80.6.1049_en_neu

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BS 80

05.2008 BS80.6.1049

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Foreword

Important notes on the Instruction

Read the instruction, in particular Chapter 1 SAFETY thoroughly, before

starting work with the machine.

Keep the instruction in a safe place for future use.

WARNING!

z Only work with the machine once these instruction have been read and completely understood.

z Observe safe working load tables in Abschnitt 3.2. z Forbid unsafe operation or unsafe maintenance. z Do not operate machine if a fault has been detected!

z Setting up, operation and maintenance of the machine is only permitted by trained personnel. The employer is responsible for the qualification and training of the personnel.

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

Recommended location to keep instructions: In the storage compartment behind the driver’s seat.

In the event of sale, disposal or loan, the operating manual must accompany the machine!

z Contact SENNEBOGEN immediately if there is anything in the operating manual that you do not understand!

Your comments will help us to make the operating manual even more user friendly.

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

DANGER

Safety devices must be fitted when working with the machine.

Current when going to press

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

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BS80

Illustration aids These instruction contain safety instructions that highlight dangerous

working practices. These safety notes are indicated with a warning symbol and a keyword.

This warning symbol means: Attention - this concerns your safety and the safety of others.

The associated keyword signifies the degree of danger:

DANGER

Is used for great, directly threatening danger. If this danger is not averted, serious physical injuries or loss of life of persons will result.

WARNING

Is used for potentially dangerous situations. If this danger is not averted, serious physical injuries or loss of life of persons may result.

CAUTION

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

Note

Indicates notes which draw attention to peculiarities.

Note

Indicates cross references to other documents.

Handling instructions are shown in table form as follows:

z Listings are marked with bullet points.

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

1 Press switch (1).

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

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Glossary of terms Operator

The operator (owner of the company/company) is responsible for operating the machine in a correct manner, or for ensuring that the product is being used by suitable and instructed personnel.

Operating personnel

The operating personnel are the person/s authorized by the operator to use the product.

Trained technicians

Trained technicians are those authorized by the operator to fulfil certain obligations such as installation, fitting, repair and maintenance and troubleshooting.

z Specialists

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

z Instructed personnel

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

z Experts

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

z Specialists

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

Authorizations can be limited to parts of checks or to certain types of crane.

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BS80

Target group The machine has been developed for demanding work.

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

The operation and deployment may only be carried out by persons suitably instructed. Initial operation, maintenance,

transportation and assembly/dismantling only by trained specialists. Detailed information on the required prior knowledge and qualifications of the operator can be found in Chapter 1 SAFETY of these instructions.

What documents go with the machine?

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

z Service checkbook.

Note

The complete scope of materials included with delivery is specified in the order confirmation.

How are the instruction divided up?

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

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

z 2: Overview

Chapter 2 illustrates the main components of the machine. z 3: Technical data

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

z 4: Starting operation

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

z 5: Operation

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

z 6: Maintenance

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

z 7: Setting up

Chapter 7 may contain information on setting up counterweight. z 8: Transportation

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

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W - 6 BS80

z 9: What to do if ...

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

z 10: Appendix

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

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-W - 7 BS80 Please contact us at SENNEBOGEN Maschinenfabrik GmbH Hebbelstrasse 30 D-94315 Straubing Technical documentation: Note

The addresses of SENNEBOGEN sales and service partners are available on the Internet through our homepage.

BAUER Maschinen GmbH Wittelsbacher Str. 5 D-86529 Schrobenhausen

Technical documentation:

Note

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

instruction

Telephone: +49 9421 540-0

Internet: http://www.sennebogen.de Fax Customer service: +49 9421 540279 Fax Spare parts storage: +49 9421 40811

E-mail: [email protected]

Fax: +49 9421 540 380

Telephone: +49 8252 97-0 Internet: http://www.bauer.de

Fax Customer service: +49 8252 972587

E-mail: [email protected]

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CE

symbol of

conformity

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

Copyright

©

Straubing 2007, SENNEBOGEN Maschinenfabrik GmbH

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

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Contents 0 - 1 BS80/ 05.2008

