Sennebogen 860 Maintenance Instruction Manual 860.0.1015 - PDF DOWNLOAD

MAINTENANCE INSTRUCTIONS Model 860

Maintenance instructions 860.0.1015_us

860 / 02.2010

Translation of original instructions

As of 860.0.1002

Important notes on the maintenance instructions

Foreword

You have decided on a brand quality product from SENNEBOGEN. Thank you for your selection.

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 regular and professionally-handled service and maintenance work.

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

For your own safety

Parts and accessories

Warranty

Functionality, reliability, availability and advanced technology, e.g. the use of modern materials and technology, requires specially adapted maintenance and repair methods. Only use genuine SENNEBOGEN spare parts. Only allow authorized SENNEBOGEN partners to perform work on your SENNEBOGEN machine.

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

Use only genuine spare 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 been approved.

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

replacement parts z Maintenance is not performed at specified maintenance intervals z Maintenance has not been performed z Service and maintenance work has not been performed by

a SENNEBOGEN partner.

In the event of damage, SENNEBOGEN retains the right to demand written verification of all maintenance work, performed completely and correctly!

SENNEBOGEN recommends special service and maintenance contracts with the authorized SENNEBOGEN partner of your choice to address these issues.

W-2

Translation of original instructions

860 / 02.2010

Important notes on the maintenance instructions

Notes on the instructions

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

ATTENTION

z Only work with/on the machine after you have read and completely

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

in the cab at all times.

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

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

anything in the instructions!

Your comments will help us to make the instructions even more user-friendly. z Operating the machine is described in separate instructions.

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

860 / 02.2010

Translation of original instructions

W-3

Important notes on the maintenance instructions

Symbols and illustrations

These instructions contain safety instructions that highlight dangerous working practices. These safety instructions are marked with a safety alert symbol and a signal word.

This safety alert symbol means: Attention – this concerns your safety and the safety of others.

The associated signal word signifies the degree of danger: DANGER Is used for serious, impending danger. If this danger is not avoided, serious physical injuries or loss of life will result.

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

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

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

Note Indicates a cross reference to other documents.

Optional/optional equipment Designates instructions and notes which depend on special applications or optional equipment.

W-4

Translation of original instructions

860 / 02.2010

Important notes on the maintenance instructions

Hand tighten.

50 Nm

13 mm

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

Fork wrench with size specification. (in this case: 13 mm)

Flat screwdriver

Phillips screwdriver

32 mm

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

32 mm

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

Connecting a meter or manometer.

Procedures are illustrated in tabular form as follows: 1

Press switch (1).

2

Actuate control lever (2).

3

Unfasten bolts (3).

z Listings are marked with bullet points.

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

860 / 02.2010

Translation of original instructions

W-5

Important notes on the maintenance instructions

Glossary of terms

Operator The operator (owner of the company/company) is responsible for operating the machine in accordance with its intended use, 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 operate the product.

Specialist personnel Specialist personnel are those authorized by the operator to fulfill certain obligations such as installation, setup, maintenance work 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 protective features, protective measures, relevant regulations, accident prevention regulations 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 relevant national occupational safety guidelines, accident prevention regulations, guidelines and generally acknowledged technical regulations (e.g. EEC guidelines, VDE regulations, VBG) as to be able to judge the operational safety of the machine. z Inspectors

Inspectors are those who are authorized by 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 inspectors for the testing of cranes" (ZH 1/518). It is linked with the issue of an identification number. This must be stated by the inspector in the test report and/or test memo.

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

W-6

Translation of original instructions

860 / 02.2010

Important notes on the maintenance instructions

Target group

The machine has been developed for demanding work.

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

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

Which documentation belongs with the machine?

The following documentation belongs with the machine: z These instructions z Operating 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.

860 / 02.2010

Translation of original instructions

W-7

Important notes on the maintenance instructions

How to contact us

SENNEBOGEN Maschinenfabrik GmbH Hebbelstraße 30 94315 Straubing, Germany Telephone:

+49 9421 540-0

Internet:

http://www.sennebogen.de

Fax for Customer Service:

+49 9421 540279

Fax for spare parts depot:

+49 9421 40811

Technical documentation: Email:

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 advanced technology and high level of quality in our machines. This may result in variations between these instructions and your machine. Errors can also not be excluded.

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

© Straubing 2010, SENNEBOGEN Maschinenfabrik GmbH Reproduction, even in part, requires the written permission of Sennebogen Maschinenfabrik GmbH, Straubing, Germany.

Printed in Germany.

W-8

Translation of original instructions

860 / 02.2010

Contents

860 / 02.2010

1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Other risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.3 Machine labeling . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.3.1 Identification plate . . . . . . . . . . . . . . . . . . . . 1-3 1.3.2 Warning and notice signs . . . . . . . . . . . . . . 1-3 1.4 Responsibilities of the operator . . . . . . . . . . . . . . . 1-4 1.5 Supplementary and operational equipment . . . . . . 1-7 1.5.1 SENNEBOGEN Diagnostic System (SDS) . 1-7 1.5.2 Oils and lubricants . . . . . . . . . . . . . . . . . . . . 1-8 1.5.3 Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 1.5.4 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1.6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 1.7 Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 1.8 Safe entry and exit . . . . . . . . . . . . . . . . . . . . . . . 1-18 1.8.1 Emergency exit . . . . . . . . . . . . . . . . . . . . . 1-22 1.8.2 Emergency exit . . . . . . . . . . . . . . . . . . . . . 1-22 1.9 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 1.10 Protective features . . . . . . . . . . . . . . . . . . . . . . . 1-24 1.11 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

2

Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1 Daily/weekly maintenance . . . . . . . . . . . . . . . . . . . 2-2 2.2 One-time maintenance . . . . . . . . . . . . . . . . . . . . . 2-5 2.2.1 After 250 hours of operation at the latest . . 2-5 2.3 Regular maintenance / Maintenance interval . . . . 2-6 2.3.1 Monthly or at the latest after 250 hours of operation 2-7 2.3.2 Semi-annually or at the latest after 500 hours of operation 2-9 2.3.3 Annually or at the latest after 1000 hours of operation 2-11 2.3.4 At the latest after 2000 hours of operation 2-14 2.3.5 At the latest, after 4,000 / 5,000 / 10,000 / 12,000 / 20,000 hours of operation 2-15

3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 Drive engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.3 Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.4 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Translation of original instructions

0-1

Contents

3.5 Inspection tools – overview . . . . . . . . . . . . . . . . . . 3-6 3.6 Lubricating the machine . . . . . . . . . . . . . . . . . . . . 3-7 3.6.1 Central lubrication system and slewing ring lubrication system 3-7 3.6.2 Lubricating nipple overview . . . . . . . . . . . . . 3-8 3.7 Tightening torques for bolts . . . . . . . . . . . . . . . . . 3-11 3.8 Wind speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 3.9 Conversion factors . . . . . . . . . . . . . . . . . . . . . . . . 3-17

0-2

4

Drive engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.3.1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.3.2 Air filter – pre-separator . . . . . . . . . . . . . . . . 4-6 4.4 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.4.1 Safety instructions . . . . . . . . . . . . . . . . . . . . 4-7 4.4.2 Water separator . . . . . . . . . . . . . . . . . . . . . . 4-8 4.5 Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4.5.1 Safety instructions . . . . . . . . . . . . . . . . . . . 4-10 4.5.2 Refrigerant – Cummins Engine . . . . . . . . . 4-10 4.5.3 Changing refrigerant . . . . . . . . . . . . . . . . . 4-11 4.6 Cleaning the cooling system . . . . . . . . . . . . . . . . 4-13 4.6.1 Safety instructions . . . . . . . . . . . . . . . . . . . 4-13 4.6.2 Fan reversal . . . . . . . . . . . . . . . . . . . . . . . 4-14 4.6.3 External cleaning . . . . . . . . . . . . . . . . . . . . 4-14 4.6.4 Internal cleaning . . . . . . . . . . . . . . . . . . . . 4-15 4.7 Checking belt drives . . . . . . . . . . . . . . . . . . . . . . 4-16

5

Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1 Cleaning and lubricating . . . . . . . . . . . . . . . . . . . . 5-1 5.2 Tire air pressure (pneumatic tires) . . . . . . . . . . . . . 5-1 5.3 Tightening wheel nuts . . . . . . . . . . . . . . . . . . . . . . 5-2 5.4 Hub drive train . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.5 Back gear and differential . . . . . . . . . . . . . . . . . . . 5-5 5.6 Parking disc brake . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

6

Swiveling connection . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2 Lubricating slewing ring path . . . . . . . . . . . . . . . . . 6-2 6.2.1 Central lubrication system . . . . . . . . . . . . . . 6-2 6.3 Lubricating live ring toothed wheel . . . . . . . . . . . . 6-3

Translation of original instructions

860 / 02.2010

Contents

6.3.1 Gear spray . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.3.2 Slewing ring lubrication (optional) . . . . . . . . 6-4 6.4 Tighten slewing ring bolts . . . . . . . . . . . . . . . . . . . 6-7 6.5 Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 6.6 Wear measurement and checking the drive system/ bearing play 6-13

860 / 02.2010

7

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.2 General information . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.2.1 Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . 7-2 7.2.2 Threaded unions . . . . . . . . . . . . . . . . . . . . . 7-2 7.3 Hydraulic hose lines . . . . . . . . . . . . . . . . . . . . . . . 7-3 7.4 De-pressurizing the hydraulic system . . . . . . . . . . 7-4 7.5 Checking hydraulic oil level . . . . . . . . . . . . . . . . . . 7-6 7.6 Changing hydraulic oil . . . . . . . . . . . . . . . . . . . . . . 7-8 7.7 Return filter – Changing filters . . . . . . . . . . . . . . . 7-11 7.8 Leakage oil filter – Changing filter . . . . . . . . . . . . 7-12 7.9 Changing the ventilation filter . . . . . . . . . . . . . . . 7-13 7.10 HydroClean – Changing the filter . . . . . . . . . . . . 7-14 7.11 Auxiliary control filter – Changing the filter . . . . . 7-15 7.12 Pressure filter – Changing filter . . . . . . . . . . . . . . 7-16 7.13 Changing the ventilation filter with dehumidifying unit (optional) 7-18 7.14 Checking preload pressure of pressure accumulator .

7-19

8

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

9

Heating / Air-conditioning system . . . . . . . . . . . . . . . 9-1 9.1 Air conditioning system . . . . . . . . . . . . . . . . . . . . . 9-1 9.1.1 Cleaning the heating system recirculating air filter 9-3 9.1.2 Cleaning the heating system outside air filter . .

