Manipulador Sennebogen (mantenimiento).pdf

MAINTENANCE INSTRUCTIONS

Model 835 + 840

835 + 840 / 03.2010

Translation Translation of the original instructions

As of 835.x.1101 / 840.x.1001

Important notes on the maintenance instructions

Foreword

You have decided on a brand quality product from SENNEBOGEN. We thank you for your decision. Our utmost concern is that your SENNEBOGEN quality product performs your work reliably, continually and with no faults. You know that the reliability and life-span of every machine is greatly influenced by regular and professionally-handled service and maintenance work. We would therefore ask that you read the following service and maintenance information thoroughly and apply it accordingly.

For your own safety

Functionality, Functionality, reliability, availability and advanced technology, e.g. the implementation of modern materials and technology, requires specially adapted maintenance and repair methods. Only use genuine SENNEBOGEN spare parts. Only allow authorized SENNEBOGEN partners to perform work on your SENNEBOGEN machine. Improperly performed maintenance or service work may result in consequential damages and associated safety risks.

Parts and accessories

Use only genuine replacement parts and accessory products that are authorized by SENNEBOGEN. These parts have been tested by SENNEBOGEN for their safety and functional suitability in SENNEBOGEN machines. SENNEBOGEN will not be held responsible for any parts or accessory products that have not be approved.

Warranty

The warranty can become void among other things, if:    

spare parts are not genuine SENNEBOGEN-approved spare parts Maintenance is not performed at specified maintenance maintenance intervals Maintenance has not been performed Service and maintenance work has not been performed by a SENNEBOG SENNEBOGEN EN partner. partner.

In the event of damage, SENNEBOGEN retains the right to demand written verification of all maintenance work, performed completely and correctly! SENNEBOGEN recommends special service and maintenance contracts with the authorized SENNEBOGEN partner of your choice to address these issues.

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Translation of the original instructions

835 + 840 / 03.2010


Foreword

You have decided on a brand quality product from SENNEBOGEN. We thank you for your decision. Our utmost concern is that your SENNEBOGEN quality product performs your work reliably, continually and with no faults. You know that the reliability and life-span of every machine is greatly influenced by regular and professionally-handled service and maintenance work. We would therefore ask that you read the following service and maintenance information thoroughly and apply it accordingly.

For your own safety

Functionality, Functionality, reliability, availability and advanced technology, e.g. the implementation of modern materials and technology, requires specially adapted maintenance and repair methods. Only use genuine SENNEBOGEN spare parts. Only allow authorized SENNEBOGEN partners to perform work on your SENNEBOGEN machine. Improperly performed maintenance or service work may result in consequential damages and associated safety risks.

Parts and accessories

Use only genuine replacement parts and accessory products that are authorized by SENNEBOGEN. These parts have been tested by SENNEBOGEN for their safety and functional suitability in SENNEBOGEN machines. SENNEBOGEN will not be held responsible for any parts or accessory products that have not be approved.

Warranty

The warranty can become void among other things, if:    

spare parts are not genuine SENNEBOGEN-approved spare parts Maintenance is not performed at specified maintenance maintenance intervals Maintenance has not been performed Service and maintenance work has not been performed by a SENNEBOG SENNEBOGEN EN partner. partner.

In the event of damage, SENNEBOGEN retains the right to demand written verification of all maintenance work, performed completely and correctly! SENNEBOGEN recommends special service and maintenance contracts with the authorized SENNEBOGEN partner of your choice to address these issues.

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Notes on the operating instructions

Read through the operating instructions thoroughly, in particular Chapter 1 SAFETY, before beginning to work with the machine. ATTENTION 

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Only work with/on the machine after you have read and completely understood these operating instructions. Refrain from operating and maintaining the machine in an unsafe manner. Do not operate machine if a fault has been detected! The machine may be set up, operated and maintained by trained personnel only. The employer is responsible responsible for the qualifications and training of person personne nel.l. These operating instructions are a part of the machine. Keep the operating instructions in the cab at all times. Recommended storage place: Storage compartment behind the driver’s driver’s seat. seat. In the event of sale, disposal or loan, the operating instructions must accompan accompanyy the machine! machine! Contact SENNEBOGEN immediately if you are unsure about anything in the instruction manual! Your comments will help us to make the instructions even more user-friendly. Operating the machine is described in separate instructions.

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

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Symbols and illustration devices

These operating instructions contain safety instructions that highlight dangerous working practices. These safety instructions are marked with a safety alert symbol and a signal word. This safety alert symbol means: Attention – this concerns your safety and the safety of others. The associated keyword signifies the degree of danger: DANGER

Is used for serious, impending danger. If this danger is not avoided, serious physical injuries or loss of life will result. WARNING

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

Is used for potentially dangerous situations. If this danger is not avoided, physical injuries or serious material damage may result. Instructions which make the work easier or contribute to better understanding when operating the machine are displayed in the following way: Note

Indicates notes which draw your attention to unusual features. Note

Indicates a cross reference to other documents.

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

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

Designates instructions or information that draws attention to a machine with crawler undercarriage.

Designates instructions or information that draws attention to a machine with platform (4-point subfr ame).

Designates instructions or information that draws attention to a machine with rail undercarriage .

Hand tighten.

50 Nm

Tightening torque for bolts or nuts. (in this case: 50 Nm) Fork wrench with size specification. (in this case: 13 mm)

13 mm

Screwdriver

Phillips screwdriver

32 mm

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


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32 mm

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

Procedures are shown in tabular form as follows: 1 Press switch (1). 2 Actuate control lever (2). 3 Unfasten bolts (3).

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


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Glossary of terms

Operator

The operator (owner of the company/company) is responsible for operating the machine in accordance with its intended use, or for ensuring that the product is being used by suitable and instructed personnel. Operating personnel

The operating personnel are the person(s) authorized by the operator to use the product. Specialist personnel

Specialist personnel are those authorized by the operator to fulfill certain obligations such as installation, setup, repair and maintenance and troubleshooting. 

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. 

Instructed personnel

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

Experts

Experts are those who, on the basis of specialist training and experience, have sufficient knowledge in the area of the product, and are sufficiently aware of relevant national occupational safety guidelines, accident prevention regulations, 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. 

Au th or ized perso ns

Authorized persons are those who are authorized by technical authorities (TÜV) or by a trade association to check the machinery. Authorization by the trade association takes place in accordance with the “Principles for the authorization of experts for the testing of cranes” (ZH 1/518). It is linked with the issue of an identity number. This must be stated by the inspector in the test report and/or test memo. Authorizations can be limited to parts of tests or specified crane types.

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Target group

The machine has been developed for demanding work. Persons working on or with the machine must be trained or instructed for that purpose. Detailed information on the prior knowledge and qualifications required of the operator can be found in Chapter 1 SAFETY of these instructions.

Which documentation belongs with the machine?

The following documentation belongs with the machine:     

These instructions Operating Instructions Spare parts catalogue Service checkbook Additional documentation from pre-suppliers.

Note

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

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How to contact us

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 depot:

+49 9421 40811

Technical documentation: E-mail:

[email protected]

Fax:

+49 9421 540380

Note

The addresses of the SENNEBOGEN Sales and service partners can be found on our homepage on the Internet.

Current when going to press

Copyright

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

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

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Contents

1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Other risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.3 Machine labeling . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.3.1 Identification plate . . . . . . . . . . . . . . . . . . . 1-3 1.3.2 Warning and notice labels . . . . . . . . . . . . . 1-3 1.4 Responsibilities of the employer . . . . . . . . . . . . . . 1-4 1.5 Supplementary and operational equipment . . . . . . 1-7 1.5.1 SENNEBOGEN-Diagnostic-System (SDS) 1-7 1.5.2 Oils and lubricants . . . . . . . . . . . . . . . . . . . 1-8 1.5.3 Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 1.5.4 Fuel (not for electric motors) . . . . . . . . . . 1-14 1.6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 1.7 Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 1.8 Safe entry and exit . . . . . . . . . . . . . . . . . . . . . . . 1-19 1.8.1 Emergency exit . . . . . . . . . . . . . . . . . . . . 1-22 1.9 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 1.10 Protective features . . . . . . . . . . . . . . . . . . . . . . . 1-24 1.11 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 2

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

2.1 Daily/weekly maintenance . . . . . . . . . . . . . . . . . . . 2-2 2.2 One-time maintenance . . . . . . . . . . . . . . . . . . . . . 2-5 2.2.1 After 50 hours of operation at the latest . . 2-5 2.2.2 After 250 hours of operation at the latest . 2-5 2.3 Regular maintenance / Maintenance interval . . . . 2-7 2.3.1 Monthly or at the latest after 250 hours of operation 2-8 2.3.2 Semi-annually or at the latest after 500 hours of operation 2-10 2.3.3 Annually or at the latest after 1000 hours of operation 2-12 2.3.4 at the latest after 2000 hours of operation 2-15 2.3.5 At the latest, after 4,000 / 5,000 / 10,000 / 12,000 / 20,000 hours of operation 2-16 3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 Drive engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.2.1 Type 835 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

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Contents

3.3

3.4 3.5

3.6 3.7 3.8 4

3.2.2 Type 840 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.3.1 Mobile . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.3.2 Crawler . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3.3.3 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3.3.4 Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Inspection tools – overview . . . . . . . . . . . . . . . . . 3-10 Lubricate machine. . . . . . . . . . . . . . . . . . . . . . . . 3-11 3.5.1 Machine – mobile . . . . . . . . . . . . . . . . . . . 3-11 3.5.2 Machine – crawler . . . . . . . . . . . . . . . . . . 3-14 3.5.3 Machine – Setup . . . . . . . . . . . . . . . . . . . 3-16 Tightening torques for bolts . . . . . . . . . . . . . . . . . 3-17 Wind speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Conversion factors . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Drive engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.3.1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.3.2 Air filter – pre-separator . . . . . . . . . . . . . . . 4-6 4.4 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.4.1 Safety instructions . . . . . . . . . . . . . . . . . . . 4-7 4.4.2 Water separator . . . . . . . . . . . . . . . . . . . . . 4-8 4.5 Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4.5.1 Safety instructions . . . . . . . . . . . . . . . . . . 4-10 4.5.2 Refrigerant – Deutz engine . . . . . . . . . . . 4-10 4.5.3 Refrigerant – Cummins engine . . . . . . . . 4-11 4.5.4 Changing refrigerant . . . . . . . . . . . . . . . . 4-11 4.6 Cleaning the cooling system . . . . . . . . . . . . . . . . 4-14 4.6.1 Safety instructions . . . . . . . . . . . . . . . . . . 4-14 4.6.2 Reverse fan . . . . . . . . . . . . . . . . . . . . . . . 4-15 4.6.3 External cleaning . . . . . . . . . . . . . . . . . . . 4-15 4.6.4 Internal cleaning . . . . . . . . . . . . . . . . . . . 4-16 4.7 Check belt drives . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 4.8 Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 5

Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Mobile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1.1 Cleaning and lubricating . . . . . . . . . . . . . . 5-1

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Contents

5.1.2 Tire air pressure (pneumatic tires) . . . . . . . 5-1 5.1.3 Retightening wheel nuts . . . . . . . . . . . . . . 5-2 5.1.4 Hub drive train . . . . . . . . . . . . . . . . . . . . . . 5-2 5.1.5 Axle distributor gear (type 835) . . . . . . . . . 5-5 5.1.6 Differential (type 835) . . . . . . . . . . . . . . . . 5-7 5.1.7 Drive shaft/universal joint (type 835) . . . . . 5-9 5.1.8 Back gear and differential (type 840) . . . . 5-11 5.1.9 Parking disc brake (type 840) . . . . . . . . . 5-13 5.2 Crawler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5.2.1 Cleaning and lubricating . . . . . . . . . . . . . 5-15 5.2.2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5.2.3 Crawler chain . . . . . . . . . . . . . . . . . . . . . . 5-17 5.2.4 Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 5.2.5 Base plates . . . . . . . . . . . . . . . . . . . . . . . 5-20 5.3 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 5.3.1 Middle bridge clamp – outrigger housing . 5-21 5.3.2 Ballast . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 5.3.3 Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 6

Swiveling connection . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2 Lubricating slewing ring path . . . . . . . . . . . . . . . . . 6-2 6.2.1 Central lubrication system . . . . . . . . . . . . . 6-2 6.3 Lubricating live ring toothed wheel . . . . . . . . . . . . 6-5 6.3.1 Gear spray . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6.3.2 Slewing ring lubrication (optional) . . . . . . . 6-6 6.4 Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 6.5 Tightening slewing ring bolts . . . . . . . . . . . . . . . . 6-13 6.6 Wear measurement and checking the drive system/ bearing play 6-15 7

Hydraulic syst em . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.2.1 Hydraulic cylinder . . . . . . . . . . . . . . . . . . . 7-2 7.2.2 Bolted joints . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.3 Hydraulic hose lines . . . . . . . . . . . . . . . . . . . . . . . 7-3 7.4 De-pressurizing the hydraulic system . . . . . . . . . . 7-4 7.4.1 Check hydraulic oil level, add hydraulic oil 7-5 7.5 Changing hydraulic oil . . . . . . . . . . . . . . . . . . . . . . 7-7

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Contents

7.6 Replacing return filters . . . . . . . . . . . . . . . . . . . . . 7-10 7.7 Auxiliary control filter – change filter element . . . 7-11 7.8 HydroClean – superfine filtration system (Optional) – Change filter element 7-12 7.9 Leak-oil filter – changing filter . . . . . . . . . . . . . . . 7-13 7.10 Changing ventilation filter . . . . . . . . . . . . . . . . . . 7-14 7.11 Changing the ventilation filter with dehumidifying unit (optional) 7-15 7.12 Checking preload pressure of pressure accumulator . 7-16 7.13 Pump distributor gearbox (optional) . . . . . . . . . . . 7-17 7.13.1 Checking oil level . . . . . . . . . . . . . . . . . . . 7-17 7.13.2 Changing gear lubricant oil . . . . . . . . . . . 7-18 8

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 8.2 8.3 8.4

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Switch/symbol change . . . . . . . . . . . . . . . . . . . . . . 8-4 Generator (optional) . . . . . . . . . . . . . . . . . . . . . . . 8-4 8.4.1 Visual check . . . . . . . . . . . . . . . . . . . . . . . . 8-4 8.5 Additional displays (special equipment) . . . . . . . . . 8-5 9

Heating/Air-conditioning system . . . . . . . . . . . . . . . . 9-1

9.1 Air conditioning system . . . . . . . . . . . . . . . . . . . . . 9-1 9.1.1 Visual check . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.1.2 Cleaning the heating recirculating air filter . 9-3 9.1.3 Cleaning the heating outside air filter . . . . 9-4 9.2 Water heater (optional) . . . . . . . . . . . . . . . . . . . . . 9-5 9.3 Air conditioning compressor (optional) . . . . . . . . . 9-6 9.4 Auxiliary heating system (optional) . . . . . . . . . . . . 9-7

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Safety - General

1

Safety

1.1 General Before starting with maintenance, the machine is to be prepared as per the following descriptions. Failure to observe these instructions can result in accidents, serious injuries or death. Perform the maintenance work described in these instructions completely and at the specified time intervals. Target group

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

Danger to life! There is a risk of serious injury or even death to persons using the machine or in its vicinity if it moves suddenly or is started involuntarily. Therefore, observe the following:  Place the machine on a firm subgrade (level, solid, flat), if necessary set back from the edge of the excavation.  Lower attached loads and booms to the ground.  Apply the brake.  Pull the safety lever to the rear (all hydraulic functions are inactive).  Switch off the machine and secure against unauthorized switching on again before beginning any work.  Attach warning sign to operating instruments.  Use a chock to stop the machine from rolling away. Additional measures: 

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Allow the machine to cool. If this is not possible, be aware that hot fluids and components can cause burns. De-pressurize the hydraulic system to avoid dangers.


