one within the danger area! The machine operator must issue warning signals where persons are endangered. If the persons do not leave the danger area despite the warning, work must be stopped. To avoid becoming crushed by solid objects, e.g. buildings, walls to be removed, scaffolding or other machinery, a sufficient safety distance (at least 19 inch (500 mm)) must be maintained. If the safety distance cannot be maintained, then the area between the solid structure and the work area of the machine must be cordoned off. If the machine operator has restricted driving and working vision, then he must be guided.

Safe entry to/exiting from the driver's cab

z If necessary, clean steps (2) and stair rail (1) prior to use. z Do not carry any items when climbing up or down.

1. While standing on the open the sliding door ground, 2. Grab the handholds (1) and place your feet on the steps (2) 3. Enter the cab by traversingthe platform from the rear to the front 1 2

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825 M / 04.2007

Safety - Safety instructions

Safe climbing (ascent/descent) on the upper structure

Gallery = Platform

4 Installation of the gallery (platform) (3) is mandatory, since it is part of the safety concept. Risk of falling! No one must be permitted on the gallery when the cab is elevated! The max. load permitted on the gallery is 200 kg (440 lb) pre grating segment (4). Overloading the gallery can result in damage to the structure and result in serious personal injury. Inspect the gallery every 3 months (especially for cracks) and repair immediately if found.

825 M / 04.2007

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Safety - Safety instructions

Emergency exit from the cab 5

Note In an emergency, you can exit via the rear window (5) after the cab (6) has been lowered. Use the emergency-hammer to knock out the window. Enter and exit the cab via the wheel hubs and tires only under unusual circumstances and while exercising extreme caution. The wheels can rotate when the machine supports are deployed and the brakes are not applied!

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825 M / 04.2007

Safety - Safety instructions

Personal safety equipment

Problems

Stability

While working on the machine, the operating personnel are obliged to wear the personal safety equipment (e.g. safety helmet, ear protection, protective gloves, safety boots) as laid down by national regulations. Report problems or damage immediately to a responsible person! Secure the machine against improper or inadvertent use. Repairs should only be performed by specialist personnel. z Position the machine on a firm, even surface. z If necessary, stabilize the ground below. z Exercise caution at excavation edge, slopes, dips, etc. z Place supports on firm, level ground as well. z with additional ballast:

Turn upper structure only if supports are extended! z Observe wind speeds! z Stability is at a minimum when the working gear is transverse to the

direction of travel. z Stability is at a maximum when the working gear is positioned

diagonally (see illustration below).

DANGER Do not carry out any form of work which will affect the stability of the machine! Note that stability is reduce when swinging the load sideways.

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Safety - Safety instructions

Working near power lines

z Clearly mark power lines in the vicinity of the construction site while

under supervision. Before starting work! z Always assume that overhead lines are live. z Guide the machine so that neither parts of the machine nor

suspended loads extend into the danger area. z Maintain a safe distance from overhead lines. If national regulations

recommend no other values, adhere to the following minimum distances: Nominal working voltage (volts)

Safety distance (meters)

to 50 kV

10 ft. (3,05 m)

over 50 kV to 200 kV

15 ft. (4,60 m)

over 200 kV to 350 kV

20 ft. (6,10 m)

over 350 kV to 500 kV

25 ft. (7,62 m)

over 500 kV to 700 kV

35 ft. (10,67 m)

over 700 kV to 1000 kV / unknown

45 ft. (13,72 m)

z Employ a signaler to observe the safety distance. z The insulating elements fitted to the machine, protective cages or

proximity warning devices do not replace the listed minimum distances. z In windy conditions, the overhead lines and the working gear can

swing and consequently decrease the distance. High voltage contact

In the case of high voltage contact, the following rules apply: z Do not leave the driver's cab. z Warn those outside from approaching or touching the machine. z If possible, move all working gear or the entire machine out of the

danger area. z Arrange for power to be switched off. z Only leave the machine once the touched or damaged line has been

disconnected from the power supply. DANGER If the machine has to be vacated in the case of an emergency, e.g. danger of fire, do not touch the machine and the ground simultaneously. Jump off the machine with feet together.

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825 M / 04.2007

Safety - Safety instructions

Qualification of personnel Extract from OSHA regulations (United States)

The machine must only be operated and maintained by qualified personnel. Operators are required to meet the following qualifications: z Pass a practical operating examination for the machine they will

operate. z Have vision of at least 20/30 Snellen in one eye and 20/50 Snellen

in the other eye, with or without corrective lenses. z Be able to distinguish colors (red, green, yellow) if color

differentiation is required for operation. z Have adequate hearing (with or without a hearing aid).

A disabling heart condition or a history of epilepsy are sufficient reason for disqualification as an operator.

825 M / 04.2007

1-9

Safety - Safety instructions

1.6.2 Starting operation WARNING z Read Chapter 1 SAFETY. Before start-up, carry out checks in accordance with Section 4.3. z Check that all machine safety devices are complete and correctly

secured. z Ensure that the gallery (platform) has been installed properly. Falling

out of an open door is then no longer possible (safety-seatbelt only optionally available). z Wear protective work clothing (safety helmet, eye protection), if

working conditions necessitate. z Take off jewelry or loose clothing. z Secure loose items e.g. tools or other accessories. z Agree on hand signals with guide. z Obtain information on first aid and rescue facilities. z Enter and exit machine only when stationary. Use the appropriate

steps and ladders: – If necessary, clean steps and ladders prior to use. – Do not carry any items when climbing up or down. Lift items of equipment onto machine using a rope or lifting gear. – Do not use operating elements as handholds in driver’s cab. z Ensure that there is no one in the danger zone. z Check machine safety features (brakes, signal and lighting devices). z Check that operating elements and safety devices are functioning

correctly while driving slowly.

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825 M / 04.2007

Safety - Safety instructions

1.6.3 Operation WARNING z Read Chapter 1 SAFETY.

Before start-up, carry out checks in accordance with Section 4.3. z 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 specialists. z Proceed with extreme caution whenever you bypass the end limit of

the arm. z Ensure that there is no one in the danger zone. z Maintain safety distance to overhead lines. z Only operate the machine from the driver's seat. z Do not transport persons on the machine. z Consider ambient conditions, e.g. poor visibility, wind speeds, etc. z Use the specific lifting capacity table for that machine. z Note performance specification. z Check that anchorage points have a sufficient safe working load. z Observe guide signals as necessary. z When driving a long distance, place the boom in the direction of

travel. z Before leaving the driver's cab:

– Lower the cab completely, if not already lowered – Position the machine on firm base, if necessary set back from the edge of the excavation – Lower suspended loads – Secure working equipment – Pull the safety lever backwards – Chock wheels/running gear – Switch off engine – Lock cab, show warning lights if necessary.

825 M / 04.2007

1 - 11

Safety - Safety instructions

1.6.4 Maintenance 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 Position the machine on firm base, if necessary set back from the

edge of the excavation. z Lower suspended loads and booms to the ground. z Apply the brake. z Switch off machine and secure against unauthorized re-starting. z Use a chock to stop the machine from rolling away.

WARNING z The work performed may only be completed by trained professionals. z Wear personal safety equipment (e.g. safety helmet, ear protection,

protective gloves, safety boots). z Observe statutory accident prevention and safety regulations. z Lower suspended loads and booms to the ground. z Pull the left safety lever backwards. z Switch off the machine and secure against unauthorized re- starting

before beginning any work. z Attach warning sign to controls. z Smoking and handling of open flames is strictly forbidden. z Use safety-compliant access ladder aids or operating platforms. z Maintain a safe distance from rotating and moving parts. z Relieve hydraulic system pressure before starting maintenance work. z Dispose of hydraulic oil according to regulations. z Wear protective gloves when working on steel wire rope. z Use only original SENNEBOGEN replacement parts. z Use only oils and lubricants listed in the lubricant table. z Do not lift heavy objects by hand. Use lifting gear. z For pneumatic tires:

When pumping up tires, maintain an adequate safety distance and use a tire cage. z Keep the cab clean and orderly.

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825 M / 04.2007

Safety - Safety instructions

z If necessary, switch off the battery isolator switch in order to interrupt

the current. z When working near batteries, these are to be covered with insulating

material; do not place tools on top of batteries. z Replace all safety devices after completing any work on the machine. z Carry out function check to ensure problem-free operation.

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

with specific knowledge of and experience with hydraulics!

825 M / 04.2007

1 - 13

Safety - Safety instructions

1.6.5 Transportation WARNING z in Germany, loading and transportation work is only to be carried out by authorized specialist personnel in accordance with VBG 40, §48 and Federal Motor Vehicle Safety Standards (StVo) §22. z Observe the relevant regulations for securing of loads. The

respective transport operator is always responsible for the transportation of machine and accessories. z Use a low loader with sufficient load-carrying capacity and size. z When loading and transporting, secure the machine and its working

equipment from unintended movement. z Clean running gear of machine sufficiently from mud, snow and ice,

so that ramps can be accessed without danger of sliding. z Provide low loader access ramps with wooden planks. z Check conditions of route before starting journey. z Only transport machine using designated tie-down and lifting points. z Ensure that the machine does not present any hazards to other road

users. z Wear personal protection equipment (e. g. safety helmet, protective

gloves, safety boots). z Notify SENNEBOGEN Customer Service of any transport damage

immediately.

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825 M / 04.2007

Safety - Responsibilities of the operator

1.7

Responsibilities of the operator

WARNING 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.

Recurring inspections

Specialist testing, required for crane or backhoe operation The machine must be thoroughly checked by a specialist. z before initial operation and 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 the Sennebogen Co.

and can assess the safe working condition of the machine. Specialist testing, only required for crane operation The following cranes must be tested by a specialist every 4 years: – Power-operated mobile cranes – Mobile, power-operated derrick cranes – Truck-mounted cranes The operator must ensure that an inspection by a specialist is performed in the 13th year of operation and annually thereafter. Faults that are detected in the course of recurring inspections must be eliminated according to the safety-relevance and within a suitable timeframe.

825 M / 04.2007

1 - 15

Safety - 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.

DANGER 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!

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825 M / 04.2007

Safety - Responsibilities of the operator

Noise protection

The sustained sound pressure level of the machine, measured from the driver's seat with the driver's cab closed, is approximately 75 dB(A). The wearing of ear protection is therefore not essential. Measurements are based on EN ISO 11201. A value of 85 dB(A) can however be exceeded due to environmental factors, e.g. through dropping or transporting material or on a construction site together with other machines. In these cases, noise protection measures are strictly specified for the operating personnel. The operator is to ensure that appropriate ear protection is available and used by the operating personnel.

Technical condition of the machine

Independent conversion and replacement-parts

The employer 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. 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.

Impermissible operating practices

z The operating safety of the machine is only ensured if it is used

correctly according to Section 1.2 of these instructions. z The performance data listed in Chapter 3 SPECIFICATIONS must not

be exceeded. z If there is a danger of heavy objects falling, the machine may only

be used if the driver's area is covered by a protective roof (FOPS). The protective roof is optionally available from SENNEBOGEN. z The machine is not intended for towing a trailer.

Because of the higher axle load, towing a trailer is permitted only with stronger axles (optional). Specific dangers

825 M / 04.2007

The machine operator must check whether the operation gives rise to specific dangers, e.g. on account of toxic gases, ground quality etc., and adopt appropriate measures to avoid or limit those dangers.

1 - 17

Safety - Responsibilities of the operator

Overseas use

If the machine is used overseas, the following must be observed: z Observe the applicable safety regulations of the respective country

of use. z Ensure that the operators have the necessary qualifications for the

intended work. z Ensure that the contents of this operating manual have been read

and completely understood. If necessary, ask SENNEBOGEN for a copy of this operating manual in the corresponding language. Dangers of noncompliance with the safety instructions

Non-compliance with the safety instructions is dangerous and can be hazardous to persons as well as to the environment and the machine.

Fire extinguisher and first aid box (optional)

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

Non-compliance with the safety instructions invalidates all claims for damages.

1 Warranty conditions

The warranty conditions of SENNEBOGEN Maschinenfabrik GmbH are summarized in the warranty manual. Important items are also covered in Section 10.8 WARRANTY CONDITIONS.

1 - 18

825 M / 04.2007

Safety - Safety devices

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.

Example.-Fig.: Fan grille

Overload warning device

The overload warning device issues an audible as well as a visual alarm whenever the permissible lifting capacity is exceeded. The risk of tipping over is not prevented by the overload warning device! DANGER Machine in danger of tipping over! Take action immediately to reduce the load (e.g. decrease reach, lower load).

Limit position sensors

The following motions are limited by limit position sensors: – Arm in – Arm out (optional) – Lift load/boom up (optional) – Lower load/boom down (optional).

825 M / 04.2007

1 - 19

Safety - Machine Labeling

1.9

Machine Labeling

The machine is provided with special warning and notice signs. z Do not remove the signs. z Ensure that all signs are undamaged and legible. z Clean signs with water and soap if necessary, not with fuel or

cleaning agents. z Replace damaged, scratched or illegible signs with new ones.

Note Signs are available from SENNEBOGEN (see spare parts catalogue).

1.9.1 Type plate

4 5 6 7 1

1 Machine type/model (e.g. 825 M) 2 Year of manufacture 3 Admissible weight on the front axle 4 Engine performance specification (in kW) 5 Machine number (Factory No.) 6 Admissible overall weight of machine 7 Admissible weight on the rear axle

1.9.2 CE stamp of conformity

1 - 20

825 M / 04.2007

Safety - Machine Labeling

1.9.3 Warning and Notice Signs

825 M / 04.2007

1 - 21

Safety - Machine Labeling

1 - 22

825 M / 04.2007

Safety - Machine Labeling

825 M / 04.2007

1 - 23

Safety - Machine Labeling

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825 M / 04.2007

Safety - Machine Labeling

Explanations of the stickers/signs affixed to the machine Drilling and welding to be performed only by authorized SENNEBOGEN partners Schematic for operation of the two control levers

Do not approach overhead power lines too closely when working; maintain a safe distance!

