Sennebogen 835 + 840 Maintenance Instruction Manual 840.0.1003 - PDF DOWNLOAD

MAINTENANCE INSTRUCTIONS Type (Model) 835 + 840

835 + 840 / 09.2008

Translation of the original instructions

from 835.x.1101 / 840.x.1001

Important notes on the maintenance instructions

Foreword

You have made the decision for a brand quality product from SENNEBOGEN. We thank you for your decision.

Our utmost concern is that your SENNEBOGEN quality product performs your work reliably, continually and with no faults.

You know that the reliability and life-span of every machine is greatly influenced by the regular and professionally handled service and maintenance work.

We would therefore ask that you read the following service and maintenance information and apply it accordingly.

For your own safety

Functionality, reliability, availability and advanced technology, e.g. the implementation of modern materials and technology requires specially adapted maintenance and repair methods. Only use genuine SENNEBOGEN spare parts. Any respective work on your SENNEBOGEN machine is therefore only to be carried out by authorized SENNEBOGEN partners.

Improperly performed maintenance or service work may result in consequential damages and the connected safety risks.

Parts and accessories

Use only genuine replacement parts and accessory products that are authorized by SENNEBOGEN. These parts have been tested by SENNEBOGEN for their safety and functional suitability in SENNEBOGEN machines. SENNEBOGEN will not be held responsible for any parts or accessory products that have not be approved.

Warranty

The warranty can become void among other things, if: z replacement parts are not genuine SENNEBOGEN-approved

replacement parts z The maintenance is not performed at the specified maintenance

intervals z No maintenance has been performed z The service and maintenance work has not be performed by

a SENNEBOGEN partner.

In the event of damage, SENNEBOGEN retains the rights to demanding written verification for all maintenance work, performed completely and correctly!

In this respect, SENNEBOGEN recommends completing special service and maintenance contracts with the authorized SENNEBOGEN partner of your choice.

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Important notes on the maintenance instructions

Notes on the operating instructions

Read through the operating instructions thoroughly, in particular chapter 1 SAFETY, before starting work with the machine.

ATTENTION z Only work with/on the machine once you have read and completely understood these operating instructions. z Refrain from operating and 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. z The employer is responsible for the qualifications and training of the

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

operating instructions in the cab at all times.

Recommended storage place: Storage compartment behind the driver’s seat.

In the event of sale, disposal or loan, the operating instructions must accompany the machine! z Contact SENNEBOGEN immediately if you are unsure about

anything in the instruction manual!

Your comments will help us to make the instructions even more user-friendly. z Operating 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!

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Important notes on the maintenance instructions

Symbols and illustration devices

These operating instructions contain safety notes that highlight dangerous working practices. These safety notes are indicated 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 of persons will result.

WARNING Is used for potentially dangerous situations. If this danger is not averted, serious physical injuries or loss of life of persons 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.

Optional / special equipment Designates instructions and information, which depends on special applications or special equipment.

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Important notes on the maintenance instructions

Designates instructions or information that draws attention to special features of a machine with a mobile undercarriage.

Designates instructions or information that draws attention to a machine with crawler undercarriage.

Designates instructions or information that draws attention to a machine with platform (4-point sub-frame).

Designates instructions or information that draws attention to a machine with rail undercarriage.

Hand tighten.

50 Nm

Tightening torque for bolts or nuts. (in this case: 50 Nm)

Open-ended wrench with size specification. (in this case: 13 mm) 13 mm Flat screwdriver

Phillips screwdriver

32 mm

835 + 840 / 09.2008

Allen wrench. The size specification refers to the perpendicular distance between two parallel sides of a hexagon cross-section. (in this case: 32 mm)

Translation of the original instructions

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Important notes on the maintenance instructions

32 mm

Square box wrench. The size specification refers to the perpendicular distance between two parallel sides of a four-cornered cross-section. (in this case: 32 mm)

Connecting the meter or gauge.

Handling instructions are shown in table form as follows: 1

Press switch (1).

2

Actuate control lever (3).

3

Unfasten pins (3).

z Listings are marked with bullet points.

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

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Important notes on the maintenance 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 Specialists

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 Experts

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 persons

Authorized persons 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 indicated by the technical expert in the test report or certificate. Authorizations can be limited to parts of tests or specified crane types.

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Important notes on the maintenance 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.

Detailed information on the prior knowledge and qualifications required of the operator can be found in chapter 1 SAFETY of these instructions.

Which documentation belongs with the machine?

The following documentation belongs to the machine: z These instructions z Operating Instructions z Spare parts catalogue z Service checkbook z Additional documentation from pre-suppliers.

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

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Important notes on the maintenance 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 addresses of the SENNEBOGEN Sales and service partners can be found on our homepage on the Internet.

Current when going to press

Copyright

Ongoing development ensures the advanced technology and the high level of quality in our machines. This may result in deviations between these 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.

© Straubing 2008, SENNEBOGEN Maschinenfabrik GmbH Reproduction, even in part, requires the written permission of Sennebogen Maschinenfabrik GmbH, Straubing, Germany.

Printed in Germany.

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Contents

1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Other risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.3 Machine Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.3.1 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.3.2 Warning and notice labels . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.4 Responsibilities of the employer . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1.5 Supplementary and operational equipment . . . . . . . . . . . . . . . . . . 1-7 1.5.1 SENNEBOGEN-Diagnostic-System (SDS) . . . . . . . . . . . . 1-7 1.5.2 Oils and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 1.5.3 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 1.5.4 Fuel (not for equipment with electric motors) . . . . . . . . . . 1-14 1.6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 1.7 Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 1.8 Safe entry and exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 1.8.1 Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 1.9 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 1.10 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 1.11 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

2

Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1 Daily/weekly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.2 One-time maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2.2.1 After 50 hours of operation at the latest . . . . . . . . . . . . . . . 2-5 2.2.2 After 250 hours of operation at the latest . . . . . . . . . . . . . . 2-5 2.3 Regular maintenance / Maintenance interval . . . . . . . . . . . . . . . . . 2-7 2.3.1 Monthly or at the latest after 250 hours of operation . . . . . 2-8 2.3.2 Semi-annually or at the latest after 500 hours of operation . . .

2-10 2.3.3 Annually or at the latest after 1000 hours of operation . . 2-12 2.3.4 At the latest after 2000 hours of operation . . . . . . . . . . . . 2-15 2.3.5 At the latest, after 4,000 / 5,000 / 10,000 / 12,000 / 20,000 hours of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

3

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 Driving engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.2.1 Type 835 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.2.2 Type 840 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.3 Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

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3.4 3.5

3.6 3.7 3.8

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3.3.1 Mobile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.3.2 Crawler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3.3.3 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 3.3.4 Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Inspection tools - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Lubricate machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3.5.1 Machine - Mobile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3.5.2 Machine - Crawler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 3.5.3 Machine - Structur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 3.5.4 Machine - Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Tightening torques for bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Wind speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Conversion factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

4

Driving engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.3.1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.3.2 Air filter - moisture separator . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.4 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.4.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.4.2 Water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4.5 Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4.5.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4.5.2 Coolant Deutz engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4.5.3 Coolant - Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . 4-11 4.5.4 Change coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 4.6 Cleaning the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 4.6.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 4.6.2 Reverse fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 4.6.3 External cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 4.6.4 Internal cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 4.7 Check belt drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 4.8 Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

5

Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1 Mobile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1.1 Cleaning and lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1.2 Tire air pressure (pneumatic tires) . . . . . . . . . . . . . . . . . . . 5-1

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Contents

5.1.3 Tightening wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.1.4 Hub drive train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.1.5 Axle distributor gear (Type 835) . . . . . . . . . . . . . . . . . . . . . 5-5 5.1.6 Differential (Type 835) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 5.1.7 Drive shafts/universal joints (Type 835) . . . . . . . . . . . . . . . 5-9 5.1.8 Back gear and differential (Typ 840) . . . . . . . . . . . . . . . . 5-11 5.1.9 Parking disc brake (Type 840) . . . . . . . . . . . . . . . . . . . . . 5-13 5.2 Crawler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5.2.1 Cleaning and lubricating . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5.2.2 Drive transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5.2.3 Crawler chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 5.2.4 Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 5.2.5 Base plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 5.2.6 Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 5.3 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 5.4 Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 6

Swiveling connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2 Lubricating slewing ring path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2.1 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.3 Lubricating slewing ring teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.3.1 Gear teeth spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.3.2 Slewing ring lubrication (optional) . . . . . . . . . . . . . . . . . . . 6-4 6.4 Tighten slewing ring bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6.5 Wear measurement and checking the drive system/bearing play . 6-9

7

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.2.1 Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.2.2 Bolted joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.3 Hydraulic hose lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 7.4 De-pressurizing the hydraulic system . . . . . . . . . . . . . . . . . . . . . . 7-4 7.4.1 Check the hydraulic oil level, Top up hydraulic oil . . . . . . . 7-5 7.5 Changing hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 7.6 Return filter – changing filter elements . . . . . . . . . . . . . . . . . . . . 7-10 7.7 Auxiliary control filter - change filter element . . . . . . . . . . . . . . . . 7-11 7.8 HydroClean – superfine filtration system (Optional) - change filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

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Contents

7.9 Leak-oil filter – changing filter element . . . . . . . . . . . . . . . . . . . . . 7-13 7.10 Changing ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 7.11 Changing the ventilation filter with dehumidifying unit (Optional) . 7-15 7.12 Checking preload pressure of pressure accumulator . . . . . . . . . . 7-16 7.13 Pump distributor gearbox (Optional) . . . . . . . . . . . . . . . . . . . . . . 7-17

0-4

8

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 8.3 Switch-/symbol change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 8.4 Generator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 8.4.1 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 8.5 Additional displays (special equipment) . . . . . . . . . . . . . . . . . . . . . 8-5

9

Heating/Air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.1 Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.1.1 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.1.2 Cleaning the heating recirculating air filter . . . . . . . . . . . . . 9-3 9.1.3 Cleaning the heating outside air filter . . . . . . . . . . . . . . . . . 9-4 9.2 Water heating (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 9.3 Air conditioning compressor (optional) . . . . . . . . . . . . . . . . . . . . . . 9-6 9.4 Auxiliary heating (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

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Safety - General

1

Safety

1.1

General

Before starting with maintenance, the machine is to be prepared as per the following descriptions.

Failure to observe these instructions can result in accidents, serious injuries or death.

Perform the maintenance work described in these instructions completely and at the specified time intervals.

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. Initial operation, maintenance, transportation and assembly/dismantling only by trained specialists.

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 Place the machine on a firm base (level, solid, flat), if necessary set back from the edge of the excavation. z Lower suspended loads and booms to the ground. z Apply the brake. z Pull the safety lever to the rear (all hydraulic functions are inactive). z Switch off the machine and secure against unauthorized switching

on again before beginning any work. z Place warning sign on operating elements. z Use a chock to stop the machine from rolling away.

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

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

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1-1

Safety - Other risks

1.2

Other risks

The safety notes in these instructions are guidelines for the safe maintenance on the machine by qualified machine operators. However, SENNEBOGEN cannot anticipate every situation, which may result in danger in practice.

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.

Signs indicating a warning or other information that are attached on the machine also refer to residual hazards.

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Safety - Machine Labeling

1.3

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 labels with soap and water if necessary, not with fuel

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

Note Signs are available from SENNEBOGEN (see Spare Parts Catalogue).

1.3.1 Identification plate

1 Machine type 2 Machine number (Manufacturer’s No.)

1.3.2 Warning and notice labels Note More information can be found in the operating instructions from chapter 1 and chapter 4.

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1-3

Safety - Responsibilities of the employer

1.4

Responsibilities of the employer

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 operating the machine after

significant modifications z at least once yearly z intermediate depending to operating and company conditions.

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

regulations and guidelines thanks to specialist training and z through special instructions of SENNEBOGEN

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: – Fuel driven mobile crane – Location changing fuel driven derrick crane – Lorry attachment cranes The specialist inspection is to be performed in the 13th year of operation and annually thereafter.

Faults that are detected in recurring inspections must be eliminated within a suitable time-frame depending on how serious a threat they pose to safety.

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Safety - Responsibilities of the employer

Personnel selection and -qualifications

The machine must only be operated and maintained by qualified personnel. z Employ only trained and instructed personnel. z Define responsibility for operation and maintenance. z Comply with the permitted statutory minimum age.

CAUTION z Personnel under training or instruction must remain under constant

supervision while working on the machine. z Work on electrical equipment of the machine may only be carried

out by an electrical specialist. 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 special knowledge and experience on hydraulics!

Excerpt from VBG 40

The independent operation or maintenance of earth moving machinery must only be carried out by personnel that z are 18 years or over, z are physically and mentally suitable, z are trained in the operation and maintenance of earth-moving

equipment and have proven their ability to do so to the employer and who z can be expected to carry out the appointed work reliably.

Noise protection

Permanent sound levels (LpA) of the machine - measured at the driver's seat with the cab closed - see value on sticker on the inside of the cab. The wearing of ear protection is not essential. Measurements are based on EN ISO 11201.

This value of 85 dB(A) can however be exceeded due to environmental influences, e.g. through dropping or transporting material or on a building site together with other machines.

In these cases, noise protection measures for operating personnel are mandatory.

The operator is to ensure that appropriate ear protection is available and used by the operating personnel.

If necessary, hearing protection is also to be worn outside the cab in special cases.

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1-5

Safety - Responsibilities of the employer

Technical condition of the machine

The operator has an ongoing responsibility to monitor the overall technical condition (obvious external faults and damage as well as changes to operational behavior) of the machine.

The machine must not be operated if faults are found!

Observe mandatory time limits for routine checks.

All damages and incidents are subject to the mandatory logging and storage regulations.

Independent conversion and manufacture of spare parts

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 not therefore 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.

Specific dangers

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.

Dangers of noncompliance with the safety instructions

Non-compliance with the safety notes is dangerous and can be hazardous to persons as well as to the environment and the machine and leads to the loss of any claims for compensation.

Fire extinguisher and first aid box

1-6

The machine is provided with spaces for fire extinguisher and first aid box. The operator is obliged to equip the machine with these items. If necessary, obtain fire extinguisher and first aid box from SENNEBOGEN.

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Safety - Supplementary and operational equipment

1.5

Supplementary and operational equipment

1.5.1 SENNEBOGEN-Diagnostic-System (SDS) Note Sensors monitor the current operating state of the machine and transmit the information to the SDS. The measured data are evaluated in the SDS and displayed automatically or at the push of a button on the unit. If irregularities occur on the machine, the indicator and warning lights are activated.

The SDS carries out a self-test after the ignition is switched on. If the SDS detects a fault condition, it is displayed on the screen and by means of LEDs. Correct a minor fault condition (clogged air filter, empty fuel tank or the like) by yourself without delay.