1-1

Safety - Other risks

1.2 Other risks The safety instructions in these instructions are guidelines for the safe maintenance on the machine by qualified machine operators. However, SENNEBOGEN cannot anticipate every situation, which may result in danger in practice. Therefore, the safety instructions and warnings on the machine and in the operating instructions cannot be all inclusive. Operators and machine operators remain responsible for safety. Warning and notice signs attached to the machine refer additionally to other risks.

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Safety - Machine labeling

1.3

Machine labeling

The machine is provided with special warning and notice signs.   



Do not remove the signs. Ensure that all signs are undamaged and legible. Clean labels with soap and water if necessary, not with fuel or solvents. Replace damaged, scratched or illegible signs with new ones.

Note

Signs are available from SENNEBOGEN (see Spare Parts Catalogue). 1.3.1 Identification plate

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

1.3.2 Warning and notice labels Note

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

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1-3

Safety - Responsibilities of the employer

1.4

Responsibilities of the employer

WARNING

The operator is obliged to supply operating instructions when working with hazardous machines or materials. The necessary information is contained in    

Recurring inspections

EC directives on safety at work National laws on safety at work Accident prevention regulations and these operating instructions.

Inspection by specialist t echnician, required for cr ane or excavating work

The machine must be thoroughly inspected by a specialist technician. 

 

before initial start-up and before operating the machine after significant modifications at least once yearly intermediate depending on operating and company conditions.

A specialist in this context is a person who 



has extensive knowledge of this machine and the relevant regulations and guidelines due to specialist training and through special instructions by SENNEBOGEN

and can assess the safe working condition of the machine. Specialist t esting, only r equired for crane operation

The following cranes must be tested by a specialist every 4 years: – Fuel driven mobile crane – Location changing fuel driven derrick – Truck attachment cranes The specialist inspection is to be performed in the 13th year of operation and annually thereafter. Faults that are detected in recurring inspections must be eliminated within a suitable time-frame depending on how serious a threat they pose to safety.

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Personn el selection and -qualifications

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

Employ only trained and instructed personnel. Define responsibility for operation and maintenance. Comply with the permitted statutory minimum age.

CAUTION

Personnel under training or instruction must remain under constant supervision while working on the machine.  Work on the machine's electrical equipment may only be carried out by a qualified electrician.  Work on undercarriage, braking and steerage systems may only be carried out by specifically trained technicians!  Work on hydraulic systems may only be carried out by personnel with special knowledge and experience on hydraulics! The independent operation or maintenance of earth moving machinery must only be carried out by personnel that 

Excerpt from VBG 40

  



Noise protection

are 18 years or over, are physically and mentally suitable, are trained in the operation and maintenance of earth-moving equipment and have proven their ability to do so to the employer and who can be expected to carry out the appointed work reliably.

For permanent sound pressure levels (LpA) of the machine, which are measured at the driver's seat with the cab closed, see the value on sticker on the inside of the cab. The wearing of ear protection is not absolutely required. Measurements are based on EN ISO 11201. This value of 85 dB(A) can however be exceeded due to environmental influences, e.g. through dropping or transporting material or at a construction site together with other machines. In these cases, noise protection measures for operating personnel are mandatory. The operator is to ensure that appropriate ear protection is available and used by the operating personnel. If necessary, ear protection is also to be worn outside the cab in special cases.

835 + 840 / 03.2010


1-5


Technical condit ion of the machine

The operator has an ongoing responsibility to monitor the overall technical condition (obvious external faults and damage as well as changes to operational behavior) of the machine. The machine must not be operated if faults are found! Observe mandatory time limits for routine checks. All damages and incidents are subject to the mandatory logging and storage regulations.

Independent modification and manufactur e of spare parts

For safety reasons the machine may not be modified or alter ed in any way. This also applies to the installation and use of safety features and valves as well as welding on load carrying parts.

Genuine SENNEBOGEN spare parts and accessories ensure the safety of personnel. Parts and fittings from other manufacturers are not tested by SENNEBOGEN and are not therefore approved. The use of other components can alter the machine's characteristics and present a safety hazard. If other components are used, SENNEBOGEN will not be considered liable for any resulting consequences.

Specific dangers

Dangers of noncompliance with safety instructions

Fire exting uisher and first-aid kit

1-6

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. Non-compliance with the safety instructions is dangerous and can be hazardous to persons as well as to the environment and the machine and leads to the loss of any claims for damages.

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


835 + 840 / 03.2010

Safety - Supplementary and operational equipment

1.5

Supplementary and operational equipment

1.5.1 SENNEBOGEN-Diagnost ic-System (SDS) Note

Sensors monitor the current operating state of the machine and transmit the information to the SDS. The measured data are evaluated in the SDS and displayed automatically or at the push of a button on the unit. The indicator and warning lights are activated if irregularities occur on the machine. The SDS carries out a self-test after the ignition is switched on. If the SDS detects a fault condition, it is displayed on the screen and by means of LEDs. Correct a minor fault condition (clogged air filter, empty f uel tank or the like) by yourself without delay. Contact SENNEBOGEN Customer Service to correct a more serious irregularity (one that you cannot correct yourself). . SENNEBOGEN Diagnosti cs System

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

CAUTION

The SENNEBOGEN Diagnostics System must never be cleaned with cleaning agents containing alcohol or solvents. Failure to observe the above could result in damage to the plastic surface.

835 + 840 / 03.2010


1-7


1.5.2 Oils and lubricants Note

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

The mixing of oils, lubricants or operating fluids of different types is not permitted! Filling or mixing oils, lubricants or operating fluids (e.g. hydraulic oil, gear lubricant oil, engine oil, refrigerant, etc.) of different types can lead to damage to the machine components resulting from chemical reactions. This damage can in turn result in severe damage to property and to personal injuries. Only use oils, lubricants and operational fluids that are approved by SENNEBOGEN. Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer! Oil diagnosis

A regular oil diagnosis helps to avoid unnecessary costs. A series of tests will determine:   

the condition of the oil the amount of worn metal in the sample the wear rate of components

Recommended for hydraulic system. Note

More helpful information is available from SENNEBOGEN customer services. Biodegradable oils and lubricants

The use of such substances is expressly required where the leakage of mineral-based oils and lubricants presents a danger to the environment. The use of environmental-friendly lubricants is mandatory, particularly in water or nature conservation areas. Only synthetic, ester-based bio-oils may be used. WARNING Switching to bio-oils and bio-lubricants is only permitted subject to agreement and written confirmation of SENNEBOGEN Customer Service.

1-8


835 + 840 / 03.2010


1.5.3 Refrigerant General infor mation WARNING

Mixing coolants and adding cooling system sealing agents or antifreeze that contains sealing agents is not permitted. By filling or mixing different types of coolant or cooling agent additives, the mixture can gel or build up to plug the cooler, resulting in the engine overheating or the cooling system failing and therefore causing damage to the engine. WARNING

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

Observe the refrigerant label in the cooler area. If the ambient temperature at the work-site is under this value (- 37°C (- 34°F)), observe the operating instructions of the engine manufacturer or contact SENNEBOGEN customer service before start-up. Note

If only a small amount (up to max. 5 l/1.3 gal.) is required to fill the water-coolant circuit and no suitable refrigerant is available, you can add clean water in the mean time. However, we recommend that you test the concentration as soon as possible before temperatures drop down to freezing. In some cases, you must refill with the respective refrigerant so that the required mixture to prevent freezing is achieved again. The refrigerant is not only required to guarantee protection from freezing, it also performs the very important task of protecting against corrosion. This also requires checking the correct concentration and adding when necessary.

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1-9


Refrigerant for DEUTZdrive engines

DEUTZ drive engines can be recognized by the identification plate. Note

DEUTZ drive engines are filled with refrigerant 

Hunold coolant ANF based on mono ethylene glycol

at the factory. Only use this refrigerant for DEUTZ drive engines! SENNEBOGEN will not accept responsibility and will not provide warranty or make any guarantees for the use of any other refrigerants. Protection from freezing down to - 37°C (- 34°F) is sufficient. Note

Observe the refrigerant label in the cooler area.

CAUTION

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

1 - 10


835 + 840 / 03.2010


Refrigerant fo r CUMMINSdrive engines

The CUMMINS drive engines can be recognized by the identificatio n plate.

Note

The CUMMINS drive engines are filled with refrigerant 

ES Compleat TM

at the factory. Use this refrigerant only for the CUMMINS drive engines! SENNEBOGEN will not accept responsibility and will not provide warranty or make any guarantees for the use of any other refrigerants. Protection from freezing down to - 36°C (- 33°F) is sufficient. Note

Observe the refrigerant label in the cooler area

CAUTION

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

835 + 840 / 03.2010


1 - 11


Water Note 

Use clean, neutral, filtered, fairly soft fresh tap water. SENNEBOGEN recommends distilled water as the best option.



Do not use ditch water, industrial drain water, salt water, sea water or rain water. Always fill using a water-coolant mixture. Observe mixing ratios. Mix before filling!



Ensure that the water has the following characteristics: pH value

7–8

Chloride content

max. 40 ppm

Sulfate content

max. 100 ppm

Water hardness

3-12°dGH

Ca + Mg

max. 70 ppm

Note

Observe the recommended mixing ratio (see manufacturer's specifications). If the refrigerant concentration is too high, the cooling and antifreeze characteristics will worsen. CAUTION

Observe the specifications of the refrigerant manufacturer. WARNING

Never fill with refrigerant when the engine is overheated. This will damage the engine. Allow the engine to cool first. WARNING

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

1 - 12


835 + 840 / 03.2010


Using other refrigerants

If you should ever use a refrigerant other than that specified, the following must be consid ered or expressly observed. SENNEBOGEN will accept no responsibility and will provide no warranty or make any guarantees for the use of any refrigerants other than those previously indicated.

Changing refrigerant WARNING

Scalding hazard! Caution when draining hot refrigerant! Allow the engine to cool first. Collect the refrigerant in a suitable container when draining and dispose of in accordance with regulations. – The cooling system is to be emptied completely before filling again.

– Rinse the cooling system several times with clear water to get rid of any residue. – Fill the cooling system and, after a short waiting period, check the level. – Start the engine and check the refrigerant levels CAUTION

Refrigerant level adjustments may have to be checked more than once to ensure they are correct . Check the following states when inspecting the refrigerant levels regularly, e.g. – lubricant incursion, – obvious opacity caused by corrosion residue or other particulate matter, in which case, the refrigerant must be replaced as indicated above. Change intervals

835 + 840 / 03.2010

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


1 - 13


1.5.4 Fuel (not for electric motors)

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

Please observe the instructions and recommendations in the operating instructions of the engine manufacturer.

1 - 14


835 + 840 / 03.2010

Safety - Maintenance

1.6

Maint enance

WARNING 

 

  

 



   

   

 



835 + 840 / 03.2010

Observe all signs and safety stickers on the machine as well as those in the instructions. They contain important information about maintenance procedures. The work performed may only be completed by trained specialists. Wear personal protective equipment (e.g. protective helmet, ear protection, protective gloves, safety shoes), where working conditions require. At working heights of 2.00 m or more, SENNEBOGEN recommends the use of safety equipment to prevent falling. At working heights above 3.00 m, using a safety harness is legally required. Hanging rings are marked. Use only original SENNEBOGEN spare parts. Use only oils and lubricants listed in the lubricant table. Collect lubricants and other consumables in suitable containers and dispose of them properly. Observe statutory accident prevention and safety regulations. Observe any additional documentation (e.g. engine, etc.) during maintenance work as well. Keep the vehicle (e.g. grips, steps, platforms, railings etc.) free from dirt, snow and ice. Smoking and working with an open flame is strictly forbidden. Use safety-compliant access ladder aids or working platforms. Maintain a safe distance from rotating and moving parts. Relieve the pressure from the hydraulic system and other operating materials before starting maintenance work. Dispose of hydraulic oil in accordance with regulations. Wear protective gloves when working on steel wire rope. Do not lift heavy objects by hand. Use lifting gear. For pneumatic tires: When pumping up tires, maintain an adequate safety clearance and use a tire cage. Keep the cab clean and orderly. Actuate the battery disconnecting switch or disconnect battery poles to interrupt the power supply. When working near batteries, they are to be covered with insulating material; do not place tools on top of batteries.


1 - 15




When handling batteries, observe the safety instructions and protective measures specified by the battery's manufacturer. Fire, sparks, open flames and smoking are prohibited when handling batteries.



When working on air conditioning systems, be aware that refrigerants and refrigerant vapors are hazardous to health. Wear the respective protective equipment.

Replace all protective features after completing any work on the machine. Exchange damaged protective features for new ones.  Carry out function check to ensure problem-free operation.  Only the machine owner or representative may approve the machine for operation following maintenance work.  If an accident occurs in spite of all safety and precautionary measures, e.g. – scalding by hot hot oil or refrigerant refrigerant – contact with strong strong acid – entry of fuel or hydraulic hydraulic into the skin skin – refrigerant- or hydraulic hydraulic oil spraying spraying into the eyes eyes etc., apply first aid immediately and contact a doctor.  After maintenance or repair work, carry out a thorough visual inspection and function check in accordance with the operating instructions in order to ensure proper and safe operation.  Further disassembly or service work that is not in the instructions may be performed only under the personal responsibility of the operator. Use necessary special tools.  Before resuming operation again, the correct and complete maintenance work is to be inspected by an authorized expert. 

Note

Parts that are tightly nested together are never to be loosened with hard objects. Parts that are loose are never to be tightened with hard objects. Anti-friction bearings, bearings, drive flanges and such that have to be disassembled/installed disassembled/ installed require the use of suitable tightening equipment or special tools.

1 - 16


835 + 840 / 03.2010


Qualifications of person personne nell

DANGER 







835 + 840 / 03.2010

Work on the machine's electrical equipment may only be carried out by a qualified electrician. Work on undercarriage, braking and steerage systems may only be carried out by specially trained trained specialists! specialists! Work on hydraulic systems may only be carried out by personnel with special knowledge and experience on hydraulics! No welding is to be performed on the device without previous discussion with the manufacturer.


1 - 17

Safety - Cleaning work

1.7

Cl ean i n g wo wo r k

CAUTION  



     





Clean machine daily. For heavy contamination, clean the machine several times per day if necessary, especially in recycling applications. Ensure that the cleaning agents used do not damage the seals and components of the machine. Do not use aggressive cleaning agents. Only use lint-free cleaning cloths. Only use dry, filtered compressed air up to max. 2 bar (29 psi). Lubricate the lubrication points after every cleaning. Replace protective caps on the lubricating nipples. nipples. After cleaning the engine compartment, check all lines for leaks, loosening or damage and correct any problems. Risk of condensation condensation After a wet cleaning, check that there is no moisture in the electrical switch cabinet. On completion of cleaning work on the machine, carry out a visual and functional check according to the machine operating instructions.