Note regarding emergency exit: in the event of impending danger, use the emergency hammer to knock out the rear window and exit the cab carefully Danger or being crushed in the vicinity of the elevating cab (between cab and upper structure) Note regarding the storage location for the fire extinguisher

Secure the machine at these attachment points when transporting

Secure the optional restraint belt when working with the machine

Read the operating and maintenance instructions carefully prior to performing any cleaning, maintenance or repair work Read the accompanying technical documentation carefully prior to starting up the machine

Note regarding danger areas and the length of the boom

825 M / 04.2007

1 - 25

Safety - Machine Labeling

Standing in certain areas of the upper structure is prohibited Starter batteries, filled with corrosive and toxic acid Do not allow to drop, do not force open Symbol for the battery isolator switch The rear of the machine swings out; maintain a safety distance of at least 0.5m Switch off the engine and remove the ignition key prior to performing maintenance Note regarding the location of the button for emergency lowering of the cab in the cab Note regarding the location of the lever for emergency lowering of the cab under the front left maintenance panel Operating voltage of the machine's electrical system: 24 volts Symbol for the central lubrication Note regarding the type of fuel for the engine: DIESEL No smoking or open flames when fueling the machine Note regarding danger areas while the machine is operating

The machine satisfies basic safety requirements

The sustained sound pressure level outside the cab is 102 dB

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825 M / 04.2007

Safety - Machine Labeling

Attachment points (eyes) for lifting the machine

Switch off and allow magnetic equipment (optional) to cool prior to starting maintenance on the alternator and engine! The equipment uses high current during operation! Note regarding engine coolant specification Use only this coolant for DEUTZ engines

for CATERPILLAR engines

.....for CUMMINS engines

Caution - hot surfaces and hot components!

Belt drive - never put hands into the drive belts or drive pulleys!

Symbol for the hydraulic oil

Note regarding the supplier and specifications for the hydraulic oil

Note regarding the supplier and specifications for the transmission fluid

825 M / 04.2007

1 - 27

Safety - Machine Labeling

1.9.4 Disposal Lubricants and Consumables CAUTION 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/EWG: 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, kept, 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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825 M / 04.2007

Safety - Hand signals

1.10 Hand signals The operator and the signal person make use of hand signals to communicate with each other when view of the work and travel area is restricted or impaired. The signal person gives the signals necessary for safe operation. Note Hand signals are displayed in the Safety Manual for Users, Operators and Maintenance Personnel published by the Construction Industry Manufacturers Association (CIMA), which is provided with the machine.

825 M / 04.2007

1 - 29

Safety - Hand signals

1 - 30

825 M / 04.2007

Overview - Complete machine

Overview

2.1 Complete machine

7 6

2 1

1 Undercarriage 2 Support 3 Upper structure 4 Working tools (Example: Grab.)

825 M / 04.2007

5 Driver's cab/cab with gallery, can be raised/elevated 6 Compact boom 7 Grab arm

2-1

Overview - Undercarriage

2.2

Undercarriage

1 Support, rear

5 Extra storage space

2 Rear axle

6 Front axle (floating axle)

3 Slewing ring

7 Support, front

4 Steps/ladder

2.3 Support

1 3 4

1 Access ladder 2 Support housing 3 Support leg 4 Support pad

2-2

825 M / 04.2007

Overview - Upper structure

2.4

1 2

Upper structure

4 5

8 9

Engine compartment (right side): 1 Water separator - fuel 2 Hydroclean

6 Engine

3 Hydraulic pump - fan drive

7 Fuel filter

4 Pump unit

8 Fan

5 Hydraulic oil level indicator

9 Combination cooler

4 5 678

9 10

Storage compartments (driver's side): 1 Windshield washer reservoir

7 Air filter

2 Emergency lowering - cab

8 Fuel tank

3 Measurement ports - hydraulic system 9 Electrical control cabinet 4 Fueling hose/pump

10 Batteries

5 Fuel filler neck

11 Battery isolator switch

6 Central lubrication system

825 M / 04.2007

2-3

Overview - Upper structure

2 3 4

7 8

6 Top view: 1 Hydraulic tank cover 2 Holding bolt for hydraulik tank gate 3 Muffler / exhaust pipe 4 Service panel - HydroClean - fine filtration system 5 Service panel - engine 6 Service panel - cooler 7 Service panel - batteries 8 Air intake pipe

2-4

825 M / 04.2007

Overview - Central electrical system

2.5 Central electrical system

1 2 3

Storage compartment, left rear: 1 Circuit breaker (40 amp) 2 Circuit breaker (80 amp) 3 Battery isolator switch

825 M / 04.2007

2-5

Overview - Driver's cab

2.6

Driver's cab

2-6

1 Pedals

5 Seat adjustment

2 Steering column

6 Control lever, left-hand

3 Steering wheel

7 Lower air discharge vents

4 Control lever, right-hand

8 Safety lever

825 M / 04.2007

Overview - Pipe rupture safety

2.7 Pipe rupture safety

1 Pipe rupture safety - hoisting cylinder 2 Pipe rupture safety - arm cylinder (optional)

825 M / 04.2007

2-7

Overview - Pipe rupture safety

2-8

825 M / 04.2007

Specifications - Basic machine

Specifications

The Section 3.1 technical data for the basic machine are listed in. Section 3.2 lists the lifting capacities. Note Shipping dimensions and weights for the base machine can be found in Section 7.2. Specific data on attachments can be found in the operating instructions for the respective component.

3.1 Basic machine Engine

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

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

Displacement

6067 cm3

Cylinders

Permitted engine inclination: left

right

front

rear

30°

Note If the incline is excessive, the engine oil level can no longer be guaranteed. Please contact SENNEBOGEN Customer Service department should you wish to operate at a steeper inclination. Further information on the engine is available in the instructions from the engine manufacturer.

825 M / 04.2007

3-1

Specifications - Basic machine

Electrical system

24 V Note Ensure that the available output power of the alternator is not exceeded when installing additional current consumers (e.g. lights).

Driving speed

Hydraulic system

Slewing drive

Ambient temperature range Limitations during wind

All terrain

5.4 km/h (3.4 mph)

Road travel

20 km/h (12.43 mph)

Max. operating pressure 350 bar maximum (5076 psi)

Slewing speed

0 - 8 rpms, continuously variable

- 20 °C ... +40 °C (-4 °F ... +104 °F)

Wind speed 25 m/s (82.0 fts)

90 km/h (56 mph)

10 Beaufort

Danger Once the specified wind speed is reached, stop operating the machine immediately (lower load, lower stick). For a table on wind strengths and wind speeds, see Section 3.3. Note Machine operation is generally possible - without any attachments - at wind speeds of up to 25 m/second. The decision concerning when operation is to be shut down is to be made by the machine operator and depends on the attachment being used. Different attachments react differently to wind and may affect the stability of the machine. These are to be determined by the operator and the machine is to be shut down accordingly.

3-2

825 M / 04.2007

Specifications - Basic machine

Machine dimensions 9.12 ft.

2.2 ft.

8.86 ft.

11.23 ft.

4.23 ft.

9.19 ft.

10.63 ft.

0.35 ft. 1.12 ft.

10.69 ft.

0.85 ft.

19.49 ft.

9.02 ft.

9.19 ft. 9.02 ft.

15.37 ft.

12.83 ft.

16.69 ft.

14.00 ft.

10.68 ft.

33.97 ft.

Machine weight

Weight

approx. 27.9 t (61,509 lb)

with Cummins 129 kW (171.6 HP) diesel engine, 4-point support, compact boom. Note The machine weight may deviate from these figures due to optional attachments.

825 M / 04.2007

3-3

Specifications - Lifting capacities

3.2

Lifting capacities

Notes The lifting capacities z are listed in metric tons (t) and correspond to 75% the static tipping

load or 87% of the hydraulic lifting force in acc. with ISO 10567. z are applicable for a machine on firm, level ground and apply over a

range of 360 degrees. z apply when the machine's supports are deployed.

Deduct the weight of the lifting gear (hook, slings) from the listed value of the lifting capacity. The values in parentheses apply in a direction along the lengthwise axis of the undercarriage. Adverse conditions

Limit or reduce lifting capacities to compensate for adverse conditions. Adverse conditions are e.g. z soft or uneven ground z slopes z wind z side loads z swinging loads z jerking or sudden stopping of load z inexperience of operating personnel z driving with load.

3-4

825 M / 04.2007

Specifications - Lifting capacities

Lifting capacity table

825 M / 04.2007

with 22.3 ft. (6.8 m) compact boom and 18.37 ft. (5.6 m) arm

3-5

Specifications - Appendix

3.3

Appendix

Wind strength

Wind speed

Beaufort scale

Designation

m/s

kph

Inland

Calm

0-0.2

Calm, smoke rises straight up

Light draft

0.3-1.5

1-5

Wind direction indicated by the direction that the smoke is blowing, but not by the weather vane

Light breeze

1.6-3.3

6-11

Wind is felt on face, leaves rustle, weather vane moves

Light breeze

3.4-5.4

12-19

Leaves and thin twigs move, wind stretches a flag

Moderate breeze

5.5-7.9

20-28

Lifts dust and loose paper, moves twigs and thin branches

Fresh breeze

8.0-10.7

29-38

Small deciduous trees start to sway, breaker foam forms on lake surface

Strong wind

10.8-13.8

39-49

Strong branches are moving, whistling in power lines, umbrellas difficult to use

Stiff wind

13.9-17.1

50-61

Whole trees are moving

Stormy wind

17.2-20.7

62-74

Branches are broken off trees, walking outdoors is made very difficult

Storm

20.8-24.4

75-88

Slight damage to houses (chimney hoods and tiles are blown off)

Heavy storm

24.5-28.4

89-102

Uproots trees, considerable damage to houses

Hurricane type storm

28.5-32.6

103-117

Extensive storm damage (rarely inland)

Hurricane

32.7-36.9

118-133

Severe devastation

3-6

Effect

825 M / 04.2007

Specifications - Conversion factors

3.4 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

825 M / 04.2007

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

3-7

Specifications - Conversion factors

3-8

825 M / 04.2007

Starting operation - Safety instructions

Starting operation

4.1 Safety instructions WARNING z Read Chapter 1 SAFETY. Before start-up, carry out checks in accordance with Section 4.3. z Check that all machine safety devices are complete and correctly

secured. z Wear protective work clothing (safety helmet, eye protection), if

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

– If necessary, clean steps and ladders prior to use. – Do not carry any items when climbing up or down. Lift items of equipment onto machine using a rope or lifting gear. – Do not use operating elements as handholds in driver’s cab. z Ensure that there is no one in the danger zone. z Check machine safety features (brakes, signal and lighting devices). z Check operating elements and safety devices are functioning

correctly while driving slowly.

825 M / 04.2007

4-1

Starting operation - Initial commissioning

4.2

Initial commissioning

The initial commissioning of the machine is carried out by SENNEBOGEN or by a trained and authorized specialist. If the machine was shutdown for a prolonged period (> 6 months), always contact SENNEBOGEN Customer Service before recommissioning. WARNING Note Chapter 1 Safety. Before start-up, carry out checks in accordance with Section 4.3.

4.3 Checks before daily start-up Safety instructions

Read the safety instructions before starting work. DANGER! z Familiarize yourself with the machine and equipment. Read these operating instructions before starting operation, in particular Chapter 1 SAFETY. z Only carry out work for which you have been trained and which is

within your scope of employment. Note The following three pages contain the check list that must be reviewed on a daily basis. It is divided into: – a general section, – a functional check section and – a visual check section.

4-2

825 M / 04.2007

Starting operation - Checks before daily start-up

General

No.

Steps to take

Are the danger areas (overhead lines, ditches, etc.) marked and secured in the operating area?

Mark and secure as necessary

Do you know the operating and environmental conditions (soil strength etc.)?

If necessary, obtain information

Is an experienced signaler available, if required?

If necessary, arrange for a signaler

Is there anyone in the danger area?

If so, advise them to leave the danger area

Do you know the weight of the load?

Obtain information as required

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

Refer to the operating instructions and rating plate as necessary

No.

Functional checks

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?

If necessary, position correctly

Is the stability of the machine assured?

If necessary, support properly

Are all safety features (brakes, monitoring/ warning indicators, signal and lighting devices) working correctly?

If necessary, locate and correct faults

Are any warning or fault messages displayed on the SDS?

If necessary, locate and correct faults, read fault log

Are electrical devices such as the windshield wipers, heating, air conditioning working correctly?

If necessary, locate and correct faults

Is the emergency lowering feature of the cab functioning?

If necessary, locate and correct faults

F10

Check steering for correct adjustment and operation?

If necessary, adjust

F11

Is the central lubrication unit functioning?

If necessary, refill with grease or locate and correct faults (grease must appear at all connected lubrication points)

825 M / 04.2007

Steps to take

4-3

Starting operation - Checks before daily start-up

No.

Visual checks

Are all protective covers, insulating materials and warning signs in place on the machine and intact?

If necessary, replace

Are all steps/ladders, handles/handholds and anti-slip surfaces in place and intact (e.g. cracks)?

If necessary, repair or replace

Is the machine clean enough to ensure no danger areas exist due to dirt (danger of slipping, falling, poor visibility)?

If necessary, clean using a high-pressure cleaner BE CAREFUL around sensitive or electrical components! !

Are the windows clean and free of ice and snow?

If necessary, clean

Is the undercarriage/running gear (tires, axles, drive shafts/universal joints) intact?

If necessary, repair or replace

Are the wheel nuts tight and the intermediate ring firmly seated?

If necessary, retighten to the specified torque

Is the tire pressure correct? For pneumatic tires

If necessary, repair leaks and pump up tires (using a tire cage)

Is the hydraulic system (lines, hoses etc.) free of leaks and intact?

If necessary, tighten connections or replace seals

Are the hydraulic cylinders (e.g. supports, arm, floating axle cylinders, steering cylinders) free of leaks and intact? Inspect piston rods for damage (cracks etc)?

If necessary, tighten connections or replace seals

V10

Is the shutoff on the hydraulic tank open?

If necessary, open

V11

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

If necessary, repair leaks and top up fluids. Follow manufacturer's instructions!

V12

Is the fan wheel intact?

If necessary, replace

V13

Is the cooling system (cooler, hoses, tubing etc.) free of leaks?

If necessary, repair leaks and top up coolant. Follow manufacturer's instructions! Replace defective components.

V14

Are all hose clamps tight and the hose connections free of leaks?

If necessary, retighten or replace

V15

Has the water separator on the fuel system been drained?

If necessary, drain

4-4

Steps to take

825 M / 04.2007

Starting operation - Checks before daily start-up

Visual checks

No.

Steps to take

V16

Are the V-belts intact and tensioned?

If necessary, retension or replace

V17

Are the electrical lines damaged?

If necessary, repair or replace

V18

Are the batteries held in place securely?

If necessary, resecure

V19

Are all service access doors closed?

If necessary, close

V20

Are all bolted connections - particularly on the elevating cab - intact and tight?

If necessary, retighten or replace

V21

Have any possible cable connections to external power sources been disconnected?

If necessary, disconnect

V22

Is the correct counterweight (ballast) installed and secured in place?

