Sennebogen 860 Operating Instruction Manual 860.0.1015 - PDF DOWNLOAD

OPERATING INSTRUCTIONS Model 860

Operating instructions 860.0.1015_us

860 / 10.2010

Translation of the original operating instructions

860.0.1015

Important instructions about the operating 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

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.

Parts and accessories

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 be approved.

Warranty

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

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Notes on the instructions

Read through the instructions thoroughly, in particular chapter 1 SAFETY, before beginning to work with 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 Maintenance of 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!

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Symbols and illustration aids

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.

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Designates instructions that draws attention to unusual features on a machine with mobile undercarriage.

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.

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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 features, 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 is to be stated by the inspector in a test report or test notation.

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

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Target group

The machine has been developed for demanding work.

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

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

Which documentation belongs with the machine?

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

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

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How are the instructions organized?

The instructions are divided into 9 chapters: z 1: Safety

Applicable safety information is found here.

z 2: Overview

The main components of the machine are shown in Chapter 2.

z 3: Specifications

Here, you can find basic machine information, e. g. lifting capacities.

z 4: Start-up

This chapter contains instructions on daily machine maintenance and start-up.

z 5: Operation

This chapter contains information on operating instruments and work application.

z 6: Transport

Dimensions and weights of the machine are found in Chapter 8.

z 7: Troubleshooting

This chapter contains instructions on recognizing the causes of faults and how to correct them.

z 8: Setup work

Chapter 9 gives information on optional attachment tools.

z 9: Appendix

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

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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

860 / 05.2010

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.

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Table of contents

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1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.3 Potential instances of misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.4 Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1.5 Other risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1.6 Machine labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1.6.1 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1.6.2 CE certificate of conformity . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1.6.3 EuroTest certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1.6.4 EC conformity declaration . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 1.6.5 Warning and notice signs . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 1.7 Responsibilities of the operator . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 1.8 Supplementary and operational equipment . . . . . . . . . . . . . . . . . 1-17 1.8.1 SENNEBOGEN Diagnostic System (SDS) . . . . . . . . . . . 1-17 1.8.2 Oils and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 1.8.3 Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 1.8.4 Fuel (not for equipment with electric motors) . . . . . . . . . . 1-21 1.9 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 1.9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 1.9.2 Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 1.9.3 Safe entry and exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 1.9.4 Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 1.9.5 Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 1.9.6 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 1.9.7 Operation/Driving operation . . . . . . . . . . . . . . . . . . . . . . . 1-34 1.9.8 Setup work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35 1.9.9 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36 1.9.10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37 1.9.11 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40 1.10 Protective features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41 1.11 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42 1.12 Hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43

2

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1 Overall machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.2 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.3 Upper structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.3.1 Side views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.3.2 View from above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

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2.3.3 Central electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2.4 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2.4.1 Compact boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2.4.2 Pipe fracture safety devices . . . . . . . . . . . . . . . . . . . . . . . 2-10

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3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 Drive engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.3 Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.4 Machine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.5 Machine weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.6 Lifting capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3.6.1 Stabilized: K18 (compact boom 10.8 m / stick 7.8 m, KIN 1) . . . . . . . . 3-8 3.7 Lubricate the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 3.7.1 Lubrication point overview . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 3.7.2 Lubricating nipple overview . . . . . . . . . . . . . . . . . . . . . . . 3-10 3.8 Warning and notice signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 3.9 Wind speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 3.10 Tightening torques for bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 3.11 Conversion factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

4

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3 Initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.4 Inspections before daily start-up . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.5 Tests before start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.5.1 Check demister level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.5.2 Check fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4.5.3 Lubricating the lubrication points manually . . . . . . . . . . . . 4-9 4.5.4 Check fill level in central lubrication system. . . . . . . . . . . . 4-9 4.5.5 Checking fill level in slewing ring lubrication . . . . . . . . . . 4-10 4.5.6 Checking fill level in slewing drive . . . . . . . . . . . . . . . . . . 4-11 4.5.7 Checking the hydraulic oil level . . . . . . . . . . . . . . . . . . . . 4-13 4.5.8 Checking and draining the fuel system . . . . . . . . . . . . . . 4-14 4.5.9 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 4.5.10 Checking refrigerant level . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 4.6 Switching on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

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4.6.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 4.6.2 Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 4.6.3 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 4.6.4 Bring machine up to operating temperature . . . . . . . . . . . 4-22 4.7 Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 4.8 Switching off the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 4.8.1 Switching the engine off . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 4.8.2 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 4.8.3 Preservation and storage . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 5

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Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.2 Operator´s station/cab with gallery, raising . . . . . . . . . . . . . . . . . . 5-2 5.2.1 Driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 5.3 Operating instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 5.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 5.3.2 Emergency stop (optional) . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5.3.3 Step plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 5.3.4 Safety lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5.3.5 Control lever, left hand . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 5.3.6 Control lever, right hand . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 5.3.7 Additional indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5.3.8 Control panel, next to the driver's seat . . . . . . . . . . . . . . . 5-16 5.3.9 Control panel engine/machine . . . . . . . . . . . . . . . . . . . . . 5-17 5.3.10 Panel pilot lamps, lower right . . . . . . . . . . . . . . . . . . . . . . 5-19 5.3.11 Control panel, lower right . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 5.3.12 Air conditioning control panel . . . . . . . . . . . . . . . . . . . . . . 5-27 5.3.13 Control panel, right bottom (rear) . . . . . . . . . . . . . . . . . . . 5-29 5.3.14 Control panel, top right on the ceiling . . . . . . . . . . . . . . . 5-30 5.3.15 SENNEBOGEN Diagnostic System (SDS) . . . . . . . . . . . 5-37 5.4 Additional displays (optional equipment) . . . . . . . . . . . . . . . . . . . 5-59 5.4.1 SENNEBOGEN Tool Control . . . . . . . . . . . . . . . . . . . . . . 5-59 5.4.2 Load moment indicator (LMI) . . . . . . . . . . . . . . . . . . . . . . 5-61 5.4.3 Generator and magnet unit . . . . . . . . . . . . . . . . . . . . . . . 5-62 5.4.4 Camera/monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63 5.4.5 Low-temperature package . . . . . . . . . . . . . . . . . . . . . . . . 5-64 5.5 Work application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 5.5.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 5.5.2 Move the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69 5.5.3 Emergency lowering, cab . . . . . . . . . . . . . . . . . . . . . . . . . 5-72 5.5.4 Driving machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74

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5.5.5 Stabilizing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77 5.5.6 Upper structure slewing/deceleration . . . . . . . . . . . . . . . . 5-81 5.5.7 Hoisting / lowering loads . . . . . . . . . . . . . . . . . . . . . . . . . 5-84 5.5.8 Limit shutdown equipment . . . . . . . . . . . . . . . . . . . . . . . . 5-85 5.5.9 Bypassing the safety limit shutdown . . . . . . . . . . . . . . . . 5-89 5.5.10 Working with the grab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90 5.5.11 Operation with generator and magnet unit (special function) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92 5.6 Refueling the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95

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6

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2 Machine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.3 Machine weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.4 Lock upper structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.5 Disconnect electrical system from battery . . . . . . . . . . . . . . . . . . . 6-4 6.6 Raising machine (upper structure) . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6.7 Tying down the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

7

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1 Drive engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.2 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.3 Heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7.3.1 Cooling capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 7.3.2 System extremely loud . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 7.4 Tires and undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 7.5 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 7.6 SDS fault indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 7.7 Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 7.7.1 Reverse airflow -insufficient cooling capacity- . . . . . . . . . 7-14 7.7.2 Steering failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

8

Setup work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.2 Dismantling/assembling the cab . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 8.3 Disassembling/mounting the counterweight . . . . . . . . . . . . . . . . . . 8-4 8.3.1 Disassembling the counterweight . . . . . . . . . . . . . . . . . . . . 8-6 8.3.2 Mounting the counterweight . . . . . . . . . . . . . . . . . . . . . . . 8-17 8.4 Installing large roller bearings, slewing gear, flange connections 8-19

860 / 05.2010

Table of contents

8.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19 8.4.2 Preparatory measures . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19 8.4.3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20 8.4.4 Mounting pylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 8.5 Quick-change couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22 8.5.1 Fastening quick couplings . . . . . . . . . . . . . . . . . . . . . . . . 8-22 8.5.2 Pull out coupling insert . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25 8.5.3 Check/change sealing ring . . . . . . . . . . . . . . . . . . . . . . . . 8-26 8.5.4 Lubricating the coupling sleeve . . . . . . . . . . . . . . . . . . . . 8-28 9

860 / 05.2010

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.1 List of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.2 Driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.3 Cleaning the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.4 Installing large roller bearings, slewing gear, flange connections . 9-2 9.5 Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.6 Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.7 Tool Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.8 Load moment indicator (LMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.9 Magnet unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.10 Camera system/monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.11 Display / auxiliary heating system . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.12 Lubricants table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

0-5

Table of contents

0-6

860 / 05.2010

Safety - General information

1

Safety

1.1 General information The machine is built to state of the art standards. Nevertheless, there may be dangers during its use to persons, machines and other property, if z the machine is not utilized in accordance with its intended use z the machine is not operated or maintained by trained personnel z the safety instructions are not observed. z the machine is found to be defective. z the attachment tools attached do not comply with the relevant safety

regulations.

z the attachment tools attached are found to be defective.

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

In the Federal Republic of Germany e. g.: z Winches, Lifting and Pulling Equipment (TUR D8) z Cranes (TUR D6) z Crane inspections (BGG 905) z EU Machinery Directive 2006/42/EC z EMC Directive 2004/108/EC z Electrical Equipment in Machines (EN 60204-1) z Safety Requirements for Fluid Power Systems and their

Components – Hydraulic Systems (EN 982)

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

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

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Safety - Intended use

1.2

Intended use

Intended use of the machine consists solely of hoisting, transport and loading of loads.

Permitted attachments are: z Grab z Magnet unit.

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

The machine is suitable for pulling a trailer but is subject to the permitted axle load. Questions should be directed to SENNEBOGEN Customer Service.

Attachments

An overview of all of the attachments that are currently available including matching machine types can be found in the appendix.

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

If any other attachment not listed is mounted, the user/operator is responsible.

Observe the performance specifications of the machine. Lifting capacities are not to be exceeded under any circumstances.

Other or additional applications are considered not in accordance with its intended use and can endanger persons or machinery.

1-2

Work station

The machine operator’s work station is in the cab of the machine.

Target group

The machine has been developed for demanding work.

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

860 / 05.2010

Safety - Potential instances of misuse

1.3

Potential instances of misuse

The following apply as potential instances of misuse, in particular: z Exceeding the permitted lifting capacities. z Using non-Sennebogen parts. z Use in unauthorized ambient conditions. z Misuse by untrained and uninstructed personnel. z Inadequate fittings for the types of use (e.g. protecting the cab

against dropping objects with guard grill).

z Operating on insufficiently firm subgrade. z Neglect of necessary inspection and maintenance work. z Neglecting to lower attached loads and boom if necessary when

shutting the machine down (e.g. work stoppages, over night).

z etc.

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1-3

Safety - Misuse

1.4

Misuse

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

pulling attached loads

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

1.5 Other risks The safety instructions in these instructions are guidelines for the safe use of the machine by qualified machine operators. However, SENNEBOGEN cannot anticipate every situation, which may result in danger in practice.

Therefore, the safety 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.

1-4

860 / 05.2010

Safety - Machine labeling

1.6

Machine labeling

The machine is provided with special warning and notice signs. z Do not remove the signs. z Ensure that all signs are undamaged and legible. z Clean 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).

1.6.1 Identification plate

860 / 05.2010

1

Machine type

2

Manufacturer's No. (Facility No.)

1-5

Safety - Machine labeling

1.6.2 CE certificate of conformity – affects machines that are operated within the EC. This machine carries the CE identification. This means that these machines meet the respective safety regulations of the EC machinery directive upon delivery. For changes that affect the safety of the machine and the respective consequences, those that make the changes are responsible and liable.

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

CE certificate

1.6.3 EuroTest certificate EuroTest is a voluntary Prototype test, which is based on the EC machinery directive and the respective European standards.

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860 / 05.2010

Safety - Machine labeling

1.6.4 EC conformity declaration

EC Conformity Declaration within the terms of the EC Machinery Directive 2006/42/EC, Appendix II A

Sennebogen Maschinenfabrik GmbH Hebbelstr. 30 94315 Straubing, Germany whose manager of technical documentation, Sennebogen Maschinenfabrik GmbH, Sennebogenstr. 10, 94315 Straubing, Germany, is authorised to compile the technical documentation for the specified machine, hereby declares that the Material loader machine TYPE (Model) : Serial no. : Year of manufacture: Engine power: in the form marketed by us, complies with the following relevant regulations:

x x x

EC Machinery Directive 2006/42/EC EMC Directive 2004/108/EC of 15.12.2004 Outdoor Directive 2000/14/EC

Harmonised standards taken into account: EN 474 – Part 1 and EN 474 – Part 5 (Requirements for hydraulic excavators)

This declaration is rendered invalid should the machine be altered in any way not approved by our company.

Straubing, SENNEBOGEN Maschinenfabrik GmbH

SENNEBOGEN Maschinenfabrik GmbH Hebbelstrasse 30 94315 Straubing, Germany Tel. +49 (0) 9421/540- 0 Fax: +49 (0) 9421/43882

860 / 05.2010

1-7

Safety - Machine labeling

1.6.5 Warning and notice signs Explanations of the stickers used on the machine: Drilling and welding work is only to be done by authorized SENNEBOGEN partners

Open flames prohibited!

Smoking prohibited!

Boarding prohibited!

Access for unauthorized prohibited!

Stay off!

Warning, hazardous area.

Warning, crushing hazard!

1-8

860 / 05.2010

Safety - Machine labeling

Warning, danger of amputation! (High pressure)

Starter batteries, filled with corrosive and poisonous acid.

Do not allow to drop and do not open with force

Warning, rotating component! (drive shaft/universal joint)

Warning, swiveling range!

Warning, electric voltage!

Before performing any maintenance work, switch the engine off and remove the ignition key!

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

Warning of hot surface or hot parts!

Warning, danger of injury! Rotating fan baffles

860 / 05.2010

1-9

Safety - Machine labeling

Maintain safety distance to overhead power lines in work application!

Crushing hazard in the vicinity of the raising cab (between the cab and the upper structure)

Note pertaining to emergency exit, in case of danger, smash the rear window with the emergency hammer and then leave the cab carefully

The machine fulfills basic safety requirements. Thus, the permanent sound pressure level outside the machine is 103 dB.

Note regarding the storage location of the fire extinguisher

Secure the machine in these tie-down locations for transport

Tie-down points (eyelets) for raising the machine

Wear the optional seat belt during work application

1 - 10

860 / 05.2010

Safety - Machine labeling

Read and understand the maintenance instructions before starting with any cleaning, service, maintenance, or repair work

Before start-up of the machine, be sure to carefully read the operating instructions and the additional technical information/additional documentation from any pre-suppliers.

Symbol for the battery disconnecting switch

Supply voltage of the on-board electrical system: 24 volts

Symbol for slewing ring lubrication

Wear personal protective equipment

Fuse for ignition lock 40 A

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

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1 - 11

Safety - Responsibilities of the operator

1.7 Recurring inspections

Responsibilities of the operator

Inspection by specialist technician, required for crane or excavating work The machine must be thoroughly inspected by a specialist technician. z before initial 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 vehicle 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.

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860 / 05.2010

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 the machine's electrical equipment may only be carried out

by a qualified electrician.

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 and experience on hydraulics!

Technical condition of the machine

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

The machine must not be operated if faults are found!

Observe mandatory time limits for routine checks.

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

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1 - 13

Safety - Responsibilities of the operator

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 spare 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.

Unauthorized operating methods

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

intended according to these instructions.

z The specified performance specifications must be observed. z The performance data listed in the instructions must not be exceeded. z If there is a danger of heavy items dropping, the machine may only

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

The protective roof is optionally available from SENNEBOGEN.

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.

International use

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

operating the machine.

z Ensure that the operators have the necessary qualifications for the

intended work.

z Ensure that the contents of these instructions have been read and

completely understood. If necessary, ask Sennebogen for a copy of these instructions in the corresponding language.

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860 / 05.2010

Safety - Responsibilities of the operator

Permissible ground pressure

The maximum permissible ground pressure of the subgrade is authoritative for the secure operation of the machine. The guidelines in the following table must be taken into consideration for applications planning.

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

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

Type of ground

Perm. ground pressure in [kg/cm2]

A) Stirred ground that has not been packed

0-1

B) Grown in, obviously untouched ground 1) Mud, peat, muck, topsoil 2) Non-binding, sufficiently solid, seasoned ground - Fine to medium sand - Coarse sand to gravel

0

1.5 2.0

3) Cohesive soil - soggy

0

- soft

0.4 1.0

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

2.0 4.0 15 - 30

C) Artificially packed surface 1) Asphalt

5 - 15

2) Concrete - Concrete group I

50 - 250

- Concrete group II

860 / 05.2010

350 - 550

1 - 15

Safety - Responsibilities of the operator

Banks and ditches

The machine must be set up/operated at a sufficient safety clearance from banks and ditches. The distance depends on the type of ground in the location.

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

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

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

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

as the ditch depth (B), bank angle a < 30°

Dangers of non-compliance 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

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

Warranty conditions

1 - 16

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

860 / 05.2010

Safety - Supplementary and operational equipment

1.8

Supplementary and operational equipment

1.8.1 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 More information for the SDS can be found in Section 5.3.15 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 / 05.2010

1 - 17

Safety - Supplementary and operational equipment

1.8.2 Oils and lubricants Note Only use oils and lubricants approved by SENNEBOGEN. These are listed in LUBRICANTS TABLE. The ambient temperature for operating the machine must be between -20 °C (- 4 °F) and + 40 °C (+ 104 °F). If the temperature at the site 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.