WARNING

Electrical and electronic components such as the generator, switch cabinet etc. as well as the bushes of the elevating cab (may cause damage to the bearing surfaces and result in sudden, uncontrolled motion when positioning the cab), must never be subjected to a direct stream of water! Wet cleaning of these components is prohibited! When wet cleaning the machine, always make sure that no water/ moisture comes into contact with electrical or electronic components. The infiltration of water can otherwise damage or destroy the electrical system of the machine. This can result in sudden, uncontrolled motion when working.

1 - 18


835 + 840 / 03.2010

Safety - Safe entry and exit

1.8  

 

    

Safe entry and exit

If necessary, clean access ladders prior to use. Enter or exit machine only when stationary and after the cab has been lowered completely, and never during any motion. Do not carry any items when climbing up or down. When entering or exiting, always ensure that you have three points of contact on the access ladders and grip handles. (e.g. two hands and one foot or two feet and one hand) lift items of equipment onto machine using rope or lifting equipment. Do not use operating instruments in the cab as grip handles. Use only the appropriate, provided access ladders and/or ladders. When the cab is raised, access to the gallery is not permitted. At working heights of 2.00 m or more, SENNEBOGEN recommends the use of safety equipment to prevent falling. At working heights above 3.00 m, using a safety harness is legally required. Hanging rings are marked.

Cab with out g allery

1 2 3

1 Open the sliding door (1) from the ground. 2 Hold onto the grip handles (2) and use your feed to step on the access ladders (3) and climb into the cab. 3 Close the sliding door.

835 + 840 / 03.2010


1 - 19


Cab wi th g allery

1 2 3 4

1 Open the door (1) from the ground. 2 Hold onto the grip handles (2) and use your feet to step on the access ladders (3). 3 Enter the cab from the rear to the front via the operator catwalk and then close the door.

CAUTION

Risk of falling! When stabilized, if the brakes are not applied, the wheels will turn! Only in extreme emergencies and with great care is the cab to be entered or exited via the wheel hub and the tire! Note

In some cases, it may be necessary to turn the upper structure to 90° offset to the undercarriage to allow safe entry/exit. Gallery/Operator catwalk

1

1 - 20


835 + 840 / 03.2010


DANGER

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

Risk of falling! No one must be permitted on the gallery when the cab is elevated! The max. load permitted on the gallery is 200 kg (440 lb) pre gridiron segment. Overloading the gallery can result in damage to the structure and result in serious personal injury. Inspect the gallery every 3 months (especially cracking) and repair immediately if found. Upper structure

2

3

2 Grip handle 3 Access ladder

DANGER Wear personal protective equipment (e.g. protective helmet, ear protection, protective gloves, safety shoes),where working conditions require. At working heights of 2.00 m or more, SENNEBOGEN recommends the use of safety equipment to prevent falling.

835 + 840 / 03.2010


1 - 21


At working heights above 3.00 m, using a safety harness is legally required. Hanging rings are marked.

1.8.1 Emergency exit CAUTION

Risk of falling! When stabilized, if the brakes are not applied, the wheels will turn! Only in extreme emergencies and with great care is the cab to be entered or exited via the wheel hub and the tire!

1 - 22


835 + 840 / 03.2010

Safety - Welding work

1.9

Welding work

WARNING

Welding work must only be carried out by an authorized and qualified welding specialist.  It is forbidden to carry out drilling or welding on – boom components – load-bearing frame parts – the engine – the hydraulic tank – the fuel tank – parts supplying fuel and oil.  Cover vulnerable components with fireproof material. 

Preliminary tasks

Before starting welding work, carry out the following preliminary tasks. 1 If necessary use the optional battery disconnecting switch to disconnect from the power supply. 2 Disconnect battery. 3 The battery must be switched off (no current flowing) when attaching or removing the battery cables. 4 Secure the earth clamp of the welding unit directly to the component to be welded. 5 Prior to any welding, remove the varnish from a generous area round the point to be welded. Hazardous gases can form and cause irritation.

835 + 840 / 03.2010


1 - 23

Safety - Protective features

1.10 Protective features DANGER  





Do not remove protective features or covers. Check protective features before switching on the machine to ensure they are all present and properly fastened. Examples of protective features are engine flaps, doors, guard grill, coverings, fire extinguisher, and first-aid kit. Replace all protective features and covers correctly on completion of assembly or maintenance work. Exchange damaged protective features for new ones.

Example. Fig.: Fan gril le

1 - 24


835 + 840 / 03.2010

Safety - Disposal

1.11 Disposal Lubricants and operational fluids CAUTION

Observe environmental guidelines! Handle and dispose of used items and materials correctly, in particular    

when working on the cooling systems when working on lubrication systems and devices when working with solvents and when working on hydraulic systems.

Excerpt from the Disposal Guideline 75/439/EEC :   

“It is prohibited to mix waste oil with other waste”. “Waste oils must not be mixed together”. “Used oil filters must be collected, kept, transported and disposed of separately from other waste.”

Notes 



Batteries

Lubricants and other operational fluids must be disposed of at suitable collection points. National environmental conditions for disposal specified in the country of use also apply.

Observe safety instructions and protective measures when handling batteries. Notes 



835 + 840 / 03.2010

Do not put batteries in the trash! Dispose of defective batteries at a recycling location for old batteries. National environmental conditions for disposal valid in the country of use also apply.


1 - 25

Safety - Disposal

1 - 26


835 + 840 / 03.2010

Maintenance schedul e -

2

Mai nten an ce sch ed ul e

Note

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

The standard engine oil change interval is every 500 hours of operation or every 3 months. In extreme operational conditions, e.g. in high ambient temperatures, the engine oil change interval can be shorted to 250 hours of operation or once per month. Please observe the operating i nstr uctio ns fro m the engine manufacturer!

Note

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

Methods of alerting user: – –

835 + 840 / 03.2010

F

= Check fill level (Fill levels, see Chapter 3)

W

= Oil or filter change


2-1

Maintenance s chedule - Daily/weekly maintenance

2.1

Daily/weekly maintenance

Note

The following pages contain the checklist to be worked through.

No.

Visual checks

Steps to take

Chapter

S1

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

If necessary, replace

-



S2

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

If necessary, repair or replace

-



S3

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

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

-



S4

Are the windows clean and free of ice and snow?

If necessary, clean

-



S5

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


5



S6

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

If necessary, retighten to the specified torque

3.6



S7

Is the tire pressure correct? For pneumatic tires:

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

3.3.1



S8

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

If necessary, tighten connections or replace seals

7



S9

Are the hydraulic cylinders (e.g. supports, arm, floating axle cylinders, steering cylinders) free of leaks and intact? Inspect piston rods for damage (cracking etc).

If necessary, tighten connections or replace seals

7.2.1



S10

Is the shutoff on the hydraulic tank open?

If necessary, open

-



S11 Are the oil and fluid reservoirs sufficiently full (hydraulic system, engine oil, fuel tank, demister, etc.)?

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

-



S12 Are TopAir and air filter cartridges damaged or contaminated?

If necessary, clean or replace

-



S13


-



If necessary, clean by reversing the fan or replace.

-



Is the fan wheel undamaged?

S14 Are the cooling fins on the combination cooler soiled or damaged?

2-2


835 + 840 / 03.2010

Maintenance schedul e - Daily/weekly maintenance

Visual checks

No.

Steps to take

Chapter

S15

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

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

-



S16

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

If necessary, retighten or replace

7.2.2



S17 Has the water separator on the fuel system been drained?

If necessary, drain

4.4.2



S18

Are the V-belts undamaged and tensioned?

If necessary, tension again or replace

4.7



S19

Are the electrical lines damaged?


8



S20 Are the cable connections (poles) of the battery corroded?

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

-



S21 Are the batteries held in place securely?

If necessary, retighten holders

8.1



S22

If necessary, close

-



7.2.2



Are all service access doors closed?

S23 Are all bolted connections undamaged and tight, particularly on the elevating cab?


S24 Are all bolt/screw connections e.g. on the mast and the gallery undamaged and tight (high-strength bolts, with/without distance tube)?


S25 Have any possible cable connections to external power sources been disconnected?

If necessary, disconnect

S26 Is the correct counterweight installed and secured in place?

If necessary, replace or retighten with specified torque

S27 Are the boom components/steel structure undamaged (corrosion, cracking)?


-



S28


-



S29 Are the pipe fracture safety devices tight and intact?


-



S30

If necessary, refill

6.2.1



S30 Is there enough grease in the lubricant reservoir of the slewing ring lubrication?

If necessary, refill

6.3.2



S31 Are the lubrication lines undamaged and all lubrication points being greased?

If necessary, replace, clean and lubricate

3.5



Are any pin-type keepers cracked or damaged?

Is there enough grease in the central lubrication system?

835 + 840 / 03.2010




-

 

2-3

Maintenance s chedule - Daily/weekly maintenance

No.

Visual checks

Steps to take

Chapter

S32 Are the hydraulic pipes and hoses secured in place?

If necessary, tighten fasteners

7



S33 Is the swiveling connection undamaged and lubricated sufficiently?

Repair or actuate pinion lubrication if necessary.

6



S35

Are the mechanical steering stops worn?


-



S36

Is the energy chain damaged/worn?


-



S37

Is the pump distributor gearbox sealed?

Repair if necessary

-



2-4


835 + 840 / 03.2010

Maintenance schedul e - One-time maintenance

2.2

One-time maintenance

2.2.1 After 50 hours of operation at the latest Note

The following maintenance work is to be performed one time only after 50 hours of operation at the latest.

Subassemblies/activities Undercarriage

Chapter

Travel dri ve

Check the wheel nuts for tightness.



5.1.3

2.2.2 After 250 hours of operation at the latest Note

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


Chapter

Travel dri ve W

Oil change

5.1.4 5.2.2

Slewing gear W

Oil change

6.4

Play in the slewing rin g 

Upper structure

835 + 840 / 03.2010

Wear measurement and checking the drive system/ bearing play The measurement is to be regarded as the base position for delivery status!

6.6

Hydraulics W

Return filter – Changing the filter

7.6

W

Leakage oil filter – change filter

7.9

W

Auxiliary control filter – change filter

7.7

W

Hydro Clean – changing filter (optional)

7.8


2-5

Maintenance s chedule - One-time maintenance

Subassemblies/activities

Chapter

Hydraulics 

Have preload pressure of hydraulic accumulator checked by hydraulic specialist company

7.12

Pump distributor gearbox W

2-6

Oil change


7.13.2

835 + 840 / 03.2010

Maintenance schedul e - Regular maintenance / Maintenance interval

2.3

Regular maintenance / Maintenance interval

Note

Observe the intervals in the following table. The consecutive intervals and the numbered sequence of steps must be maintained! Hours of operation (hrs) Section

250

500

750

1000

1250

1500

1750

2000

...

2.3.1

...

2.3.2

...

2.3.3

...

2.3.4

...

Examples of the table: – If the machine reaches 250 hours of operation for example, the maintenance plan from Section 2.3.1 must be observed. – If the machine reaches 500 hours of operation, Sections 2.3.1 and 2.3.2 must be observed. – Etc... Note

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

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

835 + 840 / 03.2010


2-7

Maintenance s chedule - Regular maintenance / Maintenance interval

2.3.1 Monthly or at the latest after 250 hours of operation Note

Observe the maintenance intervals and the maintenance plan from the respective additional documentation. (e.g. Grabber, Engine)


Chapter

Steering axle: Hub F

Checking oil level

5.1.4

Differential (type 835) F

Checking oil level

5.1.6


Checking oil level

5.1.8

Steering 

Check the steering stops



Check the steering cylinder for leaks and functionality Ax le d is tr ib ut or gear (ty pe 835)

F

Checking oil level

5.1.5

Back g ear (ty pe 840) F

Checking oil level

5.1.8

Drive shaft/universal joi nt (type 835) 

Lubricate via the grease nipple (3 each)

5.1.7

Rigid axle: Hub F

Checking oil level

5.1.4


Checking oil level

5.1.6


2-8

Checking oil level


5.1.8

835 + 840 / 03.2010



Chapter

Back gear (type 840) F

Checking oil level

5.1.8

Parking disc brake (type 840) F

Checking oil level

5.1.9

Steel structure 

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



Upper structure

Visually check all connecting elements for damage and corrosion

6

Cab air condit ioning and auxili ary heating s ystem 

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



Switch on at least 1 time per month Pump distributor gearbox

F

9.1 9.4

7.13.2

Checking oil level Engine

W F

Engine maintenance intervals (see engine manufacturer's instructions)

F

Check refrigerant level, check anti-freeze/ concentration

4.5

W

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

4.4.2

Engine: air conditioning compr essor

835 + 840 / 03.2010



Check the air conditioning compressor mounts and bolts for tightness.

9.3



Check belt status and tension

9.3


2-9


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

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


Chapter

Steering 

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

3.6

Slewing ring lubrication 

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

6.3.2

Slewing r ing: Teeth/slewing track 

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

6.5



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

6.1

Upper structure

Gallery 

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



Check the hinges, quick latches and gas pressure springs for functionality Cab: Air con ditio ning sys tem and auxiliary heating system



Have an authorized workshop perform checks on the air conditioning.

9.1

Equipment 

2 - 10

Load holding test with 1 t


835 + 840 / 03.2010



Chapter

Hydraulics 

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

7.10

Hydraulics 

Have preload pressure of hydraulic accumulator checked by hydraulic specialist company

7.12

Engine W F


W

Water separator – Change filter insert

4.4.2

Charge air cooler – Drain condensation

4.5



835 + 840 / 03.2010


2 - 11


2.3.3 Annually or at the latest after 1000 hours of operation Note



Chapter

Ax le d is tr ib ut or gear

Undercarriage 

W

Check secure fastening of gearbox and cardan shafts, retighten to required torque when necessary

3.6

Oil change

5.1.5

Steering axle: Hub W

Oil change

5.1.4

Brake 

Brake wear measurement

5.1.4

Differential (type 835) 

W

Check secure fastening of cardan shafts, retighten to required torque when necessary

3.6

Oil change

5.1.6

Differential (type 840) W

Oil change

5.1.8

Back g ear (ty pe 840) W

Oil change

5.1.8

Rigid axle: Hub W

Oil change

5.1.4

Brake 

2 - 12

Brake wear measurement


5.1.4

835 + 840 / 03.2010



Chapter

Swing axle cylinder 

Check secure fastening, tighten to required torque when necessary

3.6

Differential (type 835) 

W

Check secure fastening of cardan shafts, retighten to required torque when necessary

3.6

Oil change

5.1.6

Differential (type 840) W

Oil change

5.1.8

Back gear (type 840) W

Oil change

5.1.8

Parking disc brake (type 840) W

Oil change

5.1.9

Steel structure 

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

W

Oil change

5.1.4 5.2.2

Slewing ring: Gear teeth/slewing t rack 

Check for interference/gear teeth of the slewing ring pinion

6.3

Play in the slewing rin g 

Wear measurement and checking the drive system/ bearing play

6.6

Slewing gear 

835 + 840 / 03.2010

Check secure fastening, retighten to required torque when necessary


3.6

2 - 13


Subassemblies/activities Upper structure

Chapter

Steel structure 

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




3.6

Fuel/hydraulic tank 


3.6

Equipment 

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



Check bolted joints for cracking or damage



Check for correct lifting limit settings for stick and boom



Check pipe fracture safety devices Hydraulics



Ventilation filter – change hydraulic tank.