9-4

Translation of original instructions

0-3

Contents

9.2 Auxiliary heating system (optional) . . . . . . . . . . . . 9-5

0-4

Translation of original instructions

860 / 02.2010

Safety - General information

1

Safety

1.1

General information

Before starting with maintenance, the machine must be prepared as described in the following sections.

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

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

Target group

The machine has been developed for demanding work.

Persons working on or with the machine must be trained or instructed for that purpose. Start-up, maintenance, transport, and assembly/ disassembly should only be performed by trained specialists.

DANGER Danger to life!

There is a risk of serious injury or even death to persons using the machine or in its vicinity if it moves suddenly or is started involuntarily.

Therefore, observe the following: z Place the machine on a firm subgrade (level, solid, horizontal), if necessary set back from the edge of the excavation. z Lower attached loads and booms to the ground. z Apply the brake. z Pull back the safety lever (all hydraulic functions are inactive). z Switch off the machine and secure against unauthorized

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

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

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

860 / 02.2010

Translation of original instructionsl

1-1

Safety - Other risks

1.2

Other risks

The safety instructions in these instructions are guidelines for the safe maintenance on the machine by qualified machine operators.

However, SENNEBOGEN cannot anticipate every situation, which may result in danger in practice.

Therefore, the safety instructions and warnings on the machine and in the instructions cannot be all inclusive. Operators and machine operators remain responsible for safety.

Warning and notice signs attached to the machine also refer to other risks.

1-2

Translation of original instructions

860 / 02.2010

Safety - Machine labeling

1.3

Machine labeling

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

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

1.3.1

Identification plate

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

1.3.2

Warning and notice signs

Note More information can be found in the operating instructions from chapter 1 and chapter 3.

860 / 02.2010

Translation of original instructionsl

1-3

Safety - Responsibilities of the operator

1.4

Responsibilities of the operator

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

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

Recurring inspections

Inspection by specialist technician, required for crane or excavating work The machine must be thoroughly inspected by a specialist technician. z before start-up and before operating the machine after significant

modifications z at least once yearly z intermittently depending on operating and company conditions.

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

regulations and guidelines due to specialist training and z through special instructions by SENNEBOGEN

and can assess the safe working condition of the machine.

Inspection by an inspector, only required for crane operation The following cranes must be tested by an inspector every 4 years: – Fuel driven mobile crane – Location changing fuel driven Derrick – Truck attachment cranes The inspector 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.

1-4

Translation of original instructions

860 / 02.2010

Safety - Responsibilities of the operator

Personnel selection and qualifications

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

CAUTION z Personnel under training or instruction must remain under constant specialist 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 undercarriage, braking and steerage 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 of and experience with hydraulics!

Excerpt from VBG 40

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

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

For permanent sound pressure levels (LpA) of the machine, which are measured at the driver's seat with the cab closed, see the value on sticker on the inside of the cab. The wearing of ear protection is not absolutely required. 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 at a construction 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, ear protection is also to be worn outside the cab in special cases.

860 / 02.2010

Translation of original instructionsl

1-5

Safety - Responsibilities of the operator

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 behavior) of the machine.

The machine must not be operated if faults are found!

Observe mandatory time limits for routine checks.

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

Independent modification and manufacture of spare parts

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

This also applies to the installation and use of safety features 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.

Special dangers

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

Dangers of noncompliance with safety instructions

Non-compliance with safety instructions 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 damages.

Fire extinguisher and first-aid kit

1-6

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

Translation of original instructions

860 / 02.2010

Safety - Supplementary and operational equipment

1.5

Supplementary and operational equipment

1.5.1

SENNEBOGEN Diagnostic System (SDS)

Note Sensors monitor the current operating status of the machine and transmit the measurement results to the SDS. The measurement results 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 Diagnostic System

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

CAUTION The SENNEBOGEN Diagnostic 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.

860 / 02.2010

Translation of original instructionsl

1-7

Safety - Supplementary and operational equipment

1.5.2

Oils and lubricants

Note Only use oils and lubricants approved by SENNEBOGEN. These are listed in LUBRICANTS TABLE. The ambient temperature for operating the machine must be between -20°C (- 4°F) and + 40°C (+ 104°F). If the temperature at the site lies outside this range, discuss this with SENNEBOGEN Customer Service before start-up.

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

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

Only use 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

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 the hydraulic system.

Note More helpful information is available from SENNEBOGEN Customer Service.

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 biological oils may be used.

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

1-8

Translation of original instructions

860 / 02.2010

Safety - Supplementary and operational equipment

1.5.3 General

Refrigerant

WARNING Mixing refrigerants and adding cooling system sealing agents or antifreeze that contains sealing agents is not permitted.

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

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

Note Observe the refrigerant 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 engine 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 fill the water-coolant circuit and no suitable refrigerant is available, you can add clean water in the mean time.

However, we recommend that you test the concentration as soon as possible before temperatures drop down to freezing. In some cases, you must refill with the respective refrigerant so that the required mixture to prevent freezing is achieved again.

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

860 / 02.2010

Translation of original instructionsl

1-9

Safety - Supplementary and operational equipment

Refrigerant for CUMMINS drive engines

CUMMINS drive engines can be recognized by the identification plate.

Note CUMMINS drive engines are filled with refrigerant z ES CompleatTM at the factory. Use this refrigerant only for CUMMINS drive engines!

SENNEBOGEN will not accept responsibility and will not provide warranty or make any guarantees for the use of any other refrigerants.

Frost resistance is sufficient to -36°C (- 33°F).

Note Observe the refrigerant label in the cooler area.

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

1 - 10

Translation of original instructions

860 / 02.2010

Safety - Supplementary and operational equipment

Water Note z Use clean, neutral, filtered, fairly soft fresh tap water.

SENNEBOGEN recommends distilled water as the best option. z Do not use ditch water, industrial drain water, salt water, sea water

or rain water. z Always fill using a water-refrigerant 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 refrigerant concentration is too high, the cooling and antifreeze characteristics will worsen.

CAUTION Observe the specifications of the refrigerant manufacturer.

WARNING Never fill with refrigerant when the engine is overheated.

This will damage the engine. Allow the engine to cool first.

WARNING Observe refrigerant manufacturer instructions for using the refrigerant to avoid possible danger to health or environmental hazards.

860 / 02.2010

Translation of original instructionsl

1 - 11

Safety - Supplementary and operational equipment

Using other refrigerants

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

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

Changing refrigerant

WARNING Scalding hazard!

Caution when draining hot refrigerant!

Allow the engine to cool first. Collect the refrigerant in a suitable container when draining and dispose of in accordance with regulations.

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

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

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

– Start the engine and check the refrigerant levels CAUTION Refrigerant level adjustments may have to be checked more than once to ensure they are correct.

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

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

Changing intervals

1 - 12

Information on changing the refrigerant and the changing intervals are provided in the operating instructions of the engine manufacturer.

Translation of original instructions

860 / 02.2010

Safety - Supplementary and operational equipment

1.5.4

Fuel

Fill the tank with the specified grade of fuel. Clean fuel is essential for trouble-free operation of the diesel engine.

Note regarding fuel grade and selection Observe the instructions and recommendations in the operating instructions of the engine manufacturer.

860 / 02.2010

Translation of original instructionsl

1 - 13

Safety - Maintenance

1.6

Maintenance

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

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

instructed specialists. z Wear personal protective equipment (e.g. protective helmet,

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

Hanging rings are marked. z Use only original SENNEBOGEN spare parts. z Use only oils and lubricants listed in the lubricant table. z Collect lubricants and other operational fluids in suitable containers

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

during maintenance work as well. z Keep the vehicle (e.g. grips, steps, platforms, railing, etc.)

free from dirt, snow and ice. z Smoking and working with an open flame is strictly forbidden. z Use safety-compliant access ladder aids or working platforms. z Stay clear of rotating and moving parts. z Relieve the pressure from the hydraulic system and other

operational fluids 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 manually. Use lifting equipment. z For pneumatic tires:

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

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

insulating material; do not place tools on top of batteries.

1 - 14

Translation of original instructions

860 / 02.2010

Safety - Maintenance

z When handling batteries, observe the safety instructions 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 appropriate protective equipment. z Replace all protective features after completing any work on the

machine. Exchange damaged protective features for new ones. z Carry out function check to ensure it is working properly. z Only the machine owner or representative may approve the machine

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

measures, e.g.

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

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

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

maintenance work is to be inspected by an authorized expert.

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

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

Anti-friction bearings, drive flanges and such that have to be disassembled/assembled require the use of suitable tightening equipment or special tools.

860 / 02.2010

Translation of original instructionsl

1 - 15

Safety - Maintenance

Qualifications of personnel

DANGER

z Work on electrical equipment of the machine may only be carried

out by an electrical specialist. z Work on undercarriage, braking and steerage systems may only

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

with special knowledge of and experience with hydraulics! z No welding is to be performed on the device without previous

discussion with the manufacturer.

1 - 16

Translation of original instructions

860 / 02.2010

Safety - Cleaning work

1.7

Cleaning work

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

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

and components of the machine. z Do not use aggressive cleaning agents. z Only use lint-free cleaning cloths. z Only use dry, filtered compressed air up to max. 2 bar (29 psi). z Lubricate the lubrication points after every cleaning. z Replace protective caps on the lubricating 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 switch cabinet. z On completion of cleaning work on the machine, carry out a visual

and functional check according to the machine operating instructions. z When cleaning swiveling connections a pressure washer must not

be used. This can cause large quantities of water, cleaning agents and dirt particles, that are placed under pressure, to penetrate the sealing grooves and enter the swiveling connection. These can no longer be removed by heavy greasing. This significantly reduces the usable life of the swiveling connection.

WARNING Electrical and electronic components such as the generator, switch cabinet, etc. as well as the bushes 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 infiltration of water can otherwise damage or destroy the electrical equipment of the machine. This can result in sudden, uncontrolled motion when working.

860 / 02.2010

Translation of original instructionsl

1 - 17

Safety - Safe entry and exit

1.8

Safe entry and exit

z If necessary, clean access ladders 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 access ladders, ladders and grip handles. (e.g. two hands and one foot or two feet and one hand) z Hoist items of equipment onto machine using rope or lifting

equipment. z Do not use operating instruments in the cab as grip handles. z Use only the appropriate, provided access ladders 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 a safety harness to prevent falling. At working heights above 3.00 m, using a safety harness is legally required.

Hanging rings are marked.

Cab without gallery

1 - 18

1

Open the sliding door (1) from the ground.

2

Hold onto the grip handles (2) and use your feet to step on the access ladders (3) and climb into the cab.

3

Close the sliding door.

Translation of original instructions

860 / 02.2010

Safety - Safe entry and exit

Cab with gallery

1

Open the door (1) from the ground.

2

Hold onto the grip handles (2) and use your feed to step on the access ladders (3).

3

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

CAUTION Risk of falling!

