Sennebogen 835 M-HD Maintenance Instruction Manual 835.0.547 - PDF DOWNLOAD

Maintenance instructions

835 M-HD

08.2004

835C

Important instructions on the operating manual

Target group

The machine has been developed for demanding work.

Persons working on or with the machine must be trained or instructed for that purpose.

Maintenance must be carried out by trained specialist personnel only.

Notes on the operating instructions

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

Keep operating instructions in a safe place for future use.

Warning!

Only work with the machine once these operating instructions have been read and completely understood.

Forbid unsafe operation or unsafe maintenance.

Do not operate machine if a fault has been detected!

The employer is responsible for the qualifications and training of the personnel.

These operating instructions are a part of the machine. Keep the operating instructions in the cab at all times.

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

In the event of sale, disposal or loan, the operating instructions must accompany the machine!

Contact SENNEBOGEN immediately if there is anything in the operating instructions which you do not understand!

Your comments will help us to make the operating instructions even more user friendly.

For reasons of clarity, the specified safety devices are not shown in some of the illustrations. Operation with safety devices removed is not permitted!

Danger Safety devices must be fitted when working with the machine.

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Important instructions on the operating manual

Symbols and illustration devices

These operating instructions contain safety notes, which highlight dangerous working practices. These safety notes are marked with a warning symbol and a keyword.

This warning symbol means: Attention - this concerns your safety and the safety of others.

The associated keyword signifies the degree of danger: Danger Is used for serious, direct 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 death may result.

Caution Is used for potentially dangerous situations. If this danger is not averted, physical injuries or serious material damage may result.

Notes which make the work easier or contribute to better understanding when operating the machine are displayed in the following way: Note Indicates notes which draw attention to peculiarities.

Note Indicates cross references to other documents.

Handling instructions are shown in table form as follows: 1

Press switch (1).

2

Actuate control lever (2).

3

Unfasten pins (3).

Listings are marked with bullet points.

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

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Important instructions on the operating manual

Please contact us at

SENNEBOGEN Maschinenfabrik GmbH Hebbelstraße 30 D-94315 Straubing Telephone:

+49 9421 540-0

Internet:

http://www.sennebogen.de

Fax Customer Service:

+49 9421 540279

Fax Spare Parts Store:

+49 9421 40811

Technical Documentation:

Current when going to press

Copyright

E-mail:

doku@sennebogen.de

Fax:

+49 9421 41425

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

© Straubing 2004, SENNEBOGEN Maschinenfabrik GmbH Reproduction, also in part, only with written permission of SENNEBOGEN Maschinenfabrik GmbH, Straubing, Germany.

Printed in Germany.

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Table of contents

0-1

1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.3 Responsibilities of the operator . . . . . . . . . . . . . . . 1-3 1.4 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 1.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

2

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

3

General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1 Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 Oils and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.3 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

4

Driving engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.2 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.3 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.3.1 Water separator . . . . . . . . . . . . . . . . . . . . . . 4-6 4.4 Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4.5 Belt drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

5

Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1 Cleaning and lubricating . . . . . . . . . . . . . . . . . . . . 5-1 5.2 Tire air pressure (pnuematic tires) . . . . . . . . . . . . . 5-1 5.3 Tightening wheel nuts . . . . . . . . . . . . . . . . . . . . . . 5-2 5.4 Hub drive train . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.5 Back gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.6 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

6

Swivelling connection . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 Lubricating slewing ring path . . . . . . . . . . . . . . . . . 6-2 6.1.1 Central lubrication system . . . . . . . . . . . . . . 6-2 6.2 Lubricating slewing ring teeth . . . . . . . . . . . . . . . . 6-3 6.2.1 Gear teeth spray . . . . . . . . . . . . . . . . . . . . . 6-3 6.2.2 Slewing ring lubrication (optional) . . . . . . . . 6-4 6.3 Tighten slewing ring bolts. . . . . . . . . . . . . . . . . . . . 6-7

835 M-HD / 08.2004

Table of contents

7

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.2 General information . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.2.1 Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . 7-2 7.2.2 Screw connections . . . . . . . . . . . . . . . . . . . 7-2 7.3 Hydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 7.4 De-pressurising hydraulic system . . . . . . . . . . . . . 7-4 7.5 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 7.6 Changing hydraulic oil . . . . . . . . . . . . . . . . . . . . . . 7-7 7.7 Return filter – changing filter elements . . . . . . . . . 7-9 7.8 Auxiliary control filter – change filter element . . . 7-10 7.9 Leak-oil filter – changing filter element . . . . . . . . 7-11 7.10 Changing ventilation filter . . . . . . . . . . . . . . . . . . 7-12 7.11 Hydro-clean superfine filter (optional) . . . . . . . . . 7-13 7.12 Checking preload pressure of pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

8

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

9

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

10 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.1 Lubrication schedule . . . . . . . . . . . . . . . . . . . . . . 10-1 10.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.3 Tightening torques for bolts . . . . . . . . . . . . . . . . . 10-3

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835 M-HD / 08.2004

Safety - General

1

Safety

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

National and international regulations apply in addition to the safety notes in these operating instructions.

