830.0.3433 WA Book en 1.0

Maintenance instructions
830.0.3433
Material handling machine
830.0.3433 en
Maintenance instructions
Read this manual prior to performing any task!

SENNEBOGEN Maschinenfabrik GmbH
Hebbelstraße 30
94315 Straubing
Telephone: +49 9421 540-0
E-mail: documentation@sennebogen.de
Internet: http://www.sennebogen.com
Translation of the original maintenance instructions
830.0.3433_WA, 1, en_US
© SENNEBOGEN Maschinenfabrik GmbH
2 830.0.3433 Material handling machine 07.07.2022

Supplemental directives
Introductory remarks You have purchased a high-quality, brand name product from
SENNEBOGEN. We thank you for your decision.
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 mainte-
nance 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, such
as the use of modern materials and technology, require specially
adapted maintenance and repair methods. Only use genuine
SENNEBOGEN spare parts. Consequently only allow authorized
SENNEBOGEN partners to perform the appropriate tasks on your
SENNEBOGEN machine. Improperly performed maintenance or
service tasks can 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 be invalidated, for example, if:

n Original SENNEBOGEN spare parts are not used
n Maintenance is not performed at the specified maintenance
intervals
n Maintenance is not executed
n Service and maintenance tasks are not executed by a
SENNEBOGEN Partner.
In the event of damage, SENNEBOGEN reserves the right to
demand written verification of all correctly and completely executed
maintenance tasks!
In this regard, SENNEBOGEN, recommends special service and
maintenance contracts with the authorized SENNEBOGEN Partner
of your choice.
Instructions regarding the oper- Read through the manual carefully, in particular chapter 1,
ating manual SAFETY, before working with/on the machine.
07.07.2022 830.0.3433 Material handling machine 3

ATTENTION
n Only commence work with or on the machine once you have
read and fully understood these operating instructions.
n Refrain from operating and maintaining the machine in an
unsafe manner.
n Do not commission the machine if a defect has been detected.
n The machine must be set up, operated and maintained by
trained personnel only.
n The owner is responsible for the qualifications and training of
personnel.
n This manual is a component of the machine. Keep the manual
in the cab at all times.
Recommended storage location: Storage compartment behind
the driver seat. In the event of sale, hand-over or lease, the
manual must accompany the machine!
n Contact SENNEBOGEN immediately if there is anything in the
manual that you do not understand!
Your comments will help us to make the operating instructions
even more user-friendly.
For reasons of clarity, the specified protective devices are not
shown in some of the illustrations. Operation with protective
devices removed is not permissible!
Presentation methods This manual contains safety notices that make you aware of dan-
gerous working practices. These safety notices are marked with a
safety alert symbol and a signal word.
This warning symbol means: Notice – this concerns your safety
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
loss of life can result.

CAUTION!
Is used for potentially dangerous situations. If this
danger is not avoided, physical injuries or serious
material damage can result.
Information that makes the work easier or contributes to better

understanding when operating the machine is presented in the
following manner:
Indicates notes that draw your attention to special

features.
Optional/special equipment
Designates instructions and information, which depends on spe-
cial applications or special equipment.
Indicates instructions or notes that alert to particularities of a

machine with mobile undercarriage.
Indicates instructions or notes that alert to particularities of a

machine with crawler undercarriage.
Hand tighten.
Tightening torque for screws or nuts. (In this case: 50 Nm)
Fork wrench with width across flats. (In this case: 13 mm)
Flat-blade screw driver

Phillips screw driver
Allen key. The size specification refers to the perpendicular dis-

tance of two parallel sides of a hexagonal cross-section. (In this
case: 32 mm)
Square box key. The size specification refers to the perpendicular

distance between two parallel sides of a square cross-section. (In
this case: 32 mm)
Connect dial gauge or manometer.
Instructions are described as follows:

1. Press switch (1).
2. Activate control lever (2).
3. Unlock the bolt (3).
n Lists are marked with squares.

– Sub-points in lists or instructions are marked with dashes.
Definition of terms Owner