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

Only in extreme emergencies and with the utmost 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 upper structure to 90° offset to the undercarriage to allow safe entry/exit.

860 / 02.2010

Translation of original instructionsl

1 - 19

Safety - Safe entry and exit

Gallery/Operator catwalk

DANGER Risk of falling!

Assembly of the gallery/operator catwalk (1) is mandatory, since it is part of the safety concept.

CAUTION Risk of falling!

No one must be permitted on the gallery when the cab is elevated!

The max. load permitted on the gallery is 200 kg (440 lb) per gridiron segment. Overloading the gallery can result in damage to the structure and result in serious personal injury.

Inspect the gallery every 3 months (in particular, cracking) and repair immediately if found.

1 - 20

Translation of original instructions

860 / 02.2010

Safety - Safe entry and exit

Upper structure

1

2 1 Access ladders 2 Grip handles DANGER Wear personal protection equipment (e.g. protective equipment, ear protection, protective gloves, safety shoes), where working conditions require. At working heights of 2.00 m or more, SENNEBOGEN recommends the use of a safety harness to prevent falling. At working heights above 3.00 m, using a safety harness is legally required.

Hanging rings are marked.

860 / 02.2010

Translation of original instructionsl

1 - 21

Safety - Safe entry and exit

1.8.1

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

Note In case of emergency, you can exit via the rear window (1).

Use the emergency hammer to break the 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.

1.8.2

Emergency exit

CAUTION Risk of falling!

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

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

1 - 22

Translation of original instructions

860 / 02.2010

Safety - Welding work

1.9

Welding work

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

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

Preliminary tasks

860 / 02.2010

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

1

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

2

Disconnect battery.

3

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

4

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

5

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

Translation of original instructionsl

1 - 23

Safety - Protective features

1.10

Protective features

DANGER z Do not remove protective features or coverings. z Check protective features for completeness and proper fastening

each time before switching on the machine.

Protective features include engine flaps, doors, guard grills, coverings, fire extinguishers and first aid kits. z Replace all protective features and coverings properly on completion

of assembly or maintenance work. z Exchange damaged protective features for new ones.

Example. Fig.: Fan grille

1 - 24

Translation of original instructions

860 / 02.2010

Safety - Disposal

1.11

Disposal

Lubricants and operational fluids CAUTION Observe environmental guidelines!

Handle and dispose of used items and materials correctly, in particular 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 hydraulic oil systems.

Excerpt from the Disposal of Waste Oils Directive 75/439/EEC: z "It is prohibited to mix waste oil with other waste." z "Waste oils must not be mixed together." z "Used oil filters must be collected, kept, transported and disposed

of separately from other waste."

Notes z Lubricants and other operational fluids must be disposed of at suitable collection points. z National environmental regulations specified in the country

of use also apply to disposal.

Batteries

Observe safety instructions and protective measures when handling batteries.

Notes z Do not put batteries in the trash!

Dispose of defective batteries at a recycling location for old batteries. z National environmental regulations valid in the country of use also

apply to disposal.

860 / 02.2010

Translation of original instructionsl

1 - 25

Safety - Disposal

1 - 26

Translation of original instructions

860 / 02.2010

Maintenance schedule

2

Maintenance schedule

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

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

Please observe the operating instructions from the engine manufacturer!

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

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

860 / 02.2010

Translation of original instructions

2-1

Maintenance schedule Daily/weekly maintenance

2.1

Daily/weekly maintenance

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

No.

Visual checks

Steps to take

Chapter

5

S1

Are all protective coverings, insulating materials and warning signs in place on the machine and undamaged?

If necessary, replace

-

S2

Are all access ladders, grips and anti-slip flooring in place and undamaged (e.g. cracking)?

If necessary, repair or replace

-

S3

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

If necessary, clean using a highpressure cleaner CAUTION around sensitive or electrical components!

-

S4

Are the windows clean and free of ice and snow?

If necessary, de-ice or clean

-

S5

Is the undercarriage (tires, axles, drive shafts/universal joints) undamaged?

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

5.3

S7

Is the tire pressure correct?

(For pneumatic tires).

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

5.2

S8

Is the hydraulic system (lines, hoses etc.) free of leaks or undamaged?

If necessary, tighten connections or replace seals

7

S9

Are the hydraulic cylinders (e.g. outrigger, stick, floating axle cylinders, steering cylinders) free of leaks and undamaged?

Inspect piston rods for damage (cracking, etc).

If necessary, tighten connections or replace seals

7.2.1

S10

Is the gate on the hydraulic tank open?

If necessary, open

-

S11

Are the oil and fluid reservoirs sufficiently full (hydraulic oil, engine oil, fuel, demister, slewing gear, etc.)?

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

-

S12

Are TopAir and air filter cartridges damaged or contaminated?

If necessary, clean or replace

-

S13

Is the fan wheel undamaged?

If necessary, replace

-

S14

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

If necessary, clean by reversing the fan or replace

-

2-2

Translation of original instructions

860 / 02.2010

Maintenance schedule Daily/weekly maintenance

Visual checks

No.

Steps to take

Chapter

5

S15

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

If necessary, repair leaks and add refrigerant. Follow manufacturer's instructions! Replace defective components

-

S16

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

If necessary, retighten or replace

7.2.2

S17

Has the water separator on the fuel system been drained?

If necessary, drain

4.4.2

S18

Are the V-belts undamaged and tensioned?

If necessary, tension again or replace

4.7

S19

Are the electrical lines damaged?

If necessary, repair or replace

8

S20

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

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

-

S21

Are the batteries held in place securely?

If necessary, retighten holders

S22

Are all service access doors closed?

If necessary, close

S23

Are all bolt/screw connections undamaged and tight, particularly on the elevating cab?

If necessary, retighten or replace

S24

Are all bolt/screw connections e.g. on the mast and the gallery undamaged and tight (high-strength bolts, with/without spacers)?

If necessary, retighten or replace

S25

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

If necessary, disconnect

S26

Is the correct counterweight installed and secured in place?

Replace if necessary or retighten to specified torque

S27

Are the boom components undamaged (corrosion, cracking)?

If necessary, repair or replace

-

S28

Are any pin-type keepers cracked or damaged?

If necessary, replace

-

S29

Are the pipe fracture safety devices tight and undamaged?

If necessary, replace

-

S30

Is there enough grease in the central lubrication system?

If necessary, refill

6.2.1

S30

Is there enough grease in the grease reservoir of the slewing ring lubrication?

If necessary, refill

6.3.2

S31

Are the lubrication pipes undamaged and all lubrication points being greased?

If necessary, replace, clean and lubricate

3.6

S32

Are the hydraulic pipes and hoses secured in place?

If necessary, tighten fasteners

7

860 / 02.2010

Translation of original instructions

-

7.2.2

-

2-3

Maintenance schedule Daily/weekly maintenance

No.

Visual checks

Steps to take

Chapter

5

S33

Is the swiveling connection undamaged and lubricated sufficiently?

Repair or actuate pinion lubrication if necessary

6

S35

Are the mechanical steering stops worn?

If necessary, replace

-

S36

Is the energy chain damaged/worn?

If necessary, replace

-

2-4

Translation of original instructions

860 / 02.2010

Maintenance schedule One-time maintenance

2.2

One-time maintenance

2.2.1

After 250 hours of operation at the latest

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

5

Subassemblies/activities

Chapter

Play in the slewing ring

Wear measurement and checking the drive system/ bearing play.

The measurement is to be regarded as the base position for delivery status!

6.6

Slewing gear W Upper structure

Oil change

6.5

Hydraulics W

Return filter – Changing the filter

7.7

W

Leakage oil filter – Change filter

7.8

W

Auxiliary control filter – Change filter

7.11

W

Hydro Clean – Change filter (optional)

7.10

Hydraulics W

Pressure filter – Change filter

7.12

Hydraulics

860 / 02.2010

Have preload pressure of hydraulic accumulator checked by hydraulic specialist company

Translation of original instructions

7.14

2-5

Maintenance schedule Regular maintenance / Maintenance interval

2.3

Regular maintenance / Maintenance interval

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

Hours of operation (hrs) Section

250

500

750

1,000

1,250

1,500

1,750

2,000

...

2.3.1

U

U

U

U

U

U

U

U

...

U

...

U

...

U

...

2.3.2

U

U U

2.3.3 2.3.4

U

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

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

– Etc...

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

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

2-6

Translation of original instructions

860 / 02.2010

Maintenance schedule Regular maintenance / Maintenance interval

2.3.1

Monthly or at the latest after 250 hours of operation

Note Observe the maintenance intervals and the maintenance schedule from the respective additional documentation. (e.g. grab, engine)

5 Undercarriage

Subassemblies/activities

Chapter

Steering axle: Hub F

Checking oil level

5.4

Differential F

Checking oil level

5.5

Steering

Check the steering stops

Check the steering cylinder for leaks and functionality Back gear

F

Checking oil level

5.5

Rigid axle: Hub F

Checking oil level

5.4

Differential F

Checking oil level

5.5

Back gear F

Checking oil level

5.5

Parking disc brake F

Checking oil level

5.6

Steel structure

860 / 02.2010

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

Translation of original instructions

2-7

Maintenance schedule Regular maintenance / Maintenance interval

5

Subassemblies/activities

Chapter

Slewing ring

Upper structure

visually check all connecting elements for damage and corrosion

6

Cab air conditioning and auxiliary heating system

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

Switch on at least 1 time per month

9.1 9.2

Engine W F

Engine maintenance intervals (see engine manufacturer's instructions)

F

Check refrigerant level, check anti-freeze/ concentration

4.5

W

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

4.4.2

Engine: air conditioning compressor

Check the air conditioning compressor mounts and bolts for tightness

4

Check belt tension and status

4.7

Hydraulic tank gate

2-8

Visually check for leaks

Translation of original instructions

860 / 02.2010

Maintenance schedule Regular maintenance / Maintenance interval

2.3.2

Semi-annually or at the latest after 500 hours of operation

Note Observe the maintenance intervals and the maintenance schedule from the respective additional documentation. (e.g. grab, engine)

5 Undercarriage

Subassemblies/activities

Chapter

Steering

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

3.7

Slewing ring lubrication

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

6.3

Slewing ring: Gear teeth/slewing track

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

6.4

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

6

Upper structure

Gallery

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

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

Have an authorized workshop perform checks on the air conditioning

9.1

Equipment

860 / 02.2010

Load holding test with 1 t

Translation of original instructions

2-9

Maintenance schedule Regular maintenance / Maintenance interval

5

Subassemblies/activities

Chapter

Hydraulics

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

7.9

Hydraulics

Have preload pressure of hydraulic accumulator checked by hydraulic specialist company

7.14

Engine W F

Engine maintenance intervals (see engine manufacturer's instructions)

