80.6.1049_en_neu

Operating and Maintenance Instructions

BS 80

05.2008

BS80.6.1049

Foreword

Important notes on the Instruction

Read the instruction, in particular Chapter 1 SAFETY thoroughly, before starting work with the machine. Keep the instruction in a safe place for future use. WARNING! z Only work with the machine once these instruction have been read and completely understood. z Observe safe working load tables in Abschnitt 3.2. z Forbid unsafe operation or unsafe maintenance. z Do not operate machine if a fault has been detected! z Setting up, operation and maintenance of the machine is only

permitted by trained personnel. The employer is responsible for the qualification and training of the personnel.

z These instruction are an integral part of the machine. Always keep

the instruction in the cab. Recommended location to keep instructions: In the storage compartment behind the driver’s seat. In the event of sale, disposal or loan, the operating manual must accompany the machine!

z Contact SENNEBOGEN immediately if there is anything in the

operating manual that you do not understand! Your comments will help us to make the operating manual even more user friendly.

For reasons of clarity, the specified safety devices are not shown in some of the illustrations. Operation with safety devices removed is not permitted! DANGER Safety devices must be fitted when working with the machine. Current when going to press

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

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Illustration aids

These instruction contain safety instructions that highlight dangerous working practices. These safety notes are indicated with a warning symbol and a keyword. This warning symbol means: Attention - this concerns your safety and the safety of others. The associated keyword signifies the degree of danger: DANGER Is used for great, directly threatening danger. If this danger is not averted, serious physical injuries or loss of life of persons will result. WARNING Is used for potentially dangerous situations. If this danger is not averted, serious physical injuries or loss of life of persons may result. CAUTION Is used for potentially dangerous situations. If this danger is not averted, physical injuries or serious material damage may result. Notes which make the work easier or contribute to better understanding when operating the machine are displayed in the following way: Note Indicates notes which draw attention to peculiarities. Note Indicates cross references to other documents. Handling instructions are shown in table form as follows: 1

Press switch (1).

2

Actuate control lever (2).

3

Unfasten pins (3).

z Listings are marked with bullet points.

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

BS80

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Glossary of terms

Operator The operator (owner of the company/company) is responsible for operating the machine in a correct manner, or for ensuring that the product is being used by suitable and instructed personnel. Operating personnel The operating personnel are the person/s authorized by the operator to use the product. Trained technicians Trained technicians are those authorized by the operator to fulfil certain obligations such as installation, fitting, repair and maintenance and troubleshooting. z Specialists

Specialists are those who, on the basis of specialist training, knowledge and experience with the product and in the full knowledge of the relevant standards, can appraise the work allocated to them and can recognize potential dangers and avoid them.

z Instructed personnel

Instructed personnel are those who have received instruction in the tasks allocated to them and in the potential dangers of misuse and misbehavior, who have been taught about the necessary safety equipment, safety measures, relevant regulations, accident prevention guidelines and operating conditions and who have proved their abilities.

z Experts

Experts are those who, on the basis of specialist training and experience have sufficient knowledge in the area of the productand are sufficiently aware of the relevant national occupational safety guidelines, accident prevention guidelines, regulations and generally recognized technical regulations (e.g. EEC-Guidelines, VDE-Regulations, VBG) as to be able to judge the operational safety of the machine.

z Specialists

Specialists are those who are authorized by the German technical monitoring organization TÜV or by their professional organization to check the machine. Authorization on the part of a professional organization must comply with the “Principles for authorizing specialists to check cranes” (ZH 1/518). It is linked to the issue of an identity number. This is to be entered by the specialist in the check report and/or check notice. Authorizations can be limited to parts of checks or to certain types of crane.

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BS80

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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. The operation and deployment may only be carried out by persons suitably instructed. Initial operation, maintenance, transportation and assembly/dismantling only by trained specialists. Detailed information on the required prior knowledge and qualifications of the operator can be found in Chapter 1 SAFETY of these instructions.

What documents go with the machine?

The following documents go with the machine: z These operating and maintenance instruction z Spare parts catalog z Service checkbook.

Note The complete scope of materials included with delivery is specified in the order confirmation. How are the instruction divided up?

The instruction are divided into 10 chapters: z 1: Safety

You will find generally applicable safety instructions that must be universally observed in this section.

z 2: Overview

Chapter 2 illustrates the main components of the machine.

z 3: Technical data

You will find basic information about the machine in this section, forexample lifting capacities.

z 4: Starting operation

This section provides information about starting operation on a daily basis.

z 5: Operation

You will also find information on operating instruments and working operation.

z 6: Maintenance

Chapter 6 illustrates procedures used to ensure that the machine is suitable for use.

z 7: Setting up

Chapter 7 may contain information on setting up counterweight.

z 8: Transportation

In Chapter 8 you will find the dimensions and weights of the machine.

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z 9: What to do if ...

Here you will find information on recognizing causes of malfunctions and introducing measures to eliminate faults.

z 10: Appendix

Here you will find an index and additional information, forexample on the warranty.

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BS80

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Please contact us at

SENNEBOGEN Maschinenfabrik GmbH Hebbelstrasse 30 D-94315 Straubing Telephone:

+49 9421 540-0

Internet:

http://www.sennebogen.de

Fax Customer service:

+49 9421 540279

Fax Spare parts storage:

+49 9421 40811

Technical documentation: E-mail:

[email protected]

Fax:

+49 9421 540 380

Note The addresses of SENNEBOGEN sales and service partners are available on the Internet through our homepage. BAUER Maschinen GmbH Wittelsbacher Str. 5 D-86529 Schrobenhausen Telephone:

+49 8252 97-0

Internet:

http://www.bauer.de

Fax Customer service:

+49 8252 972587

Technical documentation: E-mail:

[email protected]

Fax:

+49 8252 2815

Note The addresses of BAUER sales and service partners are available on the Internet through the homepage. instruction

BS80

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CE symbol of

conformity

Copyright

W-8

The CE symbol indicates that basic safety requirements have been met. For more information, see the separate Declaration of conformity.

© Straubing 2007, SENNEBOGEN Maschinenfabrik GmbH

Reproduction, in whole or in part, only with written permission of SENNEBOGEN Maschinenfabrik GmbH, Straubing, Germany. Printed in Germany.

BS80

Contents

BS80/ 05.2008

1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Use as Intended . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.3 Potential instances of misuse . . . . . . . . . . . . . . . . 1-2 1.4 Abuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.5 Residual hazards . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.6 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1.6.2 Preparing to Operate . . . . . . . . . . . . . . . . . . 1-8 1.6.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 1.6.4 Setup work . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1.6.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . 1-11 1.6.6 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 1.7 Obligations of the Owner . . . . . . . . . . . . . . . . . . . 1-14 1.8 Guards and Protective Devices . . . . . . . . . . . . . . 1-17 1.9 Warning Signs and Labels on the Machine . . . . . 1-18 1.9.1 Identification plate . . . . . . . . . . . . . . . . . . . 1-18 1.9.2 CE stamp of conformity . . . . . . . . . . . . . . . 1-19 1.9.3 Euro-test identification . . . . . . . . . . . . . . . . 1-19 1.9.4 Safety signs and warning symbols . . . . . . 1-20 1.10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 1.11 Hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

2

General View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Overall Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Operator´s Station . . . . . . . . . . . . . . . . . . . . . . . . .

3

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1 Base Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

4

Preparing to Operate . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Initial Commissioning . . . . . . . . . . . . . . . . . . . . . . 4.3 Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 Starting the Machine . . . . . . . . . . . . . . . . . . . . . . .

2-1 2-1 2-2 2-4 2-6 2-7

4-1 4-1 4-2 4-2 4-4

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Contents

4.4.1 4.4.2 4.4.3 4.4.4

Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Starting the Engine . . . . . . . . . . . . . . . . . . . 4-5 Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Bring Machine up to Operating Temperature . . 4-7 4.5 Turning off the machine . . . . . . . . . . . . . . . . . . . . . 4-8 4.5.1 Switching off engine . . . . . . . . . . . . . . . . . . 4-8 4.6 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

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5

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.2 Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.3 Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.3.1 General View . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.3.2 Emergency Stop . . . . . . . . . . . . . . . . . . . . . 5-5 5.3.3 Safety Lever . . . . . . . . . . . . . . . . . . . . . . . . 5-6 5.3.4 Right-Hand Control Lever . . . . . . . . . . . . . . 5-7 5.3.5 Left-Hand Control Lever . . . . . . . . . . . . . . . 5-7 5.3.6 Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5.3.7 Sennebogen Diagnostic System (SDS) . . . . 5-9 5.3.8 Right-Hand Control Panel . . . . . . . . . . . . . 5-17 5.4 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 5.5 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . 5-22 5.5.1 Air Conditioner . . . . . . . . . . . . . . . . . . . . . . 5-22 5.5.2 Auxillary heating / Water heater . . . . . . . . 5-24 5.5.3 Hydraulicoil- , cooling water- and diesel preliminary heating, batterie preliminary heating 5-25 5.6 Operating Technique . . . . . . . . . . . . . . . . . . . . . . 5-27 5.6.1 Safety Information . . . . . . . . . . . . . . . . . . . 5-27 5.6.2 Swinging the Upper Structure . . . . . . . . . . 5-28 5.6.3 Refueling the Machine . . . . . . . . . . . . . . . . 5-30

6

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.2.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.2.2 Oils and Lubricants . . . . . . . . . . . . . . . . . . . 6-5 6.2.3 Coolant for CATERPILLAR - Drive motors . 6-6 6.2.4 Coolant - General . . . . . . . . . . . . . . . . . . . . 6-7 6.2.5 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

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Contents

6.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 6.3.1 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 6.3.2 Water separator . . . . . . . . . . . . . . . . . . . . 6-14 6.3.3 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 6.3.4 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 6.3.5 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 6.3.6 Belt Drives . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 6.4 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . 6-20 6.4.1 Hydraulic Hose Lines . . . . . . . . . . . . . . . . 6-22 6.4.2 Relieving Hydraulic System Pressure . . . . 6-23 6.4.3 Checking Hydraulic oil Level . . . . . . . . . . . 6-24 6.4.4 Changing Hydraulic Oil . . . . . . . . . . . . . . . 6-25 6.4.5 Return Flow Filter – Replacing Filter Element . . 6-28 6.4.6 Pilot Control Filter – Replacing Filter Element . 6-29 6.4.7 Leakage Oil Filter – Replacing Filter Element . . 6-30 6.4.8 Replacing Ventilation Filter . . . . . . . . . . . . 6-31 6.4.9 Checking and Cleaning Hydraulic Oil Cooler . . 6-32 6.4.10Checking Precharge Pressure of the Accumulators 6-33 6.5 Distributor Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 6.5.1 Checking Oil Level . . . . . . . . . . . . . . . . . . 6-35 6.5.2 Changing Gear Oil . . . . . . . . . . . . . . . . . . 6-35 6.6 Slewing Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 6.6.1 Lubricate the ball-type swing gear and bearing 6-36 6.7 Swing drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 6.7.1 Lubricating the gear teeth . . . . . . . . . . . . . 6-38 6.7.2 Retightening bolts . . . . . . . . . . . . . . . . . . . 6-39 6.8 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 6.8.1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 6.8.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 6.9 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 6.10 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 6.10.1Maintenance Schedule . . . . . . . . . . . . . . . 6-43 6.10.2Refill Capacities . . . . . . . . . . . . . . . . . . . . 6-46 6.10.3Tightening Torques for Screws . . . . . . . . . 6-47

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Contents

0-4

7

Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1 Detaching/Attaching Counterweight . . . . . . . . . . . 7-1 7.1.1 Detaching Counterweight . . . . . . . . . . . . . . 7-2 7.1.2 Attaching Counterweight . . . . . . . . . . . . . . . 7-4 7.2 Setting Up (Option) . . . . . . . . . . . . . . . . . . . . . . . . 7-8 7.3 Detaching/Attaching Counterweight . . . . . . . . . . . 7-8 7.3.1 Detaching Counterweight . . . . . . . . . . . . . . 7-9 7.3.2 Attaching Counterweight . . . . . . . . . . . . . . 7-11

8

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 Dimensions and Weights . . . . . . . . . . . . . . . . . . . . 8.2.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.2 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 Disconnect electrical system from battery . . . . . . . 8.4 Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Lashing and Tying Down the Machine . . . . . . . . . .

9

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.2 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 9.3 Electronic System . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 9.4 Sennebogen diagnositc system SDS . . . . . . . . . . 9-6 9.4.1 Bank of keys with LEDs . . . . . . . . . . . . . . . . 9-6 9.4.2 Indicator and warning lights . . . . . . . . . . . . . 9-8 9.5 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 9.6 Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11 9.7 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

1

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 1.1 List of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . 2-1

8-1 8-2 8-3 8-3 8-4 8-5 8-6 8-8

BS80/ 05.2008

Safety - General

1

Safety

1.1 General In the design and construction of the machine, allowance has been made for the state of the art and the recognized safety-related standards. Its operation may nevertheless involve potential hazards for persons, the machine and other property if z the machine fails to be used as intended; z operation or maintenance of the machine is performed by

unqualified personnel;

z the safety notices and messages are ignored. z the machine is found to be defective. z the operating tools attached do not comply with the relevant safety

regulations.

z the operating tools attached are found to be defective

National and international regulations apply in addition to the safety information in these instruction. In the Federal Republic of Germany e.g: z Winches, Lifting and pulling devices (VBG 8) z Crane (BGV D6) z Hoisting devices in lifting appliance operation (VBG 9a) z Earth-moving machinery (VBG 40) z EC Machinery guideline 98/37/EC z EMC Guideline 89/336/EEC z Electrical Machinery Equipment (EN 60204-1) z Safety Requirements for Fluid Engineering Systems and their

Components - Hydraulic (EN 982)

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

Note When a conflict exists between the national rules and regulations in the country of destination and our recommendations, follow the strictest procedure.

BS80/ 01.2006

1-1

Safety - Use as Intended

1.2

Use as Intended

The machine has been designed as a carrier machine for BAUER, Schrobenhausen, Germany. Any other use or any use beyond the scope set out above is considered to be improper use. Work station: The operator’s work station is in the operator’s cab of the machine. Note Study and observe the information contained in the BAUER documentation.

Target group

The machine has been designed to perform specific exacting duties. Persons who operate the machine or work on it must have received adequate training or instruction. Operation and application must be performed only by persons that have been duly instructed. Commissioning, maintenance, transport and assembly/disassembly must be assigned to trained qualified personnel.

1.3 Potential instances of misuse z Inadequate equipment for the application (e.g. protection of cab

against falling objects with guard grill).

z Operating on insufficiently firm base. z Neglect of necessary inspection and maintenance work. z Use in inadmissible ambient conditions. z Misuse by untrained and uninstructed personnel. z Counterweight disassembly or replacement of counterweight

elements with device attached (e.g. Ram)

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BS80/01.2006

Safety - Abuse

1.4

Abuse

Practices considered to be improper use (abuse) include in particular: z Lifting, moving and handling of persons z Oblique pulling of loads z Dragging of loads z Breaking loose any loads that have got stuck z Operation in a potentially explosive atmosphere

WARNING Improper use will exempt the manufacturer from any and all liability! The user will bear sole responsibility.

1.5 Residual hazards The safety information in these instruction are guidelines for the safe use of the machine by qualified machine operators. However, SENNEBOGEN cannot anticipate every situation in practice that may result in danger. Therefore, the safety notes and warnings on the machine and in the instruction cannot beall inclusive. The owner andmachine operator still remain responsible for safety.

BS80/ 01.2006

1-3

Safety - Safety Information

1.6

Safety Information

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

edge of the excavation.

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

1.6.1 General Danger area

The danger area of the machine is the surrounding area in which persons are within the reach of: z Work-related movements of the machine z Working equipment and machine attachments z Loads swinging out or dropping down z Working equipment dropping down

DANGER No persons are allowed in the danger area! In case of danger to persons, the operator must give warning signals. If the persons fail to leave the danger area in spite of the warning, operations must be stopped. To avoid crushing hazards, maintain an adequate safety clearance (at least 500 mm) to any fixed structures such as building structures, banks of excavations, scaffolds or other machines. Where maintenance of the safety clearance is precluded, mark off the area between any fixed structure and the working area of the machine. When the operator’s view of his work and travel area is restricted or impaired, a signal person must be provided.