The owner (entrepreneur/enterprise) 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
Operating personnel are those persons authorized by the owner to
operate the product.
Specialist personnel
Specialized personnel are those persons authorized by the owner
to fulfill certain tasks such as installation, setup, repair and mainte-
nance, and troubleshooting.

n Specialist
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.
n 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 regula-
tions, accident prevention guidelines and operating conditions
and who have proved their abilities.
n 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 occu-
pational safety guidelines, accident prevention guidelines, reg-
ulations, and generally recognized technical regulations (such
as EC (EU) directives, VDE regulations, ACTU) to enable them
to judge the operational safety of the machine.
n Inspectors
Experts are those who are authorized by the technical authori-
ties (TÜV) or by a trade association to check the machinery.
Authorization by the trade association is issued in accordance
with the "Principles for the authorization of inspectors for the
testing of cranes" (ZH 1/518). The authorization is linked with
the issue of an identification number. This must be specified
by the authorized expert/inspector in the test report and/or test
certificate. Authorizations can also be restricted to sub-areas of
inspections or specific crane types.
Target group This machine has been developed for sophisticated tasks. Persons
who work on or with the machine must be trained or instructed for
this purpose.
Detailed information on the prior knowledge and qualifications
required of the operator can be found in chapter 1, SAFETY, of
this manual.
What documents are part of the The following documents are considered as part of the machine:
machine?
n This manual
n Operating manual
n Spare parts catalog
n Supplemental documentation from upstream suppliers.
The order confirmation states all items included in

the scope of supply.

Accuracy when going to press Ongoing development guarantees the advanced technology and
the high quality of our machines. This may result in variations
between this manual and your machine. Also, errors cannot
be excluded. Please understand that no legal claims can be
derived from the specifications, illustrations, and descriptions in
this manual.

Table of contents
Table of contents
1 Safety................................................................................. 16
1.1 General....................................................................... 16
1.2 Residual risks............................................................. 16
1.3 Responsibilities of the owner...................................... 17
1.4 Recording service work or recurring tests.................. 21
1.5 Auxiliary materials and operating materials................ 22
1.5.1 SENNEBOGEN CONTROL System (SENCON)..... 22
1.5.2 Oils and lubricants................................................... 23
1.5.3 Diesel fuel................................................................ 23
1.5.4 Engine oil................................................................. 24
1.5.5 Coolant.................................................................... 25
1.5.6 Fuel (not for equipment with electric motors)........... 28
1.6 Maintenance............................................................... 28
1.7 Cleaning...................................................................... 32
1.8 Welding....................................................................... 36
1.9 Safe entry and exit...................................................... 37
1.9.1 General information................................................. 37
1.9.2 Cab without gallery access ladder........................... 38
1.9.3 Cab with gallery access ladder................................ 39
1.9.4 Rigid cab access ladder........................................... 40
1.9.5 Uppercarriage access ladder................................... 41
1.9.6 Uppercarriage crawler access ladder...................... 42
1.9.7 Uppercarriage attachment machine access
ladder....................................................................... 42
1.9.8 Uppercarriage with gallery access ladder................ 43
1.9.9 Uppercarriage electric motor access ladder............ 44
1.9.10 Access ladder to uppercarriage electric motor with
gallery.................................................................... 44
1.9.11 Emergency exit...................................................... 47
1.10 Safety equipment...................................................... 49
1.11 Disposal.................................................................... 49
1.11.1 Disposal of lubricants and operating fluids............ 49
1.11.2 Disposal of batteries............................................... 50
2 Maintenance schedule...................................................... 51
2.1 Safety instructions...................................................... 51
2.2 Daily/weekly maintenance.......................................... 52
2.2.1 Daily/weekly maintenance....................................... 52
2.3 One-time maintenance............................................... 55
2.3.1 After 50 operating hours at the latest....................... 55
2.3.2 After 250 operating hours at the latest..................... 55
2.4 Regular maintenance/Maintenance interval............... 57
2.4.1 Monthly or at the latest after250 operating hours.... 57
2.4.2 Every 6 months or at the latest after 500 operating
hours........................................................................ 61

