Sennebogen 840 M Maintenance Instruction Manual 840.0.209 - PDF DOWNLOAD

Maintenance instructions

840 M

10.2006

840

Important instructions on the operating manual

Target group

The machine has been developed for demanding work.

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

Maintenance must be carried out by trained specialist personnel only.

Notes on the instructions

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

Keep instructions in a safe place for future use.

WARNING! z Only work with the machine once these instructions have been read

and completely understood. z Forbid unsafe operation or unsafe maintenance. z Do not operate machine if a fault has been detected! z The employer is responsible for the qualifications and training of the

personnel. z These instructions are a part of the machine. Keep the 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 instructions must accompany the machine! z Contact SENNEBOGEN immediately if there is anything in the

instructions which you do not understand!

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

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

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

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Important instructions on the operating manual

Symbols and illustration devices

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

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

The associated keyword signifies the degree of danger: DANGER Is used for serious, direct danger. If this danger is not averted, serious physical injuries or loss of life of persons will result.

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

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

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

Note Indicates cross references to other documents.

Handling instructions are shown in table form as follows: 1

Press switch (1).

2

Actuate control lever (2).

3

Unfasten pins (3).

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

Please contact us at

SENNEBOGEN Maschinenfabrik GmbH Hebbelstraße 30 D-94315 Straubing Telephone:

+49 9421 540-0

Internet:

http://www.sennebogen.de

Fax Customer Service:

+49 9421 540279

Fax Spare Parts Store:

+49 9421 40811

Technical Documentation:

W-4

E-mail:

doku@sennebogen.de

Fax:

+49 9421 41425

Current when going to press

Ongoing development ensures the advanced technology and the high quality of our machines. This may result in deviations between these instructions and your machine. Errors can also not be totally excluded.

Please understand that no legal claims can be derived from the specifications, illustrations and descriptions within these instructions.

Copyright

© Straubing 2006, SENNEBOGEN Maschinenfabrik GmbH Reproduction, also in part, only with written permission of SENNEBOGEN Maschinenfabrik GmbH, Straubing, Germany.

Printed in Germany.

Table of contents

0-1

1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.3 Responsibilities of the operator . . . . . . . . . . . . . . . 1-4 1.4 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 1.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

2

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

3

General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1 Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 Oils and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.3 Coolant – Drive motor . . . . . . . . . . . . . . . . . . . . . . 3-3 3.3.1 Coolant for CATERPILLAR - Drive motors . 3-3 3.3.2 Coolant for DEUTZ - Drive motors . . . . . . . 3-4 3.3.3 Coolant - General . . . . . . . . . . . . . . . . . . . . 3-5 3.4 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

4

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

5

Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1 Cleaning and lubricating . . . . . . . . . . . . . . . . . . . . 5-1 5.2 Tire air pressure (pnuematic tires) . . . . . . . . . . . . . 5-1 5.3 Tightening wheel nuts . . . . . . . . . . . . . . . . . . . . . . 5-2 5.3.1 Hub drive train . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.4 Back gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.5 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

840 / 10.2006

Table of contents

6

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

7

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.2 General information . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.2.1 Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . 7-2 7.2.2 Screw connections . . . . . . . . . . . . . . . . . . . 7-2 7.3 Hydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 7.4 De-pressurising hydraulic system . . . . . . . . . . . . . 7-4 7.5 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 7.6 Changing hydraulic oil . . . . . . . . . . . . . . . . . . . . . . 7-8 7.7 Return filter – changing filter elements . . . . . . . . 7-10 7.8 Auxiliary control filter – change filter element . . . 7-11 7.9 Leak-oil filter – changing filter element . . . . . . . . 7-12 7.10 Changing ventilation filter . . . . . . . . . . . . . . . . . . 7-13 7.11 Hydro-clean superfine filter (optional) . . . . . . . . . 7-14 7.12 Checking preload pressure of pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

8

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

9

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

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

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840 / 10.2006

Safety - General

1

Safety

1.1 General The machine is built in accordance with the current state of the art. Nevertheless, there may be dangers during its use to persons, machine and other property, if z the machine is not operated according to regulations 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 operating tools attached do not comply with the relevant safety

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

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

In the Federal Republic of Germany e.g: z Winches, Lifting and Pulling Devices (VBG 8) z Crane (BGV D6) z Hoisting Equipment in Lifting Appliance Operation (VBG 9a) z EC Machinery Guideline (98/37/EEC) z EMC Guideline 89/336/EEC z Electrical Machinery Equipment (EN 60204-1) z Safety Requirements for Fluid Engineering Systems and their Com-

ponents - Hydraulic (EN 982) z Earth-Moving Machinery – Safety (EN 474-1/-5) z Safety of Machinery (DIN EN 12100 -1 and DIN EN 12100-2) z "Outdoor" Regulation 2000/14/EG

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

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1-1

Safety - Safety instructions

1.2

Safety instructions

DANGER Danger to life!