In the Federal Republic of Germany e.g: Winches, Lifting and Pulling Devices (VBG 8) Crane (BGV D6) Hoisting Equipment in Lifting Appliance Operation (VBG 9a) EC Machinery Guideline (98/37/EEC) EMC Guideline 89/336/EEC Electrical Machinery Equipment (EN 60204-1) Safety Requirements for Fluid Engineering Systems and their Components - Hydraulic (EN 982) Earth-Moving Machinery – Safety (EN 474-1/-5) Safety of Machinery (DIN EN 292 -1 and DIN EN 292-2) "Outdoor" Regulation 2000/14/EG

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

835 M-HD / 08.2004

1-1

Safety - Safety instructions

1.2

Safety instructions

Warning The maintenance work described may only be carried out by trained and instructed specialist personnel.

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

Observe statutory accident prevention and safety directives.

Lower suspended loads and booms to the ground.

Pull safety lever back.

Shut down machine and secure against unauthorised re-starting before starting with maintenance work.

Attach warning sign to controls.

Smoking and handling of open flame is strictly forbidden.

Use safety-compliant access ladder aids or operating platforms.

Maintain a distance to rotating and moving parts.

Relieve hydraulic system pressure before starting maintenance work.

Dispose of hydraulic oil according to regulations.

Wear protective gloves when working on steel wire rope.

Only use genuine Sennebogen replacement parts.

Use only oils and lubricants stated in the lubricant table.

Do not lift heavy objects by hand. Use lifting gear.

Actuate battery isolator switch to interrupt the power supply.

When working near batteries these are to be covered with insulating material; do not place tools onto batteries.

Replace all safety devices on completion of maintenance work.

Keep driver's cab clean and tidy.

Carry out function check to ensure problem-free operation.

Only the crane owner or representative may approve the machine for operation following maintenance work.

For pneumatic tyres: When inflating tyres, maintain adequate safety distance and use tyre cage.

After maintenance or repair work, carry out thorough visual and function check according to operating instructions.

1-2

835 M-HD / 08.2004

Safety - Responsibilities of the operator

1.3

Responsibilities of the operator

Warning The operator is obliged to supply operating instructions when working with hazardous machines or materials.

The necessary information is contained in EC guidelines on safety at work National laws on safety at work Accident prevention regulations and these operating instructions.

Repeated checks

Specialist check The machine must be thoroughly checked by a specialist. before initial operation and before operating the machine after significant modifications at least once yearly and in between according to operating conditions and conditions of use.

A specialist in this context is a person, who has extensive knowledge of this machine and the corresponding regulations and guidelines due to specialist training and through special instructions of Co. Sennebogen and can assess the safe working condition of the machine.

Specialist check The machine must be checked by a specialist at least every four years.

The operator is responsible for having a specialist check carried out in the 13th year of operation and every year after that.

835 M-HD / 08.2004

1-3

Safety - Responsibilities of the operator

Personnel selection and qualifications

Employ only trained and instructed personnel.

Define responsibility for operation and maintenance.

Observe the permitted minimum age.

Danger Personnel under training or instruction must remain under constant supervision while working on the machine.

Work on electrical equipment of the machine may only be carried out by an electrical technician.

Work on running gear, braking and steering systems may only be carried out by specifically trained technicians!

Work on hydraulic systems may only be carried out by personnel with specific knowledge and experience of hydraulics!

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835 M-HD / 08.2004

Safety - Responsibilities of the operator

Noise protection

The permanent sound pressure level of the machine, measured from the driver's seat with the driver's cab closed, is approximately 80 dB(A). The wearing of ear protection is therefore not essential. The measurements are carried out according to 79/113 EEC, 84/532 EEC and 86/662 EEC. 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, ear protection measures are strictly specified for the operating personnel.

The employer is to ensure that appropriate ear protection is available and used by the operators.

Technical condition of the machine

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

Do not operate machine if a fault has been detected!

Observe mandatory time limits for routine checks.

Independent conversion and replacement part production

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.

Impermissible operating practices

The operating safety of the machine is only ensured if it is used according to these operating instructions.

If there is a danger of heavy objects falling, the machine may only be used if the driver's area is covered by a protective roof (FOPS).

The protective roof is optionally available from Sennebogen.

The machine is not suitable for towing a trailer.

Due to the greater axle load, trailer operation is only permitted with stronger axles (optional).

Note The performance data listed in chapter 3 TECHNICAL DATA of the operating instructions must not be exceeded.

835 M-HD / 08.2004

1-5

Safety - Responsibilities of the operator

Specific dangers

Overseas use

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.

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

Ensure that the operators have the necessary qualifications for the intended work.

Ensure that the contents of this operating manual have been read and completely understood. If necessary, ask Sennebogen for a copy of this operating manual in the corresponding language.

Dangers of noncompliance with the safety notes

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

Fire extinguisher and first aid box (optional)

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

Non-compliance with the safety notes invalidates all claims for compensation.

1 Warranty conditions

2

The warranty conditions of Sennebogen Maschinenfabrik GmbH are summarised in the warranty manual.

You will also find an extract from the warranty conditions in the operating instructions (chapter 10).

1-6

835 M-HD / 08.2004

Safety - Safety devices

1.4

Safety devices

Danger Do not remove safety devices or covers.

Always check that safety devices are complete and correctly secured before starting the machine.

Replace all safety devices and covers correctly on completion of assembly or maintenance work.

Exchange damaged safety devices for new ones.

835 M-HD / 08.2004

1-7

Safety - Disposal

1.5

Disposal

Cleaning and lubricating materials Caution Observe environment protection!

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

Extract from the Disposal Guideline 75/439/EWG: “It is prohibited to mix spent oil with other waste.”

“Spent oils must not be mixed together.”

“Used oil filters must be collected, kept, transported and disposed of separately from other waste.”

Notes Lubricants and other consumables must be disposed of at suitable collection points.