1 Safety . . . 1-1

1.1 General . . . 1-1

1.2 Use as Intended . . . 1-2

1.3 Potential instances of misuse . . . 1-2

1.4 Abuse . . . 1-3

1.5 Residual hazards . . . 1-3

1.6 Safety Information . . . 1-4

1.6.1 General . . . 1-4

1.6.2 Preparing to Operate . . . 1-8

1.6.3 Operation . . . 1-9

1.6.4 Setup work . . . 1-10

1.6.5 Maintenance . . . 1-11

1.6.6 Transport . . . 1-13

1.7 Obligations of the Owner . . . 1-14

1.8 Guards and Protective Devices . . . 1-17

1.9 Warning Signs and Labels on the Machine . . . 1-18

1.9.1 Identification plate . . . 1-18

1.9.2 CE stamp of conformity . . . 1-19

1.9.3 Euro-test identification . . . 1-19

1.9.4 Safety signs and warning symbols . . . 1-20

1.10 Disposal . . . 1-22

1.11 Hand signals . . . 1-23

2 General View . . . 2-1

2.1 Overall Machine . . . 2-1

2.2 Engine . . . 2-2

2.3 Hydraulic System . . . 2-4

2.4 Air Filter . . . 2-6

2.5 Operator´s Station . . . 2-7

3 Technical Data . . . 3-1

3.1 Base Machine . . . 3-1

3.2 Appendix . . . 3-3

4 Preparing to Operate . . . 4-1

4.1 Safety Information . . . 4-1

4.2 Initial Commissioning . . . 4-2

4.3 Pre-Start Checks . . . 4-2

4.4 Starting the Machine . . . 4-4

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Contents

0 - 2 BS80/ 05.2008

4.4.1 Seat Belt . . . 4-4

4.4.2 Starting the Engine . . . 4-5

4.4.3 Jump start . . . 4-6

4.4.4 Bring Machine up to Operating Temperature . .

4-7

4.5 Turning off the machine . . . 4-8

4.5.1 Switching off engine . . . 4-8

4.6 Decommissioning . . . 4-9

5 Operation . . . 5-1

5.1 Safety Information . . . 5-1

5.2 Operator’s Cab . . . 5-2

5.3 Machine Controls . . . 5-4

5.3.1 General View . . . 5-4

5.3.2 Emergency Stop . . . 5-5

5.3.3 Safety Lever . . . 5-6

5.3.4 Right-Hand Control Lever . . . 5-7

5.3.5 Left-Hand Control Lever . . . 5-7

5.3.6 Pedals . . . 5-8

5.3.7 Sennebogen Diagnostic System (SDS) . . . . 5-9

5.3.8 Right-Hand Control Panel . . . 5-17

5.4 Heating System . . . 5-21

5.5 Optional Equipment . . . 5-22

5.5.1 Air Conditioner . . . 5-22

5.5.2 Auxillary heating / Water heater . . . 5-24

5.5.3 Hydraulicoil- , cooling water- and diesel

prelimi-nary heating, batterie prelimiprelimi-nary heating 5-25

5.6 Operating Technique . . . 5-27

5.6.1 Safety Information . . . 5-27

5.6.2 Swinging the Upper Structure . . . 5-28

5.6.3 Refueling the Machine . . . 5-30

6 Maintenance . . . 6-1

6.1 Safety Information . . . 6-2

6.2 General Information . . . 6-4

6.2.1 Cleaning . . . 6-4

6.2.2 Oils and Lubricants . . . 6-5

6.2.3 Coolant for CATERPILLAR - Drive motors . 6-6

6.2.4 Coolant - General . . . 6-7

6.2.5 Welding . . . 6-10

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Contents 0 - 3 BS80/ 05.2008