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860 / 05.2010

Safety - Supplementary and operational equipment

1.8.3 Refrigerant General

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.

Note Observe the refrigerant label in the cooler area.

If the ambient temperature at the work-site is under this value (-36 °C (-34 °F)), observe the operating instructions of the motor manufacturer or contact SENNEBOGEN Customer Service before start-up.

Note If only a small amount (up to max. 5 l/1.3 gal.) is required to fill the water cooling 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.

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

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1 - 19

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

or rain water.

z Always fill using a water-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.

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860 / 05.2010

Safety - Supplementary and operational equipment

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

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

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

Note regarding fuel grade and selection Please follow the instructions in the engine manufacturer operating instructions.

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Safety - Safety instructions

1.9

Safety instructions

1.9.1 General Danger area

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

DANGER No one may be in the danger area!

The machine operator must put up warning signs when there is danger to persons. If the persons do not leave the danger area despite the warning, work must be stopped.

To avoid crushing hazards by solid components, e. g. building structures, excavation banks, scaffolding or other machines, a sufficient safety clearance (at least 500 mm) must be maintained.

If the safety clearance cannot be maintained, then the area between the solid structure and the working range of the machine must be cordoned off.

If the machine operator's vision of driving and working range is restricted, then he must be guided.

Personal protective equipment

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

Eye bolts are installed as safety eyelets on the upper structure. The safety eyelets are used for hanging a safety belt to protect personnel from falling from the machine. At working heights of 2.00 m or more, SENNEBOGEN recommends the use of a safety harness to prevent falling. At working heights above 3.00 m, using a safety harness is legally required.

Hanging rings are marked.

1 - 22

860 / 05.2010

Safety - Safety instructions

Minimizing noise

Casings, coverings, cab doors and windows are to be kept closed during use to decrease noise levels (as long as this conforms with safety requirements). Operating instruments are to be used gently.

Noise emissions

Permanent sound pressure level (LpA) of the machine, measured at the driver´s seat with the cab closed, is below 80 dB. The wearing of ear protection is thus not absolutely required. The measurements are taken according to Directive 2000/14/EC. Note If the permanent sound pressure level (LpA) of the machine, measured at the driver´s seat with the cab closed, is between 80 and 85 dB: z Warning sign in the cab (specification of dB) z Ear protection within reach in the cab

Vibrations

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

Problems

Report problems or damage immediately to a responsible person!

Secure the machine against improper or inadvertent use.

Repairs should only be performed by specialist personnel.

Qualifications for personnel

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

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

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

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Safety - Safety instructions

Work underground and in enclosed spaces

Stability

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

z Position the machine on a firm, even subgrade. z If necessary, stabilize the subgrade. z Caution at excavation edge, banks, vaults, etc. z Position outriggers also on a firm, even subgrade. z With additional ballast:

Slew upper structure only if supports are extended!

z Observe wind speeds! z Stability is at a minimum when the working gear is transverse to the

direction of travel.

z Stability is at a maximum when the working gear is positioned

diagonally (see illustration below).

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

loads at great heights.

z Note that stability decreases when the load is swinging outwards. z Quick motions can lead to decreased stability or uncontrolled load

motions.

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860 / 05.2010

Safety - Safety instructions

Working near power lines

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

construction site while under supervision.

z Always assume that overhead power lines are live. z Guide the machine so that neither parts of the machine nor attached

loads extend into the danger area.

z Maintain a safety clearance from overhead power lines. If national

regulations do not recommend other values, adhere to the following minimum distances:

Nominal working voltage (volts)

Safety clearance (meters)

up to 1000 V

1.00

over 1000 V to 110 kV

3.00

over 110 kV to 220 kV

4.00

over 220 kV to 380 kV

5.00

not known

5.00

z Employ a signaling individual to monitor the safety clearance. z The insulating elements fitted to the machine, protective cages,

or proximity warning devices are no substitute for the listed minimum distances.

z In windy conditions, the overhead power lines and the working

equipment can swing outwards and consequently reduce the distance.

High voltage contact

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

danger area.

z Arrange for power to be switched off. z Only leave the machine once the touched or damaged line has been

disconnected from the power supply.

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

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Safety - Safety instructions

Lightning

Cabs on construction equipment are equipped with protection against lightning strikes. The lightning current flows through the cab to ground.

DANGER z Do not touch any metal parts that make direct contact with the

chassis during storms.

z The electromagnetic field associated with lightning current can

affect sensitive electronic components and could lead to malfunction or complete failure in certain circumstances.

Check the correct functioning of the operator and safety elements before recommissioning the machine.

z The enormous amount of heat can cause extensive damage to tires

(depending on the type of machine).

Before recommissioning the machine, check tires for damage.

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860 / 05.2010

Safety - Safety instructions

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

if necessary, especially in recycling applications.

z Ensure that the cleaning agents used do not damage the seals and

components of the machine.

z Do not use aggressive cleaning agents. z Only use lint-free cleaning cloths. z Only use dry, filtered compressed air up to max. 2 bar (29 psi). z Lubricate the lubrication points after every cleaning. z Replace protective caps on the 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.

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Safety - Safety instructions

1.9.3 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 - 28

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.

860 / 05.2010

Safety - Safety instructions

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 (4) and then close the door.

4

Close the sliding door.

CAUTION Risk of falling!

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

Only in extreme emergencies and with 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.

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Safety - Safety instructions

Gallery/Operator catwalk

HAZARD Risk of falling!

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

CAUTION Risk of falling!

No one is 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.

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860 / 05.2010

Safety - Safety instructions

Upper structure

2

3

2 Grip handles 3 Access ladders

DANGER 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.

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Safety - Safety instructions

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

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

Cab

1

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

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

CAUTION Risk of falling!

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

1.9.5 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!

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860 / 05.2010

Safety - Safety instructions

1.9.6 Start-up WARNING z Check that all machine protective features are complete and properly secured. z Ensure that the gallery/operator catwalk has been installed properly.

Falling out when the door is open (with optional seat belt in place) is no longer possible in this case.

z Wear protective work clothing (e.g. protective helmet, protective

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

access ladders and ladders:

– if necessary, clean access ladders and ladders before use – Do not carry any items when climbing up or down. Hoist items of equipment onto machine using rope or lifting equipment.

– Do not use operating instruments in the cab as grip handles. z Ensure that there is no one in the danger area. z Check machine safety features (e.g. brakes, signal and lighting

equipment).

z Check operating instruments and protective features are functioning

correctly while driving slowly.

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

instructions.

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Safety - Safety instructions

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

instructed for that purpose. Operation and work application may only be carried out by trained personnel.

z For all work, the following applies:

Work only if the work area is level and solid enough.

z Proceed with utmost caution if you bypass the stick end limitation or

other safety limit shutdown.

z Ensure that there is no one in the danger area. z Maintain safety clearance to overhead power lines. z Only operate the machine from the driver's seat. z When switching the attachment (e.g. grab), release the pressure

from the hydraulic system.

z Do not transport persons on the machine. z Consider environmental conditions, e. g. poor visibility, wind speeds, etc. z Use the specific lifting capacity tables for that machine. z Note performance specifications. z Check that attachment points have a sufficient safe working load. z Observe signaling individual signals if they are given. z If visibility is poor, ensure that a signaling individual is used for giving

the required signs when reversing.

z Before moving onto ramps or inclines, make sure to obtain the

maximum permitted values from SENNEBOGEN.

z Position boom in direction of travel during long journeys.

CAUTION! For crawler undercarriage: Heavy property damages are possible!

Driving over raised or lowered obstacles such as thresholds, rails, or curbs can lead to high point loadings for the track frame, the guide wheels, the chains, etc. This can lead to cracking or even breaks in the track frame components (e.g. guide wheel).

Driving over raised or lowered obstacles such as thresholds, rails, or curbs is prohibited.

SENNEBOGEN assumes no liability for damages resulting from this!

Transit is only permitted on even, smooth and preferably concrete (concrete slabs) paths/streets! Pay attention to ground load capacities.

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860 / 05.2010

Safety - Safety instructions

1.9.8 Setup work DANGER z The work performed may only be completed by trained and instructed specialists. z Wear personal protection 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 The following applies for all setup work:

Only carry out the work if the work area has a firm, even subgrade and is solid enough.

z Ensure that there is no one in the danger area.

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

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

with hoisting accessories.

z When dismantling components or disassembling equipment, always

use hoisting accessories with a sufficient safe working load.

z Suspend components only with the designated lifting brackets. z Do not step on equipment that is not designed for it (e.g. boom

components or ballast).

z Carry out all setup work in sequence. Never carry out more than one

setup task at a time.

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Safety - Safety instructions

1.9.9 Decommissioning Before leaving the cab: z Completely lower cab if necessary z Position the machine on firm subgrade, if necessary set back

from the edge of the excavation

z Lower attached loads z Secure attachments z Pull safety lever back z Switch off engine z Chock tires/undercarriage z Lock cab, show warning lights if necessary.

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860 / 05.2010

Safety - Safety instructions

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

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

fluids and components can cause burns.

z De-pressurize the hydraulic system to avoid dangers.

WARNING z Observe all signs and safety stickers on the machine as well as those in the instructions. They contain important information about maintenance procedures. z The work performed may only be completed by trained and

instructed specialists.

z 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.

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.

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Safety - Safety instructions

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 Maintain a safe distance from 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 according to 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 an adequate safety clearance and use a 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.

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.

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860 / 05.2010

Safety - Safety instructions

Qualifications for 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 and experience on hydraulics!

z No welding is to be performed on the device without previous

discussion with the manufacturer.

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Safety - Safety instructions

1.9.11 Transport WARNING z In Germany: loading and transport work is only to be carried out by authorized specialist personnel in accordance with VBG 40, §48 and Federal Motor Vehicle Safety Standards (FMVSS) §22. z Observe relevant regulations for securing loads.

The respective transport operator is always responsible for the transport of machine and accessories.

z Use a flatbed trailer with sufficient useful load and size. z When loading and transporting, secure the machine and its working

equipment from involuntary motions.

z Clean mud, snow and ice from undercarriage of machine so that

ramps can be accessed without danger of slipping.

z Provide flatbed trailer access ramps with wooden planks. z Check conditions of route before starting journey. z Only transport machine using designated tie down and lifting points. z Ensure that the machine does not present any hazards to other road

users.

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

protective gloves, safety shoes).

z Report any damage that occurred during shipping to SENNEBOGEN

customer service immediately.

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860 / 05.2010

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 (1) for new ones.

Overload warning device

Illustration

The overload warning device gives an acoustic warning signal if the permitted lifting capacity is exceeded. Ensure that the overload warning device is activated when working with lifting equipment.

The danger of tipping is not averted by the overload warning device!

HAZARD Danger of tipping the machine!

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

Limit shutdown equipment

The following motions are limited by the limit shutdowns: – Retract stick – Extend stick – Hoist up – Hoist down.

860 / 05.2010

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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.

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860 / 05.2010

Safety - Hand signals

1.12 Hand signals Driver and signaling individual communicate with each other using the following hand signals when vision is restricted in the driving and working range.

The signaling individual gives the necessary signals to ensure safe operation.

Safety instructions

Observe safety instructions before starting work.

CAUTION z Only reliable persons may be employed as signaling individuals.

They must receive the necessary training before starting their task. z The signaling individual must not be distracted from this task. z Follow the instructions of the TUR A8, Hand signals for signaling.

Hand signal

Explanation Attention Extend arm upwards with hand open.

Stop Stretch out both arms horizontally.

860 / 05.2010

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Safety - Hand signals

Hand signal

Explanation Stop! Danger!

Alternately stretch out both arms horizontally and bend at right angles.

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

Drive slowly forwards Bend both arms and beckon forwards with palms of hands turned inwards.

1 - 44

860 / 05.2010

Safety - Hand signals

Hand signal

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

Turn right Left thumb outwards.

Turn left Right thumb outwards.

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Safety - Hand signals

Hand signal

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

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

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

1 - 46

860 / 05.2010

Safety - Hand signals

Hand signal

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

Increase working radius Both thumbs point outwards.

Decrease working radius Both thumbs point inwards.

860 / 05.2010

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Safety - Hand signals

Hand signal

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

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

1 - 48

860 / 05.2010

Overview - Overall machine

2

Overview

2.1 Overall machine

860 / 05.2010

1

Attachment (Example: Grab)

3

Grabbing stick

5

Compact boom

6

Operator´s station/cab with gallery, raising

7

Undercarriage

8

Upper structure

9

Outrigger

10

Counterweight

2-1

Overview - Undercarriage

2.2

Undercarriage

4-point outrigger

1

2

3

4

5

6

7

Sliding front window (optional) 9

8*

1 Outrigger, rear

6 Front axle (floating axle)

2 Rear axle

7 Front outrigger

3 Slewing ring

8 Sliding front window

4 Access ladder

9 Floating axle cylinder

5 Extra storage space *: Optional model/special function

2-2

860 / 05.2010

Overview - Undercarriage

Outrigger

1

860 / 05.2010

3 4

2

1 Access ladders

3 Support leg

2 Outrigger housing

4 Outrigger pad

2-3

Overview - Upper structure

2.3

Upper structure

2.3.1 Side views Service access doors Engine compartment

1

2

3 1a*

4

5

Engine compartment rear:

2 Hydraulic oil level indicator

1 Auxiliary control filter

3 Water separator - fuel

1a HydroClean

4 Gate 5 Pump unit

5

6

7

8

Engine compartment front: 5 Drive engine

7 Combination cooler

6 Fan

8 Air conditioning system

*: Optional model/special function

2-4

860 / 05.2010

Overview - Upper structure

Service access doors Driver's side

1

2

3

4

Driver's side front:

860 / 05.2010

1 Demister container

3 Slewing ring lubrication

2 Emergency lowering - cab

4 Pressure gauge connections hydraulic system

2-5

Overview - Upper structure

4*

5

6

7

8

9

10

11

Driver's side rear:

8 Fuel tank

4 Refueling hose/pump

9 Electric switch cabinet

5 Fuel filler strainer

10 Batteries

6 Central lubrication system

11 Battery isolator

7 Air filter *: Optional model/special function

2-6

860 / 05.2010

Overview - Upper structure

2.3.2 View from above

1

4

2

5 6

3

8*

7 1 Exhaust silencer/ exhaust pipe 2 Service cover HydroClean superfine filtration system

6 Air filter pre-separator 7 Service cover cooler 8 Generator - magnet unit

3 Service cover drive engine 4 Service cover hydraulic oil tank 5 Service cover battery *: Optional model/special function

860 / 05.2010

2-7

Overview - Upper structure

2.3.3 Central electricity Service access doors Driver's side rear 1

2

3

1 Automatic circuit breaker 40 amp (terminal 15) 2 Automatic circuit breaker 80 amp (terminal 30) 3 Battery isolator

2-8

860 / 05.2010

Overview - Equipment

2.4

Equipment

2.4.1 Compact boom with grabbing stick

2

with ULM (optional)

1

3

4*

1 Compact boom

3 Grabbing stick with

2 Grabbing stick

4 ULM

*: Optional model/special function

860 / 05.2010

2-9

Overview - Equipment

2.4.2 Pipe fracture safety devices

1

2*

1 Pipe fracture safety device - lifting cylinder 2 Pipe fracture safety device - stick cylinder

*: Optional model/special function

2 - 10

860 / 05.2010

Specifications - General

3

Specifications

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

3.1 General 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 range

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.

Hydraulics

Slewing drive

Travel speed

860 / 05.2010

Operating pressure, max. 350 bar

Slewing speed

0-8 rpm, continuously variable

approx. 0 - 15 km/h / 0 - 9.32 mile/h

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 (deposit load, deposit boom). For table on wind speeds, see Section 3.9

3-2

860 / 05.2010

Specifications - Drive engine

3.2

Drive engine

QSM11-C360

860 / 05.2010

Power (according to ISO 14396)

268 kW at nominal speed of 1800 RPM

Displacement

10800 cm3

Cylinders

6

Oil capacity with filter

approx. 37.0 l / 9.8 gal (US)

Refrigerant capacity (overall system) Engine

approx. 60 l / 15.9 gal (US)

General drive engine information

See manufacturer's instructions

approx. 9.5 l / 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 per 0.5 m mast length an additional approx. 30 l (7.9 gal. (US)) of hydraulic oil is needed for special machines with mast.

3-4

860 / 05.2010

Specifications - Machine

Tire air pressure (pneumatic tires)

Tire size

barp Air pressure ppsi

14.00-24

10

145.04

Note Wheel nuts The tightening torque is 650 Nm. Use a torque wrench.

860 / 05.2010

3-5

Specifications - Machine dimensions

3.4

Machine dimensions

Note More information on the dimensions can be found in Section 6.2 MACHINE DIMENSIONS

3.5 Machine weight Note More information can be found in Section 6.3 MACHINE WEIGHT.

3-6

860 / 05.2010

Specifications - Lifting capacities

3.6

Lifting capacities

Notes The load ratings z are specified in tons (t) and equate to 75% of the static tipping load

or 87% of the hydraulic lifting force according to ISO 10 567.

z are applicable for a machine on firm, level ground and apply over a

range of 360 degrees.

z apply when the machine's supports are deployed.

Deduct the weight of the hoisting accessories (hooks, sling) from the lifting capacities. The values in parentheses apply in a direction along the lengthwise axis of the undercarriage.

Adverse conditions

Limit or reduce load ratings to compensate for adverse conditions.

Adverse conditions are e. g. z Soft or uneven ground z Slopes z Wind z Side loads z Rocking loads z Jerking or sudden stopping of load z Inexperience of operating personnel z Driving with load.

860 / 05.2010

3-7

Specifications - Lifting capacities

3.6.1 Stabilized: K18 (compact boom 10.8 m / stick 7.8 m, KIN 1)

3-8

860 / 05.2010

Specifications - Lubricate the machine

3.7

Lubricate the machine

3.7.1 Lubrication point overview

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

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

Note z The machine is equipped with a central lubrication system for the swiveling connection and 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 bearing points.