National environmental conditions valid in the country of use also apply.

Batteries

Observe safety and protective measures when handling batteries.

Notes Do not dispose of batteries in a domestic waste facility!

Dispose of defective batteries at a recollection point for spent batteries.

National environmental conditions valid in the country of use also apply.

1-8

835 M-HD / 08.2004

Maintenance schedule

2 Safety instructions

Maintenance schedule

Observe the safety notes before starting work.

Warning The maintenance work described may only be carried out by trained and instructed specialist personnel.

Wear personal protection equipment (e. g. safety helmet, ear protection, protective gloves, safety boots).

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

Task

– Carry out visual and functional check according to operating manual.

– Cab – cab mounting: check pin and screw connections.

– Check all detachable fastenings : (screws, cotter pins, etc.) for tightness.

– Pipe fracture safety device: visually check for damage and tightness.

– Hydraulic cylinder: visually check for damage and tightness.

– Check engine oil level.

Observe intervals acc. to operating instructions of engine manufacturer.

– Hydraulic system: check oil level.

– Check SDS display for Hydro Clean micro-filter.

– Lubricate slewing ring.

– Check SDS display for air filter insert.

– Check water separator for fuel system.

– Initiate pinion lubrication.

– Check coolant level; if necessary clean cooling fins.

835 M-HD / 08.2004

every 10 hrs run / daily

every 50 hrs run / weekly

once every 250 hrs run

every 500 hrs run / 3months

every 1000 hrs run / yearly

every 2000 hrs run / 2 years

Section

4.1

7.5 7.11 6 4.2 4.3 6.2.2 4.4

2-1

Maintenance schedule

Task

every 10 hrs run / daily

every 50 hrs run / weekly

once every 250 hrs run

every 500 hrs run / 3months

every 1000 hrs run / yearly

every 2000 hrs run / 2 years

Section

– Central lubrication system: 6.1.1 check to make certain it is filled.

6.2.2 – Pinion lubrication: check to make certain it is filled.

– Check and clean hydraulic oil cooler.

– For pneumatic tires: 5.2 Check tire air pressure.

5.3 – Tighten the wheel nuts 5.4 – Check hub drive train oil level.

5.6 – Check differential oil level.

6 – Swiveling connection: visually check all connecting elements for damage and corrosion 8.1 – Check cable connections of batteries and fuses.

9.1 – Check heating filter.

10.1 – Lubricate the machine.

– Check tightness of all screw fastenings.

– Tighten slewing ring bolts.

6.3 1) 1) 1) 1) 7.12 – Have preload pressure of hydraulic accumulator checked by hydraulic specialist company 1).

1) after 250 hrs run / 6 weeks and after 500 hrs run / 3 months; then every 1000 hrs run / yearly – Observe engine intervals.

– Check load-holding: Raise load (approx. 1 t), boom must not drop. Should the boom drop, inform Sennebogen Customer Service immediately!

– Check antifreeze.

4.4 5.5 – Check oil level of both back gears.

7.7 – Change filter element of return filter.

7.9 – Leak-oil filter – change filter element.

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835 M-HD / 08.2004

Maintenance schedule

every 10 hrs run / daily

Task

– Shut-off flap – hydraulic tank (optional): Visually check tightness – Change filter element of pilot filter (where present).

– Hub drive train: change oil.

– Back gear: change oil.

– Differential: change oil.

– Tighten slewing ring bolts 2).

every 50 hrs run / weekly

once every 250 hrs run

every 500 hrs run / 3months

every 1000 hrs run / yearly

every 2000 hrs run / 2 years

Section

7.8

2)

2)

2)

5.4 5.5 5.6 6.3

2)

– – –

– –

– – – –

–

once after 250 hrs run / 6 weeks; then every 2000 hrs run / yearly Slewing ring bolts examine with suitable means for tightness.

Water separator: 4.3.1 Change filter element Shut-off flap – hydraulic tank: Visually check for dirt and damage, where present.

Charge air cooling system - drain out water from condensation.

Heating / Air condition (optional): 9 Checked by authorized specialist company.

4.2 Change exchange cartridge and safety cartridge in air filter.

7.10 Change the ventilation filter on the hydraulic tank.

4.4 Change coolant.

3) 3) 7.6 Hydraulic system: change oil.

3) If necessary, have oil checked on the basis of an oil diagnosis carried out by SENNEBOGEN customer service.

4) 6 Check or change slewing ring bolts 4) 4) every 5000 hrs run / 5 years Note: Testing must be performed by an expert from an independent specialist company / independent institute.

Unrestricted use of the slewing ring bolts must be proven by means of a certificate.

The slewing ring bolts must be changed otherwise.

835 M-HD / 08.2004

2-3

Maintenance schedule

2-4

835 M-HD / 08.2004

General notes - Cleaning work

3

General notes

3.1 Cleaning work Notes Ensure that the cleaning agents used do not damage the seals and components of the machine.

Do not use aggressive cleaning agents.

Only use lint-free cleaning cloths.

Only use dry, filtered compressed air up to max. 2 bar.

On completion of cleaning work, carry out a visual and functional check of the machine acc. to section 4.3 (in the machine operating instructions).

Warning The electrical system is deck watertight acc. to IP65. Electrical and electronic components must still not be sprayed with a high pressure cleaner (steam cleaner).

Water ingress can otherwise damage the machine electronics. This can result in sudden, uncontrolled operating movements.