6.3 Engine . . . 6-11

6.3.1 Engine Oil . . . 6-12

6.3.2 Water separator . . . 6-14

6.3.3 Fuel filter . . . 6-15

6.3.4 Air Filter . . . 6-16

6.3.5 Radiator . . . 6-17

6.3.6 Belt Drives . . . 6-19

6.4 Hydraulic System . . . 6-20

6.4.1 Hydraulic Hose Lines . . . 6-22

6.4.2 Relieving Hydraulic System Pressure . . . . 6-23

6.4.3 Checking Hydraulic oil Level . . . 6-24

6.4.4 Changing Hydraulic Oil . . . 6-25

6.4.5 Return Flow Filter – Replacing Filter Element . .

6-28

6.4.6 Pilot Control Filter – Replacing Filter Element .

6-29

6.4.7 Leakage Oil Filter – Replacing Filter Element . .

6-30

6.4.8 Replacing Ventilation Filter . . . 6-31

6.4.9 Checking and Cleaning Hydraulic Oil Cooler . .

6-32

6.4.10Checking Precharge Pressure of the

Accumula-tors 6-33

6.5 Distributor Gear . . . 6-34

6.5.1 Checking Oil Level . . . 6-35

6.5.2 Changing Gear Oil . . . 6-35

6.6 Slewing Ring . . . 6-36

6.6.1 Lubricate the ball-type swing gear and bearing

6-36

6.7 Swing drive . . . 6-37

6.7.1 Lubricating the gear teeth . . . 6-38

6.7.2 Retightening bolts . . . 6-39

6.8 Electrical System . . . 6-40

6.8.1 Batteries . . . 6-40

6.8.2 Fuses . . . 6-41

6.9 Heating System . . . 6-42

6.10 Appendix . . . 6-43

6.10.1Maintenance Schedule . . . 6-43

6.10.2Refill Capacities . . . 6-46

6.10.3Tightening Torques for Screws . . . 6-47

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Contents 0 - 4 BS80/ 05.2008

7 Setting Up . . . 7-1

7.1 Detaching/Attaching Counterweight . . . 7-1

7.1.1 Detaching Counterweight . . . 7-2

7.1.2 Attaching Counterweight . . . 7-4

7.2 Setting Up (Option) . . . 7-8

7.3 Detaching/Attaching Counterweight . . . 7-8

7.3.1 Detaching Counterweight . . . 7-9

7.3.2 Attaching Counterweight . . . 7-11

8 Transport . . . 8-1

8.1 Safety Information . . . 8-2

8.2 Dimensions and Weights . . . 8-3

8.2.1 Dimensions . . . 8-3

8.2.2 Weights . . . 8-4

8.3 Disconnect electrical system from battery . . . 8-5

8.4 Lifting the Machine . . . 8-6

8.5 Lashing and Tying Down the Machine . . . 8-8

9 Troubleshooting . . . 9-1

9.1 Engine . . . 9-1

9.2 Hydraulic System . . . 9-3

9.3 Electronic System . . . 9-5

9.4 Sennebogen diagnositc system SDS . . . 9-6

9.4.1 Bank of keys with LEDs . . . 9-6

9.4.2 Indicator and warning lights . . . 9-8

9.5 Heating System . . . 9-10

9.6 Air Conditioner . . . 9-11

9.7 Cab . . . 9-12

1 Appendix . . . 2-1

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Safety - General

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BS80/ 01.2006

1 Safety

1.1 General

In the design and construction of the machine, allowance has been made for the state of the art and the recognized safety-related

standards. Its operation may nevertheless involve potential hazards for persons, the machine and other property if

z the machine fails to be used as intended;

z operation or maintenance of the machine is performed by unqualified personnel;

z the safety notices and messages are ignored. z the machine is found to be defective.

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

z the operating tools attached are found to be defective

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

In the Federal Republic of Germany e.g:

z Winches, Lifting and pulling devices (VBG 8) z Crane (BGV D6)

z Hoisting devices in lifting appliance operation (VBG 9a) z Earth-moving machinery (VBG 40)

z EC Machinery guideline 98/37/EC z EMC Guideline 89/336/EEC

z Electrical Machinery Equipment (EN 60204-1)

z Safety Requirements for Fluid Engineering Systems and their Components - Hydraulic (EN 982)

z Earth-Moving Machinery – Safety (EN 474-1/-5)

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

Note

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

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Safety - Use as Intended

1 - 2 BS80/01.2006

1.2 Use as Intended

The machine has been designed as a carrier machine for BAUER, Schrobenhausen, Germany.

Any other use or any use beyond the scope set out above is considered to be improper use.

Work station:

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

Note

Study and observe the information contained in the BAUER documentation.

Target group The machine has been designed to perform specific exacting duties.

Persons who operate the machine or work on it must have received adequate training or instruction.

Operation and application must be performed only by persons that have been duly instructed. Commissioning, maintenance, transport and assembly/disassembly must be assigned to trained qualified personnel.

1.3 Potential instances of misuse

z Inadequate equipment for the application (e.g. protection of cab against falling objects with guard grill).

z Operating on insufficiently firm base.

z Neglect of necessary inspection and maintenance work. z Use in inadmissible ambient conditions.

z Misuse by untrained and uninstructed personnel.

z Counterweight disassembly or replacement of counterweight elements with device attached (e.g. Ram)

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Safety - Abuse

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BS80/ 01.2006

1.4 Abuse

Practices considered to be improper use (abuse) include in particular: z Lifting, moving and handling of persons

z Oblique pulling of loads z Dragging of loads

z Breaking loose any loads that have got stuck z Operation in a potentially explosive atmosphere

WARNING

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

1.5 Residual hazards

The safety information in these instruction are guidelines for the safe use of the machine by qualified machine operators. However,

SENNEBOGEN cannot anticipate every situation in practice that may result in danger.