Contact SENNEBOGEN Customer Service to correct a more serious irregularity (one that you cannot correct yourself).

SENNEBOGEN Diagnostics system

Note Further information on the SDS is contained in the operating instructions.

CAUTION The SENNEBOGEN Diagnostics System must never be cleaned with cleaning agents containing alcohol or solvents. Failure to observe the above could result in damage to the plastic surface.

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1-7

Safety - Supplementary and operational equipment

1.5.2 Oils and lubricants Note Only use oils and lubricants approved by SENNEBOGEN. These are listed in LUBRICANTS TABLE. The ambient temperature for operating the machine must be between -20 °C (- 4 °F) and + 40 °C (+ 104 °F). If the temperature at the site is outside these values, discuss this with SENNEBOGEN customer services before starting operation.

WARNING The mixing of oils, lubricants or operating fluids of different types is not permitted!

Filling or mixing oils, lubricants or operating fluids (e.g. hydraulic oil, gear oil, engine oil, coolant, etc.) of different types can lead to damage to the machine components resulting from chemical reactions. This damage can in turn result in severe damage to property and to personal injuries.

Use oils, lubricants and operational fluids that are approved by SENNEBOGEN only.

Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

Oil diagnosis

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

Recommended for hydraulic system.

Note More helpful information is available from SENNEBOGEN customer services.

Biodegradable oils and lubricants

The use of such substances is expressly required where the leakage of mineral-based oils and lubricants presents a danger to the environment.

The use of environmental-friendly lubricants is mandatory, particularly in water or nature conservation areas.

Only synthetic, ester-based bio-oils may be used.

WARNING Switching to bio-oils and bio-lubricants is only permitted subject to agreement and written confirmation of SENNEBOGEN Customer Service.

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Safety - Supplementary and operational equipment

1.5.3 Coolant General information WARNING Mixing coolants and adding cooling system sealing agents or antifreeze that contains sealing agents is not permitted.

By filling or mixing different types of coolant or cooling agent additives, the mixture can gel or build up to plug the cooler, resulting in the engine overheating or the cooling system failing and therefore causing damage to the engine.

WARNING Mixing of nitrite-based cooling agents with amine-based agents produces health-hazardous nitrosamines.

Note Observe the coolant label in the cooler area.

If the ambient temperature at the work-site is under this value (-37 °C (-34 °F)), observe the operating instructions of the motor manufacturer or contact SENNEBOGEN - customer service before starting operation.

Note If only a small amount (up to max. 5 l/1.3 gal.) is required to will the water-coolant circuit and no suitable coolant is available, you can top up with clean water in the mean time.

We recommend that you test the concentration at the next possible time before freezing temperatures however. In some cases, you must refill with the respective coolant so that the required mixture is achieved again to prevent freezing.

The coolant is not only required to guarantee the protection against freezing, it also performs the very important task of protecting against corrosion. This also requires checking for the correct concentration and adding when necessary.

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1-9

Safety - Supplementary and operational equipment

Coolant for DEUTZDrive motors

The DEUTZ - Drive motors can be recognized by the ratings plate.

Note The DEUTZ - drive motors are filled with coolant z Hunold coolant ANF based on Monoethylenglycol

in the factory. Use this coolant only for the DEUTZ drive motors!

SENNEBOGEN will accept no responsibility and will provide no warranty or make any guarantees for the use of any other coolants.

The antifreeze is sufficient to - 37 °C (- 34 °F).

Note Observe the coolant label in the cooler area.

CAUTION Observe the notes in the operating instructions of the engine manufacturer. These are for the operational safety of the machine.

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Safety - Supplementary and operational equipment

Coolant for CUMMINSDrive motors

The CUMMINS drive motors can be recognized by the ratings plate.

Note The CUMMINS drive motors are filled with coolant z ES CompleatTM in the factory. Use this coolant only for the CUMMINS drive motors!

SENNEBOGEN will accept no responsibility and will provide no warranty or make any guarantees for the use of any other coolants.

The antifreeze is sufficient to - 36 °C (- 33 °F).

Note Observe the coolant label in the cooler area.

CAUTION Observe the notes in the operating instructions of the engine manufacturer. These are for the operational safety of the machine.

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Safety - Supplementary and operational equipment

Water Note z Use

clean, neutral, filtered, fairly soft fresh tap water.

SENNEBOGEN recommends distilled water as the best variant.

z Please note that Caterpillar specifies using distilled water! z Do not use ditch water, industrial drain water, salt water, sea water

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

Mix before filling!

Ensure that the water has the following characteristics: pH value

7-8

Chloride content

max. 40 ppm

Sulphate content

max. 100 ppm

Water hardness

3-12 °dGH

Ca + Mg

max. 70 ppm

Note Observe the recommended mixing ratio (see manufacturer's specifications). If the coolant concentration is too high, the cooling and antifreeze behavior will deteriorate.

CAUTION Observe the specifications of the coolant manufacturer.

WARNING Never fill with coolant when the motor is overheated. This will cause damage to the motor. Allow the motor to cool first.

WARNING Regarding possible danger to health or environmental dangers, observe the instructions for using the coolant manufacturer as well.

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Safety - Supplementary and operational equipment

Using other Coolant

If you should ever use a coolant other than that specified, the following must be considered or expressly observed.

SENNEBOGEN will accept no responsibility and will provide no warranty or make any guarantees for the use of any coolants other than those previously indicated.

Change coolant WARNING Scalding hazard!

Be careful when draining hot coolant!

Allow the motor to cool first. Catch the coolant in a suitable container when draining and dispose of according to the respective regulations.

– The cooling system is to be emptied completely before filling again.

– Rinse the cooling system several times with clear water to rid it of any residue.

– Fill the cooling system and check the level after a short waiting period.

– Start the motor and check the coolant levels CAUTION Adjusting to the correct coolant level must sometimes be checked more than once.

Check the following states when inspecting the coolant levels regularly, e.g.

– lubricant incursion, – obvious opacity caused by corrosion residue or other particulate matter, in which case, the coolant must be replaced as indicated above.

Coolant change intervals

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

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Safety - Supplementary and operational equipment

1.5.4 Fuel (not for equipment with electric motors) Fill the tank with the specified grade of fuel. Clean fuel is essential for trouble-free operation of the diesel engine.

Notes on quality and fuel selection Observe the notes and recommendations in the operating instructions of the engine manufacturer.

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Safety - Maintenance

1.6

Maintenance

WARNING z Observe all signs and safety stickers on the machine as well as those

in the instructions. They contain important information about maintenance procedures. z The work performed may only be completed by trained

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

ear protection, protective gloves, safety boots) where working conditions require. At working heights of 2.00 m or more, SENNEBOGEN recommends the use of safety equipment to prevent falling. At working heights above 3.00 m, using a safety harness is required legally.

Suspension eyelets are marked. z Only use genuine SENNEBOGEN spare parts. z Use only oils and lubricants listed in the lubricant table. z Collect lubricants and other consumables in suitable containers

and dispose of them properly. z Observe statutory accident prevention and safety regulations. z Observe any additional documentation (e.g. engine, etc.) during

maintenance work as well. z Keep the vehicle (e.g. handles, steps, platforms, hand rails etc.)

free from dirt, snow and ice. z Smoking and handling of open flame is strictly forbidden. z Use appropriate safe climbing aids or work platforms. z Stay clear of rotating and moving parts. z Relieve the pressure from the hydraulic system and other operating

materials before starting maintenance work. z Dispose of hydraulic oil in accordance with regulations. z Wear protective gloves when working on steel wire rope. z Do not lift heavy components by hand. Use lifting gear. z For pneumatic tires:

When pumping up tires, maintain adequate safety distance and use tire cage. z Keep the cab clean and orderly. z Actuate the battery quick-disconnect switch or disconnect battery

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

material; do not lay tools on the batteries.

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Safety - Maintenance

z When handling batteries, observe the safety and protective

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

refrigerants and refrigerant vapors are hazardous to health. Wear the respective protective equipment. z Replace all safety devices on completion of work. Exchange

damaged safety devices for new ones. z Carry out function check to ensure problem-free operation. z Only the machine owner or representative may approve the

machine for operation following maintenance work. z If an accident occurs in spite of all safety and precautionary

measures, e.g.

– scalding by hot oil or coolant – contact with strong acid – entry of fuel or hydraulic into the skin – coolant- or hydraulic oil spraying into the eyes etc., apply first aid immediately and contact a doctor. z After maintenance or repair work, carry out a thorough visual

inspection and function check in accordance with the operating instructions in order to ensure proper and safe operation. z Further disassembly or service work that is not in the instructions

may be performed only under the personal responsibility of the operator. Use necessary special tools. z Before resuming operation again, the correct and complete

maintenance work is to be inspected by an authorized expert.

Note Parts that are tightly nested together are never to be loosened with hard objects.

Parts that are loose are never to be tightened with hard objects.

Ball bearings, drive flanges and such that have to be dismantled/installed require the use of suitable tightening equipment or special tools.

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Safety - Maintenance

Qualifications of the personnel

DANGER z Work on electrical equipment of the machine may only be carried out by an electrical specialist. 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 special knowledge and experience on hydraulics! z No welding is to be performed on the device without previous

discussion with the manufacturer.

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Safety - Cleaning work

1.7

Cleaning work

CAUTION z Clean machine daily. z For heavy contamination, clean the machine several times per day

if necessary, especially in recycling applications. z Ensure that the cleaning agents used do not damage the seals and

components of the machine. z Do not use aggressive cleaning agents. z Only use lint-free cleaning cloths. z Only use dry, filtered compressed air up to max. 2 bar (29 psi). z Lubricate the lubrication points after every cleaning. z Replace protective caps on the grease nipples. z After cleaning the engine compartment, check all lines for leaks,

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

After a wet cleaning, check that there is no moisture in the electrical control cabinet. z On completion of cleaning work on the machine, carry out a visual and

functional check acc. to the operating instructions for the machine.

WARNING Electrical and electronic components such as the alternator, control cabinet etc. as well as the bearings of the elevating cab (may cause damage to the bearing surfaces and result in sudden, uncontrolled motion when positioning the cab), must never be subjected to a direct stream of water!

Wet cleaning of these components is prohibited!

When wet cleaning the machine, always make sure that no water/ moisture comes into contact with electrical or electronic components.

The ingress of water can otherwise damage or destroy the electrical system of the machine. This can result in sudden, uncontrolled motion when working.

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Safety - Safe entry and exit

1.8

Safe entry and exit

z If necessary, clean steps and ladders prior to use. z Enter or exit machine only when stationary.and after the cab has

been lowered completely - never - during any motion. z Do not carry any items when climbing up or down. z When entering or exiting, always ensure that you have three points

of contact on the steps, ladders and grips. (e.g. two hands and one foot or two feet and one hand) z lift items of equipment onto machine using cable or lifting gear. z Do not use operating elements as handholds in driver’s cab. z Use only the appropriate, provided steps and/or ladders. z When the cab is raised, access to the gallery is not permitted. z At working heights of 2.00 m or more, SENNEBOGEN recommends

the use of safety equipment to prevent falling. At working heights above 3.00 m, using a safety harness is required legally.

Suspension eyelets are marked.

Cab without platform

1 2 3

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1

Open the sliding door (1) from the ground.

2

Hold onto the holding grips (2) and use your feed to step on the steps (3) and climb into the cab.

3

Close the sliding door.

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Safety - Safe entry and exit

Cab with platform

1 2 3 4

1

Open the door (1) from the ground.

2

Hold onto the holding grips (2) and use your feed to step on the steps (3).

3

Enter the cab from the rear to the front via the operator catwalk and then close the door.

CAUTION Risk of falling!

When stabilized, if the brakes are not applied, the wheels will turn!

Only in extreme emergencies and with great care is the cab to be entered or exited via the wheel hub and the tire.

Note In some cases, it may be necessary to turn the superstructure to 90° offset to the undercarriage to allow safe entry/exit.

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Safety - Safe entry and exit

Gallery/Operator catwalk

1

DANGER Risk of falling!

Installation of the gallery/platform (1) is mandatory, since it is part of the safety concept.

CAUTION Risk of falling!

Gallery - access forbidden when the cab is raised!

A maximum of 200 kg (440 lbs) is permitted per segment of grid iron on the gallery. Overloading will lead to damaging the construction, the results of which can lead to personal injury.

Check the gallery for damage every 3 months (especially cracks) and repair if necessary.

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Safety - Safe entry and exit

Superstructure

2

3

2 Hand grips 3 Access steps

DANGER Wear personal protection equipment (e.g. safety helmet, ear protection, protective gloves, safety boots) where working conditions require.

At working heights of 2.00 m or more, SENNEBOGEN recommends the use of safety equipment to prevent falling. At working heights above 3.00 m, using a safety harness is required legally.

Suspension eyelets are marked.

1.8.1 Emergency exit CAUTION Risk of falling!

When stabilized, if the brakes are not applied, the wheels will turn!

Only in extreme emergencies and with great care is the cab to be entered or exited via the wheel hub and the tire!

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Safety - Welding work

1.9

Welding work

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

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

Preliminary work

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

1

If necessary use the optional battery isolator switch to disconnect from the power supply.

2

Disconnect battery.

3

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

4

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

5

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

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Safety - Safety devices

1.10 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.

Safety devices include e.g. engine flaps, doors, protective screen, clothing, fire extinguisher and first aid box. 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

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Safety - Disposal

1.11 Disposal Lubricants and Consumables CAUTION Observe environmental guidelines!

Handle and dispose of used items and materials correctly, especially z when working on the cooling systems z when working on lubrication systems and devices z when working with solvents and z when working on the cooling systems.

Extract from the Disposal of Waste Oils Directive 75/439/EEC: z “It is prohibited to mix spent oil with other waste”. z “Spent 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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Safety - Disposal

1 - 26

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Maintenance schedule

2

Maintenance schedule

Note Shorter intervals may be necessary when operating in extreme conditions, e.g. high ambient temperatures.

Note The standard engine oil change interval is every 500 hours of operation or every 3 months. In extreme operational conditions, e.g. in high ambient temperatures, the engine oil change interval can be shorted to 250 hours of operation or once per month.

Please observe the operating instructions from the engine manufacturer!

Note Observe the maintenance intervals and the maintenance plans from the additional documentation (e.g. attachment devices).

Note Methods of display: – F = Check fill level (Fill levels, see Chapter 3) – W = Oil or filter change

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2-1

Maintenance schedule Daily/weekly maintenance

2.1

Daily/weekly maintenance

Note The following pages contain the checklist to be worked through.

Chapter

5

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

-

S3

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 highpressure cleaner BE CAREFUL around sensitive or electrical components!

