Sennebogen 835 Operating Instruction Manual 835.0.1133 - PDF DOWNLOAD

OPERATING INSTRUCTIONS Type (Model) 835

835 / 01.2009

Translation of the original operating instructions

from 835.x.1101

Important instructions on the operating manual

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

z 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.

Notes on the operating instructions

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

Translation of the original operating instructions

835 / 01.2009

Important instructions on the operating manual

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: Stowing 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 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. z Maintenance of the machine is described in separate instructions.

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

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Important instructions on the operating manual

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, 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 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 specific features Note Indicates cross-references to other documents.

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

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

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 instructions on the operating manual

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, VDERegulations, VBG) as to be able to judge the operational safety of the machine. z Experts

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

Authorizations can be limited to parts of tests or specified crane types.

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Important 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.

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

Which documentation belongs with the machine?

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

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

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835 / 01.2009

Important instructions on the operating manual

How are the instructions organized?

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

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

The main components of the machine are shown here. z 3: Technical data

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

This chapter contains notes on daily machine maintenance and startup. z 5: Operation

This chapter contains the information on the operational elements and operation of the unit. z 6: Transportation

Dimensions and weights of the machine are found here. z 7: Troubleshooting

This chapter contains notes on recognizing the causes of faults and how to correct them. z 8: Setup work

This chapter gives information on optional tools. z 9: Appendix

Here you will find an index of key words and additional information, e. g. about the magnet system.

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Important instructions on the operating manual

How to contact us

SENNEBOGEN Maschinenfabrik GmbH Hebbelstraße 30 D-94315 Straubing Telepho ne:

+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 2009, 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

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1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.3 Potential instances of misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.4 Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1.5 Other risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1.6 Machine Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1.6.1 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1.6.2 CE stamp of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1.6.3 Euro-test identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1.6.4 Warning and notice labels . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 1.7 Responsibilities of the operator . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 1.8 Supplementary and operational equipment . . . . . . . . . . . . . . . . . 1-18 1.8.1 SENNEBOGEN-Diagnostic-System (SDS) . . . . . . . . . . . 1-18 1.8.2 Oils and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 1.8.3 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 1.8.4 Fuel (not with electric motors) . . . . . . . . . . . . . . . . . . . . . 1-25 1.9 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 1.9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 1.9.2 Safe entry and exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 1.9.3 Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36 1.9.4 Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36 1.9.5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37 1.9.6 Operation/Driving operation . . . . . . . . . . . . . . . . . . . . . . . 1-38 1.9.7 Setup work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39 1.9.8 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40 1.9.9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41 1.9.10 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44 1.10 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 1.11 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46 1.12 Hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47

2

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1 Complete machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.2 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.3 Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.3.1 Side views with electric motor . . . . . . . . . . . . . . . . . . . . . . 2-6 2.3.2 View from above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2.3.3 Central electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2.3.4 Electrical control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

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Table of contents

2.4 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2.4.1 Compact boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2.4.2 Pipe fracture safety devices . . . . . . . . . . . . . . . . . . . . . . . 2-11 2.4.3 Attachments and Vario Tool (optional) . . . . . . . . . . . . . . . 2-12

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3

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 Driving engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.2.1 Type 835 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.3 Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.4 Machine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.5 Machine weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.6 Lifting capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3.6.1 Kin I, K16, compact boom 9,1m and 6,9m arm . . . . . . . . . 3-8 3.6.2 Kin I, K16, compact boom 9,1m and 6,9m arm . . . . . . . . . 3-9 3.7 Lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3.7.1 Machine - Mobile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3.8 Warning and notice labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3.9 Wind speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 3.10 Conversion factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

4

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3 Initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.4 Checks before daily start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.5 Tests before start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4.5.1 Checking the windshield washer level . . . . . . . . . . . . . . . . 4-8 4.5.2 Check fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 4.5.3 Lubricating the lubrication points manually . . . . . . . . . . . 4-10 4.5.4 Check fill level in central lubrication system. . . . . . . . . . . 4-10 4.6 Setting the lubrication times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 4.7 Lubricating slewing ring teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4.7.1 Gear teeth spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4.7.2 Checking the hydraulic oil level . . . . . . . . . . . . . . . . . . . . 4-14 4.7.3 Check and drain the fuel system . . . . . . . . . . . . . . . . . . . 4-15 4.7.4 Checking engine oil level. . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 4.7.5 Check coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 4.8 Check water heating coolant level (Optional) . . . . . . . . . . . . . . . . 4-19

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Table of contents

4.9 Switch on machine - Diesel engine . . . . . . . . . . . . . . . . . . . . . . . 4-21 4.9.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 4.9.2 Restraint belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 4.9.3 Start engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 4.9.4 Bring machine up to operating temperature . . . . . . . . . . . 4-25 4.9.5 Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 4.10 Switching the machine off - Diesel engine . . . . . . . . . . . . . . . . . . 4-27 4.10.1 Switching off engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 4.11 Decommissioning - Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . 4-28 4.12 Preservation and storage - Diesel engine . . . . . . . . . . . . . . . . . . 4-29 4.13 Switch on machine - Electric motor . . . . . . . . . . . . . . . . . . . . . . . 4-30 4.13.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 4.13.2 Restraint belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 4.13.3 Start engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 4.13.4 Bring machine up to operating temperature . . . . . . . . . . . 4-32 4.14 Switching the machine off - Electric motor . . . . . . . . . . . . . . . . . . 4-33 4.14.1 Switching the motor off . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 4.15 Decommissioning - Electric motor . . . . . . . . . . . . . . . . . . . . . . . . 4-34 4.16 Preservation and storage - Electric motor . . . . . . . . . . . . . . . . . . 4-35 4.17 Starting up operating again . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 4.18 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 5

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Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.2 Driver's cab/cab with platform, raising . . . . . . . . . . . . . . . . . . . . . . 5-2 5.2.1 Driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 5.3 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 5.3.1 Overview with steering wheel control . . . . . . . . . . . . . . . . . 5-7 5.3.2 Overview with joystick control . . . . . . . . . . . . . . . . . . . . . . 5-9 5.3.3 Safety lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5.3.4 Control lever, left-hand . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 5.3.5 Control lever, right-hand . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 5.3.6 Additional displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 5.3.7 Overview of control panels . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5.3.8 Control panel, next to the driver's seat . . . . . . . . . . . . . . . 5-16 5.3.9 Control panel Engine/Machine . . . . . . . . . . . . . . . . . . . . . 5-17 5.3.10 Panel indicator lights, lower right . . . . . . . . . . . . . . . . . . . 5-19 5.3.11 Control panel, right-hand bottom . . . . . . . . . . . . . . . . . . 5-21 5.3.12 Air conditioning control panel . . . . . . . . . . . . . . . . . . . . . . 5-24 5.3.13 Control panel, right bottom (rear) . . . . . . . . . . . . . . . . . . . 5-26

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Table of contents

5.4

5.5

5.6

5.7 5.8

5.9 6

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5.3.14 Control panel, top right on the ceiling . . . . . . . . . . . . . . . . 5-28 5.3.15 SENNEBOGEN Diagnosis System (SDS) . . . . . . . . . . . . 5-34 Additional displays (special equipment) . . . . . . . . . . . . . . . . . . . . 5-56 5.4.1 SENNEBOGEN Tool Control . . . . . . . . . . . . . . . . . . . . . . 5-56 5.4.2 Load moment limiter (LML) . . . . . . . . . . . . . . . . . . . . . . . 5-58 5.4.3 Generator and Magnet Systems . . . . . . . . . . . . . . . . . . . 5-59 5.4.4 Camera/Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60 5.4.5 Auxiliary heating / Water heater . . . . . . . . . . . . . . . . . . . . 5-61 5.4.6 Low-temperature package . . . . . . . . . . . . . . . . . . . . . . . . 5-63 5.4.7 External loudspeaker system . . . . . . . . . . . . . . . . . . . . . . 5-67 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 5.5.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 5.5.2 Maneuvering cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69 5.5.3 Emergency lowering - cab . . . . . . . . . . . . . . . . . . . . . . . . 5-72 5.5.4 Driving machine - Mobile . . . . . . . . . . . . . . . . . . . . . . . . . 5-74 5.5.5 Stabilizing machine - Mobile . . . . . . . . . . . . . . . . . . . . . . . 5-77 5.5.6 Superstructure rotation/braking . . . . . . . . . . . . . . . . . . . . 5-81 5.5.7 Lifting /lowering loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84 5.5.8 End limit cut-out equipment . . . . . . . . . . . . . . . . . . . . . . . 5-85 5.5.9 Bypassing the safety limit position sensor for "Stick in" . . 5-89 5.5.10 Working with the grab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90 5.5.11 Operation with generator and magnet system (special function) 5-91 5.5.12 Working with scrap shears (special function) . . . . . . . . . . 5-94 5.5.13 Working with a hydraulic hammer (special function) . . . . 5-95 Vario Tool - Changing equipment . . . . . . . . . . . . . . . . . . . . . . . . 5-96 5.6.1 Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96 5.6.2 Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99 5.6.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99 Refueling machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102 Actions to take if the electronics fail . . . . . . . . . . . . . . . . . . . . . . 5-105 5.8.1 Reverse airflow -insufficient cooling capacity- . . . . . . . . 5-105 5.8.2 Steering failure (optional with joystick steering) . . . . . . . 5-106 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107

Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2 Machine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2.1 Mobile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.3 Machine dimensions (Pylon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

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Table of contents

6.4 6.5 6.6 6.7 6.8

835 / 01.2009

Machine weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Lock upper structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Lifting machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Tie down machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Disconnect electrical system from battery . . . . . . . . . . . . . . . . . . 6-10

7

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1 Driving engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.2 Hydraulic system: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.3 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7.4 tires and undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 7.5 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 7.6 SDS fault indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

8

Setup work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.2 Dismantling/assembling the cab . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 8.3 Mounting/dismounting counterweight . . . . . . . . . . . . . . . . . . . . . . 8-4 8.3.1 Dismantling the counterweight . . . . . . . . . . . . . . . . . . . . . . 8-5 8.3.2 Installing the counterweight . . . . . . . . . . . . . . . . . . . . . . . . 8-6 8.4 Installing large roller bearings, slewing gear, flange connections . 8-7 8.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 8.4.2 Preparatory measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 8.4.3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 8.4.4 Mounting pylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 8.5 Quick-change couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 8.5.1 Fastening quick couplings . . . . . . . . . . . . . . . . . . . . . . . . 8-10 8.5.2 Pull out coupling insert . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 8.5.3 Check/change sealing ring . . . . . . . . . . . . . . . . . . . . . . . . 8-14 8.5.4 Lubricating the coupling sleeve . . . . . . . . . . . . . . . . . . . . 8-16

9

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.1 List of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.2 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.3 Driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.4 Clean the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.5 Quick-connect couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.6 Installing large roller bearings, slewing gear, flange connections . 9-2 9.7 Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

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Table of contents

9.8 Electrical water heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.9 Lubricants table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

0-6

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835 / 01.2009

Safety - General

1

Safety

1.1 General The machine is built to state of the art standards and according to recognized technical security regulations. Nevertheless, there may be dangers during its use to persons, machines and other property, if z the machine is not utilized as intended z the machine is not operated by trained personnel or

not maintained z the safety notes are not observed z the machine is found to be defective z the attachment machinery does not comply with the relevant safety

regulations z the attachment machinery has faults.

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

In the Federal Republic of Germany e.g. : z Winches, Lifting and Pulling Devices (VBG 8) z Hoisting equipment in Lifting Appliance Operation (VBG 9a) z Earth-Moving Machinery (VBG 40) z EU Machinery Directive 98/37/EC z EMC Directive 89/336/EEA z Electrical Equipment in Machines (EN 60204-1) z Safety Requirements for Fluid Power Systems and their

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

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

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1-1

Safety - Intended use

1.2

Intended use

The correct use of the machine concerns solely the lifting, transport and loading/unloading of loads.

Permitted attachment machinery: z Grabber z Magnetic equipment.

In addition, in special cases: z Scrap metal shears z Demolition hammer z Concrete crushers z Trailer:

The machine is suitable for pulling a trailer but is subject to the permitted axle load and any questions can be directed to the SENNEBOGEN customer service.

Attachments

An overview of all of the attachment machinery that is currently available including the matching machine types can be found in the appendix.

WARNING Not every attachment is suitable for every type of machine. Only the attachment machinery (model and size) that is approved for the respective type of machine is to be attached.

If mounting any other attachment machinery that is not listed, the user/ operator is responsible.

Observe the performance details of the machine. Load capacities are not to be exceeded under any circumstances.

Other or additional applications are considered as misuse and can endanger persons or machinery.

1-2

Workplace

The machine operator’s workplace is in the driver's cab of the machine.

Target group

The machine has been developed for demanding work.

Persons working on or with the machine must be trained or instructed for that purpose. Initial operation, maintenance, transportation and assembly/dismantling only by trained specialists.

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835 / 01.2009

Safety - Potential instances of misuse

1.3

Potential instances of misuse

The following apply as potential instances of misuse: z Exceeding the permitted load capacities. z Using non-Sennebogen parts z Use in inadmissible ambient conditions. z Misuse by untrained and uninstructed personnel. z Inadequate equipment for the application (e.g. protecting the cab

against falling objects with guard grill). z Operating on insufficiently firm base. z Neglect of necessary inspection and maintenance work. z Neglecting to lower suspended loads and boom if necessary when

shutting the machine down (e.g. work stoppages - over night). z etc.

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1-3

Safety - Misuse

1.4

Misuse

Unintended use (Misuse) applies in particular to: z lifting, driving and transporting of persons z lifting loads at an angle z pulling loads z dragging loads z pulling free jammed loads z operation of the machine in explosive environment. z exceeding the permitted working load z the attachment/operation of non-approved/permitted attachment

machinery z Trailer:

pulling attached loads WARNING Misuse excludes all liability of the manufacturer! The risk is borne solely by the user/operator.

1.5 Other risks The safety notes in these operating instructions are guidelines for the safe use of the machine by qualified machine operators. However, SENNEBOGEN cannot anticipate every situation, 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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835 / 01.2009

Safety - Machine Labeling

1.6

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).

1.6.1 Identification plate

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1

Machine type

2

Manufacturer’s No. (Facility No.)

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1-5

Safety - Machine Labeling

1.6.2 CE stamp of conformity – affects machines that are operated within the EU/EEC. These machines wear the CE identification. This means that these machines meet the respective safety stipulations of the EU machine regulations upon delivery. For changes that affect the safety of the machine and the respective consequences, those that make the changes are responsible and liable.

If the machine is used for purposes other than those intended or is used with machinery other than that indicated in these instructions, safety must be guaranteed in each case. Those performing the work are responsible and liable. In certain cases, another CE identification and the completion of a new EU declaration of conformity may be required.

CE Stamp

1.6.3 Euro-test identification EuroTest is a voluntary Prototype test, which is based on the EC machine guidelines and the respective European standards.

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835 / 01.2009

Safety - Machine Labeling

1.6.4 Warning and notice labels Note More information can be found in Chapter 3.

Explanations of the stickers used on the machine Drilling- and welding work is only to be done by authorized SENNEBOGEN partners (SE: 086489)

Function diagram for both control levers (SE: 033809)

Maintain safety distance to overhead lines while working!

(SE: 027932)

Note pertaining to exiting in case of emergency, in case of danger, smash the rear windshield with the emergency hammer and then leave the cab carefully (SE: 103007)

Danger of crushing in the vicinity of the raising cab (between the cab and the superstructure) (SE: 103016)

Note regarding the storage location of the fire extinguisher (SE: 103008)

Secure the machine in these tie-down locations for transport (SE: 031148)

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1-7

Safety - Machine Labeling

Wear the optional safety belt when working with the machine (SE: 103001)

Read and understand the maintenance instructions before starting with any cleaning-, service-, maintenance- or repair work (SE: 061604) Before starting operation with the machine, be sure to read the operating instructions and the additional technical information/ additional documentation from any pre-suppliers.

"Caution! Stay off!“ (SE: 086687)

Stepping on many parts of the superstructure is forbidden (SE: 103003) Starter batteries, filled with corrosive and poisonous acid.

Do not allow to drop and do not open with force (SE: 103012) Symbol for the battery isolation switch (SE: 032307) Rear if the machine swings outward, keep a safety distance of at least 0.5 m (SE: 062287) Before performing any maintenance work, switch the engine off and remove the ignition key (SE: 009245) Note concerning the position of the button for emergency lowering of the cab (in the cab) (SE: 103030) Note concerning the position of the lever for emergency lowering of the cab (From of the superstructure), (SE: 103005)

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835 / 01.2009

Safety - Machine Labeling

Operating voltage of the on-board electrical system: 24 Volts (SE: 032574)

Symbol for the slewing ring lubrication (SE: Note concerning the type of fuel used by the drive engine: DIESEL No smoking and keep away from open flame when fueling the machine (SE: 103002)

Note referring to the hazard areas during machine operation (SE: 103034)

The machine meets all essential safety requirements. Continuous sound levels outside the machine as well, e.g. 103dB (SE: 062526)

Tie-down points (eyelets) for lifting the machine (SE: 031149)

Magnet unit (optional): Shut the generator and the drive engine down and allow them to cool before starting any maintenance work!

The system operates under high power!

(SE: 103024) Note concerning coolant specifications for the drive engine Use this coolant only for DEUTZ engines (SE: 092872)

for Cummins engines (SE: 103020)

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1-9

Safety - Machine Labeling

Warning of hot surface or hot parts!

(SE: 103009)

Belt drive, never reach into the area of the drive belts or pulleys!

(SE: 103022)

Note concerning the manufacturer and the specifications for hydraulic oil (SE: 103033)

Note concerning the manufacturer and the specifications for gear oil (SE: 103006)

Horn/Flashers

Warning of a risk of falling!

Maximum weight per grid segment 200kg (400 lb)

Warning!

Danger of falling when opening the air scoop

Important information for the driver

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835 / 01.2009

Safety - Machine Labeling

Warning concerning the danger of injuries!

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

Wear personal safety equipment

Fuse for ignition 40A

Warning of rotating components!

(Power train)

Note indicating the position of the engine diagnostics plug-in connector

Note indicating the position of the heater flange

Warning concerning the danger of injuries!

Rotating fan baffles

Warning of the danger of amputation!

(High pressure)

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1 - 11

Safety - Responsibilities of the operator

1.7

Responsibilities of the operator

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

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

Routine checks

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.

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.

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835 / 01.2009

Safety - Responsibilities of the operator

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 persons who 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 - 13

Safety - Responsibilities of the operator

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.

Do not operate machine if a fault has been detected!

Observe mandatory time limits for routine checks.

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

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

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

correctly according to these instructions. z The specified performance data must be observed. z The performance data listed in the instructions must not be

exceeded z Trailer

The machine is not suitable for towing a trailer. Due to the greater axle load, trailer operation is only permitted with stronger axles (optional).

z Protective roof (FOPS)

If there is a danger of heavy items falling, the machine may only be used if the driver's space is covered by a protective roof (FOPS). The protective roof is optionally available from SENNEBOGEN. 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.

Permissible ground pressure

The stress values for different types of ground are defined in DIN 1054.

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835 / 01.2009

Safety - Responsibilities of the operator

WARNING If there is any confusion as to the load-bearing capabilities of the ground on location, a ground inspection must be carried out prior to beginning machine operation.

Check the ground for hidden problems such as e.g. melting ice or undercutting.

Type of ground

Perm.

Ground pressure in [kg/ cm2]

A) Stirred ground that has not been packed

0-1

B) Grown in, obviously untouched ground 1) Mire, peat, muck, topsoil

0

2) Non-binding, sufficiently solid, seasoned ground - Fine to medium sand - Coarse sand to gravel

1,5 2,0

3) Cohesive soil - soggy - soft - firm - semi-solid - solid

0 0.4 1.0 2.0 4.0

4) Rock that has not been weathered, with few fissures and is well preserved

Slopes and ditches

15 - 30

C) Artificially packed surface 1) Asphalt

5 - 15

2) Concrete – Concrete group I - Concrete group II

50 - 250 350 - 550

The machine must be set up/operated at a sufficiently safe distance from slopes and ditches. The distance depends on the type of ground in the location.

DANGER The distance to the slope edge must be at least 2 m. It also depends on the type of ground in the location.

Rule of thumb: z when the ground is overgrown (or not hilly), the safe distance (A)

must be the same as the ditch depth (B), slope angle at < 45°

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1 - 15

Safety - Responsibilities of the operator

z for ground fill (or hilly), the safe distance (A) must be twice as far as

the ditch depth (B), slope angle at < 30°

Dangers of noncompliance with the safety instructions Overseas use

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.