There is a risk of serious injury or even death to persons using the machine or in its vicinity if it moves suddenly or is started unintentionally. Observe the following: z Place the machine on a firm base, if necessary set back from the

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

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

tion, protective gloves, safety boots) where working conditions require. z Observe statutory accident prevention and safety directives. z Lower suspended loads and booms to the ground. z Pull safety lever back. z Shut down machine and secure against unauthorised re-starting

before starting with maintenance work. z Attach warning sign to controls. z Smoking and handling of open flame is strictly forbidden. z Use safety-compliant access ladder aids or operating platforms. z Maintain a distance to rotating and moving parts. z Relieve hydraulic system pressure before starting maintenance

work. z Dispose of hydraulic oil according to regulations. z Wear protective gloves when working on steel wire rope. z Only use genuine Sennebogen replacement parts. z Use only oils and lubricants stated in the lubricant table. z Do not lift heavy objects by hand. Use lifting gear. z Actuate battery isolator switch to interrupt the power supply. z When working near batteries these are to be covered with insulating

material; do not place tools onto batteries.

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840 / 10.2006

Safety - Safety instructions

z Replace all safety devices on completion of maintenance work. z Keep driver's cab clean and tidy. z Carry out function check to ensure problem-free operation. z Only the crane owner or representative may approve the machine

for operation following maintenance work. z For pneumatic tyres:

When inflating tyres, maintain adequate safety distance and use tyre cage. z After maintenance or repair work, carry out thorough visual and

function check according to instructions.

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1-3

Safety - Responsibilities of the operator

1.3

Responsibilities of the operator

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

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

Inspection by specialist technician

The machine must be thoroughly checked by a specialist technician. z before starting up for the first time z before re-commissioning after major modifications z at least once a year z intermediate depending to operating and company conditions.

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

sponding regulations and guidelines through specialist training and z specific instruction from Sennebogen

and can assess the safe working condition of the machine.

Personnel selection and qualifications

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

DANGER z Personnel under training or instruction must remain under constant

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

by an electrical technician. z Work on running gear, braking and steering systems may only be

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

with specific knowledge and experience of hydraulics!

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840 / 10.2006

Safety - Responsibilities of the operator

Noise protection

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

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

Technical condition of the machine

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

Do not operate machine if a fault has been detected!

Observe mandatory time limits for routine checks.

Independent conversion and replacement part production

For safety reasons the machine may not be modified or altered in any way.

This applies also to the installation and use of safety devices and valves as well as welding on load carrying parts.

Genuine Sennebogen replacement parts and accessories ensure the safety of personnel. Parts and fittings from other manufacturers are not tested by Sennebogen and are not therefore approved. The use of other components can alter the machine's characteristics and present a safety hazard.

If other components are used, Sennebogen will not be considered liable for any resulting consequences.

Impermissible operating practices

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

according to these instructions. z If there is a danger of heavy objects falling, the machine may only

be used if the driver's area is covered by a protective roof (FOPS).

The protective roof is optionally available from Sennebogen. z The machine is not suitable for towing a trailer.

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

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

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1-5

Safety - Responsibilities of the operator

Specific dangers

Overseas use

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

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

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

intended work. z Ensure that the contents of this manual have been read and com-

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

Dangers of noncompliance with the safety notes

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

Fire extinguisher and first aid box (optional)

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

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

1 Warranty conditions

2

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

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

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Safety - Safety devices

1.4

Safety devices

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

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

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

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1-7

Safety - Disposal

1.5

Disposal

Cleaning and lubricating materials CAUTION Observe environment protection!

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

Extract from the Disposal Guideline 75/439/EWG: 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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840 / 10.2006

Maintenance schedule

2 Safety instructions

Maintenance schedule

Observe the safety notes before starting work.

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

protection, protective gloves, safety boots).

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

Task

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

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

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

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

– Hydraulic cylinder: visually check for damage and tightness.

– Check engine oil level.

Observe intervals acc. to instructions of engine manufacturer.

– Observe engine intervals.

– Hydraulic system: check oil level.

– Check SDS display for Hydro Clean micro-filter.

– Lubricate slewing ring.

– Check SDS display for air filter insert.

– Check water separator for fuel system.

– Initiate pinion lubrication.

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Section

every 10 hrs run / daily

every 50 hrs run / weekly

once every 250 hrs run

every 500 hrs run / 3months

every 1000 hrs run / yearly

every 2000 hrs run / 2 years

4.1

7.5 7.11

6 4.2

4.3

6.2

2-1

Maintenance schedule

Task

– Check coolant level; if necessary clean cooling fins.

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

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

– Check and clean hydraulic oil cooler.

– For pneumatic tires: Check tire air pressure.

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

– Check differential oil level.

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

– Check heating filter.

– Lubricate the machine.

– Check tightness of all screw fastenings.

– Air conditioning compressor: Check belt tension and status.

– Air conditioning compressor:.

