sennebogen 830 E User manual

As of 830.0.xxxxOriginal operating instructions
830 / 07.2012
OPERATING INSTRUCTIONS
Model
830 E
Operating instructions
830.0.xxxx_us

Important notes about the operating instructions
W - 2 830 / 07.2012Original operating instructions
Foreword You have decided on a brand quality product from SENNEBOGEN.
Thank you for your selection.
It is very important to us that your SENNEBOGEN quality product
performs its work reliably, continually, and with no faults.
As you know, the reliability and durability of every machine is greatly
influenced by the regular and specialist service and maintenance work
performed on it.
We would therefore ask that you read the following service and
maintenance information thoroughly and that you implement it
accordingly.
For your own
safety Functionality, reliability, availability and advanced technology, e.g. the use of modern materials and technology, requires specially adapted
maintenance and repair methods. Only use genuine SENNEBOGEN
spare parts. Only allow authorized SENNEBOGEN partners to perform
work on your SENNEBOGEN machine. Improperly performed
maintenance or service work may result in consequential damages and
associated safety risks.
Parts and
accessories Use only genuine spare parts and accessory products that are authorized by SENNEBOGEN. These parts have been tested by
SENNEBOGEN for their safety and functional suitability in
SENNEBOGEN machines. SENNEBOGEN will not be held
responsible for any parts or accessory products that have not been
approved.
Warranty The warranty can become void if, for example:
Spare parts are not genuine SENNEBOGEN-approved spare parts
Maintenance is not performed at specified maintenance intervals
Maintenance has not been performed
Service and maintenance work has not been performed by a
SENNEBOGEN partner
Alterations are not authorized
In the event of damage, SENNEBOGEN reserves the right to demand
written verification that all maintenance work has been performed
correctly and completely!
SENNEBOGEN recommends special service and maintenance
contractswiththeauthorized SENNEBOGEN partnerofyourchoiceto
address these issues.

Important notes about the operating instructions
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Original operating instructions
830 / 07.2012
Notes on the
instructions Carefully read through the instructions, in particular Chapter 1 SAFETY, before beginning work with/on the machine.
CAUTION
Only work with/on the machine once you have read and completely
understood theseoperating instructions.
Refrain from operating and maintaining the machine in an unsafe
manner.
Do not operate machine if a fault has been detected.
The machine may be set up, operated and maintained by trained
personnel only.
The employer is responsible for the qualifications and training of
personnel.
These instructions are a part of the machine. Keep the instructions
in the cab at all times.
Recommended storage location: storage compartment behind the
driver's seat.
In the event of sale, disposal or loan,the operating instructions must
accompany the machine!
Contact SENNEBOGEN immediately if there is anything in the
operating instructions that you do not understand!
Your comments will help us to make the operating instructions even
more user-friendly.
Maintenance of the machine is described in separate instructions.
For reasons of clarity, the specified protective features are not
illustrated in some of the illustrations. Operation with protective
features removed is not permitted!

Important notes about the operating instructions
W - 4 830 / 07.2012Original operating instructions
Symbols and
illustrations These operating instructions contain safety instructions that highlight dangerous working practices. These safety instructions are marked
with a warning symbol and a signal word.
Thiswarning symbol means:Attention— this concerns yoursafety and
the safety of others.
The associated signal word signifies the degree of danger:
DANGER
Is used for serious, impending danger. If this danger is not avoided,
serious physical injuries or loss of life will result.
WARNING
Is used for potentially dangerous situations. If this danger is not
avoided, serious physical injuries or death may result.
CAUTION
Is used for potentially dangerous situations. If this danger is not
avoided, physical injuries or serious material damage may result.
Notes that make the work easier or contribute to better understanding
when operating the machine are illustrated in the following way:
Note
Indicates notes that draw your attention to special features.
Note
Indicates a cross reference to other documents.
Procedures are illustrated in tabular form as follows:
Listings are marked with bullet points.
– Sub-points in listings or procedures are marked with dashes.
Optional/special equipment
Designates instructions and information that depends on special
applications or special equipment.
1Press the switch (1).
2 Actuate the control lever (2).
3Unfasten the bolt (3).

Important notes about the operating instructions
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Original operating instructions
830 / 07.2012
Glossary of terms Operator
The operator (owner of the company/company) is whoever operates
the product and uses it in accordance with its intended use or allows
the product to be operated by suitable and instructed personnel.
Operating personnel
The operating personnel are those authorized by the operator to
operate the product.
Specialist personnel
Specialist personnel are those authorized by the operator to fulfill
certain tasks such as installation, setup, repair and maintenance and
troubleshooting.
Specialists
Specialists are those who, on the basis of specialist training,
knowledge and experience with the product and in the full
knowledge of the relevant standards, can appraise the work
allocated to them and can recognize potential dangers and avoid
them.
Instructed personnel
Trained personnel are those who have received instruction in the
tasks allocated to them and in the potential dangers of misuse and
misbehavior, who have been taught about the necessary protective
features,safetymeasures,relevantregulations,accidentprevention
guidelines and operating conditions and who have proved their
abilities.
Experts
Experts are those who, on the basis of specialist training and
experience have sufficientknowledge 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. EC directives, VDE
regulations,VBG) asto beable tojudgetheoperational safety of the
machine.
Inspectors
Experts are those who are authorized by the technical authorities
(TÜV) or by a trade association to check the machinery.
Authorization by the trade association is in accordance with the
“Principles for the authorization of inspectors for the testing of
cranes” (ZH 1/518). It is linked with the issue of an identification
number. This must be stated by the inspector in the test report and/
or test memo.
Authorizations can be limited to parts of tests or specified crane
types.