Therefore, the safety notes and warnings on the machine and in the instruction cannot be all inclusive. The owner and machine operator still remain responsible for safety.

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Safety - Safety Information

1 - 4 BS80/01.2006

1.6 Safety Information

DANGER

Danger to life!

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

unintentionally. Observe the following:

z Place the machine on a firm base, if necessary set back from the edge of the excavation.

z Lower suspended loads and booms to the ground. z Apply the brake.

z Switch off machine and secure against unauthorised re-starting. z Use a chock to stop the machine from rolling away.

1.6.1 General

Danger area The danger area of the machine is the surrounding area in which

persons are within the reach of:

z Work-related movements of the machine z Working equipment and machine attachments z Loads swinging out or dropping down

z Working equipment dropping down

DANGER

No persons are allowed in the danger area!

In case of danger to persons, the operator must give warning signals. If the persons fail to leave the danger area in spite of the warning, operations must be stopped.

To avoid crushing hazards, maintain an adequate safety clearance (at least 500 mm) to any fixed structures such as building structures, banks of excavations, scaffolds or other machines.

Where maintenance of the safety clearance is precluded, mark off the area between any fixed structure and the working area of the machine. When the operator’s view of his work and travel area is restricted or impaired, a signal person must be provided.

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1 - 5

BS80/ 01.2006

Gallery = Catwalk for operators

DANGER

Risk of falling!

A maximum of 100 kg (220 lbs) is permitted per segment of grid iron on the gallery (= operator catwalk). Overloading will lead to damaging the construction, the results of which can lead to personal injury.

Check the gallery for cracks and general damaged every 3 months and repair immediately if necessary.

Personal protective equipment

While performing work on the machine, the operating personnel is obliged to wear personal protective equipment as required by the national rules and regulations (e.g., hard hat, hearing protective, safety shoes, protective gloves).

Problems Report problems or damage immediately to a responsible person!

Prevent the machine from incorrect or erroneous use.

Repairs may only be performed by trained specialist personnel.

Stability z Position the machine on a firm, level supporting surface only. z Where necessary, stabilize the supporting surface.

z Beware of edges of excavations, banks, vaults, etc. z Set outriggers on a firm, level supporting surface as well. z Pay attention to wind speeds!

DANGER

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

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1 - 6 BS80/01.2006

Working in the vicinity of power lines

z Clearly mark off the power lines in the job site area with your supervisor. Do so before starting work!

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

loads being handled enter into the danger zone.

z Maintain a safety clearance to the overhead lines. Unless otherwise provided in the national laws and regulations, maintain the following minimum clearances:

z Use a signal person to observe the safety clearance.

z The use of insulating links, cage-type guards or proximity warning devices on the machine is not a substitute for maintenance of the minimum clearances specified.

z Wind can cause both the overhead lines and any working equipment to weave or swing out and thus reduce the clearance.

High voltage contact In case of high voltage contact, proceed as follows:

z Do not leave the operator’s station.

z Caution all outside persons against approaching or touching the machine.

z Where possible, move the working equipment or the entire machine out of the danger zone.

z Arrange for the power to be disconnected.

z Do not leave the machine until after de-energization of the line that has been touched or damaged.

DANGER

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

Rated Voltage (Volts) Safety Clearance (Meters)

to 1000 V 1.00

over 1000 V to 110 kV 3.00 over 110 kV to 220 kV 4.00 over 220 kV to 380 kV 5.00

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BS80/ 01.2006

Qualifications of personnel

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

Extract from VBG 40 regulations (Germany)

Only those persons must be assigned to operate or maintain earthmoving machines on their own who

z have attained the age of 18 (majority); z are both physically and mentally fit;

z have received training in the operation or maintenance of the earthmoving machine and have proven their relevant qualification to the employer; and who

z can be expected to reliably perform the duties assigned to them. They must have been appointed by the employer to operate and maintain the earthmoving machine.

Extract from OSHA regulations (United States)

Operators are required to meet the following qualifications:

z Pass a practical operating examination for the machine they will operate.

z Have vision of at least 20/30 Snellen in one eye and 20/50 Snellen in the other eye, with or without corrective lenses.

z Be able to distinguish colors (red, green, yellow) if color differentiation is required for operation.