7.10

Pump distributor gearbox W

Oil change

7.13.2

Engine

2 - 14

W F


W

Safety cartridge – Change air filter

4.3

W

Replacement cartridge – Change air filter

4.3


835 + 840 / 03.2010


2.3.4 at the latest after 2000 hours of operation Note


Subassemblies/activities Upper structure

Chapter

Hydraulics W

Return filter – Changing the filter

7.6

W

Leakage oil filter – change filter

7.9

*

Auxiliary control filter – change filter

7.7

W

HydroClean – Change filter (optional)

7.8

**

Changing the hydraulic oil

7.5

**

Check hydraulic hoses for damages

7.3

Engine W F


W

Changing refrigerant

4.5.4

Slip ring assembly

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



Slewing gear

Undercarriage W

*:

Oil change

6.4

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

**: Only required every 4,000 hours of operation, if: – the machine is equipped with a SENNEBOGEN HydroClean system and – every 2,000 hours of operation, an oil diagnosis is performed by a SENNEBOGEN authorized laboratory and was evaluated as good

835 + 840 / 03.2010


2 - 15


2.3.5 At the latest, aft er 4,000 / 5,000 / 10,000 / 12,000 / 20,000 hours of operation Note

Observe the maintenance intervals and the maintenance plan from the respective additional documentation. (e.g. grab, engine) At th e lat est , after ... Subassemblies/activities Hydraulics

4,000 hours of operation W 

5,000 hours of operation or 5 years 10,000 hours of operation or 3 years

Chapter

Changing the hydraulic oil

7.5

Check hydraulic hoses for damages

7.3

Slewing ring connection 

Have the slewing ring bolts checked by a specialist company. Change if necessary Engine: air conditioning compressor

W

Oil change

9.3

Cab W 12,000 hours of operation or 6 years 20,000 hours of operation or 10 years

Replace seat belt Hydraulics

W 

Change hydraulic hoses

7.3

Slip ring assembly

Renew bearing point Hydraulics 

2 - 16

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


7.12

835 + 840 / 03.2010

Specifications - General

3

Specifications

3.1 General Note

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

24 V Note

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

Am bi ent tem per atu re

Operation / approx. - 20°C (- 4°F)... Operation under load approx. + 40°C (+ 104°F) Note

If a machine is to be run at ambient temperatures outside the specified temperature range, special temperature packages are available (option). Please contact SENNEBOGEN customer service if you have any other questions.

Hydraulics

Slewing drive

835 + 840 / 03.2010

Operating pressure, max. 350 bar

Slewing speed

0 - 8 rpm, continuously variable


3-1

Specifications - General

Limitations during wind

Wind speed 25 m/s

90 km/h

10 Beaufort

Note

Machine operation is generally possible, without any attachments, at wind speeds of up to 25 m/second. The decision when to halt operation must be made by the machine operator and depends on the attachment. Different attachments create different wind loads which affect stability. These are to be determined by the operator and the machine is to be shut down accordingly. DANGER

Once the specified wind speed is reached, stop operating the machine immediately (lower load, lower boom). For table on wind speeds, see Section 3.7

3-2


835 + 840 / 03.2010

Specifications - Drive engine

3.2

Drive engine

Note

Observe the engine manufacturer notes in the operating instructions. 3.2.1 Type 835 TDC 2013 L06 2V

Power (according to ISO14396)

186 kW / 249 HP at nominal speed 2000 rpm

Displacement

7,142 cm3

Cylinders

6

Oil capacity with filter

approx. 22.0 l / approx. 5.81 gal. (US)

Coolant capacity (overall system)

approx. 48 l / approx. 12.68 gal. (US)

General drive engine information

See manufacturer's instructions

QSB6.7-C260

835 + 840 / 03.2010



Displacement

6.700 cm3

Cylinders

6








150 kW at nominal speed 1480 rpm




3-3

Specifications - Drive engine

3.2.2 Type 840

QSB6.7-C260

3-4



Displacement

6.700 cm3

Cylinders

6








835 + 840 / 03.2010

Specifications - Machine

3.3

Machine

3.3.1 Mo bi le Subassembly

Quantity

Fuel tank

max. 600 l / max. 158.5 gal. (US)

Hydraulic tank Middle inspection glass:

max. 510l / max. 134.7 gal. (US) approx. 410l / approx. 108.3 gal. (US)

Hydraulic system, complete (*)

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

Axle distributor gear

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

typ e 835

Differential typ e 835  

front rear

approx. 26,0 l / approx. 6.9 gal. (US) approx. 19.5 l / approx. 5.1 gal. (US)

Hub drive train typ e 835 

front

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



rear


Back gear typ e 840  

front rear

approx. 1.5 l / approx. 0.39 gal. (US) approx. 1.5 l / approx. 0.39 gal. (US)

Differential typ e 840  

front rear

approx. 44.5 l / approx. 11.4 gal. (US) approx. 40.3 l / approx. 10.6 gal. (US)

Hub drive train typ e 840

835 + 840 / 03.2010



front




rear



3-5


Subassembly

Quantity

Parking disc brake typ e 840 

rear


Slewing ring lubrication – reservoir


Central lubrication system – reservoir (optional)

approx. 2.5 kg / approx. 5.5 lbs

Slewing gear


(*): On special machines with a mast, note that an additional approx. 30 l (approx. 7.9 gal. (US)) of hydraulic oil are needed per 0.5 m of mast length. Tire air p ressure (pneumatic t ires)

Tire size

pp bar Ai r p res su re psi

10.00-20

7.5

108.78

12.00-20

9

130.53

10.00-24

10

145.04

395/85

8.5

123.28

DANGER

When pumping up tires, maintain adequate safety clearance and use tire cage. Wheel nuts Travel speed typ e 835

Travel speed typ e 840

3-6

The tightening torque is 650 Nm. Use a torque wrench. Off-road gear (1st gear)

0-7 km/h

Street gear (2nd gear)

0-20 km/h

0-11 km/h


835 + 840 / 03.2010


3.3.2 Crawler Subassembly

Quantity

Fuel tank

max. 600 l / max. 158.5 gal. (US)


max. 510 l / max. 134.7 gal. (US) approx. 410 l / approx. 108.3 gal. (US)



Gearbox 

typ e 835




typ e 840






Slewing gear


(*): On special machines with a mast, note that an additional approx. 30 l (approx. 7.9 gal. (US)) of hydraulic oil are needed per 0.5 m of mast length. Driving s peed

835 + 840 / 03.2010

1st gear

0-1.5 km/h

2nd gear

0-3.2 km/h


3-7


3.3.3 Structure Subassembly

Quantity

Fuel tank

max. 600 l / max. 158.5 gal. (US)









Slewing gear


(*): On special machines with a mast, note that an additional approx. 30 l (approx. 7.9 gal. (US)) of hydraulic oil are needed per 0.5 m of mast length.

Driving s peed

3-8

Stationary


835 + 840 / 03.2010


3.3.4 Rails Subassembly

Quantity

Fuel tank

max. 600 l / max. 158.5 gal. (US)









Slewing gear


(*): On special machines with a mast, note that an additional approx. 30 l (approx. 7.9 gal. (US)) of hydraulic oil are needed per 0.5 m of mast length.

Driving speed

835 + 840 / 03.2010

Speed is customer-specific.


3-9

Specifications - Inspection tools – overview

3.4

Inspection tools – overview

Note

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

Item

Quantity

Seal-O-Ring for hydraulic tank

1

Return filter

2

Leakage oil filter

1

Ventilation filter

1

Auxiliary control filter *)

1

HydroClean (Optional)

1

Recirculating air filter

1

Outside air filter

1

Drier bottle

1

SE number

e h t g n l o i t t s a i a l s c t s r t a r p a r p a e e r a W p e S e s

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

Drive engine

Item

Quantity

Oil filter

1

Fuel filter

2

Water separator

1

Safety cartridge-air filter

1

Replacement cartridge-air filter

1

V-belt – alternator

1

V-belt – water pump

1

V-belt – air conditioner

1

V-belt – magnet unit (optional)

1

Valve bush sealing

1

SE number

e h t g n l o i t t s a i a l c s t s r t a r p a r p a e e r a W p e S e s

Note! If the machine is equipped with electric drive, only the ventilation air filter set (094559) is required.

3 - 10


835 + 840 / 03.2010

Specifications - Lubricate machine.

3.5

Lubricate machine.

3.5.1 Machine – mobile Manual lubri cation

= grease manually WARNING

WARNING (type 835) The grease nipple (1) on the emergency actuating mechanism is not to be used for lubrication purposes. It is used exclusively for activating th e emergency actuation. The gearbox can b e destroyed. 3

2

1

Note

Clean lubricating nipple before lubricating. Remove excess grease. The lubrication nipples are provided with a red protective cap.

835 + 840 / 03.2010


3 - 11


a Lubricating nipple overview

Centralized lubrication, f ront:

Steering knuckle (2 per side) Support cylinder in Floating axle (1)

a

Comment:

3 lubricating nipples per drive shaft/universal joint

Type 835

b

b Centralized lubrication, rear: Type 835

Support cylinders, inner

= grease manually

3 - 12


835 + 840 / 03.2010


Note

The machine is equipped with a central lubrication system for the swivel and the equipment as standard equipment. CAUTION

The reservoir for the central lubrication system must always be adequately filled in order to prevent damaging the bearings.

Central lubri cation overview

= bearings supplied with grease by the central lubrication system

835 + 840 / 03.2010


3 - 13


3.5.2 .5.2 Machine achine – crawle crawler r Note

The machine is equipped with a central lubrication system for the swiveling connection and the equipment as standard equipment. CAUTION

The reservoir for the central lubrication system must always be adequately filled filled in order to prevent damaging damaging the bearings. bearings. Lubrication points, overview


= grease manually

Note

Clean lubricating nipple before lubricating. Remove excess grease. The lubrication nipples are provided with a red protective cap.

3 - 14


835 + 840 / 03.2010


Lubricating nipples, overview

8 per side

= grease manually

835 + 840 / 03.2010


3 - 15


3.5.3 .5.3 Machine achine – Setup Note

The machine is equipped with a central lubrication system for the swiveling connection and the equipment as standard equipment. CAUTION

The reservoir for the central lubrication system must always be adequately filled filled in order to prevent damaging damaging the bearings. bearings. Lubrication points, overview


= grease manually

Note

Clean lubricating nipple before lubricating Remove excess grease. The lubrication nipples are provided with a red protective cap.

3 - 16


835 + 840 / 03.2010

Specifications - Tightening torques for bolts

3.6

Tightening torques for bolts

Note

For certain fixing bolts on the undercarriage, values differing from those listed in this table may apply. Please observe the notes in the respective sections. Strength class 8.8

835 + 840 / 03.2010

Coarse thread

Fine thread

Bolt

Tightening torque MA [Nm]

Bolt


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


3 - 17


Strength class 10.9

3 - 18

Coarse 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


835 + 840 / 03.2010


Strength class 12.9

835 + 840 / 03.2010

Coarse 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


3 - 19


Pump stop

1 CAUTION  

3 - 20

Do not over-tighten rubber buffer (1). Torque: M16 screw at 7 Nm.


835 + 840 / 03.2010

Specifications - Wind speed

3.7

Wind speed

Wind speed

Description

Beaufort scale

Name

m/s

km/h

On shore

0

Calm

0-0,2

1

Calm, smoke rises vertically

1

Light draught 0,3-1,5

1-5

Direction of wind shown by smoke but not by wind vanes

2

Light breeze

6-11

Wind felt on face; leaves rustle; wind vane moves

3

Weak breeze 3,4-5,4

12-19

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

4

Moderate breeze

20-28

Wind raises dust and loose paper; small branches move

5

Fresh breeze 8,0-10,7

29-38

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

6

Strong breeze

10,8-13,8

39-49

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

7

Moderate gale

13,9-17,1

50-61

Whole trees sway; walking against wind is difficult

8

Fresh gale

17,2-20,7

62-74

Twigs break off trees; moving cars veer

9

Storm

20,8-24,4

75-88

Slight structural damage occurs, shingles may blow away

10

Heavy storm 24,5-28,4

89-102

Trees uprooted; considerable structural damage occurs

11

Hurricane type storm

28,5-32,6

103-117 Extensive storm damages

Hurricane

32,7-36,9

12

835 + 840 / 03.2010

Wind speed

1,6-3,3

5,5-7,9

(rarely in inland)


118-133 Severe devastation

3 - 21

Specifications - Conversion factors

3.8

Conversion factors

Pressure

1 bar

100 Kpa

14.5 psi

10 psi

68.95 Kpa

0.6895 bar

1 l/min

0.0353 cfm

0.2642 gal/min (US)

1 gal/min (Brit.)

0.1605 cfm

1 gal/min(US)

3.78541 l/min

1 mm

0.03934 in

1m

39.34 in

1 in

25.4 mm

1 ft

0.3048 m

304.8 mm

1 km

39340 in

3280.8 ft

1 km

1093.6 yd

0.62137 mile

1 mile

1.609 km

1609 m

1 kg

2.205 lb

35.27 Oz

1 lb.(US)

0.454 kg

16 Oz

kW

= HP x 0.746

HP

= kW x 1.341

°C

= (°F -32) x 5/9

°F

= (°C x 9/5) + 32

Flow rate

Length

3.281 ft

Weight

Power

Temperature

3 - 22


835 + 840 / 03.2010


Volume

1 m3

1000 l

35.31 ft3

1.308 yd3

1 ft3

28.32 l

0.02832 m3

1.728 inch3

1l

0.2642 gal. (US) 0.2201 gal (Brit.)

1 gal. (US)

3.785 l

231 inch3

-

1 gal. (Brit.)

4.544 l

277 inch3

-

1 yd³

764.55 l

0.765 m³

27 ft³

1 m/s

3.281ft/s

2.237 mile/h

1 ft/s

0.305 m/s

1.097 km/h

-

Speed

835 + 840 / 03.2010


3 - 23


3 - 24


835 + 840 / 03.2010

Drive engine - Safety instructions

4

Drive engine

4.1 Safety instructions Observe safety instructions before starting work. WARNING 









Only carry out maintenance or repair work with engine shut off and cooled down. Secure machine against unauthorized re-starting before starting with maintenance work. Waste oil must not be allowed to seep into the ground or waterways. Dispose of oil and oil filters in accordance with statutory regulations. Refrigerant must not seep into the ground or into waterways. Dispose of refrigerant in accordance with statutory regulations. After maintenance work on the engine, check that all safety devices have been installed and all tools are removed from the engine.

Note

Also observe the information and recommendations in the operating instructions of the engine manufacturer. Engine with V-belt protection

13 mm

835 + 840 / 03.2010


4-1

Drive engine - Engine oil

4.2

En g i n e o i l

WARNING 



Scalding hazard! Proceed with utmost caution when draining hot oil. Waste oil must not be allowed to seep into the ground or waterways. Dispose of oil and oil filters in accordance with statutory regulations.