Important notes about the operating instructions
W - 6 830 / 07.2012Original operating instructions
Target group The machine has been developed for demanding work.
Persons working on or with the machine must be trained or instructed
for that purpose.
Detailed information on the prior knowledge and qualifications required of
the operator can be found in Chapter 1 SAFETY of these instructions.
Which documentation
belongs with the
machine?
The following documentation belongs with the machine:
These instructions
Maintenance instructions
Spare parts catalog
Service booklet
Wiring diagrams
Hydraulic layouts
Regulatory documents
Additional documentation from pre-suppliers.
Note
The complete scope of delivery is defined in the order confirmation.

Important notes about the operating instructions
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Original operating instructions
830 / 07.2012
How is the manual
organized? The manual is divided into 10 chapters:
1: Safety
Hereyouwillfind generallyvalidsafetyinstructions andmustalways
be complied with.
2: Overview
The main components of the machine are presented in chapter 2.
3: Technical data
Here you will find basic information concerning the machine,
e.g. Working loads.
4. Start-up
Here instructions on daily start-up are provided.
5: SENNEBOGEN Control System
Here you will find information on the SENNEBOGEN Control
System.
6. Operation
Here you will find information on operating elements and work
deployment.
7. Transport
Dimensions and weights of the machine are found in chapter 7.
8: Troubleshooting
This chapter contains instructions on recognizing the causes of
faults and how to correct them.
9: Setup tasks
Chapter 9 provides information on optional work tools.
10: Appendix
Here you will find an index of and additional information, about the
magnet unit.

Important notes about the operating instructions
W - 8 830 / 07.2012Original operating instructions
How to
contact us SENNEBOGEN Maschinenfabrik GmbH Hebbelstraße 30
94315 Straubing, Germany
Technical documentation:
Note
The addresses of the SENNEBOGEN sales and service partners can
be found on our homepage on the Internet.
Current when
going to press Ongoing development ensures advanced technology and a high level of quality in our machines. This may result in variations between these
instructionsandyourmachine. Errorscan alsonot beexcluded. Please
understand that no legal claims can be derived from the specifications,
illustrations and descriptions within these instructions.
Copyright ©Straubing 2012, SENNEBOGEN Maschinenfabrik GmbH
Reproduction, also in part, only with written permission of
SENNEBOGEN Maschinenfabrik GmbH, Straubing, Germany.
Printed in Germany.
Telephone: [phone]
Internet: http://www.sennebogen.de
Fax for Customer Service: [phone]
Fax for spare parts depot: [phone]
Email: [email protected]
Fax: [phone]

Table of contents
0 - 1
1 Safety 1-1
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Potential instances of misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5 Other risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6 Machine labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.6.1 USA identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.7 Responsibilities of the employer . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.8 Supplementary and operational equipment . . . . . . . . . . . . . . . . . 1-14
1.8.1 SENNEBOGEN CONTROL System (SENCON) . . . . . . . 1-14
1.8.2 Oils and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.8.3 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.8.4 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.8.5 coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.8.6 Fuel (not for equipment with electric motors) . . . . . . . . . . 1-20
1.9 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.9.2 Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
1.9.3 Safe entry and exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.9.4 Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
1.9.5 Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
1.9.6 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
1.9.7 Operation/driving operation . . . . . . . . . . . . . . . . . . . . . . . 1-34
1.9.8 Particle filter regeneration (level 4i) . . . . . . . . . . . . . . . . . 1-35
1.9.9 Setup work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
1.9.10 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
1.9.11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
1.9.12 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
1.10 Protective features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
1.11 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
1.12 Hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44
2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Overall machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Overall machine – crawler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.1 4-point outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Table of contents
0 - 2
2.3.2 Outrigger front/rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Undercarriage – crawler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5 Upper structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5.1 Side view with diesel engine . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5.2 Central electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.6 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.6.1 Compact boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.6.2 Pipe fracture safety devices . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.6.3 Attachments and Vario Tool (option) . . . . . . . . . . . . . . . . 2-13
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 Driving engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.1.2 Level 4/IIIb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.1 Crawler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Machine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4 Machine weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.5 Working loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.5.1 Lifting capacities 830 E . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.5.2 Compact boom 8.5 m and 7.0 m . . . . . . . . . . . . . . . . . . . . 3-7
3.5.3 Compact boom 8.5 m and 7.0 m . . . . . . . . . . . . . . . . . . . . 3-8
3.5.4 Compact boom 8.5 m and 7.0 m . . . . . . . . . . . . . . . . . . . . 3-9
3.5.5 Compact boom 8.5 m and 7.0 m . . . . . . . . . . . . . . . . . . . 3-10
3.5.6 Compact boom 9.0 m and 7.5 m . . . . . . . . . . . . . . . . . . . 3-11
3.5.7 Compact boom 9.8 m and 7.5 m . . . . . . . . . . . . . . . . . . . 3-12
3.6 Warning and notice labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.7 Wind speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.8 Conversion factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.9 Tightening torques for screws . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
4 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Tests before start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.1 Service access door locking device . . . . . . . . . . . . . . . . . . 4-4
4.4 Initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.5 Inspections before daily start-up . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.6 Tests before start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9