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BS80/01.2006


Gallery = Catwalk for operators

DANGER Risk of falling! A maximum of 100 kg (220 lbs) is permitted per segment of grid iron on the gallery (= operator catwalk). Overloading will lead to damaging the construction, the results of which can lead to personal injury. Check the gallery for cracks and general damaged every 3 months and repair immediately if necessary.

Personal protective equipment

Problems

Stability

While performing work on the machine, the operating personnel is obliged to wear personal protective equipment as required by the national rules and regulations (e.g., hard hat, hearing protective, safety shoes, protective gloves). Report problems or damage immediately to a responsible person! Prevent the machine from incorrect or erroneous use. Repairs may only be performed by trained specialist personnel. z Position the machine on a firm, level supporting surface only. z Where necessary, stabilize the supporting surface. z Beware of edges of excavations, banks, vaults, etc. z Set outriggers on a firm, level supporting surface as well. z Pay attention to wind speeds!

DANGER Refrain from any operating practice impairing stability of the machine! Note that stability is reduced when the load swings out to the side.

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1-5


Working in the vicinity of power lines

z Clearly mark off the power lines in the job site area with your

supervisor. Do so before starting work!

z Consider all overhead lines to be energized electric power lines. z Operate the machine so that neither parts of the machine nor any

loads being handled enter into the danger zone.

z Maintain a safety clearance to the overhead lines. Unless otherwise

provided in the national laws and regulations, maintain the following minimum clearances:

Rated Voltage (Volts)

Safety Clearance (Meters)

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

unknown

5.00

z Use a signal person to observe the safety clearance. z The use of insulating links, cage-type guards or proximity warning

devices on the machine is not a substitute for maintenance of the minimum clearances specified.

z Wind can cause both the overhead lines and any working equipment

to weave or swing out and thus reduce the clearance.

High voltage contact

In case of high voltage contact, proceed as follows: z Do not leave the operator’s station. z Caution all outside persons against approaching or touching the

machine.

z Where possible, move the working equipment or the entire machine

out of the danger zone.

z Arrange for the power to be disconnected. z Do not leave the machine until after de-energization of the line that

has been touched or damaged.

DANGER If you must leave the machine in an emergency, e.g., if there is a fire, never contact the machine and the ground at the same time. Jump clear of the machine with your feet together.

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BS80/01.2006


Qualifications of personnel

Extract from VBG 40 regulations (Germany)

The machine must be operated and maintained only by qualified personnel. Only those persons must be assigned to operate or maintain earthmoving machines on their own who z have attained the age of 18 (majority); z are both physically and mentally fit; z have received training in the operation or maintenance of the

earthmoving machine and have proven their relevant qualification to the employer; and who

z can be expected to reliably perform the duties assigned to them.

They must have been appointed by the employer to operate and maintain the earthmoving machine. Extract from OSHA regulations (United States)

Operators are required to meet the following qualifications: z Pass a practical operating examination for the machine they will

operate.

z Have vision of at least 20/30 Snellen in one eye and 20/50 Snellen

in the other eye, with or without corrective lenses.

z Be able to distinguish colors (red, green, yellow) if color

differentiation is required for operation.

z Have adequate hearing (with or without a hearing aid).

A disabling heart condition or a history of epilepsy are sufficient reason for disqualification as an operator.

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1-7


1.6.2 Preparing to Operate WARNING z Make sure that all guards and protective devices of the machine are

in place and are properly secured.

z Wear personal protective equipment (hard hat, safety glasses)

where this is required by job conditions.

z Avoid wearing jewelry or loose clothing. z Secure any loose items, e.g., tools or other accessories. z Agree on hand signals with the signal person. z Obtain information about first aid and about assistance and rescue

services.

z Perform the pre-start checks as specified in Section 4.3. z Get onto or off the machine only while it is parked. Use the means

of access and ladders provided for the purpose:

– Before using the means of access and the ladders, clean them as necessary. – While mounting or dismounting, your hands must be free of any objects. Use a hand line or a hoist to lift any items of equipment onto the machine. – Do not use controls in the operator’s cab as handholds. z Make sure that there are no persons in the danger area. z Check the safety features (brakes, signaling and lighting equipment)

of the machine.

z While traveling at slow speed, check the controls and protective

devices for proper operation.

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BS80/01.2006


1.6.3 Operation WARNING z Be sure to observe Chapter 1 SAFETY.

Before the machine is put into operation, perform the checks as specified in Section 4.3.

z Persons who operate the machine or work on it must have received

adequate training or instruction. Operation and application must be performed only by persons that have been duly instructed.

z Make sure that there are no persons in the danger area. z Maintain a safety clearance to overhead lines. z Operate the machine only while you are in the operator’s seat. z Do not use the machine for handling of personnel. z Make due allowance for ambient conditions, e.g., poor visibility,

wind speeds, etc.

z Observe performance specifications. z Check whether the load capacity of attachment points is adequate. z Obey the signals given by signal persons, where applicable. z Before leaving the operator’s cab:

– Park the machine on a safe surface. Back off from the edge of an excavation, where applicable. – Lower any attached loads to the ground. – Secure the working attachments. – Pull the safety lever backward. – Chock the tires/block the undercarriage. – Stop the engine. z Lock the operator’s cab; use warning lamps to mark the machine,

where applicable.

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1-9


1.6.4 Setup work WARNING z Wear personal protection equipment (e.g. safety helmet, ear protection, protective gloves, safety boots) if working conditions require it. z When disassembling components or equipment, always use load

suspension equipment with a sufficient load carrying capacity at the attachment points.

z Ensure that there is no one within the danger area. z Note the relevant accident prevention directives for working with load

suspension equipment.

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

up task at a time.

z Do not climb or run on equipment parts (e.g. boom components,

ballast components) suspended on the crane. Do not stand on parts suspended from the crane.

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BS80/01.2006


1.6.5 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 unintentionally. Observe the following: z Place the machine on a firm base, if necessary set back from the

edge of the excavation.

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

WARNING z Observe the applicable statutory accident prevention and safety

regulations.

z Land any attached loads to ground level. z Pull the left safety lever backwards. z Before attempting to perform any maintenance, shut down the

machine and secure it against unauthorized restarting.

z Attach a warning tag to the controls. z Do not smoke and do not allow open flames. z When working in the area of the battery, cover the battery with

isolating material; do not deposit any tools on the battery.

z Use personnel hoists or work platforms that satisfy safety

requirements.

z Stay clear of all rotating and moving parts. z Relieve the pressure before working on the hydraulic system. z Always wear protective gloves when handling wire ropes. z Use only genuine BAUER/SENNEBOGEN spare parts. z Use only those oils and lubricants that are specified in the lubricants

chart.

z Do not lift heavy components by hand. Use hoists or lifting

equipment.

z Operate the optional battery disconnect switch, if equipped, to

interrupt power supply.

z On completion of the maintenance operations, reinstall all guards

and protective devices.

z Keep the operator’s cab clean and tidy.

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z Perform a functional check to ensure proper operation. z On completion of any maintenance operations, only the machine

owner or his agent is permitted to clear the machine for service again.

z For machines with pneumatic tires:

When inflating tires, keep an adequate safe distance and use a tire cage.

DANGER z Work on the machine's electrical equipment may only be carried out by a qualified electrician. z Work on running gear, braking and steering systems may only be

carried out by specifically trained technicians!

z Work on hydraulic systems may only be carried out by personnel

with specific knowledge and experience of hydraulics!

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

discussion with the manufacturer.

WARNING Mixing oils, lubrication or operational materials of different types is not permitted! Filling or mixing oils, lubricants or any other operational fluids (e.g. hydraulic oil, transmission oil, motor oil, coolant, etc.) of different types can lead to chemical reaction damage to machine components. This damage can in turn result in severe da mage to property and to personal injuries. Use oils, lubricants and operational fluids that are approved by SENNEBOGEN only. Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

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BS80/01.2006


1.6.6 Transport WARNING z In Germany:

Loading and transportation work is only to be carried out by authorised specialist personnel in accordance with VBG 40, §48 and Federal Motor Vehicle Safety Standards (StVo) §22.

z Comply with the relevant regulations for securing loads.

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

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

equipment from unintended movement.

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

ramps can be accessed without danger of sliding.

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

users.

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

gloves, safety boots).

z Notify SENNEBOGEN customer service of any transport damage

immediately.

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Safety - Obligations of the Owner

1.7

Obligations of the Owner

WARNING The owner/user is obliged to prepare relevant instruction when dealing with dangerous machines or hazardous materials. The necessary information is to be found in z EC directives on occupational health and safety z National occupational health and safety laws z Accident prevention regulations and z the present instruction.

Recurring inspections

Specialist testing, required for crane or backhoe operation The machine must be thoroughly checked by a specialist. z before initial operation and before putting the machine back into

operation after significant modifications

z at least once yearly z and in between according to operating conditions and conditions of

use.

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

regulations and guidelines due to specialist training and

z through special instructions of Co. BAUER/Sennebogen z has obtained extensive knowledge of this machine and the

corresponding regulations and guidelines through specialist training and can assess the safe working condition of the machine.

Specialist testing, only required for crane operation The following cranes must be tested by a specialist every 4 years: – Fuel driven mobile crane – Location changing fuel driven derrick crane – Vehicle attachment crane The specialist inspection is to be performed in the 13th year of operation and annually thereafter. Faults that are determined in recurring inspections must be eliminated according to the safety-relevance and within a suitable time-frame.

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BS80/01.2006


Risks incurred by ignoring safety notices

Non-observance of the safety notices and messages is dangerous, and persons as well as the environment and the machine can be endangered as a result. Failure to observe the safety notices and messages will invalidate any entitlement to damages.

Selection and qualifications of personnel

z Employ only personnel that has been duly trained or instructed. z Define responsibilities for operation and maintenance. z Observe the minimum age permitted by law.

DANGER z Personnel that is being trained or instructed must not be allowed to work on the machine except under constant supervision of an experienced skilled person. z Have any work on electrical equipment of the machine performed by

a qualified electrician only.

z Only qualified personnel having received relevant training is allowed

to perform work on undercarriages, braking and steering systems!

z Work on hydraulic equipment must only be performed by personnel

having specific knowledge and experience of hydraulics!

Inadmissible operating practices

z Safety of operation of the machine is ensured only when it is used

as intended, consistent with the specifications in Section 1.2 of this instruction.

z The performance limits specified in Chapter 3 TECHNICAL DATA must

not be exceeded.

z When the machine is exposed to risks of falling heavy objects, it

must not be used unless the operator’s station is protected by a canopy (FOPS structure). The canopy is available from BAUER/ SENNEBOGEN as an option.

Specific dangers

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

Technical condition of the machine

It is the obligation of the owner to continuously monitor the overall technical condition of the machine (for defects and damage evident on the outside as well as changes in operational performance). Keep the time limits specified for periodic inspections.

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Noise protection

The permanent sound pressure level of the machine – measured at the operator’s seat with the operator’s cab closed – is about 80 dB(A). Wearing of hearing protective devices therefore is not a mandatory requirement. Measurements are made as specified in EN ISO 11201. It is possiblehowever that ambientinfluences cause the level to exceed 85 dB(A), e.g., owing to dropping or transport of material, or in combination with other machines on a job site. In such cases, noise protection arrangements for the operating personnel are a mandatory requirement. The owner must make sure that adequate hearing protective devices are available and are worn by the operating personnel.

Genuine BAUER/ SENNEBOGEN spare parts

Conversions and modifications of the machine are not permitted. This applies also to the installation and use of safety devices and valves as well as welding on load carrying parts. Genuine BAUER/SENNEBOGEN spare parts and accessories serve the safety of the personnel. The use of other components may change the properties of the machine and thus compromise safety. The use of non-approved components will release BAUER/ SENNEBOGEN from all and any liability for any resulting consequences.

Employment in foreign countries

When the machine is employed abroad, take the following precautions: z Observe the safety regulations applicable in the respective country

of use.

z Make sure that the operating personnel has the necessary

qualifications for the scheduled work.

z See to it that the contents of the present instruction are read and fully

understood. Where necessary, obtain a manual in the respective official language from BAUER/SENNEBOGEN.

Fire extinguisher and first aid kit (option)

Locations for mounting of a fire extinguisher and a first aid kit have been provided on the machine. The owner is obliged to equip the machine accordingly. Obtain the fire extinguisher and the first aid kit from BAUER/SENNEBOGEN, if required.

Warranty conditions

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

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BS80/01.2006

Safety - Guards and Protective Devices

1.8

Guards and Protective Devices

DANGER z Do not remove any protective devices and covers. z Whenever the machine is started, make sure first that all protective

devices of the machine are in place and are properly secured.

z On completion of fitting or maintenance operations, properly

reinstall all guards, protective devices and covers.

z Replace any damaged protective devices by new items.

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Safety - Warning Signs and Labels on the Machine

1.9

Warning Signs and Labels on the Machine

There are specific safety signs and warning symbols on the machine. z Do not remove the safety signs and labels. z Keep all safety signs and labels in an undamaged and readable

condition.

z Use water and soap to clean the safety signs, where necessary.

Do not use gasoline or solvents to clean the signs and labels.

z Replace any damaged, scratched or illegible safety sign or label by

a new item.

Note Warning signs and labels are available from BAUER/SENNEBOGEN (see spare parts catalog).

1.9.1 Identification plate

1

Machine type

2

Manufacturer’s No. (Facility No.)

3

Engine performance specification (in kW)

4

Year of manufacture

5

* actual - Permissible overall weight of machine

6

* actual - Permissible weight on the front axle

7

* actual - Permissible weight on the rear axle

(*) Note The data for positions 5, 6 and 7 is not always engraved on the type plate.

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BS80/01.2006


1.9.2 CE stamp of conformity – affects machines that are operated within the EU/EEC. These machines wear the CE identification. This means that these machines meet the respective safety stipulations of the EU machine regulations upon delivery. For changes that affect the safety of the machine and the respective consequences, those that make the changes are responsible and liable. If the machine is used for purposes other than those intended or is used with machinery other than that indicated in these instructions, safety must be guaranteed in each case. Those performing the work are responsible and liable. In certain cases, another CE identification and the completion of a new EU declaration of conformity may be required.

CE Stamp

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

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1.9.4 Safety signs and warning symbols

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1 - 21

Safety - Disposal

1.10 Disposal Lubrication and consumables CAUTION Observe environment protection! Handle and dispose of used items and materials correctly, especially z when working on lubrication systems and devices and z when working with solvents.

Extract from the Disposal Guideline 75/439/EEC: z “It is prohibited to mix spent oil with other waste”. z “Spent oils must not be mixed together”. z “Used oil filters must be collected, kept, transported and disposed of

separately from other waste”.

Notes z Dispose of lubricants and other consumables at suitable collection points. z National environmental conditions valid in the country of use also

apply.

Batteries

When working with batteries, please observe safety instructions and protective measures. Notes z Do not dispose of batteries in household trash! Return defective batteries to a collection place for old batteries. z National environmental conditions valid in the country of use also

apply.

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BS80/01.2006

Safety - Hand signals

1.11 Hand signals Driver and signaler communicate with each other with the aid of the following hand signals when vision is restricted in the driving and work area. The guide gives the necessary signals to ensure safe operation. Safety instructions

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

by other tasks.

z Observe notes of VBG 40, § 35 Guides as well as the details of DIN

33409 Hand signals for guidance.

Attention Extend arm upwards with hand open.

Stop Extend both arms horizontally.

Stop! Danger! Alternately extend and fold in both arms horizontally.

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

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

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

Turn right Left thumb outwards.

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BS80/01.2006


Turn left Right thumb outwards.

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

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

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

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

Increase reach Both thumbs point outwards.

Decrease reach Both thumbs point inwards.