If the machine is used overseas, the following must be observed: z Observe the safety regulations of the country where you are

operating the machine. z Ensure that the operators have the necessary qualifications for the

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

and completely understood. If necessary, ask Sennebogen for a copy of this operating manual in the corresponding language.

Fire extinguisher and first aid box

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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835 / 01.2009

Safety - Responsibilities of the operator

Warranty conditions

835 / 01.2009

The warranty conditions of SENNEBOGEN Maschinenfabrik GmbH are summarized in the warranty manual.

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1 - 17

Safety - Supplementary and operational equipment

1.8

Supplementary and operational equipment

1.8.1 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. The indicator and warning lamps are activated if irregularities occur on the machine.

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 can be found in Chapter 5.3.15.

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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835 / 01.2009

Safety - Supplementary and operational equipment

1.8.2 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 Mixing oils, lubricants or operational fluids of different types is not permitted!

Filling or mixing oils, lubricants or operating fluids (e.g. hydraulic oil, gear oil, motor oil, coolant, etc.) of different types can lead to damage to machine components caused by chemical reactions for example.

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 with and written confirmation from SENNEBOGEN customer services.

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Safety - Supplementary and operational equipment

1.8.3 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 cooling fluid or cooling agent additives, gelling, etc. can occur in the coolant leading to the cooler being plugged (build-up) and because of the engine overheating or if the cooling system fails for example, this can damage the machine.

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 (-36 °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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Safety - Supplementary and operational equipment

Coolant for DEUTZ

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

Note The DEUTZ - drive motors are filled with coolant 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 1

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

1.

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Safety - Supplementary and operational equipment

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

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

Sulfate 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 expresslyobserved.

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

1.8.4 Fuel (not 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 in the operating instructions of the engine manufacturer.

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Safety - Safety instructions

1.9

Safety instructions

1.9.1 General Danger area

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

DANGER There must be no-one within the danger area!

The machine operator must issue warning signals where persons are endangered. If the persons do not leave the danger area despite the warning, work must be stopped.

To avoid becoming crushed by solid components, e. g. buildings, walls to be removed, scaffolding or other machinery, a sufficient safety distance (at least 500 mm) must be maintained.

If the safety distance cannot be maintained, then the area between the solid structure and the work area of the machine must be cordoned off.

If the machine operator has restricted driving and working vision, then he must be guided.

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Personal safety equipment

While working on the machine, the operating personnel are obliged to wear the personal safety equipment as laid down by national regulations (e. g. safety helmet, ear protection, protective gloves, safety boots).

Eye bolts are installed as safety eyelets on the superstructure. The safety eyelets are used for securing a safety belt to protect personnel from falling from the machine. 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.

Problems

Report problems or damage immediately to a responsible person!

Prevent the machine from incorrect or inadvertent use. Repairs should only be performed by specialist personnel.

Minimizing noise

Housings, covers, cab doors and windows are to be kept closed to decrease noise levels (as long as this conforms with safety requirements). Operating elements are to be used gently.

Noise emissions

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.

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Safety - Safety instructions

Note The measurements are taken according to Directive 2000/14/EC. Vibration

The machine operator is protected against mechanical vibration with a shock-cushioning seat that can be adjusted for his/her weight. The seat can be adjusted for seat height and backrest. The optimal work position can be set for each individual driver. The alarm values for hand-arm vibration (2.5 m/s2) and for full-body vibration (0.5 m/s2) are not exceeded.

Note These measurements are made according to the specifications of ISO 2631/1 and ISO 5349.

Qualification of personnel Excerpt from VBG 40

The machine must only be operated and maintained by qualified personnel.

The independent operation or maintenance of earth-moving machinery must only be carried out by persons who 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.

They must be appointed by the employer specifically for the operation and maintenance of earth-moving equipment.

Work underground and in enclosed spaces

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If the machines are implemented in enclosed spaces, the spaces are to be sufficiently ventilated and the respective regulations are to be followed.

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Safety - Safety instructions

Work in ports and harbors Stability

When working in port basins, additional machine security is to be used.

The machine is to be fastened to the ground (ground anchor) in order to prevent tipping into the harbor basin in case of overloading. z Position the machine on a firm, even surface. z If necessary, stabilize the ground below. z Caution at excavation edge, slopes, dips, etc. z Position stabilizers also on a firm, even surface. z with additional ballast: z The machine must be supported when slewing the upper structure! z Observe wind speeds! z Stability is at a minimum when the working gear is transverse to the

direction of travel. z The highest stability is when the working equipment lies

diagonally (see illustration below).

DANGER Do not carry out any form of work which will affect the stability of the machine! z Stability is reduced when the cab is elevated and when working with

loads at a great height. z Note that stability decreases when the load is swinging laterally. z Quick movements can lead to decreased stability or uncontrolled

load movements.

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Safety - Safety instructions

Working near power lines

z Before starting work! Clearly mark power lines in the vicinity of

building site while under supervision. z Always assume that overhead lines are live. z Guide the machine so that neither parts of the machine nor

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

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

Safety distance (meters)

up to 1000 V

1.00

over 1000 V to 110 kV

3.00

over 110 kV to 220 kV

4.00

over 220 kV to 380 kV

5.00

not known

5.00

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

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

swing and consequently decrease the distance.

High voltage contact

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

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

line is switched off.

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

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Safety - Safety instructions

Lightning

Driver’s cabs on construction equipment are generally equipped with protection against lightning strikes. The lightning current flows through the cab to ground.

DANGER Do not touch any metal parts that make direct contact with the chassis during storms.

DANGER The electromagnetic field connected with lightning current can influence sensitive electronic components and could lead to faulty functionality or complete failure in certain circumstances.

Before putting the machine back into operation, ensure the operating and safety elements are working properly.

DANGER Mobile undercarriage: The enormous heat development can cause extensive damage to tires.

Before putting the machine back into operation, check tires for damage.

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

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Safety - Safety instructions

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 - Safety instructions

1.9.2 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

1 - 32

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 - Safety instructions

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.

4

Close the sliding 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 - Safety instructions

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 - Safety instructions

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.

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Safety - Safety instructions

1.9.3 Emergency exit Exiting the cab in a case of emergency can be done through the cab doors or the rear window.

A safety hammer that can be used to knock out the rear window is located in the cab.

Cab

1

Note In an emergency, you can exit via the rear window (1). Use the emergency hammer to break the rear window.

Protective roof (FOPS): The emergency exit through the rear window may be blocked by the optional protective roof (FOPS). In this case, emergency exit is only possible through the doors.

CAUTION Risk of falling!

Exit the cab via the rear structure with extreme caution and climb down from the vehicle.

1.9.4 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 - Safety instructions

1.9.5 Commissioning WARNING z Check that all machine safety devices are complete and correctly secured. z Ensure that the gallery/personnel platform has been installed

properly. Falling out when the door is open (with optional safety belt in place) is no longer possible in this case. z Wear protective work clothing (e.g. safety helmet, eye protection) if

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

steps and ladders: – if necessary, clean steps and ladders before use – Do not carry any items when climbing up or down. lift items of equipment onto machine using cable or lifting gear.

– Do not use operating elements as handholds in driver’s cab. z Ensure that there is no one in the danger zone. z Check machine safety features (e.g. brakes, signal and lighting

devices). z Check operating elements and safety devices are functioning

correctly while driving slowly. z Do not operate machine if a fault has been detected. z Ensure that all actuating levers are in the neutral position. z Start the machine only as described in the information in the

instructions.

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Safety - Safety instructions

1.9.6 Operation/Driving operation WARNING z Persons working on or with the machine must be trained or

instructed for that purpose. Operation and deployment may only be carried out by trained personnel. z The following applies for all work:

Work only if the work area is level and solid enough. z Proceed with utmost caution if you override the stick end limit or other

safety shut-off. z Ensure that there is no one in the danger zone. z Maintain safety distance to overhead lines. z Only operate the machine from the driver's seat. z When switching the attachment (e.g. grabber), take the pressure off

of the hydraulic system. z Do not transport persons on the machine. z Consider environment conditions, e. g. poor visibility, wind speeds,

etc. z Use the specific lifting capacity tables for that machine. z Note performance specification. z Check that anchorage points have a sufficient safe working load. z Observe guide signals as necessary. z If visibility is poor, ensure that a guide is used for giving the required

signs when reversing. z Before moving onto ramps or inclines, make sure to obtain the

maximum permitted values from SENNEBOGEN. z Position boom in direction of travel during long journeys.

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Safety - Safety instructions

1.9.7 Setup work DANGER 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 The following applies for all set-up work:

Only carry out the work if the work area is level and solid enough. z Ensure that there is no one in the danger zone.

– While setting up – before completing all tightening – no persons are allowed in the hazardous area in which loads could fall or under hanging loads.

– Keep a sufficient safety-margin from areas of unavoidable cutting or pinching/crushing danger during the set-up procedure. z Observe the relevant accident prevention directives for working with

load suspension equipment. z When dismantling components or equipment, always use load

suspension equipment with a sufficient load bearing capacity. z Suspend components only with the designated lifting brackets. z Do not step on equipment that is not designed for it (e.g. parts of the

boom or the ballast). z Carry out all set-up steps in turn. Never carry out more than one set-

up task at a time.

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Safety - Safety instructions

1.9.8 Decommissioning Before leaving the driver's cab: z Completely lower cab if necessary z Position the machine on firm base, if necessary set back from the

edge of the excavation z Lower suspended loads z Secure attachment machinery z Pull safety lever back z Switch off engine z Chock wheels/running gear z Lock cab, show warning lights if necessary.

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Safety - Safety instructions

1.9.9 Maintenance DANGER Risk of fatality!

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 Secure the machine from rolling away and use a chock if necessary.

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.

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

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Safety - Safety instructions

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. 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.

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Safety - Safety instructions

Qualifications of 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 - Safety instructions

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

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

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

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

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

gloves, safety boots). z Report any damage that occurred during shipping to

SENNEBOGEN customer service immediately.

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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

Overload warning device The overload warning device gives an acoustic warning signal if the permitted safe working load is exceeded. Ensure that the overload warning device is activated when working with lifting gear. The danger of tipping is not averted by the overload warning device!

DANGER Tip-over danger of machine!

Decrease the load immediately (e.g. decrease reach, lower load).

Limit switching equipment

The following movements are limited by the limit switching equipment: – Stick retract – Stick extend – Hoist up – Hoist down.

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Safety - Disposal

1.11 Disposal Lubricating and Consumables CAUTION Observe environment protection!

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 dispose of batteries in a domestic waste facility!

Dispose of defective batteries at a recollection point for spent batteries. z National environmental conditions valid in the country of use also

apply.

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Safety - Hand signals

1.12 Hand signals Driver and signaler communicate with each other with the aid of the following hand signals when vision is restricted in the driving and work area.

The guide gives the necessary signals to ensure safe operation.

Safety instructions

Observe the safety notes before starting work.

CAUTION z Only responsible persons may be employed as guides. They must receive the necessary training before starting their task. z The guide must not be diverted from this task

by other tasks. z Observe notes of VBG 40, § 35 Guides as well as the details of DIN

33 409 Hand signals for guidance.

Attention Extend arm upwards with hand open

Stop Extend both arms horizontally.

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Safety - Hand signals

Stop! Danger!

Alternately extend and fold in both arms horizontally

Drive off Move upwards extended arm back and forth with hand open

Drive slowly forwards Both arms bent and beckon forwards with palms of hands turned inwards.

Reverse slowly Bend both arms and wave away with palms of hands turned outward.

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Safety - Hand signals

Turn right Left thumb outwards.

Turn left Right thumb outwards.

Turn upper structure to the right Left thumb outwards to the left, rotate right index finger.

Turn upper structure to the left Right thumb outwards to the right, rotate left index finger..

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Safety - Hand signals

Hoist equipment (load) Right extended index finger points upwards, left hand moves up and down.

Lower equipment (load) Right extended index finger points downwards, left hand moves up and down.

Increase reach Both thumbs point outwards.

Decrease reach Both thumbs point inwards.

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Safety - Hand signals

Open grab Hold arm horizontal with half open hand to the side.

Close grab Hold arm horizontal with closed hand to the side.

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Safety - Hand signals

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Overview - Complete machine

2

Overview

2.1 Complete machine

L

1

2*

3

4*

5

6

7

8

9 10

1

Attachments (Example: grabber, scrap shears)

6

Dallery/platform, raising

2

Ulm

7

Undercarriage

3

Grabbing stick

8

Superstructure

4

Vario Tool

9

Stabilizer

5

Compact stick

10

Counterweight

*: Optional model / special function

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2-1

Overview - Undercarriage

2.2

Undercarriage

4-point stabilizing

1

2

3

4

5

6

7

9

Sliding front window (optional) 8*

1

Rear stabilizers

6

Front axle (swing axle)

2

Rear axle

7

Front stabilizers

3

Slewing ring

8

Sliding front window (optional)

4

Access steps

9

Floating axle cylinder

5

Extra storage space

*: Optional model / special function

2-2

Translation of the original operating instructions

835 / 01.2009

Overview - Undercarriage

Stabilizer

1

835 / 01.2009

2

3 4

1

Access steps

3

Stabilizer brackets

2

Stabilizer box

4

Stabilizer plate

Translation of the original operating instructions

2-3

Overview - Superstructure

2.3

Superstructure

Service doors Engine compartment

1a 1* 2 Engine compartment rear:

3 4 Water separator – Fuel

2

1a Auxiliary control filter (series)

3 Pump unit

1* HydroClean

4 Hydraulic oil level display

6

5 Engine compartment front: 5 Driving engine

7

6 Fan

8 Air conditioner

7

8

Combination cooler

*: Optional model / special function

2-4

Translation of the original operating instructions

835 / 01.2009

Overview - Superstructure

Service doors Driver's side

1

2

3

Driver's side front: 1 Windshield washer reservoir 2 Emergency lowering - cab

4*

5

6

7

8

9

3 Measurement ports hydraulic system

10

11

Driver's side rear: 4* Fueling hose/pump

8 Fuel tank

5 Fuel filler neck

9 Electrical control cabinet

6 Central lubrication system

10 Batteries

7 Air filter

11 Battery isolator switch

*: Optional model / special function

835 / 01.2009

Translation of the original operating instructions

2-5

Overview - Superstructure

2.3.1 Side views with electric motor

1*

2

3

4

6 7

5

4 Distributor gearbox

Engine compartment (right side): 1* HydroClean

5 Driving engine

2 Pump unit

6 Fan

3 Hydraulic oil level display

1

2

3

7 Hydraulic oil cooler

4

Storage compartments (driver's side):

5

6

7

system 4

Hydraulic oil tank

1 Windshield washer reservoir 2 Emergency lowering - cab 3 Measurement ports - hydraulic

5 Water heating system 6 Central lubrication system

*: Optional model / special function

2-6

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835 / 01.2009

Overview - Superstructure

2.3.2 View from above

1 4 2

5

6

3

7 9

8

10* Detailed view turned by 180°!

1 Exhaust silencer/ Exhaust pipe end 2 Service panel - Hydroclean superfine filtration system 3 Service panel - engine 4 Service panel Hydraulic oil tank

6 Air filter - moisture separator 7 Hydraulic oil filter 8

Cut-off flap Hydraulic oil tank

9 Service panel - Radiator 10*Generator

5 Service panel - battery *: Optional model / special function

835 / 01.2009

Translation of the original operating instructions

2-7

Overview - Superstructure

2.3.3 Central electrical system Service doors Driver's side rear 1

2

3

1 Automatic circuit breaker 40 Amp (Terminal 15) 2 Automatic circuit breaker 80 Amp (Terminal 30) 3 Battery isolator switch (not with electric motors)

2-8

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835 / 01.2009

Overview - Superstructure

2.3.4

Electrical control cabinet

2 1

1 Main switch 2 EMERGENCY STOP switch

835 / 01.2009

Translation of the original operating instructions

2-9

Overview - Equipment

2.4

Equipment

2.4.1 Compact boom with Grabbing stick

2

1

with ULM (Optional)

3

4*

1

Compact boom

2 Grabbing stick

3 Grabbing stick with 4* ULM

*: Optional model / special function

2 - 10

Translation of the original operating instructions

835 / 01.2009

Overview - Equipment

2.4.2 Pipe fracture safety devices

1

2*

1 Line rupture detector – lifting cylinder 2* Line rupture detector – adjust cylinder

*: Optional model / special function

835 / 01.2009

Translation of the original operating instructions

2 - 11

Overview - Equipment

2.4.3 Attachments and Vario Tool (optional)

1 1

2

3

Grabber

2 Scrap metal shears 3 Stick base with Vario Tool

2 - 12

Translation of the original operating instructions

835 / 01.2009

Technical data - General information

3

Technical data

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

3.1 General information 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

Limitations during wind

Operating pressure, max. 350 bar

Slewing speed

0 - 8 rpm, continuously variable

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.

835 / 01.2009

Translation of the original operating instructions

3-1

Technical data - Driving engine

DANGER Once the specified wind speed is reached, stop operating the machine immediately (lower load, lower stick). Table on wind speeds, see Section3.9

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 operating instructions

835 / 01.2009

Technical data - Driving engine

3.2.1 Type 835 TDC 2013 L06 2V Power (according to ISO 14396)

186 kW (253 PS) at Nominal speed 2,200 rpm

Capacity

7142 cm3

Cylinders

6

Oil capacity with filter

approx. 14 l / approx. 3,7 gal. (US)

Coolant quantity (complete system) Engine

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

(US) approx. 7.3 l / approx. 1.9 gal. (US)

Engine, general

see manufacturer's instructions

QSB6.7-C260 Power (according to ISO 14396)

194 kW (260 PS) at nominal speed 2,200 rpm

Capacity

7200 cm3

Cylinders

6

Oil capacity with filter

approx. 17,0 l / approx. 4.48 gal.

(US)

Coolant quantity (complete system) Engine

approx. 48 l / approx. 12,6 gal. (US)

Engine, general

see manufacturer's instructions

approx. 10 l / approx. 2.6 gal. (US)

FCMP

835 / 01.2009

Power (according to ISO 14396)

150 kW (201 PS) at nominal speed 1,500 rpm

Engine, general

see manufacturer's instructions

Translation of the original operating instructions

3-3

Technical data - Machine

3.3

Machine

Fuel tank - Middle view glass:

max. 625 l / max. 165,10 gal. (US) approx. 600 l / approx. 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(*) z Typ 835:

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

Axle distributor gear

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

Differential z front

approx. 26.0 l / approx. 6,8 gal. (US)

z rear

approx. 19.5 l / approx. 5,1 gal. (US)

Hub drive train z front

each approx. 1.2 l / approx. 0.31 gal. (US)

z rear

each approx. 1.5 l / approx. 0.39 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.

3-4

Translation of the original operating instructions

835 / 01.2009

Technical data - Machine

Tire air pressure (pneumatic tires)

Wheel nuts Driving speed

835 / 01.2009

Tire size

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

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

Translation of the original operating instructions

3-5

Technical data - Machine dimensions

3.4

Machine dimensions

Note More information on the dimensions can be found in Chapter 6.2

3.5 Machine weight Note More information can be found in Chapter 6.4

3-6

Translation of the original operating instructions

835 / 01.2009

Technical data - Lifting capacities

3.6 Lifting capacities Notes The lifting capacities z are specified in tons (t) and equate to 75% of the static tilt load or

87% of the hydraulic lifting force according to ISO 10 567. z are applicable for a machine on firm, level ground and apply over a

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

Deduct the weight of the load suspension equipment (hooks, suspension gear) from the lifting capacities. The values in parentheses apply in a direction along the lengthwise axis of the undercarriage.

Adverse conditions

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

835 / 01.2009

Translation of the original operating instructions

3-7

Technical data - Lifting capacities

3.6.1 Kin I, K16, compact boom 9,1m and 6,9m arm stabilized

3-8

Translation of the original operating instructions

835 / 01.2009

Technical data - Lifting capacities

3.6.2 Kin I, K16, compact boom 9,1m and 6,9m arm free standing

835 / 01.2009

Translation of the original operating instructions

3-9

Technical data - Lubrication points

3.7

Lubrication points

3.7.1 Machine - Mobile Manual lubrication

)

= grease manually WARNING

WARNING 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. Remove excess grease.

The lubrication nipples are provided with a red protective cap.