4

W

Water separator – Change filter insert

4.4.2

Charge air cooler – Drain condensation Hydraulic tank gate

2 - 10

Visually check for leaks

Translation of original instructions

860 / 02.2010

Maintenance schedule Regular maintenance / Maintenance interval

2.3.3

Annually or at the latest after 1000 hours of operation

Note Observe the maintenance intervals and the maintenance schedule from the respective additional documentation. (e.g. grab, engine)

5 Undercarriage

Subassemblies/activities

Chapter

Steering axle: Hub W

Oil change

5.4

Brake

Brake wear measurement

5.4

Differential W

Oil change

5.5

Back gear W

Oil change

5.5

Rigid axle: Hub W

Oil change

5.4

Brake

Brake wear measurement

5.4

Swing axle cylinder

Check secure fastening, tighten to required torque when necessary

3.7

Differential W

Oil change

5.5

Back gear W

Oil change

5.5

Parking disc brake W

860 / 02.2010

Oil change

Translation of original instructions

5.6

2 - 11

Maintenance schedule Regular maintenance / Maintenance interval

5

Subassemblies/activities

Chapter

Steel structure

Use suitable equipment to check for structural damage (e.g. deformation, damage, corrosion, cracking) Slewing ring: Gear teeth/slewing track

Check for interference/gear teeth of the slewing ring pinion

6

Play in the slewing ring

Wear measurement and checking the drive system/bearing play

6.6

Slewing gear

Upper structure

Check secure fastening, tighten to required torque when necessary

3.7

Steel structure

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

Check secure fastening, tighten to required torque when necessary

3.7

Fuel / hydraulic system tank

Check secure fastening, tighten to required torque when necessary

3.7

Equipment

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

Check pin-type keepers for cracking or damage

Check for correct lifting limit settings for stick and boom

Check pipe fracture safety devices Hydraulic system

2 - 12

Ventilation filter – change hydraulic tank

Translation of original instructions

7.9

860 / 02.2010

Maintenance schedule Regular maintenance / Maintenance interval

5

Subassemblies/activities

Chapter

Engine W F

Engine maintenance intervals (see engine manufacturer's instructions)

W

Safety cartridge – Change air filter

4.3

W

Replacement cartridge – Change air filter

4.3

Hydraulic tank gate

860 / 02.2010

Visually check for leaks

Translation of original instructions

2 - 13

Maintenance schedule Regular maintenance / Maintenance interval

2.3.4

At the latest after 2000 hours of operation

Note Observe the maintenance intervals and the maintenance schedule from the respective additional documentation. (e.g. grab, engine)

Subassemblies/activities

5

Chapter

Slewing gear

Undercarriage W Upper structure

Oil change

6.5

Hydraulic system W

Return filter – Changing the filter

7.7

W

Leakage oil filter – Change filter

7.8

*

Auxiliary control filter – Change filter

7.11

W

HydroClean – Change filter (optional)

7.10

**

Changing the hydraulic oil

7.6

**

Check hydraulic hoses for damages

7.3

Hydraulic system W

Pressure filter – Change filter

7.12

Engine W F

Engine maintenance intervals (see engine manufacturer's instructions)

W

Changing refrigerant

4.5.3

Slip ring assembly

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

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

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

2 - 14

Translation of original instructions

860 / 02.2010

Maintenance schedule Regular maintenance / Maintenance interval

2.3.5

At the latest, after 4,000 / 5,000 / 10,000 / 12,000 / 20,000 hours of operation

Note Observe the maintenance intervals and the maintenance schedule from the respective additional documentation. (e.g. grab, engine) At the latest, after ...

5 4,000 hours of operation

5,000 hours of operation or 5 years 12,000 hours of operation or 6 years 20,000 hours of operation or 10 years

Subassemblies/activities

Chapter

Hydraulic system W

Changing the hydraulic oil

7.6

Check hydraulic hoses for damages

7.3

Slewing ring connection

Have the slewing ring bolts checked by a specialist company. Change if necessary Hydraulic system

W

Change hydraulic hoses

Slip ring assembly

7.3

Renew bearing point Hydraulic system

860 / 02.2010

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

Translation of original instructions

7.14

2 - 15

Maintenance schedule Regular maintenance / Maintenance interval

2 - 16

Translation of original instructions

860 / 02.2010

Specifications - General

3

Specifications

3.1

General

Note The following values are guidelines. The level specified on the corresponding components is authoritative (upper mark on dipstick) Electrical system 24 V Note Ensure that the available output power of the alternator is not exceeded when installing additional current consumers (e.g. headlights).

Ambient temperature Operation/Operation under load

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

Note If a machine is to be run in ambient temperatures outside the specified temperature range, special temperature packages are available (option).

Please contact SENNEBOGEN Customer Service if you have any other questions.

Hydraulic system Operating pressure, max. 350 bar

Slewing drive Slewing speed

Travel speed

860 / 02.2010

0 – 8 rpm, continuously variable

approx. 0 – 15 km/h / 0 – 9.32 mile/h

Translation of original instructions

3-1

Specifications - General

Limitations during wind

Wind speed 25 m/s

90 km/h

10 Beaufort

Note Machine operation is generally possible, without any attachments, at wind speeds of up to 25 m/second.

The decision when to halt operation must be made by the machine operator and depends on the attachment.

Various attachments have varying wind loads, which affect stability.

These are to be determined by the operator and the machine is to be shut down accordingly.

DANGER Once the specified wind speed is reached, stop operating the machine immediately (lower load, lower boom). For table on wind speeds, see Section 3.8

3-2

Translation of original instructions

860 / 02.2010

Specifications - Drive engine

3.2

Drive engine

QSM11-C360

860 / 02.2010

Power (according to ISO14396)

268 kW at nominal speed 1,800 rpm

Displacement

10800 cm3

Cylinders

6

Oil capacity with filter

approx. 37.0 l/approx. 9.8 gal. (US)

Refrigerant capacity (overall system) Engine

approx. 60 l/approx. 15.9 gal. (US)

General drive engine information

See manufacturer's instructions

Translation of original instructions

approx. 9.5 l / app. 2.5 gal. (US)

3-3

Specifications - Machine

3.3

Machine

Subassembly

Quantity

Fuel tank - Middle inspection glass:

max. 880 l / 232 gal. (US) approx. 850 l / 225 gal. (US)

Hydraulic tank - Middle inspection glass:

max. 700 l / 185 gal. (US) approx. 570 l / 150 gal. (US)

Hydraulic system, complete (*)

approx. 800 l / 211 gal (US)

Differential z front

approx. 44.5 l / 11.4 gal. (US)

z rear

approx. 40.3 l / 10.3 gal. (US)

Back gear z front

approx. 1.5 l / 0.4 gal. (US)

z rear

approx. 1.5 l / 0.4 gal. (US)

Hub drive train z front

Each approx. 4.7 l / 1.23 gal. (US)

z rear

each approx. 4.7 l / 1.23 gal. (US)

Parking disc brake z rear

approx. 0.6 l / 0.17 gal. (US)

Slewing gear

approx. 4.0 l / 1.05 gal. (US)

Slewing ring lubrication – reservoir

approx. 1.0 l / 0.3 gal. (US)

Central lubrication system – reservoir (optional)

approx. 2.0 l / 0.53 gal. (US) or approx. 4.0 l / 1.06 gal. (US)

Lubricating nipple

as required

(*): Note that for special machines with a mast, an additional approx. 30 l (approx. 7.9 gal. (US)) of hydraulic oil is required per 0.5 m length of mast.

Tire air pressure (pneumatic tires)

3-4

Tire size

ppbarp Air pressure ppsi

14.00-24

10

Translation of original instructions

145.04

860 / 02.2010

Specifications - Lubricants

3.4

Lubricants

Note Observe the information and recommendations in the lubricant table.

860 / 02.2010

Translation of original instructions

3-5

Specifications - Inspection tools – overview

3.5

Inspection tools – overview

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

Machine

Quantity

Oil filter

1

Refrigerant filter (water filter)

1

Fuel filter

1

Water separator

1

Safety cartridge air filter

1

Replacement cartridge air filter

1

V-belt, alternator/water pump

1

V-belt, air conditioning system

1

V-belt, magnet unit (optional)

1

Item

Quantity

Return filter

3

Leakage oil filter

1

Ventilation filter

2

Auxiliary control filter *)

1

HydroClean (optional)

1

Pressure filter

1

Recirculating air filter

1

Outside air filter

1

SE Number

see Wear parts list in the Spare parts catalogue

Item

SE Number see Wear parts list in the Spare parts catalogue

Drive engine

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

3-6

Translation of original instructions

860 / 02.2010

Specifications - Lubricating the machine

3.6

Lubricating the machine

3.6.1

Central lubrication system and slewing ring lubrication system

Lubrication by: Central lubrication system bearings supplied with grease by the central lubrication system.

Slewing ring lubrication slewing ring supplied with grease by the slewing ring lubrication system.

Note z The machine is equipped with a central lubrication system for the swiveling connection and for the equipment. z The machine has a slewing ring lubrication system for the slewing ring.

CAUTION The reservoir for the central lubrication system and slewing ring lubrication system must always be adequately filled in order to prevent damage to the bearings.

860 / 02.2010

Translation of original instructions

3-7

Specifications - Lubricating the machine

3.6.2 Lubricating nipple overview Note z grease manually z the lubricating nipples are provided with a red protective cap.

1

2 Lubricating strip – front 1

z for support cylinder inner – front and rear z for steering axle

2

Lubricating nipple z for outrigger

Note z Clean lubricating nipple before lubrication z Remove excess grease.

3-8

Translation of original instructions

860 / 02.2010

Specifications - Lubricating the machine

1

Note z Clean lubricating nipple before lubrication z Remove excess grease.

860 / 02.2010

Translation of original instructions

3-9

Specifications - Lubricating the machine

A B

2

A

A

A B

A

A A

A B A

A

A Lubrication points

Lubrication by lubricating strip 1

B Lubrication point on joint

Lubricating nipple

Note z Clean lubricating nipple before lubrication z Remove excess grease.