835 M-HD / 08.2004

3-1

General notes - Oils and lubricants

3.2

Oils and lubricants

Only use oils and lubricants approved by Sennebogen. These are listed in LUBRICANTS TABLE. The ambient temperature range for operating the machine can be between - 20 °C and +40 °C. If the temperature at the site lies outside these values, discuss this with Sennebogen customer service before starting operation.

Oil diagnosis

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

Further information is available from Sennebogen customer service.

Biologically degradable oils and lubricants

Use is expressly specified as leakage of mineral-based oils and lubricants presents a danger to the environment. The use of environmental-friendly lubricants is above all mandatory 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.

3-2

835 M-HD / 08.2004

General notes - Welding work

3.3

Welding work

WARNING Welding work must only be carried out by an authorised and qualified welding specialist.

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 Cover vulnerable components with fireproof material.

Preliminary work

835 M-HD / 08.2004

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

1

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

2

Disconnect battery.

3

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

3-3

General notes - Welding work

3-4

835 M-HD / 08.2004

Driving engine -

4 Safety notes

Driving engine

Read the safety notes before starting work.

Caution Only carry out maintenance or repair work with engine shut down and cooled.

Secure machine against unauthorised re-starting before starting with maintenance work.

Waste oil must not ingress ground or waterways.

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

Coolant must not ingress ground or waterways.

Dispose of coolant in accordance with statutory regulations.

After maintenance work on the engine, check that all safety devices have been fitted and all tools are removed from the engine.

Note Also observe the notes and recommendations in the operating instructions of the engine manufacturer.

835 M-HD / 08.2004

4-1

Driving engine - Engine oil

4.1

Engine oil

Warning Danger of scalding!

Proceed with utmost caution when draining hot oil.

Waste oil must not ingress ground or waterways. Dispose of oil and oil filters in accordance with statutory regulations.

Note Also observe the notes in the operating instructions of the engine manufacturer.

Engine oil level - check

Changing engine oil and oil filter

4-2

1

Position machine horizontally.

2

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

3

Shut down driving engine.

4

Open right maintenance hatch.

5

Pull out oil dipstick and wipe off using a clean, fiber-free cloth.

6

Insert oil dipstick up to stop and pull out again.

7

Check oil level: The oil level must lie between the lower marking (MIN) and the upper marking (MAX).

8

Top up motor oil if necessary.

1

Warm up engine.

2

Position machine horizontally.

3

Open right service access doors.

4

Change engine oil and oil filter according to the operating instructions of the engine manufacturer.

5

Check oil level: The oil level must lie between the lower marking (MIN) and the upper marking (MAX).

6

Top up motor oil if necessary.

835 M-HD / 08.2004

Driving engine - Air filter

4.2 Safety notes

Air filter

Read the safety notes before starting work.

Caution Never use gasoline, soap or hot liquids to clean the air filter Never use compressed air to clean the housing interior, 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 situated under the service flap.

1 Locking clamp 2 Service flap

1

3 Handle 4 Air filter

2

3 4

835 M-HD / 08.2004

4-3

Driving engine - Air filter

4 5

6

4 Air filter cap 5 Locking clamp 6 Dust discharge valve 7

7 Exchange cartridge 8 Safety cartridge 9 Shackle 8

4-4

9

835 M-HD / 08.2004

Driving engine - Air filter

Cleaning

835 M-HD / 08.2004

1

Open the two locking clamps (1) on the service flap (2), front right, and lift up the service flap by the handle (3).

2

Open the locking clamps (5) of the air filter cap (4) and remove the air filter cap (4).

3

Press dust discharge valve (6) on the cover together to empty it.

4

Remove replacement cartridge (7).

5

Clean exchange cartridge (7): – Blow out from inside to outside using dry compressed air (max. 2 bar).

– Only beat out if unavoidable!

6

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

7

Exchange safety cartridge (8) after 5 filter services (at least every 2 years): – Lift the yellow shackle (9) – and remove the safety carriage.

Never clean safety cartridge (6)!

– Insert new safety carriage.

8

Insert new or cleaned exchange cartridge (7).

9

Fit cover (4) so that dust discharge valve (4) points downwards and/or with the “TOP” mark at the top.

10

Reattach the air filter cap (4) with the locking clamps (5).

11

Re-close service flap (2) and locking clamps (1).

4-5

Driving engine - Fuel system

4.3 Safety notes

Fuel system

Read the safety notes before starting work.

Warning Danger of injury through rotating parts!

Only carry out maintenance work with driving engine shut down and cooled down cooling system.

Do not handle open flames when working on the fuel system! No smoking!

Also observe the notes in the operating instructions of the engine manufacturer.

4.3.1 Water separator 1 2 3 4 5 7

6

7

1 Bleed screw

5 Bowl

2 Spring casing

6 Drainage tap

3 Hexagonal bolt

7 Shut-off valve

4 Filter element

4-6

835 M-HD / 08.2004

Driving engine - Fuel system

Drain off water

Replace filter element

1

Close the shut-off valve (7) in the tank line.

2

Open vent screw (1) and drainage tap (6).

3

Remove water and dirt from the bowl (5).

4

Close vent screw (1) and drainage tap (6) again.

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

1

Close shut-off valve (7).

2

Slacken hexagonal bolts (3) and remove cover.

3

Remove spring casing (2) and filter element (4).

4

Insert new filter element and spring casing (2).

5

Check cover seal, exchange if necessary.

6

Re-secure cover with hexagonal bolts (3).

7

Open shut-off valve (7).

8

Open vent screw (1).