-

S4

Are the windows clean and free of ice and snow?

If necessary, clean

-

S5

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

If necessary, repair or replace

5

S6

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

If necessary, retighten to the specified torque

3.6

S7

Is the tire pressure correct? For pneumatic tires.

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

3.3.1

S8

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

If necessary, tighten connections or replace seals

7

S9

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

7.2.1

S10

Is the shutoff on the hydraulic tank open?

If necessary, open

-

S11

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!

-

S12

Are TopAir and air filter cartridges damaged or contaminated?

If necessary, clean or replace

-

S13

Is the fan wheel intact?

If necessary, replace

-

S14

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

If necessary, clean by reversing the fan or replace

-

No.

Visual checks

S1

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

S2

2-2

Steps to take

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Maintenance schedule Daily/weekly maintenance

Visual checks

No.

Steps to take

Chapter

5

S15

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.

-

S16

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

If necessary, retighten or replace

7.2.2

S17

Has the water separator on the fuel system been drained?

If necessary, drain

4.4.2

S18

Are the V-belts undamaged and tensioned?

If necessary, retension or replace

4.7

S19

Are the electrical lines damaged?

If necessary, repair or replace

8

S20

Are the cable connections (poles) of the battery corroded?

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

-

S21

Are the batteries held in place securely?

If necessary, secure again

8.1

S22

Are all service access doors closed?

If necessary, close

-

S23

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

If necessary, retighten or replace

7.2.2

rS2 4

Are all bolted joints e.g. on the pylon and the gallery undamaged and tight (high-strength bolts, with/without spacers)?

If necessary, retighten or replace

rS2 5

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

If necessary, disconnect

S26

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

If necessary, replace or secure again with specified torque

S27

Are the boom components intact (corrosion, cracks)?

If necessary, repair or replace

-

S28

Are any bolts cracked or damaged?

If necessary, replace

-

S29

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

If necessary, replace

-

S30

Is there enough grease in the central lubrication system?

If necessary, refill

6.2.1

S31

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

If necessary, replace, clean and lubricate

3.5

S32

Are the hydraulic lines and hoses secured in place?

If necessary, tighten fasteners

7

S33

Is the slewing mechanism undamaged and lubricated sufficiently?

Repair or actuate pinion lubrication if necessary

6

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2-3

Maintenance schedule Daily/weekly maintenance

Chapter

5

If necessary, re-install and refill grease

6.3

Inspect the positive stops for the steering for wear.

If necessary, replace

-

S36

Inspect the power cable track for wear.

If necessary, replace

-

S37

Is the pump distributor gearbox sealed?

Repair if necessary

-

No.

Visual checks

S34

Is the slewing ring filling cover (internal teeth) in place and is there enough grease?

S35

2-4

Steps to take

Translation of the original instructions

835 + 840 / 09.2008

Maintenance schedule One-time maintenance

2.2

One-time maintenance

2.2.1 After 50 hours of operation at the latest Note The following maintenance work is to be performed one time only after 50 hours of operation at the latest.

5

Subassemblies/activities

Undercarriage

Chapter

Traction drive

Check the wheel nuts for tightness.

5.1.3

2.2.2 After 250 hours of operation at the latest Note The following maintenance work is to be performed one time only after 250 hours of operation at the latest.

5 Undercarriage

Subassemblies/activities

Chapter

Traction drive W

Oil change

5.1.4 5.2.2

Play in the slewing ring

Superstructure

Wear measurement and checking the drive system/ bearing play The measurement is to be regarded as the base position for delivery status!

6.5

Hydraulics W

Return filter – Changing the filter element

7.6

W

Leak-oil filter – change filter element

7.9

W

Auxiliary control filter - change filter element

7.7

W

Hydro Clean - changing filter element (optional)

7.8

Hydraulics

835 + 840 / 09.2008

Have preload pressure of hydraulic accumulator checked by hydraulic specialist company

Translation of the original instructions

7.12

2-5

Maintenance schedule One-time maintenance

5

Subassemblies/activities

Chapter

Pump distributor gearbox W

2-6

Oil change

Translation of the original instructions

7.13

835 + 840 / 09.2008

Maintenance schedule Regular maintenance / Maintenance interval

2.3

Regular maintenance / Maintenance interval

Note Observe the intervals of the following table. The consecutive intervals and the numbered sequence of steps must be maintained!

Hours of operation (hrs) Section

250

500

750

1000

1250

1500

1750

2000

...

2.3.1

U

U

U

U

U

U

U

U

...

U

...

U

...

U

...

2.3.2

U

U U

2.3.3 2.3.4

U

Examples of the table: – If the machine reaches 250 hours of operation for example, the maintenance plan from Section 2.3.1 must be observed.

– If the machine reaches 500 hours of operation, Sections 2.3.1 and 2.3.2 must be observed.

– Etc...

Note If the machine exceeds 2,000 hours of operation, the table begins from the start.

Note Pay close attention to the intervals after 4,000 / 5,000 / 10,000 / 12,000 / 20,000 hours of operation at the latest in Section 2.3.5

835 + 840 / 09.2008

Translation of the original instructions

2-7

Maintenance schedule Regular maintenance / Maintenance interval

2.3.1 Monthly or at the latest after 250 hours of operation Note Observe the maintenance intervals and the maintenance plan from the respective additional documentation. (e.g. Grabber, Engine)

5 Undercarriage

Subassemblies/activities

Chapter

Steering axle: Hub F

Checking oil level

5.1.4

Differential (Type 835) F

Checking oil level

5.1.6

Differential (Type 840) F

Checking oil level

5.1.8

Steering

Check the steering stops

Check the steering cylinder for leaks and functionality Axle distributor gear (Type 835)

F

Checking oil level

5.1.5

Back gear (Type 840) F

Checking oil level

5.1.8

Power train (Type 835)

Lubricate via the grease nipple (3 each)

5.1.7

Live axle: Hub F

Checking oil level

5.1.4

Differential (Type 835) F

Checking oil level

5.1.6

Differential (Type 840) F

2-8

Checking oil level

Translation of the original instructions

5.1.8

835 + 840 / 09.2008

Maintenance schedule Regular maintenance / Maintenance interval

5

Subassemblies/activities

Chapter

Back gear (Type 840) F

Checking oil level

5.1.8

Parking disc brake (Type 840) F

Checking oil level

5.1.9

Steel structure

Use suitable equipment to check for structural damage (e.g. deformation, damage, corrosion, cracks) Slewing ring

Superstructure

Visually check all connecting elements for damage and corrosion

6

Cab air conditioning and auxiliary heating system

Visual inspection of the entire system for contamination, secure fastening, seal, hose connections and cable connections

Switch on at least 1 time per month Pump distributor gearbox

F

9.1 9.4

7.13

Checking oil level Engine

W F

Engine maintenance intervals (see engine manufacturer's instructions)

F

Check coolant level, check anti-freeze/concentration

4.5

W

After draining five times, the filter cartridge for the water separator must be changed

4.4.2

Engine: Air conditioning compressor

835 + 840 / 09.2008

Check the air conditioning compressor mounts and bolts for tightness

9.3

Check belt tension and status

9.3

Translation of the original instructions

2-9

Maintenance schedule Regular maintenance / Maintenance interval

2.3.2 Semi-annually or at the latest after 500 hours of operation Note Observe the maintenance intervals and the maintenance plan from the respective additional documentation. (e.g. Grabber, Engine)

5 Undercarriage

Subassemblies/activities

Chapter

Steering

Check secure fastening of aggregates and steering parts, tighten to required torque when necessary

3.6

Slewing ring lubrication

Check the plastic sliding wear pad in the lubrication apparatus for wear

6.2 6.3

Slewing ring: Teeth/slewing track

Check the slewing ring bolts for firm seating with suitable tools and tighten to the required torque if necessary.

6.4

Check the seal between the slewing track and the teeth for damages

6.1

Superstructure

Gallery

Use suitable equipment to check for structural damage (e.g. deformation, damage, corrosion, cracks) Trim/Paneling

Check the hinges, quick latches and gas pressure springs for functionality Cab: Air conditioning and auxiliary heating

Have an authorized workshop perform checks on the air conditioning

9.1

Equipment

Load holding test with 1 t Hydraulics

2 - 10

Ventilation filter - Perform visual check of hydraulic tank for dirt and damage, change if necessary

Translation of the original instructions

7.10

835 + 840 / 09.2008

Maintenance schedule Regular maintenance / Maintenance interval

5

Subassemblies/activities

Chapter

Hydraulics

Have preload pressure of hydraulic accumulator checked by hydraulic specialist company

7.12

Engine

835 + 840 / 09.2008

W F

Engine maintenance intervals (see engine manufacturer's instructions)

4.4.2

W

Water separator - Change filter insert

4.5

Charge air cooler – Drain condensation

Translation of the original instructions

2 - 11

Maintenance schedule Regular maintenance / Maintenance interval

2.3.3 Annually or at the latest after 1000 hours of operation Note Observe the maintenance intervals and the maintenance plan from the respective additional documentation. (e.g. Grabber, Engine)

5

Subassemblies/activities

Chapter

Axle distributor gear

Undercarriage

Check secure fastening of gearbox and universal shafts, tighten to required torque when necessary

W

Oil change

3.6

5.1.5 Steering axle: Hub W

Oil change

5.1.4

Brake

Brake wear measurement

5.1.4

Differential (Type 835)

Check secure fastening of universal shafts, tighten to required torque when necessary

3.6

W

Oil change

5.1.6

Differential (Type 840) W

Oil change

5.1.8

Back gear (Type 840) W

Oil change

5.1.8

Live axle: Hub W

Oil change

5.1.4

Brake

2 - 12

Brake wear measurement

Translation of the original instructions

5.1.4

835 + 840 / 09.2008

Maintenance schedule Regular maintenance / Maintenance interval

5

Subassemblies/activities

Chapter

Floating axle cylinder

Check secure fastening, tighten to required torque when necessary

3.6

Differential (Type 835)

Check secure fastening of universal shafts, tighten to required torque when necessary

3.6

W

Oil change

5.1.6

Differential (Type 840) W

Oil change

5.1.8

Back gear (Type 840) W

Oil change

5.1.8

Parking disc brake (Type 840) W

Oil change

5.1.9

Steel structure

Use suitable equipment to check for structural damage (e.g. deformation, damage, corrosion, cracks) Traction drive

W

Oil change

5.1.4 5.2.2

Slewing ring: Teeth/slewing track

Check for interference/teeth of the slewing ring pinion

6.3

Play in the slewing ring

Wear measurement and checking the drive system/ bearing play

6.5

Slewing gear

Superstructure

3.6

Steel structure

835 + 840 / 09.2008

Check secure fastening, tighten to required torque when necessary

Use suitable equipment to check for structural damage (e.g. deformation, damage, corrosion, cracks)

Translation of the original instructions

2 - 13

Maintenance schedule Regular maintenance / Maintenance interval

5

Subassemblies/activities

Chapter

Ballast

Check secure fastening, tighten to required torque when necessary

3.6

Fuel - / hydraulic - tank

Check secure fastening, tighten to required torque when necessary

3.6

Equipment

Use suitable equipment to check for structural damage (e.g. deformation, damage, corrosion, cracks)

Check bolted joints for cracking or damage

Check for correct lifting limit settings for jib and boom

Check pipe rupture safeties Hydraulics

Ventilation filter - change hydraulic tank

7.10

Pump distributor gearbox W

Oil change

7.13

Engine

2 - 14

W F

Engine maintenance intervals (see engine manufacturer's instructions)

W

Safety cartridge - Change air filter

4.3

W

Replacement cartridge - Change air filter

4.3

Translation of the original instructions

835 + 840 / 09.2008

Maintenance schedule Regular maintenance / Maintenance interval

2.3.4 At the latest after 2000 hours of operation Note Observe the maintenance intervals and the maintenance plan from the respective additional documentation. (e.g. Grabber, Engine)

5

Subassemblies/activities

Superstructure

Chapter

Hydraulics W

Return filter – Changing the filter element

7.6

W

Leak-oil filter – change filter element

7.9

*

Auxiliary control filter - change filter element

7.7

W

HydroClean - Change filter element (optional)

7.8

**

Changing the hydraulic oil

7.5

**

Check hydraulic hoses for damages

7.3

Engine W F

Engine maintenance intervals (see engine manufacturer's instructions)

W

Change coolant

4.5.4

Slip ring body

Insulators, slip rings, carbon brushes, check feed line, clean and replace if necessary.

*:

There is no auxiliary control filter if there is a HydroClean!

**: Only required every 4,000 hours of operation, if: – the machine is equipped with a SENNEBOGEN HydroClean system and – every 2,000 hours of operation, an oil diagnosis is performed by a SENNEBOGEN authorized laboratory and has been found to be successful

835 + 840 / 09.2008

Translation of the original instructions

2 - 15

Maintenance schedule Regular maintenance / Maintenance interval

2.3.5 At the latest, after 4,000 / 5,000 / 10,000 / 12,000 / 20,000 hours of operation Note Observe the maintenance intervals and the maintenance plan from the respective additional documentation. (e.g. Grabber, Engine)

At the latest, after ...

5 4,000 hours of operation

5,000 hours of operation or 5 years 10,000 hours of operation or 3 years

Subassemblies/activities

Chapter

Hydraulics W

Changing the hydraulic oil

7.5

Check hydraulic hoses for damages

7.3

Slewing ring connection

Have the slewing ring bolts checked by a specialist company. Change if necessary Engine: Air conditioning compressor

W

Oil change

9.3

Cab W 12,000 hours of operation or 6 years 20,000 hours of operation or 10 years

Replace retaining belt Hydraulics

W

Change hydraulic hoses

Slip ring body

7.3

Renew mounting position Hydraulics

2 - 16

Preload pressure - Have the preload pressure of the hydraulic accumulator checked by a hydraulic specialist company and have the pressure testing done with the internal test by professionals

Translation of the original instructions

7.12

835 + 840 / 09.2008

Technical data - General information

3

Technical data

3.1

General information

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

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).

Ambient temperature range

Operation / Operation under load

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

Note When running a machine in environmental temperatures outside the specified temperature range, special temperature packages are available (optional!).

Please contact SENNEBOGEN customer service if you have any other questions.

Hydraulics

Slewing drive

835 + 840 / 09.2008

Operating pressure, 350 bar (5075 psi) maximum

Slewing speed

0 - 8 rpm, continuously variable

Translation of the original instructions

3-1

Technical data - Driving engine

Limitations during wind

Wind speed 25 m/s

90 km/h

10 Beaufort

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.