3 - 10

Translation of original instructions

860 / 02.2010

Specifications - Tightening torques for bolts

3.7

Tightening torques for bolts

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

Strength class 8.8

860 / 02.2010

Coarse thread

Fine thread

Bolt

Tightening torque MA [Nm]

Bolt

Tightening torque MA [Nm]

M4

2,7

M8x1

24

M5

5,4

M10x1

50

M6

9,3

M10x1.25

47

M8

23

M12x1.25

84

M10

45

M12x1.5

81

M12

77

M14x1.5

135

M14

125

M16x1.5

205

M16

190

M18x1.5

305

M18

275

M20x1.5

430

M20

385

M22x1.5

580

M22

530

M24x2

720

M24

660

M27x2

1050

M27

980

M30x2

1450

M30

1350

M33

1850

M36

2350

Translation of original instructions

3 - 11

Specifications - Tightening torques for bolts

Strength class 10.9

3 - 12

Coarse thread

Fine thread

Bolt

Tightening torque MA [Nm]

Bolt

Tightening torque MA [Nm]

M4

4.0

M8x1

36

M5

7.9

M10x1

73

M6

14

M10x1.25

69

M8

33

M12x1.25

125

M10

66

M12x1.5

120

M12

115

M14x1.5

195

M14

180

M16x1.5

300

M16

280

M18x1.5

435

M18

390

M20x1.5

610

M20

550

M22x1.5

830

M22

750

M24x2

1050

M24

950

M27x2

1500

M27

1400

M30x2

2100

M30

1900

M33

2600

M36

3300

Translation of original instructions

860 / 02.2010

Specifications - Tightening torques for bolts

Strength class 12.9

860 / 02.2010

Coarse thread

Fine thread

Bolt

Tightening torque MA [Nm]

Bolt

Tightening torque MA [Nm]

M4

4,7

M8x1

42

M5

9,2

M10x1

86

M6

16

M10x1.25

81

M8

39

M12x1.25

145

M10

77

M12x1.5

140

M12

135

M14x1.5

230

M14

210

M16x1.5

350

M16

330

M18x1.5

510

M18

455

M20x1.5

710

M20

640

M22x1.5

960

M22

880

M24x2

1200

M24

1100

M27x2

1750

M27

1650

M30x2

2450

M30

2200

M33

3000

M36

3900

Translation of original instructions

3 - 13

Specifications - Tightening torques for bolts

Pump stop

1

2

3

CAUTION The pump unit (1) rests on the rubber buffer (2); bolt (3) is tightened to 7 Nm to prevent overtightening the pump unit.

3 - 14

Translation of original instructions

860 / 02.2010

Specifications - Tightening torques for bolts

Wheel nuts Tightening torque MA [Nm] 650 Note Use a torque wrench.

860 / 02.2010

Translation of original instructions

3 - 15

Specifications - Wind speed

3.8

Wind speed

Wind force Beaufort scale

Description

Description

m/s

km/h

On shore

0

Calm

0-0.2

1

Calm, smoke rises vertically

1

Light draft

0.3-1.5

1-5

Direction of wind shown by smoke but not by wind vanes

2

Light breeze

1.6-3.3

6-11

Wind felt on face; leaves rustle; wind vane moves

3

Weak breeze

3.4-5.4

12-19

Leaves and small twigs in constant motion, wind extends light flag

4

Moderate breeze

5.5-7.9

20-28

Wind raises dust and loose paper; small branches move

5

Fresh breeze

8.0-10.7

29-38

Small-leaved trees begin to sway; crested wavelets form on inland waters

6

Strong breeze

10.8-13.8

39-49

Large branches move; overhead wires whistle; umbrellas difficult to control

7

Moderate gale

13.9-17.1

50-61

Whole trees sway; walking against wind is difficult

8

Fresh gale

17.2-20.7

62-74

Twigs break off trees; moving cars veer

9

Storm

20.8-24.4

75-88

Slight structural damage occurs, shingles may blow away

10

Heavy storm

24.5-28.4

89-102

Trees uprooted; considerable structural damage occurs

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)

Translation of original instructions

118-133 Severe devastation

860 / 02.2010

Specifications - Conversion factors

3.9

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

860 / 02.2010

Translation of original instructions

3 - 17

Specifications - Conversion factors

Volume 1 m3

1000 l

35.31 ft3

1.308 yd3

1 ft3

28.32 l

0.02832 m3

1728 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

3,281 ft/s

2.237 mile/h

1 ft/s

0.305 m/s

1,097 km/h

Speed

3 - 18

Translation of original instructions

860 / 02.2010

Drive engine - Safety instructions

4

Drive engine

4.1

Safety instructions

Observe safety instructions before starting work.

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

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

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

Dispose of refrigerant in accordance with statutory regulations. z After maintenance work on the engine, check that all protective features

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

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

Engine with V-belt protection

13 mm

1

1 V-belt protection

860 / 02.2010

Translation of original instructions

4-1

Drive engine - Engine oil

4.2

Engine oil

WARNING z Scalding hazard!

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

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

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

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

Note Observe the instructions in the engine manufacturer operating instructions.

Detailed view of engine

1

2

3

1 Oil filter

3 Oil dipstick grip

2 Oil filler strainer

4-2

Translation of original instructions

860 / 02.2010

Drive engine - Engine oil

Checking engine oil level

Changing engine oil and oil filter

860 / 02.2010

1

Put the machine in a level horizontal position.

2

Run drive 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 (3) by the grip and wipe off using a clean, lint-free cloth.

6

Insert oil dipstick (3) up to stop and pull out again.

7

Check the oil level (with handle (3) pointing upward!): The oil level must be between the lower marking (MIN) and the upper marking (MAX).

8

If necessary add engine oil of the specified grade.

9

Insert oil dipstick (3) up to stop and pull out again.

10

Close the service access door on the right.

1

Bring machine up to operating temperature.

2

Put the machine in a level horizontal position.

3

Shut down engine and secure against re-starting.

4

Open the service access door on the right.

5

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

6

Check the oil level (with handle (3) pointing upward!): The oil level must be between the lower marking (MIN) and the upper marking (MAX).

7

If necessary add engine oil of the specified grade.

8

Close the service access door on the right.

Translation of original instructions

4-3

Drive engine - Air filter

Safety instructions

4.3

Air filter

4.3.1

Air filter

Observe safety instructions before starting work.

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

as dust and contamination can enter the engine.

Air filter pilot 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 pilot lamp on the right control panel lights up the maximum permitted flow resistance has been reached.

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

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

1

1 Air filter

4-4

Translation of original instructions

860 / 02.2010

Drive engine - Air filter

Air filter maintenance

2

1

3

4

5

6

860 / 02.2010

1 Air filter cap

4 Grip

2 Locking clamps (3 pieces)

5 Safety cartridge

3 Replacement cartridge

6 Tab

1

Open rear left service access door.

2

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

3

Remove replacement cartridge (3).

4

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

– Only knock out in case of emergency!

5

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

6

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

Never clean safety carriage!

– Insert new safety cartridge.

7

Insert new or cleaned replacement cartridge (3).

8

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

9

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

10

Re-close service access door.

Translation of original instructions

4-5

Drive engine - Air filter

4.3.2

Air filter – pre-separator

The air filter pre-separator, mounted on the upper structure, is maintenance-free.

Remove the heavy contamination at regular intervals!

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

1

1 Air filter pre-separator

4-6

Translation of original instructions

860 / 02.2010

Drive engine - Fuel system

4.4

Fuel system

4.4.1

Safety instructions

Observe safety instructions before starting work.

WARNING z Injury hazard from rotating parts Do not carry out maintenance work until the drive engine has been switched off and the cooling system has been allowed to cool down. z No open flames when working on the fuel system! No smoking! z Also comply with the notes in the operating instructions of the engine

manufacturer.

860 / 02.2010

Translation of original instructions

4-7

Drive engine - Fuel system

4.4.2

Water separator

1

4

5

2

3

1 Manual feed pump 2 Filter cartridge 3 Shut-off valve 4 Sensor plug 5 Drain valve

Draining water

4-8

1

Open rear right service access door.

2

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

3

Open drain valve (5).

4

Drain the water and debris out of the water container.

5

Shut off the drain valve (5) again.

6

Close the service access door at the right rear.

Translation of original instructions

860 / 02.2010

Drive engine - Fuel system

Change filter cartridge

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

Note Observe the printed instructions on the filter cartridge!

860 / 02.2010

1

Close shut-off valve (5).

2

Remove the sensor plug (4).

3

Unscrew the filter cartridge (2) from the upper part of the housing.

4

Dispose of the cartridge and the O-ring.

5

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

6

Reconnect the sensor plug (4).

7

Open the shut-off valve (3).

8

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

9

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

Translation of original instructions

4-9

Drive engine - Cooler

4.5

Cooler

4.5.1

Safety instructions

Observe safety instructions before starting work.

WARNING z Injury hazard from rotating parts and from scalding!

Do not carry out maintenance work until the drive engine has been switched off and the cooling system has been allowed to cool down. z The refrigerant must not enter into the ground or waterways.

Dispose of refrigerant in accordance with statutory regulations.

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

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

4.5.2

Refrigerant – Cummins Engine

Note Use the following specified refrigerants: z SENNEBOGEN factory uses:

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

of 50 Vol.% refrigerant. If the refrigerant concentration is too high, the cooling and antifreeze characteristics will worsen.

Change intervals

SENNEBOGEN recommends a change interval of 2000 hours of operation or max. 24 months, whichever comes first.

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

4 - 10

Translation of original instructions

860 / 02.2010

Drive engine - Cooler

Refrigerant level pilot lamp

4.5.3

Changing refrigerant

The refrigerant level is monitored by a sensor.

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

Add refrigerant.

If the refrigerant level is too low, check the bolt/screw connections and lines for leaks.

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

1 2

3

4

1 Refrigerant expansion tank 2 Combination cooler 3 Service access door 4 Liquefier – air conditioning system

860 / 02.2010

Translation of original instructions

4 - 11

Drive engine - Cooler

Checking refrigerant level and antifreeze

4 5

1

7

6

4 - 12

4 Hand screws

6 Service panel

5 Grip

7 Sealing cap

1

Allow drive engine and cooler to cool down.

2

Unscrew the two hand screws (4).

3

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

4

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

5

Check antifreeze and refrigerant level, refill as necessary.

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

6

Re-close sealing cap (7) of expansion tank.

7

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

Translation of original instructions

860 / 02.2010

Drive engine - Cleaning the cooling system

4.6

Cleaning the cooling system

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

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

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

Note This section provides you with general instructions on cleaning the cooler. Also comply with the instructions in the engine manufacturer operating instructions.

4.6.1

Safety instructions

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

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

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

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

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

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

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

or the varnish on the machine. z Antifreeze is combustible. Do not smoke in the vicinity of the cooling

system and do not expose to an open flame.

Please observe the manufacturer's specifications when handling refrigerant or cleaning agents.

860 / 02.2010

Translation of original instructions

4 - 13

Drive engine - Cleaning the cooling system

4.6.2 1

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

2

Open the service access door (2).

3

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

4

If there is a lot of dirt, blow off cooling fins from the outlet side with dry, filtered compressed air (max. 2 bar/29 psi).

If contaminated with grease and oil, clean the cooling ribs with detergent.

5

Check cooler for leaks and damaged cooling fins.

6

Re-close service access door.