860 / 05.2010

3-9

Specifications - Lubricate the machine

3.7.2 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 - 10

860 / 05.2010

Specifications - Lubricate the machine

1

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

860 / 05.2010

3 - 11

Specifications - Lubricate 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 - 12

860 / 05.2010

Specifications - Warning and notice signs

3.8

Warning and notice signs

Note More information can be found in Section 1.6.5.

860 / 05.2010

3 - 13

Specifications - Warning and notice signs

1

2

3

4

6

25

30

31

34

41

www.sennebogen.de

3 - 14

103050

860 / 05.2010

Specifications - Warning and notice signs

860 / 05.2010

3 - 15

Specifications - Warning and notice signs

3 - 16

860 / 05.2010

Specifications - Wind speed

3.9

860 / 05.2010

Wind speed

Wind force

Wind speed

Description

Beaufort scale

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

12

Hurricane

32.7-36.9

118-133 Severe devastation

(rarely in inland)

3 - 17

Specifications - Tightening torques for bolts

3.10 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 instructions in the respective sections.

Strength class 8.8

3 - 18

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

860 / 05.2010

Specifications - Tightening torques for bolts

Strength class 10.9

860 / 05.2010

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

3 - 19

Specifications - Tightening torques for bolts

Strength class 12.9

3 - 20

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

860 / 05.2010

Specifications - Conversion factors

3.11 Conversion factors Pressure

Flow rate

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

Length

Weight

Power

Temperature

860 / 05.2010

3.281 ft

3 - 21

Specifications - Conversion factors

Volume

Speed

3 - 22

1 m3

1000 l

35.31 ft3

1.308 yd3

1 ft3

28.32 l

0.02832 m3

1.728 inch3

1l

0.2642 gal.(US)

0.2201 gal (Brit.)

-

1 gal. (US)

3.785 l

231 inch3

-

1 gal. (Brit.)

4.544 l

277 inch3

-

1 yd³

764.55 l

0.765 m³

27 ft³

1 m/s

3.281ft/s

2.237 mile/h

1 ft/s

0.305 m/s

1.097 km/h

860 / 05.2010

Start-up - Safety instructions

4

Start-up

4.1 Safety instructions WARNING z Read Chapter 1 SAFETY. Before start-up, carry out checks according to Section 4.4. z Check that all machine protective features are complete and

properly secured.

z Ensure that the gallery/operator catwalk has been installed properly.

Falling out when the door is open (with optional seat belt in place) is no longer possible in this case.

z Wear protective work clothing (e.g. protective helmet, protective

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

access ladders and ladders:

– if necessary, clean access ladders and ladders before use – Do not carry any items when climbing up or down. Hoist items of equipment onto machine using rope or lifting equipment.

– Do not use operating instruments in the cab as grip handles. z Ensure that there is no one in the danger area. z Check machine safety features (e.g. brakes, signal and lighting

equipment).

z Check operating instruments and protective features are functioning

correctly while driving slowly.

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

instructions.

860 / 05.2010

4-1

Start-up - Cleaning work

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

if necessary, especially in recycling applications.

z Ensure that the cleaning agents used do not damage the seals and

components of the machine.

z Do not use aggressive cleaning agents. z Only use lint-free cleaning cloths. z Only use dry, filtered compressed air up to max. 2 bar (29 psi). z Lubricate the lubrication points after every cleaning. z Replace protective caps on the 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.

4-2

860 / 05.2010

Start-up - Initial commissioning

4.3

Initial commissioning

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

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

WARNING Read CHAPTER 1 SAFETY. Before start-up, carry out checks according to Section 4.4.

4.4 Inspections before daily start-up Observe safety instructions before starting work.

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

within your working range.

Note The following pages contain the checklists that should be gone through before start-up with the machine every day. It is divided into: – a general section (e.g. A1), – a function section (e.g. F1) and – a visual check section (e.g. S1).

DANGER Report all irregularities to the person in charge before start-up.

Only operate machine after ensuring that it is in full working order.

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

860 / 05.2010

4-3

Start-up - Inspections before daily start-up

No.

General

A1

Are the danger areas (overhead power lines, ditches, etc.) marked and secured in the work site?

A2

Steps to take

Chapter

5

Mark and secure as necessary

-

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

If necessary, obtain information

-

A3

Is an experienced signaling individual available, if required?

If necessary, arrange for a signaling individual

-

A4

Is the danger area free of persons?

If so, advise them to leave the danger area

-

A5

Is the load weight known?

Obtain information

-

A6

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

Refer to the operating instructions and identification plate as necessary

-

No.

Functional checks

Steps to take

Chapter

5

F1

Is the stick end limitation set correctly?

If necessary, adjust

5.5.8

F2

Is the hoisting limiter set correctly?

If necessary, adjust

5.5.8

F3

Is the overload warning device activated?

If necessary, activate

5.3.14

F4

Is the machine positioned horizontally?

If necessary, position correctly

F5

Is the stability of the machine ensured?

If necessary, support properly

F6

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

If necessary, locate and correct faults

F7

Are any warning or fault messages displayed on the SDS?

If necessary, locate and correct faults, read fault log

F8

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

F9

5.5.5

-

5.3.15

If necessary, locate and correct faults

-

Is the emergency lowering feature of the cab functioning?

If necessary, locate and correct faults

5.5.3

F10

Does the steering work properly?

If necessary, adjust

-

F11

Is the central lubrication unit functioning?

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

4.5.4

4-4

860 / 05.2010

Start-up - Inspections before daily start-up

No.

Visual checks

S1

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

S2

Chapter

5

If necessary, replace

-

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/ If necessary, repair or replace universal joints) undamaged?

-

S6

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

If necessary, retighten to the specified torque

3.3

S7

Is the tire pressure set correctly?

(For pneumatic tires)

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

3.3

S8

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

If necessary, seal points of leakage or replace seals

-

S9

Are the hydraulic cylinders (e.g. outrigger, If necessary, seal points of leakage or stick, floating axle cylinders, steering replace seals cylinders) free of leaks and undamaged?

Inspect piston rods for damage (cracking, etc).

-

S10

Is the gate on the hydraulic tank open?

If necessary, open

4.6.1

S11

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

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

4.5

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.

-

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

-

860 / 05.2010

Steps to take

4-5

Start-up - Inspections before daily start-up

No.

Visual checks

Chapter

5

S17

Has the water separator on the fuel system been drained?

If necessary, drain

4.5.8

S18

Are the V-belts undamaged and tensioned?

If necessary, tension again or replace

-

S19

Are the electrical lines damaged?

If necessary, repair or replace

-

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 tightened, particularly on the elevating cab?

If necessary, retighten or replace

-

S24

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

If necessary, disconnect

-

S25

Is the correct counterweight installed and secured in place?

Replace if necessary or retighten to specified torque

-

S26

Are the boom components/steel structure undamaged (corrosion, cracking)?

If necessary, repair or replace

-

S27

Are any pin-type keepers damaged (e.g. cracking)?

If necessary, replace

-

S28

Are the pipe fracture safety devices tight and undamaged?

If necessary, replace

-

S29

Is there enough grease in the central lubrication system?

If necessary, refill

4.5.4

S30

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

If necessary, replace, clean and lubricate

-

S31

Are the hydraulic pipes and hoses secured in place?

If necessary, tighten fasteners

-

S32

Is the swiveling connection undamaged and lubricated sufficiently?

Repair or actuate pinion lubrication if necessary.

-

S33

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

If necessary, refill

4.5.5

S34

Are the mechanical steering stops worn?

If necessary, replace

-

S35

Is the energy chain damaged/worn?

If necessary, replace

-

4-6

Steps to take

860 / 05.2010

Start-up - Tests before start-up

4.5

Tests before start-up

4.5.1 Check demister level Note The container for cleaning fluid for the washer system is located behind the front left service access door.

Always fill the container with washer system antifreeze.

1

2

3

4

1 Demister container 2 Service access door lock Closing service access door

1

Carefully press lock button (3) on the lock (2) and keep it pressed.

2

Close service access door (4).

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

860 / 05.2010

4-7

Start-up - Tests before start-up

4.5.2 Check fuel level Note The fuel fill level can be determined two different ways: z with the indicator on the right next to the filler strainer (rough indicator) z with the SENNEBOGEN Diagnostic System in the initial screen,

see Section 5.3.15

1 1 Indicator Note 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 Please follow the instructions in the engine manufacturer operating instructions.

4-8

860 / 05.2010

Start-up - Tests before start-up

4.5.3 Lubricating the lubrication points manually Note More information can be found in Section 3.7.2.

4.5.4 Check fill level in central lubrication system.

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

Note The preset lubricating cycle can be shortened. See the documentation on the CENTRAL LUBRICATION SYSTEM in Chapter 9.5 of the operating instructions.

1

2 3

1 Threaded cover - for refilling with grease 2 Grease reservoir - note MIN/MAX marking 3 Lubricating nipple - add grease

860 / 05.2010

4-9

Start-up - Tests before start-up

4.5.5 Checking fill level in slewing ring lubrication The slewing ring lubrication lubricates the external teeth of the swiveling connection.

1

2

1 Threaded cover - for refilling with grease 2 Lubricant container

4 - 10

860 / 05.2010

Start-up - Tests before start-up

4.5.6 Checking fill level in slewing drive 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

1

2

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

860 / 05.2010

4 - 11

Start-up - Tests before start-up

4

Allow the oil in the slewing gear to cool.

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

4 - 12

Add oil of the specified grade as required.

860 / 05.2010

Start-up - Tests before start-up

4.5.7 Checking the hydraulic oil level

1

Machine in park position

860 / 05.2010

1

Deposit attached loads and boom to the ground.

2

Put the machine in a level horizontal position.

3

Move all hydraulic cylinders all the way inward.

4

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

5

Shut down drive engine.

6

Open the service access door on the right.

7

Check oil level on the oil level indicator (1): the oil level must reach the upper marking (MAX).

8

De-pressurize hydraulic system as needed.

9

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

– Unscrew screw cap of oil filler strainer.

– Add hydraulic oil and re-check.

– Re-tighten screw cap.

Close the cover plate again.

10

Close the service access door on the right.

4 - 13

Start-up - Tests before start-up

4.5.8 Checking and draining the fuel system WARNING z No open flames when working on the fuel system! No smoking! z Also comply with the instructions in the engine manufacturer

operating instructions.

2

1

1 Fuel filter cartridge 2 Drain valve

4 - 14

1

Open rear right service access door.

2

Set a suitable catch container under the water container of the fuel filter cartridge (1).

3

Open drain valve (2).

860 / 05.2010

Start-up - Tests before start-up

4

Drain the water and debris out of the water container.

5

Shut off the drain valve again.

6

Close the service access door at the right rear.

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

860 / 05.2010

4 - 15

Start-up - Tests before start-up

4.5.9 Checking engine oil level Note Observe the instructions in the engine manufacturer operating instructions.

1

2

1 Oil filler strainer 2 Oil dipstick

4 - 16

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

Turn oil dipstick (2) and remove.

Wipe off using a clean, lint-free cloth.

6

Insert oil dipstick up to stop and pull out again.

7

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

8

If necessary add engine oil of the specified grade.

860 / 05.2010

Start-up - Tests before start-up

9

Insert oil dipstick again.

10

Close the service access door on the right.

4.5.10 Checking refrigerant level WARNING! Risk of injury from scalding!

Check only when the cooling system has cooled.

3 2 1

4 1 Service panel 2 Grip 3 Hand screws 4 Sealing cap

Checking refrigerant level and antifreeze

860 / 05.2010

1

Allow drive engine and cooler to cool down.

2

Unscrew the two hand screws (3).

3

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

4

Pace large, thick cloths on the sealing cap (4) of the refrigerant expansion tank 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 resistance to - 36 °C (- 33 °F).

6

Close the sealing cap on the expansion tank.

7

Replace the service panel and secure using the hand screws.

4 - 17

Start-up - Switching on the machine

4.6

Switching on the machine

4.6.1 Safety instructions Observe the safety notes before starting machine.

DANGER z Risk of injury!

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

danger area.

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

Only run engine outdoors or in well-ventilated areas.

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

instruments.

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

position.

z Fit seat belt correctly. z Close the cab doors.

CAUTION Before starting the engine, ensure that the gate on the hydraulic tank is open!

1

Illustrated: Gate (1) opened

4 - 18

860 / 05.2010

Start-up - Switching on the machine

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

WARNING z Check belt for signs of wear before machine start-up. Immediately exchange a damaged belt. z Clean dirty belt using water. z Do not twist belt when fastening. z Pass belt as low as possible around the hips, not around the

stomach.

1 2 3

860 / 05.2010

1

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

An audible click indicates that the belt has engaged.

2

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

4 - 19

Start-up - Switching on the machine

4.6.3 Starting the engine DANGER Risk of poisoning!

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

Control panel right rear

1

3 4

2

5

1

Perform daily inspections in accordance with Section 4.4.

2

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

– The SDS runs a short self-test.

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

– The SDS must have no fault messages when starting the engine.

Note The pilot lamps for CUMMINS engine indicate a malfunction in the motor by means of constant light or blink codes.

Observe the instructions of the motor manufacturer for further information.

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860 / 05.2010

Start-up - Switching on the machine

Ignition key position

3

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

4

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

5

Set the desired engine rpm using rotary knob (1).

Ignition key position

Meaning

P

Enabling refueling pump

0

Ignition OFF

I

Ignition ON (Switch off ignition after 20 minutes!)

II

Starting the engine

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

DANGER Never leave the machine unattended with the engine running!

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4 - 21

Start-up - Switching on the machine

4.6.4 Bring machine up to operating temperature Guidelines for warm-up period

Procedure Warming up the engine

Ambient temperature range

Warm-up period

Max. engine speed

Down to 0 °C (32 °F)

approx.

15 min.

- 20 °C (- 4 °F) -...

0 °C (32 °F)

approx.

30 min.

Nominal speed - 250 RPM (for nominal speed, see Chapter 4)

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

Additional warm-up time can be required at temperatures below 0°C (32 °F).

z Then increase the RPM in steps up to the

nominal speed of 250 RPM (no-load)

z If approx. 20°C (54 °F) water temperature has been achieved, put a

load on the engine by carefully actuating hydraulic functions and continue to warm up the machine.

z The machine can be loaded if the temperatures indicated below

have been achieved.

Reverse fan With optional equipment reverse fan below 0 °C (32 °F): The fan speed direction changes multiple times during the warm up phase. This will feed hot air from the engine to the superfine filter (cap in front of the cooler) and blow out the ice.

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

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

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

4 - 22

860 / 05.2010

Start-up - Jump start

4.7

Jump start

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

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

1

If necessary, switch off the optional battery disconnecting switch in order to interrupt the current.

2

Remove battery cover where applicable.

3

Connect the positive terminal (+) of the power source using appropriate jumper cables.

4

Connect the negative terminal (-) of the jumping battery using the jumper cable to the engine block or a unpainted metal part of the receiver connected to it.

5

If necessary, actuate the optional battery disconnecting switch.

6

Start engine acc. to Section 4.6.3.

7

Switching on electrical consumers (protection against overvoltage)

8

Removal: – Detach jumper cable of negative terminal (-).

– Detach jumper cable of positive terminal (+).

9

Switching off electrical consumers

10

Replace battery cover where applicable.

WARNING z Danger of explosion!

Avoid creating sparks by fire, open fire, or smoking. z Battery acid is corrosive.

Avoid any contact with the skin, eyes or clothing. Rinse acid splashes and spills with clean water immediately. It may be necessary to seek the attention of a physician.

When working on electrical system, adhere to current regulations and accident prevention regulations.

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Start-up - Switching off the machine

4.8

Switching off the machine

4.8.1 Switching the engine off Note Switching off the drive engine after a work application without allowing a cooling down phase may cause heat accumulation and overheating of engine parts, in particular the turbocharger. Therefore, allow the drive engine to cool down before switching off: z Lower engine speed to approx. 50 % of the nominal speed

(see Chapter 4).

z Allow machine to run for an additional 5-10 minutes.

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

4 - 24

1

Park the machine on a firm subgrade.

2

Deposit attached loads and deposit boom if necessary.

3

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

4

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

5

Turn ignition key to position "0" and remove.

6

If necessary, pull back safety lever.

7

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

860 / 05.2010

Start-up - Switching off the machine

4.8.2 Decommissioning Proceed as follows if the machine is to be decommissioned for a prolonged period.

1

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

2

Position the machine on level ground.

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

3

Switch off machine according to Section 4.8.

4

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

5

Clean machine according to maintenance instructions.

Ensure that cleaning agents do not attack the seals nor enter the slewing track of the swiveling connection!

6

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

7

Lubricate machine according to maintenance instructions.

Lubricate the swiveling connections while slowly slewing the upper structure (fill grease supply if necessary).

8

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

9

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

Note Observe permissible ambient temperatures according to Chapter 4.

CAUTION! Check the seals every 6 months.

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4 - 25

Start-up - Switching off the machine

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

4 - 26

1

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

2

Deposit attachment on wooden planks to prevent freezing.

3

Perform maintenance for 2000 hours of operation (annual).

4

Clean and dry all bare surfaces thoroughly (e.g. piston rods).

5

Preserve all bare surfaces and bearing points with corrosion protection. The protective film must cover the surface completely without any bare spots.

6

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

7

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

8

Check the cooling system for sufficient antifreeze.

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

Do not empty the cooling system under any circumstances!

9

Prepare the diesel engine for storage. Also comply with the instructions in the engine manufacturer operating instructions.