CAUTION

The mixing of oils, lubricants or operating fluids of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) specifications) from one one manufacturer! Note

Observe the engine manufacturer instructions in the operating instructions.

Check Check engine o il l evel. evel.

1 Put the the mach machine ine in a leve levell horiz horizon ontal tal posi positio tion. n. 2 Run drive drive engin engine e for appro approx. x. 2 minute minutess until until the system system is filled filled with oil. 3 Shut Shut down down driv drive e eng engin ine. e. 4 Open Open the the servi service ce acce access ss doo doorr on the right. right. 5 Pull Pull out out oil oil dips dipstitick ck (2) (2) by the the grip and wipe off using a clean, lint-free cloth. 6 Insert Insert oil oil dipst dipstick ick (2) (2) up up to stop stop and and pull pull out out again again.. 7 Check Check the the oil oil level level (with (with handle handle pointing pointing upward!) upward!):: The oil level must be between the lower marking (MIN) and the upper marking (MAX). 8 If necessa necessary ry fill fill with with engine engine oil of of the specifie specified d grade grade (1). (1). 9 Insert Insert oil oil dipst dipstick ick (2) (2) up up to stop stop and and pull pull out out again again.. 10 Close Close the the servi service ce acce access ss doo doorr on the the rig right. ht.

4-2


835 + 840 / 03.2010

Drive engin engin e - Engine oil

Detaile Detailed d v iew of engine

1 2 3

1 Oil filler strainer

3 Oil filter

2 Oil dipstick handle

Changing Changing engin e oil and oil filter

1 Bring Bring mach machine ine up to to opera operatin ting g tempe temperat rature ure.. 2 Put the the mach machin ine e in a leve levell horiz horizon ontal tal posi positio tion. n. 3 Shut down drive drive engine engine and secure secure again against st re-star re-starting ting.. 4 Open Open the the servi service ce acce access ss doo doorr on the right. right. 5 Change Change engine engine oil and and oil oil filter filter in accordan accordance ce with with the engine engine manufacturer's manufacturer's instructions. 6 Check Check the the oil level level (with (with handle handle point pointing ing upward!): upward!): The oil level must be between the lower marking (MIN) and the upper marking (MAX). 7 If neces necessar saryy add add oil oil of the the spe specif cifie ied d grade grade.. 8 Close Close the servic service e acce access ss doo doorr on the right. right.

835 + 840 / 03.2010


4-3

Drive engine - Air filter

4.3

A i r fi fi l t er

4.3.1 Air Air filte filter r Safety instructions

Observe safety instructions before starting work. CAUTION  

Ai r f il ter pilot lamp

Never use gasoline, soap or hot fluids to clean the air filter. Never use compressed air to clean the interior of the housing because dust and contamination can enter the engine.

The condition of the air ffilter ilter is monitored by a sensor. The contamination level is measured by the flow resistance. If the air filter pilot pilot lamp on the right control panel lights, up the maximum permitted flow resistance has been reached. A warning tone also sounds. Inspect and clean the air filter without delay. Note

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

1

2

1 Air filter 2 Service access door

4-4


835 + 840 / 03.2010


Ai r f il ter mai nt enance

1

2

3

4

5

6 1 Air filter cap

4 Grip

2 Locking clamps (3 pieces)

5 Safety carriage

3 Replacement cartridge

6 Hub

1 Open rear left service access door. 2 Open the locking clamps (2) of the air filter cover (1) and remove the air filter cover. 3 Remove replacement cartridge (3). 4 Clean the replaceable cartridge: – Blow out from inside to outside using dry compressed air (max. 2 bar/29 psi). – Only knock out if unavoidable! 5 Check replacement cartridge for damage to the filter paper and the seals. Exchange if necessary. 6 Exchange safety carriage (6) after 5 filter service intervals (at least every 2 years): – Remove the safety carriage by the grip (4). Never clean safety carriage! – Insert new safety carriage. 7 Insert new or cleaned replacement cartridge (3). 8 Replace the air filter cover (1) so that the tab (6) faces downwards or the word “TOP” faces upwards. 9 Re-attach the air filter cover (1) using the locking clamps (2). 10 Re-close service access door.

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4-5


4.3.2 Air filter – pre-separator

The air filter pre-separator, mounted on the upper structure, is maintenance-free. Remove the heavy contamination at regular intervals! CAUTION

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

1

1 Air filter pre-separator

4-6


835 + 840 / 03.2010

Drive engine - Fuel system

4.4

Fuel system

4.4.1 Safety instructions

Observe safety instructions before starting work. WARNING 

 

835 + 840 / 03.2010

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


4-7


4.4.2 Water separator 1 7

2 4

5 6

3

1 4

5

2

3

1 Manual feed pump

5 Drain valve

2 Filter cartridge

6 Water reservoir

3 Shut-off valve

7 Vent screw

4 Sensor plug

4-8


835 + 840 / 03.2010


Draining water

1 Open rear right service access door. 2 Set a suitable catch container under the drain valve (5). 3 Open drain valve (5). 4 Drain the water and debris out of the water container. 5 Shut off the drain valve (5) again. 6 Close the service access door at the right rear.

Change filter cartrid ge

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

Observe the instructions printed on the filter cartridge. 1 Close shut-off valve (5). 2 Remove the sensor plug (4). 3 Screw the filter cartridge (2) out of the housing head. 4 Dispose of the cartridge and the seal-O-ring. 5 Screw the filter cartridge (2) with new seal-O-ring onto the upper part of the housing. 6 Reconnect the sensor plug (4). 7 Open the shut-off valve (3). 8 Use the hand feed pump (1) to pump fuel into the water separator. 9 Press the manual feed pump button (1) in and locked in place.

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4-9

Drive engine - Cooler

4.5

Cooler

4.5.1 Safety instructions

Observe safety instructions before starting work. WARNING 



Injury hazard from rotating parts and from scalding! Do not carry out maintenance work until the drive engine has been switched off and the cooling system has been allowed to cool down. The refrigerant must not enter into the ground or waterways. Dispose of refrigerant in accordance with statutory regulations.

CAUTION

The mixing of oils, lubricants or operational fluids of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer! 4.5.2 Refrigerant – Deutz engine Note

Use the following specified refrigerants: SENNEBOGEN factory uses: – Hunold coolant ANF based on monoethylene glycol Antifreeze sufficient to - 37°C (- 34°F).  Do not use more or less than the recommended concentration of 50 Vol.% refrigerant. If the refrigerant concentration is too high, the cooling and antifreeze characteristics will worsen. 

Change intervals

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

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

4 - 10


835 + 840 / 03.2010


4.5.3 Refrigerant – Cummins engine Note

Use the following specified refrigerants: SENNEBOGEN factory uses: – ES Compleat TM. Antifreeze sufficient to - 36°C (- 33°F).  Do not use more or less than the recommended concentration of 50 Vol.% refrigerant. If the refrigerant concentration is too high, the cooling and antifreeze characteristics will worsen. 

Change intervals

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

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

4.5.4 Changing refrigerant Refrigerant level pilot lamp

The refrigerant level is monitored by a sensor. If the level falls below a certain point, a warning tone sounds. Add refrigerant. If the refrigerant level is too low, check the bolt/screw connections and lines for leaks. Note

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

Machines with an electric motor only have one hydraulic oil cooler!

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4 - 11


1

2

3

1 Refrigerant expansion tank

3 Service access door

2 Combination cooler

Check refrigerant l evel and/or antifreeze

4 5

7

1

6

4 - 12

4 Hand screws

6 Service panel

5 Grip

7 Sealing cap


835 + 840 / 03.2010


1 Allow drive engine and cooler to cool down. 2 Unscrew the two hand screws (4). 3 Grab the service panel (6) by the grip (5) and remove. 4 Pace large, thick cloths on the cap (7) of the refrigerant expansion tank (1) and open it carefully in order to equalize the pressure. 5 Check antifreeze and refrigerant level, add if necessary. Mixing ratio: 50% antifreeze, 50% water. Frost resistant down to - 37°C (- 34°F). 6 Check antifreeze and refrigerant level, add if necessary. Mixing ratio: 50% antifreeze, 50% water. Frost resistant down to - 36°C (- 33°F). 7 Re-close sealing cap (7) of expansion tank. 8 Replace the service panel (6) and secure using the hand screws.

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4 - 13

Drive engine - Cleaning the cooling system

4.6

Cleaning the cooling system

The cooling system ensures that the engine runs at a constant operating temperature. The cooling system has an important impact on the function and service life of the engine. The cooler is adapted for each respective engine. The cooler must be kept fully operational in order to prevent damage to the drive system, e.g. owing to overheating. You should therefore check the cooler regularly and clean it if necessary. Dirt can build up on both the outside (e.g. dust) and the inside (e.g. scale) of the cooler. Note

This section provides you with general instructions on cleaning the cooler. Follow the instructions as well in the operating instructions of the engine manufacturer. 4.6.1 Safety instructions WARNING 















If the cooler is damaged, contact SENNEBOGEN Customer Service before starting on any repair work. Repair work on the cooling system should only be carried out by specialists. Do not touch the guard grill on the fan. Rotating fan blades may cause serious injury. Objects coming into contact with the fan blades may be catapulted into the air. Switch off the machine and ensure that it cannot be switched on again before starting any repair work. Always wear face protection or protective glasses when working on the cooling system. Always relieve the pressure in the cooling system before starting any repair work. Place a cloth over the sealing cap and open the cap slowly to allow the cooling system to cool down. Do not use cleaning agents that may damage the cooler materials or the varnish on the machine. Antifreeze is combustible. Do not smoke in the vicinity of the cooling system and do not have an exposed flame.

Please observe the manufacturer’s specifications when handling coolant or cleaning agents.

4 - 14


835 + 840 / 03.2010


4.6.2 Reverse fan

1 Allow the drive engine and combination cooler (1) to cool down. 2 Open the service access door (2). 3 Blow out minor dirt by reversing the ventilator direction. To do so: Actuate the fan reversal switch in the driver's cab. 4 Otherwise, blow off cooling fins from the outlet side with dry, filtered compressed air (max. 2 bar / 29 psi). If contaminated with grease and oil, clean the cooling ribs with detergent. 5 Check cooler for leaks and damaged cooling fins. 6 Re-close service access door. 4.6.3 External cleaning Dirt and cleaning procedure

Dust, insects, foliage or leaves

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

Oily and greasy deposits

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

CAUTION

Make sure that the cooling fins are not damaged.

Procedure

1 Direct the cleaning jet parallel to the longitudinal direction of the cooling fins. Make sure that the cooling fins are not damaged. 2 Allow the cooling system to dry before starting it up again.

835 + 840 / 03.2010


4 - 15


4.6.4 Internal cleaning Note

Observe the information in the engine manufacture's operating instructions as well. It is necessary to clean the interior of the cooling system if 





 

Procedure

The engine is constantly overheating even though the V-belt, thermostat and water pump are functioning properly. Dirt is visible on the cooling pipes. Remove the sealing cap and check it. Green sludge (chromium hydroxide) is present on the underside of the sealing cap. The coolant is very cloudy. Lubricant incursion has occurred. 1 Please observe the safety instructions. 2 Drain the refrigerant into suitable containers and dispose of it in accordance with regulations. 3 Add a mixture of standard cooling system cleaner and water.

CAUTION

Please note the mixing ratio and ensure that the cooling system cleaner is used properly! 4 Start the engine and allow it to run for approx. 1.5 hours. 5 Drain the mixture into suitable containers and dispose of it in accordance with regulations. 6 Flush the cooling system thoroughly with clean water; repeat this process several times. CAUTION

Always fill using a water-refrigerant mixture. Observe mixing ratios. Mix before filling! 7 Fill the cooling system with a water-refrigerant mixture. Note More thorough cleaning is only possible if the cooler is deinstalled. Contact SENNEBOGEN Customer Service before deinstalling the cooler.

4 - 16


835 + 840 / 03.2010

Drive engine - Check belt drives

4.7 Safety instructions

Ch ec k b elt dr iv es

Observe safety instructions before starting work. DANGER 







Only carry out maintenance work with drive engine shut down and stationary. Shut down machine and secure against unauthorized re-starting before starting with maintenance work. Where applicable, replace protective covering after maintenance work. Make sure that the V-belts run in parallel.

Note

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

1

2 3 4

1 Alternator 2 Generator for magnet

equipment (optional)

3 Heating/air-conditioning

system (optional) 4 Fuel pump

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

835 + 840 / 03.2010


4 - 17

Drive engine - Electric motor

4.8

Electr ic motor

Note

Observe the instructions in the engine manufacturer operating instructions.

4 - 18


835 + 840 / 03.2010

Undercarriage - Mobile

5

Undercarriage

5.1 Mo bil e WARNING

Injury hazard from rotating parts! Do not carry out maintenance work until the drive engine has been switched off. 



Maintenance and repair work must only be carried out by trained specialist personnel. Oil must not be allowed to seep into the ground or water. Dispose of waste oil in accordance with the statutory regulations.

5.1.1 Cleaning and lubricating

1 Put the machine in a level horizontal position. 2 Shut down engine and secure against re-starting. 3 Clean tires and undercarriage using a steam cleaner. Attention! Hold the steam cleaner lance at least 20 cm from the surface to be cleaned. 4 Lightly grease guides and bolts. 5 Lubricate all lubrication points (see Section 3.3).

5.1.2 Tire air pressure (pneumatic tires) DANGER

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

835 + 840 / 03.2010

Tire size

p bar p Ai r p res su rep psi

10.00-20

7.5

108.78

12.00-20

9

130.53

10.00-24

10

145.04

395/85

8.5

123.28


5-1


5.1.3 Retightening wheel nuts

Check tightness of all wheel nuts. Use a torque wrench. Fig. Twin tires, solid rubber

650 Nm

32 mm

5.1.4 Hub drive train

1

2

1 Oil filler screw 2 Oil drain screw

WARNING

The mixing of oils, lubricants or operational fluids of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer!

5-2


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Checking the oil level

1 Put machine in a level, horizontal position. 2 Turn hub until the oil drain screw (2) is at the bottom (6 o'clock position). 3 Shut down drive engine. 4 Unscrew oil filler screw (1). The oil level must reach up to lower edge of oil filler screw, add oil if necessary. 5 Clean components, check seal and replace if necessary. 6 Re-tighten oil filler screw (1). 7 Repeat procedure on the three remaining hubs.

Changing o il

1 Put machine in a level, horizontal position. 2 Turn hub until the oil drain screw (2) is at the bottom. 3 Shut down drive engine. 4 Loosen oil filler screw (1) to relieve the pressure. 5 Place a suitable container under the oil drain screw (2). For capacities, see Section 3.3.1. 6 Unscrew oil drain screw (2) and collect the waste oil in the container. 7 Clean components, check seals and exchange if necessary. 8 Re-tighten oil drain screw (2). 9 Unscrew oil filler screw (1). 10 Fill with new oil up to lower edge of oil filler screw (1). 11 Re-tighten oil filler screw (1). 12 Repeat procedure on the three remaining hubs. 13 Operate for 2 hours, then re-check the oil level.