3 - 10

Translation of the original operating instructions

835 / 01.2009

Technical data - Lubrication points

a Lubrication nipplesoverview

Sammelschmierung vorne: Achsschenkel (2 pro Seite) Abstützzylinder innen (2) Pendelachse (1)

a

Anmerkung: 3 Schmiernippel pro Kardanwelle

b

b Sammelschmierung hinten: Abstützzylinder innen (2)

= manuell Fett einpressen

835 / 01.2009

Translation of the original operating instructions

3 - 11

Technical data - Warning and notice labels

3.8

Warning and notice labels

Note More information can be found in Section1.6.4.

3 - 12

Translation of the original operating instructions

835 / 01.2009

Technical data - Warning and notice labels

835 / 01.2009

Translation of the original operating instructions

3 - 13

Technical data - Warning and notice labels

3 - 14

Translation of the original operating instructions

835 / 01.2009

Technical data - Warning and notice labels

835 / 01.2009

Translation of the original operating instructions

3 - 15

Technical data - Wind speed

3.9

Wind speed

Wind strength Beaufort scale

Effect

Designation

m/s

km/h

Inland

0

Calm

0-0,2

1

Calm, smoke rises straight up

1

Light draft

0.3-1.5

1-5

Direction of wind is displayed by direction of smoke, but not by a 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

3 - 16

Wind speed

(rarely in inland) 118-133 Severe devastation

Translation of the original operating instructions

835 / 01.2009

Technical data - Conversion factors

3.10 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

835 / 01.2009

Translation of the original operating instructions

3 - 17

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

1 m/s

3,281ft/s

2,237 mile/h

1 ft/s

0,305 m/s

1,097 km/h

Speed

3 - 18

Translation of the original operating instructions

835 / 01.2009

Commissioning - Safety instructions

4

Commissioning

4.1 Safety instructions WARNING z Read Chapter 1 SICHERHEIT. Before start-up, carry out checks according to Section4.4 . z Check that all machine safety devices are complete and correctly

secured. z Ensure that the gallery/personnel platform has been installed

properly. Falling out when the door is open (with optional safety belt in place) is no longer possible in this case. z Wear protective work clothing (e.g. safety helmet, eye protection) if

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

steps and ladders: – if necessary, clean steps and ladders before use – Do not carry any items when climbing up or down. lift items of equipment onto machine using cable or lifting gear.

– Do not use operating elements as handholds in driver’s cab. z Ensure that there is no one in the danger zone. z Check machine safety features (e.g. brakes, signal and lighting

devices). z Check operating elements and safety devices are functioning

correctly while driving slowly. z Do not operate machine if a fault has been detected. z Ensure that all actuating levers are in the neutral position. z Start the machine only as described in the information in the

instructions.

835 / 01.2009

Translation of the original operating instructions

4-1

Commissioning - Cleaning work

4.2 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.

4-2

Translation of the original operating instructions

835 / 01.2009

Commissioning - Initial operation

4.3

Initial operation

The initial commissioning of the machine is carried out by SENNEBOGEN or by a trained and authorized specialist.

If the machine is shutdown for a prolonged period (> 6 months), contact SENNEBOGEN customer services immediately before recommissioning.

WARNING Read CHAPTER 1 SICHERHEIT. Before start-up, carry out checks according to Section4.4.

4.4 Checks before daily start-up Read the safety notes before starting work.

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

within your scope of employment.

Note The following pages contain the checklists that should be gone through before starting work with the machine every day. It is divided into: – A general part (e.g. A1), – a function part (e.g. F1) and – a visual or sight check (e.g. S1).

DANGER Report all irregularities to the person in charge before start-up. Only operate machine after remedying all faults.

Note In the following checklist, a dash bullet point (-) in the chapter column indicates that there is not reference for the respective action and there are no instructions contained in the operating instructions.

835 / 01.2009

Translation of the original operating instructions

4-3

Commissioning - Checks before daily start-up

No.

General information

Steps to take

Chapte r

5

A1

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

Mark and secure as necessary

-

5

A2

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

If necessary, obtain information

-

5

A3

Is an experienced person available for signaling, if required?

If necessary, arrange for a signaler

-

5

A4

Is the danger zone free of persons?

If so, advise them to leave the danger area

-

5

A5

Is the load weight known?

Obtain information as required

-

5

A6

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

Refer to the operating instructions and rating plate as necessary

-

5

No.

Functional checks

Steps to take

Chapt er

5

F1

Is the limit sensor on the arm set correctly?

If necessary, adjust

-

5

F2

Is the hoisting limit sensor set correctly?

If necessary, adjust

-

5

F3

Is the overload warning device activated?

If necessary, activate

6.3.15

5

F4

Is the machine positioned horizontally?

If necessary, position correctly

-

5

F5

Is the stability of the machine ensured?

If necessary, support properly

-

5

F6

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

If necessary, locate and correct faults

-

5

F7

Are any warning or fault messages displayed on the SDS?

If necessary, locate and correct faults, read fault log

6.3.16

5

F8

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

If necessary, locate and correct faults

-

5

F9

Is the emergency lowering feature of the cab functioning?

If necessary, locate and correct faults

6.5.3

5

F10

Does the steering turn freely?

If necessary, adjust

-

5

4-4

Translation of the original operating instructions

835 / 01.2009

Commissioning - Checks before daily start-up

Functional checks

No.

Steps to take

Chapt er

5

F11

Is the central lubrication unit functioning?

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

4.5.4

5

F12

Does the Vario Tool function properly?

Clean if necessary

6.6

5

Chapt er

5

No.

Visual checks

S1

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

If necessary, replace

-

5

S2

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

If necessary, repair or replace

-

5

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! !

-

5

S4

Are the windows clean and free of ice and snow?

If necessary, clean

-

5

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

-

5

S7

Is the tire pressure correct? For pneumatic tires:

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

-

5

S8

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

If necessary, tighten connections or replace seals

-

5

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

-

5

S10

Is the shutoff on the hydraulic tank open?

If necessary, open

2.3.3

5

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!

-

5

835 / 01.2009

Steps to take

Translation of the original operating instructions

4-5

Commissioning - Checks before daily start-up

Chapt er

5

If necessary, clean or replace

-

5

Is the fan wheel intact?

If necessary, replace

-

5

S14

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

If necessary, clean by reversing the fan or replace.

-

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.

-

5

S16

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

If necessary, retighten or replace

-

5

Chapt er

5

No.

Visual checks

Steps to take

S12

Are TopAir and air filter cartridges damaged or contaminated?

S13

No.

Visual checks

S17

Has the water separator on the fuel system been drained?

If necessary, drain

-

5

S18

Are the V-belts undamaged and tensioned?

If necessary, tension again or replace

-

5

S19

Are the electrical lines damaged?

If necessary, repair or replace

-

5

S20

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

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

-

5

S21

Are the batteries held in place securely?

If necessary, secure again

-

5

S22

Are all service access doors closed?

If necessary, close

-

5

S23

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

If necessary, retighten or replace

-

5

rS2 4

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

If necessary, disconnect

-

5

rS2 5

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

If necessary, replace or secure again with specified torque

-

5

S26

Are the boom components intact (corrosion, cracks)?

If necessary, repair or replace

-

5

S27

Are any bolts cracked or damaged?

If necessary, replace

-

5

S28

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

If necessary, replace

-

5

4-6

Steps to take

Translation of the original operating instructions

835 / 01.2009

Commissioning - Checks before daily start-up

Visual checks

No.

Steps to take

Chapt er

5

4.5.4

5

S29

Is there enough grease in the central lubrication system?

If necessary, refill

S30

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

If necessary, replace, clean and lubricate

-

5

S31

Are the hydraulic lines and hoses secured in place?

If necessary, tighten fasteners

-

5

S32

Is the slewing mechanism undamaged and lubricated sufficiently?

Repair or actuate pinion lubrication if necessary.

-

5

S33

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

If necessary, re-install and refill grease

-

5

S34

Inspect the positive stops for the steering for wear.

If necessary, replace

-

5

S35

Inspect the power cable track for wear.

If necessary, replace

-

5

S36

Is the pump distributor gearbox sealed?

Repair if necessary

-

5

835 / 01.2009

Translation of the original operating instructions

4-7

Commissioning - Tests before start-up

4.5

Tests before start-up

Note Sections 5.5.2, 5.5.5, 5.5.6, and 5.5.7 are omitted for electric motors!

4.5.1 Checking the windshield washer level Note The reservoir for cleaning fluid for the washer system is located behind the front left-hand service access door.

Always fill the reservoir with washer system anti-freeze.

1

1 Windshield washer container

2

3

4

2 Service access door lock Closing the service access door

1

Carefully press and hold the lock button (3) on the lock (2).

2

Close the service access door (4).

WARNING If the lock button (3) is not pressed when the service access door is closed, the lock will be damaged!

4-8

Translation of the original operating instructions

835 / 01.2009

Commissioning - Tests before start-up

4.5.2 Check fuel level Note The fuel fill level can be determined with two different ways: z with the indicator on the right next to the filler neck (rough indication) z with the SENNEBOGEN diagnostics system in the initial mask, see

Chapter 5.3.15

1 1

2

Filler strainer

2 Control displays Note 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 in the operating instructions of the engine manufacturer.

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4-9

Commissioning - Tests before start-up

4.5.3 Lubricating the lubrication points manually Note More information can be found in .Chapter 3.4

4.5.4 Check fill level in central lubrication system.

The central lubrication system automatically lubricates the slew track of the slewing mechanism as well as the bearings of the equipment. The lubrication cycle is pre-set at the factory.

Note The preset lubricating cycle can be shortened. See the documentation on the CENTRAL LUBRICATION SYSTEM in Chapter 9 of the operating manual.

1

2

3

4

1 Threaded cover - replenish grease 2 Grease reservoir - note MIN/MAX markings 3 Grease nipple – Replenish grease 4 Setting the lubrication

4 - 10

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835 / 01.2009

Commissioning - Setting the lubrication times

4.6 Setting the lubrication times 1

Remove the red frame of the control unit of the motor protective housing of the pump, using a flat screwdriver, and detach the 4 crosshead screws as well as the transparent cover.

2

Set the inoperative and/or lubrication times by means of the tow lock-in switches, using a screwdriver for slotted-head screws

3

If the control system should not be closed in the correct way, water may penetrate the system. In that case, the warranty will not be valid any longer.

1) Graduating switch for setting the braek duration 2) Graduating switch for setting the luabrication duration Parameter: Lubrication time: 4 Minutes Pause time: 1 Hour

Attention: After a braek-in period about 100 hours and the controlling of all lubrication points the lubrication time can be reduced or increased.

Modify the cycle time is not allowed.

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4 - 11

Commissioning - Lubricating slewing ring teeth

4.7

Lubricating slewing ring teeth

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

4.7.1 Gear teeth spray

4 - 12

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.

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Commissioning - Lubricating slewing ring teeth

Replenish grease

1 1 Lubricant containers

835 / 01.2009

1

Open cover (1) of lubrication container.

2

Replenish lubricant (SE-no.: 047485).

3

Re-close cover.

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4 - 13

Commissioning - Lubricating slewing ring teeth

4.7.2 Checking the hydraulic oil level

1

Machine in park position

4 - 14

1

Lower suspended loads and stick to the ground.

2

Position machine horizontally.

3

Fully retract all hydraulic cylinders.

4

Put the machine in park position. Retract support cylinders.

5

Shut down drive engine.

6

Open the service access door on the right.

7

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

8

De-pressurizing hydraulic system.

9

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

– Unscrew screw cap of oil filler strainer.

– Top up hydraulic oil and re-check.

– Re-tighten screw cap.

Close the cover plate.

10

Close the service access door on the right.

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Commissioning - Lubricating slewing ring teeth

4.7.3 Check and drain the fuel system WARNING z Do not handle open flames when working on the fuel system! No smoking! z Also comply with the notes in the operating instructions of the engine

manufacturer.

1 2

1 Fuel filler filter cartridge 2 Drain valve

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4 - 15

Commissioning - Lubricating slewing ring teeth

1

Open rear right service access door.

2

Set a suitable catch container under the water container (2) of the fuel filter cartridge.

3

Open drain valve (3).

4

Drain the water and debris out of the water container.

5

Shut off the drain valve again.

6

Close the service access door at the right, rear.

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

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835 / 01.2009

Commissioning - Lubricating slewing ring teeth

4.7.4 Checking engine oil level.

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

1

1

1 Oil dipstick handle

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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 and wipe off using a clean, lint-free cloth.

6

Insert oil dipstick up to stop and pull out again.

7

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

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4 - 17

Commissioning - Lubricating slewing ring teeth

8

If necessary top up with oil of the specified grade.

9

Insert oil dipstick up to stop and pull out again.

10

Close the service access door on the right.

4.7.5 Check coolant level

WARNING !

Danger of injury from scalding!

Check only when the cooling system has cooled.

3 2 1

4 1 Service panel 2 Handle 3 Hand screw 4 Cap

Check coolant level and/ or antifreeze

4 - 18

1

Allow drive engine and cooler to cool down.

2

Unscrew the two hand screws (3).

3

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

4

Pace large, thick cloths on the cap (4) of the coolant expansion tank 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 resistance to 37 °C (- 34 °F).

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Commissioning - Check water heating coolant level (Optional)

6

Check antifreeze and coolant level, top up if necessary.

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

7

Close the cap on the expansion tank.

8

Replace the service panel and secure using the hand screws.

4.8 Check water heating coolant level (Optional) Note The expansion tank for the water heater is located behind the left-hand rear service door.

1

2

1 Coolant level indicator 2 Cap Check coolant level and/ or antifreeze

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1

Allow the water heater to cool.

2

Open rear left service access door.

3

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

4

Use a large, thick cloth to surround the cap (2) and open it carefully to let off the pressure.

5

Check antifreeze and coolant level, top up if necessary.

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

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4 - 19

Commissioning - Check water heating coolant level (Optional)

4 - 20

6

Close the cap on the expansion tank.

7

Close the service access door at the left, rear.

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Commissioning - Switch on machine - Diesel engine

4.9

Switch on machine - Diesel engine

4.9.1 Safety instructions Observe the safety notes before starting machine.

DANGER z Danger of injury!

Keep cab door and service access doors closed. z Before starting the engine, ensure that there is no one within the

danger area. z The exhaust emission of diesel engines is damaging to health. Only

run engine outdoors or in well-ventilated areas. z Do not start engine if a warning sign is present on the operating

elements. z Adjust driver's seat, steering column and mirror to the correct

position. z Fit restraint belt correctly. z Close the cab doors.

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4 - 21

Commissioning - Switch on machine - Diesel engine

4.9.2 Restraint belt The machine is equipped with a lap belt. The belt complies with standards SAE J 386 (USA) and FMVSS 209 (EU).

WARNING z Check belt for signs of wear before starting to operate the machine.

Immediately exchange a damaged belt. z Clean dirty belt using water. z Do not twist belt when fastening. z Pass belt as low as possible around the hips, not around the

stomach.

1 2 3

4 - 22

1

Push metal catch (1) into belt buckle (2).

An audible click indicates that the belt has engaged.

2

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

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Commissioning - Switch on machine - Diesel engine

4.9.3 Start engine DANGER Danger of intoxication!

Only run the engine outdoors or in well-ventilated areas. Breathing inexhaust fumes is hazardous to your health It may lead to loss of consciousness and death.

Control panel right rear

3 1 4 5 2

SENNEBOGEN Diagnostic System (SDS)

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1

Perform daily checks in accordance with Section4.4.

2

Insert key into ignition lock (2) and turn to position "1".

– The SDS runs a short self-test.

– The coolant temperature and fuel level are now indicated on the SDS display (3).

– No fault messages are to be in the SDS when starting the engine.

3

After completing the SDS self test, turn the ignition key to the right (position "II") to start the engine.

4

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

5

Set the desired engine rpm using knob (1).

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4 - 23

Commissioning - Switch on machine - Diesel engine

Position Ignition key

Ignition key position

Meaning

P

Enable filling pump

0

Ignition OFF

I

Ignition ON

II

Start engine

Note Release the safety lever if necessary to enable the hydraulic function (see also Section6.3.4 SICHERHEITSHEBEL).

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Commissioning - Switch on machine - Diesel engine

4.9.4 Bring machine up to operating temperature

Guidelines values for warm-up period

Ambient temperature range

Warm-up period

Max. engine speed

Down to 0 °C (32 °F)

approx. 15 min.

Nominal speed - 250 rpm -

- 20 °C (- 4 °F) -... 0 °C (32 °F) Procedure Warning up the engine

approx. 30 min.

1

(nominal speed, see Chapter 4)

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

Additional warm-up time can be required at temperatures under 0°C (32 °F). z Then increase the engine rpm in steps up to the

Increase nominal speed -250 rpm (not under load) z If approx. 20°C (54 °F) water temperature has been achieved, put a

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

have been achieved.

Reverse fan With optional equipment, the fan reverses at under 0 °C (32 °F): Change the direction of the fan several times during the warming up phase. This will feed hot air from the engine to the micro filter (in front of the cooler) and blow out the ice.

Note If the hydraulics are still slow to respond after the warm-up period, operate for a further 15 minutes at reduced speed.

The following temperatures should be displayed before operating the machine at full speed: z Hydraulic oil: about 30 °C (86 °F) z Water: about 35 °C (95 °F).

CAUTION Not warming up the engine and the machine can result in damage to the engine, hydraulic pump, hydraulic motor, hydraulic oil cooler and hydraulic tank.

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4 - 25

Commissioning - Switch on machine - Diesel engine

4.9.5 Jump start The machine is equipped with a 24-volt starting system. Ensure that the external power source has the same voltage.

CAUTION If a power source with a higher voltage is used, this can cause serious damage to the machine's electrical system.

1

Actuate battery isolator switch to interrupt the power supply.

2

Detach battery cover.

3

Connect the positive terminal (+) of the power source to appropriate jump leads.

4

Connect the negative terminal (-) of the power source to appropriate jump leads.

5

Actuate the battery isolator switch to regenerate the power supply.

6

Start engine acc. to Section4.9.3.

7

After the drive engine starts up: – Detach jumper cable of negative terminal (-).

– Detach jumper cable of positive terminal (+).

8

Replace battery cover.

WARNING z Explosion hazard!

Avoid excessive heating by fire, open light or smoking. z Battery acid is corrosive.

Avoid any contact with the skin, eyes or clothing. Rinse acid splashes and spills with clean water immediately. A visit to the doctor can be necessary. z When working on electrical system, adhere to current regulations

and the accident prevention regulations.

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Commissioning - Switching the machine off - Diesel engine

4.10 Switching the machine off - Diesel engine 4.10.1 Switching off engine Note Switching off the driving engine without allowing a cooling down phase may cause heat storage and overheating of engine parts and especially the turbocharger. Therefore, allow the engine to cool down before switching off: z Lower engine speed to approx. 50 % of the rated speed (see

Chapter 4). z Allow machine to run for another approx. 5-10 minutes.

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

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1

Park the machine on a firm surface.

2

Lower suspended loads and lower boom if necessary.

3

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

4

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

5

Turn ignition key to position "0" and remove.

6

If necessary, pull back safety lever.

7

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

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4 - 27

Commissioning - Decommissioning - Diesel engine

4.11 Decommissioning - Diesel engine Proceed as follows if the machine is to be decommissioned for a prolonged period.

1

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

2

Position the machine on level ground.

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

3

Switch off machine according to Section4.10.

4

Check the machine for leaks (coolant, oil, etc.).

5

Clean machine according to maintenance instructions.

Ensure that cleaning agents do not attack the seals nor enter the slewing mechanism!

6

Replenish operating fluids and lubricants; for levels see maintenance instructions.

7

Lubricate machine according to maintenance instructions.

Lubricate the swivel connections while slowly rotating the superstructure (fill grease supply if necessary).

8

Switch the battery isolator switch off or disconnect the battery poles.

9

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

Note Admissible ambient temperatures in accordance with Chapter 4.

CAUTION! Check the seals every 6 months.

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Commissioning - Preservation and storage - Diesel engine

4.12 Preservation and storage - Diesel engine Proceed as follows if the machine is to be preserved or stored for a longer period of time:

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1

Select the storage location so that there are no predictable hazards.

2

Park attachment equipment on wooden blocks to prevent them from freezing in.

3

Perform maintenance for 2000 hours of operation (annual).

4

Clean and dry all blank surfaces thoroughly (e.g. hydraulic cylinder piston rods).

5

Preserve all blank surfaces and mounting joints with anticorrosive agent. The protective film must cover the surface completely without any bare spots.

6

Check the diesel fuel for shelf life (min. -40 °C / -40 °F).

7

Fill the fuel and hydraulic oil tanks up to the maximum fill levels.

8

Check the cooling system for sufficient antifreeze.