Table of contents
2.4.3 Once a year or at the latest after 1000 operating

hours........................................................................ 64
2.4.4 Every 2 years or at the latest after 4,000 operating
hours........................................................................ 68
2.4.5 At the latest after 2000 operating hours................... 69
2.4.6 At the latest after 3000 operating hours................... 71
2.4.7 At the latest after 4,000 operating hours.................. 71
2.4.10 At the latest after 10,000 operating hours.............. 74
3 Technical data................................................................... 77
3.1 General....................................................................... 77
3.2 Drive engine................................................................ 77
3.2.2 US EPA Tier 3/EU Stage IIIa................................... 78
3.2.3 US EPA Tier 4f / EU Stage IV.................................. 78
3.2.4 US EPA Tier 4f / EU Stage V................................... 79
3.2.5 Electric motor........................................................... 79
3.3 Machine (fill levels)..................................................... 79
3.4 Conversion factors...................................................... 82
3.5 Tightening torques...................................................... 83
3.5.2 Standard connections.............................................. 83
3.5.3 Rotary connection.................................................... 85
4 General Controls............................................................... 86
4.1 Buzzer and indicator light self-test
[Quick-changer check] regeneration........................... 86
4.2 Checking the function of the hydraulic quick-changer
system........................................................................ 86
5 Lubricating the machine.................................................. 87
5.1 Lubricating the machine automatically........................ 87
5.1.1 General.................................................................... 87
5.1.2 Overview of lubrication systems.............................. 87
5.1.3 Uppercarriage central lubrication system................ 88
5.1.4 Undercarriage central lubrication system (option)... 93
5.1.5 Automatic slewing ring pinion lubrication................. 97
5.1.6 Central lubrication system of the grapple.............. 103
5.2 Lubricating the machine manually............................ 107
5.2.1 General.................................................................. 107
5.2.2 Manual operation of the central lubrication system
for the uppercarriage............................................. 108
5.2.3 Lubricating the lubricating points on the central
lubricating bar for the undercarriage...................... 108

Table of contents
5.2.4 Distributed manual lubrication points on Mobile

undercarriage......................................................... 109
5.2.5 Distributed manual crawler undercarriage lubrica-
tion points............................................................... 112
6 Drive engine..................................................................... 114
6.1 Safety instructions..................................................... 114
6.2 Engine oil.................................................................. 114
6.2.1 General information................................................ 114
6.2.2 Detailed view of the diesel engine......................... 116
6.2.3 Check engine oil level............................................ 117
6.2.4 Changing the engine oil and oil filter...................... 117
6.3 Air filter...................................................................... 117
6.3.1 General information................................................ 117
6.3.2 Detailed view – air filter system.............................. 118
6.3.3 Replacing the air filter............................................ 118
6.3.4 Cleaning the air filter pre-separator....................... 119
6.3.5 Checking the air intake system.............................. 119
6.4 Fuel system (US EPA Tier 3 / EU Stage IIIa / US EPA
Tier 4f / EU Stage IV / US EPA Tier 4f / EU Stage
V).............................................................................. 121
6.4.1 Detailed view of the fuel system............................ 121
6.4.2 Visual inspection of the water separator to check
for dirt and water.................................................... 122
6.4.3 Changing the diesel pre-filter cartridge.................. 122
6.4.4 Changing the diesel fine filter filter cartridge.......... 122
6.5 Replacing the fuel tank vent filter.............................. 122
6.6 Exhaust after-treatment system................................ 122
6.6.1 Checking the DEF level......................................... 123
6.6.2 Performing a visual check of the exhaust aftertreat-
ment system for damage, leaks............................. 123
6.6.3 Cleaning the DEF tank filling filter.......................... 124
6.6.4 Replacing the container filter for the DEF tank...... 124
6.6.5 Replacing the DEF (AdBlue) supply module......... 124
6.6.6 Checking the diesel particulate filter...................... 124
6.7 Combination cooler, coolant..................................... 124
6.7.1 Checking the coolant level..................................... 124
6.7.2 Coolant - Cummins engine.................................... 126
6.7.3 Checking the coolant level and topping up the anti-
freeze..................................................................... 126
6.8 Cleaning the cooling system..................................... 126
6.8.1 Safety instructions................................................. 126
6.8.2 Using fan reversal to clean the combination
cooler..................................................................... 127
6.8.3 Visual inspection of the combination cooler........... 128
6.8.4 Check and clean combination cooler..................... 129
6.8.5 Interior cleaning of the cooling system.................. 130
6.9 Visual inspection of the diesel engine V-belts........... 131

