Maintenance instructions

821 R-HD

05.2007 821C
Important instructions on the operating manual

Target group The machine has been developed for demanding work.
Persons working on or with the machine must be trained or instructed
for that purpose.
Maintenance must be carried out by trained specialist personnel only.

Notes on the operating Read through the operating instructions, in particular Chapter 1 SAFETY
instructions thoroughly before starting work with the machine.
Keep operating instructions in a safe place for future use.
WARNING!
z Only work with the machine once these operating instructions have
been read and completely understood.
z Forbid unsafe operation or unsafe maintenance.
z Do not operate machine if a fault has been detected!
z The employer is responsible for the qualifications and training of the
personnel.
z These operating instructions are a part of the machine. Keep the
operating instructions in the cab at all times.
Recommended storage place: stowing compartment behind the
driver’s seat.
In the event of sale, disposal or loan, the operating instructions must
accompany the machine!
z Contact SENNEBOGEN immediately if there is anything in the oper-
ating instructions which you do not understand!
Your comments will help us to make the operating instructions even
more user friendly.

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

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 Important instructions on the operating manual

Symbols and illustration These operating instructions contain safety notes, which highlight dan-
devices gerous working practices. These safety notes are marked with a warn-
ing symbol and a keyword.
This warning symbol means: Attention - this concerns your safety and
the safety of others.
The associated keyword signifies the degree of danger:
DANGER
Is used for serious, direct danger. If this danger is not averted, serious
physical injuries or loss of life of persons will result.
WARNING
Is used for potentially dangerous situations. If this danger is not
averted, serious physical injuries or death may result.
CAUTION
Is used for potentially dangerous situations. If this danger is not
averted, physical injuries or serious material damage may result.

Notes which make the work easier or contribute to better understanding

when operating the machine are displayed in the following way:
Note
Indicates notes which draw attention to
peculiarities.

Note
Indicates cross references to other documents.

Handling instructions are shown in table form as follows:

1 Press switch (1).

2 Actuate control lever (2).
3 Unfasten pins (3).

z Listings are marked with bullet points.

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

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Important instructions on the operating manual

Please contact SENNEBOGEN Maschinenfabrik GmbH

us at Hebbelstraße 30
D-94315 Straubing

Tele- +49 9421 540-0

phone:
Internet: http://www.sennebogen.de

Fax Customer Service: +49 9421 540279

Fax Spare Parts Store: +49 9421 40811

Technical Documentation:

E-mail: doku@sennebogen.de
Fax: +49 9421 41425

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

Copyright © Straubing 2007, SENNEBOGEN Maschinenfabrik GmbH

Reproduction, also in part, only with written permission of SENNEBO-
GEN Maschinenfabrik GmbH, Straubing, Germany.
Printed in Germany.

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Table of contents

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

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

3 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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

4 Driving engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

5 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Cleaning and Lubricating . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Travel gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 Crawler chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.5 Track shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

6 Swivelling connection . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 Lubricating slewing ring path . . . . . . . . . . . . . . . . . 6-2
6.1.1 Central lubrication system . . . . . . . . . . . . . . 6-2
6.2 Lubricating slewing ring teeth . . . . . . . . . . . . . . . . 6-3
6.2.1 Check the grease . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Tighten slewing ring bolts . . . . . . . . . . . . . . . . . . . 6-4

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Table of contents

7 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 General information . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2.1 Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . 7-2
7.2.2 Screw connections . . . . . . . . . . . . . . . . . . . 7-2
7.3 Hydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4 De-pressurising hydraulic system . . . . . . . . . . . . . 7-4
7.5 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.6 Changing hydraulic oil . . . . . . . . . . . . . . . . . . . . . . 7-7
7.7 Return filter – changing filter elements . . . . . . . . . 7-9
7.8 Auxiliary control filter – change filter element . . . 7-10
7.9 Leak-oil filter – changing filter element . . . . . . . . 7-11
7.10 Changing ventilation filter . . . . . . . . . . . . . . . . . . 7-12
7.11 Hydro-clean superfine filter (optional) . . . . . . . . . 7-13
7.12 Checking preload pressure of pressure
accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

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

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

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

9.1 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Air conditioner (optional) . . . . . . . . . . . . . . . . . . . . 9-2

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

0-2 821 / 05.2007

 Safety - General

1 Safety
1.1 General
The machine is built in accordance with the current state of the art. Nev-
ertheless, there may be dangers during its use to persons, machine
and other property, if
z the machine is not operated according to regulations
z the machine is not operated by trained personnel or not maintained
z the safety notes are not observed.
z the machine is found to be defective.
z the operating tools attached do not comply with the relevant safety
regulations.
z the operating tools attached are found to be defective.

National and international regulations apply in addition to the safety

notes in these operating instructions.
In the Federal Republic of Germany e.g:
z Winches, Lifting and Pulling Devices (VBG 8)
z Crane (BGV D6)
z Hoisting Equipment in Lifting Appliance Operation (VBG 9a)
z EC Machinery Guideline (98/37/EEC)
z EMC Guideline 89/336/EEC
z Electrical Machinery Equipment (EN 60204-1)
z Safety Requirements for Fluid Engineering Systems and their Com-
ponents - Hydraulic (EN 982)
z Earth-Moving Machinery – Safety (EN 474-1/-5)
z Safety of Machinery (DIN EN 12100 -1 and DIN EN 12100-2)
z "Outdoor" Regulation 2000/14/EG

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

821 / 05.2007 1-1

Safety - Safety instructions

1.2 Safety instructions

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

WARNING
z The maintenance work described may only be carried out by trained
and instructed specialist personnel.
z Wear personal protection equipment (e.g. safety helmet, ear protec-
tion, protective gloves, safety boots) where working conditions
require.
z Observe statutory accident prevention and safety directives.
z Lower suspended loads and booms to the ground.
z Pull safety lever back.
z Shut down machine and secure against unauthorised re-starting
before starting with maintenance work.
z Attach warning sign to controls.
z Smoking and handling of open flame is strictly forbidden.
z Use safety-compliant access ladder aids or operating platforms.
z Maintain a distance to rotating and moving parts.
z Relieve hydraulic system pressure before starting maintenance
work.
z Dispose of hydraulic oil according to regulations.
z Wear protective gloves when working on steel wire rope.
z Only use genuine Sennebogen replacement parts.
z Use only oils and lubricants stated in the lubricant table.
z Do not lift heavy objects by hand. Use lifting gear.
z Actuate battery isolator switch to interrupt the power supply.
z When working near batteries these are to be covered with insulating
material; do not place tools onto batteries.

1-2 821 / 05.2007

 Safety - Safety instructions

z Replace all safety devices on completion of maintenance work.

z Keep driver's cab clean and tidy.
z Carry out function check to ensure problem-free operation.
z Only the crane owner or representative may approve the machine
for operation following maintenance work.
z For pneumatic tyres:
When inflating tyres, maintain adequate safety distance and use tyre
cage.
z After maintenance or repair work, carry out thorough visual and
function check according to operating instructions.