Check the compressor mounts and bolts for tightness.1)

every 10 hrs run / daily

every 50 hrs run / weekly

once every 250 hrs run

every 500 hrs run / 3months

every 1000 hrs run / yearly

every 2000 hrs run / 2 years

Section

4.4

6.1.1

6.2.2

5.2

5.3 5.3.1 5.5 6

8.1

9.1 10.1

1)

1)

1)

1) 1)

2)

2)

2)

every 250 hrs run 2) 7.12

– Have preload pressure of

hydraulic accumulator checked by hydraulic specialist company 2) .

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

– Check load-holding:

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

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840 / 10.2006

Maintenance schedule

Task

every 10 hrs run / daily

– Check antifreeze.

– Check oil level of both back gears.

– Change filter element of return filter.

– Leak-oil filter – change filter element.

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

– Hub drive train: change oil.

– Back gear: change oil.

– Differential: change oil.

– Tighten slewing ring bolts 3).

every 50 hrs run / weekly

once every 250 hrs run

every 500 hrs run / 3months

every 1000 hrs run / yearly

every 2000 hrs run / 2 years

Section

4.4 5.4

7.7

7.9

3)

3)

7.8

3)

5.3.1 5.4 5.5 6.3

3)

– – – –

– – – –

–

once after 250 hrs run / 6 weeks; then every 2000 hrs run / yearly Slewing ring bolts examine with

suitable means for tightness.

Water seperator:

4.3.1 Changing the filter element Charge air cooling system - drain

out water from condensation.

Heating / Air condition (optional):

9 Checked by authorized specialist company.

Change exchange cartridge and

4.2 safety cartridge in air filter.

Change the ventilation filter on

7.10 the hydraulic tank.

Change coolant.

4.4 4) 4) Hydraulic system: change oil.

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

Check or change slewing ring 5) 6 5) bolts 5) every 5000 hrs run / 5 years

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2-3

Maintenance schedule

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

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

The slewing ring bolts must be changed otherwise.

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840 / 10.2006

General notes - Cleaning work

3

General notes

3.1 Cleaning work Notes z Ensure that the cleaning agents used do not damage the seals and components of the machine. z Do not use aggressive cleaning agents. z It is especially important to clean the noise suppression mats with

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

check of the machine acc. to section 4.3 (in the machine operating instructions).

WARNING Electrical and electronic components such as generators, switch cabinets etc. must not come into direct contact with the water jet!

Wet cleaning of these components is prohibited!

When wet cleaning the machine, always make sure that the water does not come into contact with electrical or electronic components.

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

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3-1

General notes - Oils and lubricants

3.2

Oils and lubricants

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

WARNING Mixing oils, lubrication or operational materials of different types is not permitted!

Filling or mixing oils, lubricants or any other operational fluids (e.g. hydraulic oil, transmission oil, motor oil, coolant, etc.) of different types can lead to damage to the machine components because of chemical reactions. The result of which can cause severe damage to property and injury to personnel.

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

Oil diagnosis

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

Recommended for hydraulic system.

Further information is available from Sennebogen customer service.

Biologically degradable oils and lubricants

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

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

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

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840 / 10.2006

General notes - Coolant – Drive motor

3.3 Coolant – Drive motor 3.3.1 Coolant for CATERPILLAR - Drive motors The Caterpillar - Drive motors can be recognized by the 17 character PIN (Product Identification Number) and the ratings plate among other things. E.g.: *CAT 0789BG 6SL12345* Note The Caterpillar - drive motors are filled with coolant z Caterpillar CAT ELCTM (Extended Life Coolant)

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

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

Note Observe the coolant label in the cooler area.

ATTENTION! Observe the notes in the operating instructions of the motor manufacturer as well as the special additional documentation on the Caterpillar CAT ELCTM- Coolant. These are for the operational safety of the machine.

Note SENNEBOGEN recommends using the pre-mixed coolant by Caterpillar CAT ELCTM, which is available in two different concentrations.

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3-3

General notes - Coolant – Drive motor

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

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

in the factory. Use this coolant only for the DEUTZ drive motors! SENNEBOGEN will accept no responsibility and will provide no warranty or make any guarantees for the use of any other coolants.

Note Observe the coolant label in the cooler area.

Hunold ANF Kühlmittel Coolant Liquide de refroidissement Refrigerante Líquido de refrigeração Liquido refrigerante Kølevæske Koelvloeistof Kjølevæske Kylvätska Jäähdytysneste DzesƝšanas šƷidrums Sennebogen Maschinenfabrik GmbH

092872

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

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840 / 10.2006

General notes - Coolant – Drive motor

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

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

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

Use the coolant indicated and described in chapter 3.3.1 and 3.3.2 depending on the motor that is installed. The antifreeze is sufficient to -37 °C (-34 °F).

Note Observe the coolant label in the cooler area.

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

Note If only a small amount (up to max. 5 l) is required to 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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3-5

General notes - Coolant – Drive motor

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

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

before filling!