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

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

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1 - 8 BS80/01.2006

1.6.2 Preparing to Operate

WARNING

z Make sure that all guards and protective devices of the machine are in place and are properly secured.

z Wear personal protective equipment (hard hat, safety glasses) where this is required by job conditions.

z Avoid wearing jewelry or loose clothing.

z Secure any loose items, e.g., tools or other accessories. z Agree on hand signals with the signal person.

z Obtain information about first aid and about assistance and rescue services.

z Perform the pre-start checks as specified in Section 4.3.

z Get onto or off the machine only while it is parked. Use the means of access and ladders provided for the purpose:

– Before using the means of access and the ladders, clean them as necessary.

– While mounting or dismounting, your hands must be free of any objects. Use a hand line or a hoist to lift any items of equipment onto the machine.

– Do not use controls in the operator’s cab as handholds. z Make sure that there are no persons in the danger area.

z Check the safety features (brakes, signaling and lighting equipment) of the machine.

z While traveling at slow speed, check the controls and protective devices for proper operation.

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BS80/ 01.2006

1.6.3 Operation

WARNING

z Be sure to observe Chapter 1 SAFETY.

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

z Persons who operate the machine or work on it must have received adequate training or instruction.

Operation and application must be performed only by persons that have been duly instructed.

z Make sure that there are no persons in the danger area. z Maintain a safety clearance to overhead lines.

z Operate the machine only while you are in the operator’s seat. z Do not use the machine for handling of personnel.

z Make due allowance for ambient conditions, e.g., poor visibility, wind speeds, etc.

z Observe performance specifications.

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

– Park the machine on a safe surface. Back off from the edge of an excavation, where applicable.

– Lower any attached loads to the ground. – Secure the working attachments.

– Pull the safety lever backward.

– Chock the tires/block the undercarriage. – Stop the engine.

z Lock the operator’s cab; use warning lamps to mark the machine, where applicable.

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1 - 10 BS80/01.2006

1.6.4 Setup work

WARNING

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

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

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

z Note the relevant accident prevention directives for working with load suspension equipment.

z Carry out all setup steps in turn. Never carry out more than one set up task at a time.

z Do not climb or run on equipment parts (e.g. boom components, ballast components) suspended on the crane. Do not stand on parts suspended from the crane.

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Safety - Safety Information 1 - 11 BS80/ 01.2006

1.6.5 Maintenance

DANGER Danger to life!

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

unintentionally. Observe the following:

z Place the machine on a firm base, if necessary set back from the edge of the excavation.

z Lower suspended loads and booms to the ground. z Apply the brake.

z Switch off machine and secure against unauthorised re-starting. z Use a chock to stop the machine from rolling away.

WARNING

z Observe the applicable statutory accident prevention and safety regulations.

z Land any attached loads to ground level. z Pull the left safety lever backwards.

z Before attempting to perform any maintenance, shut down the machine and secure it against unauthorized restarting.

z Attach a warning tag to the controls.

z Do not smoke and do not allow open flames.

z When working in the area of the battery, cover the battery with isolating material; do not deposit any tools on the battery. z Use personnel hoists or work platforms that satisfy safety

requirements.

z Stay clear of all rotating and moving parts.

z Relieve the pressure before working on the hydraulic system. z Always wear protective gloves when handling wire ropes. z Use only genuine BAUER/SENNEBOGEN spare parts.

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

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

z Operate the optional battery disconnect switch, if equipped, to interrupt power supply.

z On completion of the maintenance operations, reinstall all guards and protective devices.

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1 - 12 BS80/01.2006

z Perform a functional check to ensure proper operation.

z On completion of any maintenance operations, only the machine owner or his agent is permitted to clear the machine for service again.

z For machines with pneumatic tires:

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

DANGER

z Work on the machine's electrical equipment may only be carried out by a qualified electrician.

z Work on running gear, braking and steering systems may only be carried out by specifically trained technicians!

z Work on hydraulic systems may only be carried out by personnel with specific knowledge and experience of hydraulics!

z No welding is to be performed on the device without previous discussion with the manufacturer.

WARNING

Mixing oils, lubrication or operational materials of different types is not permitted!

Filling or mixing oils, lubricants or any other operational fluids (e.g. hydraulic oil, transmission oil, motor oil, coolant, etc.) of different types can lead to chemical reaction damage to machine components. This damage can in turn result in severe damage to property and to personal injuries.

Use oils, lubricants and operational fluids that are approved by SENNEBOGEN only.