4.6.3 Dirt and cleaning procedure

Fan reversal

External cleaning

Dust, insects, foliage or leaves

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

Oily and greasy deposits

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

CAUTION Make sure that the cooling fins are not damaged.

1

Procedure

4 - 14

1

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

Make sure that the cooling fins are not damaged.

2

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

Translation of original instructions

860 / 02.2010

Drive engine - Cleaning the cooling system

4.6.4

Internal cleaning

Note Observe the instructions in the engine manufacturer's operating instructions as well.

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

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

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

of the sealing cover. z The refrigerant is very cloudy. z Lubricant incursion has occurred.

Procedure

1

Please observe the safety instructions.

2

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

3

Add a mixture of standard cooling system cleaner and water.

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

4

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

5

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

6

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

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

Mix before filling!

7

Fill the cooling system with a water-refrigerant mixture.

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

Contact SENNEBOGEN Customer Service before removing the cooler.

860 / 02.2010

Translation of original instructions

4 - 15

Drive engine - Checking belt drives

4.7 Safety instructions

Checking belt drives

Observe safety instructions before starting work.

DANGER z Only carry out maintenance work with drive engine shut down and stationary. z Shut down machine and secure against unauthorized re-starting

before starting with maintenance work. z Where applicable, replace protective covering after maintenance work. z Make sure that the V-belts run in parallel.

Belt drives

1 2

1 V-belt, air conditioning system 2 V-belt, alternator/water pump

1

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

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

4 - 16

Translation of original instructions

860 / 02.2010

Undercarriage - Cleaning and lubricating

5

Undercarriage

WARNING Injury hazard from rotating parts and from scalding!

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

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

Dispose of waste oil in accordance with the statutory regulations.

5.1

Cleaning and lubricating

1

Put the machine in a level horizontal position.

2

Shut down drive engine and secure against re-starting.

3

Clean tires and undercarriage using a steam cleaner.

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

4

Lightly grease guides and bolts.

5

Lubricate all lubrication points (see Section 3.6).

5.2

Tire air pressure (pneumatic tires)

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

Tire air pressure (pneumatic tires)

860 / 02.2010

Tire size

ppbarp Air pressure ppsi

14.00-24

10

Translation of original instructions

145.04

5-1

Undercarriage - Tightening wheel nuts

5.3

Tightening wheel nuts

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

650 Nm

5.4

Hub drive train

1

2

1 Oil filler screw 2 Oil drain screw WARNING The mixing of oils, lubricants or operating fluids of different types is not permitted!

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

5-2

Translation of original instructions

860 / 02.2010

Undercarriage - Hub drive train

Checking the oil level

Changing oil

860 / 02.2010

1

Put machine in a level, horizontal position.

2

Turn hub until the oil drain screw (2) is at the bottom (6 o'clock position).

3

Shut down drive engine.

4

Unscrew oil filler screw (1). The oil level must reach up to lower edge of oil filler screw, add oil if necessary.

5

Clean components, check seal and replace if necessary.

6

Re-tighten oil filler screw (1).

7

Repeat procedure on the three remaining hubs.

1

Put machine in a level, horizontal position.

2

Turn hub until the oil drain screw (2) is at the bottom.

3

Shut down drive engine.

4

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

5

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

For capacities, see Section 3.3.

6

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

7

Clean components, check seals and exchange if necessary.

8

Re-tighten oil drain screw (2).

9

Unscrew oil filler screw (1).

10

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

11

Re-tighten oil filler screw (1).

12

Repeat procedure on the three remaining hubs.

13

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

Translation of original instructions

5-3

Undercarriage - Hub drive train

Brake wear measurement

Visually check the thickness of the brake linings (2) at regular intervals depending on vehicle use.

The brake shoes (1) are maintenance-free, except checking for damaged parts.

Visually inspect the expanding devices (3), threaded unions, and lines for leaks and damage, replace as necessary.

CAUTION If the residual brake lining is very thin, the inspection intervals must be shortened accordingly to prevent extensive damage to the brakes or drum.

2

1

3

1

2

1 Brake shoe 2 Brake lining 3 Expanding device Note z Note regarding riveted brake lining: At least 1.0 – 1.5 mm residual lining thickness required above the rivet head at the weakest point in the lining. z Note regarding bonded brake lining: At least 2.0 mm residual lining

thickness required at the weakest point in the lining.

CAUTION The brake linings (2) must be replaced on the axle if the residual brake lining thickness has worn down to these values.

5-4

Translation of original instructions

860 / 02.2010

Undercarriage - Back gear and differential

5.5

Back gear and differential

4

3

1

2

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

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

Checking oil

1

Bring machine up to operating temperature.

2

Put machine in a level, horizontal position.

3

Turn off the drive engine. Wait about 10 minutes for the oil to collect in the differential.

4

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

5

Clean components, check seal and replace if necessary.

6

Re-tighten oil filler screw (2).

30 mm

Note The oil level from the back gear and differential is checked using the oil filler screw (2).

860 / 02.2010

Translation of original instructions

5-5

Undercarriage - Back gear and differential

Changing oil

30 mm 50 Nm

50 Nm

50 Nm

1

Bring machine up to operating temperature.

2

Put machine in a level, horizontal position.

3

Turn off the drive engine. Wait about 10 minutes for the oil to collect in the differential.

4

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

5

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

6

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

For capacities, see Section 3.3.

7

Place a suitable collecting vessel under the oil drain screw (3).

For capacities, see Section 3.3.

8

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

9

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

10

Clean components, check seals and exchange if necessary.

11

Re-tighten oil drain screw (1).

12

Re-tighten oil drain screw (3).

13

Unscrew oil filler screw (2).

14

Unscrew oil filler screw (4).

15

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

16

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

17

Re-tighten oil filler screw (2).

18

Re-tighten oil filler screw (4).

19

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

13 mm

13 mm

13 mm

Note The oil level from the back gear and differential is checked using the oil filler screw (2).

5-6

Translation of original instructions

860 / 02.2010

Undercarriage - Parking disc brake

5.6

Parking disc brake

1 2

3

1 Oil filler screw 2 Oil level control screw 3 Oil drain screw WARNING The mixing of oils, lubricants or operating fluids of different types is not permitted!

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

Checking the oil level

860 / 02.2010

1

Bring machine up to operating temperature.

2

Put machine in a level, horizontal position.

3

Switch off drive engine. Wait approx. 10 minutes for the oil to collect in gearbox.

4

Unscrew the oil level control screw (2).

Oil flows out when the oil level has been reached.

Translation of original instructions

5-7

Undercarriage - Parking disc brake

5

If necessary, unscrew oil filler screw (1) and top up with oil.

6

Clean components, check seal and replace if necessary.

7

Re-tighten oil level check screw (2).

8

Re-tighten oil filler screw (1).

1

Bring machine up to operating temperature.

2

Put machine in a level, horizontal position.

3

Switch off drive engine. Wait approx. 10 minutes for the oil to collect in gearbox.

4

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

5

Place a suitable collecting vessel under the oil drain screw (3).

For capacities, see Section 3.3.

6

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

7

Clean components, check seals and exchange if necessary.

8

Re-tighten oil drain screw (3).

9

Unscrew oil filler screw (1).

10

Unscrew the oil level control screw (2).

11

Add new oil.

Oil flows out when the oil level has been reached.

12

Re-tighten oil level control screw (2).

13

Re-tighten oil filler screw (1).

14

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

Changing oil

5-8

Translation of original instructions

860 / 02.2010

Swiveling connection - General

6

Swiveling connection

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

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

6.1

General

Ensure that the swiveling connection is well lubricated. z Slewing track (1):

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

– with gear spray or – using slewing ring lubrication (optional). z Seal (3):

– Check the seal between the slewing track and the gear teeth for damage.

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

3

1

2

1 Slewing track 2 Gear teeth 3 Seal

860 / 02.2010

Translation of original instructions

6-1

Swiveling connection - Lubricating slewing ring path

6.2

Lubricating slewing ring path

6.2.1

Central lubrication system

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

Note The preset lubricating cycle can be shortened. See in this case the documentation on the CENTRAL LUBRICATION SYSTEM in chapter 10 of the operating instructions.

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

1

2

3 4

1 Threaded cover – for refilling with grease 2 Lubricant container 3 Lubricating nipple – adding grease 4 Adjusting the lubrication system Actuating slewing track lubrication manually

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

1

6-2

Move the switch on the control panel to the right.

Translation of original instructions

860 / 02.2010

Swiveling connection - Lubricating live ring toothed wheel

6.3

Lubricating live ring toothed wheel

Lubricate the live ring toothed wheel with SENNEBOGEN gear spray or with the optional fittings for slewing ring lubrication.

6.3.1

860 / 02.2010

Gear spray

1

Shut down drive engine.

2

Thoroughly clean gear teeth.

3

Check gear teeth of slewing ring and slewing ring pinion for wear and replace if necessary.

4

Spray gear teeth from a distance of about 30 cm withSENNEBOGEN gear teeth spray (SE No.: 011429).

5

Rotate the upper structure a number of times for a layer of lubricant to spread evenly over the gear teeth.

Translation of original instructions

6-3

Swiveling connection - Lubricating live ring toothed wheel

6.3.2

Slewing ring lubrication (optional)

1

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

1

Shut down drive engine.

2

Thoroughly clean gear teeth.

3

Check gear teeth of slewing ring and slewing ring pinion for wear and replace if necessary.

4

Start drive engine.

5

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

– Slew the upper structure 360° with the control lever to the left and to the right to distribute the lubricant evenly over the gear teeth.

6

Release the push button.

7

Check that there is an unbroken film of lubricant over the surface and repeat lubrication process if necessary.

Note Lubricate slewing ring every 10 operating hours or daily (depending on work application)!

Check the lubrication container weekly and refill with lubricant if necessary!

CAUTION Check the plastic sliding wear pad (2) in the lubrication assembly (1) once every 3 months for wear. Observe the wear limit!

Replace the plastic sliding wear pad (2) when the wear limit has been reached! The machine could otherwise suffer serious damage.

The operator of the machine alone is liable for such damage as well as any consequential damage!

6-4

Translation of original instructions

860 / 02.2010

Swiveling connection - Lubricating live ring toothed wheel

Check plastic sliding wear pad

min. 28 mm

1

2

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

before starting with maintenance work. z Attach warning sign to operating instruments.

860 / 02.2010

1

Disassemble lubrication assembly (1).

2

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

3

Replace plastic wear pad if necessary.

Translation of original instructions

6-5

Swiveling connection - Lubricating live ring toothed wheel

Replenish grease 1

6-6

1

Open cover (1) of lubricant reservoir.

2

Replenish lubricant (SE-no.: 047485).

3

Close cover.