Ensure that the water has the following characteristics: pH value

7-8

Chloride content

max. 100 ppm

Sulphate content

max. 100 ppm

Water hardness

3-12 °dGH

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

ATTENTION 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.

Using other coolants

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.

3-6

840 / 10.2006

General notes - Coolant – Drive motor

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.

Change coolant

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

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

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

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

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

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

Coolant change intervals

840 / 10.2006

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

3-7

General notes - Welding work

3.4

Welding work

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

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

Preliminary work

3-8

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

1

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

2

Disconnect battery.

3

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

840 / 10.2006

Driving engine -

4 Safety notes

Driving engine

Read the safety notes before starting work.

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

with maintenance work. z Waste oil must not ingress ground or waterways.

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

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

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

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

840 / 10.2006

4-1

Driving engine - Engine oil

4.1

Engine oil

WARNING z Danger of scalding!

Proceed with utmost caution when draining hot oil. z Waste oil must not ingress ground or waterways. Dispose of oil and

oil filters in accordance with statutory regulations.

WARNING Mixing oils, lubrication or operational materials of different types is not permitted!

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

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

Engine oil level - check

Changing engine oil and oil filter

4-2

1

Position machine horizontally.

2

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

3

Shut down driving engine.

4

Open right maintenance hatch.

5

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

6

Insert oil dipstick up to stop and pull out again.

7

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

8

Top up motor oil if necessary.

1

Warm up engine.

2

Position machine horizontally.

3

Open right service access doors.

4

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

5

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

6

Top up motor oil if necessary.

840 / 10.2006

Driving engine - Air filter

4.2 Safety notes

Air filter

Read the safety notes before starting work.

CAUTION z Never use gasoline, soap or hot liquids to clean the air filter z Never use compressed air to clean the housing interior, as dust and

contamination can enter the engine.

Air filter indicator lamp

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

The contamination level is measured by the flow resistance. If the air filter indicator lamp on the right control panel lights up the maximum permitted flow resistance has been reached.

A warning tone also sounds. Check and clean the air filter immediately.

Note The air filter is situated under the service flap.

1 Locking clamp 2 Service flap

1

3 Handle 4 Air filter

2

3 4

840 / 10.2006

4-3

Driving engine - Air filter

4 5 6

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

7 Exchange cartridge 8 Safety cartridge 9 Shackle 8

4-4

9

840 / 10.2006

Driving engine - Air filter

Cleaning

840 / 10.2006

1

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

2

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

3

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

4

Remove replacement cartridge (7).

5

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

– Only beat out if unavoidable!

6

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

7

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

Never clean safety cartridge (6)!

– Insert new safety carriage.

8

Insert new or cleaned exchange cartridge (7).

9

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

10

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

11

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

4-5

Driving engine - Fuel system

4.3 Safety notes

Fuel system

Read the safety notes before starting work.

WARNING z Danger of injury through rotating parts!

Only carry out maintenance work with driving engine shut down and cooled down cooling system. z Do not handle open flames when working on the fuel system! No

smoking! z Also observe the notes in the instructions of the engine

manufacturer.

4.3.1 Water separator

4 3

2 1

1 Quick clamp 2 Casing 3 Shut-off valve 4 Filter element

4-6

840 / 10.2006

Driving engine - Fuel system

Draining water

Changing the filter element

840 / 10.2006

1

Close shut-off valve (3).

2

Open quick clamp (1).

3

Remove water and dirt from the casing (2).

4

Close quick clamp (1).

5

Open shut-off valve (3).

1

Close shut-off valve (3).

2

Remove filter element (4).

3

Insert new filter element.

4

Check cover seal, exchange if necessary.

5

Open shut-off valve (3).

4-7

Driving engine - Cooler

4.4 Safety notes

Cooler

Read the safety notes before starting work.

WARNING z Danger of injury through rotating parts and through scalding!

Only carry out maintenance work with driving engine shut down and cooled down cooling system. z Coolant must not ingress ground or waterways. Dispose of coolant

in accordance with statutory regulations.

WARNING Mixing oils, lubrication or operational materials of different types is not permitted!

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

Coolant level indicator lamp

The coolant level is monitored by a sensor.

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

Cleaning cooler

1

4-8

1

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

2

Open service flap.

3

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

840 / 10.2006

Driving engine - Cooler

4

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

5

Check cooler for leaks and damaged cooling fins.

Check coolant level and/or antifreeze

2

1

Allow driving engine and cooler to cool down.

2

Open upper service cover.

3

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

4

Check antifreeze and coolant level, top up if necessary.

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

Further information can be found in the separate maintenance instructions.

Coolant change intervals

SENNEBOGEN recommends changing the coolant every 2000 operating hours or max. 24 months. Whichever is first.

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

840 / 10.2006

4-9

Driving engine - Belt drives

4.5 Safety notes

Belt drives

Read the safety notes before starting work.