If necessary, replace or resecure with specified torque

V23

Are the boom components intact (corrosion, cracks)?

If necessary, repair or replace

V24

Are any bolts cracked or damaged?

If necessary, replace

V25

Are the pipe rupture safeties (restraints) tight and intact?

If necessary, replace

V26

Are the lubrication lines intact and all lubrication points being greased?

If necessary, replace, clean and lubricate

V27

Are the hydraulic lines and hoses secured in place?

If necessary, tighten fasteners

V28

Are the quick-connect couplings free of leaks and the protective caps in place?

If necessary, replace couplings and attach protective caps

V29

Is the slewing mechanism lubricated sufficiently?

If necessary, lubricate gearing

V30

Is the slewing ring filling cover in place and is there enough grease?

If necessary, re-install and refill grease

V31

Inspect the positive stops for the steering for wear?

If necessary, replace

V32

Inspect the power cable track for wear?

If necessary, replace

DANGER Report all irregularities to the person in charge before start-up. Only operate machine after ensuring that it is in full working order.

825 M / 04.2007

4-5

Starting operation - Switching on the machine

4.4 Safety instructions

Switching on the machine

Read the safety instructions before starting machine. DANGER! z Danger of injury! Keep service access doors closed. z Before starting the engine, ensure that there is no one within the

danger area. z Before starting the engine, ensure that the shutoff on the hydraulic

tank (see Section 2.4) is open! z The exhaust emissions of diesel engines are damaging to health.

Only run engine outdoors or in well-ventilated rooms. z Do not start engine if a warning sign is attached to its controls. z Adjust driver's seat, steering column and mirror to the correct

position. z Fit restraint belt correctly. z Close driver’s cab door.

4.4.1 Restraint belt (optional) The machine is equipped with a lap belt. The belt complies with standards SAE J 386 (USA) and FMVSS 209 (EU). WARNING z Check belt for signs of wear before starting to operate the machine. Replace damaged belt immediately. z Clean dirty belt using water. z Do not twist belt when fastening. z Pass belt as low possible around the hips, not around the stomach. z Replace the belt after three years in use.

1 2 3

4-6

Push metal catch (1) into belt buckle (2). An audible click indicates that the belt has engaged.

To release belt, press red button (3) on belt buckle (2).

825 M / 04.2007

Starting operation - Switching on the machine

4.4.2 Start engine DANGER Danger of intoxication! Only run engine outdoors or in well-ventilated rooms. Inhaling exhaust fumes damages health. It can lead to unconsciousness and death. CAUTION Before starting the engine, ensure that the shutoff on the hydraulic tank (see Section 2.4) is open!

3 4

Control panel, right-hand, rear

SENNEBOGEN Diagnostics System (SDS)

Perform daily checks in accordance with Section 4.3.

Insert key into ignition lock (2) and turn to position “1”. – The SDS performs a quick self-check. – The coolant temperature and fuel level are now indicated on the SDS display (3).

After the self-check has ended, turn the ignition key clockwise (position “2”) to start the engine.

Press menu button -down- (5) on the SDS. – The engine oil pressure and the engine rpm are indicated on the SDS display. Press the menu button -up- (4) to return to the coolant temperature and fuel level.

Set the desired engine rpm using knob (1).

Note If necessary, release the safety lever to enable the hydraulic functions (see also Section 5.3.5 SAFETY LEVER).

825 M / 04.2007

4-7

Starting operation - Switching on the machine

4.4.3 Bring machine up to operating temperature Guidelines for warm up period

Warm-up procedures

Ambient temperature range

Warm-up period

to 0 °C (32 °F)

approx. 15 min.

0 °C ... -20 °C (32 °F ... -4 °F)

approx. 30 min.

max. engine speed Nominal speed - 250 rpm -1 (Nominal speed see Chapter 3.1)

z Allow the engine to run at idle speed for 3 minutes after starting.

Additional warm-up time can be required at temperatures under 0°F (0°C). z Then incrase the rpm in steps up to

the nominal speed of 250 rpm (no-load) z If approx. 68°F (20°C) water temperature has been achieved, put a

load on the engine by carefully actuating hydraulic functions and continue to warm-up the machine. z The machine can be loaded if the temperatures indicated below

have been achieved. Note If the machine is equipped with the optional feature “Reverse fan direction” below 0°F (0°C): Change the direction of fan rotation several times during the warm-up period. This will feed hot air from the engine to the micro filter (in front of the cooler) and blow out the ice. Note If the hydraulics are still slow to respond after the warm-up period, operate for a further 15 minutes at reduced speed. The following temperatures should be displayed before operating the machine at full speed: z Hydraulic oil: approx. 30°C (86 °F)

Water: approx. 35 °C (95 °F) ATTENTION Not warming up the engine and the machine can result in damage to the engine, hydraulic pump, hydraulic motor, hydraulic oil cooler and hydraulic tank.

4-8

825 M / 04.2007

Starting operation - Switching on the machine

4.4.4 Jump start The machine is equipped with a 24 volt starting system. Ensure that the external power source has the same voltage. CAUTION If a power source with a higher voltage is used, this can cause serious damage to the machine's electrical system. 1

Switch off the battery isolator switch in order to interrupt the current.

If necessary, remove battery cover.

Connect the positive terminal (+) of the power source using appropriate jumper cables.

Connect the negative terminal (-) of the power source using appropriate jumper cables.

Actuate the battery isolator switch.

Start engine in accordance with Section 4.4.2.

After starting the driving engine: – Detach jumper cable from negative terminal (-). – Detach jumper cable from positive terminal (+).

If necessary, replace battery cover.

WARNING z Danger of explosion! Avoid excessive heating by fire, open flame or smoking. z Battery acid is corrosive.

Avoid any contact with the skin, eyes or clothing. Rinse splashed acid immediately with clear water. A visit to the doctor can be necessary. When working on electrical system, adhere to current regulations and the accident prevention regulations.

825 M / 04.2007

4-9

Starting operation - Switching off the machine

4.5

Switching off the machine

4.5.1 Shutting down the engine. Note Switching off the engine without allowing a cooling down phase may cause heat to build up, resulting in overheating of engine components, especially the turbocharger. Therefore, allow the engine to cool down before switching off: z Lower engine speed to approx. 50 % of the rated speed (see). z Allow machine to run for another approx. 5-10 minutes.

Non-observance may cause increased wear to the engine and cooling system.

4 - 10

Park the machine on a firm surface.

Lower suspended loads and lower boom if necessary.

Lower engine speed to 50 % of the rated speed in order that the engine and cooling system are not damaged.

Allow engine to run for another approx. 5-10 minutes.

Turn ignition key to position “0” and remove.

Pull the left safety lever backwards.

Secure the machine (lights, warning triangle, chocks, etc.).

825 M / 04.2007

Starting operation - Decommissioning

4.6

Decommissioning

Proceed as follows if the machine is to be decommissioned for a prolonged period. 1

Choose as dry and dust-free storage location as possible.

Place the machine on level ground. If a location on level ground cannot be found, secure the machine additionally using chocks.

Shut down the machine in accordance with Section 4,5.

Check the machine for leaks (e.g. coolant, oil).

Clean machine in accordance with Section 6. Ensure that cleaning agents do not attack the seals nor enter the slewing mechanism!

Top up operating fluids and lubricants, for levels see.

Lubricate the machine in accordance with the maintenance instructions. Lubricate the slewing mechanism by slowly rotating the upper structure (if necessary, refill the grease reservoir).

Switch off the battery isolator switch or disconnect the battery terminal (see Section 7.4).

Protect bright metal parts (e.g. piston rods of hydraulic cylinders), see.

Note Admissible ambient temperatures see Section 3.1. ATTENTION! Inspect seals every 6 months.

825 M / 04.2007

4 - 11

Starting operation - Decommissioning

4 - 12

825 M / 04.2007

Operation - Safety instructions

Operation

5.1 Safety instructions DANGER z Read Chapter 1 SAFETY. Before start-up, carry out checks in accordance with Section 4.3. z 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 specialists. z Proceed with extreme caution whenever you bypass the limit position

sensor for the arm. z Ensure that there is no one in the danger zone. z Maintain safety distance to overhead lines. z Only operate the machine from the driver's seat. z Do not transport persons on the machine. z Consider ambient conditions, e.g. poor visibility, wind speeds, etc. z Use the specific lifting capacity table for that machine. z Note performance specification. z Check that anchorage points have a sufficient safe working load. z Observe guide signals as necessary. z When driving a long distance, place the boom in the direction of

travel. z Before leaving the driver's cab:

– Lower the cab completely, if not already lowered – Position the machine on firm base, if necessary set back from the edge of the excavation – Lower suspended loads – Secure working tools – Pull the safety lever backwards – Chock wheels/running gear – Switch off engine – Lock cab, show warning lights if necessary.

825 M / 04.2007

5-1

Operation - Cab

5.2

Cab

SENNEBOGEN MAXCAB

5 2

3 4

7 1 Working light 2 Front windshield - tilts out 3 Door lock and handle 4 Release - door latch

5 Emergency exit - rear window 6 Sliding door 7 Gallery

Emergency exit

8 Hammer - emergency exit In an emergency, you can exit via the rear window after the cab has been lowered. Use the hammer to knock out the window.

5-2

825 M / 04.2007

Operation - Cab

Sliding door

The sliding door (3) can be held open with a catch on the side panel of the cab. You can release the latch by pulling on the release lever (5) on the inside of the door.

Front windshield

To open the front windshield: tilt it forwards. The upper windshield wiper moves forward at the same time. Press the two knobs and tilt the windshield forwards. The two gas-filled struts hold it in this position. To close, grab the two handles on the windshield frame and pull inwards. Make sure that the front windshield snaps into place.

Interior lighting

The cab is equipped with interior lighting with an integrated reading lamp. Two switches are provided to turn the lights on and off again.

Windshield washer system

Driver's seat

825 M / 04.2007

The windshield wipers are operated by the switch on the upper right control panel. The reservoir for the windshield washer fluid is located behind the front left service access door. Always fill the reservoir with washer antifreeze. Operation of the driver's seat is described in separate instructions. These instructions can be found in Section 10.3.

5-3

Operation - Cab

5.2.1 Positioning the cab Safety instructions DANGER Danger of accident due to elevated cab! Check cab suspension gear, bolts and bolted connections daily! z Move the machine only with the cab lowered and retracted and the

slewing mechanism holding brake engaged. z Exit the cab only when it is in the completely lowered and retracted

position. z Maneuver the cab only when the undercarriage supports are

deployed! z Keep the driver's doors closed z Fasten restraint belt (optional) in accordance with Section 4.4.1. z Maneuvering the cab is prohibited when individuals and/or objects

are on the gallery (platform). DANGER Danger of death from shearing and crushing! Ensure that there is no one within the danger area of the suspended cab. The danger area is the area z on/under the cab, z on/under the mechanical cab supporting structure.

5-4

825 M / 04.2007

Operation - Cab

Maneuvering the cab

1 2

Elevating/lowering the cab

Press safety lever (see Chapter 5.3.5) forwards.

Switch on machine in acc. with Chapter 4.4.

Press rocker switch (1) = cab up

Press rocker switch (2) = cab down

Note Do not elevate/extend cab to the highest/farthest limit position (OT). Stop the cab about 10 cm (3.94 inch) before reaching the highest/ farthest limit position. This provides optimum damping characteristics and pleasant working conditions in the cab.

825 M / 04.2007

5-5

Operation - Cab

Dismantling/assembling the cab DANGER Danger to life from falling cab! z The cab must be assembled/dismantled by trained and instructed

technicians only! z Always replace any bolts after dismantling, do not reuse. z Bolts, tension and retaining elements for cab supports are to be

checked by qualified personnel and replaced if necessary before reusing. z Use only original SENNEBOGEN replacement parts.

5-6

825 M / 04.2007

Operation - Cab

5.2.2 Cab Emergency lowering Note The emergency lowering feature still functions in the event of engine or hydraulic system failure. The machine is equipped with the ability to lower the cab in an emergency from the following two locations: z Emergency lowering (in the cab)

Location: To the right of the right-hand control lever. This is the same switch used to lower the cab. Necessary, for instance, in case of a problem with the drive system. z Emergency lowering (outside the cab)

Location: Below the front left service access door. Necessary in case the machine operator has an emergency due to a health condition. DANGER Danger of death from shearing and crushing! Ensure that there is no one within the danger area of the suspended cab. The danger area is the area z on/under the cab, z on/under the mechanical cab supporting structure.

Emergency lowering - in the cab

Press rocker switch (2). – The cab lowers slowly.

Note Lowering ceases when the switch is released. When the battery isolator switch is in the “off” position, this function is no longer available.

825 M / 04.2007

5-7

Operation - Cab

Emergency lowering - outside the cab

shown = cab elevated 1

Press lever (2) upwards. The cab lowers slowly.

Pull lever (2) back again after reaching the lower limit position.

Note The emergency lowering lever is located under the front left maintenance panel.

5-8

825 M / 04.2007

Operation - Operating elements

5.3

Operating elements

5.3.1 Overview

Version with steering wheel

Version with joystick steering (optional)

825 M / 04.2007

1 Pedals

5 Seat adjustment

2 Steering column

6 Control lever, left-hand

3 Steering wheel

7 Lower air discharge vents

4 Control lever, right-hand

8 Safety lever

5-9

Operation - Operating elements

DANGER Risk of accident in the event of an operating error! If the boom is positioned over the rear axle, the machine moves in the opposite direction. Proceed with extreme caution whenever you wish to work or maneuver over the rear axle. Note A red indicating arrow (1) is located on the front section of the undercarriage. The arrow is visible through the window on the right side of the cab. It indicates that the boom is positioned over the front axle.

5.3.2 Control panel, left-hand

3 2 Storage compartment 3 Lever for all supports (All supports are extended/ retracted simultaneously)

5 - 10

825 M / 04.2007

Operation - Operating elements

5.3.3 Control lever, left-hand 2 3 1

Pushbutton: 1 Horn 2 Rotate grab counterclockwise 3 Rotate grab clockwise 4 Safety limit shutdown Bypassing ”stick retract”

Maneuver directions:

DANGER Danger to life when bypassing the “Arm in” safety limit position sensor! Attachments or parts of the load can strike and penetrate the cab. Proceed with extreme caution. Observe the attachments and load continuously. Operation is the sole responsibility of the machine operator. Observe the instructions in Section 5.5.8.

825 M / 04.2007

5 - 11

Operation - Operating elements

Note The ability to bypass the limit position sensor for “Arm in” is a standard feature; bypassing “Arm out” and “Load/boom up/down” is optional. DANGER All limit position sensors are deactivated.