821 / 05.2007 1-3

Safety - Responsibilities of the operator

1.3 Responsibilities of the operator

WARNING
The operator is obliged to supply operating instructions when working
with hazardous machines or materials.
The necessary information is contained in
z EC guidelines on safety at work
z National laws on safety at work
z Accident prevention regulations and
z these operating instructions.

Inspection by specialist The machine must be thoroughly checked by a specialist technician.

technician
z before starting up for the first time
z before re-commissioning after major modifications
z at least once a year
z intermediate depending to operating and company conditions.
A specialist in this context is a person, who
z has obtained extensive knowledge of this machine and the corre-
sponding regulations and guidelines through specialist training and
z specific instruction from Sennebogen
and can assess the safe working condition of the machine.

Personnel selection and z Employ only trained and instructed personnel.

qualifications z Define responsibility for operation and maintenance.
z Observe the permitted minimum age.

DANGER
z Personnel under training or instruction must remain under constant
supervision while working on the machine.
z Work on electrical equipment of the machine may only be carried out
by an electrical technician.
z Work on running gear, braking and steering systems may only be
carried out by specifically trained technicians!
z Work on hydraulic systems may only be carried out by personnel
with specific knowledge and experience of hydraulics!

1-4 821 / 05.2007

 Safety - Responsibilities of the operator

Noise protection The permanent sound pressure level of the machine, measured from the
driver's seat with the driver's cab closed, is approximately 80 dB(A). The
wearing of ear protection is therefore not essential. The measurements
are carried out according to EN ISO 11201.
This value of 85 dB(A) can however be exceeded due to environmental
influences, e.g. through dropping or transporting material or on a build-
ing site together with other machines.
In these cases, ear protection measures are strictly specified for the
operating personnel.
The employer is to ensure that appropriate ear protection is available
and used by the operators.

Technical condition of The employer has an ongoing responsibility to monitor the overall tech-
the machine nical condition (obvious external faults and damage as well as changes
to operational behaviour) of the machine.
Do not operate machine if a fault has been detected!
Observe mandatory time limits for routine checks.

Independent For safety reasons the machine may not be modified or altered in any
conversion and way.
replacement part This applies also to the installation and use of safety devices and
production valves as well as welding on load carrying parts.
Genuine Sennebogen replacement parts and accessories ensure the
safety of personnel. Parts and fittings from other manufacturers are not
tested by Sennebogen and are not therefore approved. The use of
other components can alter the machine's characteristics and present
a safety hazard.
If other components are used, Sennebogen will not be considered lia-
ble for any resulting consequences.

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

operating practices according to these operating instructions.
z If there is a danger of heavy objects falling, the machine may only
be used if the driver's area is covered by a protective roof (FOPS).
The protective roof is optionally available from Sennebogen.
z The machine is not suitable for towing a trailer.
Due to the greater axle load, trailer operation is only permitted with
stronger axles (optional).
Note
The performance data listed in chapter 3 TECHNICAL DATA of the oper-
ating instructions must not be exceeded.

821 / 05.2007 1-5

Safety - Responsibilities of the operator

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

Overseas use If the machine is used overseas, the following must be observed:
z Observe the applicable safety regulations of the respective country
of use.
z Ensure that the operators have the necessary qualifications for the
intended work.
z Ensure that the contents of this operating manual have been read
and completely understood. If necessary, ask Sennebogen for a
copy of this operating manual in the corresponding language.

Dangers of non- Non-compliance with the safety notes is dangerous and can be hazard-
compliance with the ous to persons as well as to the environment and the machine.
safety notes
Non-compliance with the safety notes invalidates all claims for com-
pensation.

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

1 2

Warranty conditions The warranty conditions of Sennebogen Maschinenfabrik GmbH are

summarised in the warranty manual.
You will also find an extract from the warranty conditions in the operat-
ing instructions (chapter 10).

1-6 821 / 05.2007

 Safety - Safety devices

1.4 Safety devices

DANGER
z Do not remove safety devices or covers.
z Always check that safety devices are complete and correctly
secured before starting the machine.
z Replace all safety devices and covers correctly on completion of
assembly or maintenance work.
z Exchange damaged safety devices for new ones.

821 / 05.2007 1-7

Safety - Disposal

1.5 Disposal
Cleaning and
lubricating materials

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

Extract from the Disposal Guideline 75/439/EWG:

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

Notes
z Lubricants and other consumables must be disposed of at suitable
collection points.
z National environmental conditions valid in the country of use also
apply.

Batteries Observe safety and protective measures when handling batteries.

Notes
z Do not dispose of batteries in a domestic waste facility!
Dispose of defective batteries at a recollection point for spent batter-
ies.
z National environmental conditions valid in the country of use also
apply.

1-8 821 / 05.2007

 Maintenance schedule

2 Maintenance schedule
Safety instructions Observe the safety notes before starting work.
WARNING
z The maintenance work described may only be carried out by trained
and instructed specialist personnel.
z Wear personal protection equipment (e. g. safety helmet, ear
protection, protective gloves, safety boots).
Note
Shorter intervals may be necessary when operating in extreme
conditions, e.g. high ambient temperatures.

Task every every 50 once every every every Section

10 hrs hrs run / every 500 hrs 1000 hrs 2000 hrs
run / weekly 250 hrs run / run / run / 2
daily run 3months yearly years
– Carry out visual and functional ‡ ‡ ‡ ‡ ‡ ‡
check according to operating
manual.
– Cab – cab mounting: check pin ‡ ‡ ‡ ‡ ‡ ‡
and screw connections.
– Check all detachable fastenings : ‡ ‡ ‡ ‡ ‡ ‡
(bolts, cotter pins, etc.) for
tightness.
– Pipe fracture safety device: ‡ ‡ ‡ ‡ ‡ ‡
visually check for damage and
tightness.
– Hydraulic cylinder: ‡ ‡ ‡ ‡ ‡ ‡
visually check for damage and
tightness.
– Check engine oil level. ‡ ‡ ‡ ‡ ‡ ‡ 4.1
Observe intervals acc. to
operating instructions of engine
manufacturer.
– Observe engine intervals.
– Hydraulic system: check oil level. ‡ ‡ ‡ ‡ ‡ ‡ 7.5
– Check SDS display for Hydro ‡ ‡ ‡ ‡ ‡ ‡ 7.11
Clean micro-filter.
– Lubricate slewing ring. ‡ ‡ ‡ ‡ ‡ ‡ 6
– Check SDS display for air filter ‡ ‡ ‡ ‡ ‡ ‡ 4.2
insert.
– Check water separator for fuel ‡ ‡ ‡ ‡ ‡ ‡ 4.3
system.
– Check coolant level; if necessary ‡ ‡ ‡ ‡ ‡ 4.3.2
clean cooling fins.