DANGER z Only carry out maintenance work with drive engine shut down and

stationary. z Shut down machine and secure against unauthorised re-starting

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

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

4 - 10

840 / 10.2006

Undercarriage - Cleaning and lubricating

5

Undercarriage

WARNING z Danger of injury through rotating parts!

Only carry out maintenance work with driving engine shut down. z Oil must not ingress ground or waterways.

Dispose of waste oil in accordance with statutory regulations.

5.1 Cleaning and lubricating 1

Position machine horizontally.

2

Shut down driving engine.

3

Clean tires and running gear using a steam cleaner.

4

Lightly grease guides and pins.

5

Lubricate all lubrication points (see Section 10.1).

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

Tyre size

840 / 10.2006

Air pressure bar

psi

10.00-20

7.5

108.78

12.00-20

9

130.53

12.00-24

10

145.04

395/85

8.5

123.28

5-1

Undercarriage - Tightening wheel nuts

5.3

Tightening wheel nuts

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

5.3.1 Hub drive train

1

2 1 Oil filler screw 2 Oil drain screw WARNING Mixing oils, lubrication or operational materials of different types is not permitted!

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

Checking oil level

5-2

1

Position machine horizontally.

2

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

3

Shut down drive engine.

4

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

840 / 10.2006

Undercarriage - Tightening wheel nuts

Changing oil

840 / 10.2006

5

Clean components, check seal and exchange if necessary.

6

Retighten oil filler screw (1).

7

Repeat the procedure on all remaining hubs.

1

Position machine horizontally.

2

Turn hub until the oil drain screw (3) is at the bottom.

3

Shut down driving engine.

4

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

5

Place a suitable container under the oil drainage screw (3). For capacities, see Section 10.2.

6

Unscrew oil drainage screw (3) and collect the waste oil in the container.

7

Clean components, check seals and exchange if necessary.

8

Re-tighten oil drainage screw (3).

9

Unscrew oil filler screw (1).

10

Slew hub until the marking (2) is horizontal.

11

Fill with new oil up to marking (2).

12

Re-tighten oil filler screw (1).

13

Repeat procedure on the three remaining hubs.

14

Re-check oil level after 2 hours run.

5-3

Undercarriage - Back gear

5.4

Back gear

3 2 1

WARNING Mixing oils, lubrication or operational materials of different types is not permitted!

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

Checking oil level

Changing oil

5-4

1

Bring machine up to operating temperature.

2

Position machine horizontally.

3

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

4

Clean exterior of back gear using a cloth.

5

Screw out oil level check screw (3). The oil level must reach up to lower edge of filler opening.

6

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

7

Clean components, check seal and exchange if necessary.

8

Re-tighten oil filler screw (3).

1

Bring machine up to operating temperature.

2

Position machine horizontally.

3

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

4

Clean exterior of back gear using a cloth.

5

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

6

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

For capacities, see Section 10.2.

840 / 10.2006

Undercarriage - Differential

7

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

8

Clean components, check seals and exchange if necessary.

9

Re-tighten oil drain screw (1).

10

Screw out oil filler screw (3).

11

Screw out oil level check screw (2).

12

Fill with new oil up to lower edge of level check opening.

13

Re-tighten oil level check screw (2).

14

Re-tighten oil filler screw (3).

15

Re-check oil level after 2 hours run.

5.5 Differential

2

1 WARNING Mixing oils, lubrication or operational materials of different types is not permitted!

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

Checking oil

840 / 10.2006

1

Bring machine up to operating temperature.

2

Position machine horizontally.

3

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

4

Clean exterior of differential using a cloth.

5-5

Undercarriage - Differential

Changing oil

5-6

5

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

6

Clean components, check seal and exchange if necessary.

7

Re-tighten oil filler screw (2).

1

Bring machine up to operating temperature.

2

Position machine horizontally.

3

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

4

Clean exterior of differential using a cloth.

5

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

6

Place a suitable container under the oil drain screw (1). For capacities, see Section 10.2.

7

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

8

Clean components, check seals and exchange if necessary.

9

Re-tighten oil drain screw (1).

10

Screw out oil filler screw (2).

11

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

12

Re-tighten oil filler screw (2).

13

Re-check oil level after 2 hours run.

840 / 10.2006

Swivelling connection -

6

Swivelling connection

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

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

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

1 Path 1

840 / 10.2006

2

2 Gear teeth

6-1

Swivelling connection - Lubricating slewing ring path

6.1

Lubricating slewing ring path

6.1.1 Central lubrication system The central lubrication system automatically lubricates the slewing ring path. The lubrication cycle is pre-set at the factory.

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

Shorter lubrication intervals are required, z in the tropics, z when humidity is high, z under very dusty and dirty conditions, z when temperatures change dramatically, z when subject to continuous swinging movement.

1 2

1 Lubricant containers 2 Lubricator nipple – replenish grease

Actuating path lubrication manually

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

1

6-2

Actuate the switch on the right of the control panel:

840 / 10.2006

Swivelling connection - Lubricating slewing ring teeth

6.2

Lubricating slewing ring teeth

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

6.2.1 Gear teeth spray

840 / 10.2006

1

Shut down driving engine.