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

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BS80/01.2006


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

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1 - 27


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BS80/01.2006

General View - Overall Machine

2

General View

2.1 Overall Machine

1

1.1

2

1 Upper structure 1.2

1.1 Engine 1.2 Hydraulic system 2 Operator’s station / cab

BS80/ 10.2007

2-1

General View - Engine

2.2

Engine

1

2

3 4

5

1 Air conditioner indicator lamp 2 Gear pumps 3 Distributor gear 4 Leakage oil block 5 Power receptacle, 24 volt, 20 amp

2-2

BS80/ 10.2007

General View - Engine

1

2b

2a

2

3 4

5

1 Main fuse 2 Engine 2a Water separator 2b Fuel filter 3 Charge air cooling system 4 Batteries 5 Battery disconnect switch 6

6 Coolant cooler

BS80/ 10.2007

2-3

General View - Hydraulic System

2.3

Hydraulic System 3 2

1

1a

1b

1 Hydraulic tank

2 Refueling pump

1a Oil level display

3 Oil cooling

1b Fuel fill strainer

4

5

6

7

4 Thermostat - Hydraulikoil preliminary heating 5 Shutt-of flap 6 Power receptacle, 24 volt, 20 amp 7 Main control valve bank

2-4

BS80/ 10.2007

General View - Hydraulic System

3

1

2

1

1 Swing gear 2 Leakage oil block 3 Brake

BS80/ 10.2007

2-5

General View - Air Filter

2.4

Air Filter

2,3

1 1 Air filter 2 Primary filter element 3 Secondary filter element

2-6

BS80/ 10.2007

General View - Operator´s Station

2.5

Operator´s Station

1

BS80/ 10.2007

2 3 4

5

6

1 Pedals

4 Emergency switch

2 Safety lever

5 Fuses

3 Water reservoir, window washer

6 Control lever

2-7

General View - Operator´s Station

1

2

Pedals: 1 Left travel pedal, with hand lever 2 Right travel pedal, with hand lever

2-8

BS80/ 10.2007

Technical Data - Base Machine

3

Technical Data

For the specifications of the base machine refer to Section 3.1. Section 3.2 provides wind speed information. Note For the shipping dimensions and weights of the base machine refer to Section 8.2. Special attachment system data can be found in the instruction of the assembly concerned.

3.1 Base Machine Engine

Caterpillar C-15 Diesel Engine Power output (acc. to ISO9349)

354 kW (475 HP) at Nominal speed 1800 rpm

Cylinders

6

Capacity

14,6 l (14634 cm3)

Permissible inclinations of engine: left

right

front

rear

30°

30°

30°

30°

Note At any greater inclinations, an adequate engine oil level is no longer ensured. In case higher degrees of inclination are required, consult with BAUER/SENNEBOGEN beforehand. For further information on the engine, consult the engine manufacturer’s instruction. Electrical system

24 volt Note Ensure that the available output power of the alternator is not exceeded when installing additional current consumers (e.g. lights).

Hydraulic system

Swing drive

BS80/ 06.2006

Max. operating pressure 300 bar

Swing speed

0 to 3 rpm, infinitely variable

3-1

Technical Data - Base Machine

Ambient temperature

On the job / Production application

ca. - 20°C ... ca. + 40°C

Note When running a machine in environmental temperatures outside the specified temperature range, special temperature packages are available (optional!). Please contact SENNEBOGEN customer service if you have any other questions.

3-2

BS80/ 06.2006

Technical Data - Appendix

3.2

Appendix

Wind Speed Wind Force

Description

Beaufort number

Name

m/s

km/h

Onshore

0

Calm

0-0.2

1

Calm; smoke rises vertically

1

Light air

0.3-1.5

1-5

Direction of wind shown by drifting of smoke but not by wind vanes

2

Light breeze

1.6-3.3

6-11

Wind felt on the face; leaves rustle; ordinary vane moved by wind

3

Gentle 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

Raises dust and loose paper; twigs and small branches are moved

5

Fresh breeze

8.0-10.7

29-38

Small trees in leaf begin to sway; crested wavelets form on inland waters

6

Strong breeze

10.8-13.8

39-49

Large branches in motion; telegraph wires whistle; umbrellas used with difficulty

7

Moderate gale

13.9-17.1

50-61

Whole trees in motion

8

Fresh gale

17.2-20.7

62-74

Breaks twigs off trees; generally impedes progress outdoors

9

Strong gale

20.8-24.4

75-88

Slight structural damage occurs (chimney pots and slates removed).

10

Whole gale

24.5-28.4

89-102

Trees uprooted; considerable structural damage occurs.

11

Storm

28.5-32.6

103-117

Widespread storm damage (very rarely experienced onshore).

12

Hurricane

32.7-36.9

118-133

Devastation occurs

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3-3

Technical Data - Appendix

3-4

BS80/ 06.2006

Preparing to Operate - Safety Information

4

Preparing to Operate

4.1 Safety Information WARNING z Be sure to observe Chapter 1 SAFETY. Before the machine is put into operation, perform the checks as specified in Section 4.3. z Make sure that all guards and protective devices of the machine are

in place and are properly secured.

z Wear personal protective equipment (hard hat, safety glasses)

where this is required by job conditions.

z Avoid wearing jewelry or loose clothing. z Secure any loose items, e.g., tools or other accessories. z Agree on hand signals with the signal person. z Obtain information about first aid and about assistance and rescue

services.

z Get onto or off the machine only while it is parked. Use the means

of access and ladders provided for the purpose:

– Before using the means of access and the ladders, clean them as necessary. – While mounting or dismounting, your hands must be free of any objects. Use a hand line or a hoist to lift any items of equipment onto the machine. – Do not use controls in the operator’s cab as handholds. z Make sure that there are no persons in the danger area. z Check the safety features (brakes, signaling and lighting equipment)

of the machine.

z While traveling at slow speed, check the controls and protective

devices for proper operation.

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4-1

Preparing to Operate - Initial Commissioning

4.2

Initial Commissioning

Initial commissioning of the machine is performed by BAUER/ SENNEBOGEN or by a trained and duly authorized skilled person. Where the machine has been idle for any length of time (> 6 months), you should contact the BAUER/SENNEBOGEN service department before putting it back in service. WARNING Be sure to observe Chapter 1 SAFETY. Before the machine is put into operation, perform the checks as specified in Section 4.3.

4.3 Pre-Start Checks Safety information

Note the safety information before you start work. DANGER z Familiarize yourself with the machine and with its equipment. To that end, study this instruction, and Chapter 1 SAFETY in particular, before putting the machine into operation. z Perform only operations for which you have been trained and which

are within the scope of your duties.

Checklist

4-2

1

Are all guards, protective covers and safety signs and labels in place on the machine and undamaged?

2

Has the machine been cleaned to the point where dirt fails to constitute a potential hazard (risk of slippage or falling off; poor visibility)?

3

Have the windows been cleaned and been cleared of ice and snow?

4

Is stability of the machine ensured?

5

Is the undercarriage undamaged?

6

Has the correct counterweight (ballast) been fitted?

7

Are the boom components undamaged?

8

Has any maintenance required been performed as specified in the maintenance schedule?

9

Are the oil reservoirs filled to the proper levels (hydraulic system, engine)?

10

Is the fuel tank of the machine filled to the proper level?

BS80/ 06.2006

Preparing to Operate - Pre-Start Checks

11

Are the V-belts undamaged and of proper tension?

12

Are all bolted/screwed connections undamaged and properly tightened?

13

Are the operating and ambient conditions known?

14

Is the weight of the load known?

15

Is an experienced signal person available if and when required?

16

Are the loads to be attached within the ratings of the machine and of the sling devices? Be sure to observe Chapter 3 TECHNICAL DATA!

17

Have any danger points at the job site been identified and marked off (overhead lines, excavations, etc.)?

18

Is the danger area clear of personnel?

19

Are all safety devices working properly (brakes, signaling and lighting equipment)?

20

Has the machine been properly leveled?

21

If necessary, switch the optional battery isolation switch on or connect the battery pole.

DANGER Report all irregularities to the person responsible before you place the machine in service. Do not put the machine into operation until after all deficiencies have been corrected.

BS80/ 06.2006

4-3

Preparing to Operate - Starting the Machine

4.4 Safety information

Starting the Machine

Note the safety information before you start the machine. DANGER z Keep service access doors closed. z Before starting the engine, make sure that there are no persons in

the danger area.

z The exhaust gases of diesel engines are harmful to health. Operate

the engine only in the open or in well ventilated areas.

z Do not start the machine if there is a warning tag attached to the

controls.

z Adjust the operator’s seat and the mirror(s) to the proper positions. z Fasten the seat belt correctly and securely.

4.4.1 Seat Belt The machine has been provided with a lap belt. The belt conforms to the standards EN ISO 6683 and SAE J 386 (for the United States). WARNING z Before placing the machine in service, check the belt for signs of wear. If the belt is damaged, immediately replace the belt. z If the belt is dirty, use water to clean the belt. z The belt must not be twisted. z The belt must fit low across the operator’s hips, not over his

stomach.

1 2 3

4-4

1

Slide the metal catch (1) into the belt buckle (2). An audible clicking noise indicates that the belt is locked.

2

To release the belt, push in the red button (3) on the belt buckle (2).

BS80/ 06.2006


4.4.2 Starting the Engine 1

2 1

Perform the checks as specified in Section 4.3.

2

Insert the key into the starter lock (2) and turn it to position “1“. – The Slewing gear brake indicator light comes on.

3

Turn the ignition key clockwise in order to start the engine.

4

Use the rotary knob (1) to adjust engine rpm to the desired speed.

5

Push the safety lever forward if you want to enable the hydraulic functions.

6

Where applicable, release the slewing gear brake if you want to rotate the upper structure. – The Slewing gear brake indicator light goes off.

Never let the machine unattended, while the engine is running!

BS80/ 06.2006

4-5


4.4.3 Jump start The machine is equipped with a 24-volt starting system. Ensure that the external power source has the same voltage. CAUTION If a power source with a higher voltage is used, this can cause serious damage to the machine's electrical system. 1

Actuate battery isolator switch to interrupt the power supply.

2

Detach battery cover.

3

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

4

Using a jump lead, connect the negative terminal (-) of the donor battery to the engine block or to a solid, unpainted metal part of the receiving vehicle that is connected to the engine block.

5

Actuate the battery isolator switch to regenerate the power supply.

6

Start engine acc. to Section4.9.3

7

Switch on the electrical consumer (protection against overvoltage). .

8

Dismantling:: – Detach jump lead from negative terminal (-). – Detach jump lead from negative terminal (-).

9

– Switch off the electrical consumer.

10

Replace battery cover.

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

Avoid any contact with the skin, eyes or clothing. Rinse acid splashes and spills with clean water immediately. A visit to the doctor can be necessary.

z When working on electrical system, adhere to current regulations

and the accident prevention regulations.

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BS80/ 06.2006


4.4.4 Bring Machine up to Operating Temperature Guidelines for warm up period

Warm-up procedures

Ambient temperature range

Warm-up period

max. engine speed

up to 0 °C

approx. 15 min.

0 °C ... -20 °C

approx. 30 min.

Nominal speed - 250 min -1 (Nominal speed see Chapter3.1)

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

Additional warm-up time can be required at temperatures under 0°C.

z Then incrase the rpm in steps up to

the nominal speed of 250 rpm (no-load)

z If approx. 20°C water temperature has been achieved, put a loadon

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.

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 z Water: approx. 35 °C.

ATTENTION 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.

BS80/ 06.2006

4-7

Preparing to Operate - Turning off the machine

4.5

Turning off the machine

4.5.1 Switching off engine Note Switching off the driving engine without allowing a cooling down phase may cause heat storage and overheating of engine parts and especially the turbocharger. Allow the driving engine to cool down before switching off. z Lower engine speed to approx. 50 % of the rated speed (see

Chapter 3).

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

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

4-8

1

Place the machine on a firm surface.

2

Lower suspended loads and lower jib if necessary.

3

Lower engine speed to approx. 50 % of the rated speed to prevent the engine and cooling system from being damaged.

4

Allow engine to run for a further 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, etc.).

BS80/ 06.2006

Preparing to Operate - Decommissioning

4.6

Decommissioning

Proceed as follows if the machine is to be decommissioned for a prolonged period. 1

Switch off machine according to Section 4.5.1.

2

Clean machine according to maintenance instructions.

3

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

4

Lubricate machine according to maintenance instructions.

5

If necessary, switch the optional battery isolation switch off or disconnect the battery pole, see Section 8.3..

6

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

7

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

Note Admissible ambient temperatures see Section 3.1

BS80/ 06.2006

4-9

Preparing to Operate - Decommissioning

4 - 10

BS80/ 06.2006

Operation - Safety Information

5

Operation

5.1 Safety Information DANGER z Be sure to observe Chapter 1 SAFETY. Before the machine is put into operation, perform the checks as specified in Section 4.3. z Persons who operate the machine or work on it must have received


z Make sure that there are no persons in the DANGER area. z Maintain a safety clearance to overhead lines. z Operate the machine only while you are in the operator’s seat. z Do not use the machine for handling of personnel. z Make due allowance for ambient conditions, e.g., poor visibility,

wind speeds, etc.

z Observe performance specifications. z Check whether the load capacity of attachment points is adequate. z Obey the signals given by signal persons, where applicable. z For any long-distance travel, put the boom in the direction of travel. z Before leaving the operator’s cab:

– Park the machine on a safe surface. Back off from the edge of an excavation, where applicable. – Lower any attached loads to the ground. – Secure the working attachments. – Pull the safety lever backward. – Chock the tires/block the undercarriage. – Stop the engine. z Lock the operator’s cab; use warning lamps to mark the machine,

where applicable.

BS80/ 10.2007

5-1

Operation - Operator’s Cab

5.2

Operator’s Cab

5 4

1

2

3

1 Release - Door locking device 2 Cab door 3 Door lock 4 Emergency exit - Side window 5 Emergency exit - Front window The comfortable operator’s cab offers you a convenient and safe work environment. You may adjust some of the features to suit your individual requirements. Emergency exit

6

6 Hammer, emergency exit In case of emergency, you can exit through the front window (5) or through the side window of the cab door (4). To that end, use the hammer to smash the window.

5-2

BS80/ 10.2007

Operation - Operator’s Cab

Cab door

While in the fully open position, the cab door can be locked in place at the side wall of the cab. Pressing the release device (1) inside the cab allows the door to be unlocked again.

Front window

To open the front window: Tilt it inwards or push it upwards. Make sure that the window wiper is supported on the bracket. Press the two vertical handles inwards and move the window accordingly. Take care to ensure that the window latches home in the desired position. Press the two vertical handles outwards again.

Interior lighting

A courtesy light is fitted in the operator’s cab. You can turn the light on and turn it off again by rotating the lamp glass.

Window washer

For control of the window wipers, use is made of the switches on the right-hand control panel. The reservoir for the window washer fluid is located at the floor of the operator’s cab. Have the reservoir filled with antifreeze at all times.

Operator’s seat

Information on handling of the operator’s seat is provided in a separate instruction.

BS80/ 10.2007

5-3

Operation - Machine Controls

5.3

Machine Controls

5.3.1 General View

1

5-4

2 3 4

5

6

1 Pedals

4 Emergency switch

2 Safety lever

5 Fuses

3 Water reservoir, window washer

6 Control lever

BS80/ 10.2007


5.3.2 Emergency Stop The Emergency Stop switch (1) puts the machine out of operation immediately.

1

Positionings: pulled = machine on pressed = machine off

BS80/ 10.2007

5-5


5.3.3 Safety Lever The safety lever (1) acts as a protective feature.

1 shown here = safety lever released (pushed to the front) With the safety lever released (see illustration) z all hydraulic functions are available for use z all work movements can be performed z the slewing gear brake must be released separately

Note The slewing gear brake remains engaged after the safety lever has been released (by pushing it forwards). Use the left-hand control lever to release the slewing gear brake (see Section 5.6.2).

1

shown here = safety lever activated (pulled back to the rear) When the safety lever is activated z all hydraulic functions are out of operation z the slewing gear brake is engaged.

5-6

BS80/ 10.2007


5.3.4 Right-Hand Control Lever 2

3

1

4

Push buttons: 1 Option 2 Option 3 Option 4 Option

Note For control lever assignment refer to the BAUER documentation.

5.3.5 Left-Hand Control Lever 2

3

1

4

Push buttons: 1 Option 2 Option 3 Option 4 Option

Note For control lever assignment refer to the BAUER documentation.