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Maintenance schedule

Task every every 50 once every every every Section

10 hrs hrs run / every 500 hrs 1000 hrs 2000 hrs
run / weekly 250 hrs run / run / run / 2
daily run 3months yearly years
– Central lubrication system: ‡ ‡ ‡ ‡ ‡ 6.1.1
check to make certain it is filled.
– Check and clean hydraulic oil ‡ ‡ ‡ ‡ ‡
cooler.
– Swiveling connection: ‡ ‡ ‡ ‡ ‡ 6
visually check all connecting
elements for damage and
corrosion
– Check cable connections of ‡ ‡ ‡ ‡ ‡ 8.1
batteries and fuses.
– Check heating filter. ‡ ‡ ‡ ‡ ‡ 9.1
– Lubricate the machine. ‡ ‡ ‡ ‡ ‡ 10.1
– Check tightness of all screw ‡ ‡ ‡ ‡ ‡
fastenings.
– Air conditioning compressor: ‡ ‡ ‡ ‡ ‡
Check belt tension and status.
– Air conditioning compressor:. ‡1) ‡1) ‡1) ‡1)
Check the compressor mounts
and bolts for tightness.1)
1)
every 250 hrs run
2) 2) 2)
– Have preload pressure of ‡ ‡ ‡ ‡2) 7.12
hydraulic accumulator checked
by hydraulic specialist company
2)
.
2)
after 250 hrs run / 6 weeks and after 500 hrs run / 3 months; then every 1000 hrs run / yearly
– Check load-holding: ‡ ‡ ‡ ‡
Raise load (approx. 1 t), boom
must not drop. Should the boom
drop, inform Sennebogen
Customer Service immediately!
– Check antifreeze. ‡ ‡ ‡ ‡ 4.3.2
– Check oil level of both travel ‡ ‡ ‡ ‡ 5.2
gears.
– Change filter element of return ‡ ‡ 7.7
filter.
– Leak-oil filter – change filter ‡ ‡ 7.9
element.

2-2 821 / 05.2007

 Maintenance schedule

Task every every 50 once every every every Section

10 hrs hrs run / every 500 hrs 1000 hrs 2000 hrs
run / weekly 250 hrs run / run / run / 2
daily run 3months yearly years
– Shut-off flap – hydraulic tank ‡ ‡ ‡ ‡
(optional):
Visually check tightness
– Change filter element of pilot ‡ ‡ 7.8
filter (where present).
– Travel gear: change oil. ‡ ‡ ‡ 5.2
– Tighten slewing ring 3). ‡ 3) ‡ 3) ‡ 3) 6.3
3) once after 250 hrs run / 6 weeks; then every 2000 hrs run / yearly

– Slewing ring bolts examine with ‡ ‡ ‡

suitable means for tightness.
– Water seperator: ‡ ‡ ‡ 4.3.1
Change filter element
– Charge air cooling system - drain ‡ ‡ ‡
out water from condensation.
– Check the gallery (= operator ‡ ‡ ‡
catwalk) for cracks and general
damaged every 3 months and
repair immediately if necessary.
– Heating / Air condition (optional): ‡ ‡ 9
Checked by authorized specialist
company.
– Change exchange cartridge and ‡ ‡ 4.2
safety cartridge in air filter.
– Change the ventilation filter on ‡ ‡ 7.10
the hydraulic tank.
– Change coolant. ‡ 4.3.2
4) 4)
– Hydraulic system: change oil. ‡ 7.6
4)
If necessary, have oil checked on the basis of an oil diagnosis carried out by SENNEBOGEN
customer service.
– Check or change slewing ring ‡5) 6
bolts5)
5)
every 5000 hrs run / 5 years

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

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Maintenance schedule

2-4 821 / 05.2007

 General notes - Cleaning work

3 General notes
3.1 Cleaning work
Notes
z Ensure that the cleaning agents used do not damage the seals and
components of the machine.
z Do not use aggressive cleaning agents.
z It is especially important to clean the noise suppression mats with
neutral cleaning agents!
z Only use lint-free cleaning cloths.
z Only use dry, filtered compressed air up to max. 29 PSI (2 bar).
z On completion of cleaning work, carry out a visual and functional
check of the machine acc. to section 4.3 (in the machine operating
instructions).

WARNING
Electrical and electronic components such as generators, switch
cabinets etc. must not come into direct contact with the water jet!
Wet cleaning of these components is prohibited!
When wet cleaning the machine, always make sure that the water does
not come into contact with electrical or electronic components.
Water ingress can otherwise damage or destroy the machine
electronics. This can result in sudden, uncontrolled operating
movements.

821 / 05.2007 3-1

General notes - Oils and lubricants

3.2 Oils and lubricants

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

WARNING
Mixing oils, lubrication or operational materials of different types is not
permitted!
Filling or mixing oils, lubricants or any other operational fluids (e.g.
hydraulic oil, transmission oil, motor oil, coolant, etc.) of different types
can lead to damage to the machine components because of chemical
reactions. The result of which can cause severe damage to property
and injury to personnel.
Only use the oils, lubricants and operational fluids that are approved by
SENNEBOGEN.
Only mix oils, lubricants and operational fluids that are of the same type
or identical (same specifications) from one manufacturer!

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

Further information is available from Sennebogen customer service.

Biologically degradable Use is expressly specified as leakage of mineral-based oils and

oils and lubricants lubricants presents a danger to the environment. The use of
environmental-friendly lubricants is above all mandatory in water or
nature conservation areas.
Only synthetic, ester-based bio-oils may be used.
WARNING
Switching to bio-oils and bio-lubricants is only permitted subject to
agreement and written confirmation of Sennebogen Customer Service.

3-2 821 / 05.2007

 General notes - Coolant – Drive motor

3.3 Coolant – Drive motor

3.3.1 Coolant for CATERPILLAR - Drive motors

The Caterpillar - Drive motors can be recognized by the
17 character PIN (Product Identification Number) and the ratings plate
among other things. E.g.: *CAT 0789BG 6SL12345*

Note
The Caterpillar - drive motors are filled with coolant
z Caterpillar CAT ELCTM (Extended Life Coolant)
in the factory. Use this coolant only for the Caterpillar drive motors!
SENNEBOGEN will accept no responsibility and will provide no war-
ranty or make any guarantees for the use of any other coolants.

Note
Observe the coolant label in the cooler area.

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

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

821 / 05.2007 3-3

General notes - Coolant – Drive motor

3.3.2 Coolant for DEUTZ - Drive motors

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

Note
The DEUTZ - drive motors are filled with coolant
z Hunold Coolant ANF based on Monoethylenglycol
in the factory. Use this coolant only for the DEUTZ drive motors! SEN-
NEBOGEN will accept no responsibility and will provide no warranty or
make any guarantees for the use of any other coolants.

Note
Observe the coolant label in the cooler area.