9

Use the manual pump (8) to pump fuel into the water separator until it starts to leak out of the vent screw.

10

Re-close vent screw (1).

8

835 M-HD / 08.2004

4-7

Driving engine - Cooler

4.4 Safety notes

Cooler

Read the safety notes before starting work.

Warning Danger of injury through rotating parts and through scalding!

Only carry out maintenance work with driving engine shut down and cooled down cooling system.

Coolant must not ingress ground or waterways. Dispose of coolant in accordance with statutory regulations.

Mixing of nitrite-based cooling system protective agents with aminebased agents produces health-hazardous nitrosamine.

Coolant level indicator lamp

The coolant level is monitored by a sensor.

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

Cleaning cooler

1

4-8

1

Allow driving engine and cooler (1) to cool down.

2

Open service flap.

3

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

4

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

5

Check cooler for leaks and damaged cooling fins.

835 M-HD / 08.2004

Driving engine - Cooler

Check coolant level and/or antifreeze

2 1

Allow driving engine and cooler to cool down.

2

Open upper service cover.

3

Carefully open sealing cap (2) of cooler expansion tank in the engine compartment to allow the pressure to equalise.

4

Check antifreeze and coolant level, top up if necessary.

Mixing ratio: 50% antifreeze, 50 % water. Frost resistant up to -40 °C.

Note To change the coolant, follow the guidelines in the engine manufacturer’s operating instructions.

835 M-HD / 08.2004

4-9

Driving engine - Belt drives

4.5 Safety notes

Belt drives

Read the safety notes before starting work.

Danger Only carry out maintenance work with drive engine shut down and stationary.

Shut down machine and secure against unauthorised re-starting before starting with maintenance work.

Replace protective covers after maintenance work if applicable.

Make sure that the V-belts run in parallel.

Note To check, tension and change the belt drives, observe the notes in the operating instructions of the engine manufacturer.

4 - 10

835 M-HD / 08.2004

Undercarriage - Cleaning and lubricating

5

Undercarriage

Warning Danger of injury through rotating parts!

Only carry out maintenance work with driving engine shut down.

Oil must not ingress ground or waterways.

Dispose of waste oil in accordance with statutory regulations.

5.1 Cleaning and lubricating 1

Position machine horizontally.

2

Shut down driving engine.

3

Clean tires and running gear using a steam cleaner.

4

Lightly grease guides and pins.

5

Lubricate all lubrication points (see Section 10.1).

5.2 Tire air pressure (pnuematic tires) Danger When pumping up tyres, maintain adequate safety distance and use tyre cage.

Tyre size

835 M-HD / 08.2004

Air pressure bar

psi

10.00-20

7.5

108.78

12.00-20

9

130.53

12.00-24

10

145.04

395/85

8.5

123.28

5-1

Undercarriage - Tightening wheel nuts

5.3

Tightening wheel nuts

Check tightness of all wheel nuts. The tightening torque is 650 Nm. Use a torque wrench.

5.4 Hub drive train

1

2 1 Oil filler screw 2 Oil drainage screw

Checking oil level

5-2

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.

835 M-HD / 08.2004

Undercarriage - Hub drive train

Changing oil

835 M-HD / 08.2004

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 (3). For capacities, see Section 10.2.

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 (2).

11

Re-tighten oil filler screw (1).

12

Repeat procedure on the three remaining hubs.

13

Re-check oil level after 2 hours run.

5-3

Undercarriage - Back gear

5.5

Back gear

3 2 1

Checking oil level

Changing oil

5-4

1

Bring machine up to operating temperature.

2

Position machine horizontally.

3

Switch off driving engine. Wait approx. 10 minutes for the oil to collect in back gear.

4

Clean exterior of back gear using a cloth.

5

Screw out oil level control screw (2). The oil level must reach up to lower edge of control opening.

6

Screw out oil filler screw (3) and top up oil if necessary.

7

Clean components, check seal and exchange if necessary.

8

Re-tighten oil filler screw (3).

1

Bring machine up to operating temperature.

2

Position machine horizontally.

3

Switch off driving engine. Wait approx. 10 minutes for the oil to collect in back gear.

4

Clean exterior of back gear using a cloth.

5

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

6

Place a suitable collecting vessel under the oil drainage screw (1). For capacities, see Section 10.2.

7

Unscrew oil drainage screw (1) and collect the waste oil in the container.

8

Clean components, check seals and exchange if necessary.

9

Re-tighten oil drainage screw (1).

835 M-HD / 08.2004

Undercarriage - Differential

10

Screw out oil filler screw (3).

11

Screw out oil level control screw (2).

12

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

13

Re-tighten oil level control screw (2).

14

Re-tighten oil filler screw (3).

15

Re-check oil level after 2 hours run.

5.6 Differential

2

1

Checking oil level

835 M-HD / 08.2004

1

Bring machine up to operating temperature.

2

Position machine horizontally.

3

Switch off driving engine. 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 exchange if necessary.

7

Re-tighten oil filler screw (2).

5-5

Undercarriage - Differential

Changing oil

5-6

1

Bring machine up to operating temperature.

2

Position machine horizontally.

3

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

4

Clean exterior of differential using a cloth.

5

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

6

Place a suitable collecting vessel under the oil drainage screw (1). For capacities, see Section 10.2.

7

Unscrew oil drainage screw (1) and collect the waste oil in the container.

8

Clean components, check seals and exchange if necessary.

9

Re-tighten oil drainage screw (1).

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 (2).

13

Re-check oil level after 2 hours run.