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

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Safety - Safety Information 1 - 13 BS80/ 01.2006

1.6.6 Transport

WARNING z In Germany:

Loading and transportation work is only to be carried out by

authorised specialist personnel in accordance with VBG 40, §48 and Federal Motor Vehicle Safety Standards (StVo) §22.

z Comply with the relevant regulations for securing loads.

The respective transport operator is always responsible for the

transportation of machine and accessories.

z When loading and transporting, secure the machine and its working equipment from unintended movement.

z Clean running gear of machine from mud, snow and ice so that ramps can be accessed without danger of sliding.

z Provide low loader access ramps with wooden planks. z Check conditions of route before starting journey.

z Only transport machine using designated tie-down and lifting points. z Ensure that the machine does not present any hazards to other road

users.

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

z Notify SENNEBOGEN customer service of any transport damage immediately.

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Safety - Obligations of the Owner

1 - 14 BS80/01.2006

1.7 Obligations of the Owner

WARNING

The owner/user is obliged to prepare relevant instruction when dealing with dangerous machines or hazardous materials.

The necessary information is to be found in

z EC directives on occupational health and safety z National occupational health and safety laws z Accident prevention regulations and

z the present instruction.

Recurring inspections

Specialist testing, required for crane or backhoe operation

The machine must be thoroughly checked by a specialist.

z before initial operation and before putting the machine back into operation after significant modifications

z at least once yearly

z and in between according to operating conditions and conditions of use.

A specialist in this context is a person, who

z has extensive knowledge of this machine and the corresponding regulations and guidelines due to specialist training and

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

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

Specialist testing, only required for crane operation

The following cranes must be tested by a specialist every 4 years: – Fuel driven mobile crane

– Location changing fuel driven derrick crane – Vehicle attachment crane

The specialist inspection is to be performed in the 13th year of operation and annually thereafter.

Faults that are determined in recurring inspections must be eliminated according to the safety-relevance and within a suitable time-frame.

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BS80/ 01.2006

Risks incurred by ignoring safety notices

Non-observance of the safety notices and messages is dangerous, and persons as well as the environment and the machine can be

endangered as a result.

Failure to observe the safety notices and messages will invalidate any entitlement to damages.

Selection and qualifications of personnel

z Employ only personnel that has been duly trained or instructed. z Define responsibilities for operation and maintenance.

z Observe the minimum age permitted by law.

DANGER

z Personnel that is being trained or instructed must not be allowed to work on the machine except under constant supervision of an experienced skilled person.

z Have any work on electrical equipment of the machine performed by a qualified electrician only.

z Only qualified personnel having received relevant training is allowed to perform work on undercarriages, braking and steering systems! z Work on hydraulic equipment must only be performed by personnel

having specific knowledge and experience of hydraulics!

Inadmissible operating practices

z Safety of operation of the machine is ensured only when it is used as intended, consistent with the specifications in Section 1.2 of this instruction.

z The performance limits specified in Chapter 3 TECHNICAL DATA must

not be exceeded.

z When the machine is exposed to risks of falling heavy objects, it must not be used unless the operator’s station is protected by a canopy (FOPS structure). The canopy is available from BAUER/ SENNEBOGEN as an option.

Specific dangers The machine operator must check whether the operation gives rise to

specific dangers, e.g. on account of toxic gases, ground quality etc., and adopt appropriate measures to avoid or limit those dangers.

Technical condition of the machine

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

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1 - 16 BS80/01.2006

Noise protection The permanent sound pressure level of the machine – measured at the

operator’s seat with the operator’s cab closed – is about 80 dB(A). Wearing of hearing protective devices therefore is not a mandatory requirement. Measurements are made as specified in EN ISO 11201. It is possible however that ambient influences cause the level to exceed 85 dB(A), e.g., owing to dropping or transport of material, or in

combination with other machines on a job site.

In such cases, noise protection arrangements for the operating personnel are a mandatory requirement.

The owner must make sure that adequate hearing protective devices are available and are worn by the operating personnel.

Genuine BAUER/ SENNEBOGEN spare parts

Conversions and modifications of the machine are not permitted. This applies also to the installation and use of safety devices and valves as well as welding on load carrying parts.

Genuine BAUER/SENNEBOGEN spare parts and accessories serve the safety of the personnel. The use of other components may change the properties of the machine and thus compromise safety.

The use of non-approved components will release BAUER/ SENNEBOGEN from all and any liability for any resulting consequences.