Hunold ANF
Kühlmittel
Coolant
Liquide de refroidissement
Refrigerante
Líquido de refrigeração
Liquido refrigerante
Kølevæske
Koelvloeistof
Kjølevæske
Kylvätska
Jäähdytysneste
DzesƝšanas šƷidrums
Sennebogen Maschinenfabrik GmbH 092872

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

3-4 821 / 05.2007

 General notes - Coolant – Drive motor

3.3.3 Coolant - General

WARNING
Mixing coolants and adding cooling system sealing agents or anti-
freeze that contains sealing agents is not permitted.
By filling or mixing different types of coolant or cooling agent additives,
the mixture can gell or build up to plug the cooler resulting in the motor
overheating or the cooling system failing and therefore causing dam-
age to the motor.
WARNING
Mixing of nitrite-based cooling agents with amine-based agents pro-
duces health-hazardous nitrosamine.

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

Note
Observe the coolant label in the cooler area.

If the ambient temperature at the work-site is under this value

(-37 °C (-34 °F)), observe the operating instructions of the motor man-
ufacturer or contact SENNEBOGEN - customer service before starting
operation.

Note
If only a small amount (up to max. 5 l) is required to will the water-cool-
ant circuit and no suitable coolant is available, you can top up with
clean water in the mean time.
We recommend that you test the concentration at the next possible
time before freezing temperatures however. In some cases, you must
refill with the respective coolant so that the required mixture is achieved
again to prevent freezing.
The coolant is not only required to guarantee the protection against
freezing, it also performs the very important task of protecting against
corrosion. This also requires checking for the correct concentration and
adding when necessary.

821 / 05.2007 3-5

General notes - Coolant – Drive motor

Water
Note
z Use clean, neutral, filtered, fairly soft fresh tap water. Sennebogen
recommends distilled water as the best variant.
z Please note that Caterpillar specifies using distilled water!
z Do not use ditch water, industrial drain water, salt water, sea water
or rain water.
z Always fill using a water-coolant mixture. Observe mixing ratios. Mix
before filling!
Ensure that the water has the following characteristics:

pH value 7-8
Chloride content max. 100 ppm
Sulphate content max. 100 ppm
Water hardness 3-12 °dGH

Note
Observe the recommended mixing ratio (see manufacturer's specifica-
tions). If the coolant concentration is too high, the cooling and anti-
freeze behavior will deteriorate.
ATTENTION
Observe the specifications of the coolant manufacturer.

WARNING
Never fill with coolant when the motor is overheated. This will cause
damage to the motor. Allow the motor to cool first.

WARNING
Regarding possible danger to health or environmental dangers, ob-
serve the instructions for using the coolant manufacturer as well.

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

3-6 821 / 05.2007

 General notes - Coolant – Drive motor

WARNING
Scalding hazard!
Be careful when draining hot coolant!
Allow the motor to cool first. Catch the coolant in a suitable container
when draining and dispose of according to the respective regulations.
Change coolant – The cooling system is to be emptied completely before filling
again.
– Rinse the cooling system several times with clear water to rid it of
any residue.
– Fill the cooling system and check the level after a short waiting
period.
– Start the motor and check the coolant levels
ATTENTION
Adjusting to the correct coolant level must sometimes be checked more
than once.

Check the following states when inspecting the coolant levels regularly,
e.g.
– lubricant incursion,
– obvious opacity caused by corrosion residue or other particulate
matter,
in which case, the coolant must be replaced as indicated above.

Coolant change inter- Information on changing the coolant and the changing intervals is
vals provided in the operating instructions of the motor manufacturer.

821 / 05.2007 3-7

General notes - Welding work

3.4 Welding work

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

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

1 If necessary use the optional battery isolator switch to

disconnect from the power supply.
2 Disconnect battery.
3 Secure the earth clamp of the welding unit directly to the
component to be welded.

3-8 821 / 05.2007

 Driving engine -

4 Driving engine
Safety notes Read the safety notes before starting work.
CAUTION
z Only carry out maintenance or repair work with engine shut down
and cooled.
z Secure machine against unauthorised re-starting before starting
with maintenance work.
z Waste oil must not ingress ground or waterways.
Dispose of oil and oil filters in accordance with statutory regulations.
z Coolant must not ingress ground or waterways.
Dispose of coolant in accordance with statutory regulations.
z After maintenance work on the engine, check that all safety devices
have been fitted and all tools are removed from the engine.

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

821 / 05.2007 4-1

Driving engine - Engine oil

4.1 Engine oil

WARNING
z Danger of scalding!
Proceed with utmost caution when draining hot oil.
z Waste oil must not ingress ground or waterways. Dispose of oil and
oil filters in accordance with statutory regulations.
WARNING
Mixing oils, lubrication or operational materials of different types is not
permitted!
Only mix oils, lubricants and operational fluids that are of the same type
or identical (same specifications) from one manufacturer!

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

Engine oil level 1 Position machine horizontally.

- check
2 Run engine approx. 2 min until the system is filled with oil.
3 Shut down driving engine.
4 Open right maintenance hatch.
5 Pull out oil dipstick and wipe off using a clean, fiber-free cloth.
6 Insert oil dipstick up to stop and pull out again.
7 Check oil level:
The oil level must lie between the lower marking (MIN) and the
upper marking (MAX).
8 Top up motor oil if necessary.

Changing engine oil and 1 Warm up engine.

oil filter
2 Position machine horizontally.
3 Open right service access doors.
4 Change engine oil and oil filter according to the operating
instructions of the engine manufacturer.
5 Check oil level:
The oil level must lie between the lower marking (MIN) and the
upper marking (MAX).
6 Top up motor oil if necessary.

4-2 821 / 05.2007

 Driving engine - Air filter

4.2 Air filter

Safety notes Read the safety notes before starting work.
CAUTION
z Never use gasoline, soap or hot liquids to clean the air filter
z Never use compressed air to clean the housing interior, as dust and
contamination can enter the engine.

Air filter indicator The condition of the air filter is monitored by a sensor.
lamp The contamination level is measured by the flow resistance. If the air
filter indicator lamp on the right control panel lights up the maximum
permitted flow resistance has been reached.
A warning tone also sounds. Check and clean the air filter immediately.
Note
The air filter is situated behind the right maintenance hatch.

1 Air filter

821 / 05.2007 4-3

Driving engine - Air filter

2 Air filter cap

3 Locking clamp
4 Dust discharge valve
5 Exchange cartridge
5
6 Safety cartridge
7 Shackle

6 7

4-4 821 / 05.2007

 Driving engine - Air filter

Cleaning
1 Open the right maintenance hatch.
2 Open the locking clamps (3) of the air filter cap (2) and remove
the air filter cap (2).
3 Press dust discharge valve (4) on the cover together to empty
it.
4 Remove replacement cartridge (5).
5 Clean exchange cartridge (5):
– Blow out from inside to outside using dry compressed air
(max. 29 PSI (2 bar)).
– Only beat out if unavoidable!
6 Check exchange cartridge for damage to the filter paper and
the seals. Exchange if necessary.
7 Exchange safety cartridge (6) after 5 filter services (at least
every 2 years):
– Lift the yellow shackle (7)
– and remove the safety carriage.
Never clean safety cartridge (4)!
– Insert new safety carriage.
8 Insert new or cleaned exchange cartridge (5).
9 Fit cover (2) so that dust discharge valve (4) points downwards
and/or with the “TOP” mark at the top.
10 Reattach the air filter cap (2) with the locking clamps (3).
11 Re-close the right maintenance hatch.