2

Thoroughly clean gear teeth.

3

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

4

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

5

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

6-3

Swivelling connection - Lubricating slewing ring teeth

6.2.2 Slewing ring lubrication (optional)

1

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

1

Shut down driving engine.

2

Thoroughly clean gear teeth.

3

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

4

Start driving engine.

5

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

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

6

Release the pushbutton.

7

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

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

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

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

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

6-4

840 / 10.2006

Swivelling connection - Lubricating slewing ring teeth

Check plastic sliding wear pad

1.1 inch

1

2

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

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

840 / 10.2006

1

Dismantle lubrication assembly (1).

2

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

3

Exchange plastic wear pad if necessary.

6-5

Swivelling connection - Lubricating slewing ring teeth

Replenish grease

1

1 Lubricant containers

6-6

1

Open cover (1) of lubrication container.

2

Replenish lubricant (SE-no.: 047485).

3

Re-close cover.

840 / 10.2006

Swivelling connection - Tighten slewing ring bolts.

6.3

Tighten slewing ring bolts.

DANGER Risk of fatality!

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

Therefore observe the service intervals without fail! z Re-tighten slewing ring bolts using torque wrench.

Observe tightening torque in accordance with Section 10.3! z Check or change slewing ring bolts every 5000 hrs run / every 5

years.

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

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

The slewing ring bolts must be changed otherwise.

Corroded or damaged bolts can shear and lead to the upper structure tipping over. z Do not tighten corroded or damaged bolts, replace immediately with

new bolts! z Adhere without fail to the number and diameter of locking bolts. z Only use genuine SENNEBOGEN spare parts! z If you suspect damage to the screw fastenings, call SENNEBOGEN

customer service and arrange for a check to be carried out. z Contact SENNEBOGEN customer services if you have any further

queries.

840 / 10.2006

1

Shut down driving engine.

2

Re-tighten slewing ring bolts crosswise using torque wrench.

6-7

Swivelling connection - Tighten slewing ring bolts.

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

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

6-8

840 / 10.2006

Hydraulic system - Safety notes

7

Hydraulic system

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

DANGER z Work on hydraulic systems may only be carried out by trained personnel with special knowledge and experience on hydraulics. z Wear personal safety equipment (e.g. safety helmet, ear protection,

protective gloves, safety boots). z Warning of high oil pressure!

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

Only carry out work on a de-pressurised hydraulic system! z De-pressurise hydraulic system before starting retrofitting work

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

remains under high pressure even after the engine is shut down.

Therefore, de-pressurise the pressure accumulator. z Danger of injury!

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

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

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

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

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

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

840 / 10.2006

7-1

Hydraulic system - General information

7.2

General information

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

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

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

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

protects the surface from the effects of environment and weather.

7.2.2 Screw connections Check hydraulic screw connections and couplings regularly for leaktightness. Seal points of leakage and remove oil residue.

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

Always seal opened screw connections immediately at both sides with plugs.

7-2

840 / 10.2006

Hydraulic system - Hydraulic lines

7.3 Storage and duration of use

Hydraulic lines

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

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

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

Check

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

Remedy any defects discovered immediately.

Defects

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

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

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

840 / 10.2006

7-3

Hydraulic system - De-pressurising hydraulic system

7.4

De-pressurising hydraulic system

De-pressurize the hydraulic system as follows: 1

Lower suspended loads and jib to the ground.

2

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

3

Move both control levers in the cab several times in all directions. This releases the pressure of the main hydraulics and the pressure in the pilot control pressure accumulator.

4

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

5

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

6

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

1 2

7-4

7

Lift cover (1).

8

Open screw cap (2) of hydraulic tank.

This releases the residual pressure in the tank.

840 / 10.2006

Hydraulic system - De-pressurising hydraulic system

9

Connect pressure gauge (up to max. 8700 PSI) to the measuring connectors (P1, P2, P3, P4, PV9).

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

840 / 10.2006

7-5

Hydraulic system - Checking oil level

7.5

Checking oil level

WARNING Mixing oils, lubrication or operational materials of different types is not permitted!

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

1

Lower suspended loads and jib to the ground.

2

Position machine horizontally.

3

Fully retract all hydraulic cylinders.

4

Shut down driving engine.

5

Open right maintenance hatch.

1

6

7-6

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

840 / 10.2006

Hydraulic system - Checking oil level

2 3

7

840 / 10.2006

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

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

– Top up hydraulic oil and re-check.

– Re-tighten screw cap (3).

– Re-close cover (2).

7-7

Hydraulic system - Changing hydraulic oil

7.6 Safety notes

Changing hydraulic oil

Observe the safety notes before starting work on hydraulic system.

DANGER z Warning of high oil pressure!

The hydraulic system is subject to high pressure.

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

Only carry out work on a de-pressurised hydraulic system! z Only trained specialist technicians with

specific knowledge and experience of hydraulics may work on the hydraulic system.