835 M-HD / 08.2004

Swivelling connection -

6

Swivelling connection

Ensure that the swivelling connection is well lubricated.

Path (1): – via central lubrication system.

Gear teeth (2): – with gear teeth spray or – via slewing ring lubrication (optional).

1 Path 1

835 M-HD / 08.2004

2

2 Gear teeth

6-1

Swivelling connection - Lubricating slewing ring path

6.1

Lubricating slewing ring path

6.1.1 Central lubrication system The central lubrication system automatically lubricates the slewing ring path. 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, in the tropics, when humidity is high, under very dusty and dirty conditions, when temperatures change dramatically, when subject to continuous swinging movement.

1

2

1 Lubricant containers 2 Lubricator nipple – replenish grease

Actuating path lubrication manually

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

1

6-2

Actuate the switch on the right of the control panel:

835 M-HD / 08.2004

Swivelling connection - Lubricating slewing ring teeth

6.2

Lubricating slewing ring teeth

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

6.2.1 Gear teeth spray

835 M-HD / 08.2004

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.

6-3

Swivelling connection - Lubricating slewing ring teeth

6.2.2 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

835 M-HD / 08.2004

Swivelling connection - Lubricating slewing ring teeth

Check plastic sliding wear pad

28 mm

1

2

Warning Before checking the plastic sliding wear pad (2): Lower suspended loads and booms to the ground.

Pull safety lever back.

Shut down machine and secure against unauthorised re-starting before starting with maintenance work.

Attach warning sign to controls.

835 M-HD / 08.2004

1

Dismantle lubrication assembly (1).

2

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

3

Exchange plastic wear pad if necessary.

6-5

Swivelling 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.

835 M-HD / 08.2004

Swivelling connection - Tighten slewing ring bolts.

6.3

Tighten slewing ring bolts.

Danger Risk of fatality!

Defective slew ring bolts can lead to the upper structure tipping over.

Therefore observe the service intervals without fail!

Re-tighten slewing ring bolts using torque wrench.

Observe tightening torque in accordance with Section 10.3!

Check or change slewing ring bolts every 5000 hrs run / every 5 years.

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

Unrestricted use of the slewing ring bolts must be proven by means of a certificate.

The slewing ring bolts must be changed otherwise.

Corroded or damaged bolts can shear and lead to the upper structure tipping over.

Do not tighten corroded or damaged bolts, replace immediately with new bolts!

Adhere without fail to the number and diameter of locking bolts.

Only use genuine SENNEBOGEN spare parts!

Contact SENNEBOGEN customer services if you have any further queries.

835 M-HD / 08.2004

1

Shut down driving engine.

2

Re-tighten slewing ring bolts crosswise using torque wrench.

6-7

Swivelling connection - Tighten slewing ring bolts.

Notes 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

835 M-HD / 08.2004

Hydraulic system - Safety notes

7

Hydraulic system

7.1 Safety notes Observe the safety notes before starting work on hydraulic system.

Danger Work on hydraulic systems may only be carried out by trained personnel with special knowledge and experience on hydraulics.

Wear personal safety equipment (e.g. safety helmet, ear protection, protective gloves, safety boots).

Warning of 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 when a leak occurs.

Only carry out work on a de-pressurised hydraulic system!

De-pressurise hydraulic system before starting retrofitting work (see Section 7.4).

The pilot control is equipped with a pressure accumulator, which remains under high pressure even after the engine is shut down.

Therefore, de-pressurise the pressure accumulator.

Danger of injury!

If leaks are present hydraulic oil will leak out under high pressure.

Hydraulic oil will leak out under high pressure, penetrate the skin and cause severe damage to health.

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

835 M-HD / 08.2004

7-1

Hydraulic system - General information

7.2

General information

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

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

Cleaning hydraulic cylinders: Do not use sharp edged tools, caustic fluids or abrasives.

Wash down piston rods regularly with steam cleaner. Do not direct the jet straight at the sealing elements.

Apply preservative to extended piston rods after cleaning. This protects the surface from the effects of environment and weather.

7.2.2 Screw connections Check hydraulic screw connections and couplings regularly for leaktightness. 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 screw connections immediately at both sides with plugs.

7-2

835 M-HD / 08.2004

Hydraulic system - Hydraulic lines

7.3 Storage and duration of use

Hydraulic 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.

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

Check

Hose lines should be inspected by a specialist technician at least once a year to ensure that they are functioning correctly.

Remedy any defects discovered immediately.

Defects

Replace hose lines in the following cases (see also DIN 20 066): Outer layer damaged as far as reinforcement (e.g. abrasion points, cuts, cracks); Outer layer brittle (cracks appearing in hose material); 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); Leaks; Hose fittings damaged or deformed (sealing function affected); Hose has separated from fittings; Corrosion of fittings which reduces function and strength; Installation requirements ignored; Storage times and/or service life exceeded.

835 M-HD / 08.2004

7-3

Hydraulic system - De-pressurising hydraulic system

7.4

De-pressurising hydraulic system

De-pressurize the hydraulic system as follows: 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 releases the pressure of the main hydraulics and the pressure in the pilot control pressure accumulator.

4

Pump the brake pedal several times. This releases the pressure in the pressure accumulator.

5

Open and close the parking brake. This releases the pressure in the pressure accumulator.

6

Activate the rotary selection switch for travel speed several times. This releases the pressure in the pressure accumulator.

1 2

7-4

7

Lift cover (1).

8

Open screw cap (2) of hydraulic tank.

This releases the residual pressure in the tank.