The antifreeze portion must be at least 60% and maximum 65%.

Do not empty the cooling system under any circumstances!

9

Prepare the diesel engine for storing. Also comply with the notes in the operating instructions of the engine manufacturer.

10

Put a warning sign on the engine and on the cab indicating the status of the machine preservation.

11

If the machine is to be stored at temperatures under -40 °C (40 °F) for a longer period of time, all LCD displays should be removed and stored in a warmer location.

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Commissioning - Switch on machine - Electric motor

4.13 Switch on machine - Electric motor 4.13.1 Safety instructions Observe the safety notes before starting machine.

DANGER z Danger of injury!

Keep cab door and service access doors closed. z Before starting the engine, ensure that there is no one within the

danger area. z Do not start engine if a warning sign is present on the operating

elements. z Adjust driver's seat, steering column and mirror to the correct

position. z Fit restraint belt correctly. z Close the cab doors.

4.13.2 Restraint belt The machine is equipped with a lap belt. The belt complies with standards SAE J 386 (USA) and FMVSS 209 (EU).

WARNING z Check belt for signs of wear before starting to operate the machine.

Immediately exchange a damaged belt. z Clean dirty belt using water. z Do not twist belt when fastening. z Pass belt as low as possible around the hips, not around the

stomach.

1 2 3

4 - 30

1

Push metal catch (1) into belt buckle (2).

An audible click indicates that the belt has engaged.

2

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

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Commissioning - Switch on machine - Electric motor

4.13.3 Start engine

Control panel right rear

5 4 3 2

1 1 Ignition lock

3 Engine "Off"

2 Engine "On"

1

Perform daily checks in accordance with Section4.4.

2

Switch on main switch at the electric switch cabinet (see Section2.3.5).

3

Insert key into ignition lock (1) and turn to position "I".

4

Start the engine with the pushbutton (3). The "green" indicator lamp (5) illuminates.

WARNING Fault!

If the "red" indicator lamp (4) is illuminated, a fault exists.

Contact the SENNEBOGEN customer service immediately.

Note Release the safety lever if necessary to enable the hydraulic function (see also Chapter 5.3.4).

WARNING Observe the safety and commissioning notes in the operating instructions of the engine manufacturer!

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4 - 31

Commissioning - Switch on machine - Electric motor

4.13.4 Bring machine up to operating temperature elines values for warm-up period

Procedure Warning up the engine

Ambient temperature range

Warm-up period

Down to 0 °C (32 °F)

approx. 15 min.

- 20 °C (- 4 °F) -... 0 °C (32 °F)

approx. 30 min.

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

Additional warm-up time can be required at temperatures under 0°C (32 °F). z The machine can be loaded if the temperatures indicated below

have been achieved.

Reverse fan With optional equipment, the fan reverses at under 0 °C (32 °F): Change the direction of the fan several times during the warming up phase. This will feed hot air from the engine to the micro filter (in front of the cooler) and blow out the ice.

Note If the hydraulics are still slow to respond after the warm-up period, operate for a further 15 minutes at reduced speed.

The following temperatures should be displayed before operating the machine at full speed: z Hydraulic oil: about 30 °C (86 °F)

CAUTION Not warming up the engine and the machine can result in damage to the engine, hydraulic pump, hydraulic motor, hydraulic oil cooler and hydraulic tank.

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Commissioning - Switching the machine off - Electric motor

4.14 Switching the machine off - Electric motor 4.14.1 Switching the motor off

5 4 3 2

1 1 Ignition lock

3 Engine "Off"

2 Engine "On"

1

Lower suspended loads and lower boom if necessary.

2

Switch off the engine with the pushbutton (2). The "green" indicator lamp (5) goes out.

3

Switch off main switch at the electric switch cabinet (see Section2.3.4).

4

Turn ignition key to position "0" and remove.

5

If necessary, pull back safety lever.

6

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

WARNING Please read the accompanying safety and commissioning instructions of the engine manufacturer!

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4 - 33

Commissioning - Decommissioning - Electric motor

4.15 Decommissioning - Electric motor Proceed as follows if the machine is to be decommissioned for a prolonged period.

1

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

2

Position the machine on level ground.

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

3

Switch off machine according to Section4.14.

4

Check the machine for leaks (coolant, oil, etc.).

5

Clean machine according to maintenance instructions.

Ensure that cleaning agents do not attack the seals nor enter the slewing mechanism!

6

Replenish operating fluids and lubricants; for levels see maintenance instructions.

7

Lubricate machine according to maintenance instructions.

Lubricate the swivel connections while slowly rotating the superstructure (fill grease supply if necessary).

8

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

Note Admissible ambient temperatures in accordance with Chapter 4.

CAUTION! Check the seals every 6 months.

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Commissioning - Preservation and storage - Electric motor

4.16 Preservation and storage - Electric motor Proceed as follows if the machine is to be preserved or stored for a longer period of time:

835 / 01.2009

1

Select the storage location so that there are no predictable hazards.

2

Park attachment equipment on wooden blocks to prevent them from freezing in.

3

Perform maintenance for 2000 hours of operation (annual).

4

Clean and dry all blank surfaces thoroughly (e.g. hydraulic cylinder piston rods).

5

Preserve all blank surfaces and mounting joints with anticorrosive agent. The protective film must cover the surface completely without any bare spots.

6

Fill the hydraulic oil tanks up to the maximum fill levels.

7

Check the cooling system for sufficient antifreeze.

The antifreeze portion must be at least 60% and maximum 65%.

Do not empty the cooling system under any circumstances!

8

Prepare the electric motor for storing. Also comply with the notes in the operating instructions of the engine manufacturer.

9

Put a warning sign on the engine and on the cab indicating the status of the machine preservation.

10

If the machine is to be stored at temperatures under -40 °C (40 °F) for a longer period of time, all LCD displays should be removed and stored in a warmer location.

Translation of the original operating instructions

4 - 35

Commissioning - Starting up operating again

4.17 Starting up operating again Proceed as follows if you want to put the machine back into operation: 1

Remove the anti-corrosive agent using a suitable means, e.g. with a pressure washer and the respective cleaning additives (be careful around sensitive and electronic components!).

2

All bare surfaces and hinged joints are to be oiled or greased according to the service measures indicated in the lubrication plan.

3

Check oil levels for sufficient fill quantities (e.g. hydraulic system, drive motor).

4

Check the fill level and mixture of the anti-freeze in the cooling system.

5

Check the machine thoroughly for leaks.

6

Check the entire machine (equipment, chassis, etc.) for damages.

7

Install the LCD displays again if necessary.

8

Check all safety equipment (brakes, signal lights, lighting, etc.) for proper functionality.

9

Investigate hazardous areas at the work site, identify them and secure sufficiently.

10

Leveling the machine.

11

Warm up the machine sufficiently before starting work. See chapter "Bringing the machine to operating temperature":

4.18 Disposal In case you must dispose of the machine, please contact SENNEBOGEN customer service.

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835 / 01.2009

Operation - Safety instructions

5

Operation

5.1 Safety instructions DANGER z Read Chapter 1 SICHERHEIT. Before start-up, carry out checks according to Section5.4 . z Persons working on or with the machine must be trained or

instructed for that purpose. Operation and deployment may only be carried out by trained personnel. z The following applies for all work:

Work only if the work area is level and solid enough. z Proceed with utmost caution if you override the stick end limit or

other safety cut-out. z Ensure that there is no one in the danger zone. z Maintain safety distance to overhead lines. z Only operate the machine from the driver's seat. z When switching the attachment (e.g. grabber), take the pressure off

of the hydraulic system. z Do not transport persons on the machine. z Consider environment conditions, e. g. poor visibility, wind speeds,

etc. z Use the specific lifting capacity tables for that machine. z Note performance specification. z Check that anchorage points have a sufficient safe working load. z Observe guide signals as necessary. z If visibility is poor, ensure that a guide is used for giving the required

signs when reversing. z Before moving onto ramps or inclines, make sure to obtain the

maximum permitted values from SENNEBOGEN. z Position boom in direction of travel during long journeys.

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Translation of the original operating instructions

5-1

Operation - Driver's cab/cab with platform, raising

5.2

Driver's cab/cab with platform, raising

1 2 8*

3

9

4 5

10

6 7*

11

Emergency exit

12

1

Working light

2

Windshield wiper, roof

3 Windshield wiper, top 4 Front window top, adjustable 5 Front window bottom 6 Door lock and handle

8* 24 V socket (rotary beacon connection) 9 Emergency exit - Rear window 10 Sliding door 11 Gallery 12 Hammer - emergency exit

7* Windshield wiper, bottom *: Optional model / special function Note In an emergency, you can exit via the rear window (9). Use the emergency hammer (12) to break the rear window.

5-2

Translation of the original operating instructions

835 / 01.2009

Operation - Driver's cab/cab with platform, raising

Sliding door

1 2

The sliding door (1) can be latched in the open position on the side panel of the cab. You can release the latch by pulling on the release lever (2) on the inside of the door.

Front windshield

3

4

Opening front windshield: Tip forwards. The top window wiper pivots ahead with the window. Press on both buttons (4) and tip the window ahead. The two shock absorbers hold it in position. Pull the two handles (3) on the window frame inward to close it. Ensure that the front window latches in place again.

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Translation of the original operating instructions

5-3

Operation - Driver's cab/cab with platform, raising

Interior lighting

A switch (5) turn the lighting (6) on and off.

5

6

Windshield washer system

The windshield wipers are operated via the switch on the top right control panel. The container for cleaning fluid for the window washer system is located behind the front left-hand service door. Always fill the reservoir with window anti-freeze agent.

radio

The radio (7) and the speaker (8) are located behind the driver's seat under the cab roof.

7 8 Note More information can be obtained from the radio manufacturer.

Document jacket

5-4

A SENNEBOGEN jacket holding the machine documentation is located in the cab.

Translation of the original operating instructions

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Operation - Driver's cab/cab with platform, raising

5.2.1 Driver's seat CAUTION z In order to avoid dangerous situations, check that all settings are

locked in place properly before putting the vehicle into operation. z The setting mechanisms for the driver's seat should not be actuated

during operation. z To prevent injury, no objects are to be stored within the pivot-range

of the driver's seat. z Functionality testing should be performed at least as often as the

maintenance intervals of the vehicle.

Note To prevent damage to the driver's back, the weight setting should be changed to match the weight of the driver, each time driver's are switched.

Note Bolted joints should be checked regularly for solid seating. The seat jiggling may be caused by a loose bolt or other defect. If irregularities are found in the functionality of the seat (e.g. in the suspension of the seat), call an authorized professional immediately to rectify the problem. Non-compliance leads to hazards to your health and increased risk of accident.

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5-5

Operation - Driver's cab/cab with platform, raising

Air-suspended driver's seat 6

7 8 9 11 5 3

10

4 1, 2

12

1 Weight adjustment 2 Height adjustment 3 Seat depth adjustment (optional) 4 Seat tilt adjustment (optional) 5 Length adjustment (optional) 6 Head rest (optional) 7 Seat heating (optional) 8 Back (spine) support (optional) 9 Arm rests (optional) 10 Arm rest tilt (optional) 11 Backrest tilt 12 Horizontal suspension

5-6

Translation of the original operating instructions

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Operation - Operating elements

5.3

Operating elements

5.3.1 Overview with steering wheel control Steering wheel control

1

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2

3

4

5

6

7

8

1 Pedals

5 Seat adjustment

2

6 Control lever, left-hand

Steering column

3 Steering wheel

7 Lower air outlet vent

4 Control lever, right-hand

8

Safety lever

Translation of the original operating instructions

5-7

Operation - Operating elements

Pedals

8

9

1*

2

3

4

5

7

6

lock

1* Slewing gear holding brake 2 Foot-rest

6 Brake pedal - Driving action

3

7 Drive pedal

Steering column

4 Release the steering column lock

8

Travel - forwards

9

Travel - reverse

5 Release the brake pedal

*: Optional model / special function Note The slewing gear holding brake is a holding brake for the superstructure but is not a service brake or a drive brake. A symbol is illuminated in the SDS when switched on.

5-8

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Operation - Operating elements

5.3.2 Overview with joystick control Joy stick steering

2

1 Pedals

3 4 5 6 4 Control lever, left-hand

2 Control lever, right-hand

5 Lower air outlet vent

3 Seat adjustment

6

1

2

Safety lever

3 4*

1*

Pushbutton: 1* Magnet system OFF

3 Steer, to right

2 Steer, to left

4* Magnet system ON or Magnet system ON/OFF

*: Optional model / special function

835 / 01.2009

Translation of the original operating instructions

5-9

Operation - Operating elements

Pedals

5

6

1*

2 3

4

1* Slewing gear holding brake

4 Drive pedal

2 Release the brake pedal lock

5

Travel - forwards

6

Travel - reverse

3 Brake pedal - Driving action

Note The slewing gear holding brake is a holding brake for the superstructure but is not a service brake or a drive brake. A symbol is illuminated in the SDS when switched on.

5 - 10

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835 / 01.2009

Operation - Operating elements

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

Safety lever released (pushed forward)

1

When safety lever is released (see illustration) z all hydraulic functions are available. z all work maneuvers can be carried out.

Note The slewing gear holding brake remains open after releasing the safety lever (pushed ahead), if the "right" switch has previously been actuated in the right control panel.

Activate the slewing gear holding brake by pressing the "left" switch in the right-hand control panel (see Chapter 5.5.6 ).

Safety lever actuated (pulled back)

1

Note All hydraulic functions are deactivated with the safety lever actuated.

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Translation of the original operating instructions

5 - 11

Operation - Operating elements

5.3.4

Control lever, left-hand

2

Pushbutton: 3

1 4

1

Horn

2

Grab, slew left

3

Grab, slew right

4 The safety end limit cut-out "Arm in“ is to be bypassed, if available, which bypasses the stick and the hoisting limits as well.

Movement directions

Note The bypasses for the safety end limit cut-out "Stick in" are series, "Stick out" and "Hoist up/down" are optional.

DANGER All safety cut-outs in the equipment are deactivated.

5 - 12

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835 / 01.2009

Operation - Operating elements

5.3.5 2 1

Control lever, right-hand 3 4

Pushbutton: 1* Magnet system OFF 2**Steer, to left 3**Steer, to right 4* Magnet system ON or Magnet system ON/OFF

Movement directions

DANGER Danger of death by bypassing the safety limit shutdown “Stick retract”!

Attachments and load elements can penetrate the driver's cab.

Proceed with utmost caution.

Watch attachments and load constantly. Operation is the sole responsibility of the machine operator.

Please also read notes in Chapter 5.5.9. *:Optional model / special function **:Optional version, only with joystick steering

835 / 01.2009

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Operation - Operating elements

5.3.6 Additional displays Analog operating hours counter

SDS

Tool Control

Generator and Magnet System

Auxiliary heater, Water heater

Camera

LML

Note More information can be found in Section5.5.9 and Section9.

5 - 14

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835 / 01.2009

Operation - Operating elements

5.3.7 Overview of control panels

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5 - 15

Operation - Operating elements

5.3.8 Control panel, next to the driver's seat Version with full stabilization

2

3

1

Version with single stabilizer (optional) 4

6

5

7

1

1 Ashtray 2 Storage compartment 3 Full stabilization lever (all stabilizers are extended/retracted simultaneously) 4 Single stabilizer left front 5 Single stabilizer left rear 6 Single stabilizer right front 7 Single stabilizer right rear

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Operation - Operating elements

5.3.9 Control panel Engine/Machine

1* 2 3

4 5* 6* 7 8 1* Emergency Stop (not with electric motors) 2 Speed adjustment (not with electric motors) 3 Basic lighting 0 = Light off 1 = Parking light 2 = Low beam 3 = High beam 4

Ignition lock - Start engine P = Enable fuel filling pump 0 = Ignition OFF I = Ignition ON II = Start engine

5* Emergency lowering - LML 6* Key switch Emergency lowering - LML 7

12V socket outlet

8

24V socket outlet

*: Optional model / special function

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5 - 17

Operation - Operating elements

Emergency lowering LML

The load moment limiter (LML) can be bypassed with the key switch Emergency lowering - LML. This may be required to move the machine out of the hazard zone if it is not possible with load-minimizing functions (Stick in, Boom down).

DANGER Danger of tipping!

Key switch Emergency loweringshould only be used in extreme emergencies!

Note The load moment limiter (LML) can be bypassed for 3 seconds only.

After a waiting time of 30 seconds, the load moment limiter (LML) can be bypasses again for another 3 seconds.

Note Bypassing the load moment limiter (LML) is completed only under full responsibility of the machine operator.

5 - 18

1

Press button (5) in the right-hand control panel.

2

Turn the key switch (6) to the right in the right-hand control panel and hold this position.

This bypasses the load moment limiter (LML).

3

By releasing the key switch (6), the load moment limiter (LML) is activated again.

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835 / 01.2009

Operation - Operating elements

5.3.10 Panel indicator lights, lower right

1*

6*

2

7

3* 4*

8

5*

1* Travel, forwards 2 Flasher left, right/hazard lights 3* Reverse fan 4* Magnet system control 5* Steering direction switch 6* Travel reverse 7

High beam

8 180° displacement *: Optional model / special function

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5 - 19

Operation - Operating elements

Reverse fan status indicator lamp

Switch setting

Indicator lamp

1 (right, single fan reversal)

flashes

0 (middle, no fan reversal)

not illuminated

2 (left, fan reversal every 60 min.)

always illuminated

Note The fan reversal indicator lamp (3) provides information on the status of the fan drive controller and on faults in the fan system. A fault is indicated with a flashing code. Contact SENNEBOGEN service in this case.

In reversal operation, the indicator lamp flashes once per second.

Travel forwards

Lamp illuminated with selected travel direction - Forward.

Travel reverse

Lamp illuminated with selected travel direction - Reverse.

Magnet system

Illuminated with magnet system switched on.

Switch steering direction

Illuminated with activated floating axle control if the superstructure is in 0°- or 180°-position (+/- 5°) to the undercarriage.

180° displacement

Illuminated with active steering direction reversal if the boom is in the area above the rear axle (90°-270° - position (+/- 7.5°)).

High beam

5 - 20

Illuminated when headlight lit.

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Operation - Operating elements

5.3.11 Control panel, right-hand bottom Note The maximum occupation of the panel is shown. The switches for functions that are not available are covered with dummy covers.

1 2 3* 4 5 6

7* 8* 9 10*

11*

12*

1 Slewing gear holding brake

7* Unlock switch / Cab "Out"

2 Driving speed slow/fast

8* Unlock switch / Cab "In"

3* Flasher left/right (only with joystick steering) 4 Floating axle lock 5 Unlock switch / Cab "Up"

9 Reverse fan 10*Dozer plate 11*Release telescoping 12*Diesel filter heating Off/On

6 Unlock switch / Cab "Down" *: Optional model / special function

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5 - 21

Operation - Operating elements

Slewing gear holding brake

The slewing gear holding brake is a holding brake for the superstructure but is not a service brake or a working brake.

When switched on, the SDS also illuminated a symbol.

WARNING Never rotate the upper structure when the slewing gear holding brake is applied!

Floating axle lock

The front axle is a floating axle. It can be blocked with a switch. After releasing the lock (switch lit) travel surface unevenness can be compensated by the floating axle.

Note The front axle only has a defined pendulum path if the superstructure is parallel wtih the undercarriage (0° and 180°). This minimizes the danger of tipping. The boom can be over the front axle or over the rear axle.

WARNING z Danger of tipping!

Lock the floating axle when traveling with load. z Unlock the floating axle when traveling on uneven terrain.

0° position

5 - 22

180° position

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835 / 01.2009

Operation - Operating elements

Reverse fan

The reverse airflow serves to clean the cooling fins of the combination cooler. This requires that the switch is pressed as described below.

Loose contamination on the cooling ribs is blown out.

Switch setting

Feature

1 (right)

Jog function, single fan reversal for 30 seconds

0 (middle)

Neutral position, no fan reversal

2 (left)

Automatic function, every 60 minutes a fan reversal for 30 seconds (switch latched in place)

Note To further clean the combination cooler, read the maintenance instructions (see).

Diesel filter heating Off/On

835 / 01.2009

The diesel filter heating is used for preheating at low temperatures.

Translation of the original operating instructions

5 - 23

Operation - Operating elements

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

1

2

3 4 5

5

6

6

1 Fan speed selection switch 2 Air distribution selection switch 3

Temperature regulator

4 Temperature display (°C or °F) 5 Combination switch: Outside temperature display, Air conditioning on/off 6 Outside/recirculating air switch Note The air conditioning can be operated with outside air or circulating inside air.