10

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

11

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

860 / 05.2010

Operation - Safety instructions

5

Operation

5.1 Safety instructions DANGER z Read Chapter 1 SAFETY. Before start-up, carry out checks according to Chapter 4.4. z Persons working on or with the machine must be trained or

instructed for that purpose. Operation and work application may only be carried out by trained personnel.

z For all work, the following applies:

Work only if the work area is level and solid enough.

z Proceed with utmost caution if you bypass the stick end limitation or

other safety limit shutdown.

z Ensure that there is no one in the danger area. z Maintain safety clearance to overhead power lines. z Only operate the machine from the driver's seat. z When switching the attachment (e.g. grab), release the pressure

from the hydraulic system.

z Do not transport persons on the machine. z Consider environmental conditions, e. g. poor visibility, wind speeds, etc. z Use the specific lifting capacity tables for that machine. z Note performance specifications. z Check that attachment points have a sufficient safe working load. z Observe signaling individual signals if they are given. z If visibility is poor, ensure that a signaling individual is used for giving

the required signs when reversing.

z Before moving onto ramps or inclines, make sure to obtain the

maximum permitted values from SENNEBOGEN.

z Position boom in direction of travel during long journeys.

860 / 05.2010

5-1

Operation - Operator´s station/cab with gallery, raising

5.2

Operator´s station/cab with gallery, raising

1 2

8*

3

9

4 5

10

6 7*

11

Emergency exit

12

1 Work lighting

7* Windscreen wiper, bottom

2 Windscreen wiper, roof

8* 24 V plug socket (connection for beacon)

3 Windscreen wiper, top 4 Front wind shield, top, adjustable

9 Emergency exit, rear window 10 Sliding door

5 Front wind shield, bottom

11 Gallery

6 Door lock and grip

12 Hammer, emergency exit

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

5-2

860 / 05.2010

Operation - Operator´s station/cab with gallery, raising

Sliding door

1 2

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

Front wind shield

3

4

Opening front wind shield: Tilt forwards. The top windscreen wiper swivels ahead with the window. Press on both buttons (4) and swivel the window ahead. The two shock absorbers hold it in position. Pull the two grips (3) on the window frame inward to close it. Ensure that the front wind shield latches in place again.

Note The front windshield with bulletproof glass cannot be opened.

860 / 05.2010

5-3

Operation - Operator´s station/cab with gallery, raising

Interior lighting

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

5

6

Washer system

The windscreen wipers are operated via the switch on the top right control panel. The container for cleaning fluid for the washer system is located behind the left front service access door. Always fill the container with window antifreeze.

Radio

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

7

8

Note More information can be obtained from the radio manufacturer.

Document jacket

5-4

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

860 / 05.2010

Operation - Operator´s station/cab with gallery, raising

5.2.1 Driver's seat CAUTION z In order to avoid danger of an accident, check that all settings are

locked in place properly before start-up.

z The setting mechanisms for the driver's seat should not be actuated

during operation.

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

of the driver's seat.

z Functionality testing should be performed at least as often as the

maintenance intervals of the vehicle.

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

Note Bolt/screw connections should be checked regularly for solid seating.

Seat jiggling may be caused by loose bolt/screw connections or other defects. If irregularities are found in the functionality of the seat (e.g. in the spring of the seat), call an authorized professional immediately to remedy the cause. Non-compliance leads to dangers for your health and increased danger of an accident.

860 / 05.2010

5-5

Operation - Operator´s station/cab with gallery, raising

Air-suspended driver's seat 6*

7*

*9

8*

11 *5 *3

10*

*4 1, 2

12

*: Optional model/special function 1 Weight adjustment 2 Height adjustment 3 Seat depth adjustment 4 Seat tilt adjustment 5 Length adjustment 6 Neck-rest 7 Seat heating 8 Disk-rest 9 Arm rests 10 Arm rest tilt 11 Backrest tilt 12 Horizontal suspension

5-6

860 / 05.2010

Operation - Operating instruments

5.3

Operating instruments

5.3.1 Overview

14 13

12 1 2 3

5 11 10 9

4 5

8 7 6

*: Optional model/special function 1 Step plates 2 Safety lever 3 Control lever, left 4 Driver´s seat 5 Control panel, next to the driver's seat 6 Control panel, right bottom (rear) 7 Control panel engine/machine 8 Air conditioning control panel 9 Control panel, top right on the ceiling

860 / 05.2010

5-7

Operation - Operating instruments

10 Control lever, right 11 Control panel, lower right 12 Panel pilot lamps, lower right 13 Sennebogen Diagnostic System 14 Additional displays (optional equipment) DANGER Risk of accident through incorrect use!

If the boom is positioned above the drive wheel, the driving actions of the machine are reversed. Proceed with utmost caution when working or when needing to travel.

5-8

860 / 05.2010

Operation - Operating instruments

5.3.2 Emergency stop (optional) Emergency stops are located z on the control panel of engine/ machine (1), z on the undercarriage (2).

The emergency stops shut down the machine immediately when actuated.

1 2

Settings: out = machine on in = machine off

860 / 05.2010

5-9

Operation - Operating instruments

5.3.3 Step plates

4a

4b

1*

2

4

3

1 Turn-cylinder ULM

4

2 Release the brake pedal lock

4a Travel, forwards

3 Brake pedal - Driving action

4b Travel, backwards

Drive pedal

* Optional

Applying the locking brake Releasing the locking brake

1

Press operational pedal (3) until the locking (2) engages.

1

Actuate the locking (2) until the service brake is (3) released.

Note For continuous use, release the locking brake and activate the safety lever (parking brake active).

5 - 10

860 / 05.2010

Operation - Operating instruments

5.3.4 Safety lever The safety lever (1) serves as a protective feature.

Safety lever released (pushed forward)

1

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

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

Activate the swing bearing holding brake by pressing the "left" switch in the right control panel (see Section 5.3.11).

Safety lever actuated (pulled back)

1

Note When safety lever is actuated z all hydraulic functions are inoperative and z the parking brake is active.

860 / 05.2010

5 - 11

Operation - Operating instruments

5.3.5 Control lever, left hand 2 1

3 4

Push buttons: 1 Horn 2 Grab, slew left 3 Grab, slew right 4 Bypass safety limit shutdown "Retract stick", if available stick and hoisting limiters are bypassed as well.

Directions of movement

Note The bypasses for the safety limit shutdown "Retract stick" are standard, "Extend stick" and "Hoist up/down" are optional.

DANGER All safety limit shutdowns in the equipment are deactivated.

5 - 12

860 / 05.2010

Operation - Operating instruments

DANGER Danger to life when bypassing the "Retract stick" safety limit shutdown!

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

Proceed with utmost caution.

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

Please also read instructions in Section 5.5.9.

860 / 05.2010

5 - 13

Operation - Operating instruments

5.3.6 Control lever, right hand 2 1

3 4

Push buttons: 1* Magnet unit OFF 2 steer left 3 steer right 4* Magnet unit ON or magnet unit ON / OFF

Directions of movement

*: Optional model / special function

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860 / 05.2010

Operation - Operating instruments

5.3.7 Additional indicators Analog hour counter

SDS

Tool Control

Generator and Magnet Unit

Auxiliary heating system

Camera

LMI

Note More information can be found in Section 5.4 and Chapter 9.

860 / 05.2010

5 - 15

Operation - Operating instruments

5.3.8 Control panel, next to the driver's seat Outrigger 1 *4

6*

*5

7*

2

3

* Optional

1 Safety lever 2 Storage compartment 3 Full outriggers lever (all outriggers are extended/retracted at the same time) 4 Single stabilizer left front 5 Single stabilizer left rear 6 Single stabilizer right front 7 Single stabilizer right rear

5 - 16

860 / 05.2010

Operation - Operating instruments

5.3.9 Control panel engine/machine

1* 2 3 4 5* 6* 7 8

1 Emergency stop 2 RPM adjustment 3 Basic lighting 0 = Light off 1 = Auxiliary light 2 = Low beam 3 = High beam 4 Ignition lock - start engine P = Enable the refueling pump 0 = Ignition OFF I = Ignition ON (switch off ignition after 20 minutes!)

II = Start engine 5 Emergency lowering - LMI 6 Emergency lowering key switch - LMI 7 24V plug socket 8 12V plug socket *: Optional model/special function

860 / 05.2010

5 - 17

Operation - Operating instruments

Emergency lowering LMI

With the key switch emergency lowering LMI the load moment indicator can be bypassed.

This could be necessary to bring the machine out of a danger area if this is not possible using load-reducing functions (retract stick, boom down).

DANGER Risk of tipping!

Key switch Emergency lowering should only be used in extreme emergencies!

Note The load moment indicator (LMI) can be bypassed for 3 seconds only.

After a waiting time of 30 seconds, the load moment indicator (LMI) can be bypassed again for another 3 seconds.

Note Bypassing the load moment indicator (LMI) is performed only under full responsibility of the machine operator.

5 - 18

1

Press button (5) in the right control panel.

2

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

This bypasses the load moment indicator (LMI).

3

By releasing the key switch (6), the load moment indicator (LMI) is activated again.

860 / 05.2010

Operation - Operating instruments

5.3.10 Panel pilot lamps, lower right

1*

6*

2

7

3*

8*

4*

9

5*

1 Travel, forwards 2 Direction indicator left, right/hazard lights 3 Fan reversal 4 Magnet unit inspection 5 Steering direction changeover 6 Travel, reverse 7 High beam 8 Central lubrication 9 180° displacement *: Optional model/special function

860 / 05.2010

5 - 19

Operation - Operating instruments

Fan reversal

Controller position

Pilot lamp

1 (right, single fan reversal)

blinks or lights up

0 (middle, no fan reversal)

does not light up

2 (left, fan reversal every 30 min.)

blinks or lights up

Note The fan reversal pilot lamp (3) provides information on the status of the fan drive controller.

Travel forwards

Lamp illuminated with selected travel direction - Forward.

Travel reverse

Lamp illuminated with selected travel direction - Reverse.

Magnet unit

Steering direction changeover

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

180° displacement

Lights up with activated floating axle control if the upper structure is in 0°- or 180°-position (+/- 5°) to the undercarriage.

High beam

5 - 20

Lights up with magnet unit switched on.

Illuminated when high beam is switched on.

860 / 05.2010

Operation - Operating instruments

Central lubrication

860 / 05.2010

Cause

Remedy

Fault in the central lubrication system

Correct fault (See manufacturer's instructions).

Container of the central lubrication system is empty

Fill container.

5 - 21

Operation - Operating instruments

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

1 2 3 4 5** 6** 7*/** 8*/** 9

10*

*: Optional model/special function **: When operating, release switch

1 Pilot lamps for CUMMINS engine 2 Swing bearing holding brake 3 Left/right direction indicator 4 Floating axle control 5 Cab "Up" 6 Cab "Down"

5 - 22

860 / 05.2010

Operation - Operating instruments

7 Cab "Off" 8 Cab "On" 9 Fan reversal 10 Diesel filter heating Off / On

860 / 05.2010

5 - 23

Operation - Operating instruments

Pilot lamps for CUMMINS engine

Swing bearing holding brake

The pilot lamps for CUMMINS engine indicate a fault in the drive motor.

Observe the instructions of the engine manufacturer for further information.

The swing bearing holding brake is a holding brake for the upper structure but is not a service or working brake.

A symbol lights up in the SDS when switched on.

WARNUNG Never slew the upper structure when the slewing gear holding brake is applied!

Fan reversal

The fan reversal is used to clean the cooling fins of the combination cooler. This requires that the switch is pressed as described below.

Loose contamination on the cooling fins is blown out.

Controller position

Feature

right

Jog function, single fan reversal for 30 seconds

centered

Neutral position, no fan reversal

left (switch engages)

Automatic function, every 30 minutes fan reversal for 30 seconds

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

Diesel filter heating Off/On

5 - 24

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

860 / 05.2010

Operation - Operating instruments

Floating axle control

The front axle is hung floating, the floating axle can be used to level out unevenness in the track.

Note The floating axle control minimizes the risk of tipping. The boom can be found above both the front and rear axles (upper structure parallel to the lower structure / 0° or 180° position).

0° position

Controller position

180° position

Conditions

Status

z 0° position

The following lights up

or 180° position – Symbol lights up

Floating axle control activated

z Driving the machine z No 0° position

or 180° position

– Floating axle free The following lights up

– Symbol does not light up Floating axle control activated

– Floating axle locked or z Machine is not driven

860 / 05.2010

5 - 25

Operation - Operating instruments

Controller position

Conditions

Status Control lamp does not light up

Floating axle control deactivated

5 - 26

– Floating axle free

860 / 05.2010

Operation - Operating instruments

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

1

2

3

4

5 6

4

5

1

Rotary selection switch: blower speeds

2

Rotary selection switch: air distribution

3

Temperature regulator

4

Combination switch: Outside temperature indicator, Air conditioning on/off

5

Outside/recirculating air switch

6

Temperature indication (°C or °F)

Note The air conditioning can be operated with outside air or recirculating air.

Note To activate the heating or air conditioning, press the air conditioning switch (4) twice!

860 / 05.2010

5 - 27

Operation - Operating instruments

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

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

Outside air mode

Recirculating air mode

Switching on the air conditioning system

When windows are misted, to dehumidify the cab.

Faster warm-up of cab and higher limit temperature.

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

1

Start drive engine.

2

Switch on fan (1) on right control panel.

3

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

4

Press switch for air conditioning (4) on the control panel

z Press 1x briefly: current status is displayed (heating or cooling) z Press 2 x: The mode will be changed

5

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

Note Switch on air conditioning system regularly. This greatly contributes to the unit being ready for operation.

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

Changing temperature indication °C/°F

5 - 28

1

Press the combination switch (5) for more than 5 sec.

2

Temperature indication changes (°C <--> °F).

860 / 05.2010

Operation - Operating instruments

5.3.13 Control panel, right bottom (rear) Auxiliary heating system

The machine is equipped with an engine-independent heater for the z preheating of engine and cab or z only cab preheating

(depending on design).

Note The battery capacity can be used by operating the heater.

1

2

3

4

5 1 Reverse push button

4

OK button

2 Forward push button

5

Display

3 Activation button Optional model / special function Note More information can be found in Chapter 9.

860 / 05.2010

5 - 29

Operation - Operating instruments

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

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

*: Optional model/special function 1 Work lighting - cab 2 Work lighting - upper structure 3 Work lighting - equipment 4 Windscreen wiper - front wind shield 5 Washer system - front wind shield 6 Windscreen wiper - skylight

5 - 30

860 / 05.2010

Operation - Operating instruments

7 Washer system - skylight 8 Windscreen wiper - front wind shield, below 9 Beacon 10 Flashing warning lights 11 ECO switch 12 Automatic idling 13 Slewing ring lubrication 14 Central lubrication

860 / 05.2010

5 - 31

Operation - Operating instruments

ECO switch

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

Note When working with magnet unit, turn off the ECO switching operation!

Automatic idling

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

Note Automatic idling remains deactivated as long as the magnet unit is on.

Slewing ring lubrication

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

Central lubrication

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

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

5 - 32

860 / 05.2010

Operation - Operating instruments

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

21*

22**

*: Optional model/special function **: When operating, release switch

15 Floating boom setting 16 Grab function Off/On 17 Grab control Off/On 18 Overload Off/On 19 Magnet unit Off/On 20 Auxiliary limiting boom, stick Off/On 21 Steering direction reversal 22 Load limit sensing control (GLR)

860 / 05.2010

5 - 33

Operation - Operating instruments

Floating boom setting

The compact boom is raised at low speed along with the "Close grab" function. This prevents the grab from scratching on the ground.

Note Instructions on working with activated floating setting are given in Section 5.5.10.

Grab control

The function "Grab control" can control the pressure for the function "Grab close".

A pressure reduction for "Grab close" is only active if the work maneuvers "Grab close" and "Slew upper structure" or "Grab close" and "Hoist up" are carried out simultaneously. With the grab closed, no loss in speed occurs with work maneuvers "Slew upper structure" and "Hoist up" this way.

– Grab symbol always lights up – If switch is pressed, green LED also lights up

5 - 34

Grab control

Closing pressure for grab

Slewing speed for upper structure

Hoisting speed Compact boom

activated

Grab closes with max. pressure. Actuating the "Hoist Up" or "Swivel" function as well decreases the pressure for "Grab close" so that no speed loss occurs in the work maneuvers.

Fast

Fast

deactivated

Grab closes with maximum pressure.

Actuating the "Hoist Up" or "Swivel" function may cause speed loss in the work maneuvers in the worst case scenario.

Slow

Slow

860 / 05.2010

Operation - Operating instruments

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

Grab function

When the grab function is switched off, accidentally actuating the functions "Grab open/Grab close" is prevented in magnetic plate mode.

Overload

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

Magnet unit

Auxiliary limiting

860 / 05.2010

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

Use the Auxiliary limiting switch to activate/deactivate the optional auxiliary limiting for "Hoist Up" and/or "Extend stick" (Section 5.5.8).

This is important when e.g. working with height limitations.

5 - 35

Operation - Operating instruments

Steering direction reversal

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

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

DANGER Danger of accident if the steering direction reversal is deactivated (lamp does not light up in the switch)!

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

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

GLR

5 - 36

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

The machine can be further operated with minimal loss of power.

860 / 05.2010

Operation - Operating instruments

5.3.15 SENNEBOGEN Diagnostic System (SDS)

A B C

A Display

C Indicator and warning lights

B Button panel

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

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

Self test

The SDS carries out a self test after the ignition is switched on. All LEDs light up. The sensors are checked. Following this, the SDS is ready for operation.

If the SDS detects a fault, the fault condition in indicated on the display and via LEDs. Arrange for faults to be corrected immediately through SENNEBOGEN Customer Service.

Cleaning

860 / 05.2010

Do not clean the SDS with cleaning agents containing alcohol or solvents!

Otherwise, the plastic surface will become brittle.

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Operation - Operating instruments

Button panel (B)

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

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

1

2

3

4

5

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

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Operation - Operating instruments

Display (A)

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

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

These are located under the button panel.

Warning lights

Symbol

Meaning Air filter - soiling display

Soiling displays: Hydraulic oil return filter HydroClean Superfine filtration system Hydraulic oil auxiliary control filter Refrigerant level

Hydraulic tank flap (optional)

Hydraulic oil level

ATTENTION symbol

Pilot lamps

Symbol

Meaning Parking brake - accumulator pressure

Swing bearing holding brake

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Operation - Operating instruments

Note The SDS screen is equipped with pictograms. These lamps light up and can be selected depending on the operating status.