821 / 05.2007 4-5

Driving engine - Fuel system

4.3 Fuel system

Safety notes Read the safety notes before starting work.

WARNING
z Danger of injury through rotating parts!
Only carry out maintenance work with driving engine shut down and
cooled down cooling system.
z Do not handle open flames when working on the fuel system! No
smoking!
z Also observe the notes in the operating instructions of the engine
manufacturer.

4.3.1 Water separator

1
2
3
4

7 6

1 Bleed screw 5 Bowl

2 Spring casing 6 Drainage tap
3 Hexagonal bolt 7 Shut-off valve
4 Filter element

4-6 821 / 05.2007

 Driving engine - Fuel system

Drain off water 1 Close the shut-off valve (7) in the tank line.
2 Open vent screw (1) and drainage tap (6).
3 Remove water and dirt from the bowl (5).
4 Close vent screw (1) and drainage tap (6) again.

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

1 Close shut-off valve (7).

2 Slacken hexagonal bolts (3) and remove cover.
3 Remove spring casing (2) and filter element (4).
4 Insert new filter element and spring casing (2).
5 Check cover seal, exchange if necessary.
6 Re-secure cover with hexagonal bolts (3).
7 Open shut-off valve (7).
8 Open vent screw (1).
9 Use the manual pump (8) to pump fuel into the water separator
until it starts to leak out of the vent screw.
10 Re-close vent screw (1).

821 / 05.2007 4-7

Driving engine - Fuel system

4.3.2 Cooler
Safety notes Read the safety notes before starting work.
WARNING
z Danger of injury through rotating parts and through scalding!
Only carry out maintenance work with driving engine shut down and
cooled down cooling system.
z Coolant must not ingress ground or waterways. Dispose of coolant
in accordance with statutory regulations.

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

Coolant level The coolant level is monitored by a sensor.

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

Cleaning cooler

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

2 Open the right service door.
3 Blow out minor dirt by reversing the ventilator direction. To do
this:
Actuate the ventilator reversing switch in the driver's cab.

4-8 821 / 05.2007

 Driving engine - Fuel system

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

Check coolant level

and/or antifreeze

1 Allow driving engine and cooler to cool down.

2 Open upper service cover.
3 Carefully open sealing cap (2) of cooler expansion tank in the
engine compartment to allow the pressure to equalise.
4 Check antifreeze and coolant level, top up if necessary.
Mixing ratio: 50% antifreeze, 50% water. Frost resistant up to
-40 °C.

Further information can be found in the separate maintenance

instructions.

Coolant change SENNEBOGEN recommends changing the coolant every 2000

intervals operating hours or max. 24 months. Whichever is first.

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

821 / 05.2007 4-9

Driving engine - Belt drives

4.4 Belt drives

Safety notes Read the safety notes before starting work.
DANGER
z Only carry out maintenance work with drive engine shut down and
stationary.
z Shut down machine and secure against unauthorised re-starting
before starting with maintenance work.
z Replace protective covers after maintenance work if applicable.
z Make sure that the V-belts run in parallel.

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

4 - 10 821 / 05.2007
 Undercarriage - Cleaning and Lubricating

5 Undercarriage
WARNING
z Rotating parts can cause personal injury!
Perform maintenance operations only with the engine shut down.
z Oil must be precluded from getting into the soil or the waters.
Dispose of spent oil according to the applicable statutory
regulations.

5.1 Cleaning and Lubricating

1 Park the machine on level ground.
2 Stop the engine.
3 Use a steam cleaner to clean tires and traveling gear.
4 Lightly grease the guides and pins.

5.2 Travel gear

Checking the oil level
1

3
1 Filling plug
2 Sprocket mounting bolts
3 Drain plug
WARNING
Mixing oils, lubrication or operational materials of different types is not
permitted!
Only mix oils, lubricants and operational fluids that are of the same type
or identical (same specifications) from one manufacturer!

1 Park the machine on level ground. The position of the drain

plug (3) must be the lowest point.
2 Stop the engine.

821 / 05.2007 5-1

Undercarriage - Travel gear

3 Unscrew the filling plug (1). The oil must reach up to the lower
edge of the filling hole (oil level mark!). Top up with oil, if ne-
cessary.
4 Reinstall the filling plug.

Changing the oil 1 Park the machine on level ground. The position of the drain
plug (3) must be the lowest point.
2 Stop the engine.
3 Place a suitable receiving container underneath the drain plug
(3).
4 Unscrew the filling plug (1).
5 Unscrew the drain plug (3) and allow the oil to drain.
6 Clean the filling and drain plugs, check the seals for wear and
replace when necessary.
7 Reinstall the drain plug (3).
8 Pour in new oil slowly and carefully through the filling hole (1).
9 Reinstall the filling plug (1).
10 Checking the oil level after 2 hours.

5-2 821 / 05.2007

 Undercarriage - Crawler chain

5.3 Crawler chain

Adequate but not excessive chain tension is essential for the chain run-
ning gear to function smoothly without overdue wear and tear.
Note
Correctly adjusted chain tension will reduce wear and tear to running
gear parts.

Checking chain tension

A A-A

A3
G E N TIT L E
15

0
2
0
1
G E N -P O S
G E N -S UM
C A N ONII

13
4
2
e dl in
m e tri c
IS O

Sag measurement “X”

Clean the running gear and crawler chains thoroughly before checking
the chain tension.
Position the machine on even, firm ground.
DANGER
z Ensure that there is no one within the danger area of the machine.
z Use lifting gear with sufficient lifting capacity (weights, see operation
manual)!
z Lattice mast cranes – remove ballast and boom!
z Raise machine using suitable means and with extreme caution
(use lifting points provided – see operation manual)!

1 Raise machine with suitable lifting gear until the chain is no

longer in contact with the ground.
2 Check sag measurement “X” between roller and chain link.
The chain is correctly tensioned when the sag measurement “X“
in the centre of the roller carrier is min. 1.77 inch and/or
max. 2.16 inch. Adjust chain tension if necessary (see following
page).
3 Lower machine and remove lifting gear.

821 / 05.2007 5-3

Undercarriage - Crawler chain

Adjusting chain tension

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

1 2

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

2 Clean lubricating nipple (3).

3 Apply high pressure grease gun to the lubricator 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
roller and chain link.
6 Repeat steps 3-5 until the sag measurement “X” is within the
tolerance (min. 1.77 inch and/or max. 2.16 inch).
7 Tighten cover (2) with the hexagon nuts (1).
8 Adjust the second crawler chain in the same way.