5.3.4 Control lever, right-hand 2 1

3 4

Pushbutton: 1 Magnet system OFF (optional) 2 Steering - left 3 Steering - right 4 Magnet system ON (optional) or Magnet system ON/OFF (optional)

Maneuver directions:

5 - 12

825 M / 04.2007

Operation - Operating elements

5.3.5 Safety lever The safety lever (1) serves as a safety device.

shown = safety lever released (pushed forwards) With the safety lever released (see figure) z all hydraulic functions are available. z all operating movements are enabled.

Note The slewing mechanism holding brake remains engaged after releasing the safety lever (pushing forwards). Disengage the slewing mechanism holding brake using the switch in the right-hand control panel (see Section 5.5.5).

shown = safety lever actuated (pulled backwards)

Note With the safety lever actuated, all hydraulic functions are disabled.

825 M / 04.2007

5 - 13

Operation - Operating elements

5.3.6 Console to the right of the driver's seat Version with common support

Version with single support (optional) 5

1 Ashtray 2 Storage compartment 3 Ashtray 4 Single support rear left 5 Single support front left 6 Single support front right 7 Single support rear right

5 - 14

825 M / 04.2007

Operation - Operating elements

5.3.7 Control panels, lower right

7 6 5 4 3 2

Switches

Indicator lamps

1 Changing the fan direction combination cooler

8 Reverse airflow active

2 Cab down + Activating Emergency lowering 3 Cab up

9 Flashing indicator 10 High beam 11 Automatic full floating axle

4 Lock floating axle 5 Flashing indicator left/right 6 Driving speed slow/fast 7 Slewing mechanism holding brake

825 M / 04.2007

5 - 15

Operation - Operating elements

Fan reversal – combination cooler

Fan reversal is used to clean the cooling fins of the combination cooler. To do this, press and hold down the button. After about 10 seconds the direction in which the fan is turning is reversed. Air and loose dust and dirt clinging to the cooling fins will be blown out. 1

Hold the button for about 60 seconds.

Check the cooling finds on the combination cooler and change the direction of the fan again if necessary.

About 10 seconds after you let go of the switch, the direction in which the fan is turning changes again. Note To further clean the combination cooler, read supplementary documentation (see Section 10.4).

Floating axle lock

The front axle is a floating axle. After releasing the lock (bulb in switch lights up), the floating axle can compensate for uneven surfaces. WARNING z Tip-over danger! When maneuvering with a load, lock the floating axle. z When driving on uneven surfaces, release the floating axle lock.

5 - 16

825 M / 04.2007

Operation - Operating elements

Slewing mechanism holding brake

20 19 18

22 23 24 25

16 15

15 24V socket outlet 16 12V socket outlet 17 Ignition - start engine 18 Dimmer switch 19 Speed (rpm) selector 20 E-Stop (optional)

825 M / 04.2007

22 Blower speeds 23 Air distribution 24 Temperature selection 25 Switch - heat/cool 26 Switch - outside/recirculated air

5 - 17

Operation - Operating elements

5.3.8 Control panel, upper right Front section

Rear section

1 11 10 2 3

4 5 6

1 Working lights 2 Front windshield wiper 3 Front windshield washer 4 Flashing warning lamps 5 ECO switch 6 Automatic idle 7 Central lubrication

5 - 18

8 GLR 9 Magnet system 10 Grab control 11 Grab control (Grab function on/off)

825 M / 04.2007

Operation - Operating elements

ECO switch

When the ECO switch is actuated, the engine speed (rpm) is lowered by approx. 8%. This reduces fuel consumption and the noise level. Note When working with magnetic equipment, turn off the ECO switch!

Automatic idle

The automatic idle feature automatically lowers the engine speed (rpm) whenever there is no motion for several seconds. Upon actuation of a control lever, the engine immediately returns to the previously set speed.

GLR

If an electrical problem occurs, GLR can be deactivated and it is then possible to switch to an emergency program.

Grab control

With the grab control feature, the pressure for the “Close grab” function can be controlled. A reduction in pressure for “Close grab” is active only when the motions “Close grab” and “Rotate upper structure” or “Close grab” and “Load/ boom up” are executed simultaneously. When the grab is closed, there is thus no loss in speed for the motions “Rotate upper structure” and “Load/boom up”. – Grab symbol illuminated continuously – If the switch is pressed, a green LED on the left side also lights up

Grab control - Grab function on/off

825 M / 04.2007

Grab control

Closing pressure for grab

Rotation speed upper structure

Movement speed compact boom

activated

reduced pressure, i.e. the grab remains closed - the load is held with reduced pressure

fast

deactivated

maximum pressure, i.e. the grab remains closed - the load is held with maximum pressure

slow

When the grab is demounted (e.g. when working with the magnet) the function grab open/close can be switched off using this switch (the light in the switch glows not). This enables even working motions of the equipment.

5 - 19

Operation - Operating elements

5.3.9 Radio (optional) Note The radio and speakers are located behind the driver's seat under the roof of the cab. 1

2 1 CD Radio 2 Speaker

Note Detailed information regarding operation can be found in the accompanying radio operating instructions.

5 - 20

825 M / 04.2007

Operation - Operating elements

5.3.10 Pedals Version with steering wheel

1 2

Version with joystick steering (optional)

1 Footholder

7 Drive pedal

2 Slewing mechanism brake (optional)

8 Drive - forward

3 Steering column

9 Drive - backward

4 Release steering column lock 5 Release brake pedal lock 6 Brake (with detent) - driving motion

825 M / 04.2007

5 - 21

Operation - Operating elements

5.3.11 SENNEBOGEN-Diagnostic-System (SDS)

B C

A Display B Keypad C Indicating and warning lights

Additional information can be retrieved via the SDS, e.g. the current temperature of the hydraulic oil. Note Do not clean the SDS with cleaning agents containing alcohol or solvents! Otherwise, the plastic surface will become brittle. Note All temperatures are displayed in degrees Celsius (°C). It is also possible to display temperature values in degrees Fahrenheit (°F). This basic setting is made at the factory. Temperatures below 68 °F (20 °C) (hydraulic oil) or below 86 °F (30 °C) (coolant) are not displayed. Sensors on the machine monitor the current operating state and transmit the measured data 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. Self-check: After the ignition is switched on, the SDS performs a self-check. All LEDs light up. The sensors are checked. Following this, the SDS is ready to operate. If the SDS detects a fault, the fault condition in indicated on the display and via LEDs. Have the fault corrected by SENNEBOGEN-Customer Service immediately.

5 - 22

825 M / 04.2007

Operation - Operating elements

Display (A)

The display is multifunctional. After switching on the ignition, it displays the SENNEBOGEN logo, the device number and, under operating state, the date, the respective symbols and a graphic representation of the operating state (depending on the screen).

Starting screen 1

Switches automatically after 4 seconds

Screen 1 7

1 SENNEBOGEN logo 2 Device number (example) 3 Software version (example) 4 Time of day

825 M / 04.2007

5 Date 6 Operating hours for the day 7 Coolant temperature 8 Fuel level (diesel)

5 - 23

Operation - Operating elements

Keypad (B)

The keypad features 5 keys (buttons). Using these keys, you can retrieve and display information. In addition, you can use them to change the screen being displayed and note any fault messages (acknowledge). Attention Immediately correct any fault conditions or irregularities displayed (refill fuel tank, clean/replace air filter etc.). Have SENNEBOGEN Service handle more serious problems immediately.

1 Arrow up 2 Arrow down 3 Daily/total hours of operation 4 Confirm (ENTER) 5 Leave (ESCAPE)

5 - 24

825 M / 04.2007

Operation - Operating elements

Note To switch from Screen 1 (starting screen) to Screens 2, 3, 4, 5 and 6, you must press the “Arrow down key”. Use the “Arrow up key” to return to the previous screen. Screen 2 1

Screen 3 3

1 Engine oil pressure 2 Engine rpm 3 Hydraulic oil temperature 4 Battery voltage

825 M / 04.2007

5 - 25

Operation - Operating elements

Note it is possible to switch to Screen 4 from Screens 1, 2 and 3 at any time. Simply press the “Hourglass key”. Screen 4 1 2 3

Setting the daily operating hours meter to 0

Pausing and restarting the daily hour meter

1 Total operating hours 2 Daily operating hours 3 Daily operating hours meter O

Press and hold the “ENTER key” four seconds long. This resets the daily operating hours meter to 0.0h.

Press the “Hourglass key” to pause and then restart the daily hour meter. Note The total operating hours meter continues to run even though the daily operating hours meter is paused. Whenever the daily operating hours meter is running, the “Hour” symbol (a) flashes and the word “ON” (b) appears. If the daily operating hours meter has been paused, the “Hour” symbol and the word “OFF” are displayed continuously.

5 - 26

825 M / 04.2007

Operation - Operating elements

Note Press the “ENTER key” to switch from Screen 5 to the Subscreens 5,1, 5.2 and 5,3.

Screen 5

Screen 5.1

Screen 5.2

1 Service - engine (operating hours - example) 2 Service - hydraulics (operating hours - example)

Note You can acknowledge any displayed service interval messages by pressing and holding the “ENTER key” five seconds. ATTENTION! Have an authorized SENNEBOGEN Service Partner perform the engine or hydraulic service without delay.

825 M / 04.2007

5 - 27

Operation - Operating elements

Screen 5.3

Setting the time and date

5 - 28

Press and hold “ENTER key” 5 seconds. Note.: The first number flashes.

Press the “Arrow up or Arrow down key” to change the number.

Press the “ENTER key” to save the new number. Note.: The next number flashes automatically.

Proceed in the same manner with the subsequent numbers.

After completing the settings, press the “ESCAPE key” to return to Screen 5.

825 M / 04.2007

Operation - Operating elements

Note You can read the number of fault messages and the associated diagnostic codes in Screen 6. ATTENTION! To correctly assign fault messages and diagnostic codes, refer to the separate diagnostic code list. Contact SENNEBOGEN Customer Service in case of doubt or when troubleshooting. Screen 6

Screen 6.1

or: 1 2

3 4 1 Fault messages present 2 No fault messages 3 Fault message not acknowledged 4 Fault message acknowledged

825 M / 04.2007

5 - 29

Operation - Operating elements

Trouble-shooting chart Fault

Diagnostic

101. 102 or 103

Coolant temperature

111. 112 or 113

Motor oil pressure

121. 122 or 123

Diesel fuel level

131. 132 or 133

Hydraulic-oil temperature

141. 142 or 143

Battery voltage

151

Air filter

161

Hydraulic-oil drainback filter

171

HydroClean micro-filter system

181

Hydraulic-oil auxiliary ctrl filter

191

Coolant level

201

Hydraulic-oil gate

211

Hydraulic-oil level

Note A Priority 1 fault (Fig. 2-6) is indicated by the dark background behind the symbol, the pulsating buzzer and the illuminated red “!” warning symbol. The buzzer is silenced only upon acknowledging the message. The dark background behind the symbol disappears, but the symbol continues to flash. The red warning symbol to the right below the keypad remains illuminated as long as the fault is active. 2

8 1 Warning triangle, general 2 Coolant temperature 3 Engine oil pressure 4 Fuel level (diesel) 5 Hydraulic oil temperature 6 Battery voltage

Display symbols

7 10

7 Service interval indicator 8 ...Engine 9 ...Hydraulics 10 after ... operating hours (example)

The fault messages can be acknowledged, but not erased, by pressing and holding the “ENTER key” five seconds.

5 - 30

825 M / 04.2007

Operation - Operating elements

Note Screen 7 is where faults registered by the SDS are displayed. It presents information on when a fault was detected, acknowledged and corrected. Screen 6 must be active in order to access Screen 7. Now press and hold the “ESCAPE+ENTER keys” simultaneously 5 seconds to switch to Screen 7. Press the “ENTER key” to switch to Screen 7,1. It is possible to select individual alarms on Screen 7.1 using the “Arrow up key”. After pressing the “ESCAPE key”, Screen 7 reappears. Screen 7

Screen 7.1

825 M / 04.2007

5 - 31

Operation - Operating elements

Indicating and warning lights (C)

The two indicating lights provide information on the current operating states (slewing mechanism holding brake engaged and accumulator pressure for parking brake attained). The warning lights illuminate whenever the SDS has detected an irregularity. The warning lights distinguish between two priorities: Priority 1: Shut down machine immediately in accordance with Chapter 4,5. Correct irregularities immediately (e.g. check cooling system and hydraulic system for leaks, top up coolant / hydraulic oil). Priority 2: Correct irregularities as soon as possible (no later than the end of the workday - e.g. clean/replace air filter -). Indicated by the four upper yellow warning lights. 1

Warning lights 1 Air filter soiled indicator Replace indicators - hydraulic system 2 Return filter

5 ATTENTION - general (also in combination with symbol on the display) 7 Hydraulic oil level 8 Hydraulic tank flap (optional) 10 Coolant level

3 Hydroclean 4 Pilot control filter

Indicating lights 6 Parking brake accumulator pressure 9 Slewing mechanism holding brake

5 - 32

825 M / 04.2007

Operation - Operating elements

Fault indicators on the display Cause

Remedy

Hydraulic oil temperature too high (>183.2 °F (84 °C))

– Allow engine to run with no load until the hydraulic oil cools.

Cooling fins on hydraulic oil cooler soiled

– Clean cooling fins on hydraulic oil cooler.

Hydraulic oil level too low

– Check oil level in accordance with maintenance instructions. – Top up hydraulic oil, if required.

Symbol flashes, buzzer sounds and red “Attention” illuminates

Cause

Remedy

Insufficient fuel in tank

– Refuel machine in accordance with Section 5.5.11.

Symbol flashes, buzzer sounds and red “Attention” illuminates

Cause

Remedy

Engine overheated

– Allow engine to idle.

Cooling fins on engine oil cooler soiled

– Clean cooling fins on hydraulic oil cooler.

Fan drive loose or defective

– Tighten fan drive; replace, if necessary.

Coolant level too low

– Top up coolant in accordance with maintenance instructions.

Engine switched off without cooling phase.

– After operating, allow engine to run in low idle for approx. 5-10 minutes before switching off.

Symbol flashes, buzzer sounds and red “Attention” illuminates

825 M / 04.2007

5 - 33

Operation - Operating elements

5 - 34

Symbol flashes, buzzer sounds and red “Attention” illuminates

Cause

Remedy

Engine oil pressure too low (<18.85 PSI (1.3 bar))

– Shut off engine immediately. – Check engine oil level in accordance with maintenance instructions. – Top up engine oil, if necessary. – Notify SENNEBOGEN Customer Service in the event of a re-occurrence

Symbol flashes, buzzer sounds and red “Attention” illuminates

Cause

Remedy

Battery charge too weak

– Check battery charge; recharge batteries or exchange, if necessary. – Check battery connections, tighten terminals if necessary. – Check V-belt tension, retension or replace, if necessary.