Employment in foreign countries

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

of use.

z Make sure that the operating personnel has the necessary qualifications for the scheduled work.

z See to it that the contents of the present instruction are read and fully understood. Where necessary, obtain a manual in the respective official language from BAUER/SENNEBOGEN.

Fire extinguisher and first aid kit (option)

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

Warranty conditions The warranty conditions of SENNEBOGEN Maschinenfabrik GmbH

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Safety - Guards and Protective Devices

1 - 17

BS80/ 01.2006

1.8 Guards and Protective Devices

DANGER

z Do not remove any protective devices and covers.

z Whenever the machine is started, make sure first that all protective devices of the machine are in place and are properly secured. z On completion of fitting or maintenance operations, properly

reinstall all guards, protective devices and covers. z Replace any damaged protective devices by new items.

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Safety - Warning Signs and Labels on the Machine

1 - 18 BS80/01.2006

1.9 Warning Signs and Labels on the Machine

There are specific safety signs and warning symbols on the machine. z Do not remove the safety signs and labels.

z Keep all safety signs and labels in an undamaged and readable condition.

z Use water and soap to clean the safety signs, where necessary. Do not use gasoline or solvents to clean the signs and labels. z Replace any damaged, scratched or illegible safety sign or label by

a new item.

Note

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

1.9.1 Identification plate

(*) Note

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

1 Machine type

2 Manufacturer’s No. (Facility No.)

3 Engine performance specification (in kW) 4 Year of manufacture

5 * actual - Permissible overall weight of machine 6 * actual - Permissible weight on the front axle 7 * actual - Permissible weight on the rear axle

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BS80/ 01.2006

1.9.2 CE stamp of conformity

– affects machines that are operated within the EU/EEC. These machines wear the CE identification. This means that these machines meet the respective safety stipulations of the EU machine regulations upon delivery. For changes that affect the safety of the machine and the respective consequences, those that make the changes are responsible and liable.

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

CE Stamp

1.9.3 Euro-test identification

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

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1 - 20 BS80/01.2006

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1 - 21

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Safety - Disposal 1 - 22 BS80/01.2006

1.10 Disposal

Lubrication and consumables CAUTION

Observe environment protection!

Handle and dispose of used items and materials correctly, especially z when working on lubrication systems and devices and

z when working with solvents.

Extract from the Disposal Guideline 75/439/EEC: z “It is prohibited to mix spent oil with other waste”. z “Spent oils must not be mixed together”.

z “Used oil filters must be collected, kept, transported and disposed of separately from other waste”.

Notes

z Dispose of lubricants and other consumables at suitable collection points.

z National environmental conditions valid in the country of use also apply.

Batteries When working with batteries, please observe safety instructions and

protective measures.

Notes

z Do not dispose of batteries in household trash!

Return defective batteries to a collection place for old batteries. z National environmental conditions valid in the country of use also

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Safety - Hand signals

1 - 23

BS80/ 01.2006

1.11 Hand signals

Driver and signaler communicate with each other with the aid of the following hand signals when vision is restricted in the driving and work area.

The guide gives the necessary signals to ensure safe operation.

Safety instructions Observe the safety notes before starting

work.

CAUTION

z Only responsible persons may be employed as guides. They must receive the necessary training before starting their task.

z The guide must not be diverted from this task by other tasks.

z Observe notes of VBG 40, § 35 Guides as well as the details of DIN 33409 Hand signals for guidance.

Attention

Extend arm upwards with hand open.

Stop

Extend both arms horizontally.

Stop! Danger!

Alternately extend and fold in both arms horizontally.

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1 - 24 BS80/01.2006

Drive off

Move upwards extended arm back and forth with hand open.

Drive slowly forwards

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

Reverse slowly

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

Turn right

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BS80/ 01.2006

Turn left

Right thumb outwards.

Turn upper structure to the right

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

Turn upper structure to the left

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

Hoist equipment (load)

Right extended index finger points upwards, left hand moves up and down.

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1 - 26 BS80/01.2006

Lower equipment (load)

Right extended index finger points downwards, left hand moves up and down.

Increase reach

Both thumbs point outwards.

Decrease reach

Both thumbs point inwards.

Open grab

Hold arm horizontal with half open hand to the side.

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1 - 27

BS80/ 01.2006

Close grab

Hold arm horizontal with closed hand to the side.