Note Keep windows and cab door closed to ensure effective air conditioning.

The air conditioner regulates the temperature in relation to the outside temperature.

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835 / 01.2009

Operation - Operating elements

Outside air mode

Recirculating air mode

Air conditioning system - switch-on

When windows are misted, to dehumidify the cab.

Faster warm-up of cab and higher limit temperature.

The air in the cab interior is re-circulated, i. e. very little fresh air is drawn in from outside. Do not leave in this mode for longer than 15 minutes, as the air quality in the cab will deteriorate significantly. Ensure that there is a sufficient outside air supply.

1

Start driving engine.

2

Switch on fan (1) on right-hand control panel.

3

Open the air-inlet vents in the cab to prevent the evaporator from icing up.

4

Set the switch for the air conditioning (5) on the right of the control panel to cooling .

5

Set the desired temperature with the temperature controller (3) on the right of the control panel.

Note Switch on air conditioning system regularly. This greatly contributes to the operation readiness.

Switch on air conditioning system once a month for at least 30 minutes at maximum fan rate in this case; open windows and doors.

Change temperature display °C/°F

835 / 01.2009

1

Press the combination swtich (5) for more than 5 seconds.

2

The temperature display changes (°C <--> °F).

Translation of the original operating instructions

5 - 25

Operation - Operating elements

5.3.13 Control panel, right bottom (rear) Note The maximum occupation of the panel is shown. The switches for functions that are not available are covered with dummy covers.

1*

2* 3*

1* Auxiliary heater 2* Vario Tool Open-0-Close 3* Vario Tool enable *: Optional model / special function

Vario Tool Open-0-Close

The Vario Tool lock is actuated. The switch to the left opens the lock, switch to the right closes the lock. Neutral position in the middle.

WARNING Never rotate the upper structure when the slewing gear holding brake is applied!

Vario Tool enable

5 - 26

The Vario Tool is enabled. A signal tone sounds.

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835 / 01.2009

Operation - Operating elements

Auxiliary heater

1

2

3

4

5 1 Reverse control button

4

OK button

2 Forward control button

5

Display

3 Activation button Note More information can be found in Chapter 10.

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5 - 27

Operation - Operating elements

5.3.14 Control panel, top right on the ceiling Note The maximum occupation of the panel is shown. The switches for functions that are not available are covered with dummy covers.

Front part 1 2* 3* 4 5 6* 7* 8* 9* 10 11* 12* 13* 14* 1 Work floodlights Cab

9* Beacon lights

2* Working lights Superstructure

10 Flashing warning lamps

3* Working lights Equipment

11*ECO switch

4

12* Automatic idle

Wiper rear window

5 Front window washer system 6* Skylight wiper 7* Roof light washer system

13*Slewing ring lubrication (not available) 14*Central lubrication

8* Wiper rear window bottom *: Optional model / special function

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835 / 01.2009

Operation - Operating elements

ECO Switch

With the ECO switch activated, the drive motor speed is set to 92% of the nominal speed. This reduces the fuel consumption and noise generation.

Note When working with magnetic equipment, turn off the ECO switch!

Automatic idle

The automatic idle control automatically decreases the rpm of the drive engine if no operating actions are carried out for several seconds. Once a control lever is actuated, the preset speed of the rpm adjustment is immediately restored.

Note The automatic idle function remains deactivated as long as the magnetic equipment is on.

Slewing ring lubrication

The slewing ring lubrication system lubricates the teeth of the slewing ring. Lubrication can be actuated manually.

Central lubrication

The central lubrication system automatically lubricates the slew track of the slewing mechanism as well as the bearings of the equipment. The lubrication cycle is pre-set at the factory.

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

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5 - 29

Operation - Operating elements

Rear part 15* 16* 17 18* 19* 20*

21* 22* 23* 24*

25 15*Floating boom setting

0° position rear axle

16*Grabber function Off/On

22*All-wheel steering switch

17*Grabber control Off/On

23*Boom suspension system

18*Overload Off/On

24*Steering direction reversal

19*Unlock switch/Magnet system Off/On

25*Load limit sensing control (GLR)

20*Unlock switch/Auxiliary limiting main boom Off/On 21*Normal steering control *: Optional model / special function

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835 / 01.2009

Operation - Operating elements

Float setting Boom

The floating position function depends on the working tool.

Grabber floating position: The compact boom is raised at low speed along with the "Close grabber" function. Scratching the grabber on the ground is prevented this way.

Hammer floating position: The full weight of the Stick affects the hammer. The job cylinder is not pressurized in this case.

Grab control

The Grab Control function can be used for controlling the pressure for the "Grab Close" function.

A pressure reduction for "Grab Close" is only active if the working movements "Grab Close" and "Pivot superstructure" or "Grab Close" and "Hoist Up" are performed simultaneously. With the grabber closed, no speed loss occurs with working movements "Pivot superstructure" and "Hoist Up" this way.

– Grabber symbol always illuminated – switch pressed, green LED also illuminated

Grab function

835 / 01.2009

Grab control

Grab closing pressure

Pivot speed for superstruct ure

Hoisting speed Compact boom

Activate d

Grabber closes at maximum pressure.

Actuating the "Hoist Up" or "Pivot" function as well decreases the pressure for "Grab Close" so that no speed loss occurs in the working movements.

fast

fast

deactivat ed

Grabber closes at maximum pressure.

Actuating the "Hoist Up" or "Pivot" function may cause speed loss in the working movements in worst case scenarios.

Slow

Slow

Note If working with the machine equipment in a negative area (e.g. unloading ships) or the load is to be stored up high or pivoted over a large radius, it may be advantageous to active the grabber control. This will achieve quicker working cycles.

When the grabber function is switched off, accidentally actuating the functions "Grab Open/Grab Close" is prevented in magnet plate mode.

Translation of the original operating instructions

5 - 31

Operation - Operating elements

5 - 32

Overload

When the Overload warning unit is activated, a green LED is illuminated on the respective switch. If the machine is in a critical area (load too heavy, boom/Stick extended too far), a horn signal sounds.

Magnet system

Using the Magnet system switch, the optional magnet system can be activated/deactivated.

Auxiliary limiting

Use the Auxiliary limitation switch to activate/deactivate the optional auxiliary limiting for "Hoist Up" and/or "Stick out" (Section5.5.8). This is important when e.g. working with height limitations.

Control normal steering

Road (2-wheel) steering. The steering is via the front wheel. The back wheels remain straight (0°). Control: The rear wheels must be in the straight position.

Switch All-wheel steering

Use the All-wheel steering switch to switch to all-wheel (Lamp is illuminated in the switch).

Boom suspension system

When driving with a load over longer distances, bouncing or rocking of the machine is prevented with the suspension for the boom cylinder.

This enables comfortable driving with a load.

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835 / 01.2009

Operation - Operating elements

Steering direction reversal

When the Steering direction reversal is activated (Lamp is illuminated in the switch), the steering direction of the machine is switched automatically.

I.e.: For the steering movement, the machine does not differentiate between using the rear axle or the front axle.

DANGER Danger of accident with deactivated Steering direction reversal (Lamp not illuminated in the switch)!

If the boom is positioned above the rear axle, the driving actions of the machine are reversed.

Be very careful if you want to work or move with deactivated Steering direction reversal over the rear axle.

GLR

835 / 01.2009

The GLR system keeps the set engine speed constant under load. If a problem occurs in the GLR system, it can be deactivated with the switch.

The machine can continue in operation with minor power loss.

Translation of the original operating instructions

5 - 33

Operation - Operating elements

5.3.15 SENNEBOGEN Diagnosis System (SDS)

A

B C

A Display

C Indicator and warning lights

B Keypad

Note Additional information can be pulled up via the SDS, e. g. actual hydraulic oil temperature.

Sensors on the machine monitor the current operating state and transmit the measured data to the SDS. The measurement results are evaluated in the SDS and are shown on the display automatically or when a key is pressed. If irregularities occur on the machine, the indicator and warning lights are activated.

Self test

The SDS carries out a self-test after the ignition is switched on. All LEDs are illuminated. The sensors are checked. Following this, the SDS is ready to operate.

If the SDS detects a fault, the fault condition in indicated on the display and via LEDs. Arrange for immediate rectification of faults through SENNEBOGEN customer service.

Cleaning

5 - 34

Do not clean the SDS with alcohol or liquids containing solvents!

These will corrode the plastic surface.

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835 / 01.2009

Operation - Operating elements

Keypad (B)

The keypad has 5 function keys. Information can be pulled up and shown on the display using these keys. You can also use these to change the screen mask and for acknowledging any possible error messages that occur.

CAUTION Faults or irregularities that are shown are to be rectified immediately (fill fuel tank, clean/replace air filter, etc.). More significant faults are to be rectified immediately by SENNEBOGEN service.

1

2

3

4

5

1 Up arrow (previous mask) 2 Down arrow (next mask) 3 Activate daily operating hours counter 4 Confirm (ENTER) 5 ESCAPE

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Operation - Operating elements

Display (A)

The screen is multifunctional. After switching the ignition on, it shows the SENNEBOGEN logo, and the daily data in operating status, respective symbols and a graphic view of the operating status (depending on the mask) in the operating status.

Note The SDS has a warning and indicator lamps on a colored background.

These are located under the keypad.

warning lights

Symbol

Meaning 1 Air filter - contamination indicator

Contamination indicators: Hydraulic oil return filter HydroClean Superfine filtration system Hydraulic pilot control filter Coolant level

Hydraulic tank flap (Optional)

Hydraulic oil level

WARNING symbol

Indicator lights

Symbol

Meaning Parking brake - accumulator charge pressure Slewing mechanism holding brake

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835 / 01.2009

Operation - Operating elements

Note The SDS screen is equipped with pictograms. These lamps are illuminated and/or can be selected depending on the operational status.

Pictograms

Pictogram

Meaning Coolant temperature

Fill level - Diesel fuel

Engine oil pressure

Engine rpm

Hydraulic oil temperature

Battery voltage

Switch on daily operating hours counter Switch off daily operating hours counter Warning triangle, general (in connection with other symbols) Time

Date

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Operation - Operating elements

Pictogram

Meaning Date/time setting and in connection with error memory

Error message exists

Error memory

Number of error messages

Confirm (ENTER)

ESCAPE

Engine

5 - 38

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835 / 01.2009

Operation - Operating elements

Sequential overview

000.0h 4 sec.

4.02

000.0h 4 sec.

000.0h 4 sec.

000.0h 4 sec.

5 sec.

+ SPN

5 sec.

5 sec.

SPN

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5 - 39

Operation - Operating elements

Start-up mask 1

2

4.02

Automatic change after 4 seconds

to screen 7 3

4

5

Screen 1

Coolant temperature

6 7

Fill level - Diesel fuel

8

1 SENNEBOGEN logo

5 Daily hours of operation

2 Software version (E.g.)

6 Coolant temperature

3

7 Warning threshold Coolant temperature too high

Time

4 Date

8 Fill level - Diesel fuel

5 - 40

Translation of the original operating instructions

835 / 01.2009

Operation - Operating elements

Note To switch from Screen 1 to Screens 2, 3, 4, 5, 6 and 7, you must press the ‘Arrow down key‘. Use the 'Arrow up key' to return to the previous screen.

Screen 2

Engine oil pressure

1 2 3

Engine rpm

Screen 3

Hydraulic oil

4 5 6

Battery voltage

835 / 01.2009

1 Engine oil pressure

4

Hydraulic oil temperature

2 Warning threshold Engine oil too low

5 Warning threshold Hydraulic oil temperature too high

3 Engine rpm

6 Battery voltage

Translation of the original operating instructions

5 - 41

Operation - Operating elements

or:

Screen 4

1

Daily operating hours counter

2

3 1 Daily operating hours counter ON 2 Daily hours of operation Note Switching to mask 4 can be done at any time from masks 1, 2 and 3.

This is done by pressing the "Hourglass button".

Set daily hours of operation counter to 0

Press the "ENTER button" for four seconds . This resets the daily hours of operation counter to 0.0 h.

Stopping or restarting the daily hours of operation counter

Press the "Hourglass button", to stop or restart the daily hours of operation counter.

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835 / 01.2009

Operation - Operating elements

Screen 5

IMPORTANT! Before setting the time and date, perform the basic setting (see mask 7)!

Set time

5 sec.

Time

"Set date"

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5 - 43

Operation - Operating elements

Setting the date

Date EC version: DD.MM.YY US version: YY.MM.DD

Screen 5

5 - 44

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835 / 01.2009

Operation - Operating elements

Screen 6

Error messages

Engine error code

Machine error code

2

1

SPN

3

5 sec.

SPN

4

1 2 3 4 5

835 / 01.2009

7 5 6 Total error messages selected error message error mess. not ack. error mess. ack.

Error detected: Time

6 7 8 9

9 8 Error detected: Date Error detected: Hours of operation SPN error code (97) FMI error code (3)

Translation of the original operating instructions

5 - 45

Operation - Operating elements

Note In mask 6 you can read the number of error messages and the respective diagnostic codes.

ATTENTION! To allocate the error messages and the respective diagnostic codes properly, read the following diagnostic code list. Call upon SENNEBOGEN customer service if you have questions and for fault rectification.

Note A severe error is indicated by the symbol with the dark background, the pulsating buzzer and the illuminated red "!" warning symbol. The buzzer will only stop after acknowledging the fault. The symbol will no longer have the dark background but it will flash. As long as the fault is active, the red warning sign will be illuminated on the right, under the button field.

Note The fault messages can be acknowledged by pressing the "ENTER button" for 5 seconds but they are not deleted.

Note The diagnostics codes indicated in the list are by no means complete.

Other diagnostics codes (flash codes) and possible disruptive influence on the engine performance are located in the respective chapter of the operating instructions for the respective engine manufacturer.

Note Example of an engine error code (SPN/FMI diagnostics codes): SPN = 100; FMI = 4: i.e. engine oil pressure sensor - short circuit – SPN = Suspect Parameter Number – FMI = Failure Mode Identifier

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Operation - Operating elements

List of possible error codes

835 / 01.2009

101, 102 or 103

Coolant temperature

111, 112 or 113

Engine oil pressure

121, 122 or 123

Diesel fill level

131, 132 or 133

Hydraulic oil temperature

141, 142 or 143

Battery voltage

151

Air filter

161

Hydraulic oil return filter

171

HydroClean superfine filtration system

181

Hydraulic pilot control filter

191

Coolant level

201

Hydraulic oil flap

211

Hydraulic oil level

Translation of the original operating instructions

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Operation - Operating elements

Error memory

+ 5 sec.

1

2

3

4 5 6

1 Error memory

5 Error acknowledged

2 Number of stored errors (10)

6 Error cleared

3 Selected error (7) 4 Error detected

Note The error memory mask shows the storage location for faults registered by the SDS. It provides information on the time of the fault, the acknowledgement and the rectification.

Mask 6 must be active to open error memory 7. First, press the "ESCAPE key", then add the "ENTER key" and hold both pressed down for 5 seconds to enter this mask.

In this mask, selecting individual alarms is possible with the "arrow up button". After pressing the "ESCAPE button", mask 6 appears again.

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Operation - Operating elements

Screen 7 1 Perform basic setting

to screen 1 2 3

1 Temperature: °C or °F 2 Printing: bar or psi 3 Date: Day, Month, Year or Year, Month, Day

5 sec.

Temperature

Pressure

"Change date"

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Operation - Operating elements

Date

Start-up mask

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Operation - Operating elements

Indicator and warning lights (C)

The two indicator lights provide information on the current operating status (Slewing gear holding brake closed or accumulator pressure for the parking brake built up).

The warning lights are illuminated if the SDS determines an irregularity.

The warning lights indicate two different priorities: Priority 1: Switch off machine immediately according to Section5.8.

Rectify the irregularity immediately (e.g. check cooling system or hydraulic system for leaks, fill with coolant/hydraulic oil).

Priority 2:Rectify irregularities as soon as possible (rectify by the end of the work day at the latest - e.g. clean/replace air filter -). Clean/replace air filter -). Indicated by the four top yellow warning lights.

1

2

3

5

4

a b

10

9

8 Warning lights: 1

Air filter - contamination indicator Replace indicators - hydraulic system

2

Auxiliary control filter

5 ATTENTION - General (in combination with symbols from the screen as well) 7

835 / 01.2009

6

8 Hydraulic tank cover (Optional) 10 Coolant level a Priority 2 b Priority 1

Hydraulic return filter

3 HydroClean 4

7

Indicating lights 6

Parking brake Accumulator pressure

9 Slewing mechanism holding brake

Hydraulic oil level

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Operation - Operating elements

Error displays on the screen Symbol flashes, Buzzer sounds and red "Attention" illuminates

Cause

Remedy

Hydraulic oil temperature too high (> 84 °C/183 °F)

– Allow engine to run without load until hydraulic oil has cooled.

Cooling fins on hydraulic oil cooler soiled

– Clean cooling fins on oil cooler.

Hydraulic oil level too low

– Check oil level acc. to maintenance instructions.

– Top up hydraulic oil, if required .

Symbol flashes, Buzzer sounds and red "Attention" illuminates

Cause

Remedy

Insufficient fuel in tank

– Refuel machine acc. to Section5.7.

Symbol flashes, Buzzer sounds and red "Attention" illuminates

Cause

Remedy

Engine overheating

– Run engine at idling speed.

Cooling fins on engine oil cooler soiled

– Clean cooling fins on oil cooler.

Fan drive loose or defective

– Tighten fan drive; replace, if necessary.

Coolant level too low

– Top up coolant according to maintenance instructions.

Engine switched off without cooling phase.

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

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Operation - Operating elements

Symbol flashes, Buzzer sounds and red "Attention" illuminates

Cause

Remedy

Motor oil pressure too low (< 1.3 bar/18.9 psi)

– Shut down engine immediately.

– Check engine oil level acc. to maintenance instructions.

– Top up motor oil if necessary.

– If it happens again, Notify SENNEBOGEN customer service

Symbol flashes, Buzzer sounds and red "Attention" illuminates

Cause

Remedy

Battery charge too weak

– Check battery charge; recharge batteries or exchange, if necessary.

– Check battery connections, tighten terminals if necessary.

– Check the belt tension and tighten or replace if necessary.

SDS buffer battery

If the battery symbol appears on the start screen, there is a fault!

Voltage diplay <= 2.50V Battery is too low!

Insert new battery! It is possible that system data will not be stored securely anymore!

Voltage diplay >= 3.50V Battery is defective or missing completely!

Install new battery! System data is no longer stored.

Note Have the battery installed by an authorised SENNEBOGEN - Partner of your choice.

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Operation - Operating elements

Warning and indicator lights

illuminate, warning buzzer sounds

Cause

Remedy

Coolant level too low

– Top up coolant.

Illuminates when engine is

Cause

Remedy

Accumulator pressure too low

– Have a hydraulic specialist check the hydraulic system.

illuminates, buzzer sounds

Cause

Remedy

Hydraulic oil level too low

– Top up hydraulic oil

lights up

Cause

Remedy

Slewing gear holder brake applied

– Deactivate slewing gear holding brake

Cause

Remedy

Return filter is clogged

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

Cause

Remedy

HydroClean Superfine filter is plugged

– HydroClean Check micro-filter, replace if necessary.

lights up

lights up

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835 / 01.2009

Operation - Operating elements

lights up

lights up

Cause

Remedy

Auxiliary control filter is blocked

– Check auxiliary control filter, if necessary change acc. to maintenance instructions.

Cause

Remedy

Air filter contaminated

– Clean filter acc. to maintenance instructions.

– If necessary, replace filter element.

Note The indicator and warning lamp template foil cannot be exchanged. It is possible however to print the template for the three free fields individually with a laser printer. Remove the entire front plate and pull or push the fields out or in.

Note The internal battery for the SDS has a minimum life-span of three years. Practice testing shows periods of up to 10 years however.

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Operation - Additional displays (special equipment)

5.4

Additional displays (special equipment)

5.4.1 SENNEBOGEN Tool Control The SENNEBOGEN Tool Control enables operation of several working tools (e.g. Grabber, Demolition hammer) with different requirements for maximum permissible flow volumes and pressures.

The maximum permissible flow volume and pressure is adapted to the respective working tool by the SENNEBOGEN Tool Control.

CAUTION Before starting work, select the operating mode for the respective tool!

1 2 Selecting the operating mode

3

4

1

Start engine acc. to Section5.7.3.

2

Loosen the safety lever (see Section5.3.3).

Note After releasing the safety lever, the last selected tool is indicated on the display (3).

3

Press buttons (1) and (2) and select the desired operating mode.