Pictograms

Pictogram

Meaning Refrigerant temperature

Diesel fuel level

Engine oil pressure

Engine rpm

Hydraulic oil temperature

Battery voltage

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

Date

Date/time setting and in combination with error memory

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Operation - Operating instruments

Pictogram

Meaning There are error messages

Error memory

Number of error messages Confirm (ENTER)

ESCAPE

Engine

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Operation - Operating instruments

Sequence overview

4 sec.

000.0h

4.02

4 sec.

4 sec.

000.0h

000.0h

000.0h

4 sec.

5 sec.

+ SPN

5 sec.

5 sec.

SPN

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Operation - Operating instruments

Start-up screen 1

2

4.02

Automatic changeover after 4 seconds

3

4

to screen 7

5

Screen 1

Refrigerant temperature

6 7

Diesel fuel level

8

1 SENNEBOGEN logo

5 Daily hours of operation

2 Software version (example)

6 Refrigerant temperature

3 Time of day

7 Warning threshold refrigerant temperature too high

4 Date

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8 Diesel fuel level

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Operation - Operating instruments

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

Screen 2

Engine oil pressure

1 2 3

Engine rpm

Screen 3

Hydraulic oil temperature

4 5 6

Battery voltage

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1 Engine oil pressure

4 Hydraulic oil temperature

2 Warning threshold Engine oil too low

5 Warning threshold Hydraulic oil temperature oil too high

3 Engine speed

6 Battery voltage

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Operation - Operating instruments

or:

Screen 4

1

Daily operating hours counter

2

1 Daily operating hours counter ON

3

2 Daily hours of operation 3 Daily operating hours counter OFF Note Switching to screen 4 can be done at any time from screens 1, 2 and 3.

This is done by pressing the "Hourglass button".

Set daily hours of operation counter to 0

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

Stopping or restarting the daily hours of operation counter

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

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Operation - Operating instruments

Screen 5

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

Set time of day

Time of day

5 sec.

'Set date'

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Operation - Operating instruments

Setting the date

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

Screen 5

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Operation - Operating instruments

Screen 6

Error messages

Engine error code

Machine error code

2

1

3

SPN

5 sec.

4

1 2 3 4 5

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7 5 6 Total error messages Selected error message Error mess. not ack.

Error mess. ack.

Error detected: Time of day

SPN

6 7 8 9

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

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Operation - Operating instruments

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

ATTENTION! To allocate the error messages and the respective diagnostic codes properly, read the following diagnostic code list. Call SENNEBOGEN Customer Service if you have questions and to correct faults.

Note A severe error is indicated by the symbol with dark background, pulsating buzzer and an illuminated red "!" warning symbol. The buzzer will only stop if the fault is acknowledged. The symbol will no longer have a dark background but it will flash. As long as the fault is active, the red warning sign will light up on the right, under the button panel.

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

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

Other diagnostics codes (flash codes) and possible disruptive effects in engine power are located in the corresponding chapter of the operating instructions for the individual engine manufacturer.

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

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Operation - Operating instruments

List of possible error codes

5 - 50

101, 102 or 103

Refrigerant temperature

111, 112 or 113

Engine oil pressure

121, 122 or 123

Diesel fill level

131, 132 or 133

Hydraulic oil temperature

141, 142 or 143

Battery voltage

151

Air filter

161

Hydraulic oil return filter

171

HydroClean superfine filtration system

181

Hydraulic oil auxiliary control filter

191

Refrigerant level

201

Hydraulic oil gate

211

Hydraulic oil level

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Operation - Operating instruments

Error memory

+ 5 sec.

1

2

3

4 5 6 1 Error memory

4 Error detected

2 Number of stored errors (10)

5 Error acknowledged

3 Selected error (7)

6 Error cleared

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

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

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

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Operation - Operating instruments

Screen 7 1

Perform basic setting

2 3

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

5 sec.

Temperature

Pressure

'Change date'

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Operation - Operating instruments

Date

Start-up screen

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Operation - Operating instruments

Indicator and warning lights (C)

The two pilot lamps provide information on the current operating status (swing bearing holding brake closed or accumulator pressure for the parking brake built up).

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

The warning lights indicate two different priorities: Priority 1: Switch off machine immediately according to Section 4.8.

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

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

1

2

3

5

4

a b

10 9

8

7

6

Warning lights:

8 Hydraulic tank flap (optional)

1 Air filter - soiling display

10 Refrigerant level

Replace indicators - hydraulic system 2 Return filter 3 HydroClean 4 Auxiliary control filter 5 ATTENTION - General (in combination with symbols from the screen as well)

a Priority 2 b Priority 1 Pilot lamps: 6 Parking break accumulator pressure 9 Swing bearing holding brake

7 Hydraulic oil level

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Operation - Operating instruments

Error displays on the screen Symbol flashes, buzzer sounds and red 'Attention' lights up

Symbol flashes, buzzer sounds and red 'Attention' lights up

Symbol flashes, buzzer sounds and red 'Attention' lights up

860 / 05.2010

Cause

Remedy

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

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

Cooling fins on hydraulic oil cooler soiled

– Clean cooling fins on oil cooling.

Hydraulic oil level too low

– Check oil level acc. to maintenance instructions.

– Add hydraulic oil, if required.

Cause

Remedy

Insufficient fuel in tank

– Refuel machine acc. to Section 5.6.

Cause

Remedy

Engine overheating

– Run engine at idling speed.

Cooling fins on engine oil cooler soiled

– Clean cooling fins on oil cooling.

Fan drive loose or defective

– Tighten fan drive; replace if necessary.

Refrigerant level too low

– Add refrigerant according to maintenance instructions.

Engine switched off without cooling phase.

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

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Operation - Operating instruments

Symbol flashes, buzzer sounds and red 'Attention' lights up

Symbol flashes, buzzer sounds and red 'Attention' lights up

SDS buffer battery

Cause

Remedy

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

– Shut down engine immediately.

– Check engine oil level acc. to maintenance instructions.

– Add engine oil if necessary.

– Notify SENNEBOGEN Customer Service in the event of a re-occurrence

Cause

Remedy

Battery charge too weak

– Check battery charge; recharge batteries or replace if necessary.

– Check battery connections, tighten terminals if necessary.

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

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

Voltage display <= 2.50V Insufficient battery charge!

Use new battery! System data can no longer be stored!

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

Use new battery! System data are no longer stored.

Note Only use a battery from an authorized SENNEBOGEN - partner of your choice.

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Operation - Operating instruments

Warning and pilot lamps

lights up, buzzer sounds

Cause

Remedy

Refrigerant level too low

– Add refrigerant.

Lights up while engine is running

Cause

Remedy

Accumulator pressure too low

– Have a hydraulics specialist check the hydraulic system.

lights up, buzzer sounds

Cause

Remedy

Hydraulic oil level too low

– Add hydraulic oil

lights up

Cause

Remedy

Swing bearing holding brake applied

– Deactivate swing bearing holding brake

Cause

Remedy

Return filter is plugged

– Check return filter; if necessary, replace acc. to maintenance instructions.

Cause

Remedy

HydroClean Superfine filter is plugged

– HydroClean Check superfine filter, replace if necessary according to maintenance instructions.

lights up

lights up

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Operation - Operating instruments

lights up

lights up

Cause

Remedy

Auxiliary control filter is plugged

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

Cause

Remedy

Air filter contaminated

– Clean filter acc. to maintenance instructions.

– If necessary, replace filter.

Note The indicator and warning lamp film overlay cannot be replaced.

It is possible however to print the film overlay for the three open fields individually with a laser printer. Remove the entire front plate and pull or push the fields out or in.

Note The internal battery for the SDS has a minimum life-span of three years.

However, in practice, testing shows periods of up to 10 years.

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Operation - Additional displays (optional equipment)

5.4

Additional displays (optional equipment)

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

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

CAUTION Before the work application, select the rating for the respective tool!

4 3

1

2

Selecting the rating 1

Start engine acc. to Section 4.6.3.

2

Loosening the safety lever (see Section 5.3.4).

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

3

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Press buttons (1) and (2) and select desired rating.

The selected tool (rating) appears in the display (3).

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Operation - Additional displays (optional equipment)

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

Note If no button is pressed for a longer period of time, the button lock is activated. The button lock can be triggered by simultaneously pressing buttons (+) and (-).

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

Note More information can be found in Chapter 9.

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Operation - Additional displays (optional equipment)

5.4.2 Load moment indicator (LMI)

or (depending on design)

The machine is equipped with a load moment indicator (LMI) as a load limiting device.

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

Note More information can be found in Chapter 9.

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Operation - Additional displays (optional equipment)

5.4.3 Generator and magnet unit Note Automatic idling remains deactivated as long as the magnet unit is on.

Note More information can be found in Chapter 9.

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Operation - Additional displays (optional equipment)

5.4.4 Camera/monitor

Note More information can be found in Chapter 9.

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Operation - Additional displays (optional equipment)

5.4.5 Low-temperature package Auxiliary heating system

The machine is equipped with an engine-independent heating device for the z preheating of engine and cab or z only cab preheating

(depending on design).

Note The battery capacity can be used by operating the heater.

1

2

3

4

5 1 Reverse push button

4

OK button

2 Forward push button

5

Display

3 Activation button

Note More information can be found in Chapter 9.

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Operation - Additional displays (optional equipment)

Heating system for water separator

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

1

2

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

860 / 05.2010

1

Start engine acc. to Section 4.6.3.

2

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

– The pilot lamp in switch (2) lights up until the fuel has achieved operating temperature (=thermostat).

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Operation - Additional displays (optional equipment)

Hydraulic oil pre-heater

The hydraulic oil pre-heater (1) is attached to the hydraulic tank. The warm-up period is significantly reduced by the hydraulic oil pre-heater.

2

1

3

To activate the hydraulic oil pre-heater, the plug socket (3) in the left storage space of the machine must be connected to a power source (230 V).

Only the plug and not the cable for the power supply to the socket are supplied by Sennebogen!

The cable may only be connected by trained specialist personnel!

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

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

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

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

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Operation - Additional displays (optional equipment)

Battery heater

The machine is equipped with a battery heater(1).

2

1 To activate the battery heater, the plug socket (2) in the left storage space of the machine must be connected to a power source (230 V).

Only the plug and not the cable for the power supply to the socket are supplied by Sennebogen!

The cable may only be connected by trained specialist personnel!

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

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Operation - Work application

5.5

Work application

5.5.1 Safety instructions DANGER z Read Chapter 1 SAFETY. Before start-up, carry out checks according to Chapter 4.4. z Persons working on or with the machine must be trained or

instructed for that purpose.

Operation and work application may only be carried out by trained specialists.

z Proceed with extreme caution whenever you bypass the limit position

sensor for the arm.

z Ensure that there is no one in the danger area. z Maintain safety clearance to overhead power lines. z Only operate the machine from the driver's seat. z Do not transport persons on the machine. z Consider environmental conditions, e. g. poor visibility, wind speeds, etc. z Use the specific lifting capacity table for that machine. z Note performance specifications. z Check that attachment points have a sufficient safe working load. z Observe signaling individual signals if they are given. z Never allow the machine to roll with the ignition switched off.

When the engine is not running, there is no power-assisted steering.

z Position boom in direction of travel during long journeys. z Before leaving the cab:

– Position the machine on firm subgrade, if necessary set back from the edge of the excavation – Lower attached loads – Secure equipment – Pull safety lever back – Chock tires/undercarriage – Switch off engine – Lock cab, show warning lights if necessary – Lock the floating axle.

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Operation - Work application

5.5.2 Move the cab Safety instructions DANGER Danger of accident due to raised cab!

Check cab suspension, bolt, and bolt/screw connections daily! z Move the machine only with the cab lowered and retracted and the

swing bearing holding brake engaged.

z Exit the cab only when it is in the completely lowered and retracted

position.

z Maneuver the cab only when the undercarriage supports are deployed! z Keep the cab doors closed. z Fasten seat belt (optional) in accordance with Section 4.6.2. z Maneuvering the cab is prohibited when individuals and/or objects

are on the gallery (operator catwalk).

DANGER Danger of death from shearing or crushing!

Ensure that there is no one within the danger area of cab suspension.

The danger area is the area z on/under the cab, z on/under the mechanical cab suspension.

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Operation - Work application

Move the cab

1 2 3* 4*

*: Optional model/special function

Elevating/ lowering cab

1

Press safety lever (see Section 5.3.4) forwards.

2

Switch the machine on as described in Section 4.6.

3

Press rocker switch (1).

The cab is raised (cab up).

4

Press rocker switch (2).

The cab is lowered (cab down).

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

Stop the cab approx. 10 cm before the uppermost/foremost limit.

This provides optimum damping characteristics and pleasant working conditions in the cab.

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Operation - Work application

Cab extend/move inward (optional)

860 / 05.2010

1

Press safety lever (see Section 5.3.4) forwards.

2

Switch the machine on as described in Section 4.6.

3

Press rocker switch (3*).

The cab is extended (cab out).

4

Press rocker switch (4*).

The cab is retracted (cab in).

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Operation - Work application

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

Location: To the right of the right-hand control lever. This is the same switch used to "cab down".

Necessary, for instance , in case of a problem with the drive system.

z Emergency lowering (outside the cab)

Location: Below the front left service access door.

Necessary in case the machine operator has an emergency due to a health condition.

DANGER Danger of death from shearing or crushing!

Ensure that there is no one within the danger area of cab suspension.

The danger area is the area z on/under the cab, z on/under the mechanical cab suspension.

Emergency lowering in the cab

2

1

Press rocker switch (2).

– The cab lowers slowly.

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

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

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Operation - Work application

Emergency lowering outside the cab

2

illustrated = cab elevated 1

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

2

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

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

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Operation - Work application

5.5.4 Driving machine DANGER Danger of accident from improper operation!

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

Driving with suspended load

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

Keep loads as close as possible to the ground when moving.

z Always position boom lengthwise to undercarriage. z Only carry 50 % of the permitted safe working load. z Mast (optional) Only drive the machine lengthwise and without load. z Only drive on even ground with sufficient load-bearing capacity. z Reduce pendulum movements of load by sensitive driving. z Negotiate corners with as wide a radius as possible.

DANGER Risk of accident from improper operation!

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

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

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

1

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Operation - Work application

1

2

4 3

Driving

1

Actuate and lock the service brake (1).

2

Start engine (2).

3

Push safety lever (3) forward.

4

Retract stabilizers (4) if necessary.

6

5

860 / 05.2010

Release the floating axle (6) if necessary.

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Operation - Work application

7 8 9 10

6

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

7

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

1

2

Push buttons: 1 steer left

2 steer right

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

5 - 76

8

Slow the machine via the service brake (8).

9

Switch off machine according to Section 4.8.

10

Always apply the service brake (8) when leaving!

11

Pull back the safety lever (10).

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Operation - Work application

5.5.5 Stabilizing the machine The machine is stabilized on an uneven surface by using the claw support.

This increases the stability. For lifting capacities see Chapter 3.6.1.

CAUTION Position the supports on a firm even foundation.

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

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

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

correct

incorrect

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Operation - Work application

a

1 b Actuation of full outriggers: 1 Outrigger lever a forward = extend b back = move inward

Extending full outriggers

1

Applying the parking and service brakes.

2

Start engine acc. to Section 4.6.3.

3

Loosening the safety lever (see Section 5.3.4).

4

Lock the floating axle with the switch on the front right of the control panel.

5

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

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

Extend single stabilizer

5 - 78

1

Applying the parking and service brakes.

2

Start engine acc. to Section 4.6.3.

860 / 05.2010

Operation - Work application

a

1 b 3

4

2

5

Actuation of full outriggers:

Single actuation for stabilizers:

1 Outrigger lever

2 left rear

a forward = extend

3 left front

b back = move inward

4 right front 5 right rear

3

Loosening the safety lever (see Section 5.3.4).

4

Lock the floating axle with the switch on the front right of the control panel.

5

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

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

– Proceed in the same way for the other three fork hooks.

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Operation - Work application

Move outrigger inward

1

Applying the parking and service brakes.

2

Start engine acc. to Section 4.6.3.

3

Loosening the safety lever (see Section 5.3.4).

4

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

5

Check that all four outriggers are retracted completely.

1 b Actuation of full outriggers: 1 Outrigger lever b back = move inward

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Operation - Work application

5.5.6 Upper structure slewing/deceleration The upper structure is slewed using the left control lever.

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

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

c

1

2

d

1 Switch for swing bearing holding brake 2 Motions of left control lever c Slew upper structure, left d Slew upper structure, right *: Optional model / special function

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Operation - Work application

Note In order to slew the upper structure, the ignition must be switched on, the safety lever must be released (pushed forwards) and the swing bearing holding brake switch "right" must be pressed.

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

Slewing speed

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

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

Stopping swinging movement (deceleration)

Swing bearing holding brake

1

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

The upper structure is hydraulically braked. The swinging movement gradually stops. NOTE: Counter-steering with the control lever increases the braking process.

OR optional: Actuate the swing bearing holding brake step plate (2).

The upper structure is braked hydro-dynamically.

The swing bearing holding brake is not an operational brake for decelerating the upper structure. The swing bearing holding brake serves exclusively as a parking and holding brake when the upper structure is at rest.

The upper structure must have stopped swinging completely before the swing bearing holding brake is applied.

WARNING If the swing bearing holding brake is used to decelerate the upper structure, serious damage will be caused to the brake or the slewing gear. This damage can be of the following nature: z Slackened braking effect due to clutch plate damage z Irreparable damage to the brake or other components z Irreparable damage to the swing bearing

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

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Operation - Work application

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

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

Activate swing bearing holding brake

Press the switch (1) "left" in the front right control panel.

The swing bearing holding brake is activated, the indicator lamp in the switch does not light up. The red indicator symbol also illuminates in the SDS.