835 M-HD / 08.2004

Hydraulic system - De-pressurising hydraulic system

9

Connect pressure gauge (up to max. 600 bar) to the measuring connectors (P1, P2, P3, P4, PV9).

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

835 M-HD / 08.2004

7-5

Hydraulic system - Checking oil level

7.5

Checking oil level

1

Lower suspended loads and jib to the ground.

2

Position machine horizontally.

3

Fully retract all hydraulic cylinders.

4

Shut down driving engine.

5

Open right maintenance hatch.

1

6

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

2 3

7

7-6

Top up hydraulic oil, if required: – Lift cover (2).

– Unscrew screw cap (3) of oil filler neck.

– Top up hydraulic oil and re-check.

– Re-tighten screw cap (3).

– Re-close cover (2).

835 M-HD / 08.2004

Hydraulic system - Changing hydraulic oil

7.6 Safety notes

Changing hydraulic oil

Observe the safety notes before starting work on hydraulic system.

Danger Warning of high oil pressure!

The hydraulic system is subject to high pressure.

When a hydraulic connector is loosened, escaping hydraulic oil can cause serious injury.

Only carry out work on a de-pressurised hydraulic system!

Only trained specialist technicians with specific knowledge and experience of hydraulics may work on the hydraulic system.

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

Use the opening of the return filter for this.

Procedure

1

Lower suspended loads and jib to the ground.

2

Position machine horizontally.

3

Fully retract all hydraulic cylinders.

4

De-pressurise hydraulic system acc. to Section 7.4.

5

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

6

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

For capacities, see Section 10.2.

Caution Ensure that the container is large enough to hold the volume of oil.

Hydraulic oil must not ingress ground or waterways.

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

1

7

835 M-HD / 08.2004

Unscrew cover nut (1).

7-7

Hydraulic system - Changing hydraulic oil

2 3

8

Screw in drain plug (2) until the waste oil emerges via the plastic hose (3). Collect waste oil in a suitable container.

9

Screw out drain plug (2).

10

Screw cover nut (1) back on.

11

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

12

Bleed hydraulic pump: – Clean housing.

– Slacken vent screw on the pump. Do not fully unscrew, hold with light thumb pressure.

– Wait several seconds until the air has escaped.

– Re-tighten vent screw.

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

7-8

835 M-HD / 08.2004

Hydraulic system - Return filter – changing filter elements

7.7

Return filter – changing filter elements B

3

A

2

1

835 M-HD / 08.2004

1

Open screw cap (1) of hydraulic tank.

This releases the residual pressure in the tank.

2

There are two return filters (A, B). Change both!

Unscrew the four socket head bolts (2).

3

Remove cover (3).

4

Remove filter element and dispose of as hazardous waste.

5

Clean components, check seal and exchange if necessary.

6

Insert new filter element.

7

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

8

Tighten screw cap (1).

7-9

Hydraulic system - Auxiliary control filter – change filter element

7.8

Auxiliary control filter – change filter element

Note If the machine is fitted with the optional “hydro-clean” fine filter system there is no auxiliary control filter.

1

2

7 - 10

1

Unscrew 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 for leaks.

835 M-HD / 08.2004

Hydraulic system - Leak-oil filter – changing filter element

7.9

Leak-oil filter – changing filter element

2

1

1

Slacken hexagonal nuts (1).

2

Remove cover (2).

3

835 M-HD / 08.2004

3

Unscrew filter element (3) from return pipe.

4

Screw new filter element to the return pipe.

5

Insert cover with return pipe in tank.

6

Tighten hexagonal nuts (1).

7 - 11

Hydraulic system - Changing ventilation filter

7.10 Changing ventilation filter Note The ventilation filter is integrated in the screw cap (2) of the filler strainer. The ventilation filter limits the over-pressure and underpressure 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.

1

2

2 3

7 - 12

1

Lift cover (1).

2

Open screw cap (2) of hydraulic tank.

3

Remove filter element (3) from the screw cap (2).

4

Dispose of screw cap (3) as hazardous waste.

5

Place new filter element (3) onto the screw cap (2).

6

Screw on screw cap (2) with new ventilation filter (3).

7

Re-close cover (1).

835 M-HD / 08.2004

Hydraulic system - Hydro-clean superfine filter (optional)

7.11 Hydro-clean superfine filter (optional) Note The dirt of the hydro-clean filter insert is monitored by the SDS. The filter insert must be changed when the warning light is shown.-

Change filter element

1 3

2

835 M-HD / 08.2004

1

De-pressurise hydraulic system acc. to Section 7.4.

2

Unscrew cover (2) with integrated socket head.

3

Pull out filter element.

4

Dispose of filter element as hazardous waste.

5

Clean components, check seal and exchange if necessary.

6

Insert new filter element.

7

Re-tighten screw cap (2).

8

Start driving engine.

9

Unscrew socket head bolt (3) slightly until vent opening is open.

10

Re-close socket bolt (3) as soon as oil leaks out.

11

Deposit driving engine and check filter for leaks.

7 - 13

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 measuring bar.

3

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

4

Move the two control levers in the cab several times in all directions.

5

Observe 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 before the pressure drop equates to the preload pressure in the pressure accumulator.

6

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

7

Disconnect pressure gauge.

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

7 - 14

835 M-HD / 08.2004

Electrical system - Batteries

8

Electrical system

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

8.1 Batteries Danger Explosion hazard!

Smoking and handling of open flame is forbidden. Avoid sparks in vicinity of the battery.

Danger of acid burns!