5-4 821 / 05.2007

 Undercarriage - Sprocket

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

5.4 Sprocket
Tighten screws

1 Sprocket mounting bolts

Note
Check the sprocket mounting bolts for firm seating; tighten as necessa-
ry by means of the torque spanner.

5.5 Track shoes

Tighten screws

1 Track shoe mounting bolts

Note
Tighten the track shoe mounting bolts with a torque spanner.

821 / 05.2007 5-5

Undercarriage - Track shoes

5-6 821 / 05.2007

 Swivelling connection -

6 Swivelling connection
Ensure that the swivelling connection is well lubricated.
z Path (1):
– via central lubrication system.
z Gear teeth (2):
– with grease

1 Path
1 2 2 Gear teeth

821 / 05.2007 6-1

Swivelling connection - Lubricating slewing ring path

6.1 Lubricating slewing ring path

6.1.1 Central lubrication system

The central lubrication system automatically lubricates the slewing ring
path. The lubrication cycle is pre-set at the factory.
Note
The pre-set lubrication cycle can be shortened. See in this case the
documentation on the CENTRAL LUBRICATION SYSTEM in chapter 10 of
the operating manual.
Shorter lubrication intervals are required,
z in the tropics,
z when humidity is high,
z under very dusty and dirty conditions,
z when temperatures change dramatically,
z when subject to continuous swinging movement.

1 Lubricant containers
2 Lubricator nipple – replenish grease

Actuating path Lubrication can be manually actuated in addition to the pre-set

lubrication manually lubrication cycle.

1 Actuate the switch on the right of the control panel:

6-2 821 / 05.2007

 Swivelling connection - Lubricating slewing ring teeth

6.2 Lubricating slewing ring teeth

6.2.1 Check the grease

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

1 Rotate the upper structure 360° counterclockwise starting from

travel direction.
2 Rotate the upper structure further in counterclockwise direction
until the boom is at right angles to the undercarriage (90° to
travel direction.
3 Rotate the upper structure 90° in clockwise direction (boom is
beeing set in driving direction):
4 Remove the cover (1).
5 You must see a „peak of grease“ (min. 0.8 inch (20mm)). Add
more grease if necessary.
6 Refit the cover (1).

821 / 05.2007 6-3

Swivelling connection - Tighten slewing ring bolts

6.3 Tighten slewing ring bolts

DANGER
Risk of fatality!
Defective slew ring bolts can lead to the upper structure tipping over.
Therefore observe the service intervals without fail!
z Re-tighten slewing ring bolts using torque wrench.
Observe tightening torque in accordance with Section 10.3!
z Check or change slewing ring bolts every 5000 hrs run / every 5
years.
Note:
Testing must be performed by an expert from an independent specialist
company / independent institute.
Unrestricted use of the slewing ring bolts must be proven by means of
a certificate.
The slewing ring bolts must be changed otherwise.

Corroded or damaged bolts can shear and lead to the upper structure
tipping over.
z Do not tighten corroded or damaged bolts, replace immediately with
new bolts!
z Adhere without fail to the number and diameter of locking bolts.
z Only use genuine SENNEBOGEN spare parts!
z Contact SENNEBOGEN customer services if you have any further
queries.

1 Shut down driving engine.

2 Re-tighten slewing ring bolts crosswise using torque wrench.

Notes
The tension of the bolt tightened first is influenced by the tensioning of
the other bolts. It is therefore necessary to make at least two full turns.
Bolts over M30 should preferably be tightened with a hydraulic socket
wrench.

6-4 821 / 05.2007

 Hydraulic system - Safety notes

7 Hydraulic system
7.1 Safety notes
Observe the safety notes before starting work on hydraulic system.
DANGER
z Work on hydraulic systems may only be carried out by trained
personnel with special knowledge and experience on hydraulics.
z Wear personal safety equipment (e.g. safety helmet, ear protection,
protective gloves, safety boots).
z Warning of high oil pressure!
The hydraulic system is subject to high pressure. Serious injuries
can be caused by escaping hydraulic oil when loosening a hydraulic
connection or when a leak occurs.
Only carry out work on a de-pressurised hydraulic system!
z De-pressurise hydraulic system before starting retrofitting work
(see Section 7.4).
z The pilot control is equipped with a pressure accumulator, which
remains under high pressure even after the engine is shut down.
Therefore, de-pressurise the pressure accumulator.
z Danger of injury!
If leaks are present hydraulic oil will leak out under high pressure.
Hydraulic oil will leak out under high pressure, penetrate the skin
and cause severe damage to health.
Danger of infection. In the case of injury contact a doctor
immediately!
z Danger of injury from scalding
The hydraulic oil can reach temperatures of 70°C and above. Only
carry out maintenance work once the hydraulic oil system has
cooled down.
z Danger of injury from rotating parts.
Only carry out maintenance work when the engine is switched off,
and then only if you are sure that the fan wheel has come to a stop
and there is no risk of automatic start-up.
Before starting up again, ensure that:
– No items (e.g. tools) are in the vicinity of the fan wheels or could
fall into this area as a result of vibrations, for example
– The protective features have been fitted.

821 / 05.2007 7-1

Hydraulic system - General information

7.2 General information

7.2.1 Hydraulic cylinder

Pressure cylinders are subject to slight leakage. Remove excess
leakage residue with a cloth. Dispose of oil-soaked cloth as hazardous
waste.
The sliding surfaces of the piston rods are chrome-plated. Heavier
leakage indicates damaged sliding surfaces or defective seals.
Cleaning hydraulic cylinders:
z Do not use sharp edged tools, caustic fluids or abrasives.
z Wash down piston rods regularly with steam cleaner. Do not direct
the jet straight at the sealing elements.
z Apply preservative to extended piston rods after cleaning. This
protects the surface from the effects of environment and weather.

7.2.2 Screw connections

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

7-2 821 / 05.2007

 Hydraulic system - Hydraulic lines

7.3 Hydraulic lines

Storage and duration of Even when used correctly at permissible loads, hoses and hose lines
use are subject to natural wear and tear. Their service life is therefore
limited.
The operator is responsible for ensuring that hose lines are replaced at
suitable intervals, even when there are no obvious defects to be seen
in the hose line.
Hose lines must be replaced at least every six years, including a
maximum of two years storage time, where applicable.

Check Hose lines should be inspected by a specialist technician at least once

a year to ensure that they are functioning correctly.
Remedy any defects discovered immediately.

Defects Replace hose lines in the following cases (see also DIN 20066):
z Outer layer damaged as far as reinforcement (e.g. abrasion points,
cuts, cracks);
z Outer layer brittle (cracks appearing in hose material);
z Deformation, which does not conform to the natural shape of the
hose or hose line, both when under and not under pressure, or when
bent (e.g. layer separation, bubbles forming);
z Leaks;
z Hose fittings damaged or deformed (sealing function affected);
z Hose has separated from fittings;
z Corrosion of fittings which reduces function and strength;
z Installation requirements ignored;
z Storage times and/or service life exceeded.