825 M / 04.2007

Operation - Operating elements

Warning and indicating lights

Lights up, buzzer sounds

Cause

Remedy

Coolant level too low

– Top up coolant.

Lights up while engine is running

Cause

Remedy

Accumulator pressure too low

– Have a hydraulic specialist check the hydraulic system.

Lights up, buzzer sounds

Cause

Remedy

Hydraulic oil level too low

– Top up hydraulic oil

Lights up

Cause

Remedy

Slewing mechanism holding brake engaged

– Disengage slewing mechanism holding brake

Cause

Remedy

Pilot control filter clogged

– Check pilot control filter; if necessary, replace in accordance with maintenance instructions.

Cause

Remedy

Hydro-Clean micro filter is clogged

– Check Hydro-Clean micro filter; if necessary, replace in accordance with maintenance instructions.

Lights up

825 M / 04.2007

5 - 35

Operation - Operating elements

Lights up

5 - 36

Cause

Remedy

Return filter is clogged

– Check return filter; if necessary, replace in accordance with maintenance instructions.

Cause

Remedy

Air filter soiled

– Clean filter in accordance with maintenance instructions. – If necessary, replace filter element.

825 M / 04.2007

Operation - Operating elements

5.3.12 Central lubrication system The central lubrication system automatically lubricates the raceway of the slewing mechanism as well as the bearings of the equipment and the cab. The lubrication cycle is preset at the factory. Note The preset lubrication cycle can be shortened. 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 3 Grease nipple - for refilling with grease

Initiating raceway lubrication manually

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

825 M / 04.2007

Actuate the switch on the upper right control panel:

5 - 37

Operation - Automatic climate control

5.4

Automatic climate control

Note The machine is equipped with an automatic climate control system that permits precise heating or cooling.

3 4

1 Selector switch: blower speeds 2 Selector switch: air distribution 3 Temperature regulator 4 Temperature display 5 Combination switch: Outside temp. display, climate control On/Off 6 Selector switch: Outside air/ recirculated air

5 6

The automatic climate control system can operate with outside air or recirculated air. Outside air mode Recirculated air mode

When windows are misted, to dehumidify the cab. Faster warm-up of cab and higher final temperature. The air in the cab interior is re-circulated, i.e. no fresh air is drawn in from outside. Do not leave in this mode for longer than 15 minutes, as the air quality in the cab will deteriorate significantly. Ensure that there is a sufficient outside air supply. Attention! The automatic climate control system switches off automatically when the outside temperature drops below 5°C (41.0 °F) and back on again when the temperature is above 5°C (41.0 °F) once again. This is necessary to prevent icing of the evaporator. For this reason, it is absolutely essential to switch to the outside air (fresh air) mode, select the maximum blower speed and open all air vents. Proper air circulation can only be achieved in this way and visibility-hindering fogging of the windows minimized.

5 - 38

825 M / 04.2007

Operation - Automatic climate control

5.4.1 Safety instructions - climate control system WARNING 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 Danger of burns!

Allow unit and components inside unit (heat exchanger, resistors) to fully cool down first. z Freezing hazard! Avoid touching the air conditioning tubing and hoses. z Danger of intoxication! Avoid contact with refrigerant. Coolant gives

off toxic gases. z Wear eye protection (safety goggles) and gloves. z Use only R134a coolant. z No fluorescent additives (tracer-agents, sticks).

Note Keep windows and cab door closed to ensure effective air conditioning. The automatic climate control system regulates the temperature in relation to the outside temperature. Switching on the climate control system

Start engine (see Section 4.4.2).

Switch on the blower at the right-hand control panel (see figure on previous page).

Open the air inlet vents in the cab to prevent icing of the evaporator.

Place the switch for the automatic climate control system on the right-hand control panel in the Cooling position.

Set the desired temperature using the temperature regulator on the right-hand control panel.

Note Switch on the automatic climate control system on a regular basis. This contributes significantly to maintaining its functionality. Accordingly, switch on the automatic climate control system monthly for at least 30 minutes with the blower set to maximum speed and the windows and doors open.

825 M / 04.2007

5 - 39

Operation - Starting work

5.5

Starting work

5.5.1 Safety instructions DANGER z Read Chapter 1 SAFETY. Before start-up, carry out checks in accordance with Section 4.3. z 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 specialists. z Proceed with extreme caution whenever you bypass the limit position

sensor for the arm. z Ensure that there is no one in the danger zone. z Maintain safety distance to overhead lines. z Only operate the machine from the driver's seat. z Do not transport persons on the machine. z Consider ambient conditions, e.g. poor visibility, wind speeds, etc. z Use the specific lifting capacity table for that machine. z Note performance specification. z Check that anchorage points have a sufficient safe working load. z Observe guide signals as necessary. z Never allow the machine to roll with the ignition switched off. When

the engine is not running, there is no power-assisted steering. z When driving a long distance, place the boom in the direction of

travel. z Before leaving the driver's cab:

– Position the machine on firm base, if necessary set back from the edge of the excavation – Lower suspended loads – Secure working equipment – Pull the safety lever backwards – Chock wheels/running gear – Switch off engine – Lock cab; show warning lights if necessary – Lock the floating axle.

5 - 40

825 M / 04.2007

Operation - Starting work

5.5.2 Driving the machine DANGER Risk of accident in the event of an operating error! If the boom is positioned over the rear axle, the machine moves in the opposite direction. Proceed with extreme caution whenever you wish to work or maneuver over the rear axle. Driving with a suspended load

Please note the following points when driving with a suspended load: z Tip-over danger!

Keep loads as close as possible to the ground when moving. z Always position the boom along the lengthwise axis of the

undercarriage. z Suspend only 50% of the rated lifting capacity. z Only drive on even ground with sufficient load-bearing capacity. z Lock the floating axle. z Reduce pendulum movements of load by sensitive driving. z Negotiate corners with as wide a radius as possible.

3 4 Driving

825 M / 04.2007

Apply and set parking and driving brake (1).

Start engine (2).

Push Savety lever (4) forwards.

If necessary, retract supports (3).

5 - 41

Operation - Starting work

5 6

CAUTION Risk of damage! Do not change from on-road travel to off-road travel while machine is in motion. 5

Select off-road or on-road operation (5).

If necessary, release the floating axle (6).

9 10

b 7

Release (7) the parking and driving brake (8).

Choose driving direction using the drive pedal (9). – (f) forward, (b) backward

Slow the machine using the parking and driving brake (8).

Park machine in acc. with Section 4.5.1.

Before exiting, always engage the parking and driving brake (8)!

Pull safety lever (10) backwards.

Note Avoid excessive heating of the hydraulic oil. Do not hold the steering at full lock longer than necessary.

5 - 42

825 M / 04.2007

Operation - Starting work

5.5.3 Towing ATTENTION! Use a steel cable with an appropriate strength rating when towing a defective machine. Do not use the holes in the shackles and eyes welded to the undercarriage for towing (these are intended solely for securing the machine during transport). Note An emergency actuating mechanism that permits emergency towing of the vehicle in the event of loss of control pressure or a faulty hydraulic motor is located on the power shift transmission. CAUTION! If the emergency actuating mechanism is not properly deactivated, the transmission will be damaged during normal operation. Because the transmission is not lubricated during towing, the following procedures must be observed: z Towing speed: max. 10 km/h (6.21 mph) z Distance towed: max. 5 km (3.10 miles)

For longer distances, the defective machine is to be transported using a suitable lowboy trailer. ATTENTION! The parking brake does not function, if the emergency actuating mechanism has been activated. No attempt to shift gears should be made, if the emergency actuating mechanism has been activated. The grease nipple on the emergency actuating mechanism is not to be used for lubrication purposes.

825 M / 04.2007

5 - 43

Operation - Starting work

Overview of valves and nipples

1 3

1 Pressure relief valve 2 Bleed valve 3 Grease nipple Activating the emergency actuating mechanism

Deactivating the emergency actuating mechanism

5 - 44

Shut off the engine.

Prevent the vehicle from rolling away.

Using a commercially available grease gun, pump grease into the grease nipple (3) until it appears again at the pressure relief valve (1) on the emergency actuating mechanism.

Open the bleed valve (2) on the emergency actuating mechanism.

Select on-road operation.

Apply the driving brake.

Close the bleed valve again.

825 M / 04.2007

Operation - Starting work

5.5.4 Supporting the machine The machine is stabilized on an uneven surface by using the support legs. This increases the stability. See also Section 3.2 for the lifting capacity. ATTENTION! Deploy the supports on a firm, even base. Do not lift the machine with the supports. The tires must remain in contact with the ground. ATTENTION! Never extend the supports completely (= to the positive stop). In this case, uniform distribution of the weight to the individual support pads, i.e. maximum stability, is no longer assured. If you extended the supports completely (audible sound), retract them slightly!

correct

825 M / 04.2007

incorrect

5 - 45

Operation - Starting work

1 b Actuation of all supports: 1 Lever for supports a forward = down b back = up

Deploying (extending) all supports

Actuation Single support (optional)

Actuation Single support (optional): 2 rear left 3 front left 4 front right 5 rear right

Set the parking and driving brake.

Start engine in accordance with Section 4.4.2.

Release safety lever (see Section 5.3.5).

Lock the floating axle using the switch on the right front control panel (bulb in switch does not light up).

Push the lever for actuating all supports (1) forwards until the supports are extended completely. Then pull the lever back until the wheels are in contact with the ground.

On uneven ground, level the machine by actuating the support legs individually. Example: Deploying the front left support leg: – Press (and hold) switch (3) while simultaneously pushing lever (1) forward. – Proceed in the same way with the remaining three support legs.

5 - 46

825 M / 04.2007

Operation - Starting work

DANGER! The lifting capacity of the machine is reduced when the supports are not used. Retracting all supports

825 M / 04.2007

Set the parking and driving brake.

Start engine in accordance with Section 4.4.2.

Release safety lever (see Section 5.3.5).

Pull the lever for actuating all supports (1) back.

Check that all four supports are retracted completely.

5 - 47

Operation - Starting work

5.5.5 Rotating/braking the upper structure The upper structure is rotated using the left control lever. DANGER! Tip-over danger with additional ballast! Turn upper structure only if supports are deployed! c

d Version with Joystick steering 1

1 Slewing mechanism holding brake switch 2 Slewing mechanism brake pedal (optional) Motions of left control lever: c Rotate upper structure counterclockwise d Rotate upper structure clockwise

Slewing speed

The slewing speed depends on the: z Speed (rpm) of the engine z Distance the left control lever is moved.

DANGER No individuals, buildings or machines must be within the slewing radius of the upper structure (danger area). Stopping (braking) the slewing motion

5 - 48

Place the left control lever in the neutral position (0-position). The upper structure is braked hydraulically. The slewing motion slowly stops. Note: Moving the control lever in the opposite direction intensifies the braking action. OR optionally: Actuate the slewing mechanism brake pedal (2). The upper structure is braked hydrodynamically.

825 M / 04.2007

Operation - Starting work

Slewing mechanism holding brake

The slewing mechanism holding brake is not a brake for stopping/ slowing the upper structure. The slewing mechanism holding brake serves solely as a parking and holding brake while the upper structure is stationary. The slewing motion of the upper structure must have come to a complete stop before the slewing mechanism holding brake is engaged. WARNING If the slewing mechanism holding brake is used to slow/stop the upper structure, considerable damage to the brake and slewing mechanism will result. The following damage may occur: z Reduced braking action as the result of damage to the plates z Destruction of the brake or other components z Destruction of the slewing mechanism

This damage is excluded from the terms of the warranty issued by SENNEBOGEN Maschinenfabrik GmbH. The operator of the machine alone is liable for such damage as well as any consequential damage - for instance, that resulting from reduced braking action! WARNING Never rotate the upper structure when the slewing mechanism holding brake is engaged! Note The slewing mechanism holding brake engages automatically as soon as z the safety lever is pulled backwards z the engine is shut down (e.g. by means of the E-stop or ignition key).

In unfavorable circumstances, it may take approx. 30 seconds before the full braking action takes effect. Activating the slewing mechanism holding brake

Move switch (1) in the front right control panel “to the right”. The slewing mechanism holding brake is activated; the switch goes out. The corresponding symbol also appears in the SDS.

Releasing the slewing mechanism holding brake

Move switch (1) in the front right control panel “to the left”. When initiating the slewing motion by means of the left control lever, the automatic slewing mechanism holding brake is released (disengaged); the bulb in the switch lights up. Have also a look at page before.

825 M / 04.2007

5 - 49

Operation - Starting work

5.5.6 Lifting/lowering loads Observe the following safety instructions: DANGER! z Suspended loads can cause accidents! Always lower the load when work is interrupted. Never leave the driver's cab when a load is suspended. z Activate the overload warning device (see also chapter 1.8). z Do not carry out any form of work which will reduce the stability of

the machine! z Attachments (e.g. grab) and parts of the load can swing. Proceed

with extreme caution. z Observe danger area.

The load is raised/lowered via the left control lever and/or via the right control lever. A

Control lever, left-hand Control lever motions: A Lift load (arm out) B Lower load (arm in)

Arm speed

Control lever, right-hand Control lever motions: a Lower load (boom down) b Lift load (boom up)

The arm speed depends on the: z Speed (rpm) of the engine z Distance the left control lever is moved.

Lift (hoist) speed

The lift (hoist) speed depends on the: z Speed (rpm) of the engine z Distance the right control lever is moved.

5 - 50

825 M / 04.2007

Operation - Starting work

5.5.7 Limit position sensors Limit position sensor

The limit position sensor prevents the hydraulic cylinder from hitting the positive stop. DANGER Never change the factory-set position of the limit position sensor! Adjusting the position of the sensor may be carried out only by SENNEBOGEN Customer Service or an authorized SENNEBOGEN Service Partner! The following damage can occur, if the operator adjusts the limit position sensor on his own: z Wear in the cylinder mounting bearings and boom. z Damage to the hydraulic cylinder. z Increased machine wear.