DANGER Once the specified wind speed is reached, stop operating the machine immediately (lower load, lower jib). Table on wind speeds, see Section 3.7

3.2

Driving engine

Permitted engine inclination: left

right

front

rear

30°

30°

30°

30°

Note If the incline is excessive, the engine oil level can no longer be guaranteed. If you require a greater angle, please contact SENNEBOGEN customer service in advance.

Observe the notes in the operating instructions of the engine manufacturer.

3-2

Translation of the original instructions

835 + 840 / 09.2008

Technical data - Driving engine

3.2.1 Type 835 TDC 2013 L06 2V Power (according to ISO14396)

186 kW / 249 PS at nominal speed 2.000 rpm

Capacity

7142 cm3

Cylinders

6

Oil capacity with filter

approx. 22 l / approx. 5,81 gal. (US)

Coolant capacity (overall system)

approx. 48 l / approx. 12,68 gal.

(US)

Engine, general

see manufacturer's instructions

QSB6.7-C260 Power (according to ISO14396)

194 kW / 260 PS) with nominal speed 2.000 rpm

Capacity

7200 cm3

Cylinders

6

Oil capacity with filter

approx. 17,0 l / approx. 4,50 gal. (US)

Coolant capacity (overall system)

approx. 48 l / approx. 12,68 gal.

(US)

Engine, general

see manufacturer's instructions

FCMP 280

835 + 840 / 09.2008

Power (according to ISO14396)

150 kW with nominal speed 1,500 rpm -1

Engine, general

see manufacturer's instructions

Translation of the original instructions

3-3

Technical data - Driving engine

3.2.2 Type 840

QSB6.7-C260

3-4

Power (according to ISO14396)

194 kW / 260 PS with nominal speed 2000 rpm

Capacity

7200 cm3

Cylinders

6

Oil capacity with filter

approx. 17,0 l / approx. 4,50 gal.

(US)

Coolant capacity (overall system)

approx. 48 l / approx. 12,68 gal.

(US)

Engine, general

see manufacturer's instructions

Translation of the original instructions

835 + 840 / 09.2008

Technical data - Machine

3.3

Machine

3.3.1 Mobile Subassembly

Quantity

Fuel tank

max. 600 l / max. 158,5 gal. (US)

Hydraulic tank - Middle view glass:

max. 510 l / max. 134,7 gal. (US) approx. 410 l / approx. 108,3 gal.

(US)

Hydraulic system, overall (*)

approx. 680 l / approx. 180 gal. (US)

Axle distributor gear Type 835

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

Differential Type 835 z front

approx. 23,5 l / approx. 6,2 gal. (US)

z rear

approx. 19,5 l / approx. 5,1 gal. (US)

Hub drive train Type 835 z front

each approx. 1,2 l / approx. 0,31 gal. (US)

z rear

each approx. 1,5 l / approx. 0,39 gal. (US)

Back gear Type 840 z front

approx. 1,5 l / approx. 0,39 gal. (US)

z rear

approx. 1,5 l / approx. 0,39 gal. (US)

Differential Type 840 z front z rear

approx. 44,5 l / approx. 11,4 gal.

(US) approx. 39,5 l / approx. 10,3 gal.

(US)

Parking disc brake Type 840 z rear

835 + 840 / 09.2008

Translation of the original instructions

approx. 0,25 l / approx. 0,07 gal.

(US)

3-5

Technical data - Machine

Subassembly

Quantity

Hub drive train Type 840 z front

each approx. 3,4 l / approx. 0,89 gal. (US)

z rear

each approx. 4,7 l / approx. 1,23 gal. (US)

Slewing ring lubrication - reservoir

approx. 3 kg / approx. 6.615 lb

Central lubrication system reservoir (optional)

approx. 2,5 kg / approx. 5,5 lb

(*): On special pylon-equipped machines, note that an additional approximately 30 l (appr. 7,9 gal. (US)) of hydraulic oil is required per 0.5 m pylon length.

3-6

Translation of the original instructions

835 + 840 / 09.2008

Technical data - Machine

Tire air pressure (pneumatic tires)

Tire size

ppbarp Air pressure ppsi

10.00-20

7,5

108,78

12.00-20

9

130.53

10.00-24

10

145,04

395/85

8.5

123.28

DANGER When pumping up tires, maintain adequate safety distance and use tire cage.

Wheel nuts Driving speed Type 835

Driving speed Type 840

835 + 840 / 09.2008

The tightening torque is 650 Nm. Use a torque wrench.

Off-road gear (1st gear)

0-7 km/h

Street gear (2nd gear)

0-20 km/h

0-11 km/h

Translation of the original instructions

3-7

Technical data - Machine

3.3.2 Crawler Subassembly

Quantity

Fuel tank

max. 600 l / max. 158,5 gal. (US)

Hydraulic tank - Middle view glass:

max. 510 l / max. 134,7 gal. (US) approx. 410 l / approx. 108,3 gal. (US)

Hydraulic system, overall(*)

approx. 680 l / approx. 180 gal. (US)

Gearbox

each approx. 9.0 l / approx. 2.8 gal. (US)

Slewing ring lubrication reservoir

approx. 3 kg / approx. 6,615 lb

Central lubrication system reservoir (optional)

approx. 2,5 kg / approx. 5,5 lb

(*):On special pylon-equipped machines, note that an additional approximately 30 l (appr. 7,9 gal. (US)) of hydraulic oil is required per 0.5 m pylon length.

Driving speed

3-8

1st gear

0-1.5 km/h

2nd gear

0-3.2 km/h

Translation of the original instructions

835 + 840 / 09.2008

Technical data - Machine

3.3.3 Structure Subassembly

Quantity

Fuel tank

max. 600 l / max. 158,5 gal. (US)

Hydraulic tank - Middle view glass:

max. 510 l / max. 134,7 gal. (US) approx. 410 l / approx. 108,3 gal. (US)

Hydraulic system, overall(*)

approx. 680 l / approx. 180 gal. (US)

Slewing ring lubrication reservoir

approx. 3 kg / approx. 6,615 lb

Central lubrication system reservoir (optional)

approx. 2,5 kg / approx. 5,5 lb

(*):On special pylon-equipped machines, note that an additional approximately 30 l (appr. 7,9 gal. (US)) of hydraulic oil is required per 0.5 m pylon length.

Driving speed

835 + 840 / 09.2008

Stationary

Translation of the original instructions

3-9

Technical data - Machine

3.3.4 Rails Subassembly

Quantity

Fuel tank

max. 600 l / max. 158,5 gal. (US)

Hydraulic tank - Middle view glass:

max. 510 l / max. 134,7 gal. (US) approx. 410 l / approx. 108,3 gal.

(US)

Hydraulic system, overall(*)

approx. 680 l / approx. 180 gal.

(US)

Slewing ring lubrication reservoir

approx. 3 kg / approx. 6,615 lb

Central lubrication system reservoir (optional)

approx. 2,5 kg / approx. 5,5 lb

(*):On special pylon-equipped machines, note that an additional approximately 30 l (appr. 7,9 gal. (US)) of hydraulic oil is required per 0.5 m pylon length.

Driving speed

3 - 10

Speed is customer-specific.

Translation of the original instructions

835 + 840 / 09.2008

Technical data - Inspection tools - overview

3.4

Inspection tools - overview

Note The following items are needed to inspect the machine at the specified maintenance intervals. Detailed information can be found at the corresponding inspection intervals.

Item

Quantity

O-ring for hydraulic tank

1

Return filter:

2

Leakage oil filter

1

Ventilation filter

1

Pilot control filter *)

1

HydroClean (Optional)

1

Recirculating air filter

1

Outside air filter

1

Drier bottle

1

SE Number see Wear parts list in the replacement parts catalog

Machine

*) There is no auxiliary control filter if there is a HydroClean!

Quantity

Oil filter

1

Fuel filter

2

Water separator

1

Safety cartridge-air filter

1

Replacement cartridge-air filter

1

V-belt - alternator

1

V-belt - water pump

1

V-belt - air conditioner

1

V-belt - magnetic equipment (optional)

1

Valve cover gasket

1

SE Number

see Wear parts list in the replacement parts catalog

Driving engine

Item

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

835 + 840 / 09.2008

Translation of the original instructions

3 - 11

Technical data - Lubricate machine.

3.5

Lubricate machine.

3.5.1 Machine - Mobile Manual lubrication

= grease manually WARNING

WARNING (Type 835) The grease nipple on the emergency actuating mechanism is not to be used for lubrication purposes. It is used exclusively for activating the emergency actuation. The gearbox can be destroyed.

3

2 1

Note Clean lubricating nipple before lubricating. Press grease in according to Chapter 5. Remove excess grease.

The lubrication nipples are provided with a red protective cap.

3 - 12

Translation of the original instructions

835 + 840 / 09.2008

Technical data - Lubricate machine.

a Lubrication nipples overview

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

a

Comment: 3 grease nipples per drive shaft/ universal joint

Typ 835

b

b = grease manually

835 + 840 / 09.2008

Typ 835

Translation of the original instructions

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

3 - 13

Technical data - Lubricate machine.

Note The machine is equipped with a central lubrication system for the swivel and the equipment as standard equipment.

CAUTION The reservoir for the central lubrication system must always be adequately filled in order to prevent damaging the bearings.

Central lubrication overview

= bearings supplied with grease by the central lubrication system

3 - 14

Translation of the original instructions

835 + 840 / 09.2008

Technical data - Lubricate machine.

3.5.2 Machine - Crawler Note The machine is equipped with a central lubrication system for the swivel and the equipment as standard equipment.

CAUTION The reservoir for the central lubrication system must always be adequately filled in order to prevent damaging the bearings.

Lubrication points – overview

= bearings supplied with grease by the central lubrication system = grease manually

835 + 840 / 09.2008

Translation of the original instructions

3 - 15

Technical data - Lubricate machine.

Note Clean lubricating nipple before lubricating. Grease according to chapter 5.

Remove excess grease.

The grease nipples are provided with a red protective cap.

Lubrication nipples-overview

8 per side

= grease manually

3 - 16

Translation of the original instructions

835 + 840 / 09.2008

Technical data - Lubricate machine.

3.5.3 Machine - Structur preliminary empty

835 + 840 / 09.2008

Translation of the original instructions

3 - 17

Technical data - Lubricate machine.

3.5.4 Machine - Rail preliminary empty

3 - 18

Translation of the original instructions

835 + 840 / 09.2008

Technical data - Tightening torques for bolts

3.6

Tightening torques for bolts

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

Strength class 8.8

835 + 840 / 09.2008

Coarse thread

Fine thread

Bolt

Tightening torque MA [Nm]

Bolt

Tightening torque MA [Nm]

M4

2,7

M8x1

24

M5

5,4

M10x1

50

M6

9,3

M10x1.25

47

M8

23

M12x1.25

84

M10

45

M12x1.5

81

M12

77

M14x1.5

135

M14

125

M16x1.5

205

M16

190

M18x1.5

305

M18

275

M20x1.5

430

M20

385

M22x1.5

580

M22

530

M24x2

720

M24

660

M27x2

1050

M27

980

M30x2

1450

M30

1350

M33

1850

M36

2350

Translation of the original instructions

3 - 19

Technical data - Tightening torques for bolts

Strength class 10.9

3 - 20

Coarse thread

Fine thread

Bolt

Tightening torque MA [Nm]

Bolt

Tightening torque MA [Nm]

M4

4,0

M8x1

36

M5

7,9

M10x1

73

M6

14

M10x1.25

69

M8

33

M12x1.25

125

M10

66

M12x1.5

120

M12

115

M14x1.5

195

M14

180

M16x1.5

300

M16

280

M18x1.5

435

M18

390

M20x1.5

610

M20

550

M22x1.5

830

M22

750

M24x2

1050

M24

950

M27x2

1500

M27

1400

M30x2

2100

M30

1900

M33

2600

M36

3300

Translation of the original instructions

835 + 840 / 09.2008

Technical data - Tightening torques for bolts

Strength class 12.9

835 + 840 / 09.2008

Coarse thread

Fine thread

Bolt

Tightening torque MA [Nm]

Bolt

Tightening torque MA [Nm]

M4

4,7

M8x1

42

M5

9,2

M10x1

86

M6

16

M10x1.25

81

M8

39

M12x1.25

145

M10

77

M12x1.5

140

M12

135

M14x1.5

230

M14

210

M16x1.5

350

M16

330

M18x1.5

510

M18

455

M20x1.5

710

M20

640

M22x1.5

960

M22

880

M24x2

1200

M24

1100

M27x2

1750

M27

1650

M30x2

2450

M30

2200

M33

3000

M36

3900

Translation of the original instructions

3 - 21

Technical data - Tightening torques for bolts

Pump hard stop

Do not over-tighten the rubber buffer !

Torque: M16 screw with 7 NM

3 - 22

Translation of the original instructions

835 + 840 / 09.2008

Technical data - Wind speed

3.7

Wind strength

Wind speed

Effect

Beaufort scale

Designation

m/s

km/h

Inland

0

Calm

0-0,2

1

Calm, smoke rises straight up

1

Light draught 0,3-1,5

1-5

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

2

Light breeze

1,6-3,3

6-11

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

3

Weak breeze 3,4-5,4

12-19

Leaves and thin twigs move, wind stretches a flag

4

Moderate breeze

5,5-7,9

20-28

Lifts dust and loose paper, moves twigs and thin branches

5

Fresh breeze 8,0-10,7

29-38

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

6

Strong wind

10,8-13,8

39-49

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

7

Stiff wind

13,9-17,1

50-61

Whole trees are moving

8

Stormy wind

17,2-20,7

62-74

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

9

Storm

20,8-24,4

75-88

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

10

Heavy storm

24,5-28,4

89-102

Uproots trees, considerable damage to houses

11

Hurricane type storm

28,5-32,6

103-117 Extensive storm damages

Hurricane

32,7-36,9

12

835 + 840 / 09.2008

Wind speed

(rarely in inland)

Translation of the original instructions

118-133 Severe devastation

3 - 23

Technical data - Conversion factors

3.8

Conversion factors

Pressure 1 bar

100 Kpa

14.5 psi

10 psi

68.95 Kpa

0.6895 bar

1 l/min

0,0353 cfm

0,2642 gal/min(US)

1 gal/min (Brit.)

0,1605 cfm

1 gal/min (US)

3,78541 l/min

1 mm

0,03934 in

1m

39,34 in

1 in

25,4 mm

1 ft

0,3048 m

304,8 mm

1 km

39340 in

3280,8 ft

1 km

1093,6 yd

0,62137 mile

1 mile

1,609 km

1609 m

1 kg

2,205 lb

35,27 Oz

1 lb (US)

0,454 kg

16 Oz

kW

= HP x 0.746

HP

= kW x 1.341

°C

= (°F -32) x 5/9

°F

= (°C x 9/5) + 32

Flow rate

Length

3,281 ft

Weight

Power

Temperature

3 - 24

Translation of the original instructions

835 + 840 / 09.2008

Technical data - Conversion factors

Volume 1 m3

1000 l

35,31 ft3

1,308 yd3

1 ft3

28,32 l

0,02832 m3

1,728 inch3

1l

0,2642 gal.(US)

0,2201 gal (Brit.)