The selected tool (operating mode) appears on the display (3).

Note To change the setup parameters, use special tools and contact SENNEBOGEN customer service if necessary.

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Operation - Additional displays (special equipment)

Note If a button is pressed and held for a longer period of time, the button lock is activated. The button lock can be triggered by simultaneously pressing buttons (+) and (-).

If no button is pressed for a longer period of time, the display (3) switches off (energy/screen-saver), the operation LED (4) continues to be lit however. By pressing any button, the display (3) is activated again.

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Operation - Additional displays (special equipment)

5.4.2 Load moment limiter (LML)

The machine is equipped with a load moment limiter (LML) as an overload safety.

Danger Working with switched off, bypassed or defective load moment limitation is not allowed.

Note More information can be found in Chapter 10.

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Operation - Additional displays (special equipment)

5.4.3 Generator and Magnet Systems Note The automatic idle function remains deactivated as long as the magnetic equipment is on.

Note More information can be found in Chapter 10.

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Operation - Additional displays (special equipment)

5.4.4 Camera/Monitor

Note More information can be found in Chapter 10.

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Operation - Additional displays (special equipment)

5.4.5 Auxiliary heating / Water heater The machine is equipped with an engine-independent water heater for engine-heating and cab-pre-heating.

The electric water heater is set up in the factory and is controlled along with the automatic air conditioning (see Section5.3.12).

Note The battery power can be used by operating the water heater.

1 1 Control element for water heater

Note More information can be found in Chapter 10.

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Operation - Additional displays (special equipment)

Maintenance flap rear, left

2

WARNING Fault!

If the "red" indicator lamp is illuminated, the coolant level is low in the water heater. The electric water heater (2) is then deactivated by the safety cut-out.

Check the coolant level according to Section5.5.9.

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Operation - Additional displays (special equipment)

5.4.6 Low-temperature package Auxiliary heater/ Water heater

The machine is equipped with an engine-independent water heater for engine-heating and cab-pre-heating.

Note The battery power can be used by operating the water heater.

1 1 Control element for water heater Note More information can be found in Chapter 10.

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Operation - Additional displays (special equipment)

Heater for Water separator

The machine is equipped with a heated water separator (1).

1

2

In order to activate the heater for the water separator (1), activate the switch (2) in the right-hand control panel.

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1

Start engine acc. to Section5.7.3.

2

Switch on the heater for the water separator with switch (2).

– The indicator lamp in switch (2) is illuminated until the fuel has achieved operating temperature (=Thermostat).

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835 / 01.2009

Operation - Additional displays (special equipment)

Hydraulic oil pre-heater

The hydraulic oil pre-heater (1) is attached to the hydraulic tank. The heating time is significantly reduced by the hydraulic oil pre-heater.

2 1

3

To activate the hydraulic oil pre-heater, the socket (3) on the left-hand storage space of the machine must be connected to the power supply (230 V).

Sennebogen supplies only the plug, not the cable for the power supply to the socket (3)!

The cable must be connected by trained specialist personnel.

Set the temperature using the regulator (2) on the thermostat (presetting: 20 °C (68 °F)).

The thermostat switches off once the operating temperature has been reached.

Note To increase the effectiveness of the hydraulic oil preheating, retract all hydraulic cylinders.

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

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Operation - Additional displays (special equipment)

Batter heater

The machine is equipped with a battery heater.

3

To activate the battery heater, the socket (3) on the left-hand storage space of the machine must be connected to the power supply (230 V).

Sennebogen supplies only the plug, not the cable for the power supply to the socket (3)!

The cable must be connected by trained specialist personnel.

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

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Operation - Additional displays (special equipment)

5.4.7 External loudspeaker system Note The machine is equipped with an external loudspeaker system (1).

Use switch (2) to switch the microphone (3) on.

There is no intercom system.

1

3

2

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Operation - Application

5.5

Application

5.5.1 Safety instructions DANGER z Read Chapter 1 SICHERHEIT. Before start-up, carry out checks according to Section5.4 . z Persons working on or with the machine must be trained or

instructed for that purpose.

Operation and deployment may only be carried out by suitably trained personnel. z Proceed with utmost caution if you override the Stick end limit. z Ensure that there is no one in the danger zone. z Maintain safety distance to overhead lines. z Only operate the machine from the driver's seat. z Do not transport persons on the machine. z Consider environment conditions, e. g. poor visibility, wind speeds,

etc. z Use the specific lifting capacity table for that machine. z Note performance specification. z Check that anchorage points have a sufficient safe working load. z Observe guide signals as necessary. z Never allow the machine to roll with the ignition switched off. When

the engine is not running, there is no power-assisted steering. z Position boom in direction of travel during long journeys. z Before leaving the driver's cab:

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

– Lock the floating axle.

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Operation - Application

5.5.2 Maneuvering cab Safety instructions DANGER Danger of accident when cab is tilted!

Cab mounting, check bolts and screw fastenings daily! z Move the machine only with the cab lowered and retracted and the

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

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

deployed! z Keep the driver's doors closed z Fasten restraint belt (optional) in accordance with Section5.7.2. z Maneuvering the cab is prohibited when individuals and/or objects

are on the gallery (platform).

DANGER Danger to life through shearing and crushing forces!

Make sure that there is no one within the danger area of the suspended cab. The danger area is the area z on and under the cab, z on/under the mechanical cab supporting structure.

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Operation - Application

Maneuvering cab

1 2

3* 4*

*: Optional model / special function

Cab elevating/lowering

1

Press safety lever (see Section5.3.3) forwards.

2

Switch the machine on as described in Section5.7.

3

Press rocker switch (1).

The cab is raised (Cab up).

4

Press rocker switch (2).

The cab is lowered (Cab down).

Note Do not elevate the cab to the uppermost/furthest forward limit setting (OT).

Stop the cab approx. 10 cm before the uppermost/foremost limit. This provides optimum damping characteristics and pleasant working conditions in the cab.

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Operation - Application

Cab extend/retract (optional)

835 / 01.2009

1

Press safety lever (see Section5.3.3) forwards.

2

Switch the machine on as described in Section5.7.

3

Press rocker switch (3*).

The cab is extended (Cab out).

4

Press rocker switch (4*).

The cab is retracted (Cab in).

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Operation - Application

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

Location: To the right of the right-hand control lever. This is the same button that is used for "Cab down".

Necessary e. g. in event of a fault in drive system. z Emergency lowering (outside the cab)

Location: Under the front left-hand service door.

Necessary for situations in which the machine driver has a health complaint which places him/her in a hazardous situation.

DANGER Danger to life through shearing and crushing forces!

Make sure that there is no one within the danger area of the suspended cab. The danger area is the area z on and under the cab, z on/under the mechanical cab supporting structure.

Emergency loweringin the cab

2

1

Press rocker switch (2).

– The cab lowers slowly.

DANGER The lowering movement is ended if the button is released.

This function is no longer possible with battery isolator switch "off".

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Operation - Application

Emergency loweringoutside the cab

2

shown = cab elevated

1

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

2

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

Note The emergency lowering lever is located under the front left-hand service doors.

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Operation - Application

5.5.4 Driving machine - Mobile DANGER Risk of accident through incorrect use!

If the boom is positioned above the rear axle, the driving actions of the machine are reversed. Proceed with extreme caution whenever you wish to work or maneuver over the rear axle.

Driving with suspended load

Please note the following points when driving with a suspended load: z Danger of tipping!

Keep loads as close as possible to the ground when moving. z Always position stick lengthwise to undercarriage. z Only carry 50 % of the permitted safe working load. z Pylon (option) /Drive only along machine and without load z Only drive on even ground with sufficient load-bearing capacity. z Reduce pendulum movements of load by sensitive driving. z Negotiate corners with as wide a radius as possible.

DANGER Risk of accident through incorrect use!

If the boom is positioned above the rear axle, the driving actions of the machine are reversed. Proceed with extreme caution whenever you wish to work or maneuver over the rear axle.

Note A red indicator arrow (1) is located at the front of the undercarriage.

This can be seen through the right-hand cab window. It indicates that the boom is over the front axle.

1

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Operation - Application

1

2

4 3

Driving

1

Actuate and lock the service brake (1).

2

Start engine (2).

3

Push safety lever (3) forward.

4

Retract stabilizers (4) if necessary.

Note Further information on steering can be found in Section5.3.

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Operation - Application

5

6

5

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

6

Release the floating axle (6) if necessary.

7 8 9

10

7

Actuate the release lever (7) for the service brake (8).

8

Select the direction of travel by actuating the accelerator pedal (9).

9

Slow the machine via the service brake (8).

10

Switch off machine according to Section5.8.

11

Always apply the service brake (8) when leaving!

12

Pull back the safety lever (10).

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

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Operation - Application

5.5.5 Stabilizing machine - Mobile The machine is stabilized on an uneven surface by using the support legs. This increases the standing stability. Load capacities see Section3.2.

CAUTION Position stabilizers on a firm, even base.

Do not raise machine using the stabilisers. The tires must remain in contact with the ground.

CAUTION Never extend the stabilizers completely (= to the stop). The weight will not be distributed evenly over the individual stabilizers this way, i.e. the maximum standing safety is not guaranteed.

If you extended the supports completely (audible sound), retract them slightly!

correct

incorrect

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Operation - Application

a

1 b Actuation of all supports: 1 Outrigger lever a ahead = extend b back = retract

Extending full stabilizers

1

Applying the parking and service brakes.

2

Start engine acc. to Section5.7.3.

3

Loosen the safety lever (see Section5.3.3).

4

Lock the floating axle with the switch on the front right of the control panel (lamp in switch does not light up).

5

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

DANGER Observe reduced lifting capacities for a machine that is not stabilized!

Extend single stabilizer (optional)

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1

Applying the parking and service brakes.

2

Start engine acc. to Section5.7.3.

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835 / 01.2009

Operation - Application

a

1 b

Actuation of all supports: 1 Outrigger lever a ahead = extend b back = retract

3

4

2

5

Single actuation for stabilizers: 2 rear left 3 front left 4 front right 5 rear right

3

Loosen the safety lever (see Section5.3.3).

4

Lock the floating axle with the switch on the front right of the control panel (lamp in switch does not light up).

5

On uneven ground, make sure to level the machine by using the individual stabilizers.

E.g.: Extend the front left outrigger: – Press button (3) (and hold pressed) and simultaneously press the lever (1) ahead.

– Proceed in the same way for the other three outriggers.

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Operation - Application

Retracting outrigger

1

Applying the parking and service brakes.

2

Start engine acc. to Section5.7.3.

3

Loosen the safety lever (see Section5.3.3).

4

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

5

Check that all four supports are retracted completely.

1 b Actuation of all supports: 1 Outrigger lever b back = retract

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Operation - Application

5.5.6 Superstructure rotation/braking The upper structure is slewed using the left-hand control lever.

DANGER There is a danger of tipping with additional counterweight in which case, the machine must be stabilized when slewing the superstructure!

WARNING Never rotate the upper structure when the slewing gear holding brake is applied!

2*

Joystick steering version 1

c

d

Left control lever

1 Slewing gear holding brake switch 2* Slewing gear holding brake pedal (optional) Motions of left control lever: c

Slew upper structure, left

d Slew upper structure, right

*: Optional model / special function

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Operation - Application

Note In order to rotate the superstructure, the ignition must be switched on, the safety lever must be released (pressed ahead) and the slewing gear holding brake switch "right" must be pressed.

If only one of these criteria is not met, rotation is impossible.

Slewing speed

The slewing speed is dependent on the: z speed of the driving engine z Distance the left control lever is moved.

DANGER No persons, buildings or machines may be within the slewing range of the upper structure (danger area).

Rotation stop (braking)

Slewing gear holding brake

1

Place the left control lever in the neutral position (0-position).

The upper structure is hydraulically braked. The slewing maneuver gradually stops. Note: Moving the control lever in the opposite direction intensifies the braking action.

OR optional: Actuate the slewing gear holding brake pedal (2). The upper structure is braked hydro-dynamically.

the slewing gear holding brake is not an operational brake for braking the superstructure. The slewing gear holding brake serves exclusively as a parking and holding brake when the superstructure is at rest.

The superstructure must have stopped rotating completely before the slewing gear holding brake is applied.

WARNING If the slewing gear holding brake is used to stop the upper structure, serious damage will be caused to the brake and/or the slewing gear.

This damage can be of the following nature: z Diminished braking effect due to clutch plate damage z Irreparable damage to the brake or other components z Irreparable damage to the slewing gear

This damage is excluded from the terms of warranty issued by SENNEBOGEN Maschinenfabrik GmbH The operator of the machine alone is liable for such damage as well as any consequential damage - for instance, that resulting from reduced braking action!

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Operation - Application

Note The slewing gear holding brake is applied automatically as soon as z the safety lever is pulled back or z the engine is switched off (e.g. emergency shut-down, key switch).

In adverse conditions it may take 30 seconds before the full braking effect is applied.

Activate slewing gear holding brake

Move switch (1) to the "left" on right-hand control panel.

The slewing gear holding brake is activated, the indicator lamp in the switch is not illuminated. The red indicator symbol also illuminates in the SDS.

Deactivate/release the slewing gear holding brake

Move switch (1) to the "right" on right-hand control panel.

The slewing gear holding brake is released. The green LED is illuminated in the switch and the red indicator lamp in the SDS goes out.

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Operation - Application

5.5.7 Lifting /lowering loads Heed the following safety instructions: DANGER z A suspended load is an accident risk!

Always lower the load when work is interrupted.

Never leave the driver's cab when a load is suspended. z Activate the overload warning device z Do not carry out any form of work which will reduce the stability of

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

extreme caution. z Observe danger area.

The load is hoisted/lowered using theleft-hand and/or the right-hand control lever.

A a

B

Arm speed

b

Control lever, left-hand

Control lever, right-hand

Movement directions:

Movement directions

A Lift load (Stick out)

a Lower load (hoist down)

B Lower load (Stick in)

b Lift load (hoist up)

The arm speed depends on the: z speed of the driving engine z Distance the left control lever is moved. z Load on end of Stick

Lift speed

The lift speed depends on the: z speed of the driving engine z inclination of the right control lever. z Load on end of Stick

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Operation - Application

5.5.8 End limit cut-out equipment The end limit cut-out switch prevents the hydraulic cylinders from striking against the end stop.

DANGER Under no circumstances should the settings for limit cut-out made in the factory (3) be changed!

This setting may only be adjusted by SENNEBOGEN Customer Service or an authorized SENNEBOGEN service partner!

The following damage can occur, if the operator adjusts the end limit cut-out on his own: z Wear in the cylinder mounting bearings and boom. z Damage to the hydraulic cylinder. z Increased machine wear.

This damage is excluded from the terms of warranty issued by SENNEBOGEN Maschinenfabrik GmbH The operator of the machine alone is liable for such damage as well as any consequential damage!

Safety limit position sensor for "Arm in"

The safety limit cut out “Retract stick” is set at the factory as follows: z Stick in: Stick (without attachment) approx. 2.5 m in front of lowered

cab

1 2 3 2,5m

1

Compact boom

3 Grabbing stick

2 Sensor element

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Operation - Application

DANGER Danger to life if the safety limit position sensor for "Stick in" is set incorrectly!

Attachments or parts of the load can strike and penetrate the cab.

Always adjust the basic factory setting to take into account any attachment (e. g. grab). The operator alone is responsible for operation of the machine with an incorrectly set safety limit position sensor for "Stick in"!

Additional limitations

With the optional additional limitations, you can limit the "Stick out" or "Hoist up". This is useful z near power lines (see Section1.9) z in buildings with limited headroom z under bridges z when working with attachments not supplied by SENNEBOGEN.

Note The following safety end limit cut-outs can be used optionally: z "Stick out" z "Boom up" (Hoist up) z "Boom down" (Hoist down)

Note The optional additional limit cut-outs cannot be bypassed.

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Operation - Application

Auxiliary limiting - Hoist

1

Additional limitation "Hoist down" (Optional)

2

Limit cut out – hoist down

3

Additional limitation "Hoist up" (Optional)

4

Limit cut out – Hoist up 1 2 3

4

DANGER Under no circumstances should the setting for limit shutdown made in the factory (2, 4) be changed!

This setting may only be adjusted by SENNEBOGEN Customer Service or an authorized SENNEBOGEN service partner!

With additional limitation installation - Set hoist as follows: 1

Raise the compact boom carefully to just below the maximum height/depth limit (maintain safety distance!).

2

Loosen the hexagon nuts for the additional limits (1) or (3).

3

Additional limits (1) or (3) are to be moved until the sensors are triggered (LED on sensor goes out).

4

Tighten the hexagon nuts for the additional limits (1) or (3).

5

Switch the rocker switch Additional limitation on at the control panel.

6

Check setting and repeat if necessary.

Note The optional additional limit cut-outs (1, 3) cannot be bypassed.

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Operation - Application

Auxiliary limiting - Stick out

5

6

5 Additional limit "Stick out" (optional) 6 Lift limit "Stick out" (optional)

DANGER Under no circumstances should the setting for limit shutdown made in the factory (6) be changed!

This setting may only be adjusted by SENNEBOGEN Customer Service or an authorized SENNEBOGEN service partner!

With additional limitation installation - Set stick as follows: 1

Raise the Stick carefully to just below the maximum height limit (maintain safety distance!).

2

Loosen the hexagon nuts for the additional limits (5).

3

Adjust additional limits (5) until sensors responds (LED on sensor goes out).

4

Tighten the hexagon nuts for the additional limits (5).

5

Switch the rocker switch Additional limitation on at the control panel.

6

Check setting and repeat if necessary.

Note The optional additional limit (5) cannot be bypassed.

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Operation - Application

5.5.9 Bypassing the safety limit position sensor for "Stick in" In exceptional circumstances it may be necessary to move beyond the safety end limit (bypass safety end limit cut-out).

Note The optional additional limit cut-outs cannot be bypassed.

1 2

1 Pushbutton 2

Control lever, left-hand

DANGER Danger to life through overriding safety end limit cut-out!

835 / 01.2009

1

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

2

Move the control lever in the respective direction with extra care depending on the work function (Stick in/out, Hoist up/ down). See also Section5.3.4 and Section5.3.5.

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Operation - Application

5.5.10 Working with the grab Heed the following safety instructions: WARNING z A suspended load is an accident risk!

Always lower the load when work is interrupted.

Never leave the driver's cab when a load is suspended. z Activate the overload warning device. z Do not carry out any form of work which will reduce the stability of

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

extreme caution. z Observe danger area.

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

c

Grab motions

Movement directions:

1 Rotate counterclockwise

c

Close grab

2 Rotate clockwise

d

Open grab

1,2

c, d

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Operation - Application

5.5.11 Operation with generator and magnet system (special function) Heed the following safety instructions: DANGER z Risk of fatality!

A suspended load is an accident risk!

If the magnet system fails, the load will fall.

Always lower the load when work is interrupted.

Never leave the driver's cab when a load is suspended. z Activate the overload warning device and check that it is operating

properly. z Ensure that the Automatic idle is deactivated. z During operation, dangerous voltages can occur. z Parts of the generator can become very hot even after operation. z Inserting or removing plugged connections during operation is not

permitted. z Installation/start-up as well as maintenance and service work on the

magnet system are to be performed only by authorized and qualified technicians. z Before using the magnet system, read the manual. z Use permitted accessories only. For more information, please

contact SENNEBOGEN customer service. z Operation is only allowed with magnet plates: other applications are

not permitted. z Observe operating data. z Cleaning with a high-pressure washer (steam cleaner) is not

allowed. z The openings for the condensation vent must be at the lowest point. z Observe further safety guidelines. z No changes may be made to the generator (e. g. location, drive

type).

Note Deactivate the ECO switch when working with the Magnet unit (see Section5.3.14)!

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Operation - Application

Operation 1

1

Start engine acc. to Section5.7.3.

2

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

3

Set the magnet according to the load material.

WARNING Ensure that the permitted load limits are not exceeded.

3

2

4

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

– Press the front pushbutton (2) on the right control lever.

5

Dropping the load: – Press pushbutton (2) or *(3). * Customer-specific switch allocation!

6

Switching off the magnetic equipment.

– Actuate the switch on the control panel:

CAUTION If the magnet system is not switched off after use, the entire system (generator and magnet plate) can overheat.

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Operation - Application

Note The automatic idle function remains deactivated as long as the magnetic equipment is on.

4

Note Further information on the control unit (MMI) (4) can be found in Chapter 10.

835 / 01.2009

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5 - 93

Operation - Application

5.5.12 Working with scrap shears (special function) Heed the following safety instructions: WARNING z A suspended load is an accident risk!