BS80/ 10.2007

5-7


5.3.6 Pedals

1

2

Pedals: 1 Left travel pedal, with hand lever 2 Right travel pedal, with hand lever

5-8

BS80/ 10.2007


5.3.7 Sennebogen Diagnostic System (SDS)

1

2 n min

1

3 1 Display 2 Bank of keys with LEDs 3 Indicator and warning lights The SDS offers a means of retrieving additional information, e.g., current hydraulic oil temperature. Note Do not clean the Sennebogen Diagnostic system with fluids containing alcohol or solvents! These may cause the plastic surface to become brittle. Note All temperature readings are in degrees Celsius (°C). Sensors on the machine serve to continuously monitor the operating condition, and the measurement results are transmitted to the SDS. The measurement results are analyzed in the SDS, and pressing a key causes them to be shown on the display. In the event of irregularities occurring on the machine, the indicator and warning lights are activated. Self-test: Once ignition is turned on, the SDS system performs a self-test. All segments of the display are activated; all LEDs come on. The sensors are checked. After that the SDS system is ready for operation. Any fault detected by the SDS will be indicated on the display and by the LED. Have any faults corrected by the BAUER/SENNEBOGEN customer service.

BS80/ 10.2007

5-9


Display (1)

The two-line display serves to show additional information, e.g., the time of day. Press a function key in the bank of keys (2) to retrieve the corresponding information and have it shown on the display.

Bank of keys with LEDs (2)

The bank of keys is fitted with 8 function keys. You can use these keys to retrieve information and have it shown on the display. Each key has a red light-emitting diode (LED) assigned to it. The LED comes on when the associated key is pressed. When an intolerable level has been reached, e.g., excessive engine temperature, the LED flashes. The intolerable value flashes on the display, and a buzzer sounds. Acknowledge the fault alarm by pressing the respective key. Eliminate the cause. 1

2

3

4

6

5

n min

8

7

1 Battery charge

5 Time of day

2 Fuel level

6 Service hour meter

3 Coolant temperature

7 Speed indication - Engine

4 Oil pressure - Engine

8 Hydraulic oil temperature

Note Temperatures below 20°C (hydraulic oil) or below 30°C (coolant) respectively will not be shown.

5 - 10

BS80/ 10.2007


Adjusting time of day: 1

Press keys (6) and (7) at the bank of keys simultaneously for 5 seconds. The time of day as set will flash on the display, e.g., 16:52.

2

To adjust the time of day, press the keys as follows: (8) = Hour indication - Tens place (16:52) (7) = Hour indication - Units place (16:52) (6) = Minute indication - Tens place (16:52) (5) = Minute indication - Units place (16:52).

3

To accept the time setting, press keys (6) and (7) simultaneously until the display stops flashing.

Resetting daily service hour meter: 1

Press key (6). The service hour meter function is showing on the display.

2

Press key (6) for about 3s. This serves to reset service hours to zero.

Note The service hour meter on the right-hand control panel shows the overall service hours of the machine. This meter cannot be reset.

BS80/ 10.2007

5 - 11


Fault Signaling

LED flashes, continuous alarm sounds

Cause

Remedy

Fuel level in tank too low

– Refuel machine as specified in Section 5.6.3.

LED flashes, buzzer sounds

Cause

Remedy

Engine overheated

– Idle engine.

Cooling fins on engine oil cooler dirty

– Clean cooling fins on oil cooler.

Fan drive loose or defective

– Tighten fan drive, replace if necessary.

Coolant level too low

– Add coolant as specified in Section 6.3.5.

Engine switched off without cooling phase.

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

Note Overall performance of the machine is reduced to 65%. When the coolant temperature continues to rise, z the temperature reading on the display flashes in addition; z a continuous alarm sounds; z the engine is shut down.

Pressing the function key allows the engine to be started again. CAUTION There is a risk of engine and hydraulic units being destroyed. Use the acknowledgement procedure only for the purpose of moving the machine out of the danger area. Eliminate the cause of the fault immediately.

5 - 12

BS80/ 10.2007



Cause

Remedy

Engine oil pressure too low (<1.3 bar)

– Stop engine immediately. – Check engine oil level as specified in Section 6.3.1. – Add engine oil as necessary. – If fault continues to occur, inform the BAUER/SENNEBOGEN service department accordingly.

Note Overall performance of the machine is reduced to 65%. When the oil pressure falls below 1.0 bar, z the pressure reading on the display flashes in addition; z a continuous alarm sounds; z the engine is shut down.



Cause

Remedy

Hydraulic oil temperature excessive (>84°C)

– Operate engine at no load until the hydraulic oil has cooled down.

Cooling fins on hydraulic oil cooler dirty


Hydraulic oil level too low

– Check oil level as specified in Section 6.4.3. – Add hydraulic oil as necessary.

Note When the hydraulic oil temperature rises to more than +94 °C, the temperature reading on the display flashes in addition.

BS80/ 10.2007

5 - 13


IIndicator and warning lights (3)

Indicator lights provide information on current operating states, e.g., Slewing gear brake engaged. Warning lights come on whenever immediate action has to be taken on the machine, e.g., Clean air filter. 1

2

3

4

5

9

8

7

6

1

10

Indicator lights: 1 Slewing gear brake 6 Unassigned 8 Shut-off flap - Hydraulic tank Warning lights: 2 Air filter service indicator 3 Hdyr. Main filter contamination 4 Hydr. Secondary filter contamination A / B 5 Hydr. Secondary filter contamination C 7 Hydraulic oil level 9 Coolant level 10 Coolant temperature Note In order to properly identify the contaminated filter, the plug-connector must be removed from the differential pressure switch If the display goes out, the respective contaminated filter has been I identified.

5 - 14

BS80/ 10.2007


Fault Signaling

comes on, warning signal sounds

Cause

Remedy

Air filter foul/blocked

– Clean filter as specified in Section 6.3.4. – Where necessary, replace filter element.

comes on during engine operation (3)

Cause

Remedy

Hydraulic oil return flow filter foul/blocked or defective

– Replace return flow filter as specified in Section 6.4.5.


Cause

Remedy

Group fault signal Hydraulic filter foul/ blocked or defective (e.g. Pilot control filter, Hydro Clean Superfine-Filter)

– Replace hydraulic filter (e.g. pilot control filter as specified in Section 6.4.6.).

comes on, warning signal sounds, engine is stopped

Cause

Remedy


– Add hydraulic oil as specified in Section 6.4.

WARNING Engine starting is prevented until after the cause of the fault has been eliminated. In case of emergency, you can override this shutdown function however (refer to OVERRIDING SHUTDOWN FUNCTION on page 5-16).

comes on during engine operation, warning signal

BS80/ 10.2007

Cause

Remedy

Shut-off flap on hydraulic tank closed

– Open shut-off flap.

5 - 15



Cause

Remedy


– Add coolant.

WARNING Engine starting is prevented until after the cause of the fault has been eliminated. In case of emergency, you can override this shutdown function however (refer to OVERRIDING SHUTDOWN FUNCTION on page 5-16). comes on during engine operation, warning signal sounds

Overriding shutdown function

Cause

Remedy

Coolant temperature excessive

– Operate engine at no load until the coolant has cooled down. – Where necessary, check and clean the radiator as specified in Section 6.3.5.

This lets you start the engine, even though a fault has been signaled, and move the machine out of the danger area. 2

2

28

28

z Remove the cover. z Remove the two fuses in positions 2 and 28 in the fuse distribution

box.

z Move the machine out of the danger area. z Re-install the fuses 2 and 28. z Eliminate the cause of the fault immediately.

WARNING The functions of the SDS system are disabled. No further warning will be given in the event of faults occurring!

5 - 16

BS80/ 10.2007


5.3.8 Right-Hand Control Panel 1 2 3

4

5 6

7

11 8 9 10

13

1 Intermittent operation Front window wiper

7 Blower fan

2 Engine speed control

9 Service hour meter

3 Automatic idling 4 Air conditioner 5 Limit load control – Emergency operation 6 Indicator lights - engine 6a Diagnostic light (yellow) 6b Warning light (red)

BS80/ 10.2007

12

8 24 volt power receptacle 10 Starter lock/Start engine 11 Skylight wiper 12 Front window wiper 13 Working light

5 - 17


Automatic idling

Limit load control – Emergency operation

The automatic idling feature reduces engine speed automatically when no work movement has been performed for a few seconds. When a control lever is operated, adjustment to the speed level preset at the engine speed control is effected immediately. 1

After starting the motor's switch, switch on Automatic idling

2

Preselect the required RPM for the work application and/or for travel using the RPM adjustment.

3

Trigger the corresponding work function using the respective control lever or the drive pedal. The engine switches over immediately from the idling RPM to the preselected RPM.

4

Once the working and/or travel function has been completed (control lever or drive pedal in zero position), the engine will be redirected automatically to the idling RPM after a brief delay.

The load limit sensing control monitors the setting of the hydraulic pumps in terms of the power output of the diesel motor, in accordance with changing operating conditions. The location of the control unit of the limit load control system is on the wall behind the operator’s seat.

1

Function of the LED (1): LED lights up - working operation LED flashes - in the event of a failure Note The LED (1) is a reliable indicator only when the engine is running. If further use of the limit load control system is precluded by a defect in the electronic system, operation can be continued without any downtime by changing over from “Automatic” to “Manual”.

5 - 18

BS80/ 10.2007


Calibrating the power metering regulator

Calibrate the power metering regulator if the hand throttle, foot throttle or power metering regulator have been replaced. Note The calibration can be made through the switch input up to 5 minutes after switching the ignition on. If the calibration is unsuccessful, the power metering regulator must be switched off and then back on again (ignition off/on).

1

Calibration process

BS80/ 10.2007

1

Set both set-point potentiometers (hand throttle, foot throttle) to minimum.

2

Make the bridge between the red and blue connectors (1) on the right-hand console and remove again after one second.

3

The initialisation run begins (initialisation run means that the engine accelerates automatically, until 1350 - 1450 rpm are attained)..

4

Set both set-point potentiometers (hand throttle, foot throttle) to maximum.

5

Make the bridge between the red and blue connectors and remove again after one second.

6

The engine starts the initialisation run, slowly progressing from full speed to idling speed.

7

Once the engine has reached the lower idling speed, the initialisation run is complete.

8

If the LED on the power metering module box flashes, an error has occurred. Repeat the process.

5 - 19


Indicator lamps engine

Further information is available in the instruction supplied by the engine manufacturer. WARNING Eliminate the cause immediately.

5 - 20

BS80/ 10.2007

Operation - Heating System

5.4

Heating System

1

2

3

4

3

1 Outside air/ recirculation air selector knob 2 Temperature variable control 3 Air vents 4 Blower fan switch, three-stage (right-hand control panel)

The heating system can be run on outside air, on recirculation air or in mixed air mode. Outside air mode

Recirculation air mode

Mixed air mode (neutral position)

BS80/ 10.2007

To defog the cab when moisture has formed on the windows. Faster heating-up of the cab and also higher end temperature. The air is made to circulate inside the cab, i.e., there is no supply of fresh air from the outside. Do not leave this mode of operation on for more than 15 minutes, otherwise air quality in the cab will deteriorate markedly. Take care to ensure adequate supply of outside air. Normal mode of operation.

5 - 21

Operation - Optional Equipment

5.5

Optional Equipment

5.5.1 Air Conditioner WARNING z Have any maintenance and repair work performed by adequately trained skilled personnel only. z Do not reach into the conditioner and do not insert any objects. z Perform maintenance operations only with the engine shut down

and with the blower fan disconnected.

z Burning hazard!

Allow the conditioner and the components fitted inside (heat exchanger, resistors) to cool completely first.

z Avoid contact with refrigerant. z Wear safety glasses. z Allways use PAG oil for compressor. No ester-based oils! z No fluorescing additives (tracer agent, sticks)!

Note Close windows and doors, to ensure an efficient air conditioning. The air conditioner controls the temperature as a function of the outside temperature. Activating air conditioner

1

5 - 22

1

Operate engine until it has reached operating temperature.

2

Switch on the blower fan at the right-hand control panel.

BS80/ 10.2007


3

Close the air vents (foot vents) under the operator’s seat.

4

Open air inlet vent at the front window and behind the operator’s seat.

5

Press switch for air conditioner on the right-hand control panel, the green control light (1) goes on.

6

Use temperature variable control (2) on the heater to adjustthe desired temperature.

Note Operate the air conditioner at regular intervals. This will help to keep the air conditioner in a serviceable condition. Put the air conditioner into operation for at least 30 minutes at maximum fan rate every month, open windows and doors.

BS80/ 10.2007

5 - 23


5.5.2 Auxillary heating / Water heater The machine is mounted with an engine independent water heater for warming up the motor and the cab. Note The capacitiy of the batteries can be take off when the water heater is used.

5 4

Note Adjust temperature variable control (5) at maximum setting for activte the water heater. Note For warming up the cab turn on the blower fan (4) on fan stage1 (minimum setting).

Note Information on handling of the water heater is provided in a separate instruction. The instruction can be found in Section 10.3.

5 - 24

BS80/ 10.2007


5.5.3 Hydraulicoil- , cooling water- and diesel preliminary heating, batterie preliminary heating The Hydraulic oil heating system (1) is mounted on the hydraulic tank. Therefor the time of warming up of the hydraulic oil is shorter (Section 4.4.5). You can choose the temperature with the regulator (2) on the thermostat (normal: 20°C). When the oil has the right temperature the thermostat switches off.

2 1

3

4

Through connect the plug socket (3) underneath the operator‘s cab of the machinery with the circuit (230 V) the z hydraulic oil preliminary heating z cooling water preliminary heating z diesel preliminary heating

are activated.

BS80/ 10.2007

5 - 25


Through connect the plug socket (3) at the operator‘s cab of the machinery with the circuit (230 V) the z cooling water preliminary heating

is activated. Only the plug (3 and 4) but not the feeder cable is availabled by Sennebogen. DANGER The feeder cable and the plug´s must be connected by a qualified person. WARNING z Service and maintenance shall only be done by qualified persons. z Protection for voltage feeding must be supplied/mounted by the

customer!

5 - 26

BS80/ 10.2007

Operation - Operating Technique

5.6

Operating Technique

5.6.1 Safety Information DANGER z Be sure to observe Chapter 1 SAFETY. Before the machine is put into operation, perform the checks as specified in Section 4.3. z Persons who operate the machine or work on it must have received


z Make sure that there are no persons in the danger area. z Maintain a safety clearance to overhead lines. z Operate the machine only while you are in the operator’s seat. z Do not use the machine for handling of personnel. z Make due allowance for ambient conditions, e.g., poor visibility,

wind speeds, etc.

z Observe performance specifications. z Check whether the load capacity of attachment points is adequate. z Obey the signals given by signal persons, where applicable. z For any long-distance travel, put the boom in the direction of travel. z Before leaving the cabin:

– Park the machine on a safe surface. Back off from the edge of an excavation, where applicable. – Lower any attached loads to the ground. – Secure the working attachments. – Pull the safety lever backward. – Chock the tires/block the undercarriage. – Stop the engine. z Lock the cabin; use warning lamps to mark the machine, where

applicable.

BS80/ 10.2007

5 - 27


5.6.2 Swinging the Upper Structure To swing the upper structure, use is made of the left-hand control lever. 2

3

c

Swing speed

d

Push buttons:

Directions of movement:

2 Release slewing gear brake

c Swing upper structure to left

3 Engage slewing gear brake

d Swing upper structure to right

Swing speed is dependent on: z Speed of the engine z Deflection of the left-hand control lever

DANGER The area of swing of the upper structure (danger area) must be clear of personnel, building structures or machines. Stopping swing motion (deceleration)

Move the control lever to the neutral (zero) position. The upper structure is decelerated hydraulically. Swing motion eases off to a stop. Note Moving the control lever in the opposite direction will intensify deceleration.

5 - 28

BS80/ 10.2007


Slewing gear brake

The slew gear brake is not an operational brake for braking the superstructure. The slew gear brake is designed as a parking and holding break for when the superstructure is at rest. Note The slewing gear holding brake cannot be applied until 3 seconds after the slewing action has completely finished. Check on the Sennebogen SDS diagostic system whether the holding brake is active. The slewing gear holding brake indicator light must be on. WARNING Using the slew gear brake to brake the superstructure will result in considerable damage to the brake and/or to the slewing gear. The following damage may occur: z Diminished braking effect due to damage to discs z Irreparable damage to slewing gear z Irreparable damage to brakes or other components.

This damage is not covered by the warranty issued by Sennebogen Maschinenfabrik GmbH. The operator of the machine is solely liable for damage of this kind and for any consequential damage, for example, due to diminished braking effect. WARNING Never rotate the superstructure when the slew gear brake is applied.

Note The slew gear brake is applied automatically as soon as the z safety lever is actuated (pulled backward) or z the motor is switched off (emergency shut-down, key switch).