Deactivate/release the swing bearing holding brake

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

The swing bearing holding brake is released. The green LED lights up in the switch and the red pilot lamp in the SDS goes out.

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Operation - Work application

5.5.7 Hoisting / lowering loads Follow the following safety instructions: DANGER z Danger of accident from suspended loads!

Always lower the load when work is interrupted.

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

machine!

z Attachments (e. g. grab) and load elements can rock. Proceed with

extreme caution.

z Observe danger area.

The load is hoisted/lowered using the left and/or the right control lever.

A a

B

Stick speed

b

Control lever, left-hand

Control lever, right

Directions of movement:

Directions of movement

A Hoist load (extend stick)

a Lower load (hoist down)

B Lower load (retract stick)

b Hoist load (hoist up)

The stick speed depends on the: z speed of the drive engine z distance the left control lever is moved z load on end of stick.

Lift speed

The hoisting speed depends on the: z speed of the drive engine z deflection of the right control lever z load on end of stick.

5 - 84

860 / 05.2010

Operation - Work application

5.5.8 Limit shutdown equipment The limit shutdown prevents the hydraulic cylinders from striking against the end stops.

DANGER Never change the factory-set position of the limit shutdowns!

Adjusting the setting may be carried out only by SENNEBOGEN Customer Service or an authorized SENNEBOGEN Service Partner!

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

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

Safety limit position sensor for "Arm in"

The safety limit shutdown "retract stick" is set at the factory as follows: z Retract stick: stick (without attachment) approx. 2.5 m in front of

lowered cab

1 2 3 2.5m

1 Compact boom

3 Grabbing stick

2 Sensor element

860 / 05.2010

5 - 85

Operation - Work application

DANGER Danger to life if the safety limit shutdown for "Arm in" is set incorrectly!

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

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

Auxiliary limiting

With the optional Auxiliary limiting, you can limit the "Extend stick" or "Hoist up". This is useful z near power lines (see Section 1.9) z in buildings with limited headroom z under bridges z when working with attachments not supplied by SENNEBOGEN.

Note The following safety limit shutdowns can be used optionally: z "Extend stick" z "Boom up" (Hoist up) z "Boom down" (Hoist down)

Note The optional Auxiliary limiting cannot be bypassed.

5 - 86

860 / 05.2010

Operation - Work application

Auxiliary limiting - hoist

1 Auxiliary limiting "Hoist down" (optional) 2 Limit shutdown - Hoist down 3 Auxiliary limiting "Hoist up" (optional) 4 Limit shutdown - Hoist up 1 2 3

4

DANGER Never change the factory-set position of the limit shutdown (2, 4)!

Adjusting the setting may be carried out only by SENNEBOGEN Customer Service or an authorized SENNEBOGEN Service Partner!

With auxiliary limiting installation - Set hoist as follows: 1

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

2

Loosen the hexagonal nuts for auxiliary limiting (1) or (3).

3

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

4

Tighten the hexagonal nuts for the auxiliary limiting (1) or (3).

5

Switch the flip switch Auxiliary limiting on at the control panel.

6

Check setting carefully and repeat if necessary.

Note The optional Auxiliary limiting (1,3) cannot be bypassed.

860 / 05.2010

5 - 87

Operation - Work application

Auxiliary limiting - Extend stick

5

6

5 Auxiliary limiting "extend stick" (optional) 6 Limit shutdown "extend stick" (optional) DANGER Never change the factory-set position of the limit shutdown (6)!

Adjusting the setting may be carried out only by SENNEBOGEN Customer Service or an authorized SENNEBOGEN Service Partner!

With auxiliary limiting installation - Set stick as follows: 1

Raise the stick carefully to just below the maximum height limit (maintain safety clearance!).

2

Loosen the hexagonal nuts for the auxiliary limiting (5).

3

Adjust Auxiliary limiting (5) until sensors respond (LED on sensor goes out).

4

Tighten the hexagonal nuts for the Auxiliary limiting (5).

5

Switch the flip switch Auxiliary limiting on at the control panel.

6

Check setting carefully and repeat if necessary.

Note The optional Auxiliary limiting (5) cannot be bypassed.

5 - 88

860 / 05.2010

Operation - Work application

5.5.9 Bypassing the safety limit shutdown In exceptional circumstances it may be necessary to move beyond the safety limit shutdown (bypass safety limit shutdown).

Note The optional Auxiliary limiting cannot be bypassed.

1 2

1 Push button 2 Control lever, left DANGER Danger to life through bypassing safety limit shutdown!

860 / 05.2010

1

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

2

Move the control lever in the respective direction with extra care depending on the work function (retract/extend stick, hoist up/down). See also Section 5.3.5 and Section 5.3.6.

5 - 89

Operation - Work application

5.5.10 Working with the grab Follow the following safety instructions: WARNING z Danger of accident from suspended loads!

Always lower the load when work is interrupted.

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

of the machine!

z Attachments (e. g. grab) and load elements can rock. Proceed with

extreme caution.

z Observe danger area.

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

c

Grab motions

Directions of movement:

1 slewing, left

c Close grab

2 slewing, right

d Open grab 1,2

Note

5 - 90

c,d

860 / 05.2010

Operation - Work application

When the floating setting is actuated fill the grabber as follows:

860 / 05.2010

1

Carefully lower boom with open grabber, until the grabber is lying on the loading material.

2

Lower boom while closing the grab This allows filling to take place even while the subgrade is moving (e.g. ship).

5 - 91

Operation - Work application

5.5.11 Operation with generator and magnet unit (special function) Follow the following safety instructions: DANGER z Risk to life!

Danger of accident from suspended load!

If the magnet unit fails, the load will drop.

Always lower the load when work is interrupted.

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

properly.

z Ensure that automatic idling is deactivated. z During operation, dangerous voltages can occur. z Parts of the generator can become very hot even after operation. z Inserting or removing plugged connections during operation

is not permitted.

z Assembly/start-up of the generator as well as maintenance and

service work on the magnet unit are to be performed only by authorized and qualified specialists.

z Before using the magnet unit, read the operating instructions. z Use permitted accessories only. For more information, please

contact SENNEBOGEN Customer Service.

z Operation is only allowed with magnet plates: other applications are

unauthorized.

z Observe operating data. z Cleaning with a high-pressure washer (steam cleaner) is not allowed. z The openings for the condensation vent must be at the lowest point. z Observe further safety guidelines. z No changes may be made to the generator (e. g. location, drive type).

Note Deactivate the ECO switching operation when working with the magnet unit (see Section 5.3.14)!

5 - 92

860 / 05.2010

Operation - Work application

Operation 1

1

Start engine acc. to Section 4.6.3.

2

Set the RPM adjustment (1) on the right rear control panel to maximum.

3

Set the magnet according to the load material.

WARNING Ensure that the permitted load limits are not exceeded.

3

2

4

Switching on the magnet unit: – Actuate the switch on the upper right control panel.

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

5

Depositing the load: – Press push button (2) or *(3). * Customer-specific switch allocation!

6

Switch off the magnet unit.

– Actuate the switch on the control panel.

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

860 / 05.2010

5 - 93

Operation - Work application

Note Automatic idling remains deactivated as long as the magnet unit is on.

4

Note More information for the control device (4) can be found in Chapter 9.

5 - 94

860 / 05.2010

Operation - Refueling the machine

5.6

Refueling the machine

The machine can be refueled in two ways: z Manually z Using a refueling pump

DANGER z Fuel is hazardous to the health and easily ignitable.

Smoking and any type of open flame are strictly forbidden. z Position the machine on a firm, even subgrade. z Only refuel when engine is shut down! z Fuel must not be allowed to seep into the ground or waterways.

Always ensure that fuel does not overflow when refueling.

z Before filling, the fluid level in the tank must be determined, and thus

how much more fuel the tank can hold.

z When refueling from a tank-truck or trailer, the following applies:

The maximum filling speed is 200 l/min. (52 U.S.GPM), otherwise, the fuel will overflow.

z The filling procedure must be monitored at all times, no matter how

the filling is done.

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

Manually

1

Deposit attached loads and boom on the ground.

2

Shut down engine.

1 2 4

860 / 05.2010

3

5 - 95

Operation - Refueling the machine

using a refueling pump

3

Open left rear service access door.

4

Open cover (1) of filler strainer.

5

Clean strainer.

6

Insert funnel in filler strainer.

7

Carefully pour in fuel through the funnel.

8

Replace cap (1) and close side doors.

1

Deposit attached loads and boom on the ground.

2

Shut down engine.

3

Place the key switch in the "P" position.

4

Open left rear service access door.

5

Open the cap (1) on the filler strainer.

This allows the air in the fuel tank to escape.

DANGER If the cap is not open, excess pressure can build up in the tank while it is being filled. The tank can become deformed or can burst and potentially cause damage to property or injure personnel. Spilled fuel also causes environmental damage.

6

Insert refueling hose (4) in the external fuel tank.

Note Risk of cavitation!

Ensure that the maximum suction height of 3 m (3.28 ft) is not exceeded.

7

Use the green button (2) to switch on the refueling pump.

The tank fills automatically.

CAUTION Ensure that the pump does not run dry (> 30 s).

If necessary, use the red button (3) to switch off the refueling pump to prevent damage.

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860 / 05.2010

Operation - Refueling the machine

8

Observe the inspection glass on the fuel tank to monitor the fuel level.

Use the red button (3) to switch off the pump as soon as the tank is full.

9

Remove the refueling hose (4) from the external fuel tank and stow.

10

Re-close cover (1) of filler strainer.

11

Close service access door again.

Note Check the following points if the refueling pump does not start after approx. 5 seconds:

860 / 05.2010

1

Is the battery charged?

2

Are all fuses in order?

3

Is the suction side free of leaks?

4

Is the maximum suction height 3 m or less?

5 - 97

Operation - Refueling the machine

5 - 98

860 / 05.2010

Transport - Safety instructions

6 Preliminary tasks

Transport

Transport the machine using a flatbed trailer. Carry out the following preliminary tasks: z Select a suitable transport vehicle.

Note dimensions (Section 6.2) and weights (Section 6.3) of the machine.

z Clean machine. z Place the boom and stick in the transport position. z Lock upper structure and undercarriage according to Section 6.4. z Secure the outriggers in accordance with instructions. z If necessary, take down attachments.

6.1 Safety instructions WARNING z In Germany: loading and transport work is only to be carried out by authorized specialist personnel in accordance with VBG 40, §48 and Federal Motor Vehicle Safety Standards (FMVSS) §22. z Observe relevant regulations for securing loads.

The respective transport operator is always responsible for the transport of machine and accessories.

z When loading and transporting, secure the machine and its working

equipment from involuntary motions.

z Clean mud, snow and ice from undercarriage of machine so that

ramps can be accessed without danger of slipping.

z Provide flatbed trailer access ramps with wooden planks. z Check conditions of route before starting journey. z Only transport machine using designated tie down and lifting points. z Ensure that the machine does not present any hazards to other road

users.

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

protective gloves, safety shoes).

z Report any damage that occurred during shipping to SENNEBOGEN

Customer Service immediately.

860 / 05.2010

6-1

Transport - Machine dimensions

6.2

Machine dimensions

Machine

L

15500

H

W

3800

H*

*: Also consider height of mast (if present)

K18

Transport length (L)

Transport width (W)

Transport height (H)

15.60 m

3.76 m

3.98 m

Mast

1205

H

3000

W 1370

Transport width (W) -

6-2

Transport height (H) -

860 / 05.2010

Transport - Machine weight

6.3 Machine weight Note The machine weight may deviate from these figures due to optional attachments. The information on the weight of the engine, the undercarriage and the compact loading equipment may also vary.

Quantity

Component

Weight

1

Machine

approx. 65.0 t.

1

Mast

-

6.4 Lock upper structure 1

Move the upper structure in direction of travel.

2

Engage swing bearing holding brake.

1 3

860 / 05.2010

Bolt and secure the locking rod (1) on undercarriage and upper structure.

6-3

Transport - Disconnect electrical system from battery

6.5

Disconnect electrical system from battery

If the machine is idle for an extended period or for long transport distances, the electrical system must be isolated from the battery using the mechanical battery disconnecting switch (optional).

WARNING Do not switch off mechanical battery disconnecting switch if: z the engine is still running z or other electrical consumers are still switched on.

Doing so may damage the electrical system and its systems of control.

1

1

Open left rear service access door.

2

Turn the battery disconnecting switch (1) to the left (counter-clockwise) and remove.

The electrical system is now disconnected from the battery.

3

Close service access door.

Note If there is no mechanical battery disconnecting switch, the battery poles must be disconnected. Properly install the battery protective caps again.

6-4

1

Open left rear service access door.

2

IMPORTANT! Avoid short circuits!

Disconnecting: 1. Disconnect the negative pole 2. Disconnect the positive pole Connecting: 1. Connect the positive pole 2. Connect the negative pole

3

Close service access door.

860 / 05.2010

Transport - Raising machine (upper structure)

6.6 Safety instructions

Raising machine (upper structure)

Observe safety instructions before starting work.

DANGER z Sling machine only at the designated lifting points. The lifting points are marked green and have a green loading hook symbol. z Ensure that the lifting equipment has a sufficient safe working load

and stability is secure.

z The following is suitable lifting equipment:

– Crane – Telescopic crane z Ensure that the sling devices have sufficient safe working load and

are undamaged.

z The following are suitable sling devices:

– Chain suspension – Cable suspension – Round loops/Sling devices z Beware of danger area!

There must be no-one next to, on or below the machine.

Procedure with counterweight

35F1 to

A 35F2 to

860 / 05.2010

1

Select suitable lifting crane and sling devices.

Observe weight and center of gravity of the machine.

2

Fasten the sling devices on lifting points F1 and F2.

3

Hoist machine carefully.

6-5

Transport - Raising machine (upper structure)

DANGER There must be no one below a suspended load!

Hoisting point weight

6-6

Upper structure

Upper structure

K18

Boom - transport position (see Machine dimensions)

Boom - 45 ° position

F1

40,6 t

36,1 t

F2

7,3 t

11,8 t

FTot.

47,9 t

47,9 t

A

3,0 m

3,0 m

860 / 05.2010

Transport - Tying down the machine

6.7

Tying down the machine

CAUTION z Sling machine at the designated tie-down points (1). The tie-down points are marked in green and are located on the undercarriage. z Ensure that the sling devices have sufficient safe working load and

are undamaged.

z Ensure that the machine is not damaged if additional securing

is necessary.

z The respective transport operator is always responsible for the

transport of machine and accessories.

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6-7

Transport - Tying down the machine

6-8

860 / 05.2010

Troubleshooting - Drive engine

7

Troubleshooting

WARNING z Read Chapter 1 SAFETY. z The personnel for maintenance, inspection and troubleshooting

must have the appropriate qualifications for this work.

z For work not described in detail, please notify SENNEBOGEN

Customer Service.

7.1 Drive engine Engine does not start

Engine power drops

Machine does not move

Oil or fuel leaks from engine

Cause

Remedy

Battery power too low

– Check fluid level of batteries.

– Recharge or replace battery.

– Start machine using auxiliary battery.

Fuel tank empty

– Refuel machine.

Cause

Remedy

Suction resistance too high

– Exchange filter in water separator.

Cause

Remedy

Brake pedal actuated

– Release the brake pedal.

Gearbox defective

– Have fault remedied.

Cause

Remedy

Hose connections loose

– Tighten hose connections.

Hoses or seals damaged

– Replace hoses or seals.

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

860 / 05.2010

7-1

Troubleshooting - Hydraulic system

7.2 Oil leaks from hydraulic system

Hydraulic pump not working

No or faulty function of operating equipment

Noises when moving a working cylinder

7-2

Hydraulic system

Cause

Remedy

Hose connections loose

– Tighten hose connections.

Hoses or seals damaged

– Replace hoses or seals.

Cause

Remedy

Fault in pump circuit

– Have fault inspected and corrected by hydraulics specialist.

Cause

Remedy

Hydraulic oil level too low

– Check hydraulic oil level.

– Add hydraulic oil if required.

Leaks in hydraulic system

– Check working cylinder, connections and hoses for leaks.

– Have fault corrected by hydraulics specialist.

Fault in one of the working circuits

– Have fault corrected by hydraulics specialist.

Cause

Remedy

Cylinder piston rod without lubricant film

– Have repair carried out by hydraulics specialist.

860 / 05.2010

Troubleshooting - Hydraulic system

No or little power in the hydraulic system

Noises in hydraulic system

860 / 05.2010

Cause

Remedy

Hose connections loose

– Tighten hose connections.

Hoses or seals damaged

– Replace hoses or seals.

Pressure relief valve opens too soon

– Have fault corrected by hydraulics specialist.

Hydraulic pump worn or defective

– Have pump replaced by hydraulics specialist.

Cause

Remedy

Hydraulic pump takes in air

– Have fault corrected by hydraulics specialist.

Hydraulic pump delivers insufficient oil

– Check hydraulic oil level.

– Add hydraulic oil if required.

Pressure relief valve chatters

– Have fault corrected by hydraulics specialist.

7-3

Troubleshooting - Heating system

7.3 Fan not working

Fan will not shut down

Fan works with decreased power

7-4

Heating system

Cause

Remedy

Fuse defective or loose

– Check the fuse seating and insert correctly if necessary. Replace defective fuse. If another defect occurs shortly, it indicates a shortcircuit or a blockage. Check the fan for blockages or other defects and rectify the cause.

Power supply interrupted

– Check lines for loose contacts or open circuit.

Blower engine defective

– Replace fan.

Defective operating instrument

– Check operating instrument and replace if necessary.

Cause

Remedy

Short circuit in the cable

– Rectify short-circuit, install new cable if necessary

Cause

Remedy

Contacts dirty

– Clean plug contact. Be careful to avoid short-circuits.

Electric line dimensions too small

– Run recommended cable size.

Heat exchanger contaminated

– Clean thoroughly and prevent damages that could lead to leaks.