Always lower the load when work is interrupted.

Never leave the driver's cab when a load is suspended. z Activate the overload warning device. z Do not carry out any form of work which will reduce the stability of

the machine! z Attachments (e. g. scrap metal shears) and load elements can

swing. Proceed with extreme caution. z Observe danger area.

CAUTION Select the correct operating mode in SENNEBOGEN Tool Control (see Section5.4.1).

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

5 - 94

c

Scrap shear motions:

: Movement directions

1 Rotate counterclockwise

c Close scrap shears

2 Rotate clockwise

d Open scrap shears

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835 / 01.2009

Operation - Application

5.5.13 Working with a hydraulic hammer (special function) Note The hydraulic hammer is tipped with the left pedal.

1

2

CAUTION Select the correct operating mode in SENNEBOGEN Tool Control (see Section5.4.1).

1

Press button (2) and hold pressed to activate the hydraulic hammer.

2

Push pedal (1) forward. The turning cylinder is retracted, the hydraulic hammer tips upward

3

Push pedal (1) back. The turning cylinder is extended, the hydraulic hammer tips downward

Note Preselecting function floating position (see Section5.3.14). The full weight of the boom affects the hammer.

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5 - 95

Operation - Vario Tool - Changing equipment

5.6

Vario Tool - Changing equipment

The machine can be optionally equipped with a Stick for grabber operation, scrap cutters, reversing inserts (ULM) and other attachments released by SENNEBOGEN. The rubber mounted coupling element is on the attachment side, the non-rubber mounted coupling element is on the base unit!

Note Operating the grabber and the scrap cutter is described in Section5.5.10 and Section5.5.12.

DANGER Tool attachments can fall!

With mounted attachment tools and locked Vario Tool, the locking mechanism is under pressure.

If the pressure drops to under the value defined by SENNEBOGEN, a signal tone will sound.

Contact the SENNEBOGEN customer service immediately!

5.6.1 Coupling

1

3

2

5 - 96

2

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835 / 01.2009

Operation - Vario Tool - Changing equipment

1

Coupling (1), guides (2) and hooks (3) on the base part and on the adapter of the attachment tool are to be cleaned thoroughly.

4

5

4

6

7

1

Illustrated: Base part (4) hung in place DANGER Squashing and crushing can occur.

There must be no one below a suspended load.

835 / 01.2009

2

Position the machine so that the equipment of the machine and the attachment tools create a line (aligned)

3

Carefully hang the base part (4) with the hooks (5) inside in the bolts (7) of the adapter (6).

4

Carefully raise the stick base (4) and the compact boom.

Note: Only life the base part (4) as shown above.

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5 - 97

Operation - Vario Tool - Changing equipment

10 9 8

5

Press the switch (8) on the "right" and release the Vario Tool A signal tone sounds.

6

Press the button (9) "left" approx. 3-5 sec. The lock (10), cannot be seen, is opened.

4

1

Illustrated: Stick base (4) hung in place and coupled 7

Carefully lift the Stick base (4) and the compact boom until both parts couple into place.

NOTE! The faster the coupling takes place, the less oil is lost.

5 - 98

8

Press the button (9) "right" and close the lock (10).

9

Press the switch (8) "left" and lock the Vario Tool The signal tone no longer sounds.

10

Set the attachment tool in the SENNEBOGEN-Tool-Control (see Section5.4.1).

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835 / 01.2009

Operation - Vario Tool - Changing equipment

5.6.2 Disconnecting 1

Set down the attachment tool so that it cannot fall over after disconnecting.

2

Disconnecting the attachment tools is done in reverse order to connecting them.

DANGER Danger of tipping!

The attachment tool can tip over, if the lock (10) is released and the hook (5) is unhooked.

Before releasing the lock (10) and before unhooking the hook (5), ensure that the attachment tool can be set down securely and is secured against tipping over.

5.6.3 Cleaning Depending on the environmental conditions (e.g. dust development) and/or the amount of times that the attachment tool has to be changed, the cleaning of the couplings on the base part as well as on the attachment part may have to be done several times per day.

DANGER Risk of fatality!

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.

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5 - 99

Operation - Vario Tool - Changing equipment

1

Disconnect the attachment tool and secure against tipping over. Perform cleaning on the base part and the attachment tool.

2

Hold the coupling protection (1), unscrew the retaining bushing (2) completely. Make sure that the parts (3, 4) remain in the coupling unit and do not fall out.

2

3 1

4 5

5

5 - 100

3

Flip the coupling protector (1) to the rear.

4

Check the guides (5) and the 8 hydraulic couplings (6) for cleanliness and clean with a soft cloth and cleaning spray if necessary.

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835 / 01.2009

Operation - Vario Tool - Changing equipment

6

5

5

5

Check hydraulic couplings for leaks. Small drops of hydraulic fluid (7) are allowed. If several drops occur within 5 - 10 minutes, contact the SENNEBOGEN customer service.

8

7

835 / 01.2009

7

6

Check the seal (8) for damage and replace if necessary.

7

Close the coupling protection (1), hold and tighten the retaining bushing (2) until resistance is detected.

8

The Vario Tool is ready for application again.

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5 - 101

Operation - Refueling machine

5.7

Refueling machine

The machine can be refueled in two ways: z Manually z using a refueling pump

DANGER z Fuel is damaging to health and easily inflammable.

Smoking and working near an open flame is strictly forbidden. z Position the machine on a firm, even surface. z Only refuel when engine is shut down! z Fuel must not ingress ground or waterways.

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

amount of fuel that the tank can taken on. z When refuelling from a tank-truck or trailer, the following applies:

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

the filling is done.

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

Manually

1

Lower suspended loads and Stick to the ground.

2

Shut down engine.

1 2 4

5 - 102

3

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835 / 01.2009

Operation - Refueling machine

using a refueling pump

3

Open left rear maintenance panel.

4

Open cap (1) of filler strainer.

5

Clean strainer.

6

Insert funnel in filler strainer.

7

Carefully pour in fuel through the funnel.

8

Replace cap (1) and close side panel.

1

Lower suspended loads and Stick to the ground.

2

Shut down engine.

3

Place the key switch in the "P" position.

4

Open left rear maintenance panel.

5

Open cap (1) of filler strainer.

This will allow air to escape from the fuel tank.

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

6

Insert refueling hose (4) in the external fuel container.

Note Danger of cavitation!

Ensure that the maximum suction height of 3 m (3.28 ft) is not exceeded.

7

Switch on refueling pump with the green button (2).

The tank is automatically filled.

CAUTION Ensure that the pump does not run dry (> 30 s).

Switch off refueling pump with the red button (3) if necessary to prevent damage.

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5 - 103

Operation - Refueling machine

8

Monitor fuel level via the inspection glass on the fuel tank.

Switch the pump off with the red button (3) as soon as the tank is full.

9

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

10

Re-close cover (1) of filler strainer.

11

Close service access door again.

Note Check the following points if the refueling pump does not start after approx. 5 seconds:

5 - 104

1

Is the battery charged?

2

Are all fuses in order?

3

Is the suction side free of leaks?

4

Is the maximum suction height 3 m or less?

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Operation - Actions to take if the electronics fail

5.8

Actions to take if the electronics fail

Note An electronic failure is indicated only if the corresponding function can no longer be performed.

5.8.1 Reverse airflow -insufficient cooling capacity-

1

1 Plug for hydraulic cooling pump

1

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Pull the plug (1).

– Fan goes to maximum speed, 100% cooling capacity.

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5 - 105

Operation - Actions to take if the electronics fail

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

2 3

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

5 - 106

1

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

2

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

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Operation - Towing

5.9

Towing

CAUTION Use a steel cable with an appropriate strength rating when towing a defective machine. Do not use the holes in the shackles and eyes welded to the undercarriage for towing (these are intended solely for securing the machine during transport).

Note An emergency actuating mechanism that permits emergency towing of the vehicle in the event of loss of control pressure or a faulty hydraulic motor is located on the power shift transmission CAUTION If the emergency actuating mechanism is not properly deactivated, the transmission will be damaged during normal operation. Because the transmission is not lubricated during towing, the following procedures must be observed: z Towing speed: max. 10 km/h (6 mph) z Distance towed: max. 5 km (3 miles)

For longer distances, the defective machine is to be transported using a suitable lowboy trailer.

)

CAUTION The parking brake does not function, if the emergency actuating mechanism has been activated.

No attempt to shift gears should be made, if the emergency actuating mechanism has been activated.

WARNING The grease nipple (1) 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

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5 - 107

Operation - Towing

Valve and nipple overview

3

2

1

)

3 Pressure-relief valve 2 Bleed valve 1 Lubrication nipple

3

2 1

Emergency actuation activated

Emergency actuation deactivated

5 - 108

1

Shut off the engine.

2

Prevent the vehicle from rolling away.

3

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

1

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

2

Select on-road operation.

3

Apply the driving brake.

4

Close the bleed valve again.

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835 / 01.2009

Transportation - Safety instructions

6 Preliminary work

Transportation

Transport the machine using a flat bed truck. Carry out the following preliminary work: z Select a suitable transport vehicle.

Note the dimensions (Section6.2) and weight (Section6.4) of the machine. z Clean machine. z Place the boom and arm in the transport positions. z Lock upper structure and undercarriage according to Section6.5. z Secure the stabilizers in accordance with instructions. z If necessary, remove attachments.

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

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

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

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

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

gloves, safety boots). z Report any damage that occurred during shipping to

SENNEBOGEN customer service immediately.

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6-1

Transportation - Machine dimensions

6.2 Type MP 41 D

Machine dimensions

6.2.1 Mobile

Measurement information [mm]

K16

6-2

Load boom

Grab arm

Transport length (L)

Transport height (H)

9,1 m

6,9 m

13,40 m

3,45 m

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835 / 01.2009

Transportation - Machine dimensions

Type MP 42 D (Optional)

Measurement information [mm]

K16

835 / 01.2009

Load boom

Grab arm

Transport length (L)

Transport height (H)

9,1 m

6,9 m

13,40 m

3,45 m

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6-3

Transportation - Machine dimensions (Pylon)

6.3

6-4

Machine dimensions (Pylon)

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835 / 01.2009

Transportation - Machine weight

6.4

Machine weight

Undercarriag e Weight

Mobile approx. 46.0 t

Note The machine weight may deviate from these figures due to optional attachments. The information on the weight of the engine, the undercarriage and the compact loading equipment may also vary.

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6-5

Transportation - Lock upper structure

6.5

Lock upper structure

1

Move the upper structure to driving position.

2

Close slewing gear holding brake.

3

Pin and secure the locking rod (1) on undercarriage and upper structure.

1

6-6

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Transportation - Lifting machine

6.6 Safety instructions

Lifting machine

Observe the safety notes before starting work.

DANGER z Sling machine only at the designated slinging points. The slinging points are marked green and have a green loading hook symbol. z Ensure that the lifting gear has a sufficient safe working load and a

secure stability. z The following is suitable lifting gear:

– crane – telescopic crane z Ensure that the slinging equipment has sufficient safe working load

and is intact. z The following is suitable slinging gear:

– chain slinging gear – cable slinging gear – round loops / sling devices z Be careful of the danger zone!

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

Procedures with counterweights

F1

F2

1

Select a suitable hoisting crane and slinging equipment.

Observe weight and centre of gravity of the machine.

2

Fasten the suspension equipment on hoisting points F1 and F2.

3

Hoist machine carefully.

DANGER There must be no one below a suspended load!

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6-7

Transportation - Lifting machine

Hoisting point weight Weight on hoisting points F1 and F2:

6-8

MP 41 D

MP 42 D

F1

t

t

F2

t

t

FTot.

approx. 46 t

approx. 46 t

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Transportation - Tie down machine

6.7

Tie down machine

CAUTION z Secure machine at the designated tie-down points (1). The tie-down points are marked in green and are located on the undercarriage. z Ensure that the slinging equipment has sufficient safe working load

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

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

transportation of machine and accessories.

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1

1

Front view

Rear view

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6-9

Transportation - Disconnect electrical system from battery

6.8

Disconnect electrical system from battery

If the machine is idle for an extended period or for long transport distances, the electrical system must be isolated from the battery using the mechanical battery isolator switch.

WARNING Do not switch off mechanical battery isolator switch if: z the engine is still running z or other electrical consumers are still switched on.

Doing so may damage the electrical system and its controller.

1

1

Open left rear maintenance panel.

2

Turn the battery isolation switch (1) to the left (counterclockwise) and extract.

The electrical system is now isolated from the battery.

3

Close maintenance panel.

Note If no mechanical battery isolation switch exists, the battery poles must be disconnected. Properly install the battery protective caps again.

6 - 10

1

Open left rear service panel.

2

IMPORTANT! Prevent short circuits!

Disconnecting: 1. Disconnect the negative pole 2. Disconnect the positive pole Connecting: 1. Connect the positive pole 2. Connect the negative pole

3

Close service panel.

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835 / 01.2009

Troubleshooting - Driving engine

7

Troubleshooting

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

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

Customer Service Desk.

7.1 Driving engine Engine does not start

Engine performance

Machine does not move

Oil or fuel leaks from engine

Cause

Remedy

Battery power too low

– Check fluid level of batteries.

– Recharge or replace battery.

– Start machine using auxiliary battery.

Fuel tank empty

– Refuel machine.

Cause

Remedy

Suction resistance too high

– Exchange filter element in water separator.

Cause

Remedy

Parking brake actuated

– Release parking brake.

Transmission defective

– Have fault remedied.

Cause

Remedy

Hose connections loose

– Tighten hose connections.

Hoses or seals damaged

– Exchange hoses or seals.

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

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7-1

Troubleshooting - Hydraulic system:

7.2 Oil leaks from hydraulic system

Hydraulic system:

Cause

Remedy

Hose connections loose

– Tighten hose connections.

Hoses or seals damaged

– Exchange hoses or seals.

Hydraulic pump not working

Cause

Remedy

Fault in pump circuit

– Have fault inspected and rectified by hydraulic specialist.

No or faulty function of operating equipment

Cause

Remedy

Hydraulic oil level too low

– Check hydraulic oil level.

– Top up hydraulic oil , if required.

Leaks in Hydraulic system

– Check working cylinder, connections and hoses for leaks.

– Have fault rectified by hydraulic specialist.

Fault in one of the working circuits

– Have fault rectified by hydraulic specialist.

Cause

Remedy

Piston rod of cylinder without lubrication

– Have repair carried out by hydraulic specialist.

Noises when moving a working cylinder

7-2

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835 / 01.2009

Troubleshooting - Hydraulic system:

No or low power in hydraulic system

Noises in Hydraulic system

835 / 01.2009

Cause

Remedy

Hose connections loose

– Tighten hose connections.

Hoses or seals damaged

– Exchange hoses or seals.

Pressure relief valve opens too soon

– Have fault rectified by hydraulic specialist.

Hydraulic pump worn or defective

– Have pump exchanged by hydraulic specialist.

Cause

Remedy

Hydraulic pump takes in air

– Have fault rectified by hydraulic specialist.

Hydraulic pump delivers insufficient oil

– Check hydraulic oil level.

– Top up hydraulic oil , if required.

Pressure relief valve chatters

– Have fault rectified by hydraulic specialist.

Translation of the original operating instructions

7-3

Troubleshooting - Heater

7.3 No or insufficient heat output

No air flow

Heater cannot be switched off

7-4

Heater

Cause

Remedy

Water intake temperature too low

– Allow engine to warm up.

– Replace thermostat (in air conditioning system).

Thermostat on vehicle defective

– Replace vehicle thermostat.

Water valve does not open

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

Heat exchanger fins dirty

– Clean heat exchanger.

Filter contaminated

– Clean filter, replace if necessary.

No air flow

– see below.

Cause

Remedy

Fuse defective

– Replace fuse.

Power supply interrupted

– Check lines for loose contacts or open circuit.

Fan motor defective

– Have blower motor replaced.

Blower switch defective

– Check switch, replace if necessary.

Resistor defective

– Have resistor replaced.

Cause

Remedy

Bowden cable for water valve incorrectly adjusted

– Adjust Bowden cable.

Heating valve incorrectly fitted

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

Actuation or Bowden cable defective

– Exchange actuation or Bowden cable.

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835 / 01.2009

Troubleshooting - tires and undercarriage

7.4

tires and undercarriage

Oil leaks on differential, hubs or Axle distributor gear

Cause

Remedy

Sealing plug loose

– Tighten sealing plug.

Seals damaged

– Replace seals.

Oil leaks from slewing gear

Cause

Remedy

Loose connections

– Tighten connections.

Rotary transmission leaking

Cause

Remedy

Seals damaged

– Replace seals.

Lines loose

– Tighten locking bolts.

Cause

Remedy

Insufficient lubrication on slewing ring gearing

– Lubricate spur ring according to lubrication plan.

Noises in slewing gear

7.5 Cab Cab moves or swings drastically

835 / 01.2009

Cause

Remedy

Cab mounting or cab fastening damaged

– Check all connection elements, bolts and pins of cab mounting and fastening for damage, cracks or deformation.

– Have damaged components exchanged immediately by trained and instructed specialist personnel.

Translation of the original operating instructions

7-5

Troubleshooting - SDS fault indicators

7.6 Symbol flashes, Buzzer sounds and red "Attention" illuminates

SDS fault indicators

Cause

Remedy

Hydraulic oil temperature too high (> 84 °C/183 °F)

– Allow engine to run without load until hydraulic oil has cooled.

Cooling fins on hydraulic oil cooler soiled

– Clean cooling fins on oil cooler.

Hydraulic oil level too low

– Check oil level acc. to maintenance instructions.

– Top up hydraulic oil, if required .

Symbol flashes, Buzzer sounds and red "Attention" illuminates

Cause

Remedy

Insufficient fuel in tank

– Refuel machine acc. to Section6.7.

Symbol flashes, Buzzer sounds and red "Attention" illuminates

Cause

Remedy

Engine overheating

– Run engine at idling speed.

Cooling fins on engine oil cooler soiled

– Clean cooling fins on oil cooler.

Fan drive loose or defective

– Tighten fan drive; replace, if necessary.

Coolant level too low

– Top up coolant according to maintenance instructions.

Engine switched off without cooling phase.

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

7-6

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835 / 01.2009

Troubleshooting - SDS fault indicators

Symbol flashes, Buzzer sounds and red "Attention" illuminates

Cause

Remedy

Motor oil pressure too low (< 1.3 bar/18.9 psi)

– Shut down engine immediately.

– Check engine oil level acc. to maintenance instructions.

– Top up motor oil if necessary.

– If it happens again, Notify SENNEBOGEN customer service

Symbol flashes, Buzzer sounds and red "Attention" illuminates

Cause

Remedy

Battery charge too weak

– Check battery charge; recharge batteries or exchange, if necessary.

– Check battery connections, tighten terminals if necessary.

– Check the belt tension and tighten or replace if necessary.

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7-7

Troubleshooting - SDS fault indicators

Warning and indicator lights

illuminate, warning buzzer sounds

Cause

Remedy

Coolant level too low

– Top up coolant.

Illuminates when engine is

Cause

Remedy

Accumulator pressure too low

– Have a hydraulic specialist check the hydraulic system.

illuminates, buzzer sounds

Cause

Remedy

Hydraulic oil level too low

– Top up hydraulic oil

lights up

Cause

Remedy

Slewing gear holder brake applied

– Deactivate slewing gear holding brake

Cause

Remedy

Return filter is clogged

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

Cause

Remedy

HydroClean Superfine filter is plugged

– HydroClean Check micro-filter, replace if necessary.

lights up

lights up

7-8

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835 / 01.2009

Troubleshooting - SDS fault indicators

lights up

lights up

835 / 01.2009

Cause

Remedy

Auxiliary control filter is blocked

– Check auxiliary control filter, if necessary change acc. to maintenance instructions.

Cause

Remedy

Air filter contaminated

– Clean filter acc. to maintenance instructions.

– If necessary, replace filter element.

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7-9

Troubleshooting - SDS fault indicators

7 - 10

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835 / 01.2009

Setup work - Safety instructions

8

Setup work

8.1 Safety instructions DANGER 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. z The following applies for all set-up work:

Only carry out the work if the work area is level and solid enough. z Ensure that there is no one in the danger zone.

– While setting up – before completing all tightening – no persons are allowed in the hazardous area in which loads could fall or under hanging loads.

– During the set-up procedure keep a sufficient safety-margin from areas of unavoidable cutting or pinching/crushing danger. z Observe the relevant accident prevention directives for working with

load suspension equipment. z When dismantling components or equipment, always use load

suspension equipment with a sufficient load bearing capacity. z Suspend components only with the designated lifting brackets. z Do not step on equipment that is not designed for it (e.g. parts of the

boom or the counterweights), hanging on a crane. z Carry out all set-up steps in turn. Never carry out more than one set-

up task at a time.