If circumstances are unfavorable it can take approx. 30 seconds before the full breaking effect is achieved.

BS80/ 10.2007

5 - 29


5.6.3 Refueling the Machine There are two possible ways of refueling the machine: z Manually z Using a refueling pump

WARNING z Fuel is detrimental to health and is flammable. Smoking and handling of naked flames are strictly prohibited. z For refilling the machine must be stopped. z Position the machine on a firm, even surface z Before filling, the fluid level must be determined in the tank - the

amount of fuel that the tank can taken on.

z Fuel must be precluded from getting into the soil or the waters.

While refueling keep a constant watch to avoid spillage of fuel.

z When fuelling from the tank vehicle, the maximum tanking speed

limit of 200 l/min (52 U.S.GPM) applies, as it could otherwise result in an overflow of the fuel.

z The fuelling procedure must be monitored, regardless of the type of

fuelling.

Note You should also observe the fuel system information provided in the engine manufacturer’s instruction. Manually 1

Land any attached loads to the ground.

2

Stop the engine.

1

3

5 - 30

Open the cover plate at the upper structure.

BS80/ 10.2007


Using a refueling pump

4

Open cap (1) of the filler neck.

5

Clean the strainer.

6

Install a funnel in the filler neck.

7

Fill in fuel carefully through the funnel.

8

Re-close cap (1) and the cover plate.

1

Land any attached loads to the ground.

2

Stop the engine.

3

Move keylock switch to position “P”.

4

Open the service access door.

5

Open the filler neck lid (1). This tets the air escape from the fuel tank.

DANGER If the cap (1) 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.

2

6

Fit the refueling hose (1) into the external fuel tank.

Note Risk of cavitation! Take care not to exceed the maximum suction head of 3 meters.

BS80/ 10.2007

5 - 31


3 4

7

Press the green key (2) to turn the refueling pump on. The tank is filled automatically.

CAUTION Take care to avoid the pump running dry (> 30 s). Where necessary, use the red key (4) to turn off the refueling pump to prevent damage. 8

Monitor the filling level at the sight gauge of the fuel tank. Switch the pump off with the red button (4) as soon as the tank is full..

9

Remove the refueling hose from the external fuel tank and store it securely.

10

Re-close the filler neck lid (1).

11

Re-close the service access door.

Should the refueling pump fail to start after about 5 seconds, perform the following checks:

5 - 32

1

Is battery charge adequate?

2

Are all fuses OK?

3

Is the suction side free of leaks?

4

Is the suction head less than the maximum lift of 3 meters?

BS80/ 10.2007

Maintenance -

6

Maintenance

WARNING The maintenance operations set out below must only be performed by qualified personnel that has received adequate training and instruction. Section 6.1 SAFETY INFORMATION lists basic safety precautions relating to machine maintenance. Section 6.2 GENERAL INFORMATION provides specifications and information on cleaning operations, on oils and greases, and on welding. Section 6.3 to Section 6.8 provide instructions for maintenance of the individual assemblies. Section 6.10 APPENDIX provides additional information such as maintenance schedule, lubrication points schedule and bolt tightening torques.

BS80/ 10.2007

6-1

Maintenance - Safety Information

6.1

Safety Information

DANGER Danger to life! There is a risk of serious injury or even death to persons using the machine or in its vicinity if it moves suddenly or is started unintentionally. Observe the following: z Place the machine on a firm base, if necessary set back from the edge of the excavation. z Lower suspended loads and booms to the ground. z Apply the brake. z Switch off machine and secure against unauthorised re-starting. z Use a chock to stop the machine from rolling away.

WARNING z The maintenance operations set out below must only be performed by qualified personnel that has received adequate training and instruction. z Wear personal protective equipment (e.g. hard hat, hearing

protective devices, protective gloves, safety shoes).

z Observe the applicable statutory accident prevention and safety

regulations.

z Land any attached loads to ground level. z Pull the left safety lever backwards. z Before attempting to perform any maintenance, shut down the

machine and secure it against unauthorized restarting.

z Attach a warning tag to the controls. z Do not smoke and do not allow open flames. z Operate the optional battery disconnect switch, if equipped, to

interrupt power supply.

z When working in the area of the batteries, cover the batteries with

isolating material; do not deposit any tools on the batteries.

z Use personnel hoists or work platforms that satisfy safety

requirements.

z Stay clear of all rotating and moving parts. z Relieve the pressure before working on the hydraulic system

(section 6.4.2).

z Dispose of hydraulic oil according to the applicable regulations. z Always wear protective gloves when handling wire ropes. z Use only genuine BAUER/SENNEBOGEN spare parts.

6-2

BS80/ 10.2007

Maintenance - Safety Information

z Use only those oils and lubricants that are specified in the lubricants

chart.

z Do not lift heavy components by hand. Use hoists or lifting

equipment.

z On completion of the maintenance operations, reinstall all guards

and protective devices.

z Keep the operator’s cab clean and tidy. z Perform a functional check to ensure proper operation.

2 1

z Only one person (max. 100 kg) may step onto the upper structure’s

step grid (1) at a time.

z On completion of any maintenance operations, only the machine

owner or his agent is permitted to clear the machine for service again.

Gallery = Catwalk for operators

DANGER Risk of falling! A maximum of 100 kg (220 lbs) is permitted per segment of grid iron on the gallery (= operator catwalk). Overloading will lead to damaging the construction, the results of which can lead to personal injury. Check the gallery for cracks and general damaged every 3 months and repair immediately if necessary.

DANGER z Have any work on electrical equipment of the machine performed by a qualified electrician only. z Only qualified personnel having received relevant training is allowed

to perform work on undercarriages, braking and steering systems!

z Work on hydraulic equipment must only be performed by personnel

having specific knowledge and experience of hydraulics!

BS80/ 10.2007

6-3

Maintenance - General Information

6.2

General Information

6.2.1 Cleaning Notes z Take care to ensure that the cleaning solvents used will not damage the seals, gaskets and other machine components. z Do not use any aggressive cleaning solvents. z It is especially important to clean the noise suppression mats with

neutral cleaning agents!

z Use only lint-free cleaning rags. z Use only dry filtered compressed air of a maximum pressure of 2

bar.

z On completion of cleaning, perform a visual inspection and a

functional check of the machine as specified in Section 4.3.

WARNING z Electrical and electronic components such as generators, switch

cabinets etc. must not come into direct contact with the water jet!

z Wet cleaning of these components is prohibited! z When wet cleaning the machine, always make sure that the water

does not come into contact with electrical or electronic components.

z There is a risk of damage to the electrics of the machine from

penetrating water. This can result in uncontrolled working movements being suddenly performed.

6-4

BS80/ 10.2007


6.2.2 Oils and Lubricants Use only oils and lubricants that have been approved by BAUER/ SENNEBOGEN. For a list refer to Lubricants chart. For proper operation of the machine, ambient temperature may range between ca. - 20°C and ca. + 40°C. When job site temperatures are outside this range, consult the BAUER/SENNEBOGEN service department before placing the machine in service. Oil analysis

Sampling and analyzing the oil at regular intervals will help to avoid unnecessary costs. A number of tests are carried out to establish: z Condition of the oil z Amounts of the wear metals in the sample z Rates of component wear

Recommended for the hydraulic system. Further information is available from the BAUER/SENNEBOGEN service department.

Biodegradable oils and lubricants

Use of these materials is mandatory in those cases where leakage of oils and lubricants on a mineral-oil basis would present a hazard to the environment. The use of environmentally friendly lubricants is a requirement in water and nature reserve areas in particular. Use must only be made of synthetic ester based biological oil. WARNING Any conversion to bio-oils and biological lubricants is not permitted until after the BAUER/SENNEBOGEN service department has been consulted and written approval has been obtained. WARNING Mixing oils, lubrication or operational materials of different types is not permitted! Filling or mixing oils, lubricants or any other operational fluids (e.g. hydraulic oil, transmission oil, motor oil, coolant, etc.) of different types can lead to chemical reaction damage to machine components. This damage can in turn result in severe damage toproperty and topersonal injuries. Use oils, lubricants and operational fluids that are approved by SENNEBOGEN only. Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

BS80/ 10.2007

6-5


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

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

ATTENTION! Observe the notes in the operating instructions of the motor manufacturer as well as the special additional documentation on the Caterpillar CAT ELCTM- Coolant. These are for the operational safety of the machine. Note SENNEBOGEN recommends using the pre-mixed coolant by Caterpillar CAT ELCTM, which is available in two different concentrations.

6-6

BS80/ 10.2007


6.2.4 Coolant - General WARNING Mixing coolants and adding cooling system sealing agents or antifreeze that contains sealing agents is not permitted. By filling or mixing different types of cooling fluid or cooling agent additives, gelling, etc. can occur in the coolant leading to the cooler being plugged (build-up) and because of the engine overheating or if the cooling system fails for example, this can damage the machine. WARNING Mixing of nitrite-based cooling agents with amine-based agents produces health-hazardous nitrosamine. Use the coolant indicated and described in chapter 3.3.1 and 3.3.2 depending on the motor that is installed. The antifreeze is sufficient to 37 °C (-34 °F). Note Observe the coolant label in the cooler area.

If the ambient temperature at the work-site is under this value (-37 °C (-34 °F)), observe the operating instructions of the motor manufacturer or contact SENNEBOGEN - customer service before starting operation. Note If only a small amount (up to max. 5 l) is required to will the water-coolant circuit and no suitable coolant is available, you can top up with clean water in the mean time. We recommend that you test the concentration at the next possible time before freezing temperatures however. In some cases, you must refill with the respective coolant so that the required mixture is achieved again to prevent freezing. The coolant is not only required to guarantee the protection against freezing, it also performs the very important task of protecting against corrosion. This also requires checking for the correct concentration and adding when necessary.

BS80/ 10.2007

6-7


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

or rain water.

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

before filling!

Ensure that the water has the following characteristics: pH value

7-8

Chloride content

max. 100 ppm

Sulphate content

max. 100 ppm

Water hardness

3-12 °dGH

Note Observe the recommended mixing ratio (see manufacturer's specifications). If the coolant concentration is too high, the cooling and antifreeze behaviour will deteriorate. ATTENTION Observe the specifications of the coolant manufacturer. WARNING Never fill with coolant when the motor is overheated. This will cause damage to the motor. Allow the motor to cool first. WARNING Regarding possible danger to health or environmental dangers, observe the instructions for using the coolant manufacturer as well. Using other coolants

If you should ever use a coolant other than that specified, the following must be considered or expresslyobserved. SENNEBOGEN will accept no responsibility and will provide no warranty or make any guarantees for the use of any coolants other than those previously indicated.

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BS80/ 10.2007


WARNING Scalding hazard! Be careful when draining hot coolant! Allow the motor to cool first. Catch the coolant in a suitable container when draining and dispose of according to the respective regulations. Change coolant

– The cooling system is to be emptied completely before filling again. – Rinse the cooling system several times with clear water to rid it of any residue. – Fill the cooling system and check the level after a short waiting period. – Start the motor and check the coolant levels ATTENTION Adjusting to the correct coolant level must sometimes be checked more than once. Check the following states when inspecting the coolant levels regularly, e.g. – lubricant incursion, – obvious opacity caused by corrosion residue or other particulate matter, in which case, the coolant must be replaced as indicated above.

Coolant change intervals

BS80/ 10.2007

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

6-9


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

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

Preliminary operations

6 - 10

Before you begin welding, perform the following preliminary operations: 1

Stop the engine.

2

Operate the optional battery disconnect switch to interrupt power supply or disconnect the battery.

3

Connect the ground terminal of the welding apparatus directly to the component to be welded.

BS80/ 10.2007

Maintenance - Engine


Engine

Note the safety information before you start work. CAUTION z Perform maintenance operations or repairs only with the engine stopped and cooled down. z Secure the machine against unauthorized restarting before starting

any maintenance procedure.

z Spent oil must be precluded from getting into the soil or the waters.

Dispose of oil and oil filters according to the applicable statutory regulations.

z Coolant must be precluded from getting into the soil or the waters.

Dispose of coolant according to the applicable statutory regulations.

z On completion of maintenance work on the engine, make sure that

all protective guards are installed correctly and that all tools have been removed from the engine.

Note You should also observe the information and recommendations provided in the engine manufacturer’s instruction (Section 1).

BS80/ 10.2007

6 - 11


6.3.1 Engine Oil WARNING z Scalding hazard! Exercise extreme caution when draining hot oil. z Spent oil must be precluded from getting into the soil or the waters.

Dispose of oil and oil filters according to the applicable statutory regulations.

WARNING Mixing oils, lubrication or operational materials of different types is not permitted! Filling or mixing oils, lubricants or any other operational fluids (e.g. hydraulic oil, transmission oil, motor oil, coolant, etc.) of different types can lead to chemical reaction damage to machine components. This damage can in turn result in severe da mage to property and to personal injuries. Use oils, lubricants and operational fluids that are approved by SENNEBOGEN only. Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer! Note Note the information provided in the engine manufacturer’s instruction (section 1).

1

Checking engine oil level WARNING Mixing oils, lubrication or operational materials of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

6 - 12

BS80/ 10.2007


1

Park the machine on level ground.

2

Operate the engine for about 2 minutes until the system is filled with oil.

3

Stop the engine.

4

Open the service access door - Engine.

5

Withdraw the oil dipstick (1) and wipe it with a clean lint-free cloth.

6

Insert the oil dipstick as far as its stop and withdraw it again.

7

Check the oil level: The oil level must be in the area between the lower mark (MIN) and the upper mark (MAX).

8

Add engine oil as necessary.

Changing engine oil and replacing oil filter WARNING Mixing oils, lubrication or operational materials of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

BS80/ 10.2007

1

Warm up the engine.

2


3

Open the service access doors - Engine.

4

Change the engine oil and replace the oil filter as specified in the engine manufacturer’s instruction.

5

Check the oil level: The oil level must be in the area between the lower mark (MIN) and the upper mark (MAX).

6

Add engine oil as necessary.

6 - 13


6.3.2 Water separator Safety instructions

Observe all safety instructions before beginning work. WARNING z Danger of injury due to rotating parts! Perform maintenance operations only after the engine has been shut down and the cooling system has cooled off. z No open fire with working on the fuel system! Do not smoke! z You should also observe the information provided in the engine

manufacturer's operation manual.

5

2

4

1

3 1 Shut-off valve 2 Quick clamp 3 Casing 4 Filter element 5 Fuel filter

6 - 14

BS80/ 10.2007


Draining water

Changing the filter element

1

Close shut-off valve (1).

2

Open quick clamp (2).

3

Remove water and dirt from the casing (3).

4

Close quick clamp (2).

5

Open shut-off valve (1).

1


2

Remove filter element (4).

3

Insert new filter element.

4

Check cover seal, exchange if necessary.

5


6.3.3 Fuel filter Changing the fuel filter

5

1

1 Shut-off valve 5 Fuel filter

BS80/ 10.2007

6 - 15


1


2

Unscrew fuel filter.

3

Clean sealing surfaces.

4

Lightly oil the gasket of the new fuel filter and/or wet with diesel fuel.

5

Tighten fuel filter by hand.

6


6.3.4 Air Filter Safety information

Note the safety information before you start work. CAUTION z Never use benzine, alkaline solutions or hot liquids for cleaning of the air filter. z On no account must the inside of the housing be cleaned by using

compressed air, otherwise dust and contaminants could get blown into the engine.

Air filter indicator light

The condition of the air filter is monitored by a sensor. To determine the degree of fouling, resistance to air flow is measured. When the maximum permissible resistance to air flow has been reached, the Air filter indicator light on the Sennebogen diagnostic system SDS comes on. An audible warning signal sounds at the same time. Check and clean the air filter immediately.

1 2 3,4

6 - 16

1

Loosen wing nut (1) and remove the cap (2).

2

Loosen the nut of the filter insert.

BS80/ 10.2007


3

Remove main filter and safety element (3, 4).

4

Blow out the filter elements with dry compressed air (max. 2 bar) from the inside outwards. Do not damage the cartridge in the process.

5

Replace the main filter and safety element (3, 4), if necessary.

6

Insert filter elements (3, 4).

7

Attach nut to filter insert.

8

Put cap (2) on and use wing nut (1) to screw down the cap (2).