Wear eye protection and gloves.

Do not tilt battery. Battery electrolyte is caustic and must not come into contact with eyes or skin.

Do not lay tools on the battery.

Disconnect battery before starting welding work.

Do not interchange battery connections.

Dispose of old batteries as hazardous waste.

Check terminals and cable connections of batteries:

835 M-HD / 08.2004

1

Open service flap, front right (see Section 4.2).

2

Clean battery (2) terminals and cable connections.

Check for tightness and preserve with terminal grease.

8-1

Electrical system - Fuses

8.2

Fuses

Danger Fire hazard!

Do not repair fuses. Always insert new fuses with the same ampere value.

1

1

Shut down engine.

2

Remove fuse box cover.

3

Replace defective fuse.

4

Check contacts, clean oxidized contacts.

5

Replace cover of fuse box.

Note Wiring, see inside of cover and electrical diagram.

8-2

835 M-HD / 08.2004

Heating/air-conditioning system - Heating

9

Heating/air-conditioning system

9.1 Heating Cleaning filter element 1 2

1

Unscrew knurled bolts (1) behind driver's seat.

2

Remove cover (2).

3

835 M-HD / 08.2004

3

Remove filter element (3).

4

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

5

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

9-1

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

9.2

Air conditioner (optional)

Warning Maintenance and repair work must only be carried out by trained specialist personnel.

Do not reach inside the unit and do not insert objects.

Only carry out maintenance work with driving engine shut down and fan disconnected.

Danger of burns!

Allow unit and components inside unit (heat exchanger, resistors) to fully cool down first.

Avoid contact with refrigerant.

Wear eye protection.

Always use PAG oil for compressor. No ester-based oils.

No fluorescing additives (tracer agent, sticks).

9-2

835 M-HD / 08.2004

Appendix - Lubrication schedule

10 Appendix 10.1Lubrication schedule

Lubrication via: Central lubrication system (optional) On the standard versions without optional central lubrication system, lubrication nipples are fitted at the lubrication points.

Lubrication nipple The lubrication nipples are provided with a red protective cap.

835 M-HD / 08.2004

10 - 1

Appendix - Capacities

10.2 Capacities The following values are guidelines. The level specified on the corresponding components is authoritative.

Subassembly

Capacity

Driving engine

see manufacturer's instructions

Fuel tank

approx. 500 l

Hydraulic tank

approx. 300 l

Hydraulic system, complete

approx. 360 l

Differential front

approx. 44.5 l

rear

approx. 35.0 l

Back gear front

approx. 1.2 l

rear

approx. 1.2 l

Hub drive train

10 - 2

front

approx. 3.5 l

rear

approx. 3.5 l

Slewing ring gear teeth

as required

Slewing ring lubrication (optional)

as required

Central lubrication system

as required

Lubrication points

as required

835 M-HD / 08.2004

Appendix - Tightening torques for bolts

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

Strength class 8.8

835 M-HD / 08.2004

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

10 - 3

Appendix - Tightening torques for bolts

Strength class 10.9

10 - 4

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

835 M-HD / 08.2004

Appendix - Tightening torques for bolts

Strength class 12.9

835 M-HD / 08.2004

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

10 - 5

Appendix - Tightening torques for bolts

10 - 6

835 M-HD / 08.2004

Index

A Actuating path lubrication manually 6-2 Air filter 4-3 Antifreeze 4-9 B Belt drives 4-10 Bio-oils 3-2 C Capacities 10-2 Central lubrication system 6-2, 10-1 Checking hydraulic oil level 7-6 Cleaning hydraulic cylinders 7-2 Constant sound-pressure level 1-5 Conversion of the machine 1-5 Coolant 4-8 Coolant level 4-8, 4-9 Cooler 4-8 Cooling system 4-8 Customer Service W-4 D De-pressurizing hydraulic system 7-4 Disposal 1-8 Batteries 1-8 Consumables 1-8 Lubricants 1-8 E Engine Changing oil 4-2 Changing oil filter 4-2 Checking oil level 4-2 Environmental guidelines 1-8 environmental protection 1-8 F Fire extinguisher 1-6 First aid box 1-6 FOPS protective roof 1-5 Fuel system 4-6

835 M-HD / 08.2004

G Gear teeth 6-1 Gear teeth spray 6-3 H Hub drive train 5-2 Hydraulic screw connections 7-2 I Impermissible operating practices 1-5 International regulations 1-1 K Keyword W-3 L 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 10-1 M Maintenance schedule 2-1 Measurement connections 7-5 N National regulations 1-1 Noise protection 1-5

R Responsibilities of the operator 1-3 reverse fan 4-8 S Safety notes 1-2 Safety regulations 1-6 Service flap 4-3 Slewing ring lubrication (optional) 6-4 Spare parts manufacture 1-5 Spare Parts Store W-4 Specialist check 1-3 Strength classes for bolts 10-3 Swivelling connection 6-1 Symbols and illustration devices W-3 T Technical condition 1-5 Telephone W-4 Tightening torque 10-3 Top up hydraulic oil 7-6 V V-belt 4-10 W Warning symbol W-3 Warranty conditions 1-6 Warranty manual 1-6 Water separator 4-6 Wear limit 6-4

O Oil diagnosis 3-2 Oil filler strainer 7-6 Overseas use 1-6 P Path 6-1 Personal safety equipment 1-2 Personnel selection 1-4 Plastic sliding wear pad 6-4 Pressure cylinders 7-2 Protective roof (FOPS) 1-5

S-1