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5-3


Brake w ear measurement

Visually check if the thickness of the lining on the brake lining (2) at regular intervals depending on vehicle use. The brake shoes (1) themselves are maintenance-free. It is only important here to check for damaged parts. CAUTION

If the residual brake pads are very thin , the inspection intervals must be shortened accordingly to prevent extensive damage to the brakes and/or drum.

2

1

1

2

1 Brake shoe 2 Brake lining

Note 



Note regarding riveted brake lining: At least 1.0 – 1.5 mm residual pad thickness required above the rivet head at the weakest point in the pad. Note regarding bonded brake pads: At least 2.0 mm residual pad thickness required at the weakest point in the pad.

CAUTION If remaining brake pad thickness reaches these values, the brake pads (2) must be replaced on the axle.

5-4


835 + 840 / 03.2010


5.1.5 Axle distributor gear (type 835) 50 Nm 13 mm

1 2


1

2

CAUTION

The mixing of oils, lubricants or operational fluids of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer! Checking the oil l evel

1 Bring machine up to operating temperature. 2 Put the machine in a level horizontal position. 3 Switch off driving engine and secure against restarting. Wait approx. 10 minutes for the oil to collect in axle gear box. 4 Clean exterior of the transfer case using a cloth.

50 Nm 13 mm

5 Unscrew oil filler screw (1). The oil level must reach up to lower edge of filler opening, add oil if necessary. 6 Clean components, check seal and replace if necessary. 7 Tighten the oil filler screw (1) again (MA = 50Nm).

835 + 840 / 03.2010


5-5


Changing oi l

1 Bring machine up to operating temperature. 2 Put the machine in a level horizontal position. 3 Switch off drive engine and secure against restarting. Wait approx. 10 minutes for the oil to collect in axle gear box. 4 Clean exterior of the transfer case using a cloth. 5 Loosen oil filler screw (1) to relieve the pressure.

50 Nm 13 mm

50 Nm 13 mm

6 Place a suitable collecting vessel under the oil drain screw (2). For capacity, see Section 3.1. 7 Unscrew oil drain screw (2) and collect the waste oil in the container. 8 Clean components, check seals and exchange if necessary. 9 Re-tighten oil drain screw (2). 10 Unscrew oil filler screw (1). 11 Fill with new oil up to lower edge of filler opening. 12 Re-tighten oil filler screw (1). 13 Re-check oil level after 2 hours run; add oil if necessary. WARNING The lubricating nipple (4) on the emergency actuating mechanism is not to be used for lubrication pu rposes. It is used exclus ively for activating t he emergency actuation. The gearbox can be destroyed.

4

5-6


835 + 840 / 03.2010


5.1.6 Differential (type 835)

1

2


CAUTION


1 Bring machine up to operating temperature. 2 Shut down engine and secure against re-starting. 3 Switch off driving engine and secure against restarting. Wait approx. 10 minutes for the oil to collect in the differential. 4 Clean exterior of differential using a cloth.

30 mm

5 Unscrew oil filler screw (1). The oil level must reach up to lower edge of filler opening. Add oil if necessary. 6 Clean components, check seal and replace if necessary. 7 Re-tighten oil filler screw (1).

835 + 840 / 03.2010


5-7


Changing oi l

1 Bring machine up to operating temperature. 2 Shut down engine and secure against re-starting. 3 Shut down engine and secure against re-starting. Wait approx. 10 minutes for the oil to collect in differential. 4 Clean exterior of differential using a cloth. 5 Loosen oil filler screw (1) to relieve the pressure.

30 mm 50 Nm 13 mm

6 Place a suitable collecting vessel under the oil drain screw (2). 7 Unscrew oil drain screw (2) and collect the waste oil in the container. 8 Clean components, check seals and exchange if necessary. 9 Re-tighten oil drain screw (2). 10 Unscrew oil filler screw (1). 11 Fill with new oil up to lower edge of filler opening. 12 Re-tighten oil filler screw (1). 13 Re-check oil level after 2 hours run; add oil if necessary.

5-8


835 + 840 / 03.2010


5.1.7 Drive shaft/universal joint (type 835) Note

The two drive shafts/universal joints have three lubricating nipples each. Each joint is lubricated via one lubricating nipple; the third nipple is used to lubricate the telescopic profile. CAUTION

To avoid damaging the seals and prevent the ingress of water and dirt, high-pressure cleaning must not be used to clean the drive shafts/ universal joints. Note

Check the following items regularly:  Fittings and connecting flanges  Drive shaft/universal joints for unusual noises and vibration during operation  Drive shaft/universal joints for play in the bearings and length compensation prior to lubricating

1

2

1 Lubricating nipple for cross joint (shown here with protective cap) 2 Lubricating nipple for telescopic profile (shown here without

protective cap) Lubricating the drive shafts/universal joints

1 Lift the machine using all four supports. 2 Shut down engine and secure against re-starting. 3 Turn the wheels until the lubricating nipples on the universal joints are in an accessible position. 4 Remove the protective caps from the lubricating nipples.

835 + 840 / 03.2010


5-9


5 Press the fill valve on the grease pistol onto the lubricating nipple until it snaps into place. 6 Grease the joint by pumping the grease gun with a smooth motion. Note: Grease must exit from the seals of the cross joints visibly. But: When lubricating the telescopic profile, pump the grease gun only a few times (not until grease appears, as otherwise excessive axial forces and damage to the seals will result!). 7 Repeat these steps with the remaining lubricating nipples. 8 Wipe off excess grease with a cloth. 9 Replace all protective caps on the lubricating nipples. 10 Retract the supports completely.

5 - 10


835 + 840 / 03.2010


5.1.8 Back gear and differential (type 840)

4

3

1

2

WARNING

The mixing of oils, lubricants or operational fluids of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer! Checking o il

1 Bring machine up to operating temperature. 2 Put machine in a level, horizontal position. 3 Turn off the engine. Wait about 10 minutes for the oil to collect in the differential.

30 mm

4 Unscrew oil filler screw (2). The oil level must reach up to lower edge of filler opening, add oil if necessary. 5 Clean components, check seal and replace if necessary. 6 Re-tighten oil filler screw (2). Note

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

835 + 840 / 03.2010


5 - 11


Changing oi l

1 Bring machine up to operating temperature. 2 Put machine in a level, horizontal position. 3 Turn off the engine. Wait about 10 minutes for the oil to collect in the differential. 4 Loosen oil filler screw (2) to relieve the pressure.

30 mm 50 Nm 13 mm

5 Loosen oil filler screw (4) to relieve the pressure. 6 Place a suitable collecting vessel under the oil drain screw (1). For capacities, see Section 3.3.1. 7 Place a suitable collecting vessel under the oil drain screw (3). For capacities, see Section 3.3.1.

50 Nm 13 mm

8 Unscrew oil drain screw (1) and collect the waste oil in the container. 9 Unscrew oil drain screw (3) and collect the waste oil in the container. 10 Clean components, check seals and exchange if necessary. 11 Re-tighten oil drain screw (1).

50 Nm 13 mm

12 Re-tighten oil drain screw (3). 13 Unscrew oil filler screw (2). 14 Unscrew oil filler screw (4). 15 Fill with new oil up to lower edge of filler opening (2). 16 Fill with new oil up to lower edge of filler opening (4). 17 Re-tighten oil filler screw (2). 18 Re-tighten oil filler screw (4). 19 Operate for 2 hours, then re-check the oil level. Note

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

5 - 12


835 + 840 / 03.2010


5.1.9 Parking disc brake (type 840)

1

2

3

1 Oil filler screw 2 Oil level control screw 3 Oil drain screw WARNING


1 Bring machine up to operating temperature. 2 Put machine in a level, horizontal position. 3 Switch off drive engine. Wait approx. 10 minutes for the oil to collect in gearbox.

835 + 840 / 03.2010


5 - 13


4 Unscrew the oil level control screw (2). Oil flows out when the oil level has been reached. 5 If necessary, unscrew oil filler screw (1) and top up with oil. 6 Clean components, check seal and replace if necessary. 7 Re-tighten oil level control screw (2). 8 Re-tighten oil filler screw (1). Changing o il

1 Bring machine up to operating temperature. 2 Put machine in a level, horizontal position. 3 Switch off drive engine. Wait approx. 10 minutes for the oil to collect in gearbox. 4 Slacken oil filler screw (1) to relieve the pressure. 5 Place a suitable container under the oil drain screw (3). For capacities, see Section 3.3. 6 Unscrew oil drain screw (3) and collect the waste oil in the container. 7 Clean components, check seals and exchange if necessary. 8 Re-tighten oil drain screw (3). 9 Unscrew oil filler screw (1). 10 Unscrew the oil level control screw (2). 11 Top up with new oil. Oil flows out when the oil level has been reached. 12 Re-tighten oil level control screw (2). 13 Re-tighten oil filler screw (1). 14 Operate for 2 hours, then re-check the oil level.

5 - 14


835 + 840 / 03.2010

Undercarriage - Crawler

5.2

Crawler

WARNING 





Injury hazard from rotating parts! Do not carry out maintenance work until the drive engine has been switched off. Maintenance and repair work must only be carried out by trained specialist personnel. Oil must not be allowed to seep into the ground or water. Dispose of waste oil in accordance with the statutory regulations.

5.2.1 Cleaning and lubricating

1 Put the machine in a level horizontal position. 2 Shut down engine and secure against re-starting. 3 Clean crawler running gear, crawler chain and pulleys with steam cleaner. Attention! Hold the steam cleaner lance at least 20 cm from the surface to be cleaned. 4 Lightly grease guide mechanisms and bolts. 5 Lubricate all lubrication points (see Section 3.3). 5.2.2 Gearbox Checking the oil level

1 2 3

1 Fixing bolts – sprocket 2 Oil filler screw 3 Oil drain screw

1 Put the machine in a level horizontal position. Take care that the oil drainage screw (3) is at its lowest position. 2 Shut down engine and secure against re-starting.

835 + 840 / 03.2010


5 - 15


35 Nm

8 mm

3 Unscrew oil filler screw (2). The oil level must reach up to lower edge of filler opening, add oil if necessary. 4 Re-tighten oil filler screw (2).

Changing oi l

1 Put the machine in a level horizontal position. Take care that the oil drainage screw (3) is at its lowest position. 2 Shut down engine and secure against re-starting. 3 Place a suitable collecting vessel under the oil drain screw (3). For capacities, see Section 5.1.5.

35 Nm

4 Unscrew oil filler screw (2). 8 mm

5 Unscrew oil drain screw (3) and collect the waste oil in the container. 6 Clean components, check seals and exchange if necessary. 7 Re-tighten oil drain screw (3). 8 Pour fresh oil in through the oil filler screw (2) up to lower edge of filler opening. 9 Re-tighten oil filler screw (2). 10 Re-check oil level after 2 hours run, add oil if necessary.

5 - 16


835 + 840 / 03.2010


5.2.3 Crawler chain

Adequate but not excessive chain tension is essential for the chain running gear to function smoothly without overdue wear and tear. Note

Correctly adjusted chain tension will reduce wear and tear to components of the undercarriage. Checking c hain tension A

A - A

A3 G E NTLE T I 15 0 2 0 1 G E N - P O S GEN-SUM C A N OI N I 13 4 2 e d l i n metr ic ISO

A

Sag measurement “X” Clean the undercarriage and crawler chains thoroughly before checking the chain tension. Position the machine on even, firm ground. DANGER    

Ensure that there is no one within the danger area of the machine. Use slings with sufficient load bearing capacity! For lattice mast cranes – remove ballast and boom! Raise machine using suitable means and with extreme caution (use lifting points provided). 1 Raise machine with suitable lifting gear until the chain is no longer in contact with the ground. 2 Check the sag measurement “X” between the track roller and the chain link. The chain is correctly tensioned when the sag measurement “X” in the center of the track wheel carrier lies between a minimum of 70 mm and a maximum of 80 mm. Adjust the tension if necessary (see following page). 3 Lower machine and remove sling.

835 + 840 / 03.2010


5 - 17


Ad ju st in g c hai n t ens io n

The chain tension is determined by the position of the front idler. The position of the front idler is dictated by the quantity of grease in the tensioning cylinder of the idler unit.

1

2

1 Slacken hexagonal bolts (1) and remove cover (2). 16 mm

3

2 Clean lubricating nipple (3). 3 Apply a high-pressure grease pistol to the lubricating nipple and actuate until the crawler chain is sufficiently tensioned. 4 Drive machine forwards and backwards. 5 Raise machine and check sag measurement “X” between the track roller and the chain link. 6 Repeat steps 3-5 until the sag measurement “X” is within tolerance (min. 70 mm, max. 80 mm). 7 Tighten cover (2) with the hexagonal nuts (1). 8 Adjust the second crawler chain in the same way. Note

To relax the chain, unscrew the lubricating nipple approx. 3 turns until grease starts to seep out. Check the chain tension again.

5 - 18


835 + 840 / 03.2010


5.2.4 Sprocket Retight en bolts

1

1050 Nm

1 Fixing bolts – sprocket 36 mm Note

Tighten the fixing bolts using a torque wrench.

835 + 840 / 03.2010


5 - 19


5.2.5 Base plates Retight en bolts

390 Nm

27 mm 1

1 Fixing bolts – base plates Note

Tighten the base plate fixing bolts using a torque wrench.

5 - 20


835 + 840 / 03.2010

Undercarriage - Structure

5.3

Structure

5.3.1 Middle bridge clamp – outrigger housing

1

3

1 Clamping

2

3 Middle bridge

2 Outrigger housing

Note

The following is to be checked at regular intervals:

36 mm

835 + 840 / 03.2010

– The correct clamping between the middle bridge and the outrigger housing.


5 - 21


5.3.2 Ballast

3

2

1 1 Locking bolts

3 Ballast

2 Bolts

Note

The following is to be checked at regular intervals: – The correct locking (locking bolts (1) including the retaining spring) on the ballasts. – The secure fastening/guying of the ballasts (2).

5 - 22


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5.3.3 Outrigger

1

2 3 4

1 Spindle

3 Lubricating nipple

2 Clamping – spindle

4 Adapter, bracket,

outrigger pads Lubricate outriggers

Note

The lubricating nipples are provided with a red protective cap. 1 Clean lubricating nipple (3). (see Section 1.7) 2 Apply high pressure grease gun to the lubricating nipple and actuate.

Note

The following is to be checked at regular intervals: 60 mm

24 mm

835 + 840 / 03.2010

– The horizontal alignment of the overall machine. Set the spindle (1) again if necessary. – The clamp (2) for the spindle. Reclamp if necessary. – The correct bracket seating (4). – The lubrication for the spindle.


5 - 23


5 - 24


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Swiveling connection - General

6

Swiveling connection

CAUTION


6.1 General Ensure that the swiveling connection is well lubricated. Slewing track (1): – via central lubrication.  Gear teeth (2): – with gear spray or – via slewing ring lubrication (optional)  Seal (3): – Check the seal between the slewing track and the gear teeth for damages. 