Translation of original instructions

860 / 02.2010

Swiveling connection - Tighten slewing ring bolts

6.4

Tighten slewing ring bolts

DANGER Risk of death!

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

For this reason, always observe the maintenance intervals! z Check or replace the slewing ring bolts every 5000 operating hrs

or every 5 years.

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

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

Otherwise, replace the slewing ring bolts!

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

with new bolts! z Do not tighten loose bolts, replace immediately with new bolts. z Tighten slewing ring bolts using torque wrench. z It is essential that the correct number and diameter of bolts are used. z Use only original SENNEBOGEN replacement parts. z If you suspect damage to the bolt connections, call SENNEBOGEN

Customer Service and arrange for a check to be carried out. z Contact SENNEBOGEN Customer Service if you have any other

questions.

1

860 / 02.2010

Translation of original instructions

6-7

Swiveling connection - Tighten slewing ring bolts

1

Shut down drive engine.

2

Tighten the slewing ring bolts with a torque wrench in alternating sequence.

Note The tension of the bolt tightened first is influenced by the tensioning of the other bolts.

It is therefore necessary to make at least two full turns. Bolts over M30 should preferably be tightened with a hydraulic socket wrench.

6-8

Translation of original instructions

860 / 02.2010

Swiveling connection - Slewing gear

6.5

Slewing gear

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

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

Note Depending on the machine type, multiple slewing gears may be used with the respective oil expansion tank. The maintenance is therefore to be carried out on all slewing gears.

Checking the oil level 1

Lower attached loads and boom to the ground.

2

Put the machine in a level horizontal position.

3

Shut down drive engine and secure against re-starting.

3 2

1

1 Slewing gear 2 Fill level at 15°C–20°C oil temperature (approx. quarter full marking on the oil expansion tank) 3 Oil expansion tank for each slewing gear

4

860 / 02.2010

Allow the oil in the slewing gear to cool.

Translation of original instructions

6-9

Swiveling connection - Slewing gear

5

Check oil level: – Fill level at 15°C–20°C oil temperature (approx. quarter full marking on the oil expansion tank).

– The oil level can vary depending on temperature, filling up to three quarters is possible.

6

6 - 10

Add oil of the specified grade as required.

Translation of original instructions

860 / 02.2010

Swiveling connection - Slewing gear

Changing gear oil 1

Lower attached loads and boom to the ground.

2

Put the machine in a level horizontal position.

3

Shut down drive engine and secure against re-starting.

2

5

3

1

4

1 Slewing gear 2 Gear bleeder 3 Oil drain with cover nut 4 Connector with hose

860 / 02.2010

4

Unscrew oil expansion tank (5) cap.

5

Unscrew cover nut (3).

6

Screw in connector with hose (4) until the waste oil drains through the hose. Collect waste oil in a suitable container.

7

Unscrew connector with hose (4).

8

Screw cover nut (3) back on.

Translation of original instructions

6 - 11

Swiveling connection - Slewing gear

Adding oil

2

5

3

1

1 Slewing gear 2 Gear bleeder 3 Oil drain with cover nut 4 Connector with hose 5 Oil expansion tank 9

Unscrew the gear bleeder (2).

10

Top up with new oil via the oil expansion tank (5).

11

When oil flows out of the gear bleeder (2), screw it closed again.

12

Top up with new oil via the oil expansion tank (5).

13

Check oil level: – Fill level at 15°C–20°C oil temperature (approx. quarter full marking on the oil expansion tank).

– The oil level can vary depending on temperature, filling up to three quarters is possible.

6 - 12

14

Screw in oil expansion tank (5) cap.

15

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

Translation of original instructions

860 / 02.2010

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

6.6

Wear measurement and checking the drive system/bearing play

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

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

1

Put the machine in a level horizontal position.

2

Place upper structure parallel to the undercarriage.

3

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

4

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

860 / 02.2010

Translation of original instructions

6 - 13

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

5

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

6

Measure at the 4 measuring points.

7

Now, apply a forwards turning torque, if necessary, by taking on the load.

8

After swiveling, repeat the measurement on the marked positions.

9

Record the measurement values in the table and compare.

10

The measurement value difference provides information on the wear.

11

Maximum permitted wear limit.

12

The measurement value difference provides information on the wear.

Note If the wear limit has been reached, contact SENNEBOGEN Customer Service!

6 - 14

Translation of original instructions

860 / 02.2010

Hydraulic system - Safety instructions

7

Hydraulic system

7.1

Safety instructions

Observe the safety notes before starting work on hydraulic system.

DANGER z Warning: High oil pressure!

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

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

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

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

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

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

The pressure accumulator must therefore be de-pressurized. z Danger of injury!

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

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

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

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

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

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

860 / 02.2010

Translation of original instructions

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 oil residue with a cloth. Dispose of oil-soaked cloth as hazardous waste.

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

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 the environment and weather.

Fig.: Hydraulic cylinder on boom

7.2.2

Threaded unions

Check hydraulic threaded unions and couplings regularly for leaks.

Seal points of leakage and remove oil residue.

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

Always seal opened threaded unions immediately at both sides with stoppers.

7-2

Translation of original instructions

860 / 02.2010

Hydraulic system - Hydraulic hose lines

7.3 Storage and service life

Hydraulic hose lines

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

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

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

Inspection

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

Remedy any defects discovered immediately.

Defects

Replace hose lines in the following cases (see also DIN 20066): z Outer layer damaged up to the lining (e.g.chafe marks, cuts, cracking); z Outer layer embrittlement (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, formation of blisters); z Leaks; z Damaged or deformed hose fittings (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.

860 / 02.2010

Translation of original instructions

7-3

Hydraulic system - De-pressurizing the hydraulic system

7.4

De-pressurizing the hydraulic system

WARNING Danger of injury! Danger of injury from scalding.

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

The hydraulic oil can attain temperatures of 70°C (158°F) and higher.

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

1

Lower attached loads and boom to the ground.

2

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

3

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

1

1

7-4

4

Open the cover plate.

5

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

This releases the preload pressure in the tank.

Translation of original instructions

860 / 02.2010

Hydraulic system - De-pressurizing the hydraulic system

6

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

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

860 / 02.2010

Translation of original instructions

7-5

Hydraulic system - Checking hydraulic oil level

7.5

Checking hydraulic oil level

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

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

1

Lower attached loads and boom to the ground.

2

Put the machine in a level horizontal position.

Machine in park position

7-6

3

Put the machine in park position. Move support cylinders inward.

4

Shut down drive engine and secure against re-starting.

5

Open the service access door on the right.

6

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

Translation of original instructions

860 / 02.2010

Hydraulic system - Checking hydraulic oil level

2

2 1

7

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

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

– Add hydraulic oil and re-check.

– Re-tighten screw cap.

– Close the cover plate again.

8

860 / 02.2010

Close the service access door on the right.

Translation of original instructions

7-7

Hydraulic system - Changing hydraulic oil

7.6 Safety instructions

Changing hydraulic oil

Observe the safety instructions before starting work on hydraulic system.

DANGER z Warning, high oil pressure and scalding.

The hydraulic system is subject to high pressure.

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

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

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

personnel with specialist knowledge and experience of hydraulics.

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

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

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

Use the opening of the return filter for this.

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

Procedure

7-8

1

Lower attached loads and boom to the ground.

2

Put the machine in a level horizontal position.

3

Put the machine in park position. Move support cylinders inward.

4

De-pressurize hydraulic system in accordance with Section 7.4.

5

Shut down drive engine and secure against re-starting.

6

Remove filter of return filter acc. to Section 7.7.

7

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

For capacities, see Section 3.3.

Translation of original instructions

860 / 02.2010

Hydraulic system - Changing hydraulic oil

1

8

Close the gate (1) – illustrated: open.

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

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

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

2

9

860 / 02.2010

Unscrew cover nut (2).

Translation of original instructions

7-9

Hydraulic system - Changing hydraulic oil

3 4

10

Screw in drain plug (3) until the waste oil emerges from the plastic hose (4). Collect waste oil in a suitable container.

11

Unscrew drain plug (3).

12

Screw cover nut (2) back on.

13

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

14

Open the gate (1) again.

15

Bleed the hydraulic pumps: – Clean housing.

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

– Wait several seconds until the air has escaped.

– Re-tighten vent screw.

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

7 - 10

Translation of original instructions

860 / 02.2010

Hydraulic system - Return filter – Changing filters

7.7

Return filter – Changing filters 2

1 3

2

6 mm

860 / 02.2010

1

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

This will release the preload pressure in the tank.

2

There are three return filters. They must all be replaced!

Unscrew the four socket head bolts (1).

3

Remove cover (3).

4

Remove filter and dispose of as hazardous waste.

5

Clean components, check seal and replace if necessary.

6

Insert new filter.

7

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

8

Tighten screw cap (2).

Translation of original instructions

7 - 11

Hydraulic system - Leakage oil filter – Changing filter

7.8

Leakage oil filter – Changing filter

1 2

17 mm

7 - 12

1

Loosen hexagon nuts (1).

2

Remove cover (2).

3

Unscrew filter (3) from return pipe.

4

Screw new filter onto the return pipe.

5

Re-attach cover with return pipe to tank.

6

Tighten hexagon nuts (1).

Translation of original instructions

860 / 02.2010

Hydraulic system - Changing the ventilation filter

7.9

Changing the ventilation filter

Note The ventilation filter is integrated in the screw cap (2) of the filler strainer. The ventilation filter limits the positive pressure and vacuum in the hydraulic system that occurs during hydraulic operations.

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

1

860 / 02.2010

1

Open the cover plate.

2

Replace the ventilation filter (1) as a complete unit.

3

Close the cover plate.

Translation of original instructions

7 - 13

Hydraulic system - HydroClean – Changing the filter

7.10

HydroClean – Changing the filter

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

Changing filter

1

2

3 4 5

13 mm 36 mm

1

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

2

De-pressurize hydraulic system according to Section 7.4.

3

Unscrew the cover (5) with integrated external socket head (4).

4

Remove filter.

5

Dispose of filter as hazardous waste.

6

Clean components, check seal and replace if necessary.

7

Insert new filter.

8

Screw on the cover (5) until the stop and unscrew a fourth of a turn.

9

Start drive engine.

10

Unscrew the socket head bolt (3) a little until the ventilation opening becomes free.

11

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

12

Switch off drive engine and check filter for leaks.

13

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

10 mm

7 - 14

Translation of original instructions

860 / 02.2010

Hydraulic system - Auxiliary control filter – Changing the filter

7.11

Auxiliary control filter – Changing the filter

Note If the machine is fitted with the optional "HydroClean" fine filter system there is no auxiliary control filter.

1 2 3

27 mm

860 / 02.2010

1

De-pressurize hydraulic system according to Section 7.4.