Note The setup works to be carried out depend on the operating tools that have been selected. Observe the notes in the operating instructions of the tool manufacturer.

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Translation of the original operating instructions

8-1

Setup work - Safety instructions

WARNING There may be dangers during operation to persons, machine and other property, if z the setting of the safety limit position sensor for "Arm in" was not

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

regulations z the tools have not been approved by SENNEBOGEN z the operating tools attached are found to be defective.

The machine operator is wholly liable for any damage or consequential damage caused by tools!

This damage is excluded from the terms of the warranty issued by SENNEBOGEN Maschinenfabrik GmbH.

8-2

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Setup work - Dismantling/assembling the cab

8.2

Dismantling/assembling the cab

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

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

checked by qualified personnel and replaced if necessary before reusing. z Only use genuine SENNEBOGEN spare parts.

Note The locking bar can also be used for fastening the cab. This requires using the two fastening points (1).

1

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8-3

Setup work - Mounting/dismounting counterweight

8.3

Mounting/dismounting counterweight

Note The mass of the counterweight is cast into its upper surface. The counterweight can be removed to transport the machine.

DANGER Machine can tip over.

The machine is not operational with counterweight removed.

4

5 6 1

a

max. 90° 2 7

3 8

1 Threaded attachment points for lifting eyes 2 Rear hexagonal bolt 3 Lower hexagonal bolt 4 Tail light plug connector

8-4

5 Tail light fastening bolts 6 Suspension equipment 7 Counterweight 8 Spacer packs a

Bracket for suspension equipment: 90°

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Setup work - Mounting/dismounting counterweight

8.3.1 Dismantling the counterweight 1

Place the upper structure in the direction of travel.

Place the working tools/equipment on the ground.

2

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

3

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

4

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

DANGER Bracket “a“ between the machine and the suspension equipment must always be 90°.

If the angle is greater or less, the counterweight can tip away from the machine or injure persons or damage parts of the machine.

5

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

6

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

DANGER Squashing and crushing can occur.

Occupying the space under a suspended load is prohibited.

835 / 01.2009

7

Swing the counterweight (7) to the rear slightly and lift away.

Deposit the counterweight in a safe location and secure against tipping.

8

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

Translation of the original operating instructions

8-5

Setup work - Mounting/dismounting counterweight

8.3.2 Installing the counterweight

1

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

2

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

DANGER Squashing and crushing can occur.

There must be no one below a suspended load.

3

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

CAUTION Secure the bolts (2) and (3) with “Loctite 270“ each time you mount the counterweight!

Follow the instructions on the “Loctite” package!

8-6

4

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

5

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

6

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

7

Remove the slinging gear (6).

8

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

9

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

Translation of the original operating instructions

835 / 01.2009

Setup work - Installing large roller bearings, slewing gear, flange connections

8.4

Installing large roller bearings, slewing gear, flange connections

8.4.1 General This supplementary information applies to the installation of large roller bearings and flange connections (FV). This concerns e.g.: z Flange connection between the upper structure and the gearing z Flange connection between the upper structure and the slewing ring z Flange connection between the slewing ring and the lower assembly z Flange connection between the slewing ring and intermediate ring

and the lower assembly z Flange connection between the slewing ring and the pylon and

intermediate ring and the lower assembly z Flange connection between the pylon and pylon

DANGER z Make sure that there is no-one within the hazardous area before

starting the installation! z Pay attention to dimensions and weight according to the operating

instructions. z Observe general safety information for the installation according to

the operating instructions.

8.4.2 Preparatory measures In order to guarantee a secure connection between the individual components, several important preparations are required: z The flange surfaces on the slewing ring are to be kept free of

corrosion. z Make absolutely sure that all surfaces including holes, e.g. the lower

assembly flange are free of grease. If there is grease in the holes, there is a danger of pushing the grease into the threads in the slewing ring with the bolts.

This additional grease in the threads can greatly decrease the required friction under certain circumstances. The bolt can be damaged without your recognizing it or it could even break eventually. z No additional oil or grease is to be used for bolted connections e.g.

"lower assembly flange-slewing ring, pylon-slewing ring". The bolts and pins are to be installed as delivered.

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Translation of the original operating instructions

8-7

Setup work - Installing large roller bearings, slewing gear, flange connections

8.4.3 Assembly There are a few important points to observe for the installation: z Slewing gear bolts that are already used are not to be reused under

any circumstances. z Clean all contact surfaces of the flange connections of any oil and

grease. z Galvanized or coated surfaces must be treated previously with

AKTIVATOR T 747 because LOCTITE - 586 is only permitted on activated surfaces. z LOCTITE - 586 is to be applied on a surface with a brush. z Centering pins are not to come into contact with Loctite since

disassembly can become difficult --> Apply wax or grease to centering pins! z Tighten bolts according to the torque specifications in alternating

sequence (i.e. 2nd across from the 1st). After approx. 2 hours, the Loctite begins to adhere. Full strength is achieved after 12 - 24 hours.

1) Upper structure 2) Slewing ring 3) Pylon or lower assembly 4) Pylon Flange connection with Loctite

Flange connection with Loctite 1 2

3

4 3

8-8

Translation of the original operating instructions

835 / 01.2009

Setup work - Installing large roller bearings, slewing gear, flange connections

8.4.4 Mounting pylon Danger z Place machine on firm, completely horizontal ground. z The (stationary) sub-frame must be aligned horizontally on all sides

before mounting the pylon. z The ballast must be attached to the sub frame before mounting the

pylon.

Caution When mounting the pylon ensure that there is no one in the danger area below the machine/pylon.

1

Raise the machine using a suitable auxiliary crane in order to fit the pylon Section6.6

2

Attach pylon using the bolts (2) provided to the undercarriage note tightening torque!

3

Attach base unit to pylon using the bolts (2) provided - note tightening torque!

3 4 2 1 4 2 5 4 6 3 4 5 2

1 Ball bearing slewing rim 2 hexagonal bolt 3 Hexagonal nut 4 Washer 5 Spacer tube 6 Pylon

5 4

835 / 01.2009

Translation of the original operating instructions

8-9

Setup work - Quick-change couplings

8.5

Quick-change couplings

8.5.1 Fastening quick couplings To ensure problem-free functioning and operating safety of the hydraulic system, follow these instructions.

Note Ignoring or infringing against these instructions exonerates SENNEBOGEN from any responsibility for parts which are damaged or lose their tightness as a result of getting dirty.

3 5 2

1

4

3 Coupling insert

5

Coupling sleeve

Before fastening the quick couplings:

8 - 10

1

De-pressurize the hydraulic system as described in .

2

Remove protective caps (3) from coupling sleeve (4) and coupling insert (1).

3

Clean coupling sleeve (4) and coupling insert (1), particularly the end surfaces (5) with a clean cloth.

4

Coupling insert (1): Check the contact surface (2) of the ball insert for wear. If the contact surface (2) is heavily worn, replace with a new coupling insert.

Check sealing ring for wear and replace if necessary (see Chapter 8.5.3).

Translation of the original operating instructions

835 / 01.2009

Setup work - Quick-change couplings

3 5 2

1

4

3 Coupling insert

5

incorrec

835 / 01.2009

Coupling sleeve

correct

5

Lay the end surfaces (5) of the coupling insert (1) and the coupling sleeve (4) flat against one another.

6

Insert the coupling insert (1) into the coupling sleeve (4) until you hear the coupling insert (1) engage.

Translation of the original operating instructions

8 - 11

Setup work - Quick-change couplings

7

4

Illustrated: Safety ring (7) opened

7 6 1 3

7

Quick coupling fastened

8 - 12

Illustrated: Safety ring (7) engaged

7

Push safety ring (7) down onto the coupling sleeve (4) and rotate slightly until the safety ring (7) engages.

This will prevent the catch from opening by itself.

8

Push together the protective caps (3) of the coupling sleeve (4) and the coupling insert (1) to protect from dirt.

Translation of the original operating instructions

835 / 01.2009

Setup work - Quick-change couplings

8.5.2 Pull out coupling insert

7

4

Illustrated: Safety ring (7) opened

7 6 1 3

7

Quick coupling fastened

835 / 01.2009

Illustrated: Safety ring (7) engaged

1

De-pressurizing hydraulic system.

2

Twist safety ring (7) on the coupling sleeve until it automatically disengages.

3

Hold the coupling insert (1) firmly and push the outer part (6) of the coupling sleeve carefully upwards.

4

Remove coupling insert (1).

5

Clean coupling insert (1), coupling sleeve (4) and protective caps (3) with a clean cloth.

Push protective caps (3) onto the coupling insert (1) and the coupling sleeve (4).

Translation of the original operating instructions

8 - 13

Setup work - Quick-change couplings

8.5.3 Check/change sealing ring Check the sealing ring in the coupling insert at regular intervals for wear. Replace if necessary.

Check sealing ring

3 2 1

To check the sealing ring (2), push down on the sealing disc of the coupling insert (1) with a suitable tool ((3) e.g. drift).

Change the sealing ring 4 3 2 1

1

Push down on the sealing disc of the coupling insert (1) with a suitable tool ((3) e.g. drift).

2

Lever out the sealing ring (2) with special tool (4).

Note The special tool (4) is supplied by SENNEBOGEN (serial No.: 078581).

8 - 14

Translation of the original operating instructions

835 / 01.2009

Setup work - Quick-change couplings

3

2 1

835 / 01.2009

3

Place new sealing ring (2) with the open side facing down onto the sealing disc.

4

Push down on the sealing disc of the coupling insert (1) with a suitable tool ((3) e.g. drift).

5

Press sealing ring (2) together and insert into the groove.

6

Remove tool (3).

The sealing disc must rise upwards.

If necessary, adjust the sealing ring until the sealing disc can move.

Translation of the original operating instructions

8 - 15

Setup work - Quick-change couplings

8.5.4 Lubricating the coupling sleeve

Lubrication nipple for coupling The lubrication nipple for the coupling sleeve enables easy coupling and decoupling in summer and winter.

Lubricating the coupling sleeve reduces water and dust from penetrating the coupling.

Note Lubricating the coupling sleeve and/or using the lubrication nipple is not a replacement for use of the protective cap.

The lubrication nipple for the coupling sleeve is available from the SENNEBOGEN Service Center (telephone +49 9421 540277 or 540278).

Procedure

8 - 16

1

Remove the protective cap of the coupling sleeve.

2

Clean coupling sleeve and its lubrication nipple, particularly the end surfaces with a clean cloth.

3

Lay the end surfaces of the coupling sleeve lubrication nipple and the coupling sleeve itself flat against one another.

4

Insert the lubrication nipple into the coupling sleeve until you hear the nipple engage.

5

Place a hand grease gun onto the lubrication nipple and lubricate the coupling sleeve with cold-resistant grease.

6

Remove the hand grease gun and the lubrication nipple for the coupling sleeve.

7

Attach the safety cap to the coupling sleeve.

Translation of the original operating instructions

835 / 01.2009

Appendix - List of abbreviations

9

Appendix

9.1 List of abbreviations

835 / 01.2009

TUR

Trade Union Regulations

Oh

Hours of operation

or

or

EMC

Electromagnetic compatibility

Fa.

Firm

FOPS

Falling Objects Protective Structure

FV

Flange connection

ggf.

if necessary

GmbH

Limited liability corporation

HAB

Lifting platform

LED

Light emitting diodes

HGV

Truck

LMB

Load moment limiter

LpA

Constant sound-pressure level

LWA

Sound power level

max.

maximum

min.

minimum

No.

Number

MMI

Control/display unit for magnet system

SDS

SENNEBOGEN Diagnostic System

FMVSS

Federal Motor Vehicle Safety Standards

UCTU

Underground Construction Trade Union

ACTU

Association of Commercial Trade Unions

e.g.:

for example

Translation of the original operating instructions

9-1

Appendix - Index

9.2

Index

9.3 Driver's seat 9.4 Clean the cooling system 9.5 Quick-connect couplings 9.6 Installing large roller bearings, slewing gear, flange connections 9.7 Warranty conditions 9.8 Electrical water heater 9.9 Lubricants table

9-2

Translation of the original operating instructions

835 / 01.2009

Index

A Adverse conditions 3-7 Air filter 2-6 Air pressure 3-5 Ambient temperature range 3-1 Antifreeze 4-18, 4-19 Attachments 1-2 Automatic idle 5-29 Automatic rpm 5-29 Axle distributor gear 3-4

Disposing of the oil filter 1-46 Drive forward 5-51 reverse 5-51 with a suspended load 5-74 Drive pedal 5-8, 5-24 Driver's doors 5-3 Driving earth-moving machinery 1-27 Driving engine 3-3 Driving the machine 5-74

B Batteries 2-6 Battery Acid 4-26 Battery isolator switch 2-4, 2-6 Beaufort scale 3-16 Bio-oils 1-19 Bypassing the safety limit position sensor for "Arm in" 5-89

E Ear protection 1-26 Effect wind 3-16 Electrical control cabinet 2-6 Electrical switching cabinet 2-5 Emergency exit 5-2 Emergency lowering Cab 2-5 in cab 5-72 in storage compartment 5-73 Emergency lowering – cab 2-6 EMERGENCY STOP switch 2-9 Engine compartment 2-6 Environmental protection 1-46 Environmental regulations 1-46 Exhaust silencer 2-7 Extending outriggers 4-8

C Cab suspension 5-69 CE certificate of conformity 1-6 Central lubrication system 2-5, 2-6, 4-10, 5-29 Chloride 1-23 Chloride content 1-23 Commissioning 4-1 Control lever 5-7, 5-9 Control lever, left-hand 5-12 Coolant level 4-18, 4-19 Cooling system 4-18 Customer service W-8 D Danger area 1-26 Danger of crushing 1-26 Decommissioning 4-28, 4-34 Decommissioning machine 4-28, 4-29, 4-34, 435 Deploying (extending) the supports 5-78 Differential: 3-4 Disposal Batteries 1-46 Lubricants 1-46 Disposal Guideline 75/439/EEC 1-46 Disposal of consumables 1-46 Disposing of batteries 1-46 Disposing of lubricants 1-46

835 / 01.2009

F Fault diagnosis 7-1 Fault Displays (SDS) 5-52, 7-6 Filler hose 2-5 Filler neck - fuel tank 2-5 First aid box 1-14, 1-15 Floating axle 2-2 Floating axle lock 5-22, 5-29 FOPS protective roof 1-14 Front windshield 5-3 Fuel filler neck 2-5 Fuel system 4-15 Fuel tank 2-5, 3-4 Fuel tank display 5-35 Fuse Preheat 2-8

Translation of the original operating instructions

S-1

Index

G Gear teeth spray 4-12 Grab, slew right 5-12 Grabber, slew left 5-12, 5-16 H Hand signals 1-47 Hand signals for directing 1-47 Heater 5-7, 5-9 High voltage contact 1-29 Hoisting limit sensor 5-87, 5-88 Holding open driver’s doors 5-3 Hydraulic oil pre-heater 5-65 Hydraulic oil tank 2-6 Hydraulic system: 3-4 Hydraulic tank 3-4 Hydraulics 3-1 HydroClean - fine filtration system (optional) 2-7 I Ignition key 4-23 Illustration aids W-4 Impermissible operating practices 1-14 Indicator light - EMR 5-51 Indicator lights 5-51 Inhaling exhaust gasses 4-23 Initial operation 4-3 Installing/removing the counterweight 8-4 Intended use 1-2 Interior lighting 5-4 J Jump start 4-26 K Keypad (SDS) 5-35 Keyword W-4 L Lifting capacities 3-7 Lifting force 3-7 Lifting gear 6-7 Lifting points 6-7 Light emitting diodes 5-35 Limitations during wind 3-1 List of abbreviations 9-1 Load lift 5-84

S-2

lower 5-84 Load moment limiter (LML) 5-58 Locking rod 6-6 Lowering/reducing lifting capacities 3-7 Lubricate the machine 3-10 Lubricating path 4-10, 5-29 Lubricating slewing ring teeth 4-12 Lubrication cycle 4-10 Lubrication nipple 3-10 M Machine hoisting 6-7 machine 5-74 stabilizing 5-77 tie-down 6-9 Machine Labeling 1-5 Machine operating area 1-26 Machine operator’s workplace 1-2 Main fuse Electrics 2-8 Main switch 2-9 Maintaining earth moving machines 1-27 Maintenance instructions W-6 Maintenance schedule 3-1 Maneuvering cab 5-70 Manual lubrication 3-10 Maximum stability 1-28 Measurement ports - hydraulic system 2-6 Misuse 1-2, 1-3, 1-4 N National regulations 1-1 Noise protection 1-13 Nominal speed 4-25 O Oil diagnosis 1-19 Oil filler pipe 4-14 Opening front windshield 5-3 Operation 5-1 operation of the machine in an explosive environment. 1-4 Outside air mode 5-25 Overhead lines 1-29 Overload warning device 1-45 Overseas use 1-16 Overview of the machine as a whole 2-1

Translation of the original operating instructions

835 / 01.2009

Index

P Parking brake 5-8, 5-10, 5-24 Pedals 5-7, 5-9, 5-34 Personal safety equipment 1-26, 1-35, 1-41 Personnel qualifications 1-12 Personnel selection 1-12 pH value 1-23 pH value, water 1-23 Pipe rupture safety - arm cylinder 2-11 Pipe rupture safety - hoisting cylinder 2-11 Potential instances of misuse 1-3 Power lines 1-29 Preheat 5-51 Protective features 1-45 Protective gloves 1-26 Protective roof (FOPS) 1-14 Prototype Testing 1-6 Pump unit 2-4, 2-6 Q Qualification of personnel 1-27 R Recirculating air mode 5-25 Refueling pump 2-5 Remedying faults 7-1 Reservoir - washer water 5-7 Responsibilities of the employer 1-12 Restraint belt 4-22, 4-30 Retracting stabilizers 5-80 Reverse airflow – combination cooler 5-17, 521, 5-23, 5-26 S Safe working loads 3-7 Safety boots 1-26 Safety distance 1-26, 1-29 Safety distance from overhead lines 1-29 Safety equipment 1-26 Safety helmet 1-26 Safety lever 5-7, 5-9, 5-11 Safety limit position sensor for "Arm in" 5-85 Safety regulations 1-16 Sales and service partners W-8 Schmiernippel-Übersicht 3-11 SDS 5-34 SDS fault indicators 7-6 Securing the upper structure 6-6

835 / 01.2009

SENNEBOGEN Diagnostic System Self test 5-34 Service panel - engine 2-7 Service partners W-8 Setup work 8-1 Shutting down the engine. 4-27 Signaling individual 1-47 Slewing drive 3-1 Slewing gear brake 5-82 Slewing mechanism holding brake 5-11 Slewing ring lubrication (optional) 4-13 Slewing the upper structure 5-81 Slewing upper structure 5-81 Slinging equipment 6-7, 6-9 Spare parts catalogue. W-6 Spare parts warehouse W-8 Special dangers 1-14 speed of 3-1 Stability 1-26, 1-28, 1-30 Stabilizer 2-2 Start engine 4-23, 4-31 Starting up daily operation 4-3 Starting up operating again 4-3 Steering column 5-7, 5-21 Steering wheel 5-7 Storage compartment 2-6 Storage location 4-28, 4-34 Sulfate content 1-23 Superstructure 2-4 Support housing 2-3 Supporting the machine 5-77 Swinging the load 1-28 Switching the motor off 4-33 T Technical condition 1-14 Telephone W-8 the machine environment 1-26 The operating instructions are structured as follows W-7 Tie-down points 6-9 Tip-over danger! 1-45, 5-22 Tipping load 3-7 Tire size 3-5 Tires - Air pressure 3-5 Top up hydraulic oil 4-14 Transmission 2-4, 2-6 Troubleshooting 7-1

Translation of the original operating instructions

S-3

Index

Type plate 1-5 U use contrary to regulations 1-4 W Warm-up period 4-25, 4-32 warning lights 5-51 Warning lights (SDS) 5-51 Warranty conditions 1-17 Warranty manual 1-17 Water hardness 1-23 Water heating system 2-6 Water separator 2-4 Weight of lifting gear 3-7 Wheel nuts 3-5 Wind forces 3-2 Wind speed 3-16 Wind strength 3-16 Windscreen wiper 5-4 Windshield washer reservoir 2-6 Windshield washer system 5-4 Working tools 8-1

S-4

Translation of the original operating instructions

835 / 01.2009