Table of contents
6.10 Electric motor.......................................................... 132

6.10.1 Performing the initial inspection........................... 132
6.10.2 Performing the major inspection.......................... 132
6.10.3 Lubricating the roller bearings............................. 133
7 Undercarriage.................................................................. 134
7.1 Safety instructions.................................................... 134
7.2 Notice........................................................................ 134
7.3 Mobile undercarriage................................................ 135
7.3.1 Cleaning the mobile undercarriage........................ 135
7.3.2 Tightening the wheel lug nuts................................ 135
7.3.3 Measuring the wear of the brake........................... 136
7.3.4 MP38E axle distribution gearbox........................... 137
7.3.5 MP26E / MP30E / MP31E - Hub drives................. 140
7.3.6 MP38E hub gear.................................................... 141
7.3.7 MP26E / MP30E / MP31E - Differential................. 143
7.3.8 MP38E differential.................................................. 145
7.3.9 Oil change at differential........................................ 146
7.3.10 MP42E - Intermediate gear and differential......... 149
7.3.11 Oil change at parking disc brake.......................... 150
7.3.12 MP31E/MP38E drive shafts................................. 152
7.4 Crawler undercarriage.............................................. 154
7.4.1 Carrying out a visual inspection of the crawler
chassis................................................................... 154
7.4.2 Cleaning and lubricating........................................ 154
7.4.3 Crawler travel drive................................................ 155
7.4.4 Crawler track.......................................................... 156
7.4.5 Retighten the sprocket screws............................... 158
7.4.6 Checking the fastening screws on the base plates
for firm seat and tightening if necessary................ 158
7.5 Rail undercarriage.................................................... 158
7.5.1 Cleaning and lubricating........................................ 158
7.5.2 Travel gear............................................................. 159
7.5.3 Track wheels.......................................................... 160
7.5.4 Cable drum............................................................ 161
7.5.5 Geared motor......................................................... 161
7.6 Structure................................................................... 161
7.6.1 Middle bridge clamp - Stabilizer box...................... 161
7.6.2 Ballast.................................................................... 162
7.6.3 Outrigger................................................................ 163
8 Rotary connection.......................................................... 164
8.2 General information.................................................. 164
8.3 Lubricating the slewing ring bearing race................. 165
8.3.1 Central lubrication system..................................... 165
8.4 Lubricating the slewing ring gearing......................... 168

Table of contents
8.4.1 Gear spray (option)................................................ 168

8.4.2 Lubricating the slewing ring pinion......................... 168
8.5 Slewing gear box...................................................... 171
8.6 Visual inspection of the seals on the rotary connec-
tion for the slewing ring............................................. 174
8.7 Visual inspection of the slewing ring screw connec-
tion............................................................................ 175
8.8 Using wear measurement to check the bearing play
of the rotary connection for the slewing ring............. 176
8.9 Checking the preload of the bolts of the rotary con-
nection of the slewing ring........................................ 176
9 Hydraulic system............................................................ 177
9.2 General information.................................................. 178
9.2.1 Hydraulic hoses..................................................... 178
9.2.2 Hydraulic cylinder.................................................. 180
9.2.3 Piston accumulators.............................................. 181
9.2.4 Safety valves......................................................... 183
9.2.5 Threaded unions.................................................... 183
9.2.6 Hydraulic pumps.................................................... 183
9.2.7 Depressurizing the hydraulic system..................... 185
9.3 Measuring the hydraulic pressure............................. 185
9.3.1 General.................................................................. 185
9.3.2 Measurement equipment....................................... 186
9.3.3 Check hydraulic pressure on measuring block...... 186
9.4 Hydraulic oil.............................................................. 193
9.4.1 General information............................................... 193
9.4.2 Checking the hydraulic oil level and topping up the
hydraulic oil............................................................ 194
9.4.3 Remove hydraulic oil sample for Shell LubeAna-
lyst......................................................................... 196
9.4.4 Removing oil sludge.............................................. 197
9.4.5 Checking the hydraulic oil tank for cracks............. 197
9.4.6 Adding hydraulic oil................................................ 197
9.4.7 Changing the hydraulic oil and removing oil
sludge.................................................................... 197
9.4.8 Change hydraulic leakage oil filter......................... 198
9.4.9 Change the hydraulic oil return filter...................... 198
9.4.10 Replacing the aeration filter................................. 199
9.4.11 Change HydroClean filter element....................... 200
9.4.12 Change pilot filter................................................. 200
9.4.13 Boom high-pressure filter (option) – change filter
element................................................................ 200
9.4.14 Replacing supply pressure filter elements........... 201
9.4.15 Having the hydraulic oil cooler checked by an
authorized workshop............................................ 201
9.5 Pump distributor gearbox.......................................... 201