Note

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

3

1

2 1 Slewing track 2 Gear teeth 3 Seal

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6-1

Swiveling connection - Lubricating slewing ring path

6.2

Lubricating slewing ring path

6.2.1 Central lubrication system

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

The preset lubricating cycle can be shortened. For more information, see the documentation on the C ENTRAL LUBRICATION SYSTEM in Chapter 10 of the operating manual. Shorter lubrication intervals are required,     

in the tropics, when humidity is high, for high levels of dust and contamination, when temperatures change dramatically, when subject to continuous swinging movement.

1 2 3

4

1 Grease reservoir - note MIN/MAX markings 2 Replenish grease **/*** 3 Replenish grease */** 4 Setting parameters Ac tu ati ng path lubrication manually

Lubrication can be manually actuated in addition to the pre-set lubrication cycle. 1 Move the switch on the control panel to the right:

6-2


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Replenish grease (2/3)

Setting parameters (4)

1 Using the flat screwdriver, remove the red frame of the control on the motor protective housing of the pump and remove the four Phillips screws as well as the clear cover. 2 Using a Phillips screwdriver, adjust the pause or lubrication time on both click switches. 3 If the control is closed improperly, water will infiltrate, which will void the guarantee.

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6-3


5

4

1

2

3

1. Click switch to set the pump speed

– Factory setting: 

typ e 835 - 110 revol uti ons



typ e 840 - 130 revol uti ons

2. Click switch to set the cycle time

– Factory setting: 1 hour 3. Green LED for function display 4. Red LED to display malfunctions 5. Button to start intermediate lubrication or to reset a malfunction ATTENTION

After a run-in phase of approx. 100 hours and checking all lubrication points, the lubrication time can be increased or decreased as needed. Note

Observe the notes in the operating instructions of the central lubrication system manufacturer.

6-4


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Swiveling connection - Lubricating live ring toothed wheel

6.3

Lubricating live ring toothed wheel

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

6.3.1 Gear spray

1 Shut down drive engine. 2 Thoroughly clean gear teeth. 3 Check teeth of slewing ring and slewing ring pinion for wear and replace if necessary. 4 Spray gear teeth from a distance of about 30 cm with SENNEBOGEN gear teeth spray (SE No.: 011429). 5 Rotate the upper structure a number of times for a layer of lubricant to spread evenly over the gear teeth.

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6-5


6.3.2 Slewing ring lubrication (optional)

1

Note

Clean the lubrication point thoroughly down to the bare metal before the first application of lubricant to ensure that the lubricant creates an unbroken lubricant film over the surface. 1 Shut down drive engine. 2 Thoroughly clean gear teeth. 3 Check teeth of slewing ring and slewing ring pinion for wear and replace if necessary. 4 Start drive engine. 5 Actuate slewing ring lubrication: – Press the pushbutton for slewing ring lubrication on the right of the control panel and hold down. – Rotate the upper structure 360° to the left and to the right using the control lever to distribute the lubricant evenly over the gear teeth. 6 Release the pushbutton. 7 Check that there is an unbroken lubricant film over the surface and repeat lubrication process if necessary. Note

Lubricate slewing ring every 10 operating hours or daily (depending on work application)! Check the lubrication container weekly and refill with lubricant if necessary! CAUTION

Check the plastic sliding wear pad (2) in the lubrication assembly (1) once every 3 months for wear. Observe wear limit! Replace the plastic sliding wear pad (2) when the wear limit has been reached! The machine could otherwise suffer serious damage. The operator of the machine alone is liable for such damage as well as any consequential damage!

6-6


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Check plasti c slidi ng wear pad

1

. m m 8 2 . n i m 2

WARNING

Before checking the plastic sliding wear pad (2):  Lower attached loads and booms to the ground.  Pull the left-hand safety lever back.  Shut down machine and secure against unauthorized re-starting before starting with maintenance work.  Attach warning sign to operating instruments. 1 Disassemble lubrication assembly (1). 2 Check plastic sliding wear pad (2) for wear (min. 28 mm). 3 Replace plastic wear pad if necessary.

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6-7


Replenish grease

1 1 Lubricant container

1 Open cover (1) of lubricant reservoir. 2 Replenish lubricant (SE No.: 047485). 3 Close cover.

6-8


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Swiveling connection - Slewing gear

6.4

Slewing gear

WARNING

The mixing of oils, lubricants or operational fluids of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer! Note

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

1 Lower attached loads and boom to the ground. 2 Put the machine in a level horizontal position. 3 Shut down drive engine and secure against re-starting.

3 2

1

1 Slewing gear 2 Fill level at 15°C–20°C oil temperature

(approx. quarter full marking on the oil expansion tank) 3 Oil expansion tank for each slewing gear

4 Allow the oil in the slewing gear to cool.

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6-9


5 Check oil level: – Fill level at 15°C–20°C oil temperature (approx. quarter full marking on the oil expansion tank). – The oil level can vary depending on temperature, filling up to three quarters is possible. 6 Add oil of the specified grade as required.

6 - 10


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Changing gear o il

1 Lower attached loads and boom to the ground. 2 Put the machine in a level horizontal position. 3 Shut down drive engine and secure against re-starting.

2

5

3

1

4

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

4 Unscrew oil expansion tank (5) cap. 5 Unscrew cover nut (3). 6 Screw in connector with hose (4) until the waste oil drains through the hose. Collect waste oil in a suitable container.

7 Unscrew connector with hose (4). 8 Screw cover nut (3) back on.

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6 - 11


Ad di ng oi l

2

5

1

3

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

9 Unscrew the gear bleeder (2). 10 Top up with new oil via the oil expansion tank (5). 11 When oil flows out of the gear bleeder (2), screw it closed again. 12 Top up with new oil via the oil expansion tank (5). 13 Check oil level: – Fill level at 15°C–20°C oil temperature (approx. quarter full marking on the oil expansion tank). – The oil level can vary depending on temperature, filling up to three quarters is possible. 14 Screw in oil expansion tank (5) cap. 15 Operate for 2 hours, then re-check the oil level.

6 - 12


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Swiveling connection - Tightening slewing ring bolts

6.5

Tightening slewing ring bolts

DANGER

Danger of death! Defective slewing ring bolts can cause the upper structure to tip over. For this reason, always observe the maintenance intervals! 



Re-tighten slewing ring bolts using torque wrench. Observe the tightening torque specified in Section 3.4! Check or replace the slewing ring bolts every 5000 operating hrs or every 5 years.

Note

Testing must be performed by an expert from an independent specialist company or an independent institute. The unrestricted further use of the slewing ring bolts must be guaranteed and verified by means of a certificate. Otherwise, replace the slewing ring bolts! Corroded or damaged bolts can shear and cause the upper structure to tip over. 

  



Do not tighten corroded or damaged bolts, replace immediately with new bolts! It is essential that the correct number and diameter of bolts are used. Use only original SENNEBOGEN spare parts. Contact SENNEBOGEN customer services if you have any further queries. If you suspect damage to the bolt/screw connections, call SENNEBOGEN customer services and arrange for them to be checked.

Fig.: Tightening wi th a torque wrench 280 Nm

835 + 840 / 03.2010

24 mm


6 - 13

Swiveling connection - Tightening slewing ring bolts

1 Shut down drive engine. 2 Retighten the slewing ring bolts with a torque wrench, following an alternating pattern. Note

The tension of the bolt tightened first is influenced by the tensioning of the other bolts. It is thus necessary to make at least two passes. Use of a hydraulic bolt-tensioning cylinder is recommended when tightening bolts larger than M30 in size.

6 - 14


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

6.6

Wear measurement and checking the drive system/bearing play

Note

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

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

1 Put the machine in a level horizontal position. 2 Place upper structure parallel to the undercarriage. 3 Move the boom to a defined position, which can be precisely replicated again for the next measurement. Do not put the boom on the ground for this. 4 Define 4 measuring points in 90° clearance around the slewing ring – In case the first measurement is being taken, 4 measuring points are to be defined according to the following images and these are to be marked permanently (e.g. center punched) – Perform the measurement as close to the bearing as possible – The measurement is between the lower connecting construction and the mounting ring bolted with the top construction – Precision of the meters: 0.01 mm

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6 - 15

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

5 For the zero setting of the meters, a maximum maximal restoring moment is to be applied on the slewing ring first. 6 Measure on the 4 measuring points. 7 Now, apply a forwards turning torque, in circumstances by taking on the load. 8 After pivoting, repeat the measurement on the marked positions. 9 Record the measurement values in the table and compare. 10 The measurement value difference provides information about the wear. 11 Maximum permitted wear limit: 12 The measurement value difference provides information about the wear. Note

If the wear limit has been reached, contact the SENNEBOGEN customer service!

6 - 16


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Hydraulic system - Safety instructions

7

Hydraulic system

7.1 Safety instructions Observe the safety notes before starting work on hydraulic system DANGER 

Warning – high oil pressure! The hydraulic system is subject to high pressure. Serious injuries can be caused by escaping hydraulic oil when loosening a hydraulic connection or if a leak should occur. Only carry out work on the de-pressurized hydraulic system.



Work on hydraulic systems may only be carried out by trained personnel with special knowledge of and experience with hydraulics.

Wear personal protective equipment (e.g. protective helmet, ear protection, protective gloves, safety shoes).  De-pressurize the hydraulic system before starting maintenance work (see Section 7.4).  The pilot control is equipped with a pressure accumulator, which remains under high pressure even after the engine is shut down. The pressure accumulator must therefore be de-pressurized.  Danger of injury! If leaks are present, hydraulic oil will escape under high pressure. Hydraulic oil escaping under high pressure will penetrate the skin and cause severe damage to health. Danger of infection. In the case of injury contact a physician immediately!  Danger of injury from scalding The hydraulic oil can reach temperatures of 70°C (158°F) and above. Only carry out maintenance work once the hydraulic oil system has cooled down.  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, as an example – The protective features have been installed. 

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7-1

Hydraulic system - General

7.2

General

7.2.1 Hydraulic cylinder

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

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

 



Do not use sharp edged tools, caustic fluids or abrasives. Wash down piston rods regularly with steam cleaner. Do not direct the jet straight at the sealing elements. Apply preservative to extended piston rods after cleaning. This protects the surface from the effects of the environment and weather.

Fig.: Hydraulic cylinder on boom

7.2.2 Bolted joints

Check hydraulic screw connections and couplings regularly for leaks. Seal points of leakage and remove oil residue. Leaking hydraulic oil endangers the environment and presents a hazard due to danger of slipping. Always seal opened connections immediately at both sides with plugs.

7-2


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Hydraulic system - Hydraulic hose lines

7.3 Storage and servic e life

Hydraulic hose lines

Even when mounted correctly at permissible loads, hoses and hose lines are subject to natural wear and tear. Their service life is therefore limited. The operator is responsible for ensuring that flexible tubes are replaced at suitable intervals, even when there are no obvious defects to be seen in the flexible tube. Note

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

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

Defects

Replace hose lines in the following cases (see also DIN 20066): 

 

     

835 + 840 / 03.2010

Outer layer damaged as far as reinforcement (e.g. chafe marks, cuts, cracking); Outer layer embrittlement (cracks appearing in hose material); Deformation, which does not conform to the natural shape of the hose or flexible tube, both when under and not under pressure, or when bent (e.g. layer separation, formation of blisters); Leaks; Damaged or deformed hose fittings (sealing function affected); Hose has separated from fittings; Corrosion of fittings which reduces function and strength; Installation requirements ignored; Storage times and/or service life exceeded.


7-3

Hydraulic system - De-pressurizing the hydraulic system

7.4

De-pressurizing the hydraulic system

WARNING

Danger of injury! Danger of injury due to scalding The hydraulic system is subject to high pressure. Serious injuries can be caused by escaping hydraulic oil when loosening a hydraulic connection. The hydraulic oil can reach temperatures of 70°C (158°F) and above. Only carry out maintenance work once the hydraulic oil system has cooled down.

1 Lower attached loads and boom to the ground. 2 Shut down engine, move ignition key immediately back to position “1”. 3 Move both control levers in the driver's cab in all directions several times. This relieves the pressure in the main hydraulic circuit and the pressure accumulator for pilot control.

1

4 Open the cover plate. 5 Unscrew the threaded cap (1) on the hydraulic tank. This releases the residual pressure in the tank.

7-4


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

The pressure gauge must indicate 0 bar / 0 psi. If the pressure is not completely released, repeat points 2 to 6. 7.4.1 Check hydraulic oil level, add hydraulic oil CAUTION


1 Lower attached loads and boom to the ground. 2 Put the machine in a level horizontal position.

Machine in park position

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7-5


3 Put the machine in park position. Retract support cylinders. 4 Shut down engine and secure against re-starting. 5 Open the service access door on the right. 6 Check oil level at the oil level indicator (1): The oil level must reach to the upper marking (MAX).

1 2

7 Add hydraulic oil, if required: – Open the cover plate. – Unscrew the threaded cap (2) on the hydraulic tank. – Add hydraulic oil and re-check. – Re-tighten screw cap – Close the cover plate. 8 Close the service access door on the right.

7-6


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Hydraulic system - Changing hydraulic oil

7.5 Safety instructions

Changing hydraulic oil

Read the safety instructions before starting work on the hydraulic system. DANGER 





Warning of high oil pressure and scalding. The hydraulic system is subject to high pressure. Serious injuries can be caused by escaping hydraulic oil when loosening a hydraulic connection. Only carry out work on the de-pressurized hydraulic system. The hydraulic oil can reach temperatures of 70°C (158°F) and above. Only carry out maintenance work once the hydraulic oil system has cooled down Work on the hydraulic system may only be carried out by trained personnel with specialist knowledge and experience of hydraulics.

CAUTION

The mixing of oils, lubricants or operational fluids of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer! Note:

The task can be made easier by pumping out as much oil as possible. Use the opening of the return filter for this. While changing the hydraulic oil, change all filters in the hydraulic system as well. Procedure

1 Lower attached loads and boom to the ground. 2 Put the machine in a level horizontal position. 3 Put the machine in park position. Retract support cylinders. 4 De-pressurize hydraulic system in accordance with Section 7.4. 5 Shut down drive engine and secure against re-starting. 6 Remove filter of return filter acc. to Section 7.6. 7 Place a suitable container under the drain opening of the tank. For the capacity, see Section 3.1. 8 Close the hydraulic tank cap – if existing.

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7-7


CAUTION:

Ensure that the container is large enough to hold the relevant quantity of oil. Hydraulic oil must not be allowed to seep into the ground or water. Dispose of waste oil and oil filters in accordance with statutory regulations.

1

9 Unscrew cover nut (1).

2 3

10 Screw in drain plug until the waste oil emerges via the plastic hose. Collect waste oil in a suitable container. 11 Unscrew drain plug (2). 12 Screw cover nut (1) back on. 13 Fill with new hydraulic oil via the filler strainer (2) on top of the tank. 14 Bleed the hydraulic pumps: – Clean housing. – Slacken vent screw on the pump. Do not unscrew completely; hold in place by applying slight pressure with your thumb. – Wait several seconds until the air has escaped. – Re-tighten vent screw.

7-8


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CAUTION

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

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7-9

Hydraulic system - Replacing return filters

7.6

Replacing return filters

A 1 2 3 B

1 Unscrew the threaded cap (2) on the hydraulic tank. This releases the residual pressure in the tank. 2 There are two return filters (A, B). Both filter elements must be replaced! Unscrew the four socket head bolts (1). 6 mm

3 Remove cover (3). 4 Remove filter and dispose of as hazardous waste. 5 Clean components, check seal and replace if necessary. 6 Insert new filter. 7 Secure cover (3) with the four socket head bolts (1). 8 Tighten screw cap (2).