The safety limit position sensor for “Arm in” is set at the factory in the following manner: z Arm in: Arm (without attachment) approx. 8.2 ft. (2.5 m) in front of

lowered cab

1 2 3 8.2 ft

1 Compact boom 2 Sensor element 3 Grab arm

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5 - 51

Operation - Starting work

DANGER Danger to life if the safety limit position sensor for “Arm in” is set incorrectly! Attachments or parts of the load can strike and penetrate the cab. Always readjust the basic factory setting for the particular attachment (e.g. grab). The operator alone is responsible for operation of the machine with an incorrectly set safety limit position sensor for “Arm in”! Note The following limit position sensors are optionally available: z “Grab arm out” z “Boom up” z “Boom down”.

Auxiliary limits (optional)

With the aid of the optional auxiliary limits, you can limit “Arm out” or “Load/boom up”. This is useful z in the vicinity of power lines (see Chapter 1.6.1) z in buildings with limited headroom z under bridges z when working with attachments not supplied by SENNEBOGEN.

Note The optional auxiliary limits cannot be bypassed.

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825 M / 04.2007

Operation - Starting work

5.5.8 Bypassing the safety limit position sensor In exceptional circumstances, it may be necessary to move past the safety limit position (bypass the safety limit position sensor).

1 2

1 Pushbutton 2 Control lever, left-hand

DANGER Danger to life when bypassing the safety limit position sensor!

Press and hold pushbutton (1) on the left control lever (2).

Cautiously move the left control lever in the appropriate direction, depending on the desired function (Arm in/out, Boom up/down). See also section 5.3.3 and 5.3.4.

Note The optional auxiliary limits cannot be bypassed.

825 M / 04.2007

5 - 53

Operation - Starting work

5.5.9 Grab operation Observe the following safety instructions: WARNING z Suspended loads can cause accidents! Always lower the load when work is interrupted. Never leave the driver's cab when a load is suspended. z Activate the overload warning device. z Do not carry out any form of work which will reduce the stability of

the machine! z Attachments (e.g. grab) and parts of the load can swing. Proceed

with extreme caution. z Observe danger area.

The grab is opened/closed using the right control lever, and rotated using the two front pushbuttons on the left control lever. d 1 2

Grab motions: 1 Rotate counterclockwise 2 Rotate clockwise

Control lever movements: c Close grab d Open grab

1,2

c,d

5 - 54

825 M / 04.2007

Operation - Starting work

5.5.10 Generator and magnet system (optional) Heed the following safety instructions: Danger z Danger to life! Suspended loads can cause accidents! The load will drop in the event the magnet system fails. Always lower the load when work is interrupted. Never leave the driver's cab when a load is suspended. z Activate the overload warning device and check that it is operating

properly. z Ensure that the automatic idle function is deactivated. z Dangerous voltages can arise during operation. z Parts of the generator can still be very hot after work has ceased. z Do not plug in/unplug connectors during operation. z Installation/start-up as well as maintenance and service work on the

magnet system are to be performed only by authorized and qualified technicians. z Read the operating instructions prior to using the magnet system. z Use only approved accessories. In this regard, please contact

Sennebogen-Customer Service. z Operation is permitted only with magnetic plates; other applications

are not allowed. z Note operating data. z Cleaning with a high-pressure cleaner (steam cleaner) is prohibited. z The condensate drain openings must be at the lowest position. z Heed the additional safety instructions. z No modifications to the generator are permitted (e.g. installation

location, type of drive). Note When working with magnetic equipment, turn off the ECO switch (see Section 5.3.8)!

825 M / 04.2007

5 - 55

Operation - Starting work

Operation 1

Start engine in accordance with Section 4.4.2.

Set the speed (rpm) selector (1) on the right rear control panel to maximum.

Place the magnet on the load.

WARNING! Take care not to exceed the rated lifting capacity.

Switching on the magnetic equipment: – Actuate the switch on the upper right control panel. – Press the front pushbutton (2) on the right control lever.

Depositing the load: – Press pushbutton (2) or* (3). * Switch assignment is customer-specific!

Switching off the magnetic equipment. – Actuate the switch on the upper right control panel.

Attention! If the magnetic equipment is not switched off after use, overheating of the entire system (generator and magnet plate) may result.

5 - 56

825 M / 04.2007

Operation - Starting work

5.5.11 Refueling the machine You can refuel the machine in two ways: z Manually z Using the fueling pump

DANGER z Fuel is hazardous to the health and easily ignitable. Smoking and any type of open flame are strictly forbidden. z Position the machine on a firm, even surface. z Only refuel when engine is shut down! z Fuel must not be allowed to seep into the ground or waterways.

Always ensure that fuel does not overflow when refueling. z Before filling, the fluid level in the tank must be determined - the

amount of fuel that the tank can taken on. z When refueling from a tanker, note the following: Delivery rate from

tank max. 200 l/min. (52 U.S.GPM), as otherwise the fuel will overflow. z The filling procedure must be monitored at all times - no matter how

the filling is done. Note Please observe the directions and recommendations regarding the fuel system in the engine manufacturer’s instructions.

Manually

Lower suspended loads and boom to the ground.

Shut down engine.

1 2 4

825 M / 04.2007

5 - 57

Operation - Starting work

Using the fueling pump

Open left rear maintenance panel.

Open cap (1) from the filler strainer.

Clean strainer.

Insert funnel into filler strainer.

Carefully pour in fuel through the funnel.

Replace cap (1) and close side panel.

Lower suspended loads and boom to the ground.

Shut down engine.

Place the key switch in the “1” position.

Open left rear maintenance panel.

Open the cap (1) on the filler strainer. This allows the air in the tank to escape.

DANGER! If the cap is not open, excess pressure can build up in the tank while it is being filled. The tank can become deformed or can burst and potentially cause damage to property or injure personnel. Spilled fuel also causes environmental damage.

Place the refueling hose (4) into the external fuel container.

Note Danger of cavitation! Ensure that the maximum suction lift does not exceed 3 m.

Use the green button (2) to switch on the fueling pump. The tank fills automatically.

CAUTION Ensure that the pump does not run dry (> 30 s). If necessary, use the red button (3) to switch off the fueling pump to prevent damage.

5 - 58

825 M / 04.2007

Operation - Starting work

Observe the sightglass on the fuel tank to monitor the fuel level. Use the red button (3) to switch off the pump as soon as the tank is full.

Remove the fueling hose (4) from the external fuel container and stow.

Close the cap (1) on the filler strainer.

Close maintenance panel again.

Note Check the following items, if the fueling pump does not start operating after approx. 5 seconds:

825 M / 04.2007

Is the battery charged?

Are all fuses o.k.?

Is the suction end free of leaks?

Is the maximum suction lift of 3 m exceeded?

5 - 59

Operation - Actions to take if the electronics fail

5.6 Actions to take if the electronics fail Note An electronic failure is indicated only if the corresponding function can no longer be performed.

5.6.1 Reverse airflow -insufficient cooling capacity-

1 Plug for hydraulic cooling pump

5 - 60

Pull the plug (1). – Fan goes to maximum speed, 100% cooling capacity.

825 M / 04.2007

Operation - Actions to take if the electronics fail

5.6.2 Steering failure (optional with joystick steering) Note In the event of steering failure, the angle of the wheel can be adjusted by manually pressing the corresponding valve spool.

2 3

2 Left valve spool (not visible, opposite side) 3 Right valve spool (in direction of travel)

825 M / 04.2007

Press and hold right valve spool (3): – Wheel turns to the right.

Press and hold left valve spool (2): – Wheel turns to the left.

5 - 61

Operation - Actions to take if the electronics fail

5 - 62

825 M / 04.2007

Inspecting, maintaining and cleaning -

Inspecting, maintaining and cleaning

WARNING The work described below must only be carried out by trained and instructed technical personnel. The maintenance work is described in separate instructions.

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 Position the machine on firm base, if necessary set back from the

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

with specific knowledge of and experience with hydraulics! z After maintenance or repair work, carry out a thorough visual

inspection and functional check in acc. with Section 4.3. WARNING Mixing oils, lubrication or operational materials 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!

825 M / 04.2007

6-1

Inspecting, maintaining and cleaning - Safety instructions

6.1

Safety instructions

WARNING z The work performed may only be completed by trained professionals. z Wear personal safety equipment (e.g. safety helmet, ear protection,

work (see maintenance instructions). z Dispose of hydraulic oil according to regulations. z Wear protective gloves when working on steel wire rope. z Use only original SENNEBOGEN replacement parts. z Use only oils and lubricants listed in the lubricant table. z Do not lift heavy objects by hand. Use lifting gear. z For pneumatic tires:

When pumping up tires, maintain an adequate safety distance and use a tire cage. z Keep the cab clean and orderly. z If necessary, switch off the optional battery isolator switch in order to

interrupt the current. z When working near batteries, these are to be covered with insulating

material; do not place tools on top of batteries. z Replace all safety devices after completing any work on the

machine. z Carry out a functional check to ensure problem-free operation.

6-2

825 M / 04.2007

Inspecting, maintaining and cleaning - Daily/weekly checks

6.2 Daily/weekly checks Note The following three pages contain the check list that must be reviewed on a daily or weekly basis. It is divided into: a general section, a functional check section and a visual check section. Note: The visual checks V15, V18, V19 and V21 (in italics) are to be performed on a weekly basis, all others on a daily basis.

825 M / 04.2007

6-3

Inspecting, maintaining and cleaning - Daily/weekly checks

No.

General

Steps to take

Are the danger areas (overhead lines, ditches, etc.) marked and secured in the operating area?

Mark and secure as necessary

Do you know the operating and environmental conditions (soil strength etc.)?

If necessary, obtain information

Is an experienced signaler available, if required?

If necessary, arrange for a signaler

Is there anyone in the danger area?

If so, advise them to leave the danger area

Do you know the weight of the load?

Obtain information as required

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

Refer to the operating instructions and rating plate as necessary

No.

Functional checks

Is the limit sensor on the arm set correctly?

If necessary, adjust; see section 5.5.7

Is the hoisting limit sensor set correctly?

If necessary, adjust

Is the overload warning device activated?

If necessary, activate

Is the machine positioned horizontally?

If necessary, position correctly

Is the stability of the machine assured?

If necessary, support properly; see section 5.5.4

Are all safety features (brakes, monitoring/ warning indicators, signal and lighting devices) working correctly?

If necessary, locate and correct faults

Are any warning or fault messages displayed on the SDS?

If necessary, locate and correct faults, read fault log

Are electrical devices such as the windshield wipers, heating, air conditioning working correctly?

If necessary, locate and correct faults

Is the emergency lowering feature of the cab functioning?

If necessary, locate and correct faults; see section 5.2.2

F10

Check steering for correct adjustment and operation?

If necessary, adjust

F11

Is the central lubrication unit functioning?

If necessary, refill with grease or locate and correct faults (grease must appear at all connected lubrication points)

6-4

Steps to take

825 M / 04.2007

Inspecting, maintaining and cleaning - Daily/weekly checks

No.

Visual checks

Are all protective covers, insulating materials and warning signs in place on the machine and intact?

If necessary, replace

Are all steps/ladders, handles/handholds and anti-slip surfaces in place and intact (e.g. cracks)?

If necessary, repair or replace

Is the machine clean enough to ensure no danger areas exist due to dirt (danger of slipping, falling, poor visibility)?

If necessary, clean using a high-pressure cleaner BE CAREFUL around sensitive or electrical components! !

Are the windows clean and free of ice and snow?

If necessary, clean

Is the undercarriage/running gear (tires, axles, drive shafts/universal joints) intact?

If necessary, repair or replace

Are the wheel nuts tight and the intermediate ring firmly seated?

If necessary, retighten to the specified torque

Is the tire pressure correct? For pneumatic tires

If necessary, repair leaks and pump up tires (using a tire cage)

Is the hydraulic system (lines, hoses etc.) free of leaks and intact?

If necessary, tighten connections or replace seals

Are the hydraulic cylinders (e.g. supports, arm, floating axle cylinders, steering cylinders) free of leaks and intact? Inspect piston rods for damage (cracks etc)?

If necessary, tighten connections or replace seals

V10

Is the shutoff on the hydraulic tank open?

If necessary, open; see chapter 2.4

V11

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

If necessary, repair leaks and top up fluids. Follow manufacturer's instructions!

V12

Is the fan wheel intact?

If necessary, replace

V13

Is the cooling system (cooler, hoses, tubing etc.) free of leaks?

If necessary, repair leaks and top up coolant. Follow manufacturer's instructions! Replace defective components.

V14

Are all hose clamps tight and the hose connections free of leaks?

If necessary, retighten or replace

V15

Is there enough grease in the central lubrication system?

If necessary, refill

V16

Has the water separator on the fuel system been drained?

If necessary, drain

825 M / 04.2007

Steps to take

6-5

Inspecting, maintaining and cleaning - Daily/weekly checks

No.

Visual checks

Steps to take

V17

Are the V-belts intact and tensioned?

If necessary, retension or replace

V18

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

If necessary, clean by reversing the fan or replace

V19

If the air inlet port is undamaged, are the air filter inserts dirty?

If necessary, replace or blow out

V20

Are the electrical lines damaged?

If necessary, repair or replace

V21

Are the batteries held in place securely?

If necessary, resecure

V22

Are the cable connections or terminals on the battery dirty or corroded?

If necessary, clean and grease; cover terminals with protective caps

V23

Are all service access doors closed?

If necessary, close

V24

Are all bolted connections - particularly on the elevating cab - intact and tight?

If necessary, retighten or replace

V25

Have any possible cable connections to external power sources been disconnected?

If necessary, disconnect

V26

Is the correct counterweight (ballast) installed and secured in place?

If necessary, replace or resecure with specified torque

V27

Are the boom components intact (corrosion, cracks)?

If necessary, repair or replace

V28

Are any bolts cracked or damaged?

If necessary, replace

V29

Are the pipe rupture safeties (restraints) tight and intact?

If necessary, replace

V30

Are the lubrication lines intact and all lubrication points being greased?

If necessary, replace, clean and lubricate

V31

Are the hydraulic lines and hoses secured in place?

If necessary, tighten fasteners

V32

Are the quick-connect couplings free of leaks and the protective caps in place?

If necessary, replace couplings and attach protective caps

V33

Is the slewing mechanism lubricated sufficiently?

If necessary, lubricate gearing

V34

Is the slewing ring filling cover in place and is there enough grease?

If necessary, re-install and refill grease

V35

Inspect the positive stops for the steering for wear?

If necessary, replace

V36

Inspect the power cable track for wear?

If necessary, replace

6-6

825 M / 04.2007

Inspecting, maintaining and cleaning - Daily/weekly checks

6.2.1 Check engine oil level Note Also comply with the notes in the operating instructions of the engine manufacturer. Detailed view of Cummins engine

1 Oil dipstick handle

Checking engine oil level

825 M / 04.2007

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.