6.3.5 Radiator Safety information

Note the safety information before you start work. WARNING z Risk of injury caused by rotating parts! Scalding hazard! Perform maintenance operations only with the engine shut down and after the cooling system has cooled. z Coolant must be precluded from getting into the soil or the waters.

Dispose of coolant according to the applicable statutory regulations.

z Mixing nitrite-base cooling system conditioners with amine-base

conditioners will result in formation of nitrosamines which are injurious to health.

Coolant level indicator light

The filling level of the coolant is monitored by a sensor. When the filling level falls below a specific mark, the engine shuts down automatically. The Coolant level indicator light on the Sennebogen diagnostic system SDS comes on. WARNING In case of emergency, this function can be overridden. This will allow you to start the engine and to move the machine out of the danger area. Refer to “OVERRIDING SHUTDOWN FUNCTION” on page 5-16. WARNING Mixing oils, lubrication or operational materials of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

Checking and cleaning

BS80/ 10.2007

1

Allow the engine and the radiator to cool.

2

Open the filler cap of the radiator slowly and carefully to relieve the pressure.

6 - 17


3

Check antifreeze content and coolant level; add as necessary. The coolant must contain at least 60% (not more than 65%) antifreeze (diethylene glycol) all the year round.

4

Use dry filtered compressed air (max. 2 bar) to blow-clean the cooling fins from the exhaust air side. If grease and oil has accumulated on the cooling fins, clean them by means of a cold cleaner.

5

Check the radiator for leaks and for damaged cooling fins.

Note For change of the coolant, refer to the information provided in the engine manufacturer’s instruction (section 1). You should also observe the information and recommendations provided in the manual „Cleaning the Cooling System“ (Additional Documentation).

6 - 18

BS80/ 10.2007


6.3.6 Belt Drives Safety information

Note the safety informations before you start work. DANGER z Perform any maintenance operations only with the engine shut down at standstill.. z Secure the machine against unauthorized restarting before starting

any maintenance procedure.

z On completion of maintenace work on the engine, make sure that all

protective guards are installed correctly.

z Take care to ensure that the V-belts operate in parallel. z Risk of injury caused!

Never reach into an current belt.

Note For inspecting, adjusting and replacing the belt drives, erfer to the information provided in the engine manufacture’s operation (Section 1).

BS80/ 10.2007

6 - 19

Maintenance - Hydraulic System


Hydraulic System

Note the safety information before you attempt to perform operations on the hydraulic system. DANGER z High oil pressure warning! The hydraulic system is under high pressure. When a hydraulic line or fitting is disconnected, or in case of a leakage, escaping hydraulic oil can cause serious personal injury. Perform any work on the hydraulic system only after all pressure has been relieved! z Relieve the pressure before working on the hydraulic system

(Section 6.4.2).

z The pilot system incorporates an accumulator which continues to be

under high pressure even after the engine has been shut down. The accumulator pressure must therefore be relieved.

z Do not open any hydraulic lines and fittings unless all pressure has

been relieved.

z Work on the hydraulic system must only be performed by trained

qualified personnel having specific knowledge and experience of hydraulics.

z The hydraulic valves may be adjusted only by trained BAUER/

SENNEBOGEN service personnel.

z Wearing personnel equipment (e.g., hard hat, hearing protective

devices, protective gloves, safety shoes).

zDanger of injury!

If leaks are present hydraulic oil will leak out under high pressure. Hydraulic oil will leak out under high pressure, penetrate the skin and cause severe damage to health. Danger of infection. In the case of injury contact a doctor immediately!

z Danger of injury from scalding

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

z Danger of injury from rotating parts.

Only carry out maintenance work when the engine is switched off, and then only if you are sure that the fan wheel has come to a stop and there is no risk of automatic start-up. Before starting up again, ensure that: – No items (e.g. tools) are in the vicinity of the fan wheels or could fall into this area as a result of vibrations, for example

– The protective features have been fitted.

6 - 20

BS80/ 10.2007


Cylinders

Pressure cylinders show minor leakages. Use a rag to remove any excessive leakage oil. Dispose of the oily rag as hazardous waste. The sliding surfaces of the piston rods are chrome plated. Any major leakages are indicative of damaged sliding surfaces or defective seals. To clean hydraulic cylinders: z Use neither sharp-edged tools nor corrosive liquids or scouring

agents.

z Wash the piston rods at regular intervals, using a high-pressure

cleaner.

z On completion of cleaning, provide the extended piston rods with a

protective coating. This serves to protect the surface against environmental and atmospheric influences.

Fittings

Check hydraulic fittings and couplings for leaks at regular intervals. Seal any points of leakage and remove oil stains. Leaked or spilled hydraulic oil is harmful to the environment and is a source of danger as it involves a risk of slippage. Be sure to immediately seal both sides of disconnected fittings by means of plugs.

Shut-off flap

Close the shut-off flap: z When performing work on the pump regulators; z When replacing pumps; z When performing repair or maintenance work.

This prevents outflow of major amounts of hydraulic oil. An indicator light in the SDS system monitors the shut-off flap (Refer to “SENNEBOGEN DIAGNOSTIC SYSTEM (SDS)” on page 5-9.). CAUTION Hydraulic oil must be precluded from getting into the soil or the waters.

BS80/ 10.2007

6 - 21


6.4.1 Hydraulic Hose Lines Time limits for storage and use

Even when stored and used properly, hoses and hose lines are subject to natural deterioration due to aging. For this reason, their use is limited to a specific period of time. The operator is responsible for ensuring that hose lines are changed in adequate time intervals, even if there are no evident signs of damage to hose line that could pose a safety hazard. Use of a hose line, including possible storage for up to two years, is not to exceed a period of six years.

Routine checks

Hose lines must be checked by qualified personnel at least once a year to ensure that they are safe and in working order. Any problems with hoses must be eliminated immediately.

Defective hoses

Hose lines must be replaced in the following instances (see also DIN 20066): z Damage found on outer layer up to the lining (e. g. chafe marks,

cuts, cracking);

z Outer layer has become brittle (formation of cracks in the hose

material);

z Deformation affecting the original shape of the hose or hose line and

occurring in both a pressurized and non-pressurized state or when hose is bent (e. g. layer separation, formation of blisters);

z Presence of leaks; z Damaged or deformed hose fittings (sealing capability is impaired); z Hose has slipped out of hose fittings; z Corrosion of the hose fittings which affects the ability of the hose to

function and seal properly;

z Hose does not fulfil installation requirements; z Permitted period of storage and/or use has been exceeded.

6 - 22

BS80/ 10.2007


6.4.2 Relieving Hydraulic System Pressure To relieve the pressure in the hydraulic system, proceed as follows: 1

Lower the moving parts as far as possible and land the attached loads to the ground.

2

Stop the engine, turn the ignition key back to position “1” immediately.

3

Operate both control levers in the operator’s cab in all directions several times. This serves to relieve the pressures both in the main hydraulic system and in the pilot system accumulator.

1

4

Open the cover.

5

Open screw cap (1) of the hydraulic tank. This serves to relieve the precharge pressure in the tank.

2

6

Connect a pressure gauge (to a maximum of 600 bar) to the gauge fittings (2).

7

Close the cover.

Note The pressure gauge must read 0 bar. If the pressure has not been relieved completely yet, repeat Steps 2 through 6.

BS80/ 10.2007

6 - 23


6.4.3 Checking Hydraulic oil Level WARNING Mixing oils, lubrication or operational materials of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer! 1


2


3

Retract all hydraulic cylinders as far as possible.

4

Stop the engine.

5

Open the service access door - Hydraulic system.

1

6

Check the oil level at oil level gauge (1): The oil level must reach as far as the upper mark (MAX).

A thermometer is integrated in the sight gauge. Here you can take a reading of the current temperature (°C/°F) of the hydraulic oil as well.

2

6 - 24

BS80/ 10.2007


7

If necessary, add hydraulic oil: – Open the cover and unscrew screw cap (2) of the oil filler neck. – Add hydraulic oil and check the oil level again as necessary. – Replace and tighten screw cap (2) and close the cover.

6.4.4 Changing Hydraulic Oil Safety information

Note the safety information before you attempt to perform operations on the hydraulic system. DANGER z High oil pressure warning! The hydraulic system is under high pressure. When a hydraulic line or fitting is disconnected, escaping hydraulic oil can cause serious personal injury. Perform any work on the hydraulic system only after all pressure has been relieved! z Work on the hydraulic system must only be performed by trained

qualified personnel having specific knowledge and experience of hydraulics.

WARNING Mixing oils, lubrication or operational materials of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer! Note It will make work easier for you if you pump off as much of the oil as possible. Use the opening of the return flow filter for the purpose. Procedure

BS80/ 10.2007

1


2


3

Retract all hydraulic cylinders as far as possible.

4

Relieve hydraulic system pressure as specified in Section 6.4.2.

5

Remove filter element of return flow filter as specified in Section 6.4.5.

6 - 25


6

Place a suitable container underneath the drain port of the tank. For refill capacity refer to Section 6.10.2.

CAUTION Take care to ensure that the container is of adequate capacity to hold the amount of oil. Hydraulic oil must be precluded from getting into the soil or the waters. Dispose of spent oil and oil filters according to the applicable statutory regulations.

1

7

Unscrew cover nut (1).

2 3

6 - 26

8

Screw in drain plug (2) until the spent oil comes out by way of plastic hose (3). Collect the spent oil in a suitable container.

9

Screw drain plug (2) back out.

10

Screw cover nut (1) back on.

BS80/ 10.2007


4 5

11

Fill in new hydraulic oil through the filler neck (4 or 5) at the top of the tank.

12

Monitor the filling level at the sight gauge of the hydraulic tank.

13

Prime the hydraulic pumps: – Clean the housing. – Release the vent screw at the pump. Do not screw it out completely; apply light thumb pressure to keep hold of it. – Allow a few seconds for the air to be expelled. – Retighten the vent screw.

CAUTION Whenever the hydraulic oil has been changed, prime the pumps before returning them to service to avoid damage.

BS80/ 10.2007

6 - 27


6.4.5 Return Flow Filter – Replacing Filter Element

1

6 - 28

2 3 4

1


2

Unscrew the four hexagon nuts (2) and the hexagon bolt (3).

3

Remove cover (4).

4

Withdraw the filter element and dispose of as hazardous waste.

5

Clean the components; check the seal and replace if necessary.

6

Install a new filter element.

7

Screw down cover (4) by means of the four hexagon nuts (2) and the hexagon bolt (3).

8

Tighten screw cap (1).

BS80/ 10.2007


6.4.6 Pilot Control Filter – Replacing Filter Element 1

1


2

Place a suitable receiving container underneath.

1

2

3

BS80/ 10.2007

3

Unscrew the head screw (1) at the cover and remove the cover.

4

Withdraw the filter element (2) and dispose of as hazardous waste.

5

Clean the components; check the seal and replace if necessary.

6

Fit new filter element (2) into filter housing (3).

7

Screw down cover by means of the head screw (1).

8

Check the filter for leaks.

6 - 29


6.4.7 Leakage Oil Filter – Replacing Filter Element

1 2

1

Loosen hexagon nuts (1).

2

Remove cover (2).

3

6 - 30

3

Unscrew filter element (3) from the return tube.

4

Screw a new filter element to the return tube.

5

Install the cover (2) with the return tube in the tank.

6

Tighten hexagon nuts (1).

BS80/ 10.2007


6.4.8 Replacing Ventilation Filter Note The ventilation filter is integrated in the screw cap (1) of the filler strainer. The ventilation filter limits the over-pressure and underpressure in the hydraulic system occurring during hydraulic operations. CAUTION Dirty ventilation filters let dust and dirt unfiltered into the hydraulic system. This can cause damage to the hydraulic system (e.g. to the pumps) and increased hydraulic oil wear.

1

2

BS80/ 10.2007

1


2

Pull of filter element (2) from the screw cap (1).

3

Dispose of filter element (2) as hazardous waste.

4

Fit new filter element (2) in the screw cap (1).

5

Screw on screw cap (1) complete with new breather filter.

6 - 31


6.4.9 Checking and Cleaning Hydraulic Oil Cooler WARNING Risk of injury caused by rotating parts! Scalding hazard! Perform maintenance operations only with the engine shut down and after the hydraulic system has cooled.

1

6 - 32

1

Use dry filtered compressed air (max. 2 bar) to blow-clean the cooling fins. Be careful not to damage the cooling fins.

2

Use cold cleaner to remove any grease and oil. Collect the cleaning fluid and dispose of as hazardous waste.

3

Check the cooler (1) for leaks and for bent and/or damaged cooling fins.

BS80/ 10.2007


6.4.10 Checking Precharge Pressure of the Accumulators Note Checking of the precharge pressure is outlined below using the pilot system accumulator as an example. 1


2

Connect a pressure gauge to the PV fitting at the test panel.

3

Stop the engine, turn the ignition key back to position “1” immediately.

4

Operate both control levers in the operator’s cab in all directions several times.

5

Watch the pressure gauge. Once the precharge pressure has been reached, the valve in the accumulator closes. The pressure gauge indicator drops to “0” abruptly. The reading prior to the pressure drop corresponds to the precharge pressure in the accumulator.

6

Compare the reading with the tolerance specification on the accumulator. If the precharge pressure is outside the tolerance, replace the accumulator or have it recharged with nitrogen.

7

Disconnect the pressure gauge.

CAUTION Have an expert subject the accumulator to a pressure test and an internal check every 10 years/20,000 service hours.

BS80/ 10.2007

6 - 33

Maintenance - Distributor Gear

6.5

Distributor Gear

WARNING z Risk of injury caused by rotating parts! Scalding hazard! Perform maintenance operations only with the engine shut down and with the pump distributor gear at standstill and cooled. z Oil must be precluded from getting into the soil or the waters.

Dispose of spent oil according to the applicable statutory regulations.

1 3 2

4 1 Vent plug 2 Oil dipstick 3 Oil filling hole 4 Oil drain plug

6 - 34

BS80/ 10.2007

Maintenance - Distributor Gear

6.5.1 Checking Oil Level WARNING Mixing oils, lubrication or operational materials of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer! 1


2

Stop the engine.

3

Open vent plug (1).

4

Unscrew oil dipstick (2). The oil level should be at the Max. notch on the oil dipstick.

5

Add gear oil as necessary. (For specification refer to Lubricants Chart)

6

Re-install and tighten vent plug (1) and oil dipstick (2).

6.5.2 Changing Gear Oil WARNING Mixing oils, lubrication or operational materials of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer! 1


2

Stop the engine.

3

Place a suitable receiving container underneath oil drain plug (4). For refill capacity refer to Section 6.10.2.

4

Unscrew vent plug (1) and oil dipstick (2).

5

Unscrew oil drain plug (4) and collect the spent oil in the container.

6

Clean the components; check the seals and replace if necessary.

7

Re-install and tighten oil drain plug (4).

8

Fill in new gear oil by way of oil filling hole (3).

9

Re-install and tighten oil dipstick (2) and vent plug (1).

10

BS80/ 10.2007

Re-check the oil level after 2 service hours.

6 - 35

Maintenance - Slewing Ring

6.6

Slewing Ring

6.6.1 Lubricate the ball-type swing gear and bearing WARNING Mixing oils, lubrication or operational materials of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer! Note Shorter greasing intervals apply z in tropical countries z in high-humidity enviroments z at major exposure to dust and dirt z in case of important temperature changes and z in case of continuous rotation.

1

6 - 36

1

Stop the engine.

2


3

Lubricate the nipples (1) until grease emerges at the sealing lips.

4

Rotate the upper structure several times in either direction to allow the grease to spread out evently.

5

The operation must be continued until the ball-type swing gear and bearing is complete filled with grease.

BS80/ 10.2007

Maintenance - Swing drive

6.7 Swing drive WARNUNG z Danger of injury through rotating parts and through scalding! Do not carry out maintenance work until the drive engine has been switched off. z Oil must not be allowed to seep into the ground or waterways.

Dispose of old oil in accordance with statutory regulations.

3 1

2

2

1)

Oil filler

2)

Oil drain screw

3)

Expansion tank

Level must always be between Min and Max and the transmission must be completely ventilated.

BS80/ 10.2007

6 - 37


6.7.1 Lubricating the gear teeth WARNING Mixing oils, lubrication or operational materials of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

6 - 38

1

Stop the engine.

2

Thoroughly clean the gearing.

3

Check slewing ring and swing drive pinion for wear; replace if necessary.