2

Place suitable collecting vessel beneath.

3

Unscrew fixing bolt (1) on cover and remove cover.

4

Remove filter (2) and dispose of it as hazardous waste.

5

Clean components, check seals and exchange if necessary.

6

Insert new filter (2) in filter housing (3).

7

Put on cover and tighten fixing bolt.

8

Check filter for leaks.

Translation of original instructions

7 - 15

Hydraulic system - Pressure filter – Changing filter

7.12

Pressure filter – Changing filter 1

3 4

2

7 - 16

1

De-pressurize hydraulic system according to Section 7.4.

2

Unscrew vent screw (1).

3

Place a suitable container under the drainage opening.

4

Remove the oil drain screw (2).

5

Unscrew cover (3).

6

Remove filter (4) from the element mounting post.

7

Clean components, check seals and replace if necessary.

– Check sealing surfaces and threads for damage.

8

Coat seals and sealing surfaces with clean operating fluid.

9

Carefully install a filter on the element mounting post.

10

Screw in the oil drain screw (2).

11

Screw on the cover (3) until the stop and unscrew a fourth of a turn.

12

Screw in the vent screw (1) until the stop.

Translation of original instructions

860 / 02.2010

Hydraulic system - Pressure filter – Changing filter

860 / 02.2010

13

Venting the filter housing (pressure filter) – Operate the hydraulic system.

– Loosen the vent screw, but do not unscrew it completely.

– Wait several seconds until the air has escaped.

– Tighten the vent screw.

14

Check pressure filter for leaks.

Translation of original instructions

7 - 17

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

7.13

Changing the ventilation filter with dehumidifying unit (optional)

1

3 2

Replacing desiccant beads 1

Completely unscrew the dehumidifying unit (1)

2

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

3

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

4

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

5

Completely bolt down the dehumidifying unit (1).

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

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

7 - 18

Translation of original instructions

860 / 02.2010

Hydraulic system - Checking preload pressure of pressure accumulator

7.14

Checking preload pressure of pressure accumulator

Note The preload pressure is shown on the pressure accumulator of the pilot control system.

1

Lower attached loads and boom to the ground.

2

Connect manometer to the measurement port (Section 7.4).

3

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

4

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

5

Observe the manometer.

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

6

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

7

Disconnect manometer.

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

860 / 02.2010

Translation of original instructions

7 - 19

Hydraulic system - Checking preload pressure of pressure accumulator

7 - 20

Translation of original instructions

860 / 02.2010

Electrical system - Batteries

8

Electrical system

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

8.1

Batteries

Note The batteries are maintenance-free.

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

DANGER z Explosion hazard!

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

Wear eye protection and gloves.

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

860 / 02.2010

Translation of original instructions

8-1

Electrical system - Batteries

Checking cable connections and fill level of batteries 2

1 1

Open the service access door

2

Clean the terminals (1) and cable connections on the batteries.

Check for firm seating and grease with terminal grease.

3

The acid level is important for the service life and function of the battery.

– Unscrew cap.

– The level must reach the marking, add distilled water if necessary.

Repeat this process for all battery cells.

4

8-2

Close service access door.

Translation of original instructions

860 / 02.2010

Electrical system - Fuses

8.2

Fuses

WARNING Fire hazard!

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

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

3

2

1 1

Shut down engine.

2

Replace faulty fuses in the fuse box (1 and 2).

3

Check contacts, clean oxidized contacts.

4

Check automatic circuit breakers (3), if necessary, press the automatic circuit breakers to activate them.

Note You will find an overview of fuse and relay assignment in a table on the cover of the fuse box.

860 / 02.2010

Translation of original instructions

8-3

Electrical system - Changing the switch/symbol

8.3

Changing the switch/symbol

NOTE Switches can only be replaced as complete units.

Exception: The symbols can be removed by carefully easing them out with a screwdriver, and fitted back in again.

8.4

Generator (optional)

NOTE Please also refer to the information in the generator manufacturer's instructions.

8.4.1

Visual check

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

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

8-4

Translation of original instructions

860 / 02.2010

Electrical system - Additional displays (special equipment)

8.5

Additional displays (special equipment)

Analog hour counter

SDS

Tool Control

Generator and Magnet Unit

Auxiliary heating system

Camera

LMB

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

860 / 02.2010

Translation of original instructions

8-5

Electrical system - Additional displays (special equipment)

Note More information can be found in the operating instructions from the chapter Work application.

8-6

Translation of original instructions

860 / 02.2010

Heating / Air-conditioning system - Air conditioning system

9

Heating / Air-conditioning system

9.1

Air conditioning system

WARNING Remember that the refrigerant and the related vapors are dangerous to your health when working with the air conditioning system.

Wear the appropriate protective equipment. z Maintenance and repair work must only be carried out by trained

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

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

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

the refrigerant with bare skin. z Wear protective glasses! If refrigerant does come into contact

with your eyes however, see a physician. z Danger of injury! Avoid contact with the sharp edged fins

on the liquefier and the heat exchanger. z Welding and soldering on components of the air conditioning

system is not permitted! The pressure in the system is increased by the extreme heating and can cause an explosion. z Only refrigerant R134a is to be used in accordance with DIN 8960

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

GmbH.

860 / 02.2010

Translation of original instructions

9-1

Heating / Air-conditioning system - Air conditioning system

Visual check

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

2

1

3

Air conditioning system: 1 Compressor 2 Collector drier 3 Liquefier

9-2

Translation of original instructions

860 / 02.2010

Heating / Air-conditioning system - Air conditioning system

9.1.1

Cleaning the heating system recirculating air filter

Cleaning the filter

1 Grip

2

1

2 Filter

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

860 / 02.2010

1

Pull the filter (2) on the grip (1).

2

Beat out filter or carefully blow out with compressed air.

3

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

Translation of original instructions

9-3

Heating / Air-conditioning system - Air conditioning system

9.1.2

Cleaning the heating system outside air filter

Cleaning the filter

1

1

2

2

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

9-4

1

Loosen bolts (1) and hold the cover.

2

Remove filter (2).

3

Beat out filter or carefully blow out with compressed air.

4

Insert the filter. Ensure correct position.

5

Re-tighten bolts (1).

Translation of original instructions

860 / 02.2010

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

9.2

Auxiliary heating system (optional)

1

1 Display Note Observe the information and recommendations in the manufacturer's operating instructions as well.

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

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

860 / 02.2010

Translation of original instructions

9-5

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

9-6

Translation of original instructions

860 / 02.2010

Index

A Accessories W-2 Actuating slewing track lubrication manually 6-2 Additional documentation W-7 After 1000 hours of operation 2-11 After 2000 hours of operation 2-14 After 250 hours of operation 2-7 After 500 hours of operation 2-9 Air filter 4-4 Air filter – pre-separator 4-6 Air pressure 3-4, 5-1 Annually 2-11 Antifreeze 4-12, 4-13 B Beaufort scale 3-16 Belt drives 4-16 Biological oils 1-8 C Central lubrication system 6-2 Chloride 1-11 Chloride content 1-11 Chromium hydroxide 4-15 Cleaning agents 4-13 Cleaning hydraulic cylinders 7-2 Cleaning procedure 4-14 Cleaning the cooler 4-13 Conversion factors 3-17 Cooler 4-10 Cooling system 4-10 Copyright W-8 Customer Service W-8 D Description Wind 3-16 Differential 3-4 Disposal Batteries 1-25 Lubricants 1-25

860 / 02.2010

Disposal Guideline 75/439/ EEC 1-25 Disposal of operational fluids 1-25 Disposing of batteries 1-25 Disposing of lubricants 1-25 Disposing of the oil filter 1-25 Drive engine 3-4 E Ear protection 1-5 Engine Changing oil 4-3 Changing the oil filter 4-3 Checking oil level 4-3 Engine overheating 4-15 Environmental protection 1-25 Environmental regulations 1-25 every 4000 hrs run 2-14 Experts W-6 F Fan reversal 4-14 For your own safety W-2 Foreword W-2 Fuel system 4-7 Fuel tank 3-4 G Gear spray 6-3 Gear teeth 6-1 Going to press W-8 H Hunold refrigerant ANF 4-10 Hydraulic system 3-4 Hydraulic tank 3-4 Hydraulic threaded unions 7-2 I Identification plate 1-3 Inspection by specialist technician 1-4 Inspection tools 3-6 Inspectors W-6 Instructed personnel W-6

L Limitations during wind 3-2 Lubricating slewing ring path 6-2 Lubricating slewing ring track 6-2 Lubricating slewing track 6-2 Lubricating the live ring toothed wheel 6-3 Lubrication cycle 6-2 Lubrication intervals 6-2 M Machine labeling 1-3 Maintaining earth-moving machinery 1-5 Maintenance instructions W-7 Maintenance schedule 2-1, 3-1 Manufacturing of spare parts 1-6 Modification of the machine 1-6 Monthly 2-7 N Noise protection 1-5 Noise protection measures 1-5 Notes on the instructions W-3 Notice signs 1-3 O Oil diagnosis 1-8 Operating earth-moving machinery 1-5 Operating personnel W-6 Operating temperature 4-13 Operator W-6 Original spare parts W-2 Other risks 1-2 Overheating 4-13 P Parts W-2 Personal protective equipment 1-14, 1-21 Personnel qualifications 1-5

S-1

Index

Personnel selection 1-5 pH value 1-11 pH value, water 1-11 Plastic sliding wear pad 6-4 Pressure cylinders 7-2 Pressure gauge connections 7-5 Protective features 1-24 R Refrigerant 4-10 Refrigerant level 4-11, 4-12 Refrigerant R134a 9-1 Repair work 4-13 S Safety alert symbol W-4 Safety instructions 1-1, 1-2, 4-13 Sales and Service Partners W-8 Semi-annually 2-9 Service booklet W-7 Service Partners W-8 Signal word W-4 Signs Clean 1-3 Slewing ring bolts 6-7 Slewing ring lubrication (optional) 6-4 Slewing track 6-1 Spare parts catalogue W-7 Spare parts depot W-8 Special dangers 1-6 Specialist personnel W-6 Specialists W-6 Strength class 10.9 3-12 Strength class 12.9 3-13 Strength classes for bolts 3-11 Sulfate content 1-11 Swiveling connection 6-1 Symbols and illustrations W-4

Tightening torque 3-11 Tires, air pressure 3-4, 5-1 V V-belt 4-16 W Warning signs 1-3 Warranty W-2 Water hardness 1-11 Water separator 4-8 Wear limit 6-4 Wheel nuts 3-4 Wind force 3-16 Wind forces 3-2 Wind speed 3-2, 3-16 Y Year of manufacture 1-3

T Target group W-7, 1-1 Technical condition 1-6 Telephone W-8

860 / 02.2010

S-2