WARNING Mixing oils, lubrication or operational materials of different types is not permitted!

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

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

Use the opening of the return filter for this.

Procedure

1

Lower suspended loads and jib to the ground.

2

Position machine horizontally.

3

Fully retract all hydraulic cylinders.

4

De-pressurise hydraulic system acc. to Section 7.4.

5

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

6

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

For capacities, see Section 10.2.

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

Hydraulic oil must not ingress ground or waterways.

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

7-8

840 / 10.2006

Hydraulic system - Changing hydraulic oil

1

7

Unscrew cover nut (1).

2 3

8

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

9

Screw out drain plug (2).

10

Screw cover nut (1) back on.

11

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

12

Bleed hydraulic pump: – Clean housing.

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

– Wait several seconds until the air has escaped.

– Re-tighten vent screw.

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

840 / 10.2006

7-9

Hydraulic system - Return filter – changing filter elements

7.7

Return filter – changing filter elements B

3

A

2

1

7 - 10

1

Open screw cap (1) of hydraulic tank.

This releases the residual pressure in the tank.

2

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

Unscrew the four socket head bolts (2).

3

Remove cover (3).

4

Remove filter element and dispose of as hazardous waste.

5

Clean components, check seal and exchange if necessary.

6

Insert new filter element.

7

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

8

Tighten screw cap (1).

840 / 10.2006

Hydraulic system - Auxiliary control filter – change filter element

7.8

Auxiliary control filter – change filter element

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

1

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2

1

Unscrew filter housing (1).

2

Dispose of filter element (2) as hazardous waste.

3

Clean components, check seals and exchange if necessary.

4

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

5

Screw filter housing in by hand.

6

Check filter for leaks.

7 - 11

Hydraulic system - Leak-oil filter – changing filter element

7.9

Leak-oil filter – changing filter element

2

1

1

Slacken hexagonal nuts (1).

2

Remove cover (2).

3

7 - 12

3

Unscrew filter element (3) from return pipe.

4

Screw new filter element to the return pipe.

5

Insert cover with return pipe in tank.

6

Tighten hexagonal nuts (1).

840 / 10.2006

Hydraulic system - Changing ventilation filter

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

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

1

2

2 3

840 / 10.2006

1

Lift cover (1).

2

Open screw cap (2) of hydraulic tank.

3

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

4

Dispose of screw cap (3) as hazardous waste.

5

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

6

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

7

Re-close cover (1).

7 - 13

Hydraulic system - Hydro-clean superfine filter (optional)

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

1 3

2

7 - 14

1

De-pressurise hydraulic system acc. to Section 7.4.

2

Unscrew cover (2) with integrated socket head.

3

Pull out filter element.

4

Dispose of filter element as hazardous waste.

5

Clean components, check seal and exchange if necessary.

6

Insert new filter element.

7

Re-tighten screw cap (2).

8

Start driving engine.

9

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

10

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

11

Deposit driving engine and check filter for leaks.

840 / 10.2006

Hydraulic system - Checking preload pressure of pressure accumulator

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

1

Lower suspended loads and jib to the ground.

2

Connect pressure gauge to the measuring bar.

3

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

4

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

5

Observe pressure gauge.

As soon as the preload pressure is reached, the valve in the pressure accumulator closes. The pressure gauge pointer drops suddenly to "0". The value before the pressure drop equates to the preload pressure in the pressure accumulator.

6

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

7

Disconnect pressure gauge.

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

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7 - 15

Hydraulic system - Checking preload pressure of pressure accumulator

7 - 16

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Electrical system - Batteries

8

Electrical system

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

8.1 Batteries DANGER z Explosion hazard!

Smoking and handling of open flame is forbidden. Avoid sparks in vicinity of the battery. z Danger of acid burns!

Wear eye protection and gloves.

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

Check terminals and cable connections of batteries:

840 / 10.2006

1

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

2

Clean battery terminals and cable connections.

Check for tightness and preserve with terminal grease.

8-1

Electrical system - Fuses

8.2

Fuses

DANGER Fire hazard!

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

1

1

Shut down engine.

2

Remove fuse box cover.

3

Replace defective fuse.

4

Check contacts, clean oxidized contacts.

5

Replace cover of fuse box.

Note Wiring, see inside of cover and electrical diagram.

8-2

840 / 10.2006

Heating/air-conditioning system - Heating

9

Heating/air-conditioning system

9.1 Heating Cleaning filter element 1 2

1

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

2

Remove cover (2).

3

840 / 10.2006

3

Remove filter element (3).

4

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

5

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

9-1

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

9.2

Air conditioner (optional)

WARNING z Maintenance and repair work must only be carried out by trained specialist personnel. z Do not reach inside the unit and do not insert objects. z Only carry out maintenance work with driving engine shut down and

fan disconnected. z Danger of burns!