4

Use BAUER/SENNEBOGEN gear spray to spray the gear teeth from a distance of approx 30 cm.

5

Rotate the upper structure several times for the lubricating layer to spread out evenly over the gearing.

BS80/ 10.2007


6.7.2 Retightening bolts DANGER Danger to life! Defective live ring screw can cause the upper structure to tip over. For this reason, be sure to observe the following intervals: z Once a week, tighten the live ring screws with a torque wrench. z Check or change slewing ring bolts at least every 5000 hrs run/

every 5 years.

Note Testing must be performed by an expert from an independent specialist company/ independent institut. Unrestricted use of the slewing ring bolts must be proven by means of a certificate. The slewing ring bolts must be changed otherwise. Corroded and damaged bolts can shear off and cause the upper structure to tilt. z Do not retighten corroded or damaged bolts. Replace immediately

with new bolts.

z Ensure that you adhere to the number and diameter of fixing bolts. z Only use genuine BAUER/SENNEBOGEN replacement parts! z If you suspect damage to the screw fastenings, call SENNEBOGEN

customer service and arrange for a check to be carried out.

z Please contact BAUER/SENNEBOGEN customer service with any

further questions.

Notes z Pretension bolts anticlockwise carefully to prescribed values. The pretensioning of initially tightened bolts is affected by tensioning further bolts. It is therefore necessary to go round at least twice. z Ideally tighten bolts over M30 with a hydraulic screw tension cylin-

der.

BS80/ 10.2007

6 - 39

Maintenance - Electrical System

6.8

Electrical System

DANGER z Have any work on the electrical system performed by adequately trained qualified electricians only. z Before performing operations on the electrical system, disconnect

the main fuse and change over the battery disconnect switch.

6.8.1 Batteries DANGER z Explosion hazard! Smoking and handling of naked flames is prohibited. Take care to avoid sparking in the vicinity of the battery. z Acid can cause burns!

Wear safety glasses and gloves. Do not tilt the battery. Battery electrolyte can cause burns and must not get into the eyes or come into contact with the skin.

z Do not deposit any tools on the battery. z Disconnect the battery before welding. z Mind not to interchange battery posts. z Dispose of spent batteries as hazardous waste.

1 2

Check the terminals and cable connections of the batteries:

6 - 40

1


2

Change over battery disconnect switch (1).

3

Clean the terminals and cable connections of the batteries (2). Verify that they are firmly secured in place and coat them with petroleum jelly.

4

Restore battery disconnect switch (1) to its initial position.

BS80/ 10.2007

Maintenance - Electrical System

6.8.2 Fuses DANGER Fire hazard! Fuses must not be repaired. Always install new fuses of the same ampere rating.

1

BS80/ 10.2007

1

Stop the engine.

2

Remove cover (1).

3

Replace the defective fuse.

4

Check the contacts, clean any oxidized contacts.

5

Re-install cover (1).

6 - 41

Maintenance - Heating System

6.9

Heating System

Cleaning filter element 1 2

1

Unscrew knurled screws (1) at the back of the operator’s seat.

2

Remove cover (2).

3

6 - 42

3

Take out filter element (3).

4

Tap out the filter element or blow it out carefully by means of compressed air.

5

Re-install the filter element. Make sure you install it in the correct position. Filtered air should be discharged in the direction of travel.

BS80/ 10.2007

Maintenance - Appendix

6.10 Appendix Safety information

Note the safety informations before you start work. WARNING z The maintenance operations set out below must only be performed by qualified personnel that has received adequate training and instruction. z Wearing personnel equipment (for example Helmet, protective

gloves, protective shoes).

6.10.1 Maintenance Schedule Note When working in extreme-duty conditions, e.g., at high ambient temperatures, it may be necessary to reduce the intervals. (* sh = service hours) Operation

every 10 sh*/ daily

every 50 sh* / weekly

once after 250 sh/ 6weeks

every 500 sh* / 3months

every 1000 sh*/ 1 year

every 2000 sh*/ 2 years

– Perform visual inspection and functional check.

– Cab - Check the cab support, bolts and screwed connections.

– All separable connections (screws, bolts, cotter pins, etc.) – verify firm seating.

– Engine oil level – check. Observe intervals specified in engine manufacturer’s manual.

6.3.1

– Coolant level – check; clean cooling fins, if necessary.

6.3.5

– Hydraulic system – check oil level.

6.4.3

– Slewing ring – lubricate.

6.6

– Distributor gear – Check oil level.

6.5

– Hydraulic oil cooler – check and clean.

6.4.9

BS80/ 10.2007

Section

6 - 43


Operation

every 10 sh* / daily


once after 250 sh*/ 6weeks




– Swivelling connection: Visually check all connecting elements for damage and corrosion

– Battery cable connections and fuses – check.

6.8

– Heating system filter – check.

6.9

– Shut-off flap -hydraulic tank: visual check of leckage – Lubrication points – grease.

– Radiator – clean.

– Air conditioning compressor: Check belt tension and status.

1)

1)

1)

1)

– Hydraulic accumulator precharge pressure - have it checked by a hydraulics specialist 1). 1)

Section

6.3.5

6.4.10

After 250 sh*/6 weeks and after 500 sh*/3 month; then every 1000 sh*/1 year

– All screwed/bolted connections – verify firm seating.

– Antifreeze content – check.

2)

2)

2

2)

– Air conditioning compressor:. Check the compressor mounts and bolts for tightness.2)

2)

– Distributor gear – change oil.

– Retighten slewing ring bolts3). – Swing drive (.closed oil sys-

6.3.5

every 250 sh*, then every 6 weeks

6.5

3)

3)

6.6

3)

3)

tem)

3)

– Return flow filter - replace filter element .

6 - 44

After 250 sh*/6 weeks, then every 2000 sh*/yearly

6.4.5

BS80/ 10.2007


– Leakage oil filter – replace filter element. Operation

every 10 sh* / daily

– Pilot control filter – replace filter element.


once after 250 sh*/ 6weeks



6.4.7


Section

6.4.6

– Slewing ring bolts –check of verify firm seating with suitable device.

– Ventilation filter-hydraulic tank: visual check for dirt and damage, change if necessary.

– Check the gallery (= operator catwalk) for cracks and general damaged every 3 months and repair immediately if necessary.

– Primary and secondary filter elements of air filter – replace.

6.3.4

– Filter element of ventilation filter on hydraulic tank – replace.

6.4.8

– Heating system/airconditioner (option): check for adequately trained skilled person only.

6.9

6.3.5

4)

6.4.4

– Coolant – change. – Hydraulic system – change oil4). 4)

If necessary, have the oil checked via an oil diagnosis by SENNEBOGEN customer service 5)

– Slewing ring fixing bolts check and change 5) 5)

6.6

every 5000 sh* / every 5 years

Note Testing of the slewing ring bolts must be performed by an expert from an independent specialist company/ independent institut. Unrestricted use of the slewing ring bolts must be proven by means of a certificate. The slewing ring bolts must be changed otherwise.

BS80/ 10.2007

6 - 45


6.10.2 Refill Capacities WARNING Mixing oils, lubrication or operational materials of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer! The capacities shown below are approximate values. What matters is the filling level indicated on the compartment concerned.

6 - 46

Assembly or Compartment

Quantity

Engine

refer to manufacturer’s manual

Fuel tank

approx 775 l

Hydraulic tank

approx 660 l

Overall hydraulic system

approx 920 l

Distributor gear

approx. 8.5 l

Swing drive

approx. 3.5 l

Slewing ring gearing

as required

Central lubrication system

as required

Lubrication points

as required

BS80/ 10.2007


6.10.3 Tightening Torques for Screws Note Exceptions to the specifications in the table below may apply in the case of some mounting bolts on the undercarriage. Please note the information provided in the relevant sections. Strength grade 8.8

BS80/ 10.2007

Standard Thread

Fine Thread

Screw

Tightening torque MA [Nm]

Screw


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

6 - 47


Strength grade 10.9

6 - 48

Standard Thread

Fine Thread

Screw


Screw


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

BS80/ 10.2007


Strength grade 12.9

BS80/ 10.2007

Standard Thread

Fine Thread

Screw


Screw


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

6 - 49


6 - 50

BS80/ 10.2007

Setting Up - Detaching/Attaching Counterweight

7

Setting Up

Note Operations required for setting up the machine vary with the working attachments selected. Observe the relevant information provided in the attachment manufacturers’ instructions.

7.1 Preconditions

Safety notes

Detaching/Attaching Counterweight

Second person present for instructing and bolting. Observe the safety notes before starting work. DANGER z Accident risk through tipping of machine! The machine is not operational with counterweight removed. z Accident risk through using counterweights faulty z Switch off engine and allow detaching/attaching counterweight. Se-

cure machine against unauthorized re-starting.

z Place the machine in horizontal position on flat and firm ground.

Accident risk through tipping of parts of conuterweight!

z Carry out ballasting process with a guide.

Observe danger area!

z There must be no one in the danger area while raising and lowering

the counterweight. It is forbidden to stand on or beneath the counterweight. Keep a safe distance.

z Only attach or dismantle 10,5 t counterweight completely. z Installing /Removing counterweights individually. z Accident risk through tipping of machine ! Disassembling the coun-

terweight or replacing counterweight elements with the device (e.g. Ram) attached is not permitted !

BS80/ 03.2006

7-1


7.1.1 Detaching Counterweight DANGER Before releasing or dismantling safety components, secure the counterweights to prevent them from tipping or falling down.

7-2

BS80/ 03.2006


1

Attach suitable sling devices Minimum strand length 1,6 m to the lifting equipment and to the lifting points (1) of the 10,5 t counterweight (2).

2

Lightly tension sling devices.

3

Releasing the screw only, when the counterweight is secured on a prestressed hanger. Release hexagon screw (item 5). Remove items 5, 6, 7, 8.

4

Slacken hexagon screw (3).

5

Slacken securing bolts (4) on underside of machine. Keep bolts in a safe place.

DANGER Do not walk under suspended loads. 6

Lower 10,5 t counterweight (2) safely using lifting equipment and secure against tipping.

7


8


Option

BS80/ 03.2006

7-3


9

Releasing the screw only, when the counterweight is secured on a prestressed hanger. Slacken securing bolts (4) on underside of machine. Keep bolts in a safe place.

10


11


12


13

Releasing the screw only, when the counterweight is secured on a prestressed hanger. Slacken securing bolts (4) on underside of machine. Keep bolts in a safe place.

14


7.1.2 Attaching Counterweight

7-4

1

Attach suitable Minimum strand length 1.6 m sling devices to the lifting equipment and to the lifting points (12) of the 5,0 t counterweight (10)..

2


BS80/ 03.2006



Hoist counterweight (10) onto machine using lifting equipment. Counterweight has to rest against the forepart.

4


5

Bolt ballast to rear panel of the machine using both bolts (4).

6

Primary torquing the screws (4), then hang out the sling devices.

1


2


3

Hoist counterweight (10) onto machine using lifting equipment.

Option

Counterweight has to rest against the forepart. 4


5


6


DANGER Tighten the bolts (4) with a torque wrench. Tighten with torque of 500 Nm.

BS80/ 03.2006

7-5


A-A

7-6

7

Attach suitable Minimum strand length 1.6 m sling devices to the lifting equipment and to the lifting points (1) of the 10,5 t counterweight (2).

8


BS80/ 03.2006


9

Hoist counterweight (2) onto machine using lifting equipment.(Releasing the screw only, when the counterweight is secured on a prestressed hanger)

10


11


12

Secure counterweight to rear panel of the machine with the hexagon screw (3) provided.

13

Tighten bolt (3) with torque wrench to tightening torque 1200 - 1500 Nm.

14

Move lock plate (8) over screw head (3)

15

Fasten hexagon screw (5) to the screw (3), with washers (6, 7) (tightening torque 50 Nm)

16

Hang out the sling divices.

DANGER Tighten the bolts (3) and (4) with a torque wrench. Please note the individual torques. WARNING After each assembly of the counterweight you have to check additionally after 50 hours of operation the individual torques of the screws.

BS80/ 03.2006

7-7

Setting Up - Setting Up (Option)

7.2

Setting Up (Option)

Note Operations required for setting up the machine vary with the working attachments selected. Observe the relevant information provided in the attachment manufacturers’ instructions.

7.3 Preconditions

Safety notes

Detaching/Attaching Counterweight

Second person present for instructing and bolting. Observe the safety notes before starting work. DANGER z Accident risk through tipping of machine! The machine is not operational with counterweight removed. z Accident risk through using counterweights faulty z Switch off engine and allow to cool down before detaching/attaching

counterweight. Secure machine against unauthorized re-starting.

z Place the machine in horizontal position on flat and firm ground.

Accident risk through tipping of parts of conuterweight!

z Carry out ballasting process with a guide.

Observe danger area!

z There must be no one in the danger area while raising and lowering

the counterweight. It is forbidden to stand on or beneath the counterweight. Keep a safe distance.

z Only attach or dismantle 10,5 t counterweight completely. z Installing /Removing counterweights individually. z Accident risk through tipping of machine ! Disassembling the coun-

terweight or replacing counterweight elements with the device (e.g. Ram) attached is not permitted !

7-8

BS80/ 03.2006


7.3.1 Detaching Counterweight DANGER Before releasing or dismantling safety components, secure the counterweights to prevent them from tipping or falling down. A

1

2

3

A

A-A

BS80/ 03.2006

1


2


7-9


3

Releasing the screw only, when the counterweight is secured on a prestressed hanger. Slacken hexagon screw (3).

4

Slacken securing bolts (4) on underside of machine. Keep bolts in a safe place.



5

6

6

Attach suitable sling devices Minimum strand length 1,6 m to the lifting equipment and to the lifting points of the 5,0 t counterweight (6).

7


8

Slacken securing bolts on underside of machine. Keep bolts in a safe place. Releasing the screw (4) only, when the counterweight is secured on a prestressed hanger.

9

7 - 10


BS80/ 03.2006


7.3.2 Attaching Counterweight 5

6

1


2



Hoist counterweight (6) onto machine using lifting equipment. Counterweight has to rest against the forepart.

4


5


6


DANGER Tighten the bolts (4) with a torque wrench. Tighten with torque of 500 Nm.

BS80/ 03.2006

7 - 11


A

1

2

3

A

A-A

7

Attach suitable Minimum strand length 1.6 m sling devices to the lifting equipment and to the lifting points (1) of the 10,5 t counterweight (2).

8

Lightly tension sling devices. Counterweight has to rest against the forepart.

7 - 12

BS80/ 03.2006


9

Hoist counterweight (2) onto machine using lifting equipment.(Releasing the screw only, when the counterweight is secured on a prestressed hanger)

10


11


12

Secure counterweight to rear panel of the machine with the hexagon screw (3) provided.

13

Tighten bolt (3) with torque wrench to tightening torque 1200 -1500 Nm.

14

Hang out the sling divices.

DANGER Tighten the bolts (3) and (4) with a torque wrench. Please note the individual torques. WARNING After each assembly of the counterweight you have to check additionally after 50 hours of operation the individual torques of the screws.

BS80/ 03.2006

7 - 13


7 - 14

BS80/ 03.2006

Transport -

8 Preliminary operations

Transport

Transport the machine by means of a flatbedtrailer. Be sure to perform the following preliminary operations: z Select an appropriate vehicle for transport.

Observe the machine dimensions and weights as specified in Section 8.2.

z Clean the machine. z Remove working attachments and tools, if any. z Fold the running board on the upper carriage (1).

1

BS80/ 03.2006

8-1

Transport - Safety Information

8.1 Safety Information Warning z For loading and transport work in Germany: Any loading and transport work must only be performed by duly authorizied qualified personnel observing section 48 of VBG 40 (German accident prevention regulations for earthmoving machinery) and section 22 of StVO (German highway code). z Observe the applicable cargo securing rules and regulations.

Transport of the machine and of the accessories is the responsibility of the respective carrier as a general principle.

z During loading and transport, secure the machine and its working

equipment against any accidental movement.

z Remove mud, snow and ice from the undercarriage of the machine

sufficiently to allow the use of ramps without the risk of slippage.

z Provide ramps of flatbed trailers with wood blocking. z Before setting off, investigate the condition of the travel route. z For transport of the machine, use only the lashing, tie-down and

lifting points provided for the purpose.

z Take care to ensure that the machine does not constitute a source

of danger for other road users.

z Wearing personnel equipment (e.g., hard hat, hearing protective

devices, protective gloves, safety shoes).