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General View - Overall Machine 2 - 1 BS80/ 10.2007

2 General View

2.1 Overall Machine

1 1.1 1.2 2 1 Upper structure 1.1 Engine 1.2 Hydraulic system

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General View - Engine

2 - 2 BS80/ 10.2007

2.2 Engine

1 2 3 4 5

1 Air conditioner indicator lamp 2 Gear pumps

3 Distributor gear 4 Leakage oil block

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General View - Engine 2 - 3 BS80/ 10.2007 6 2 1 2b 2a 3 4 5 1 Main fuse 2 Engine 2a Water separator 2b Fuel filter

3 Charge air cooling system 4 Batteries

5 Battery disconnect switch

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General View - Hydraulic System

2 - 4 BS80/ 10.2007

2.3 Hydraulic System

2

1

4 Thermostat - Hydraulikoil preliminary

heating

5 Shutt-of flap

6 Power receptacle, 24 volt, 20 amp 7 Main control valve bank

3 6 4 5 7 1a 1b 2 Refueling pump 3 Oil cooling 1 Hydraulic tank

1a Oil level display 1b Fuel fill strainer

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General View - Hydraulic System 2 - 5 BS80/ 10.2007 1 2 1 3 1 Swing gear 2 Leakage oil block 3 Brake

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General View - Air Filter

2 - 6 BS80/ 10.2007

2.4 Air Filter

1 Air filter

2 Primary filter element 3 Secondary filter element

1

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General View - Operator´s Station 2 - 7 BS80/ 10.2007

2.5 Operator´s Station

4 Emergency switch 5 Fuses 6 Control lever 1 Pedals 2 Safety lever

3 Water reservoir, window washer

2 3 4 6

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General View - Operator´s Station

2 - 8 BS80/ 10.2007

1 2

Pedals:

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

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Technical Data - Base Machine

3 - 1

BS80/ 06.2006

3 Technical Data

For the specifications of the base machine refer to Section 3.1. Section 3.2 provides wind speed information.

Note

For the shipping dimensions and weights of the base machine refer to Section 8.2. Special attachment system data can be found in the instruction of the assembly concerned.

3.1 Base Machine

Permissible inclinations of engine:

Note

At any greater inclinations, an adequate engine oil level is no longer ensured. In case higher degrees of inclination are required, consult with BAUER/SENNEBOGEN beforehand.

For further information on the engine, consult the engine manufacturer’s instruction.

Note

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

Engine Caterpillar C-15 Diesel Engine

Power output

(acc. to ISO9349) 354 kW (475 HP)at Nominal speed 1800 rpm

Cylinders 6

Capacity 14,6 l (14634 cm3)

left right front rear

30° 30° 30° 30°

Electrical system 24 volt

Hydraulic system Max. operating pressure 300 bar

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Technical Data - Base Machine

3 - 2 BS80/ 06.2006

Note

When running a machine in environmental temperatures outside the specified temperature range, special temperature packages are available (optional!).

Please contact SENNEBOGEN customer service if you have any other questions.

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Technical Data - Appendix 3 - 3 BS80/ 06.2006

3.2 Appendix

Wind Force Wind Speed Description Beaufort

number Name m/s km/h Onshore

0 Calm 0-0.2 1 Calm; smoke rises vertically

1 Light air 0.3-1.5 1-5 Direction of wind shown by drifting of smoke but not by wind vanes

2 Light breeze 1.6-3.3 6-11 Wind felt on the face; leaves rustle; ordinary vane moved by wind

3 Gentle

breeze 3.4-5.4 12-19 Leaves and small twigs in constant motion; wind extends light flag

4 Moderate

breeze 5.5-7.9 20-28 Raises dust and loose paper; twigs and small branches are moved 5 Fresh breeze 8.0-10.7 29-38 Small trees in leaf begin to sway; crested

wavelets form on inland waters

6 Strong

breeze 10.8-13.8 39-49 Large branches in motion; telegraph wires whistle; umbrellas used with difficulty

7 Moderate

gale 13.9-17.1 50-61 Whole trees in motion

8 Fresh gale 17.2-20.7 62-74 Breaks twigs off trees; generally impedes progress outdoors

9 Strong gale 20.8-24.4 75-88 Slight structural damage occurs (chimney pots and slates removed).

10 Whole gale 24.5-28.4 89-102 Trees uprooted; considerable structural damage occurs.

11 Storm 28.5-32.6 103-117 Widespread storm damage (very rarely experienced onshore).

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Technical Data - Appendix

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Preparing to Operate - Safety Information 4 - 1 BS80/ 06.2006

4 Preparing to Operate

4.1 Safety Information