Allow unit and components inside unit (heat exchanger, resistors) to fully cool down first. z Avoid contact with refrigerant. z Wear eye protection. z Always use PAG oil for compressor. No ester-based oils. z No fluorescing additives (tracer agent, sticks).

9-2

840 / 10.2006

Appendix - Lubrication schedule

10 Appendix 10.1Lubrication schedule

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

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

840 / 10.2006

10 - 1

Appendix - Capacities

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

WARNING Mixing oils, lubrication or operational materials of different types is not permitted!

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

System

Capacity

Drive engine

see manufacturer's instructions

Fuel tank

About 132 gal (500 l)

Hydraulic tank

About 79 gal (300 l)

Hydraulic system, complete

About 95 gal (360 l )

Back gear

About 0.32 gal. (1.2 l)

Differential z front

About 10.10 gal. (44.5 l)

z rear

About 9.3 gal. (41.0 l)

Hub drive train

10 - 2

z front

About 0.9 gal. (3.4 l each)

z rear

About 0.9 gal. (3.4 l each)

Slewing ring lubrication

as required

Central lubrication system

as required

Lubrication points

as required

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Appendix - Tightening torques for bolts

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

Strength class 8.8

840 / 10.2006

Coarse thread

Fine thread

Bolt

Tightening torque MA [Nm]

Bolt

Tightening torque MA [Nm]

M4

2,7

M8x1

24

M5

5,4

M10x1

50

M6

9,3

M10x1.25

47

M8

23

M12x1.25

84

M10

45

M12x1.5

81

M12

77

M14x1.5

135

M14

125

M16x1.5

205

M16

190

M18x1.5

305

M18

275

M20x1.5

430

M20

385

M22x1.5

580

M22

530

M24x2

720

M24

660

M27x2

1050

M27

980

M30x2

1450

M30

1350

M33

1850

M36

2350

10 - 3

Appendix - Tightening torques for bolts

Strength class 10.9

10 - 4

Coarse thread

Fine thread

Bolt

Tightening torque MA [Nm]

Bolt

Tightening torque MA [Nm]

M4

4,0

M8x1

36

M5

7,9

M10x1

73

M6

14

M10x1.25

69

M8

33

M12x1.25

125

M10

66

M12x1.5

120

M12

115

M14x1.5

195

M14

180

M16x1.5

300

M16

280

M18x1.5

435

M18

390

M20x1.5

610

M20

550

M22x1.5

830

M22

750

M24x2

1050

M24

950

M27x2

1500

M27

1400

M30x2

2100

M30

1900

M33

2600

M36

3300

840 / 10.2006

Appendix - Tightening torques for bolts

Strength class 12.9

840 / 10.2006

Coarse thread

Fine thread

Bolt

Tightening torque MA [Nm]

Bolt

Tightening torque MA [Nm]

M4

4,7

M8x1

42

M5

9,2

M10x1

86

M6

16

M10x1.25

81

M8

39

M12x1.25

145

M10

77

M12x1.5

140

M12

135

M14x1.5

230

M14

210

M16x1.5

350

M16

330

M18x1.5

510

M18

455

M20x1.5

710

M20

640

M22x1.5

960

M22

880

M24x2

1200

M24

1100

M27x2

1750

M27

1650

M30x2

2450

M30

2200

M33

3000

M36

3900

10 - 5

Appendix - Tightening torques for bolts

10 - 6

840 / 10.2006

Index

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

840 / 10.2006

G Gear teeth 6-1 Gear teeth spray 6-3

1-2 Personnel selection 1-4 pH value, water 3-6 Plastic sliding wear pad 6-4 Pressure cylinders 7-2 Protective roof (FOPS) 1-5

H Hub drive train 5-2, 5-3 Hydraulic screw connections 7-2

R Responsibilities of the operator 1-4 reverse fan 4-8

I Impermissible operating practices 1-5 Inspection by specialist technician 1-4 International regulations 1-1

S Safety notes 1-2 Safety regulations 1-6 Service flap 4-3 Slewing ring lubrication (optional) 6-4 Spare parts manufacture 1-5 Spare Parts Store W-4 Strength classes for bolts 10-3 Swivelling connection 6-1 Symbols and illustration devices W-3

FOPS protective roof 1-5 Fuel system 4-6

K Keyword W-3 L Lubricating path 6-2 Lubricating slewing ring path 6-2 Lubricating slewing ring teeth 6-3 Lubrication cycle 6-2 Lubrication intervals 6-2 Lubrication nipple 10-1 M Maintenance schedule 2-1 Measurement connections 7-5 N National regulations 1-1 Noise protection 1-5 O Oil diagnosis 3-2 Oil filler strainer 7-7 Overseas use 1-6

T Technical condition 1-5 Telephone W-4 Tightening torque 10-3 Top up hydraulic oil 7-7 V V-belt 4-10 W Warning symbol W-3 Warranty conditions 1-6 Warranty manual 1-6 Water separator 4-6 Wear limit 6-4

P Path 6-1 Personal safety equipment

S-1