6-7

Inspecting, maintaining and cleaning - Daily/weekly checks

6.2.2 Check coolant level and antifreeze Top view with generator for magnetic equipment (optional)

3 2

1 1 Service panel 2 Handle 3 Hand screws 4 Cap

6-8

Allow engine and cooler to cool down.

Unscrew the two hand screws (3).

Grab the service panel (1) by the handle (2) and remove.

Pace large, thick cloths on the cap (4) 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 °C (-40°F).

Close the cap on the expansion tank.

Replace the service panel and secure using the hand screws.

825 M / 04.2007

Inspecting, maintaining and cleaning - Daily/weekly checks

6.2.3 Check hydraulic 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.

Check hydraulic 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 on oil filler neck. – Top up hydraulic oil and re-check. – Tighten threaded cap again. – Close the cover plate. See also maintenance instructions!

825 M / 04.2007

Close the service access door.

6-9

Inspecting, maintaining and cleaning - Daily/weekly checks

6.2.4 Check fuel level Note The fuel level can be determined in two ways: z via the ‘bull's eye’ to the right of the filler neck (rough indicator) z via the SENNEBOGEN Diagnostics System (in the starting screen),

refer to Chapter 5.3.9.

1 Fuel filler neck 2 ‘Bull's eye’ 1

6.2.5 Check windshield washer fluid level Note The reservoir for the windshield washer fluid is located behind the front left service access door. Always fill the reservoir with washer antifreeze.

1 Washer fluid reservoir 2 Service access door

6 - 10

825 M / 04.2007

Inspecting, maintaining and cleaning - Daily/weekly checks

6.2.6 Drain off water - fuel system WARNING! 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. Water separator

1 Filter cartridge 2 Water reservoir 3 Drain valve

Open the service access door rear right.

Place a suitable collection vessel under the water reservoir (2).

Open the drain valve (3).

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

Close the drain valve again.

Close the service access door.

Note The filter cartridge (1) must be changed after draining the water five times.

825 M / 04.2007

6 - 11

Inspecting, maintaining and cleaning - Daily/weekly checks

6.2.7 Check belt drives 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 are not damaged and run in parallel.

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

Belt drives of DEUTZ engine 1

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

6 - 12

825 M / 04.2007

Inspecting, maintaining and cleaning - Daily/weekly checks

6.2.8 Check and clean airfilter cartridges 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. 1 2

1 Air filter cover 2 Nose 3 Locking clamps (3 each)

825 M / 04.2007

4 Replaceable cartridge 5 Handle 6 Safety cartridge

Open the left rear service access door.

Open the locking clamps (3) of the air filter cover (1) and remove the air filter cover.

Remove replacement cartridge (4).

Clean the replaceable cartridge: – Blow out from inside to outside using dry compressed air (max. 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 (5). Never clean the safety cartridge! – Insert new safety cartridge.

Insert new or cleaned replaceable cartridge (4).

Replace the air filter cover (1) so that the nose (2) faces downwards or the word “TOP” faces upwards.

Reattach the air filter cover (1) using the locking clamps (3).

Close the service access door.

6 - 13

Inspecting, maintaining and cleaning - Daily/weekly checks

6.2.9 Check grease fill level - slewing ring

6 - 14

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 (min. 20mm / 0.79 inch). If necessary, refill with grease.

Remount cover plate (1).

825 M / 04.2007

Inspecting, maintaining and cleaning - Daily/weekly checks

6.2.10 Check fill level - central lubrication The central lubrication system automatically lubricates the raceway of the slewing mechanism as well as the bearings of the equipment and the cab. 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

825 M / 04.2007

Actuate the switch on the upper right control panel.

6 - 15

Inspecting, maintaining and cleaning - Daily/weekly checks

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

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

6.2.12 Check tightness of wheel nuts Check that the intermediate rings are seated firmly. Check tightness of all wheel nuts. The tightening torque is 650 Nm. Use a torque wrench. Fig. Twin tires, solid rubber

6 - 16

825 M / 04.2007

Inspecting, maintaining and cleaning - Maintaining and cleaning

6.3

Maintaining and cleaning

Notes 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 It is especially important to clean the noise suppression mats with

neutral cleaning agents! z Only use lint-free cleaning cloths. z Only use dry, filtered compressed air up to max. 2 bar (29 PSI). z On completion of cleaning work, carry out a visual and functional

check of the machine in acc. with Section 4.3. WARNING Electrical and electronic components such as the alternator, control cabinet etc. 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 the water does not come 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.

825 M / 04.2007

6 - 17

Inspecting, maintaining and cleaning - Maintaining and cleaning

6 - 18

825 M / 04.2007

Transportation - Safety instructions

7 Preliminary work

Transportation

Transport the machine using a lowboy trailer. Carry out the following preliminary work: z Select a suitable transport vehicle.

Note the dimensions and weight of the machine listed in Section 7.2. z Clean the machine. z Place the boom and arm in the transport positions. z Secure the upper structure and undercarriage in acc. with

Section 7.3. z Secure the supports in acc. with Section 5.5.4. z If necessary, remove working tools.

7.1 Safety instructions WARNING z In Germany: loading and transportation work is only to be carried out by authorized specialist personnel in accordance with VBG 40, §48 and Federal Motor Vehicle Safety Standards (StVo) §22. z Observe the relevant regulations for securing of loads.

The respective transport operator is always responsible for the transportation of machine and accessories. z When loading and transporting, secure the machine and its working

equipment from unintended movement. z Clean running gear of machine sufficiently from mud, snow and ice,

users. z Wear personal protection equipment (e. g. safety helmet, protective

gloves, safety boots). z Notify SENNEBOGEN Customer Service of any transport damage

immediately.

825 M / 04.2007

7-1

Transportation - Dimensions and weight

7.2

Dimensions and weight

7.2.1 Transportation dimensions

9.12 ft.

2.2 ft.

8.86 ft.

11.23 ft.

4.23 ft.

10.63 ft.

9.19 ft.

0.35 ft. 1.12 ft.

10.69 ft.

0.85 ft.

19.49 ft.

9.02 ft.

9.19 ft. 9.02 ft.

15.37 ft.

12.83 ft.

16.69 ft.

14.00 ft.

10.68 ft.

33.97 ft.

7.2.2 Weight Machine

Weight

approx. 27.9 t (61,509 lb)

with Cummins 129 kW (171.6 HP) diesel engine, 4-point support, compact boom. Note The machine weight may deviate from these figures due to optional attachments.

7-2

825 M / 04.2007

Transportation - Securing the upper structure

7.3

Securing the upper structure

Place the upper structure in the direction of travel.

Engage slewing mechanism holding brake.

825 M / 04.2007

Bolt and secure the locking bar (1) to the undercarriage and the upper structure.

7-3

Transportation - Disconnect electrical system from battery

7.4

Disconnect electrical system from battery

If the machine is idle for an extended period or for long transport distances, the electrical system must be isolated from the battery using the mechanical battery isolator switch (optional). WARNING Do not switch off mechanical battery isolator switch if: z the engine is still running z or other electrical devices are still switched on.

Doing so may damage the electrical system and its controller.

Open left rear maintenance panel.

Turn the battery isolator switch (1) to the left (counterclockwise) and remove. The electrical system is now isolated from the battery.

Close maintenance panel.

Note If no mechanical battery isolator switch exists, the battery terminals must be disconnected. Properly install the protective caps on the battery again.

7-4

Open left rear maintenance panel.

IMPORTANT! Prevent short circuits! Disconnecting: 1. Disconnect the negative terminal 2. Disconnect the positive terminal Connecting: 1. Connect the positive terminal 2. Connect the negative terminal

Close maintenance panel.

825 M / 04.2007

Transportation - Lifting machine

7.5 Safety instructions

Lifting machine

Read the safety instructions before starting work. DANGER! z Sling machine only at the designated lifting points. The slinging points are marked in green and have a green loading hook symbol. z Ensure that the lifting equipment has sufficient lifting capacity and is

stable. z The following is suitable lifting gear:

– crane – telescopic crane z Ensure that the slinging gear has sufficient lifting capacity and is

intact. z The following is suitable slinging gear:

– chain slinging gear – steel wire rope slinging gear – round loops / sling devices z Observe the danger area!

There must be no-one next to, on or below the machine. 48,281 lb

Procedure with counterweight

13,227 lb

Select a suitable hoisting crane and slinging gear. Note the weight and center of gravity of the machine.

Attach the lifting gear to the lifting points.

Hoist machine carefully.

DANGER There must be no one below a suspended load!

825 M / 04.2007

7-5

Transportation - Tie down the machine

7.6

Tie down the machine

CAUTION z Secure machine at the designated tie-down points (1). The tie-down points are marked in green and are located on the undercarriage. z Ensure that the slinging gear has sufficient lifting capacity and is

intact. z Ensure that the machine is not damaged if additional securing is

necessary. z The respective transport operator is always responsible for the

transportation of machine and accessories.

7-6

825 M / 04.2007

Troubleshooting - Engine

Troubleshooting

WARNING z Read Chapter 1 SAFETY. z The personnel for maintenance, inspection and troubleshooting

must have the appropriate qualifications for this work. z For work not described in detail, please notify the SENNEBOGEN

Customer Service Desk.

8.1 Engine Engine does not start

Cause

Remedy

Battery power too low

– Check fluid level of batteries. – Recharge or replace battery. – Start machine using auxiliary battery.

Start inhibit not active

– Release drive pedal.

Fuel tank empty

– Refuel machine.

Engine performance drops

Cause

Remedy

Suction resistance too high

– Exchange filter element in water separator.

Machine does not move

Cause

Remedy

Parking brake actuated

– Release parking brake.

Transmission defective

– Have fault remedied.

Cause

Remedy

Hose connections loose

– Tighten hose connections.

Hoses or seals damaged

– Exchange hoses or seals.

Oil or fuel leaks from engine

Note Please also observe the notes and recommendations in the engine manufacturer's operating instructions.

825 M / 04.2007

8-1

Troubleshooting - Hydraulic system

8.2 Oil leaks from hydraulic system

Hydraulic system

Cause

Remedy

Hose connections loose

– Tighten hose connections.

Hoses or seals damaged

– Exchange hoses or seals.

Hydraulic pump not working

Cause

Remedy

Fault in pump circuit

– Have fault inspected and rectified by hydraulic specialist.

No or faulty function of operating equipment

Cause

Remedy

Hydraulic oil level too low

– Check hydraulic oil level. – Top up hydraulic oil, if required.

Leaks in the hydraulic system

– Check working cylinder, connections and hoses for leaks. – Have fault rectified by hydraulic specialist.

Fault in one of the working circuits

– Have fault rectified by hydraulic specialist.

Cause

Remedy

Piston rod in the cylinder has no lubricating film

– Have repair carried out by hydraulic specialist.

Noises when moving a working cylinder

8-2

825 M / 04.2007

Troubleshooting - Hydraulic system

No/little performance from hydraulic system

Noises in hydraulic system

825 M / 04.2007

Cause

Remedy

Hose connections loose

– Tighten hose connections.

Hoses or seals damaged

– Exchange hoses or seals.

Pressure relief valve opens too soon

– Have fault rectified by hydraulic specialist.

Hydraulic pump worn or defective

– Have pump exchanged by hydraulic specialist.

Cause

Remedy

Hydraulic pump takes in air

– Have fault rectified by hydraulic specialist.

Hydraulic pump delivers insufficient oil

– Check hydraulic oil level. – Top up hydraulic oil, if required.

Pressure relief valve chatters

– Have fault rectified by hydraulic specialist.

8-3

Troubleshooting - Heating

8.3 No heat or insufficient heating power

No air flow

Heater cannot be switched off

8-4

Heating

Cause

Remedy

Water intake temperature too low

– Allow engine to warm up. – Replace thermostat (in air conditioning system).

Thermostat on vehicle defective

– Replace vehicle thermostat.

Water valve does not open

– Check valve and valve actuation, if necessary replace. Note direction of flow.

Heat exchanger fins dirty

– Clean heat exchanger.

Filter contaminated

– Clean filter, replace if necessary.

No air flow

– see below.

Cause

Remedy

Fuse defective

– Replace fuse.

Power supply interrupted

– Check lines for loose contacts or open circuit.

Blower motor defective

– Have blower motor replaced.

Blower switch defective

– Check switch, replace if necessary.

Resistor defective

– Have resistor replaced.

Cause

Remedy

Bowden cable for water valve incorrectly adjusted

– Adjust Bowden cable.

Heating valve incorrectly fitted

– Check flow direction at valve, if necessary change supply and return line.

Actuation or Bowden cable defective

– Exchange actuation or Bowden cable.

825 M / 04.2007

Troubleshooting - Tires and undercarriage

8.4 Oil leaks in differential, hubs or gearbox

Tires and undercarriage

Cause

Remedy

Sealing plug loose

– Tighten sealing plug.

Seals damaged

– Replace seals.

Oil leaks in slewing mechanism transmission

Cause

Remedy

Connections loose

– Tighten connections.

Rotary union leaks

Cause

Remedy

Seals damaged

– Replace seals.

Lines loose

– Tighten fasteners.

Cause

Remedy

Insufficient lubrication on slewing ring gearing

– Lubricate gearing in acc. with lubrication schedule.

Noises in slewing mechanism

8.5 Cab Cab moves or swings drastically

825 M / 04.2007

Cause

Remedy

Cab mounting or cab fastening damaged

– Check all connection elements, bolts and pins of cab mounting and fastening for damage, cracks or deformation. – Have damaged components exchanged immediately by trained and instructed specialist personnel.

8-5

Troubleshooting - SDS fault indicators

8.6 Symbol flashes, buzzer sounds and red “Attention” illuminates

8-6

SDS fault indicators

Cause

Remedy

Hydraulic oil temperature too high (>183.2 °F (84 °C))

– Allow engine to run with no load until the hydraulic oil cools.

Cooling fins on hydraulic oil cooler soiled

– Clean cooling fins on hydraulic oil cooler.

Hydraulic oil level too low

– Check oil level in accordance with maintenance instructions. – Top up hydraulic oil, if required.

Symbol flashes, buzzer sounds and red “Attention” illuminates

Cause

Remedy

Insufficient fuel in tank

– Refuel machine in accordance with Section 5.5.11.

Symbol flashes, buzzer sounds and red “Attention” illuminates

Cause

Remedy

Engine overheated

– Allow engine to idle.

Cooling fins on engine oil cooler soiled

– Clean cooling fins on hydraulic oil cooler.

Fan drive loose or defective

– Tighten fan drive; replace, if necessary.