-

1 gal. (US)

3,785 l

231 inch3

-

1 gal. (Brit.)

4,544 l

277 inch3

-

1 yd³

764,55 l

0,765 m³

27 ft³

1 m/s

3,281ft/s

2,237 mile/h

1 ft/s

0,305 m/s

1,097 km/h

Speed

835 + 840 / 09.2008

Translation of the original instructions

3 - 25

Technical data - Conversion factors

3 - 26

Translation of the original instructions

835 + 840 / 09.2008

Driving engine - Safety instructions

4

Driving engine

4.1

Safety instructions

Observe the safety notes before starting work.

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

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

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

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

have been installed and all tools are removed from the engine.

Note Observe the notes in the operating instructions of the engine manufacturer.

Engine with protective belt cover

13 mm

835 + 840 / 09.2008

Translation of the original instructions

4-1

Driving engine - Engine oil

4.2

Engine oil

WARNING z Scalding hazard!

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

Dispose of oil and oil filters in accordance with statutory regulations.

CAUTION The mixing of oils, lubricants or operating fluids of different types is not permitted!

Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

Note Observe the notes in the operating instructions of the engine manufacturer.

Check engine oil level

4-2

1

Position machine horizontally.

2

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

3

Shut down drive engine.

4

Open the service access door on the right.

5

Pull out oil dipstick (2) by the grip and wipe off using a clean, lint-free cloth.

6

Insert oil dipstick (2) up to stop and pull out again.

7

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

8

If necessary top up with oil of the specified grade (1).

9

Insert oil dipstick (2) up to stop and pull out again.

10

Close the service access door on the right.

Translation of the original instructions

835 + 840 / 09.2008

Driving engine - Engine oil

Detailed view of engine

1 2 3

1 Oil filler strainer

3 Oil filter

2 Oil dipstick handle

Changing engine oil and oil filter

835 + 840 / 09.2008

1

Bring machine up to operating temperature.

2

Position machine horizontally.

3

Shut down engine and secure against re-starting

4

Open the service access door on the right.

5

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

6

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

7

If necessary top up with oil of the specified grade.

8

Close the service access door on the right.

Translation of the original instructions

4-3

Driving engine - Air filter

4.3

Air filter

4.3.1 Air filter Safety instructions

Observe the safety notes before starting work.

CAUTION z Never use gasoline, soap or hot liquids to clean the air filter. z Never use compressed air to clean the interior of the housing

as dust and contamination can enter the engine.

Air filter indicator lamp

The condition of the air filter is monitored by a sensor.

The contamination level is measured by the flow resistance. If the air filter indicator lamp on the right control panel lights up the maximum permitted flow resistance has been reached. A warning tone also sounds. Check and clean the air filter immediately.

Note The air filter is located behind the left rear service access door service access door.

1

2

1 Air filter 2 Service access door

4-4

Translation of the original instructions

835 + 840 / 09.2008

Driving engine - Air filter

Air filter maintenance

1

2

3

4

5

6

835 + 840 / 09.2008

1 Air filter cap

4 Handle

2 Locking clamps (3 pieces)

5 Safety cartridge

3 Replacement cartridge

6 Hub

1

Open rear left service access door.

2

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

3

Remove replacement cartridge (3).

4

Clean the replaceable cartridge: – Blow out from inside to outside using dry compressed air (max. 2 bar/29 psi).

– Only knock out if unavoidable!

5

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

6

Exchange safety cartridge (6) after 5 filter service intervals (at least every 2 years): – Remove the safety cartridge by the handle (4).

Never clean safety cartridge!

– Insert new safety carriage.

7

Insert new or cleaned replaceable cartridge (3).

8

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

9

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

10

Re-close service access door.

Translation of the original instructions

4-5

Driving engine - Air filter

4.3.2 Air filter - moisture separator The air filter moisture separator, mounted on the superstructure, is maintenance-free.

Remove the heavy contamination in regular intervals!

CAUTION Never use compressed air to clean the interior of the housing as dust and contamination can enter the engine.

1

1 Air filter moisture separator

4-6

Translation of the original instructions

835 + 840 / 09.2008

Driving engine - Fuel system

4.4

Fuel system

4.4.1 Safety instructions Observe the safety notes before starting work.

WARNING z Injury hazard from rotating parts!

Do not carry out maintenance work until the driving engine has been switched off and the cooling system has been allowed to cool down. z Do not handle open flames when working on the fuel system!

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

manufacturer.

835 + 840 / 09.2008

Translation of the original instructions

4-7

Driving engine - Fuel system

4.4.2 Water separator 1 7

2 4

5 6

3

1 4

5

2

3

1 Manual feed pump

5 Drain valve

2 Filter cartridge

6 Water reservoir

3 Shut-off valve

7 Vent screw

4 Sensor plug connector

4-8

Translation of the original instructions

835 + 840 / 09.2008

Driving engine - Fuel system

Draining water

Change filter cartridge

1

Open rear right service access door.

2

Set a suitable catch container under the drain valve (5).

3

Open drain valve (5).

4

Drain the water and debris out of the water container.

5

Shut off the drain valve (5) again.

6

Close the service access door at the right, rear.

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

Note Observe the printed instructions on the filter cartridge.

835 + 840 / 09.2008

1

Close shut-off valve (5).

2

Remove the sensor connector (4).

3

Screw the filter cartridge (2) out of the housing head.

4

Dispose of the cartridge and the o-ring.

5

Screw the filter cartridge (2) with new O-ring onto the upper part of the housing.

6

Reconnect the sensor plug (4).

7

Open the shut-off valve (3).

8

Use the hand feed pump (1) to pump fuel into the water separator.

9

Press the manual feed pump button (1) in and locked in place.

Translation of the original instructions

4-9

Driving engine - Cooler

4.5

Cooler

4.5.1 Safety instructions Observe the safety notes before starting work.

WARNING z Injury hazard from rotating parts and from scalding!

Do not carry out maintenance work until the driving engine has been switched off and the cooling system has been allowed tocool down. z The coolant must not enter into the ground or waterways.

Dispose of coolant in accordance with statutory regulations.

CAUTION The mixing of oils, lubricants or operating fluids of different types is not permitted!

Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

Change intervals

SENNEBOGEN recommends a change interval of 2,000 hours of operation or max. 24 months, whichever comes first.

4.5.2 Coolant Deutz engine Note Use the following specified coolants: z SENNEBOGEN factory uses:

– Hunold coolant ANF based on Monoethylenglycol Antifreeze sufficient to -37 °C (-34 °F). z Do not use more or less than the recommended concentration

of 50 Vol. % coolant. If the coolant concentration is too high, the cooling and antifreeze behavior will deteriorate.

Note Further information on changing the coolant can be found in the engine manufacturer's operating instructions.

4 - 10

Translation of the original instructions

835 + 840 / 09.2008

Driving engine - Cooler

4.5.3 Coolant - Cummins Engine Note Use the following specified coolants: z SENNEBOGEN factory uses:

– ES Compleat TM. Antifreeze sufficient to - 36 °C (- 33 °F). z Do not use more or less than the recommended concentration

of 50 Vol. % coolant. If the coolant concentration is too high, the cooling and antifreeze behavior will deteriorate.

Note Further information on changing the coolant can be found in the engine manufacturer's operating instructions.

4.5.4 Change coolant Coolant level indicator light

The coolant level is monitored by a sensor.

If the level falls below a certain point, a warning tone sounds.

Top up coolant.

If the coolant level is too low, check the fittings and lines for leaks.

Note The machine is equipped with a combination cooler for coolant, hydraulic oil and charge air.

Note Machines with electric motors do not have a coolant cooler!

835 + 840 / 09.2008

Translation of the original instructions

4 - 11

Driving engine - Cooler

1

2

3

1 Coolant expansion tank

3 Service access door

2 Combination cooler

Check coolant level and/or antifreeze

4 7

1

5 6

4 - 12

4 Hand screws

6 Service panel

5 Handle

7 Cap

Translation of the original instructions

835 + 840 / 09.2008

Driving engine - Cooler

835 + 840 / 09.2008

1

Allow drive engine and cooler to cool down.

2

Unscrew the two hand screws (4).

3

Grab the service panel (6) by the handle (5) and remove.

4

Pace large, thick cloths on the cap (7) of the coolant expansion tank (1) and open it carefully in order to equalize the pressure.

5

Check antifreeze and coolant level, top up if necessary.

Mixing ratio: 50% antifreeze, 50% water. Frost resistant up to - 37 °C (- 34°F).

6

Check antifreeze and coolant level, top up if necessary.

Mixing ratio: 50% antifreeze, 50% water. Frost resistant up to - 36 °C (- 33° F).

7

Re-close cap (7) of expansion tank.

8

Replace the service panel (6) and secure using the hand screws.

Translation of the original instructions

4 - 13

Driving engine - Cleaning the cooling system

4.6

Cleaning the cooling system

The cooling system ensures that the engine runs at a constant operating temperature. The cooling system has an important impact on the function and service life of the engine.

The cooler is adapted for each respective engine. The cooler must be kept fully operational in order to prevent damage to the drive system, e.g. owing to overheating. You should therefore check the cooler regularly and clean it if necessary.

Dirt can build up on both the outside (e.g. dust) and the inside (e.g. scale) of the cooler.

Note This section provides you with general notes on cleaning the cooler.

Also comply with the notes in the operating instructions of the engine manufacturer.

4.6.1 Safety instructions WARNING z If the cooler is damaged, contact SENNEBOGEN Customer Service

before starting on any repair work. z Repair work on the cooling system should only be carried out

by specialists. z Do not touch the guard grill on the fan. Rotating fan blades may

cause serious injury. Objects coming into contact with the fan blades may be catapulted into the air. z Switch off the machine and ensure that it cannot be switched

on again before starting any repair work. z Always wear face protection or protective glasses when working

on the cooling system. z Always relieve the pressure in the cooling system before starting

any repair work. Place a cloth over the sealing cap and open the cap slowly to allow the cooling system to cool down. z Do not use cleaning agents that may damage the cooler materials

or the paint on the machine. z Antifreeze is. Do not smoke in the vicinity of the cooling system

and do not ignite a naked flame.

Please observe the manufacturer’s specifications when handling coolant or cleaning agents.

4 - 14

Translation of the original instructions

835 + 840 / 09.2008

Driving engine - Cleaning the cooling system

4.6.2 Reverse fan 1

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

2

Open the service access door (2).

3

Blow out minor dirt by reversing the ventilator direction. To do so: Actuate the fan reversal switch in the driver's cab.

4

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

5

Check cooler for leaks and damaged cooling fins.

6

Re-close service access door.

4.6.3 External cleaning Dirt and cleaning procedure

Dust, insects, foliage or leaves

– Compressed air. (max. 2 bar / 29 psi)

Oily and greasy deposits

– Steam cleaner (max. 100 bar / 1450 psi)

CAUTION Make sure that the cooling fins are not damaged.

Procedure

835 + 840 / 09.2008

1

Direct the cleaning jet parallel to the longitudinal direction of the cooling fins.

Make sure that the cooling fins are not damaged.

2

Allow the cooling system to dry before starting it up again.

Translation of the original instructions

4 - 15

Driving engine - Cleaning the cooling system

4.6.4 Internal cleaning Note Observe the notes in the operating instructions of the engine manufacturer.

It is necessary to clean the interior of the cooling system if z The engine is constantly overheating even though the V-belt,

thermostat and water pump are functioning properly. z Dirt is visible on the cooling pipes. Remove the sealing cap

and check it. z Green sludge (chromium hydroxide) is present on the underside

of the sealing cap. z The coolant is very cloudy. z Lubricant incursion has occurred.

Procedure

1

Please observe the safety instructions.

2

Drain the coolant into suitable containers and dispose of it in accordance with regulations.

3

Add a mixture of standard cooling system cleaner and water.

CAUTION Please note the mixing ratio and ensure that the cooling system cleaner is used properly!

4

Start the engine and allow it to run for approx. 1.5 hours.

5

Drain the mixture into suitable containers and dispose of it in accordance with regulations.

6

Flush the cooling system thoroughly with clean water; repeat this process several times.

CAUTION Always fill using a water-coolant mixture. Observe mixing ratios.

Mix before filling!

7

Fill the cooling system with a water-coolant mixture.

Note More thorough cleaning is only possible if the cooler is deinstalled.

Contact SENNEBOGEN Customer Service before deinstalling the cooler.

4 - 16

Translation of the original instructions

835 + 840 / 09.2008

Driving engine - Check belt drives

4.7 Safety instructions

Check belt drives

Observe the safety notes before starting work.

DANGER z Only carry out maintenance work with driving 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.

Note More information on testing, tightening and changing the belt drives can be found in the engine manufacturer's operating instructions.

Belt drives

1

2 3 4

1 Alternator 2 Generator for magnet equipment (optional)

835 + 840 / 09.2008

3 Heating/air-conditioning system (optional) 4 Fuel pump

1

Removing/installing protective belt cover.

2

Make sure that the V-belts are not damaged and that they run in parallel.

Translation of the original instructions

4 - 17

Driving engine - Electric motor

4.8

Electric motor

Note Observe the notes in the operating instructions of the engine manufacturer.

4 - 18

Translation of the original instructions

835 + 840 / 09.2008

Undercarriage - Mobile

5

Undercarriage

5.1

Mobile

WARNING Injury hazard from rotating parts and from scalding!

Do not carry out maintenance work until the drive engine has been switched off. z Maintenance and repair work must only be carried out by trained

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

Dispose of waste oil in accordance with the statutory regulations.

5.1.1 Cleaning and lubricating 1

Position machine horizontally.

2

Shut down engine and secure against re-starting.

3

Clean tires and running gear using a steam cleaner.

Attention! Hold the steam cleaner lance at least 20 cm from the surface to be cleaned.

4

Lightly grease guides and bolts.

5

Lubricate all lubrication points (see Section 3.5).

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

835 + 840 / 09.2008

Tire size

ppbarp Air pressure ppsi

10.00-20

7,5

108,78

12.00-20

9

130.53

10.00-24

10

145,04

395/85

8.5

123.28

Translation of the original instructions

5-1

Undercarriage - Mobile

5.1.3 Tightening wheel nuts Check tightness of all wheel nuts. Use a torque wrench.

Fig. Twin tires, solid rubber

650 Nm 32 mm

5.1.4 Hub drive train

1

2

1 Oil filler/drain screw 2 Oil level mark

CAUTION The mixing of oils, lubricants or operating fluids of different types is not permitted!

Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

5-2

Translation of the original instructions

835 + 840 / 09.2008

Undercarriage - Mobile

Checking the oil level

Changing oil

835 + 840 / 09.2008

1

Position machine horizontally.

2

Slew hub until the oil drain screw (2) is bottom (vertical position).

3

Shut down drive engine.

4

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

5

Clean components, check seal and exchange if necessary.

6

Retighten oil filler screw (1).

7

Repeat the procedure on all remaining hubs.

1

Position machine horizontally.

2

Slew hub until the oil drain screw (2) is bottom (vertical position).

3

Shut down driving engine.

4

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

5

Place a suitable container under the oil drainage screw (2). For capacities, see Section 3.3.1.

6

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

7

Clean components, check seals and exchange if necessary.

8

Re-tighten oil drainage screw (2).

9

Unscrew oil filler screw (1).

10

Fill with new oil up to the lower edge of oil filler screw (1).

11

Re-tighten oil filler screw (1).

12

Repeat procedure on the three remaining hubs.

13

Re-check oil level after 2 hours run.

Translation of the original instructions

5-3

Undercarriage - Mobile

Brake wear measurement

The thickness of the brake pads (2) must be visually inspected at regular intervals depending on vehicle usage.

The brake shoes (1) are basically maintenance-free; they only require an inspection for damaged parts.

CAUTION If the residual brake pads are very thin, the inspection intervals must be shortened accordingly to prevent extensive damage to the brakes and/or drum.

2

1

1

2

1 Brake shoes 2 Brake pad

Note z Regarding riveted brake pads: At least 1.0 - 1.5 mm residual pad

thickness required above the rivet head at the weakest point in the pad. z Regarding bonded brake pads: At least 2.0 mm residual pad

thickness required at the weakest point in the pad.

CAUTION If remaining brake pad thickness reaches these values, the brake pads (2) must be replaced on the axle.

5-4

Translation of the original instructions

835 + 840 / 09.2008

Undercarriage - Mobile

5.1.5 Axle distributor gear (Type 835) 50 Nm 13 mm

1 2

1 Oil filler screw 2

Oil drain screw

1

2

CAUTION The mixing of oils, lubricants or operating fluids of different types is not permitted!

Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

Checking the oil level

50 Nm

1

Bring machine up to operating temperature.

2

Position machine horizontally.

3

Switch off driving engine and secure against restarting.

Wait approx. 10 minutes for the oil to collect in axle gear box.

4

Clean exterior of the transfer case using a cloth.

5

Screw out oil filler screw (2). The oil level must reach up to lower edge of filler opening, top up if necessary.

6

Clean components, check seal and replace if necessary.

7

Tighten the oil filler screw (1) again (MA = 50Nm).

13 mm

835 + 840 / 09.2008

Translation of the original instructions

5-5

Undercarriage - Mobile

Changing oil

50 Nm 13 mm 50 Nm

1

Bring machine up to operating temperature.

2

Position machine horizontally.

3

Switch off driving engine and secure against restarting.

Wait approx. 10 minutes for the oil to collect in axle gear box.

4

Clean exterior of the transfer case using a cloth.

5

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

6

Place a suitable container under the oil drain screw (2).

7

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

8

Clean components, check seals and exchange if necessary.

9

Re-tighten oil drain screw (2).

10

Screw out oil filler screw (2).

11

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

12

Re-tighten oil filler screw (1).

13

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

Top up hydraulic oil, if required.

13 mm

WARNING The grease nipple (4) on the emergency actuating mechanism is not to be used for lubrication purposes. It is used exclusively for activating the emergency actuation. The gearbox can be destroyed.

4

5-6

Translation of the original instructions

835 + 840 / 09.2008

Undercarriage - Mobile

5.1.6 Differential (Type 835)

1

2

1 Oil filler screw 2 Oil drain screw

CAUTION The mixing of oils, lubricants or operating fluids of different types is not permitted!

Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

Checking the oil level

1

Bring machine up to operating temperature.

2

Shut down engine and secure against re-starting.

3

Switch off driving engine and secure against restarting.

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

4

Clean exterior of differential using a cloth.

5

Screw out oil filler screw (2). The oil level must reach up to lower edge of filler opening. Top up if necessary.

6

Clean components, check seal and replace if necessary.

7

Re-tighten oil filler screw (1).

30 mm

835 + 840 / 09.2008

Translation of the original instructions

5-7

Undercarriage - Mobile

Changing oil

30 mm 50 Nm

1

Bring machine up to operating temperature.

2

Shut down engine and secure against re-starting.

3

Shut down engine and secure against re-starting.

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

4

Clean exterior of differential using a cloth.

5

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

6

Place a suitable container under the oil drain screw (2).

7

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

8

Clean components, check seals and exchange if necessary.

9

Re-tighten oil drain screw (2).

10

Screw out oil filler screw (2).

11

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

12

Re-tighten oil filler screw (1).

13

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

Top up hydraulic oil, if required.

13 mm

5-8

Translation of the original instructions

835 + 840 / 09.2008

Undercarriage - Mobile

5.1.7 Drive shafts/universal joints (Type 835) Note The two drive shafts/universal joints have three grease nipples each.

Each joint is lubricated via one grease nipple; the third nipple is used to lubricate the telescopic profile.

CAUTION To avoid damaging the seals and prevent the ingress of water and dirt, high-pressure cleaning must not be used to clean the drive shafts/ universal joints.

Note Check the following items regularly: z Fittings and connecting flanges z Drive shaft/universal joints for unusual noises and vibration during

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

compensation prior to lubricating

1

2

1 Grease nipple for cross joint (shown here with protective cap) 2 Grease nipple for telescopic profile (shown here without protective cap)

Lubricating the drive shafts/universal joints

835 + 840 / 09.2008

1

Lift the machine using all four supports.

2

Shut down engine and secure against re-starting.

3

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

4

Remove the protective caps from the grease nipples.

Translation of the original instructions

5-9

Undercarriage - Mobile

5 - 10

5

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

6

Grease the joint by pumping the grease gun with a smooth motion.

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

7

Repeat these steps with the remaining grease nipples.

8

Wipe off excess grease with a cloth.

9

Replace all protective caps on the grease nipples.

10

Retract the supports completely.

Translation of the original instructions

835 + 840 / 09.2008

Undercarriage - Mobile

5.1.8 Back gear and differential (Typ 840)

4

3

1

2

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!

Checking oil

1

Bring machine up to operating temperature.

2

Position machine horizontally.

3

Shut down driving engine. Wait ca. 10 minutes for the oil to collect in differential.

4

Screw out oil filler screw (2). The oil level must reach up to lower edge of filler opening, top up if necessary.

5

Clean components, check seal and exchange if necessary.

6

Re-tighten oil filler screw (2).

30 mm

Note The oil level of back gear and differential is only controlled over the oil filler screw (2).

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5 - 11

Undercarriage - Mobile

Changing oil

30 mm 50 Nm

1

Bring machine up to operating temperature.

2

Position machine horizontally.

3

Shut down driving engine. Wait ca. 10 minutes for the oil to collect in differential.

4

Slacken oil filler screw (2) to relieve the pressure.

5

Slacken oil filler screw (4) to relieve the pressure.

6

Place a suitable container under the oil drain screw (1). For capacities, see Section 3.3.1.

7

Place a suitable container under the oil drain screw (3). For capacities, see Section 3.3.1.

8

Screw out oil drain screw (1) and collect the waste oil in the container.

9

Screw out oil drain screw (3) and collect the waste oil in the container.

10

Clean components, check seals and exchange if necessary.

11

Re-tighten oil drain screw (1).

12

Re-tighten oil drain screw (3).

13

Screw out oil filler screw (2).

14

Screw out oil filler screw (4).

15

Fill with new oil up to lower edge of filler opening (2).

16

Fill with new oil up to lower edge of filler opening (4).

17

Re-tighten oil filler screw (2).

18

Re-tighten oil filler screw (4).

19

Re-check oil level after 2 hours run.

13 mm

50 Nm 13 mm

50 Nm 13 mm

Note The oil level of back gear and differential is only controlled over the oil filler screw (2).

5 - 12

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Undercarriage - Mobile

5.1.9 Parking disc brake (Type 840)

3

4*

2 4* 1

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!

Checking oil level

835 + 840 / 09.2008

1

Bring machine up to operating temperature.

2

Position machine horizontally.

3

Shut down driving engine. Wait ca. 10 minutes for the oil to collect in back gear.

4

Screw out oil level check screw (2).

Oil flows out when the oil level has been reached.

5

If necessary, unscrew oil filler screw (3) and top up with oil.

6

Clean components, check seal and exchange if necessary.

7

Re-tighten oil level check screw (2).

8

Re-tighten oil filler screw (3).

Translation of the original instructions

5 - 13

Undercarriage - Mobile

Changing oil

5 - 14

1

Bring machine up to operating temperature.

2

Position machine horizontally.

3

Shut down driving engine. Wait ca. 10 minutes for the oil to collect in back gear.

4

Slacken oil filler screw (3) to relieve the pressure.

5

Place a suitable container under the oil drain screw (1).

For capacities, see Section 3.3.1.

6

Screw out oil drain screw (1) and collect the waste oil in the container.

7

Screw out oil drain screw (4*) and collect the waste oil in the container. (*Optional)

8

Clean components, check seals and exchange if necessary.

9

Re-tighten oil drain screw (1).

10

Re-tighten oil drain screw (4*). (*Optional).

11

Screw out oil filler screw (3).

12

Screw out oil level check screw (2).

13

Add new oil.

Oil flows out when the oil level has been reached.

14

Re-tighten oil level check screw (2).

15

Re-tighten oil filler screw (3).

16

Re-check oil level after 2 hours run.

Translation of the original instructions

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Undercarriage - Crawler

5.2

Crawler

WARNING z Injury hazard from rotating parts and from scalding!

Do not carry out maintenance work until the drive engine has been switched off. z Maintenance and repair work must only be carried out by trained

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

Dispose of waste oil in accordance with the statutory regulations.

5.2.1 Cleaning and lubricating 1

Position machine horizontally.

2

Shut down engine and secure against re-starting.

3

Clean crawler running gear, crawler chain and pulleys with steam cleaner.

Attention! Hold the steam cleaner lance at least 20 cm from the surface to be cleaned.

4

Lightly grease guides and bolts.

5

Lubricate all lubrication points (see Section 3.5).

5.2.2 Drive transmission Checking the oil level 1 2

3

1 Locking bolts - sprocket

3

Oil drain screw

2 Oil filler screw

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5 - 15

Undercarriage - Crawler

35 Nm

1

Position machine horizontally. Take care that the oil drainage screw (3) is at its lowest position.

2

Shut down engine and secure against re-starting.

3

Unscrew oil filler screw (2). The oil level must reach up to lower edge of filler opening, top up if necessary.

4

Re-tighten oil filler screw (2).

1

Position machine horizontally. Take care that the oil drainage screw (3) is at its lowest position.

2

Shut down engine and secure against re-starting.

3

Place a container under the oil drain screw (3).

4

Unscrew oil filler screw (2).

5

Screw out oil drain screw (3) and collect the waste oil in the container.

6

Clean components, check seals and exchange if necessary.

7

Re-tighten oil drain screw (3).

8

Pour fresh oil in through the oil filler screw (2) up to lower edge of filler opening.

9

Re-tighten oil filler screw (2).

10

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

Top up hydraulic oil, if required.

8 mm

Changing oil

35 Nm 8 mm

5 - 16

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Undercarriage - Crawler

5.2.3

Crawler chain

Adequate but not excessive chain tension is essential for the chain running gear to function smoothly without overdue wear and tear.

Note Correctly adjusted chain tension will reduce wear and tear to components of the running gear.

Checking chain tension A

A-A

A3 G EN T IT L E 15 0 2 0 1 G EN -P O S G EN -S UM C AN O NII 13 4 2 ed li n m et ric ISO

A

Sag measurement “X” Clean the running gear and crawler chains thoroughly before checking the chain tension.

Position the machine on even, firm ground.

DANGER z Ensure that there is no one within the danger area of the machine. z Use hangers with sufficient capacities! z For lattice mast cranes – remove ballast and boom! z Raise machine using suitable means and with extreme caution

(use lifting points provided).

835 + 840 / 09.2008

1

Raise machine with suitable lifting gear until the chain is no longer in contact with the ground.

2

Check the sag measurement "X" between the track roller and the chain link.

The chain is correctly tensioned when the sag measurement "X" in the centre of the track wheel carrier lies between a minimum of 70 mm and a maximum of 80 mm. Adjust the tension if necessary (see following page).

3

Lower machine and remove tackle.

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5 - 17

Undercarriage - Crawler

Adjusting chain tension

The chain tension is determined by the position of the front idler.

The position of the front idler is dictated by the quantity of grease in the tensioning cylinder of the idler unit.

1 1

2

Slacken hexagonal bolts (1) and remove cover (2).

16 mm

3

5 - 18

2

Clean lubricating nipple (3).

3

Apply a high-pressure grease pistol to the lubricating nipple and actuate until the crawler chain is sufficiently tensioned.

4

Drive machine forwards and backwards.

5

Raise machine and check sag measurement “X” between the track roller and the chain link.

6

Repeat steps 3-5 until the sag measurement “X” is within the range (min. 70 mm, max. 80 mm).

7

Tighten cover (2) with the hexagonal nuts (1).

8

Adjust the second crawler chain in the same way.

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Undercarriage - Crawler

Note To relax the chain, unscrew the lubrication nipple approx. 3 turns until grease starts to seep out. Check the chain tension again.

5.2.4 Sprocket Tighten bolts

1050 Nm

1

36 mm

1 Locking bolts - sprocket Note Tighten the securing screws using a torque wrench.

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5 - 19

Undercarriage - Crawler

5.2.5 Base plates Tighten bolts

390 Nm 27 mm 1

1 Locking bolts - Base plate Note Tighten the base plate fixing bolts (2) using a torque wrench.

5.2.6 Beam

Note Every 1,000 hours of operation, the beam must be checked to ensure that it is not slanted.

5 - 20

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Undercarriage - Structure

5.3

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Structure

Translation of the original instructions

5 - 21

Undercarriage - Rails

5.4

5 - 22

Rails

Translation of the original instructions

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Swiveling connection - General information

6

Swiveling connection

CAUTION The mixing of oils, lubricants or operating fluids of different types is not permitted!

Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

6.1

General information

Ensure that the swivelling connection is well lubricated. z Path (1):

– via central lubrication system. z Gear teeth (2):

– with gear teeth spray or – via slewing ring lubrication (optional).