821 / 05.2007 7-3

Hydraulic system - De-pressurising hydraulic system

7.4 De-pressurising hydraulic system

De-pressurize the hydraulic system as follows:

1 Lower suspended loads and jib to the ground.

2 Shut down engine, move ignition key immediately back to
position "1".
3 Move both control levers in the cab several times in all
directions. This releases the pressure of the main hydraulics
and the pressure in the pilot control pressure accumulator.

4 Lift hydraulic oil cooler (1).

5 Open screw cap (2) of hydraulic tank.
This releases the residual pressure in the tank.

6 Connect pressure gauge (up to max. 8700 PSI (600 bar)) to the
measuring connectors (P1, P2, P3, P4, PV9).

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

7-4 821 / 05.2007

 Hydraulic system - Checking oil level

7.5 Checking oil level

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

1 Lower suspended loads and jib to the ground.

2 Position machine horizontally.
3 Fully retract all hydraulic cylinders.
4 Shut down driving engine.
5 Open right maintenance hatch.

6 Check oil level at the oil level indicator (1):

The oil level must reach to the upper marking (MAX).

821 / 05.2007 7-5

Hydraulic system - Checking oil level

7 Top up hydraulic oil, if required:

– Lift hydraulic oil cooler (2).
– Unscrew screw cap (3) of oil filler neck.
– Top up hydraulic oil and re-check.
– Re-tighten screw cap (3).
– Re-close hydraulic oil cooler (2).

7-6 821 / 05.2007

 Hydraulic system - Changing hydraulic oil

7.6 Changing hydraulic oil

Safety notes Observe the safety notes before starting work on hydraulic system.
DANGER
z Warning of high oil pressure!
The hydraulic system is subject to high pressure.
When a hydraulic connector is loosened, escaping
hydraulic oil can cause serious injury.
Only carry out work on a de-pressurised hydraulic system!
z Only trained specialist technicians with
specific knowledge and experience of hydraulics may work on the
hydraulic system.

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

Note
The task can be made easier by pumping out as much oil as possible.
Use the opening of the return filter for this.

Procedure
1 Lower suspended loads and jib to the ground.
2 Position machine horizontally.
3 Fully retract all hydraulic cylinders.
4 De-pressurise hydraulic system acc. to Section 7.4.
5 Remove filter element of return filter acc. to Section 7.7.
6 Place a suitable container under the drain opening of the tank.
For capacities, see Section 10.2.

CAUTION
Ensure that the container is large enough to hold the volume of oil.
Hydraulic oil must not ingress ground or waterways.
Dispose of waste oil and oil filters in accordance with statutory
regulations.

821 / 05.2007 7-7

Hydraulic system - Changing hydraulic oil

7 Unscrew cover nut (1).

8 Screw in drain plug (2) until the waste oil emerges via the
plastic hose (3). Collect waste oil in a suitable container.
9 Screw out drain plug (2).
10 Screw cover nut (1) back on.
11 Fill with new hydraulic oil via the filler neck on top of the tank.
12 Bleed hydraulic pump:
– Clean housing.
– Slacken vent screw on the pump. Do not fully unscrew, hold
with light thumb pressure.
– Wait several seconds until the air has escaped.
– Re-tighten vent screw.

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

7-8 821 / 05.2007

 Hydraulic system - Return filter – changing filter elements

7.7 Return filter – changing filter elements

2
3

1 Open screw cap (1) of hydraulic tank.

This releases the residual pressure in the tank.
2 Unscrew the four hexagonal head bolts (2).
3 Remove cover (3).
4 Remove filter element and dispose of as hazardous waste.
5 Clean components, check seal and exchange if necessary.
6 Insert new filter element.
7 Secure cover (3) with the four hexagonal head bolts (2).
8 Tighten screw cap (1).

821 / 05.2007 7-9

Hydraulic system - Auxiliary control filter – change filter element

7.8 Auxiliary control filter – change filter element

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

1 2

1 Unscrew filter housing (1).

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

7 - 10 821 / 05.2007
 Hydraulic system - Leak-oil filter – changing filter element

7.9 Leak-oil filter – changing filter element

1 Slacken hexagonal nuts (1).

2 Remove cover (2).

3 Unscrew filter element (3) from return pipe.

4 Screw new filter element to the return pipe.
5 Insert cover with return pipe in tank.
6 Tighten hexagonal nuts (1).

821 / 05.2007 7 - 11
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 under-
pressure 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 Open screw cap (2) of hydraulic tank.

2 Remove filter element (3) from the screw cap (2).
3 Dispose of screw cap (3) as hazardous waste.
4 Place new filter element (3) onto the screw cap (2).
5 Screw on screw cap (2) with new ventilation filter (3).

7 - 12 821 / 05.2007
 Hydraulic system - Hydro-clean superfine filter (optional)

7.11 Hydro-clean superfine filter (optional)

Note
The dirt of the hydro-clean filter insert is monitored by the SDS. The
filter insert must be changed when the warning light is shown.-

Change
filter element

1 De-pressurise hydraulic system acc. to Section 7.4.

2 Unscrew cover (1) with integrated socket head (2).
3 Pull out filter element.
4 Dispose of filter element as hazardous waste.
5 Clean components, check seal and exchange if necessary.
6 Insert new filter element.
7 Re-tighten screw cap (1).
8 Start driving engine.
9 Unscrew socket head bolt (3) slightly until vent opening is
open.
10 Re-close socket bolt (3) as soon as oil leaks out.
11 Deposit driving engine and check filter for leaks.

821 / 05.2007 7 - 13
Hydraulic system - Checking preload pressure of pressure accumulator

7.12 Checking preload pressure of pressure

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

1 Lower suspended loads and jib to the ground.

2 Connect pressure gauge to the measuring bar.
3 Shut down engine, move ignition key immediately back to
position "1".
4 Move the two control levers in the cab several times in all
directions.
5 Observe pressure gauge.
As soon as the preload pressure is reached, the valve in the
pressure accumulator closes. The pressure gauge pointer
drops suddenly to "0". The value before the pressure drop
equates to the preload pressure in the pressure accumulator.
6 Compare indicated value with the tolerance specification on
the pressure accumulator. If the preload pressure lies outside
the tolerance, exchange pressure accumulator or have it
refilled with nitrogen.
7 Disconnect pressure gauge.

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

7 - 14 821 / 05.2007
 Electrical system - Batteries

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

8.1 Batteries
DANGER
z Explosion hazard!
Smoking and handling of open flame is forbidden. Avoid sparks in
vicinity of the battery.
z Danger of acid burns!
Wear eye protection and gloves.
Do not tilt battery. Battery electrolyte is caustic and must not come
into contact with eyes or skin.
z Do not lay tools on the battery.
z Disconnect battery before starting welding work.
z Do not interchange battery connections.
z Dispose of old batteries as hazardous waste.

Check terminals and cable connections of batteries:

1 Open the right mainenance hatch.

2 Dismantle battery cover (1).
3 Clean battery (2) terminals and cable connections.
Check for tightness and preserve with terminal grease.
4 Assemble battery cover (1).
5 Close the right mainenance hatch.