8-2

BS80/ 03.2006

Transport - Dimensions and Weights

8.2

Dimensions and Weights

8.2.1 Dimensions

BS80/ 03.2006

8-3

Transport - Dimensions and Weights

8.2.2 Weights DANGER Attachment of BAUER equipment will increase the weight of the machine.

Machine

Weight: approx 15,4 metric tons

Counterweight (ballast)

8-4

5,3 t

10,5 t

Weight [kg]

5300

10500

Length [mm]

3000

3000

Width [mm]

200

563

Height [mm]

1500

1500

BS80/ 03.2006

Transport - Disconnect electrical system from battery

8.3

Disconnect electrical system from battery

If the machine is idle for an extended period or for long transport distances, the electrical system must be isolated from the battery using the mechanical battery isolator switch (optional). WARNING Do not switch off mechanical battery isolator switch if: z the engine is still running z or other electrical consumers are still switched on.

Doing so may damage the electrical system and its controller.

1

1

Open service access doors.

2

Turn the battery isolation switch (1) to the left (counterclockwise) and extract. The electrical system is now isolated from the battery.

3

Close service access doors.

Note If no mechanical battery isolation switch exists, the battery poles must be disconnected. Properly install the battery protective caps again.

BS80/ 03.2006

1

Open service access doors.

2

IMPORTANT! Prevent short circuits! Disconnecting: 1. Disconnect the negative pole 2. Disconnect the positive pole Connecting: 1. Connect the positive pole 2. Connect the negative pole

3

Close service access doors.

8-5

Transport - Lifting the Machine


Lifting the Machine

Note the safety information before you start work. DANGER z To sling the machine, use only the lifting points provided for the purpose. The lifting points are marked with green paint and identified by a green load hook symbol.

z Take care to ensure that the sling devices are of adequate load

capacity and undamaged.

z Mind the danger area!

No persons are allowed at, on or underneath the machine.

Procedure

10 t

7,1 t

8-6

5,4 t

8,3 t

BS80/ 03.2006

Transport - Lifting the Machine

1

Select an appropriate lifting crane and proper rated sling devices. Allow for the machine weight and center of gravity.

2

Fasten the sling devices to the lifting points.

3

Carefully lift the machine.

DANGER People must keep clear of the area under a suspended load!

BS80/ 03.2006

8-7

Transport - Lashing and Tying Down the Machine

8.5

Lashing and Tying Down the Machine

CAUTION z To lash the machine, use the tie-down points provided for the purpose. Tie-down points are marked with green paint and are located on the upper structure. They are identified by the following symbol.

z Take care to ensure that the sling devices are of adequate load

capacity and undamaged.

z In the event of an additional securing device being required, take

care to avoid the machine getting damaged.

z Transport of the machine and of the accessories is the responsibility

of the respective carrier as a general principle.

8-8

BS80/ 03.2006

Troubleshooting - Engine

9

Troubleshooting

WARNING z Be sure to observe Chapter 1 SAFETY. z The maintenance, inspection and troubleshooting personnel must

have the appropriate qualification for these operations.

z In case of operations not described in detail, consult the BAUER/

SENNEBOGEN service department.

9.1 Engine Engine fails to start

Loss of engine power

Machine fails to move

BS80/ 03.2006

Cause

Remedy

Battery capacity inadequate

– Check electrolyte level of batteries. – Recharge or replace batteries. – Use auxiliary battery to start the machine.

Starter interlock not active

– Unlock travel pedal.

Fuel tank empty

– Refuel the machine.

Emergency Stop switch is pressed

– Pull out the Emergency Stop switch.

Shut-off flap on hydraulic tank closed or not correct opened


Cause

Remedy

Suction resistance excessive

– Replace filter element of water separator.

Cause

Remedy

Parking brake applied

– Release parking brake.

Transmission/gear defective

– Have the fault corrected.

9-1

Troubleshooting - Engine

Oil or fuel leaks at the engine

Cause

Remedy

Loose hose connections

– Tighten hose connections.

Hoses or seals damaged

– Replace hoses or seals.

Note You should also observe the information provided in the engine manufacturer’s instruction.

9-2

BS80/ 03.2006

Troubleshooting - Hydraulic System

9.2 Oil leaks at the hydraulic system

Hydraulic System

Cause

Remedy





Hydraulic pump fails to operate

Cause

Remedy

Fault in pump circuit

– Have fault investigated and corrected by a hydraulics specialist.

No functions, or malfunctioning, of the working equipment

Cause

Remedy


– Check hydraulic oil level. – Add hydraulic oil as necessary.

Leaks in the hydraulic system

– Check the working cylinders, connections, fittings and hoses for leaks. – Have the fault corrected by a hydraulics specialist.

Fault in one of the attachment operation circuits

– Have the fault corrected by a hydraulics specialist.

Cause

Remedy

Lack of lubricant film on cylinder piston rod

– Have cylinder repaired by a hydraulics specialist.

Working cylinder movement produces noises

BS80/ 03.2006

9-3

Troubleshooting - Hydraulic System

No or inadequate output of the hydraulic system

Noises at the hydraulic system

9-4

Cause

Remedy





Relief valve opens prematurely


Hydraulic pump worn or defective

– Have pump replaced by a hydraulics specialist.

Cause

Remedy

Hydraulic pump sucks in air

– Check hydraulic oil level. – Have the fault corrected by a hydraulics specialist.

Oil delivery of hydraulic pump is inadequate

– Check hydraulic oil level. – Add hydraulic oil as necessary.

Relief valve knocking


BS80/ 03.2006

Troubleshooting - Electronic System

9.3 Electronic System Loss of power – Limit load control LED flashing

BS80/ 03.2006

Cause

Remedy

Fault in electronic system

– Emergency operation (refer to “LIMIT LOAD CONTROL – EMERGENCY OPERATION” on page 5-18). – Inform service department.

9-5

Troubleshooting - Sennebogen diagnositc system SDS

9.4

Sennebogen diagnositc system SDS

9.4.1 Bank of keys with LEDs

LED flashes, continuous alarm sounds

Cause

Remedy

Fuel level in tank too low

– Refuel machine as specified in Abschnitt 5.6.3.


Cause

Remedy

Engine overheated

– Idle engine.

Cooling fins on engine oil cooler dirty


Fan drive loose or defective

– Tighten fan drive, replace if necessary.


– Add coolant as specified in Abschnitt 6.3.5.

Engine switched off without cooling phase.

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

Note Overall performance of the machine is reduced to 65%. When the coolant temperature continues to rise, z the temperature reading on the display flashes in addition; z a continuous alarm sounds; z the engine is shut down.


9-6

BS80/ 03.2006



Cause

Remedy

Engine oil pressure too low (<1.3 bar)

– Stop engine immediately. – Check engine oil level as specified in Abschnitt 6.3.1. – Add engine oil as necessary. – If fault continues to occur, inform the BAUER/SENNEBOGEN service department accordingly.

Note Overall performance of the machine is reduced to 65%. When the oil pressure falls below 1.0 bar, z the pressure reading on the display flashes in addition; z a continuous alarm sounds; z the engine is shut down.



Cause

Remedy

Hydraulic oil temperature excessive (>84°C)

– Operate engine at no load until the hydraulic oil has cooled down.

Cooling fins on hydraulic oil cooler dirty



– Check oil level as specified in Abschnitt 6.4.3. – Add hydraulic oil as necessary.

Note When the hydraulic oil temperature rises to more than +94 °C, the temperature reading on the display flashes in addition.

BS80/ 03.2006

9-7


9.4.2 Indicator and warning lights comes on, warning signal sounds

Cause

Remedy


– Clean filter as specified in Abschnitt 6.3.4. – Where necessary, replace filter element.


Cause

Remedy

Hydraulic oil return flow filter foul/blocked or defective

– Replace return flow filter as specified in Abschnitt 6.4.5.


Cause

Remedy

Group fault signal Hydraulic filter foul/ blocked or defective (e.g. Pilot control filter, Hydro Clean Superfine-Filter)

– Replace hydraulic filter (e.g. pilot control filter as specified in Abschnitt 6.4.6.).


Cause

Remedy


– Add hydraulic oil as specified in Abschnitt 6.4.

WARNING Engine starting is prevented until after the cause of the fault has been eliminated. In case of emergency, you can override this shutdown function however (refer to “SENNEBOGEN DIAGNOSTIC SYSTEM (SDS)” on page 5-9).

comes on during engine operation, warning signal

9-8

Cause

Remedy

Shut-off flap on hydraulic tank closed


BS80/ 03.2006



Cause

Remedy


– Add coolant.

WARNING Engine starting is prevented until after the cause of the fault has been eliminated. In case of emergency, you can override this shutdown function however (refer to “SENNEBOGEN DIAGNOSTIC SYSTEM (SDS)” on page 5-9). comes on during engine operation, warning signal sounds

Cause

Remedy

Coolant temperature excessive

– Operate engine at no load until the coolant has cooled down. – Where necessary, check and clean the radiator as specified in Abschnitt 6.3.5.

Switches do not work

BS80/ 03.2006

Cause

Remedy

Fuse defective

– Replace fuse.

Switch faulty or fault in circuit

– Have fault inspected and rectified by an electrical engineer.

9-9

Troubleshooting - Heating System

9.5 No or inadequate heater output

No air flow

Heater will not turn off

9 - 10

Heating System

Cause

Remedy

Water inlet temperature too low

– Operate engine to warm it up. – Replace thermostat (with air conditioner fitted).

Thermostat on vehicle defective

– Replace vehicle thermostat.

Water valve fails to open

– Check valve and valve control; replace as necessary. Mind the direction of flow.

Heat exchanger louvers dirty

– Clean heat exchanger.

Filter foul/blocked

– Clean filter; replace if necessary.

No air flow

– See below.

Cause

Remedy

Fuse failed

– Replace fuse.

Power supply interrupted

– Check wiring for loose contacts or open circuits.

Blower motor defective

– Have blower motor replaced.

Blower switch defective

– Check switch, replace if necessary.

Resistor defective

– Have resistor replaced.

Cause

Remedy

Bowden cable for water valve maladjusted

– Re-adjust Bowden cable.

Heater valve not mounted properly

– Check direction of flow at the valve; where necessary, exchange inlet/return flow.

Control and/or Bowden cable defective

– Replace control or Bowden cable respectively.

BS80/ 03.2006

Troubleshooting - Air Conditioner

9.6 Cooling efficiency inadequate

Air conditioner cooling intermittently

Air conditioner extremely noisy

BS80/ 03.2006

Air Conditioner

Cause

Remedy

Fuse failed

– Replace fuse.



Pressure switch defective

– Have pressure switch replaced.

Refrigerant line broken

– Have line replaced.

Expansion valve sticking

– Have customer service replace the valve.

Compressor clutch slipping

– Have customer service replace the clutch.


– Clean air filter.

Cause

Remedy



Temperature variable control defective

– Replace temperature variable control.

System iced

– Have air conditioner checked by the customer service.

Blower switch defective

– Check switch, replace if necessary.

Cause

Remedy



V-belts loose or worn

– Increase V-belt tension or replace Vbelt.

System overcharged

– Have refrigerant extracted by the customer service.

Lack of refrigerant in the system

– Have customer service check the system for leaks. – Have system charged with refrigerant.

9 - 11

Troubleshooting - Cab

No function of the contol lamp of the selected air conditioning

Cause

Remedy

Refrigerant too low

– Have customer service check the system for leaks. – Have system charged with refrigerant.



Pressure switch defective

– Have pressure switch replaced.

Pressure switch is out

– Reduce overpressure.

Thermostat defective

– Have customer service replace the thermostat.

Thermostat is out

– Ambient temperature
9.7 Cab Cab moves or swings drastically

9 - 12

Cause

Remedy

Cab mounting or cab fastening damaged

– Check all connection elements, bolts and pins of cab mounting and fastening for damage, cracks or deformation. – Have damaged components replaced immediately by trained and instructed specialist personnel.

BS80/ 03.2006

Index

A Abuse 1-3 Adding hydraulic oil 6-25 Adjusting time of day 5-11 Automatic idling 5-18 Automatic speed control 5-18 B ballast 8-4 Bank of keys 5-10 Battery Acid 4-6 Battery disconnect switch 2-3, 6-40 Biological oils 6-5 Bolt strength grades 6-47 C Calibration of the load limit sensing controller 5-19 CE certificate of conformity 1-8, 1-19 CE symbol 1-8 Checking hydraulic oil level 6-24 Chloride 6-8 Cleaning hydraulic cylinders 6-21 Conversion of the machine 1-16 Copyright 1-8 Counterweight 8-4 Crushing hazards 1-4 Current when going to press 1-2 Customer service 1-7 D Danger area 1-4 Declaration of conformity 1-8 Decommissioning 4-9 Decommissioning machine 4-9 Description Effects of wind 3-3 Display (SDS) 5-10 Disposal 1-22 Batteries 1-22 Disposal Guideline 75/439/ EEC 1-22

BS80/ 05.2008

Disposal of consumables 1-22 Disposing of batteries 1-22 Disposing of lubricants 1-22 Disposing of the oil filter 1-22 E Emergency exit 5-2 Emergency Stop 5-5 Employment in foreign countries 1-16 Engine Changing oil 6-13 Engine speed control 5-17 environmental protection 1-22 Environmental regulations 1-22 F Fax Customer service 1-7 Documentation 1-7 Spare parts warehouse 1-7 Fire extinguisher 1-16 First aid kit 1-16 Fuses 6-41 G Gauge fittings 6-23 H Hand signals for directing 1-23 High voltage contact 1-6 Hydraulic fittings 6-21 I Illustration aids 1-3 Inadmissible operating practices 1-15 Indicator lights 5-14 International regulations 1-1 J Jump starting 4-6

K Keyword 1-3 L LEDs 5-10 Lifting points 8-6 Limit load control – Emergency operation 5-18 List of abbreviations 2-1 M Main fuse 2-3 Misuse 1-2 Multiple disc brake 5-29 N National regulations 1-1 National rules and regulations 1-1 Noise protection 1-16 Not-Aus 2-7, 5-4 O Oil analysis 6-5 Oil filler neck 6-25 Operator’s work station 1-2 Overhead lines 1-6 Overriding shutdown function 5-16 P Permanent sound pressure level 1-16 Personal protective equipment 1-5 Personnel qualifications 1-15 Personnel selection 1-15 pH value, water 6-8 Potential instances of misuse 1-2 Preparing to operate Checklist 4-2 Pressure cylinders 6-21 Prototype Testing 1-19 Q Qualifications of personnel 1-7

S-1

Index

R Release (cab door) 5-2 Relieving hydraulic system pressure 6-23 Replacing oil filter 6-13 Resetting daily service hour meter 5-11 Residual hazards 1-3 Riementriebe 6-19

W Warm-up period 4-7 Warning lights 5-14, 9-8 Warning symbol 1-3 Warranty conditions 1-16 Warranty manual 1-16 Water separator 6-15 Wind force 3-3 Wind speed 3-3

S Safety clearance 1-4, 1-6 Safety clearance to overhead lines 1-6 Safety instructions 1-3 Safety lever 2-7, 5-4, 5-6 Sales and service partners 1-7 Service checkbook 1-5 Service partners 1-7 Shut-off flap 2-4, 6-21 Signaling individual 1-23 Slewing gear brake 5-29 Spare parts catalog 1-5 Spare parts warehouse 1-7 Specialist check 1-14 Specific dangers 1-15 Stability 1-5 Storage location 4-9 Subdivision of the operating instructions 1-5 Swinging the upper structure 5-28 Switching off engine 4-8 T Target group 1-5, 1-2 Telephone 1-7 The maintenance instructions 1-5 Tie-down points 8-8 Tightening torque 6-47 Type plate 1-18 U Upper structure swing 5-28 Use as intended 1-2

S-2

BS80/ 05.2008

Appendix - List of abbreviations

1

Appendix

1.1 List of abbreviations

BS80/ 03.2006

TUR

Trade Union Regulations

Oh

Hours of operation

LED

LEDs

SDS

SENNEBOGEN Diagnosis System

FMVSS

Federal Motor Vehicle Safety Standards

UCTU

Underground Construction Trade Union

ACTU

Association of Commercial Trade Unions

1-1

Appendix - List of abbreviations

1-2

BS80/ 03.2006

80.6.1049_en_neu

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