Table of contents
9.5.1 General.................................................................. 201

9.5.2 Checking the oil level............................................. 202
9.5.3 Changing the gear oil............................................. 203
9.5.4 Checking seals and bolts for leaks........................ 203
9.5.5 Refilling the roller bearings with grease................. 204
10 Electrical system............................................................. 205
10.1 Safety instructions.................................................. 205
10.2 Checking the battery, the battery cable, and the bat-
tery connections...................................................... 205
10.3 Disconnecting the electrical system from the battery
(battery disconnect switch)..................................... 206
10.4 Using the maintenance lock (lockout-tagout) for the
battery disconnect switch (option).......................... 207
10.4.1 Attaching the maintenance lock........................... 208
10.4.2 Removing the maintenance lock.......................... 209
10.5 Replacing fuses...................................................... 209
10.6 Replacing switches or switch bulbs........................ 210
10.7 Generator (option)................................................... 211
10.8 Additional displays (optional equipment)................ 211
10.9 Electrical system switch cabinet............................. 213
10.9.1 Replacing switch cabinet filter elements.............. 213
10.9.2 Clean the switch cabinet...................................... 216
11 Heating/air conditioning evaporator............................. 217
11.1 Safety instructions................................................... 217
11.2 Air conditioning system........................................... 217
11.2.1 Safety instructions................................................ 217
11.2.2 Visual inspection of the air conditioning system... 218
11.2.3 Checking the air conditioning system.................. 218
11.2.4 Cleaning the fresh air filter................................... 221
11.2.5 Cleaning the recirculating-air filter of the air condi-
tioner.................................................................... 221
11.2.6 Air conditioning compressor................................. 222
11.2.7 Cleaning the recirculating air filter of the heating
system.................................................................. 223
11.2.8 Cleaning/replacing the heating system outside air
filter...................................................................... 224
11.2.9 Topping up/replacing refrigerant.......................... 224
11.2.10 Have heating system/air conditioning system
checked by authorized workshop....................... 224
11.2.11 Change climate control system collection dryer. 225
11.2.12 Change climate control system oil..................... 225
11.3 Auxiliary heating system (option)............................ 225
12 Steel structure and static load-bearing parts............... 226
12.1 Safety instructions.................................................. 226
12.2 Checking static load-bearing parts and steel compo-
nents for damage.................................................... 226

Table of contents
13 Checking the safe mounting of the counterweight ele-

ments............................................................................... 227
14 List of abbreviations....................................................... 228
Appendix.......................................................................... 229
A Warranty manual.......................................................... 230