Attention! Please observe the safety instructions.

Air flow insufficient because air filter is plugged

– Clean or replace filter.

860 / 05.2010

Troubleshooting - Heating system

No heat or insufficient heating power

Water escaping on unit

Air flaps can no longer be adjusted

860 / 05.2010

Cause

Remedy

Water intake temperature too low

– Wait until the vehicle engine is warm

Vehicle thermostat defective

– Replace thermostat

Heat exchanger fins dirty

– Check heat exchanger and clean if necessary

Water lines kinked or squashed

– Rectify cause of fault or run new hose.

Water pump pressure too low

– Cooling water is not flowing through the heat exchanger. Install an additional or more powerful pump.

Air flow insufficient because air filter is plugged

– Clean or replace filter.

Resistor defective

– Replace resistor

Climate control defective

– Check and replace if necessary.

Cause

Remedy

Hose connection loose

– Check hoses and tighten hose clips

Water hose damaged

– Run and connect new hose

Heat exchanger damaged

– Install original replacement part and connect.

Attention! Observe the safety instructions.

Cause

Remedy

Servomotor defective

– Replace servomotor

Foreign object blocking flap

– Check flap, remove foreign object.

Flap deformed

– Check flap and straighten if necessary.

Flap mount defective

– Check flap mount and replace if necessary.

Control system defective

– Check control system and replace if necessary.

7-5

Troubleshooting - Heating system

7.3.1 Cooling capacity Compressor not working

Evaporator flooding

Evaporator icing up

Evaporator clogged

7-6

Cause

Remedy

Open circuit in the solenoid coil on the compressor

– Check the current flow to the coupling.

V-belt loose or broken

– Adjust the V-belt tension, replace V-belt.

V-belt pulley does not turn, even though the magnetic clutch is engaged

– Check compressor, replace if necessary.

Compressor coupling slipping

– Repair coupling or replace compressor.

Control system defective

– Check control system and replace if necessary.

Cause

Remedy

Expansion valve is stuck open or is hanging

– Replace expansion valve.

Cause

Remedy

Thermostat sensor in wrong position

– Reposition sensor.

Expansion valve, thermostat or collector drier defective

– Replace expansion valve, thermostat or collector drier

Cause

Remedy

Cooling ribs dirty

– Clean evaporator

860 / 05.2010

Troubleshooting - Heating system

Loss of refrigerant

Cooling capacity inadequate

System cools intermittently

860 / 05.2010

Cause

Remedy

Break in refrigerant line

– Check all lines for break due to external effects or abrasion

Leakage in the system

– Evacuate, fill, check for leaks and repair where necessary.

Cause

Remedy

Air flow insufficient because air filter is plugged

– Clean or replace filter.

Relay defective

– Replace relay.

Fan flow hindered

– Check air channels for hindrances.

Rectify fault.

Outside air-/recirculating air flap set to outside air at higher outside air temperature

– Set to recirculating air.

Air flow of liquefier insufficient because cooling ribs are dirty

– Clean the cooling ribs.

Fill level for refrigerant too low

– Fill with refrigerant (service engineer).

Moisture in the system

– Empty the air conditioning system, replace the collector drier, evacuate and fill (service engineer).

Collector drier saturated

– Empty the air conditioning system, replace the collector drier, evacuate and fill (service engineer).

Cause

Remedy

Line break, faulty ground connection or loose contacts in the solenoid coil of the compressor

– Check lines, repair or replace.

Blower engine defective

– Replace fan.

7-7

Troubleshooting - Heating system

7.3.2 System extremely loud System extremely loud

7-8

Cause

Remedy

V-belt loose or worn excessively

– Tighten or replace V-belt.

Coupling loud

– Repair coupling.

The holder for the compressor is loose or the internal components of the compressor are worn

– Repair holder; replace compressor.

Excessive wear on blower engine

– Replace fan.

System overfilled

– Remove refrigerant by suction until the high-pressure display is back to normal.

Insufficient refrigerant in the system

– Check for leaks; fill system.

860 / 05.2010

Troubleshooting - Tires and undercarriage

7.4 Oil leaks on differential, hubs or axle distributor gearbox

Oil leaks in swing bearing transmission

Rotary transmission leaking

Noises in swing bearing

Tires and undercarriage

Cause

Remedy

End plugs loose

– Tighten end plugs.

Seals damaged

– Replace seals.

Cause

Remedy

Loose connections

– Tighten connections.

Cause

Remedy

Seals damaged

– Replace seals.

Lines loose

– Tighten fixing bolts.

Cause

Remedy

Insufficient lubrication on gear rim

– Lubricate gear rim according to lubrication plan.

7.5 Cab Cab moves or rocks drastically

860 / 05.2010

Cause

Remedy

Cab suspension or cab attachment damaged

– Check all connection elements, screws and bolts of cab suspension and fastening for damage, cracking or deformation.

– Have damaged parts exchanged immediately by trained and instructed specialist personnel.

7-9

Troubleshooting - SDS fault indicators

7.6 Symbol flashes, buzzer sounds and red 'Attention' lights up

SDS fault indicators

Cause

Remedy

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

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

Cooling fins on hydraulic oil cooler soiled

– Clean cooling fins on oil cooling.

Hydraulic oil level too low

– Check oil level acc. to maintenance instructions.

– Add hydraulic oil, if required.

Symbol flashes, buzzer sounds and red 'Attention' lights up

Cause

Remedy

Insufficient fuel in tank

– Refuel machine acc. to Section 6.7.

Symbol flashes, buzzer sounds and red 'Attention' lights up

Cause

Remedy

Engine overheating

– Run engine at idling speed.

Cooling fins on engine oil cooler soiled

– Clean cooling fins on oil cooling.

Fan drive loose or defective

– Tighten fan drive; replace if necessary.

Refrigerant level too low

– Add refrigerant according to maintenance instructions.

Engine switched off without cooling phase.

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

7 - 10

860 / 05.2010

Troubleshooting - SDS fault indicators

Symbol flashes, buzzer sounds and red 'Attention' lights up

Symbol flashes, buzzer sounds and red 'Attention' lights up

860 / 05.2010

Cause

Remedy

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

– Shut down engine immediately.

– Check engine oil level acc. to maintenance instructions.

– Add engine oil if necessary.

– Notify SENNEBOGEN Customer Service in the event of a re-occurrence

Cause

Remedy

Battery charge too weak

– Check battery charge; recharge batteries or replace if necessary.

– Check battery connections, tighten terminals if necessary.

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

7 - 11

Troubleshooting - SDS fault indicators

Warning and pilot lamps

lights up, buzzer sounds

Cause

Remedy

Refrigerant level too low

– Add refrigerant.

Lights up while engine is running

Cause

Remedy

Accumulator pressure too low

– Have a hydraulics specialist check the hydraulic system.

lights up, buzzer sounds

Cause

Remedy

Hydraulic oil level too low

– Add hydraulic oil

lights up

Cause

Remedy

Swing bearing holding brake applied

– Deactivate swing bearing holding brake

Cause

Remedy

Return filter is plugged

– Check return filter; if necessary, replace acc. to maintenance instructions.

Cause

Remedy

HydroClean Superfine filter is plugged

– HydroClean Check superfine filter, replace if necessary according to maintenance instructions.

lights up

lights up

7 - 12

860 / 05.2010

Troubleshooting - SDS fault indicators

lights up

lights up

860 / 05.2010

Cause

Remedy

Auxiliary control filter is plugged

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

Cause

Remedy

Air filter contaminated

– Clean filter acc. to maintenance instructions.

– If necessary, replace filter.

7 - 13

Troubleshooting - Electrics

7.7

Electrics

Note An electronic failure is indicated only if the corresponding function can no longer be performed.

7.7.1 Reverse airflow -insufficient cooling capacity-

1

1 Plug for hydraulic cooling pump

1

7 - 14

Pull the plug (1).

– Fan goes to maximum speed, 100% cooling capacity.

860 / 05.2010

Troubleshooting - Electrics

7.7.2 Steering failure Note In the event of steering failure, the angle of the wheel can be adjusted by manually pressing the corresponding valve pin.

2 3

2 Left valve pin (not visible, opposite side) 3 Right valve pin (in direction of travel)

860 / 05.2010

1

Press and hold right valve pin (3): – Wheel turns to the right.

2

Press and hold left valve pin (2): – Wheel turns to the left.

7 - 15

Troubleshooting - Electrics

7 - 16

860 / 05.2010

Setup work - Safety instructions

8

Setup work

8.1 Safety instructions DANGER z The work performed may only be completed by trained professionals. z Wear personal protection equipment (e. g. safety helmet, ear

protection, protective gloves, safety boots) where working conditions require. At working heights of 2.00 m or more, SENNEBOGEN recommends the use of safety equipment to prevent falling.

z The following applies for all set-up work:

Only carry out the work if the work area is level and solid enough.

z Ensure that there is no one in the danger zone.

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

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

load suspension equipment.

z When dismantling components or equipment, always use load

suspension equipment with a sufficient load bearing capacity.

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

boom or the counterweights), hanging on a crane.

z Carry out all set-up steps in turn. Never carry out more than one set-

up task at a time.

Note The setup works to be carried out depend on the operating tools that have been selected. Observe the notes in the operating instructions of the tool manufacturer.

860 / 05.2010

8-1

Setup work - Safety instructions

WARNING There may be dangers during operation to persons, machine and other property, if z the setting of the safety limit position sensor for "Arm in" was not

adjusted for the attached tool

z the operating tools attached do not comply with the relevant safety

regulations

z the tools have not been approved by SENNEBOGEN z the operating tools attached are found to be defective.

The machine operator is wholly liable for any damage or consequential damage caused by tools!

This damage is excluded from the terms of the warranty issued by SENNEBOGEN Maschinenfabrik GmbH.

8-2

860 / 05.2010

Setup work - Dismantling/assembling the cab

8.2

Dismantling/assembling the cab

DANGER Danger to life from falling cab z The cab must be assembled/dismantled by trained and instructed

technicians only!

z Always replace any bolts after dismantling, do not reuse. z Bolts, tension and retaining elements for cab supports are to be

checked by qualified personnel and replaced if necessary before reusing.

z Only use genuine SENNEBOGEN spare parts.

Note The locking bar can also be used for fastening the cab. This requires using the two fastening points (1).

1

860 / 05.2010

8-3

Setup work - Disassembling/mounting the counterweight

8.3 Safety instructions

Disassembling/mounting the counterweight

Observe safety instructions before starting work.

DANGER z Move the upper structure in direction of travel.

Deposit the equipment on the ground.

Position machine horizontally on firm and even ground.

Stabilize the machine to prevent rolling away if necessary (for mobile undercarriage).

Danger of accident through tipping of counterweight parts! z Switch off engine before detaching/attaching counterweight.

Secure machine against unauthorized re-starting.

z Danger of accident through tipping of machine! The machine is not

ready for operation with counterweight removed.

z When raising or lowering the counterweight, ensure that there is

no one within the danger area. It is forbidden to stand on or under the counterweight.

Maintain the safety clearance.

z Only hoist counterweight parts individually. z Danger of accident due to counterweights if handled improperly. z Carry out ballasting procedure with a signaling individual.

Pay attention to the danger area!

Note The mass of the counterweight is cast into its upper surface.

The counterweight can be disassembled to transport the machine.

8-4

860 / 05.2010

Setup work - Disassembling/mounting the counterweight

Applications planning

When planning an application, the following anticipatory inspections must be performed: z Inspection for conformity of the pending application with the

specifications of the machine, e.g. with the pending crane application: required safe working load, working radius etc.

z Inspection of the external conditions, e.g. effects of wind, snow,

unfavorable temperatures, visibility.

z Inspection of subgrade characteristics at the work site for safe

working load for maximum load stresses.

z Inspection of suitability of use for all parts, such as components,

additional parts, sling devices, sling aids, sling ropes (slings) etc.

5

6

7

1

2 3 4

1 Hook block or load hook on auxiliary crane 2 Sling 3 Sling aid 4 Sling device in the tie-down point 5 Eye bolt - sling device 6 Eye bolt - sling device 7 Eye bolt - sling device

860 / 05.2010

8-5

Setup work - Disassembling/mounting the counterweight

8.3.1 Disassembling the counterweight Overview 8

9 10

11

8 Counterweight 1.5 t - optional 9 Counterweight 4.0 t 10 Counterweight 4.0 t 11 Counterweight 9.7 t Disassembling the counterweight (8) 11

12 13 14 15

1

8-6

Loosen the hexagonal nut from the hexagonal screw (12).

Unscrew hexagonal screw (12) until there is a distance of approx. 2 cm between the bolt head and counterweight (11).

860 / 05.2010

Setup work - Disassembling/mounting the counterweight

2

Unscrew hexagonal screws (13), (14) and (15).

16

17

18

3

Unscrew hexagonal screws (16) and (17). Deposit the bracket (18) and hexagonal screws (16 and 17) in a safe location.

5 8

860 / 05.2010

4

Screw the eye bolt (5) into the tie-down point (thread of the hexagonal screw (16)).

5

Attach sling (2) with sling aid (3) to the auxiliary crane and to the eye bolt (5) on the counterweight (8).

8-7

Setup work - Disassembling/mounting the counterweight

DANGER Risk of being crushed or trapped.

There must be no one below a suspended load.

6

Lift the counterweight (8) safely from the machine using the auxiliary crane, deposit it, and secure against tipping.

Disassembling the counterweight (9, 10 and 11)

18

18 7

Unscrew the taillight fixing bolts; withdraw the taillights (18) slightly. Carefully unplug the plug from both lights.

21 23 22

20 22

19

8

Unscrew the hexagonal screws (19).

– If the counterweight (8) was not used as an option.

8-8

860 / 05.2010

Setup work - Disassembling/mounting the counterweight

9

Unscrew the hexagonal screws (20) and deposit in a safe location. Unscrew the hexagonal screws (21).

10

Rotate bracket (22) 180°.

Align bracket (22) horizontally with washers.

Screw in hexagonal screws (21) into position (23) again.

25

24

11

Unscrew hexagonal screw (24) and deposit in a safe location.

Unscrew hexagonal screws (25).

25 26

12

860 / 05.2010

Rotate bracket (26) 180°.

Screw in hexagonal screws (25) again.

8-9

Setup work - Disassembling/mounting the counterweight

3

2

11

7

3

7

29

13

Screw eye bolts (7) into the tie-down points (thread of hexagonal screws (19 and 23)).

14

Attach sling (2) with sling aids (3) to the auxiliary crane and to the eye bolts (7) on the counterweight (11).

15

Lightly apply tension to the sling (2) using the auxiliary crane.

28 29

27

8 - 10

16

Unscrew hexagonal screw (27). Deposit hexagonal screw (27), conical spring washer and washer in a safe location.

17

Remove locking plate (28) and deposit in a safe location.

18

Only loosen the bolt when the counterweight is attached securely and the sling (2) is pre-tensioned!

Unscrew hexagonal screw (29) and deposit in a safe location.

860 / 05.2010

Setup work - Disassembling/mounting the counterweight

DANGER Risk of being crushed or trapped.

There must be no one below a suspended load.

19

Lift the counterweight (11) safely from the machine using the auxiliary crane, deposit it, and secure against tipping.

30

20

Remove both spacer packs (30) if necessary and retain for re-assembly in the future.

– Do not mix up the left and right sides!

31 10

21

860 / 05.2010

Loosen the hexagonal nut from the hexagonal screw (31).

Unscrew hexagonal screw (31) until there is a distance of approx. 2 cm between the bolt head and counterweight (10).

8 - 11

Setup work - Disassembling/mounting the counterweight

25

2

26

3

3

6

10

6

22

Unscrew the hexagonal screws (25) and deposit with bracket (26) in a safe location.

23

Screw eye bolts (6) into the tie-down points (thread of hexagonal screws (21 and 25)).

24

Attach sling (2) with sling aids (3) to the auxiliary crane and to the eye bolts (6) on the counterweight (10).

25

Lightly apply tension to the sling (2) using the auxiliary crane.

23B

23A

22

26

8 - 12

Unscrew hexagonal screw (23A) and deposit in a safe location.

860 / 05.2010

Setup work - Disassembling/mounting the counterweight

DANGER Do not unscrew hexagonal screw (23B).

Danger of counterweight (9) tipping!

27

Loosen hexagonal screw (23B) until the bracket (22) can be turned 90°.

DANGER Risk of being crushed or trapped.

There must be no one below a suspended load.

28

Lift the counterweight (10) safely from the machine using the auxiliary crane, deposit it, and secure against tipping.

31

29

Remove both spacer packs (31) if necessary and retain for re-assembly in the future.

– Do not mix up the left and right sides!

860 / 05.2010

8 - 13

Setup work - Disassembling/mounting the counterweight

32 9 30

Loosen the hexagonal nut from the hexagonal screw (32).

Unscrew hexagonal screw (32) until there is a distance of approx. 2 cm between the bolt head and counterweight (9).

3 2 6

3

9 6

33

6

8 - 14

31

Screw eye bolts (6) into the tie-down points (thread of hexagonal screws (21 and 25)).

32

Attach sling (2) with sling aids (3) to the auxiliary crane and to the eye bolts (6) on the counterweight (9).

33

Lightly apply tension to the sling (2) using the auxiliary crane.

34

Remove the intermittent horn (33) if necessary.

860 / 05.2010

Setup work - Disassembling/mounting the counterweight

23B 22

34 9

34 35

35

Unscrew hexagonal screw (23B) and deposit in a safe location.

36

Unscrew the hexagonal screws (34) and deposit with bracket (35) in a safe location.

DANGER Risk of being crushed or trapped.

There must be no one below a suspended load.

37

860 / 05.2010

Lift the counterweight (9) safely from the machine using the auxiliary crane, deposit it, and secure against tipping.

8 - 15

Setup work - Disassembling/mounting the counterweight

36

38

Remove both spacer packs (36) if necessary and retain for re-assembly in the future.

– Do not mix up the left and right sides!