7 - 10


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Hydraulic system - Auxiliary control filter – change filter element

7.7

Auxiliary control filter – change filter element

Note

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

1

2

1 Unscrew the filter housing (1). 27 mm

2 Dispose of filter (2) as hazardous waste. 3 Clean components, check seals and exchange if necessary. 4 Insert new filter element (2) in filter housing (1). 5 Screw filter housing in by hand. 6 Check filter (1) for leaks.

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7 - 11

Hydraulic system - HydroClean – superfine filtration system (Optional) – Change filter element

7.8 HydroClean – superfine filtration syst em (Optional) – Change filter element Note The contamination of the HydroClean filter insert is monitored by the SDS. The filter insert must be changed when the relevant warning light shows. Replacing the filter

1

2

3 4 5

1 Remove both screws (2) and lift off perforated cover plate (1). 13 mm

2 De-pressurize hydraulic system in accordance with Section 7.4. 3 Unscrew the cover (5) with integrated hexagon head (4).

36 mm

4 Remove filter. 5 Dispose of filter (3) as hazardous waste. 6 Clean components, check seal and replace if necessary. 7 Insert new filter. 8 Screw on the cover (5) until the stop and unscrew a fourth of a turn. 9 Start drive engine.

10 mm

10 Unscrew the socket head screw (3) somewhat until the ventilation opening becomes free. 11 As soon as oil appears, screw the socket heat bolt back in. 12 Switch off drive engine and check filter for leaks. 13 Replace perforated cover plate (1) and tighten screws (2) again.

7 - 12


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Hydraulic system - Leak-oil filter – changing filter

7.9

Leak-oil filter – changing filter

1 2

1 Slacken hexagon nuts (1). 17 mm

2 Remove cover (2).

3 Unscrew filter (3) from return pipe. 4 Screw new filter onto the return pipe. 5 Re-attach cover with return pipe to tank. 6 Tighten hexagon nuts (1).

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7 - 13

Hydraulic system - Changing ventilation filter

7.10 Changing ventilation filter Note

The ventilation filter is integrated in the screw cap (2) of the filler strainer. The ventilation filter limits the over-pressure and underpressure in the hydraulic system occurring during hydraulic operations. CAUTION Dirty ventilation filters let dust and dirt unfiltered into the hydraulic system. This can cause damage to the hydraulic system (e.g. to the pumps) and increased hydraulic oil wear.

1

1 Open the cover plate. 2 Changing ventilation filter (1). 3 Close the cover plate.

7 - 14


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

7.11 Changing the ventilation filter with dehumidifying unit (option al)

1

3 2

Replace desiccant beads

1 Completely unscrew the dehumidifying unit (1) 2 Slacken wing nuts (2) and remove cover (3). 3 Replace the used desiccant beads (colorless) for new desiccant beads (orange). 4 Put the cover (3) on and tighten the wing nuts (2). 5 Completely bolt down the dehumidifying unit (1) Note

The desiccant beads can be regenerated in a drying oven at approximately 150°C (302°F). Keep desiccant beads dry and tightly sealed and protect them from moisture.

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7 - 15

Hydraulic system - Checking preload pressure of pressure accumulator

7.12 Checking preload pressure of pressure accumulator Note

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

1 Lower attached loads and boom to the ground. 2 Connect manometer to the measurement port (Section 7.4). 3 Shut down engine, move ignition key immediately back to position “1”. 4 Move both control levers in the cab several times in all directions. 5 Observe the manometer. As soon as the preload pressure is reached, the valve in the pressure accumulator closes. The manometer pointer drops suddenly to “0”. The value displayed just prior to the pressure drop corresponds to the preload pressure of the pressure accumulator. 6 Compare the indicated value with the tolerance specification on the pressure accumulator. If the preload pressure lies outside the tolerance, replace the pressure accumulator or have it refilled with nitrogen. 7 Disconnect manometer. CAUTION

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

7 - 16


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Hydraulic system - Pump distributor gearbox (optional)

7.13 Pump distributor gearbox (optional) With certain options, distribution gearboxes can be mounted on the drive unit connection. Note

Perform a daily visual inspection for leaks. An increased oil level in the gearbox or the mounting flange with its own oil filling means that the seals on the hydraulic power units are defective. Procedure 1

2

4

3

1 Air bleed 2 Oil filler screw with dipstick 3 Oil drain screw 4 Oil filler screw (optional) WARNING 



Injury hazard from rotating parts and from scalding! Only carry out maintenance work with the drive engine switched off with the distributor gearbox stationary and cooled down. Oil must not be allowed to seep into the ground or water. Dispose of waste oil in accordance with the statutory regulations.

7.13.1 Checking oi l level

1 Put the machine in a level horizontal position. 2 Shut down drive engine.

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7 - 17

Hydraulic system - Pump distributor gearbox (optional)

3 Unscrew oil filler screw (2) with dipstick. 4 Remove oil from dipstick. 5 Insert dipstick in the opening until the thread of the dipstick is against the gear-housing. 6 Pull out oil dipstick again. 7 The oil level must be between the lower marking (MIN) and the upper marking (MAX) on the dipstick. 8 Add gear lubricant oil if necessary. 9 Re-tighten oil filler screw with dipstick (2). 7.13.2 Changi ng gear lubr icant oil WARNING

The mixing of oils, lubricants or operational fluids of different types is not permitted! Only mix oils, lubricants and operational fluids that are of the same type or identical (same specifications) from one manufacturer! 1 Put the machine in a level horizontal position. 2 Shut down drive engine. 3 Place a suitable container under the oil drain screw (3). 4 Unscrewing oil filler screw (2) with dipstick 5 Unscrew oil drain screw (3) and collect the waste oil in the container. 6 Clean components, check seals and replace if necessary. 7 Re-tighten oil drain screw (3). 8 Fill with new gear lubricant oil. 9 Check oil level acc. to Section 7.13.1. 10 Re-tighten oil filler screw with dipstick (2). 11 Operate for 2 hours, then re-check the oil level.

7 - 18


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Electrical system - Batteries

8

Electrical system

DANGER

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

8.1 Batteries Note

The batteries are maintenance-free. Special conditions of use (climatic conditions, high operating hours) as well as older batteries may require regular monitoring of the acid level in the battery. DANGER 



   

Explosion hazard! No smoking or open flames. Avoid sparks in the vicinity of the battery. Danger of acid burns! Wear protective glasses and gloves. Do not tilt the battery. Battery electrolyte is caustic and must not come into contact with eyes or skin. Do not lay tools down on the battery. Disconnect battery before starting welding work. Do not interchange battery connections. Dispose of old batteries as hazardous waste.

1 2

Inspect connections and cable connectio ns

835 + 840 / 03.2010

1 Open left rear service access door.


8-1

Electrical system - Batteries

2 Remove battery terminal covers (1). Ensure that no metal parts come into co ntact with bo th the posit ive and negative terminals of th e battery (2) (risk of short circuit!)

3 Clean the terminals and cable connections on the batteries. Check for firm seating and grease with terminal grease. 4 Replace battery terminal covers. 5 Close service access door again.

8-2


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Electrical system - Fuses

8.2

Fuses

WARNING

Fire hazard! Do not repair fuses. Always insert new fuses with the same amperage rating, never higher. If a newly inserted fuse blows again after only a short period of time, the electrical system must be inspected by a professional electrician. 1

2

Replacing fuses

1 Shut down engine and secure against re-starting. 2 Open left rear service access door (1). 3 Remove fuse box cover (2). 4 Replace defective fuse. 5 Check contacts, clean oxidized contacts. 6 Replace cover of fuse box (1). 7 Close service access door again. Note

For wiring, see inside of cover and electrical diagram.

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8-3

Electrical system - Switch/symbol change

8.3 Switch/symbol change NOTE

Switches can only be replaced as complete units. Exception: The symbols can be removed and installed again carefully with a screwdriver.

8.4 Generator (optional) NOTE

Pay attention to the instructions in the manufacturer's instructions. 8.4.1 Visual check

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

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

8-4


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Electrical system - Additional displays (special equipment)

8.5

Additional displays (special equipment)

Analog hour counter

SDS

Tool Control

Generator and magnet unit

Auxiliary heating system, Water heater

Camera

LML

CAUTION

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

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8-5

Electrical system - Additional displays (special equipment)

Note

More information can be found in the operating instructions from the Work application chapter and Chapter 8.

8-6


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Heating/Air-conditioning system - Air conditioning system

9

Heating ting//AirAir-co cond ndit itio ioni ning ng sy syst ste em

9.1 Air condi conditio tionin ning g syste system WARNING

Remember that the refrigerant and the related vapors are dangerous to your health when working working with the air conditioning conditioning system. Wear the respective respective protec protective tive equipme equipment. nt. 

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Maintenance and repair work must only be carried out by trained specialist personnel. Do not reach inside the unit and do not insert any object. Only carry out maintenance work with the engine shut down and fan disconnected. disconnected. Allow unit and components inside unit (heat exchanger, resistors) to fully cool down down before starting starting any maintenance maintenance work. Freezing Freezing hazard , wear protective gloves! Avoid touching the refrigerant with bare skin. Wear eye protection! If refrigerant does contact your eyes however, see a Doctor. Danger Danger of inju ry! Contact with the sharp edged fins on the liquefier and the heat exchanger. Welding and soldering on components of the air conditioning system is not permitted! The pressure in the system is increased by the extreme heating and can cause an explosion. R134a is to be used in accordance with DIN 8960 Only refri gerant R134a (fill quantity approx. 1.7 kg). No fluorescent additives (tracer agents, sticks). Observe filling instructions from SENNEBOGEN Maschinenfabrik-GmbH.


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9.1.1 Visual isual check check

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

1

1 Air conditioning

system

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9.1.2 .1.2 Cleanin Cleaning g the heating heating recirculating recirculating air filter Cleaning Cleaning the fi lter

1 Grip

2

1

2 Filter

NOTE

The filter is located behind the driver's seat.

1 Pull Pull out out the the filte filterr (2) (2) using using the grip grip (1). (1). 2 Beat out filter filter or carefull carefullyy blow blow out with compress compressed ed air. air. 3 Insert Insert the filter. filter. Ensure Ensure corre correct ct positio position. n. Clean Clean air air must must exit exit in direction of travel.

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9.1.3 Cleaning the heating outside air filter Cleaning th e filt er

1

1 2

2

NOTE

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

1 Slacken screws (1) and hold the cover. 2 Remove filter (2). 3 Beat out filter or carefully blow out with compressed air. 4 Insert the filter. Ensure correct position. 5 Re-tighten screws (1).

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Heating/Air-conditioning system - Water heater (optional)

9.2 Water heater (optional) WARNING

Fault! If the “red” pilot lamp is illuminated, the refrigerant level is low in the water heater. The electric water heater is then deactivated by the safety shut-off.

1

2

1 Water pump 2 Built-in radiator

Note

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

The motor bearings of the water pump are enclosed and permanently lubricated!

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Heating/Air-conditioning system - Air conditioning compressor (optional)

9.3

Air conditioning compressor (optional)

Note

Observe the information in the manufacturer’s operating instructions as well. WARNING

During operation, surface temperatures of above 60°C or under 0°C can occur. Risk of severe burns! WARNING

Compressor is under pressure! Severe injuries are possible if handled incorrectly!

1 Check the oil level before putting into operation.

1 1 Oil drain screw

2

3

3 Oil filler screw

2 Inspection glass

WARNING

Use only Ester oil BSE 55 as compressor oil! Ester oils are very deliquescent, handle carefully. An oil change is to be performed every 3 years or 10,000 hours of operation. The oil filter and magnet plugs are to be cleaned at the same time.

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

9.4

Auxiliary heating system (optional)

Note

Observe the instructions and recommendations in the manufacturer’s operating instructions as well. WARNING

Switch the auxiliary heating system on at least once a month for approximately 10 minutes, even if heating is not required. Before heating is required, test the auxiliary heating system once (e.g. danger of smoke)

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

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Index

A

Accessories W-2 Adding hydraulic oil 7-5 Additional documentation W-8 after 1000 hours of operation 2-12 after 2000 hours of operation 2-15 after 250 hours of operation 2-8 after 500 hours of operation 2-10 Air filter 4-4 Air filter - pre-separator 4-6 Air pressure 3-6, 5-1 Ambient temperature 3-1 Annually 2-12 Anti-freeze 4-13 Antifreeze 4-14 Axle distributor gear 3-5 B

Beaufort scale 3-21 Belt drives 4-17 Biological oils 1-8 C

Central lubrication system 3-13, 3-14, 3-16, 6-2 Check cable connections 8-1 Chloride 1-12 Chloride content 1-12 Chromium hydroxide 4-16 Cleaning agents 4-14 Cleaning hydraulic cylinders 7-2 Cleaning procedure 4-15 Cleaning the cooler 4-14 Conversion factors 3-22 Cooler 4-10, 4-11 Cooling system 4-10 Copyright W-9 Customer Service W-9 D

Description Wind 3-21

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Differential 3-5 Disposal Batteries 1-25 Lubricants 1-25 Disposal Guideline 75/439/ EEC 1-25 Disposal of operational fluids 1-25 Disposing of batteries 1-25 Disposing of lubricants 1-25 Disposing of the oil filter 1-25 Drive engine 3-3 Driving earth-moving machinery 1-5 E

Ear protection 1-5 Engine Changing oil 4-3 Changing the oil filter 4-3 Checking oil level 4-2 Engine overheating 4-16 Environmental protection 1-25 Environmental regulations 1-25 every 4000 hrs run 2-15 Experts W-7 F

For your own safety W-2 Foreword W-2 Fuel system 4-7 Fuel tank 3-5, 3-7, 3-8, 3-9 G

Gear spray 6-5 Gear teeth 6-1 Going to press W-9 H

Hunold coolant ANF 4-10, 4-11 Hydraulic fittings 7-2 Hydraulic system 3-7, 3-8, 3-9 Hydraulic system: 3-5 Hydraulic tank 3-5, 3-7, 3-8,

3-9 Hydraulics 3-1 I

Identification plate 1-3 Inspection by specialist technician 1-4 Inspection tools 3-10 Instructed personnel W-7 K

Keyword W-4 L

Labels cleaning 1-3 Limitations during wind 3-2 Lubricate the machine 3-11, 3-15 Lubricating nipple 3-11, 3-14, 3-15, 3-16 Lubricating nipples, overview 3-12, 3-13 Lubricating path 6-2 Lubricating slewing ring path 6-2, 6-5 Lubricating the live ring toothed wheel 6-5 Lubrication cycle 6-2 Lubrication intervals 6-2 M

Machine Labeling 1-3 maintain earth-moving machinery 1-5 Maintenance instructions W-8 Maintenance schedule 2-1, 3-1 Manual lubrication 3-11 Manufacturing of spare parts 1-6 Modifying the machine 1-6 Monthly 2-8 N

Noise protection 1-5 Noise protection measures

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Manipulador Sennebogen (mantenimiento).pdf

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