Note Before and after longer periods that the machine sits without working (longer than 3 months), relubricating is necessary!

3

1

2 1 Slewing track 2 Gear teeth 3 Seal

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6-1

Swiveling connection - Lubricating slewing ring path

6.2

Lubricating slewing ring path

6.2.1 Central lubrication system The central lubrication system automatically lubricates the slewing track of the slewing mechanism as well as the bearings of the equipment and the adjustable cab. The lubrication cycle is pre-set at the factory.

Note The pre-set lubrication cycle can be shortened. See in this case the documentation on the CENTRAL LUBRICATION SYSTEM in chapter 10 of the operating manual.

Shorter lubrication intervals are required, z in the tropics, z when humidity is high, z for high levels of dust and contamination, z when temperatures change dramatically, z when subject to continuous swinging movement.

1

2

3

1 Threaded cover - replenish grease 2 Grease reservoir - note MIN/MAX markings 3 Grease nipple – Replenish grease

Actuating path lubrication manually

Lubrication can be manually actuated in addition to the pre-set lubrication cycle.

1

6-2

Move the switch on the control panel to the right:

Translation of the original instructions

835 + 840 / 09.2008

Swiveling connection - Lubricating slewing ring teeth

6.3

Lubricating slewing ring teeth

Lubricate the slewing ring teeth with the SENNEBOGEN gear teeth spray and/or with the optional slewing ring lubrication attachment.

6.3.1 Gear teeth spray

835 + 840 / 09.2008

1

Shut down driving engine.

2

Thoroughly clean gear teeth.

3

Check teeth of slewing ring and slewing ring pinion for wear, exchange if necessary.

4

Spray gear teeth from approximately 30 cm distance with SENNEBOGEN gear teeth spray (SE no.: 011429).

5

Slew upper structure a number of times for lubricant to spread evenly over gear teeth.

Translation of the original instructions

6-3

Swiveling connection - Lubricating slewing ring teeth

6.3.2 Slewing ring lubrication (optional)

1

Note Clean the lubrication point thoroughly and degrease before the first application of lubricant to ensure that the lubricant creates an unbroken film over the surface.

1

Shut down driving engine.

2

Thoroughly clean gear teeth.

3

Check teeth of slewing ring and slewing ring pinion for wear, exchange if necessary.

4

Start driving engine.

5

Actuate slewing ring lubrication: – Press the pushbutton for slewing ring lubrication on the right of the control panel and hold down.

– Rotate the upper structure 360° to the left and right to distribute the lubricant evenly over the gear teeth.

6

Release the pushbutton.

7

Check that there is a complete film of lubricant over the surface, repeat lubrication process if necessary.

Note Lubricate slewing ring every 10 operating hours / daily (depending on workload)!

Check the lubrication containers every week and replenish lubricant as required!

CAUTION Check the plastic sliding wear pad (2) once a month for wear in the direction of lubrication (1). Observe wear limit!

Replace the plastic sliding wear pad when the wear limit has been reached (2)! The machine could otherwise suffer serious damage. The machine operator is wholly liable for any such damage or consequential damage!

6-4

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835 + 840 / 09.2008

Swiveling connection - Lubricating slewing ring teeth

Check plastic sliding wear pad

min. 28 mm

1

2

WARNING Before checking the plastic sliding wear pad (2): z Lower suspended loads and booms to the ground. z Pull safety lever back. z Shut down machine and secure against unauthorised re-starting

before starting with maintenance work. z Attach warning sign to controls.

835 + 840 / 09.2008

1

Dismantle lubrication assembly (1).

2

Check plastic sliding wear pad (2) for wear (minimum 28 mm).

3

Exchange plastic wear pad if necessary.

Translation of the original instructions

6-5

Swiveling connection - Lubricating slewing ring teeth

Replenish grease

1 1 Lubricant containers

6-6

1

Open cover (1) of lubrication container.

2

Replenish lubricant (SE-no.: 047485).

3

Re-close cover.

Translation of the original instructions

835 + 840 / 09.2008

Swiveling connection - Tighten slewing ring bolts.

6.4

Tighten slewing ring bolts.

DANGER Danger of death!

Defective slewing ring bolts can cause the superstructure to tip over.

For this reason, always observe the maintenance intervals! z Re-tighten slewing ring bolts using torque wrench.

Observe tightening torque in accordance with Section 3.6! z Check or replace the slewing ring bolts every 5,000 operating

hrs or every 5 years.

Note Testing must be performed by an expert from an independent specialist company or an independent institute.

The unrestricted further use of the slewing ring bolts must be guaranteed and verified by means of a certificate.

Otherwise, replace the slewing ring bolts!

Corroded or damaged bolts can shear and cause the superstructure to tip over. z Do not tighten corroded or damaged bolts, replace immediately with

new bolts. z It is essential that the correct number and diameter of bolts are used. z Use only original SENNEBOGEN replacement parts. z Contact SENNEBOGEN customer services if you have any further

queries. z If you suspect damage to the bolt connections, call SENNEBOGEN

customer services and arrange for a check to be carried out.

Fig.: Tightening with a torque wrench

280 Nm 24 mm

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Translation of the original instructions

6-7

Swiveling connection - Tighten slewing ring bolts.

1

Shut down drive engine.

2

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

Note The tension of the bolt tightened first is influenced by the tensioning of the other bolts. It is therefore necessary to make at least two full turns.

Bolts over M30 should preferably be tightened with a hydraulic socket wrench.

6-8

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835 + 840 / 09.2008

Swiveling connection - Wear measurement and checking the drive system/bearing play

6.5

Wear measurement and checking the drive system/bearing play

Note Make sure that the slewing ring bolts are seated properly before measuring.

Note After 250 hours of operation, the play in the bearing must be measured, noted and reported to SENNEBOGEN. The measurement is to be regarded as the base position for delivery status!

1

Position machine horizontally.

2

Place upper structure parallel to the undercarriage.

3

Move the boom to a defined position, which can be precisely replicated again for the next measurement. Do not put the boom on the ground for this.

4

Define 4 measuring points in 90° clearance around the slewing ring – In case the first measurement is being taken, 4 measuring points are to be defined according to the following images and these are to be marked permanently (e.g. center punched) – Perform the measurement as close to the bearing as possible – The measurement is between the lower connecting construction and the mounting ring bolted with the top construction – Precision of the meters: 0.01 mm

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Translation of the original instructions

6-9

Swiveling connection - Wear measurement and checking the drive system/bearing play

5

For the zero setting of the meters, a maximum maximal restoring moment is to be applied on the slewing ring first.

6

Measure on the 4 measuring points.

7

Now, apply a forwards turning torque, in circumstances by taking on the load.

8

After pivoting, repeat the measurement on the marked positions.

9

Record the measurement values in the table and compare.

10

The measurement value difference provides information on the wear.

11

Maximum permitted wear limit:

12

The measurement value difference provides information on the wear.

Note If the wear limit has been reached, contact the SENNEBOGEN customer service!

6 - 10

Translation of the original instructions

835 + 840 / 09.2008

Hydraulic system - Safety instructions

7

Hydraulic system

7.1

Safety instructions

Observe the safety notes before starting work on hydraulic system.

DANGER z Warning - high oil pressure!

The hydraulic system is subject to high pressure. Serious injuries can be caused by escaping hydraulic oil when loosening a hydraulic connection or if a leak should occur.

Only carry out work on the de-pressurized hydraulic system. z Work on hydraulic systems may only be carried out by trained

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

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

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

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

If leaks are present, hydraulic oil will escape under high pressure.

Hydraulic oil emerging under high pressure will penetrate the skin and cause severe injuries.

Danger of infection. In the case of injury contact a doctor immediately! z Danger of injury from scalding

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

Only carry out maintenance work when the engine is switched off, and then only if you are sure that the fan wheel has come to a stop and there is no risk of automatic start-up.

Before starting up again, ensure that: – No items (e.g. tools) are in the vicinity of the fan wheels or could fall into this area as a result of vibrations, for example – The protective features have been installed.

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Translation of the original instructions

7-1

Hydraulic system - General

7.2

General

7.2.1 Hydraulic cylinder Pressure cylinders are subject to slight leakage. Remove excess leakage residue with a cloth. Dispose of oil-soaked cloth as hazardous waste.

Note The sliding surfaces of the piston rods are chrome-plated. Heavier leakage indicates damaged sliding surfaces or defective seals.

Clean hydraulic cylinders

z Do not use sharp edged tools, caustic fluids or abrasives. z Wash down piston rods regularly with steam cleaner. Do not direct

the jet straight at the sealing elements. z Apply preservative to extended piston rods after cleaning.

This protects the surface from the effects of the environment and weather.

Fig.: Hydraulic cylinder on boom

7.2.2 Bolted joints Check hydraulic screw connections and couplings regularly for leaks.

Seal points of leakage and remove oil residue.

Leaking hydraulic oil endangers the environment and presents a hazard due to danger of slipping.

Always seal opened connections immediately at both sides with plugs.

7-2

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Hydraulic system - Hydraulic hose lines

7.3 Storage and service life

Hydraulic hose lines

Even when used correctly at permissible loads, hoses and hose lines are subject to natural wear and tear. Their service life is therefore limited.

The operator is responsible for ensuring that hose lines are replaced at suitable intervals, even when there are no obvious defects to be seen in the hose line.

Note Hose lines must be replaced at least every six years, including a maximum of two years storage time, where applicable.

Inspection

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

Remedy any defects discovered immediately.

Defects

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

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

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

835 + 840 / 09.2008

Translation of the original instructions

7-3

Hydraulic system - De-pressurizing the hydraulic system

7.4

De-pressurizing the hydraulic system

WARNING Danger of injury! Danger of injury from scalding The hydraulic system is subject to high pressure. Serious injuries can be caused by escaping hydraulic oil when loosening a hydraulic connection.

The hydraulic oil can reach temperatures of 70°C (158 °F) and above.

Only carry out maintenance work once the hydraulic oil system has cooled down.

1

Lower suspended loads and jib to the ground.

2

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

3

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

1

7-4

4

Open the cover plate.

5

Unscrew the threaded cap (1) on the hydraulic tank.

This releases the residual pressure in the tank.

Translation of the original instructions

835 + 840 / 09.2008

Hydraulic system - De-pressurizing the hydraulic system

6

Connect the pressure gauge (up to a maximum of 600 bar / 8700 psi) to the measurement connections (M1, M3, M25, M34, M41).

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

7.4.1 Check the hydraulic oil level, Top up hydraulic oil CAUTION The mixing of oils, lubricants or operating fluids of different types is not permitted!

Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

1

Lower suspended loads and jib to the ground.

2

Position machine horizontally.

Machine in park position

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Translation of the original instructions

7-5

Hydraulic system - De-pressurizing the hydraulic system

3

Put the machine in park position. Retract support cylinders.

4

Shut down engine and secure against re-starting.

5

Open the service access door on the right.

6

Check oil level at the oil level indicator (1): The oil level must reach to the upper marking (MAX).

1 2

7

Top up hydraulic oil, if required: – Open the cover plate.

– Unscrew the threaded cap (2) on the hydraulic tank.

– Top up hydraulic oil and re-check.

– Re-tighten screw cap – Close the cover plate.

8

7-6

Close the service access door on the right.

Translation of the original instructions

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Hydraulic system - Changing hydraulic oil

7.5 Safety instructions

Changing hydraulic oil

Observe the safety notes before starting work on hydraulic system.

DANGER z Warning of high oil pressure and scalding.

The hydraulic system is subject to high pressure.

Serious injuries can be caused by escaping hydraulic oil when loosening a hydraulic connection.

Only carry out work on the de-pressurized hydraulic system. z The hydraulic oil can reach temperatures of 70°C (158 °F)

and above. Only carry out maintenance work once the hydraulic oil system has cooled down z Work on the hydraulic system may only be carried out by trained

personnel with specialist knowledge and experience of hydraulics.

CAUTION The mixing of oils, lubricants or operating fluids of different types is not permitted!

Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

Note: The task can be made easier by pumping out as much oil as possible.

Use the opening of the return filter for this.

While changing the hydraulic oil, change all filters in the hydraulic system as well.

Procedure

835 + 840 / 09.2008

1

Lower suspended loads and jib to the ground.

2

Position machine horizontally.

3

Put the machine in park position. Retract support cylinders.

4

De-pressurize hydraulic system in accordance with Section 7.4.

5

Shut down engine and secure against re-starting.

6

Remove filter element of return filter acc. to Section 7.6.

7

Place a suitable container under the drain opening of the tank.

8

Close the hydraulic tank cap - if existing.

Translation of the original instructions

7-7

Hydraulic system - Changing hydraulic oil

CAUTION: Ensure that the container is large enough to hold the relevant quantity of oil.

Hydraulic oil must not be allowed to seep into the ground or water.

Dispose of waste oil and oil filters in accordance with statutory regulations.

1

9

Unscrew cover nut (1).

2 3

7-8

10

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

11

Unscrew drain plug (2).

12

Screw cover nut (1) back on.

13

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

14

Bleed the hydraulic pumps: – Clean housing.

– Slacken vent screw on the pump. Do not unscrew completely; hold in place by applying slight pressure with your thumb.

– Wait several seconds until the air has escaped.

– Re-tighten vent screw.

Translation of the original instructions

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Hydraulic system - Changing hydraulic oil

CAUTION Always bleed pumps after every hydraulic oil change before operating to prevent damage.

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Translation of the original instructions

7-9

Hydraulic system - Return filter – changing filter elements

7.6

Return filter – changing filter elements

A

1 2 3 B

6 mm

7 - 10

1

Unscrew the threaded cap (2) on the hydraulic tank.

This releases the residual pressure in the tank.

2

There are two return filters (A, B). Both filter elements must be replaced!

Unscrew the four socket head bolts (1).

3

Remove cover (3).

4

Remove filter element and dispose of as hazardous waste.

5

Clean components, check seal and replace if necessary.

6

Insert new filter element.

7

Secure cover (3) with the four socket head bolts (1).

8

Tighten screw cap (2).

Translation of the original instructions

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Hydraulic system - Auxiliary control filter - change filter element

7.7

Auxiliary control filter - change filter element

Note if the machine is fitted with the optional „HydroClean“ fine filter system there is no auxiliary control filter.

Replace filter element

1

27 mm

835 + 840 / 09.2008

2

1

Unscrew the filter housing 1.

2

Dispose of filter element (2) as hazardous waste.

3

Clean components, check seals and exchange if necessary.

4

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

5

Screw filter housing in by hand..

6

Check filter (1) for leaks.