ATTENTION After assembly of the counterweight, the fixing bolts much also be checked with their respective torque after 50 operating hours.

8 - 16

860 / 05.2010

Setup work - Disassembling/mounting the counterweight

8.3.2 Mounting the counterweight NOTE The counterweight is mounted in the reverse order of disassembly.

NOTE Applies to counterweights (9, 10 and 11)

11

12 31 32

1

37 10 9

Hold and deposit counterweight on the hexagonal screw (37).

– Counterweight is aligned in the original position.

2

860 / 05.2010

Adjust the distance between bolt head and counterweight with each hexagonal screw (12, 31 or 32).

Secure the hexagonal screw with a hexagonal nut.

8 - 17

Setup work - Disassembling/mounting the counterweight

NOTE Re-tighten hexagonal screws using a torque wrench.

Observe tightening torque in accordance with Section 3.10!

29

8 - 18

Screw

Tightening torque MA [Nm]

29 Hexagonal screw

1850

860 / 05.2010

Setup work - Installing large roller bearings, slewing gear, flange connections

8.4

Installing large roller bearings, slewing gear, flange connections

8.4.1 General This supplementary information applies to the installation of large roller bearings and flange connections (FV). This concerns e.g.: z Flange connection between the upper structure and the gearing z Flange connection between the upper structure and the slewing ring z Flange connection between the slewing ring and the lower assembly z Flange connection between the slewing ring and intermediate ring

and the lower assembly

z Flange connection between the slewing ring and the pylon and

intermediate ring and the lower assembly

z Flange connection between the pylon and pylon

DANGER z Make sure that there is no-one within the hazardous area before

starting the installation!

z Pay attention to dimensions and weight according to the operating

instructions.

z Observe general safety information for the installation according to

the operating instructions.

8.4.2 Preparatory measures In order to guarantee a secure connection between the individual components, several important preparations are required: z The flange surfaces on the slewing ring are to be kept free of

corrosion.

z Make absolutely sure that all surfaces including holes, e.g. the lower

assembly flange are free of grease. If there is grease in the holes, there is a danger of pushing the grease into the threads in the slewing ring with the bolts.

This additional grease in the threads can greatly decrease the required friction under certain circumstances. The bolt can be damaged without your recognizing it or it could even break eventually.

z No additional oil or grease is to be used for bolted connections e.g.

"lower assembly flange-slewing ring, pylon-slewing ring". The bolts and pins are to be installed as delivered.

860 / 05.2010

8 - 19

Setup work - Installing large roller bearings, slewing gear, flange connections

8.4.3 Assembly There are a few important points to observe for the installation: z Slewing gear bolts that are already used are not to be reused under

any circumstances.

z Clean all contact surfaces of the flange connections of any oil and

grease.

z Galvanized or coated surfaces must be treated previously with

AKTIVATOR T 747 because LOCTITE - 586 is only permitted on activated surfaces.

z LOCTITE - 586 is to be applied on a surface with a brush. z Centering pins are not to come into contact with Loctite since

disassembly can become difficult --> Apply wax or grease to centering pins!

z Tighten bolts according to the torque specifications in alternating

sequence (i.e. 2nd across from the 1st). After approx. 2 hours, the Loctite begins to adhere. Full strength is achieved after 12 - 24 hours.

1) Upper structure 2) Slewing ring 3) Pylon or lower assembly 4) Pylon Flange connection with Loctite

1 C

2 3

C (1 : 5)

D

4 3 D (1 : 5)

8 - 20

860 / 05.2010

Setup work - Installing large roller bearings, slewing gear, flange connections

8.4.4 Mounting pylon Danger z Place machine on firm, completely horizontal ground. z The (stationary) sub-frame must be aligned horizontally on all sides

before mounting the pylon.

z The ballast must be attached to the sub frame before mounting the

pylon.

Caution When mounting the pylon ensure that there is no one in the danger area below the machine/pylon.

1

Raise the machine using a suitable auxiliary crane in order to fit the pylon. Observe Section 7.5.

2

Attach pylon using the bolts (2) provided to the undercarriage note tightening torque!

3

Attach base unit to pylon using the bolts (2) provided - note tightening torque!

2 1

4 2 5

4

3

1 Ball bearing slewing rim 2 hexagonal bolt 3 Hexagonal nut 4 Washer 5 Spacer tube 6 Pylon

6 3 4

2 5 4 3

860 / 05.2010

8 - 21

Setup work - Quick-change couplings

8.5

Quick-change couplings

8.5.1 Fastening quick couplings To ensure problem-free functioning and operating safety of the hydraulic system, follow these instructions.

Note Ignoring or infringing against these instructions exonerates SENNEBOGEN from any responsibility for parts which are damaged or lose their tightness as a result of getting dirty.

3 5 2

1

4

3 Coupling insert

5

Coupling sleeve

Before fastening the quick couplings:

8 - 22

1

De-pressurize the hydraulic system as described in .

2

Remove protective caps (3) from coupling sleeve (4) and coupling insert (1).

3

Clean coupling sleeve (4) and coupling insert (1), particularly the end surfaces (5) with a clean cloth.

4

Coupling insert (1): Check the contact surface (2) of the ball insert for wear. If the contact surface (2) is heavily worn, replace with a new coupling insert.

Check sealing ring for wear and replace if necessary (see Chapter 8.5.3).

860 / 05.2010

Setup work - Quick-change couplings

3 5 2

1

4

3 Coupling insert

incorrect

860 / 05.2010

5

Coupling sleeve

correct

5

Lay the end surfaces (5) of the coupling insert (1) and the coupling sleeve (4) flat against one another.

6

Insert the coupling insert (1) into the coupling sleeve (4) until you hear the coupling insert (1) engage.

8 - 23

Setup work - Quick-change couplings

7

4

Illustrated: Safety ring (7) opened

7 6 1 3

7

Quick coupling fastened

8 - 24

Illustrated: Safety ring (7) engaged

7

Push safety ring (7) down onto the coupling sleeve (4) and rotate slightly until the safety ring (7) engages.

This will prevent the catch from opening by itself.

8

Push together the protective caps (3) of the coupling sleeve (4) and the coupling insert (1) to protect from dirt.

860 / 05.2010

Setup work - Quick-change couplings

8.5.2 Pull out coupling insert

7

4

Illustrated: Safety ring (7) opened

7 6 1 3

7

Quick coupling fastened

860 / 05.2010

Illustrated: Safety ring (7) engaged

1

De-pressurizing hydraulic system.

2

Twist safety ring (7) on the coupling sleeve until it automatically disengages.

3

Hold the coupling insert (1) firmly and push the outer part (6) of the coupling sleeve carefully upwards.

4

Remove coupling insert (1).

5

Clean coupling insert (1), coupling sleeve (4) and protective caps (3) with a clean cloth.

Push protective caps (3) onto the coupling insert (1) and the coupling sleeve (4).

8 - 25

Setup work - Quick-change couplings

8.5.3 Check/change sealing ring Check the sealing ring in the coupling insert at regular intervals for wear. Replace if necessary.

Check sealing ring

3 2 1

To check the sealing ring (2), push down on the sealing disc of the coupling insert (1) with a suitable tool ((3) e.g. drift).

Change the sealing ring 4 3 2 1

1

Push down on the sealing disc of the coupling insert (1) with a suitable tool ((3) e.g. drift).

2

Lever out the sealing ring (2) with special tool (4).

Note The special tool (4) is supplied by SENNEBOGEN (serial No.: 078581).

8 - 26

860 / 05.2010

Setup work - Quick-change couplings

3

2 1

860 / 05.2010

3

Place new sealing ring (2) with the open side facing down onto the sealing disc.

4

Push down on the sealing disc of the coupling insert (1) with a suitable tool ((3) e.g. drift).

5

Press sealing ring (2) together and insert into the groove.

6

Remove tool (3).

The sealing disc must rise upwards.

If necessary, adjust the sealing ring until the sealing disc can move.

8 - 27

Setup work - Quick-change couplings

8.5.4 Lubricating the coupling sleeve

Lubrication nipple for coupling sleeve The lubrication nipple for the coupling sleeve enables easy coupling and decoupling in summer and winter.

Lubricating the coupling sleeve reduces water and dust from penetrating the coupling.

Note Lubricating the coupling sleeve and/or using the lubrication nipple is not a replacement for use of the protective cap.

The lubrication nipple for the coupling sleeve is available from the SENNEBOGEN Service Center (telephone +49 9421 540277 or 540278).

Procedure

8 - 28

1

Remove the protective cap of the coupling sleeve.

2

Clean coupling sleeve and its lubrication nipple, particularly the end surfaces with a clean cloth.

3

Lay the end surfaces of the coupling sleeve lubrication nipple and the coupling sleeve itself flat against one another.

4

Insert the lubrication nipple into the coupling sleeve until you hear the nipple engage.

5

Place a hand grease gun onto the lubrication nipple and lubricate the coupling sleeve with cold-resistant grease.

6

Remove the hand grease gun and the lubrication nipple for the coupling sleeve.

7

Attach the safety cap to the coupling sleeve.

860 / 05.2010

Appendix - List of abbreviations

9

Appendix

9.1 List of abbreviations

860 / 05.2010

TUR

Trade Union Regulations

Oh

Hours of operation

or

or

EMC

Electromagnetic compatibility

Co.

Company

FOPS

Falling Objects Protective Structure

FV

Flange connection

if necessary

if necessary

GmbH

Limited Liability Corporation

HAB

Lifting working platform

LED

Light emitting diodes

HGV

Truck

LMI

Load moment indicator

LpA

Permanent sound pressure level

LWA

Sound power level

max.

maximum

min.

minimum

No.

Number

MMI

Control/indicator for magnet unit

SDS

SENNEBOGEN Diagnostic System

FMVSS

Federal Motor Vehicle Safety Standards

UCTU

Underground Construction Trade Union

ACTU

Association of Commercial Trade Unions

e.g.:

for example

9-1

Appendix - Driver's seat

9.2

Driver's seat

9.3

Cleaning the cooling system

9.4

Installing large roller bearings, slewing gear, flange connections

9.5

Central lubrication system

9.6

Warranty conditions

9.7

Tool Control

9.8

Load moment indicator (LMI)

9.9

Magnet unit

9.10 Camera system/monitor 9.11 Display / auxiliary heating system 9.12 Lubricants table Note In the "Appendix - Chapter 9", only references to the additional documentation is found; these can be found in the back section of the book depending on machine equipment.

9-2

860 / 05.2010

Index

A Abuse 1-4 activated floating setting 5-91 Adding hydraulic oil 4-13 Adverse conditions 3-7 Air pressure 3-5 Antifreeze 4-17 Attachment tools 2-1 Attachments 1-2 Automatic idling 5-32 Automatic rpm 5-32 B Battery acid 4-23 Battery disconnecting switch 2-4 Beaufort scale 3-17 Biological oils 1-18 Button panel (SDS) 5-38 Bypassing the safety limit shutdown 5-89 C Cab doors 5-3 Cab suspension 5-69 CE certificate of conformity 1-6 Central lubrication system 2-5, 2-6, 4-9, 4-10, 532 Chloride 1-20 Chloride content 1-20 Control lever, left-hand 5-12 Cooling system 4-17 Crushing hazard 1-22 Customer Service W-9 D Daily start-up 4-3 Danger area 1-22 Danger of tipping 1-41 Decommissioning 4-25 Decommissioning the machine 4-25, 4-26 Description Wind 3-17 Differential 3-4 Disposal Batteries 1-42 Lubricants 1-42 Disposal Guideline 75/439/EEC 1-42 Disposal of operational fluids 1-42 Disposing of batteries 1-42

860 / 05.2010

Disposing of lubricants 1-42 Disposing of the oil filter 1-42 Driving forward 5-54 reverse 5-54 with a suspended load 5-74 Driving the machine 5-74 E Ear protection 1-22, 1-23 Electric switch cabinet 2-6 Emergency exit 5-2 Emergency lowering Cab 2-5 in cab 5-72 in storage space 5-73 Emergency stop 5-9 Environmental protection 1-42 Environmental regulations 1-42 Exhaust silencer 2-7 Extending the outriggers 5-78 F Fan reversal, combination cooler 5-17, 5-22, 525, 5-27 Fault diagnosis 7-1 Fault indicators (SDS) 5-55, 7-10 Filler strainer - fuel tank 2-6 Fire extinguisher 1-16 First-aid kit 1-15, 1-16 Floating axle 2-2 Floating axle cylinder 2-2 FOPS protective roof 1-14 Front axle 2-2 Front wind shield 5-3 Fuel filler strainer 2-6 Fuel system 4-14 Fuel tank 2-5, 3-4 Fuel tank display 5-38 Full floating axle lock 5-32 Fuse Preheat 2-8 G Gearbox 2-4 Grab, slew left 5-12 Grab, slew right 5-12

S-1

Index

H Hand signals 1-43 High voltage contact 1-25 Hoisting limiter 5-87, 5-88 Hydraulic oil pre-heater 5-66 Hydraulic system: 3-4 Hydraulic tank 3-4 HydroClean - superfine filtration system (optional) 2-7 I Identification plate 1-5 Ignition key 4-20 Inhaling exhaust gases 4-20 Initial commissioning 4-3 Inspection by specialist technician 1-12 Installing/removing the counterweight 8-4 Intended use 1-2 Interior lighting 5-4 International regulations 1-1 International use 1-14 J Jump start 4-23 L Lifting capacities 3-7 Lifting equipment 6-5 Lifting force 3-7 Lifting points 6-5 Light emitting diodes 5-38 List of abbreviations 9-1 Load moment indicator (LMI) 5-61 Load ratings 3-7 Loads - hoisting 5-84 - lowering 5-84 Lock upper structure 6-3 Locking cab doors 5-3 Locking rod 6-3 Lowering/reducing load ratings 3-7 Lubricating cycle 4-9 Lubricating slewing track 4-9, 5-32 M Machine machine 5-74 raising 6-5

S-2

stabilizing 5-77 tying down 6-7 Machine Labeling 1-5 Machine operator's work station 1-2 Machine working range 1-22 Main fuse Electrics 2-8 Maintaining earth-moving machinery 1-23 Maintenance instructions W-7 Maintenance schedule 3-1 Manufacturing of spare parts 1-14 Maximum stability 1-24 Misuse 1-2, 1-3, 1-4 Modification of the machine 1-14 Move outrigger inward 5-80 Move the cab 5-70 N National regulations 1-1 Nominal speed 4-22 Notice signs 1-5 O Oil diagnosis 1-18 Oil filler strainer 4-13 Opening front wind shield 5-3 Operating earth-moving machinery 1-23 Operation 5-1 Operation of the machine in an explosive environment 1-4 Operator´s station 2-1 Other risks 1-4 Outrigger 2-2 Outrigger housing 2-3 Outrigger pad 2-3 Outside air mode 5-28 Overhead power lines 1-25 Overload warning device 1-41 Overview of the overall machine 2-1 P Parking brake 5-10 Personal protective equipment 1-22, 1-31, 1-37 Personnel qualifications 1-13 Personnel selection 1-13 pH value 1-20 pH value, water 1-20 Pilot lamp - EMR 5-54

860 / 05.2010

Index

Pilot lamps 5-54 Pilot lamps (SDS) 5-54 Pipe fracture safety device - lifting cylinder 2-10 Pipe fracture safety device - stick cylinder 2-10 Potential instances of misuse 1-3 Power lines 1-25 Preheat 5-54 Protective equipment 1-22 Protective features 1-41 Protective gloves 1-22 Protective helmet 1-22 Protective roof (FOPS) 1-14 Prototype test 1-6 Pump unit 2-4 Q Qualifications for personnel 1-23 R Rear axle 2-2 Recirculating air mode 5-28 Recommissioning 4-3 Refrigerant level 4-17 Refueling hose 2-6 Refueling pump 2-6 Remedying faults 7-1 Responsibilities of the operator 1-12 S Safety alert symbol W-4 Safety clearance 1-22, 1-25 Safety clearance from overhead power lines 125 Safety instructions 1-4 Safety lever 5-11 Safety limit shutdown for "Retract stick" 5-85 Safety regulations 1-14 Safety rope 2-3 Safety shoes 1-22 Sales and Service Partners W-9 SDS 5-37 SDS fault indicators 7-10 Seat belt 4-19 SENNEBOGEN Diagnostic System Self-check 5-37 Service panel - drive engine 2-7 Service Partners W-9 Setup work 8-1

860 / 05.2010

Signal word W-4 Signaling individual 1-43 Signs Clean 1-5 Slewing ring 2-2 Slewing the upper structure 5-81 Slewing upper structure 5-81 Sling devices 6-5, 6-7 Spare parts catalogue W-7 Spare parts depot W-9 Special dangers 1-14 Stability 1-23, 1-24, 1-26 Stabilizing the machine 5-77 Starting the engine 4-20 Start-up 4-1 Step plates 5-37 Storage location 4-25 Strength classes for bolts 3-18 Sulfate content 1-20 Support leg 2-3 Swing bearing brake 5-82 Swing bearing holding brake 5-11 Swinging the load outwards 1-24 Switching the engine off 4-24 Symbols and illustration aids W-4 T Target group 1-2 Technical condition 1-13 Telephone: W-9 The machine environment 1-22 The operating instructions are structured as follows W-8 Tie-down points 6-7 Tightening torque 3-18, 8-18 Tipping load 3-7 Tires, air pressure 3-5 Troubleshooting 7-1 U Unauthorized operating methods 1-14 Upper structure 2-4 W Warm-up period 4-22 Warning lights 5-54 Warning lights (SDS) 5-54 Warning signs 1-5

S-3

Index

Warranty conditions 1-16 Warranty manual 1-16 Washer system 5-4 Water hardness 1-20 Water separator 2-4 Weight of hoisting accessories 3-7 Wheel nuts 3-5 Wind force 3-17 Wind forces 3-2 Wind speed 3-2, 3-17 Windscreen wiper 5-4 Working tools 8-1

S-4

860 / 05.2010