Coolant level too low

– Top up coolant in accordance with maintenance instructions.

Engine switched off without cooling phase.

– After operating, allow engine to run in low idle for approx. 5-10 minutes before switching off.

825 M / 04.2007

Troubleshooting - SDS fault indicators

Symbol flashes, buzzer sounds and red “Attention” illuminates

Cause

Remedy

Engine oil pressure too low (<18.85 PSI (1.3 bar))

Symbol flashes, buzzer sounds and red “Attention” illuminates

Cause

Remedy

Battery charge too weak

– Check battery charge; recharge batteries or exchange, if necessary. – Check battery connections, tighten terminals if necessary. – Check V-belt tension, retension or replace, if necessary.

Lights up, buzzer sounds

Cause

Remedy

Coolant level too low

– Top up coolant.

Lights up while engine is running

Cause

Remedy

Accumulator pressure too low

– Have a hydraulic specialist check the hydraulic system.

Lights up, buzzer sounds

Cause

Remedy

Hydraulic oil level too low

– Top up hydraulic oil

825 M / 04.2007

8-7

Troubleshooting - SDS fault indicators

Lights up

8-8

Cause

Remedy

Slewing mechanism holding brake engaged

– Disengage slewing mechanism holding brake

Cause

Remedy

Pilot control filter clogged

– Check pilot control filter; if necessary, replace in accordance with maintenance instructions.

Cause

Remedy

Hydro-Clean micro filter is clogged

– Check Hydro-Clean micro filter; if necessary, replace in accordance with maintenance instructions.

Cause

Remedy

Return filter is clogged

– Check return filter; if necessary, replace in accordance with maintenance instructions.

Cause

Remedy

Air filter soiled

– Clean filter in accordance with maintenance instructions. – If necessary, replace filter element.

825 M / 04.2007

Set-up work -

Set-up work

Note The set-up work to be carried out depends on the working tools that have been selected. Please refer to the tool manufacturer's instructions for more detailed information. WARNING There may be dangers during operation to persons, machine and other property, if z the setting of the safety limit position sensor for “Arm in” was not

adjusted for the attached tool z the tools attached do not comply with the relevant safety regulations

(see Section 1.2) z the tools have not been approved by SENNEBOGEN z the tools attached are found to be defective.

The operator of the machine alone is liable for any damage or consequential damage caused by tools! This damage is excluded from the terms of the warranty issued by SENNEBOGEN Maschinenfabrik GmbH.

825 M / 04.2007

9-1

Set-up work - Installing/dismantling the counterweight

9.1

Installing/dismantling the counterweight

Note The mass of the counterweight is cast into its upper surface. The counterweight can be removed to transport the machine. DANGER! The machine can tip over. Without the counterweight, the machine is not suitable for operation. 4

5 6 1

1 Threaded attachment points for lifting eyes 2 rear hex-head bolt 3 lower hex-head bolt 4 Taillight connector 5 Taillight mounting screws

9-2

6 Slinging gear 7 Counterweight 8 Spacer pack a Bracket for slinging gear: 90°

825 M / 04.2007

Set-up work - Installing/dismantling the counterweight

9.1.1 Dismantling the counterweight 1

Place the upper structure in the direction of travel. Place the working tools/equipment on the ground.

Unscrew the taillight mounting screws (5); withdraw the taillights slightly. Carefully unplug the connector (4) from each taillight.

Screw the two lifting eyes included with the on-board accessories into the threaded attachment points (1) for the counterweight completely.

Attach suitable slinging gear (6) to the assisting crane and the lifting eyes on the counterweight (7).

DANGER! The angle “a” between the machine and the slinging gear must always be 90°. If the angle is larger or smaller, the counterweight can tip away from the machine, causing injury to people or damage to the machine.

Unscrew the lower hex-head bolt (3) from the counterweight.

Carefully unscrew the rear hex-head bolt (2).

DANGER! Risk of being crushed or trapped. There must be no one below a suspended load.

825 M / 04.2007

Swing the counterweight (7) to the rear slightly and lift away. Deposit the counterweight in a safe location and secure against tipping.

Remove both spacer packs (8) and retain for use when reinstalling in the future. ATTENTION! Do not interchange the left and right sides.

9-3

Set-up work - Installing/dismantling the counterweight

9.1.2 Installing the counterweight

Attach suitable slinging gear (6) to the assisting crane and the lifting eyes on the counterweight (7).

Place both spacer packs (8) on the support blocks in the correct positions.

DANGER! Risk of being crushed or trapped. There must be no one below a suspended load.

Lift the counterweight (7) onto the machine by means of the assisting crane.

ATTENTION! Secure bolts (2) and (3) with “Loctite 270” each time the counterweight is installed! Follow the instructions on the “Loctite” package!

9-4

Attach the counterweight (7) to the machine using the rear hexhead bolt (2).

Screw in the lower hex-head bolt (3).

Using a torque wrench, tighten the rear hex-head bolt (2) with a torque of 2350 Nm. Using a torque wrench, tighten the lower hex-head bolt (3) with a torque of 960 Nm.

Remove the slinging gear (6).

Unscrew both lifting eyes from the counterweight (7) stow with the on-board accessories.

Re-attach the taillight connectors (4), place the taillights in the recesses in the counterweight (7) and tighten the mounting screws (5).

825 M / 04.2007

Appendix - List of abbreviations

10 Appendix 10.1 List of abbreviations

825 M / 04.2007

BGV

Trade association directive

Operating hours

EMC

Electromagnetic compatibility

LED

Light emitting diodes

SDS

SENNEBOGEN-Diagnostic-System

StVO

Road traffic ordinance

TBG

Mining trade association

VBG

Union of commercial trade associations

10 - 1

Appendix - Index

10.2 Index 10.3 Driver's seat 10.4 Cleaning the cooling system 10.5 Quick-connect couplings 10.6 Installing large roller bearings, gearing and flange connections 10.7 Magnet system 10.8 Warranty conditions 10.9 Lubricants table

10 - 2

825 M / 04.2007

Index

A Adverse conditions 3-4 Air filter 2-3 Ambient temperature 3-2 Antifreeze 6-8 Automatic rpm control 5-19 B Batteries 2-3 Battery acid 4-9 Battery isolator switch 2-3 Beaufort scale 3-6 Belt drives 6-12 Blended air mode 5-39 Bypassing the safety limit position sensor for "Arm in" 5-53 C Cab 2-1 Assembly 5-6 Dismantling 5-6 Cab suspension 5-4 CE Conformity Symbol 1-7 CE Stamp 1-7 CE stamp of conformity 1-20 Central lubrication system 2-3, 5-37, 6-15 Clean signs 1-20 Cleaning agents 6-17 Combination cooler 2-3 Compact boom 2-1 Conformity declaration 1-7 Control lever 2-6 Control lever, left-hand 5-11 Control lever, right-hand 5-12 Conversion of the machine 1-17 Coolant level 6-8 Copyright 1-7 Correct use 1-2 Current when going to press 1-2 Customer Service Desk 1-7 D Daily start up 4-2 Danger area 1-4

825 M / 04.2007

Danger of crushing 1-4 Decommissioning 4-11 Decommissioning the machine 4-11 Deploying (extending) the supports 5-46 Dimensions 7-2 Disposal Batteries 1-28 Lubricants 1-28 Disposal of batteries 1-28 Disposal of oil filters 1-28 Disposal regulation 75/439/ EEC 1-28 Dispose of Lubricants 1-28 Disposing of consumables 1-28 Drive pedal 5-21 Driver's cab 2-1, 2-6 Driver's doors 5-3 Driver's seat 5-3 Driving backwards. 5-32 forwards. 5-32 with a suspended load 5-41 Driving the machine 5-41 E Ear protection 1-7, 1-17 Effect wind 3-6 Electrical control cabinet 2-3 Electrical system 3-2 Emergency exit 5-2 Emergency hammer 1-6, 5-2 Emergency lowering Cab 2-3 in cab 5-7 in storage compartment 5-8 Engine 2-3, 3-1 Changing the oil 6-7 Checking oil level 6-7, 6-8 Engine compartment 2-3 Environmental guidelines 1-28

Environmental protection 1-28 EuroTest 1-7 F Fan reversal – combination cooler 5-16 Fault diagnosis 8-1 Fault indicators (SDS) 5-33 Fax Customer Service Desk 1-7 Documentation 1-7 Spare parts depot 1-7 Filler neck - fuel tank 2-3 Fire extinguisher 1-18 First aid box 1-18 Floating axle 2-2 Floating axle cylinder 2-2 Floating axle lock 5-16 FOPS protective roof 1-17 Front axle 2-2 Front windshield 5-3 Fuel system 6-11 Fuel tank 2-3 Fuel tank display 5-24 Fueling pump 2-3 Fuse Preheat 2-5 G Grab arm 2-1 H Hand signals 1-29 Heating 2-6, 5-9 High beam 5-32 High voltage contact 1-8 Holding open driver’s doors 5-3 Hydraulic oil cooler 2-3 Hydraulic system 3-2 Hydraulic tank 2-4 HydroClean - fine filtration system (optional) 2-4 I Ignition key 4-7 Impermissible operating

S-1

Index

practices 1-17 Indicating light - EMR 5-32 Indicating lights 5-32 Indicating lights (SDS) 5-32 Inhalation of exhaust fumes 4-7 Inhaling exhaust fumes 4-7 Initial commissioning 4-2 Initiating raceway lubrication manually 5-37, 6-15 Installing/removing the counterweight 9-2 Interior lighting 5-3 International regulations 1-1 J Jump start 4-9 K Keypad (SDS) 5-24 Keyword 1-3 L Lifting capacities 3-4 Lifting capacity table 3-5 Lifting force 3-4 Lifting gear 7-5 Lifting points 7-5 Light emitting diodes 5-24 Limit position sensor 5-51 Limitations during wind 3-2 List of abbreviations 10-1 Load lift 5-50 lower 5-50 Locking bar 7-3 Lowering/reducing lifting capacities 3-4 Lubricating the raceway 5-37, 6-15 Lubrication cycle 5-37, 6-15 Lubrication intervals 5-37, 6-15 M Machine hoisting 7-5 tie-down 7-6 transportation 7-1

S-2

Machine Labeling 1-20 Machine Number 1-20 Machine operating area 1-4 Main fuse Electrical system 2-5 Maintenance instructions 1-6 Maneuvering the cab 5-5 Maximum stability 1-7 Misuse 1-2, 1-3 Monitoring duty 1-17 Muffler 2-4

Potential instances of misuse 1-2 Power lines 1-8 Preheat 5-32 Protective gloves 1-7 Protective roof (FOPS) 1-17 Prototype Testing 1-7 Pump unit 2-3

N National regulations 1-1 Noise protection 1-17 Noise protection measures 1-17 Notes regarding the operating instructions 1-2 Notice signs 1-20

R Rear axle 2-2 Recirculated air mode 5-38 Recommissioning 4-2 Remedying faults 8-1 Reservoir - washer fluid 5-9, 5-15 Reservoir - washer water 2-6 Responsibilities of the operator 1-15 Restraint belt 4-6 Retracting the supports 5-47 Reverse airflow – combination cooler 5-15 Rotating grab to the left (counterclockwise) 5-11, 5-14 Rotating grab to the right (clockwise) 5-11 Rotating the upper structure 5-48

O Oil filler pipe 6-9 Opening the front windshield 5-3 Operation of the machine in an explosive environment. 1-3 Other risks 1-3 Outside air mode 5-38 Overhead lines 1-8 Overload warning device 1-19 Overseas use 1-18 Overview of the complete machine 2-1 P Parking brake 5-21 Pedals 2-6, 5-9, 5-20 Permitted overall weight 1-20 Personal safety equipment 1-7 Personnel qualifications 1-16 Personnel selection 1-16 Pipe rupture safety - arm cylinder 2-7 Pipe rupture safety - hoisting cylinder 2-7

Q Qualification of personnel 1-9

S Safety boots 1-7 Safety cable 2-2 Safety devices 1-19 Safety distance 1-4, 1-8 Safety distance from overhead lines 1-8 Safety equipment 1-7 Safety helmet 1-7 Safety instructions 1-3 Safety lever 2-6, 5-9, 5-13, 5-15 Safety limit position sensor for "Arm in" 5-51 Safety regulations 1-18

825 M / 04.2007

Index

Sales and Service Partners 1-7 SDS 5-22 Securing the upper structure 7-3 SENNEBOGEN-DiagnosticSystem Self-check 5-22 Service panel - engine 2-4 Service Partners 1-7 Set-up work 9-1 Shutoff 2-3 Shutting down the engine 4-10 Slewing drive 3-2 Slewing mechanism brake 5-49 Slewing mechanism holding brake 5-13 Slewing ring 2-2 Slinging gear 7-5, 7-6 Spare parts catalogue 1-6 Spare parts depot 1-7 Spare parts manufacture 1-17 Specialist check 1-15 Specific dangers 1-17 Specifications 3-1 Stability 1-7 Start engine 4-7 Starting operation Safety instructions 4-1 Steering column 2-6, 5-9, 5-15 Steering wheel 2-6, 5-9, 5-15 Steering/control lever 5-9, 5-15 Storage compartment 2-3 Storage location 4-11 Support 2-1, 2-2 Support housing 2-2 Support leg 2-2 Support pad 2-2 Supporting the machine 5-45 Sustained sound-pressure level 1-17 Swinging the load 1-7

825 M / 04.2007

Symbols and illustration devices 1-3 T Target group 1-5, 1-2 Technical condition 1-17 Telephone 1-7 The machine environment 1-4 The operating instructions are structured as follows 1-6 Tie-down points 7-6 Tip-over danger! 1-19, 5-16 Tipping load 3-4 Topping up hydraulic oil 6-9 Towing a trailer 1-17 Transmission 2-3 Transport weight 3-3, 7-2 Transportation dimensions 7-2 Transportation work 7-1 Troubleshooting 8-1 Type plate 1-20

5-3 Windshield wiper 5-3 Working tools 2-1, 9-1 Workplace of machine operator 1-2 Y Year of manufacture 1-20

U Undercarriage 2-1, 2-2 Upper structure 2-1, 2-3 Use contrary to regulations 1-3 V V-belt 6-12 W Warm-up period 4-8 Warning lights 5-32 Warning lights (SDS) 5-32 Warning signs 1-20 Warning symbol 1-3 Warranty conditions 1-18 Warranty manual 1-18 Water separator 2-3 Weight of lifting gear 3-4 Weights 7-2 Wind forces 3-2 Wind speed 3-6 Wind strength 3-6 Windshield washer system

S-3