Translation of the original instructions

7 - 11

Hydraulic system - HydroClean – superfine filtration system (Optional) - change filter element

7.8

HydroClean – superfine filtration system (Optional) - change filter element

Note The contamination of the HydroClean filter insert is monitored by the SDS. The filter insert must be changed when the relevant warning light shows.

Replace filter element

1

2

3 4 5

13 mm

36 mm

1

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

2

De-pressurize hydraulic system in accordance with Section 7.4.

3

Unscrew the cover (5) with integrated hexagon head (4).

4

Withdraw filter element.

5

Dispose of filter element (3) as hazardous waste.

6

Clean components, check seal and replace if necessary.

7

Insert new filter element.

8

Re-tighten screw cap (5).

9

Start driving engine.

10

Unscrew the socket head screw (3) somewhat until the ventilation opening becomes free.

11

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

12

Switch off drive engine and check filter for leaks.

13

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

10 mm

7 - 12

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Hydraulic system - Leak-oil filter – changing filter element

7.9

Leak-oil filter – changing filter element

1 2

17 mm

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1

Slacken hexagon nuts (1).

2

Remove cover (2).

3

Unscrew filter element (3) from return line.

4

Screw new filter element onto the return line.

5

Re-attach cover with return line to tank.

6

Tighten hexagon nuts (1).

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7 - 13

Hydraulic system - Changing ventilation filter

7.10 Changing ventilation filter Note The ventilation filter is integrated in the screw cap (2) of the filler neck.

The ventilation filter limits the over-pressure and under-pressure in the hydraulic system occurring during hydraulic operations.

CAUTION Dirty ventilation filters let dust and dirt unfiltered into the hydraulic system. This can cause damage to the hydraulic system (e.g. to the pumps) and increased hydraulic oil wear.

2

1

7 - 14

1

Open the cover plate.

2

Unscrew threaded cap (1) from the hydraulic tank.

3

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

4

Dispose of filter element (3) as hazardous waste.

5

Place new filter element on the threaded cap.

6

Replace threaded cap with ventilation filter.

7

Close the cover plate.

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Hydraulic system - Changing the ventilation filter with dehumidifying unit (Optional)

7.11 Changing the ventilation filter with dehumidifying unit (Optional)

1

3 2

Replace desiccant beads 1

Completely unscrew the dehumidifying unit (1)

2

Slacken wing nuts (2) and remove cover (3).

3

Replace the used desiccant beads (colorless) for new desiccant beads (orange).

4

Put the cover (3) on and tighten the wing nuts (2).

5

Completely bolt down the dehumidifying unit (1)

Note The desiccant beads can be regenerated in a drying oven at approximately 150 °C (302 °F).

Keep desiccant beads dry and tightly sealed and protect them from moisture.

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Hydraulic system - Checking preload pressure of pressure accumulator

7.12 Checking preload pressure of pressure accumulator Note The check of the preload pressure is indicated using the pressure accumulator of the pilot control system.

1

Lower suspended loads and jib to the ground.

2

Connect pressure gauge to the measurement port (Section 7.4).

3

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

4

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

5

Observe the pressure gauge.

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

6

Compare the indicated value with the tolerance specification on the pressure accumulator. If the preload pressure lies outside the tolerance, replace the pressure accumulator or have it refilled with nitrogen.

7

Disconnect pressure gauge.

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

7 - 16

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Hydraulic system - Pump distributor gearbox (Optional)

7.13 Pump distributor gearbox (Optional) With certain options, distribution gearboxes can be mounted on the drive unit connection.

Note Perform a daily visual inspection for leaks. An increased oil level in the gearbox or the mounting flange with its own oil filling means that the seals on the hydraulic fittings are defective.

Procedure

1

Lower suspended loads and jib to the ground.

2

Position machine horizontally.

3

Shut down engine and secure against re-starting.

4

Open the service access door on the right.

1

5

Check oil level (1): – The MIN/MAX mark applies when unscrewed (2).

– The MIN/MAX mark applies when inserted (3).

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7 - 17

Hydraulic system - Pump distributor gearbox (Optional)

2

3

7 - 18

6

Top up hydraulic oil, if required:

7

Close the service access door on the right.

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Electrical system - Batteries

8

Electrical system

DANGER Work on electrical system must be carried out by trained electrical technicians.

8.1

Batteries

Note The batteries are maintenance-free.

Special conditions of use (climatic conditions, high operating hours) as well as older batteries may require regular monitoring of the acid level in the battery.

DANGER z Explosion hazard!

No smoking or naked flames. Avoid sparks in the vicinity of the battery. z Danger of acid burns!

Wear eye protection and gloves.

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

1 2

Inspect terminals and cable connections

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1

Open left rear maintenance panel.

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8-1

Electrical system - Batteries

8-2

2

Remove battery terminal covers (1).

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

3

Clean the terminals and cable connections on the batteries.

Check for firm seating and grease with terminal grease.

4

Replace battery terminal covers.

5

Close service access door again.

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Electrical system - Fuses

8.2

Fuses

WARNING Fire hazard!

Do not repair fuses. Always insert new fuses with the same amperage rating, never higher.

If a newly inserted fuse blows again after only a short period of time, the electrical system must be inspected by a professional electrician.

1

2

Replacing fuses

1

Shut down engine and secure against re-starting.

2

Open left rear maintenance panel (1).

3

Remove fuse box (2) cover (2).

4

Replace defective fuse.

5

Check contacts, clean oxidized contacts.

6

Replace cover of fuse box (1).

7

Close service access door again.

Note Wiring, see inside of cover and electrical diagram.

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8-3

Electrical system - Switch-/symbol change

8.3

Switch-/symbol change

NOTE Switches can only be replaced as complete units.

Exception: The symbols can be removed and installed again carefully with a screwdriver.

8.4

Generator (Optional)

Note Pay attention to the information in the manufacturer's instructions.

8.4.1 Visual check Check the cabling, the MMI and the generator for visible damage, correct seating of the plug connections and dirt at least once per month.

Note Every 20,000 hours of operation, both ball bearings of the generator must be replaced.

8-4

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Electrical system - Additional displays (special equipment)

8.5

Additional displays (special equipment)

Analog operating hours counter

SDS

Tool Control

Generator and Magnet System

Auxiliary heating, Water heater

Camera

LML

CAUTION The auxiliary displays are not ever to be cleaned with alcohol or cleaning agents containing solvents. Failure to observe the above could result in damage to the plastic surface.

Note More information can be found in the operating instructions from chapter 1 Working Applications and chapter 10.

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8-5

Electrical system - Additional displays (special equipment)

8-6

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Heating/Air-conditioning system - Air conditioner

9

Heating/Air-conditioning system

9.1

Air conditioner

WARNING Remember that the coolant and the related vapors are dangerous to your health when working with the air conditioning. Wear the respective protective equipment. z Maintenance and repair work must only be carried out by trained

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

and fan disconnected. z Allow unit and components inside unit (heat exchanger, resistors)

to fully cool down before starting any maintenance work. z Freezing hazard, wear protective gloves! Avoid touching

the coolant with bare skin. z Wear eye protection! If coolant does contact your eyes however,

see a Doctor. z Danger of injury! Contact with the sharp edged fins on the

condenser and the heat exchanger. z Welding and soldering on components of the air conditioning is not

permitted! The pressure in the system is increased by the extreme heating and can cause an explosion. z Only coolant R134a is to be used in accordance with DIN 8960

(fill quantity approx. 1.7 kg (3,74 ib)). No fluorescent additives (tracer agents, sticks). z Observe filling instructions from SENNEBOGEN Maschinenfabrik-

GmbH.

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9-1

Heating/Air-conditioning system - Air conditioner

9.1.1 Visual check Check the cabling, the status of the coolant and heating lines, the condensation discharge and the filter for visible damage, the correct seating of the plug connections and dirt at least once per month.

1

1 Air conditioning system

9-2

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Heating/Air-conditioning system - Air conditioner

9.1.2 Cleaning the heating recirculating air filter Cleaning filter element

1 Handle

2

1

2 Filter element

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

835 + 840 / 09.2008

1

Pull the filter element (2) on the handle (1).

2

Beat out filter element or carefully blow out with compressed air.

3

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

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9-3

Heating/Air-conditioning system - Air conditioner

9.1.3 Cleaning the heating outside air filter Cleaning filter element

1

1 2

2

NOTE The filter element is located behind a cover on the outside of the cab!

9-4

1

Slacken bolts (1) and hold the cover.

2

Remove filter element (2).

3

Beat out filter element or carefully blow out with compressed air.

4

Insert the filter element. Ensure correct position.

5

Re-tighten bolt (1).

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Heating/Air-conditioning system - Water heating (Optional)

9.2

Water heating (Optional)

WARNING Fault!

If the "red" indicator lamp is illuminated, the coolant level is low in the water heater. The electric water heater is then deactivated by the safety shut-off.

Check coolant level.

1

2

1 Water pump 2 Built-in radiator

Note Observe the information in the manufacturer’s operating instructions.

Note The motor bearings of the water pump are enclosed and permanently lubricated!

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9-5

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

9.3

Air conditioning compressor (optional)

Note Observe the information in the manufacturer’s operating instructions as well.

WARNING During operation, surface temperatures of above 60 °C (140 °F) or under 0 °C (32 °F) can occur. Risk of severe burns!

WARNING Compressor is under pressure! Severe injuries are possible if handled incorrectly!

1

Check the oil level before putting into operation.

1 1

Oil drain screw

2

3

3 Oil filler screw

2 View glass

WARNING Use only Ester oil BSE 55 as compressor oil! Ester oils are very deliquescent, handle carefully.

An oil change is to be performed every 3 years or 10,000 hours of operation. The oil filter and magnet plugs are to be cleaned at the same time.

9-6

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Heating/Air-conditioning system - Auxiliary heating (Optional)

9.4

Auxiliary heating (Optional)

Note Observe the information in the manufacturer’s operating instructions as well.

WARNING Switch the auxiliary heating on at least once a month for approximately 10 minutes, even if heating is not required.

Before heading is required, test the auxiliary heating once (e.g. danger of smoke)

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9-7

Heating/Air-conditioning system - Auxiliary heating (Optional)

9-8

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Index

A Accessories W-2 Actuating path lubrication manually 6-2 Additional documentation W-8 after 1000 hours of operation 2-12 after 2000 hours of operation 2-15 after 250 hours of operation 2-8 after 500 hours of operation 2-10 Air filter 4-4 Air filter - moisture separator 4-6 Ambient temperature range 3-1 Annually 2-12 Antifreeze 4-13, 4-14 Axle distributor gear 3-5 B Beaufort scale 3-23 Belt drives 4-17 Bio-oils 1-8 C Central lubrication system 3-14, 3-15, 6-2 Check cable connections 8-1 Chloride 1-12 Chloride content 1-12 Chromium hydroxide 4-16 Cleaning agents 4-14 Cleaning hydraulic cylinders 7-2 Cleaning procedure 4-15 Cleaning the cooler 4-14 Conversion factors 3-24 Conversion of the machine 1-6 Coolant 4-10, 4-11 Coolant level 4-11, 4-13 Coolant R134a 9-1 Cooler 4-10 Cooling system 4-10 Copyright W-9 Customer service W-9 D Differential: 3-5 Disposal Batteries 1-25 Lubricants 1-25 Disposal Guideline 75/439/EEC 1-25 Disposal of consumables 1-25 Disposing of batteries 1-25

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Disposing of lubricants 1-25 Disposing of the oil filter 1-25 Driving earth-moving machinery 1-5 Driving engine 3-3, 3-4 E Ear protection 1-5 Effect wind 3-23 Engine Changing oil 4-3 Changing the oil filter 4-3 Checking oil level 4-2 Engine overheating 4-16 Environmental protection 1-25 Environmental regulations 1-25 every 4000 hrs run 2-15 Experts W-7 F For your own safety W-2 Foreword W-2 Fuel system 4-7 Fuel tank 3-5, 3-8, 3-9, 3-10 G Gear teeth 6-1 Gear teeth spray 6-3 going to press W-9 H Hub drive train 5-3 Hunold coolant ANF 4-10, 4-11 Hydraulic fittings 7-2 Hydraulic system: 3-5, 3-8, 3-9, 3-10 Hydraulic tank 3-5, 3-8, 3-9, 3-10 Hydraulics 3-1 I Illustration aids W-4 Inspection tools 3-11 Instructed personnel W-7 K Keyword W-4 L Labels

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S-1

Index

Clean 1-3 Limitations during wind 3-2 Lubricate the machine 3-12, 3-16 Lubricating path 6-2 Lubricating slewing ring path 6-2 Lubricating slewing ring teeth 6-3 Lubrication cycle 6-2 Lubrication intervals 6-2 Lubrication nipple 3-12, 3-15, 3-16 Lubrication nipples-overview 3-13, 3-14 Luftdruck 3-7, 5-1 M Machine Labeling 1-3 Maintaining earth moving machines 1-5 Maintenance instructions W-8 Maintenance schedule 2-1, 3-1 Manual lubrication 3-12 Manufacturing of replacement parts 1-6 Measurement connections 7-5 Monthly 2-8 N Noise protection 1-5 Noise protection measures 1-5 Notes on the operating instructions W-3 Notice signs 1-3 O Oil diagnosis 1-8 Operating personnel W-7 Operating temperature 4-14 Operator W-7 Original spare parts W-2 Other risks 1-2 Overheating 4-14

S Safety instructions 1-1, 1-2, 4-14 Sales and service partners W-9 Semi-annually 2-10 Service booklet W-8 Service partners W-9 Slewing drive 3-1 Slewing ring lubrication (optional) 6-4 Spare parts catalogue. W-8 Spare parts warehouse W-9 Special dangers 1-6 Specialist check 1-4 Specialist personnel W-7 Specialists W-7 speed of 3-2, 3-23 Strength class 10.9 3-20 Strength class 12.9 3-21 Strength classes for bolts 3-19 Sulphate content 1-12 Swivelling connection 6-1 T Target group W-8, 1-1 Technical condition 1-6 Telephone W-9 Tightening torque 3-19 Tires - Air pressure 3-7 Top up hydraulic oil 7-5 Type plate 1-3 V V-belt 4-17

P Parts W-2 Path 6-1 Personal safety equipment 1-15, 1-22 Personnel qualifications 1-5 Personnel selection 1-5 pH value 1-12 pH value, water 1-12 Plastic sliding wear pad 6-4 Pressure cylinders 7-2 Protective features 1-24

S-2

R Repair work 4-14 Replacing fuses 8-3 Reverse fan 4-15

W Warning signs 1-3 Warning symbol W-4 Warranty W-2 Water hardness 1-12 Water separator 4-8 Wear limit 6-4 Wheel nuts 3-7, 3-9 Wind forces 3-2 Wind strength 3-23

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Index

Y Year of manufacture 1-3

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S-3