821 / 05.2007 8-1

Electrical system - Fuses

8.2 Fuses
DANGER
Fire hazard!
Do not repair fuses. Always insert new fuses with the same ampere
value.

1 Shut down engine.

2 Open the left maintenance hatch.
3 Remove fuse box cover.
4 Replace defective fuse.
5 Check contacts, clean oxidized contacts.
6 Replace cover of fuse box.
7 Close the left maintenance hatch.

Note
Wiring, see inside of cover and electrical diagram.

8-2 821 / 05.2007

 Heating/air-conditioning system - Heating

9 Heating/air-conditioning system
9.1 Heating

Cleaning filter element

1

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

2 Remove cover (2).

3 Remove filter element (3).

4 Tap the filter element or carefully blow out with compressed air.
5 Insert filter element. Ensure correct position. Clean air must
exit in direction of travel.

821 / 05.2007 9-1

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

9.2 Air conditioner (optional)

WARNING
z Maintenance and repair work must only be carried out by trained
specialist personnel.
z Do not reach inside the unit and do not insert objects.
z Only carry out maintenance work with driving engine shut down and
fan disconnected.
z Danger of burns!
Allow unit and components inside unit (heat exchanger, resistors) to
fully cool down first.
z Avoid contact with refrigerant.
z Wear eye protection.
z Always use PAG oil for compressor. No ester-based oils.
z No fluorescing additives (tracer agent, sticks).

9-2 821 / 05.2007

 Appendix - Lubrication schedule

10 Appendix
10.1Lubrication schedule

Lubrication via:
Central lubrication system (optional)
On the standard versions without optional central lubrication
system, lubrication nipples are fitted at the lubrication points.
Lubrication nipple
The lubrication nipples are provided with a red protective cap.

821 / 05.2007 10 - 1
Appendix - Capacities

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

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

System Capacity
Drive engine see manufacturer's
instructions
Fuel tank About 300 l (68.10 gal)
Hydraulic tank About 250 l (56.75 gal)
Hydraulic system, complete About 320 l (72.64 gal)
Travel gear About 4.0 l (0.90 gal)
Slewing ring lubrication as required
Central lubrication system as required
Lubrication points as required

10 - 2 821 / 05.2007
 Appendix - Tightening torques for bolts

10.3 Tightening torques for bolts

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

Strength class 8.8 Coarse thread Fine thread

Bolt Tightening torque Bolt Tightening torque
MA [Nm] MA [Nm]
M4 2,7 M8x1 24
M5 5,4 M10x1 50
M6 9,3 M10x1.25 47
M8 23 M12x1.25 84
M10 45 M12x1.5 81
M12 77 M14x1.5 135
M14 125 M16x1.5 205
M16 190 M18x1.5 305
M18 275 M20x1.5 430
M20 385 M22x1.5 580
M22 530 M24x2 720
M24 660 M27x2 1050
M27 980 M30x2 1450
M30 1350
M33 1850
M36 2350

821 / 05.2007 10 - 3
Appendix - Tightening torques for bolts

Strength class 10.9 Coarse thread Fine thread

Bolt Tightening torque Bolt Tightening torque
MA [Nm] MA [Nm]
M4 4,0 M8x1 36
M5 7,9 M10x1 73
M6 14 M10x1.25 69
M8 33 M12x1.25 125
M10 66 M12x1.5 120
M12 115 M14x1.5 195
M14 180 M16x1.5 300
M16 280 M18x1.5 435
M18 390 M20x1.5 610
M20 550 M22x1.5 830
M22 750 M24x2 1050
M24 950 M27x2 1500
M27 1400 M30x2 2100
M30 1900
M33 2600
M36 3300

10 - 4 821 / 05.2007
 Appendix - Tightening torques for bolts

Strength class 12.9 Coarse thread Fine thread

Bolt Tightening torque Bolt Tightening torque
MA [Nm] MA [Nm]
M4 4,7 M8x1 42
M5 9,2 M10x1 86
M6 16 M10x1.25 81
M8 39 M12x1.25 145
M10 77 M12x1.5 140
M12 135 M14x1.5 230
M14 210 M16x1.5 350
M16 330 M18x1.5 510
M18 455 M20x1.5 710
M20 640 M22x1.5 960
M22 880 M24x2 1200
M24 1100 M27x2 1750
M27 1650 M30x2 2450
M30 2200
M33 3000
M36 3900

821 / 05.2007 10 - 5
Appendix - Tightening torques for bolts

10 - 6 821 / 05.2007
 Index

A First aid box 1-6 Personnel selection 1-4

Actuating path lubrication FOPS protective roof 1-5 pH value, water 3-6
manually 6-2 Fuel system 4-6 Pressure cylinders 7-2
Air filter 4-3 Protective roof (FOPS) 1-5
Antifreeze 4-9 G
Gear teeth 6-1 R
B Responsibilities of the
Belt drives 4-10 H operator 1-4
Bio-oils 3-2 Hydraulic screw connections reverse fan 4-8
7-2
C S
Capacities 10-2 I Safety notes 1-2
Central lubrication system Impermissible operating Safety regulations 1-6
6-2, 10-1 practices 1-5 Spare parts manufacture 1-5
Changing the oil 5-2 Inspection by specialist Spare Parts Store W-4
Checking hydraulic oil level technician 1-4 Strength classes for bolts
7-5 International regulations 1-1 10-3
Checking the oil level 5-1 Swivelling connection 6-1
Chloride 3-6 K Symbols and illustration
Cleaning hydraulic cylinders Keyword W-3 devices W-3
7-2
L T
Constant sound-pressure
Lubricating path 6-2 Technical condition 1-5
level 1-5
Lubricating slewing ring path Telephone W-4
Conversion of the machine
6-2 Tightening torque 10-3
1-5
Lubricating slewing ring teeth Top up hydraulic oil 7-6
Coolant 4-8
6-3
Coolant level 4-8, 4-9
Lubrication cycle 6-2 V
Cooler 4-8
Lubrication intervals 6-2 V-belt 4-10
Cooling system 4-8
Lubrication nipple 10-1
Customer Service W-4
W
M Warning symbol W-3
D
Maintenance schedule 2-1 Warranty conditions 1-6
De-pressurizing hydraulic
Measurement connections Warranty manual 1-6
system 7-4
7-4 Water separator 4-6
Disposal 1-8
Batteries 1-8 N
Consumables 1-8 National regulations 1-1
Lubricants 1-8 Noise protection 1-5
E O
Engine Oil diagnosis 3-2
Changing oil 4-2 Oil filler strainer 7-6
Changing oil filter 4-2 Overseas use 1-6
Checking oil level 4-2
Environmental guidelines 1-8 P
environmental protection 1-8 Path 6-1
Personal safety equipment
F 1-2
Fire extinguisher 1-6

821 / 05.2007 S-1