Safety
General
1 Safety
1.1 General
The machine is built to state-of-the art standards. Nevertheless,
there may be dangers during its use to personnel, machine, and
other material assets, if
n The machine is not used as intended
n The machine is not operated or maintained by trained per-
sonnel
n The safety instructions are not complied with
n The machine has defects
n The attached tools do not comply with the relevant safety regu-
lations
n the attached tools have defects.
National and international regulations apply in addition to the safety
instructions in this manual.
In the Federal Republic of Germany, for example:
n Winches, Lifting and Pulling Equipment (BGV D8)
n Cranes (BGV D6)
n Crane Inspections (BGG 905)
n EC Machinery Directive 2006/42/EC
n EMC Directive 2004/108/EC
n Electrical Equipment of Machinery (EN 60204-1)
n Safety Requirements for Fluid Power Systems and their Com-
ponents – Hydraulic Systems (EN 982)
n Earth-Moving Machinery – Safety (EN 474-1/-5)
n Safety of Machinery (DIN EN 12100-1 and DIN EN 12100-2)
n "Outdoor" guideline 2000/14/EC and 2005/88/EC
If national regulations in the country of operation

deviate from our recommendations, the more strin-
gent procedure should be followed.
1.2 Residual risks

The safety instructions in this operating manual are guidelines
for the safe use of the machine by qualified machine operators.
However, SENNEBOGEN cannot foresee every situation that can
create a hazard in practice.
This is why the safety notices and warnings on the machine and in
the operating manuals are not exhaustive. The owner and machine
operator still remain responsible for safety.
Warning signs and information signs attached to the machine also
refer to residual risks.

Safety
Responsibilities of the owner
1.3 Responsibilities of the owner

Definition of terms Owner
The owner (entrepreneur / enterprise) 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
Operating personnel are those persons authorized by the owner to
operate the product.
Specialized personnel
Specialized personnel are those persons authorized by the owner
to fulfill certain tasks such as installation, setup, repair and mainte-
nance, and troubleshooting.
n Specialists
Specialists are those persons 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 and avert potential
dangers.
n Instructed personnel
Instructed personnel are those persons who have received
instruction in the tasks allocated to them and in the potential
dangers of misuse and improper behavior, who have been
taught about the necessary safety equipment, safety meas-
ures, relevant regulations, accident prevention guidelines and
operating conditions and who have proved their abilities.
n Experts
Experts are those persons 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 reg-
ulations (e.g., EC directives, VDE regulations, VBG) as to be
able to judge the operational safety of the machine.
n Authorized experts
Authorized experts are those persons who are authorized by
the technical authorities (TÜV) or by a trade association to
inspect the machinery. Authorization by the trade association is
issued in accordance with the "Principles for the authorization
of inspectors for the testing of cranes" (ZH 1/518). The authori-
zation is linked to the issuing of an identification number. This
identification number must be quoted by the authorized expert
in the test report and/or on the test certificate. Authorizations
can also be restricted to sub-areas of inspections or specific
crane types.

Safety
Operating instructions
WARNING!
The owner is obliged to supply operating
instructions when working with hazardous
machinery or materials.
The necessary information is contained in:
– EC directives on occupational health and
safety
– National laws on occupational health and
safety
– Accident prevention regulations
– This operating manual
Routine checks Expert inspection, required for crane or excavating operation

The machine must be thoroughly inspected by an expert:
n before commissioning and before operating the machine after
significant modifications
n at least once yearly
n intermittently depending on operating and company conditions.
An expert in this context is a person who
n has extensive knowledge of this machine and the relevant reg-
ulations and guidelines due to technical training and
n through special instruction by SENNEBOGEN
can assess the safe working condition of this machine, and the
directives and regulations that apply for this machine, and can
evaluate the operationally reliable status of the machine.
Expert inspection, only required for crane operation
The following cranes must be inspected by an authorized expert
every 4 years:
n Power operated vehicle cranes
n Truck-mounted cranes
The inspection by an authorized expert must be carried out in the
13th year of operation and every year thereafter.
Faults that are detected in recurring inspections must be eliminated
within a suitable time frame depending on how serious a safety
hazard they pose.
Personnel selection and qualifica- The machine must only be operated and maintained by qualified
tions personnel.
n Only assign work to trained or instructed personnel.
n Define responsibilities for operation and maintenance.
n Comply with the permitted statutory minimum age.

Safety
CAUTION!
– Personnel undergoing training or instruction
must remain under the constant supervision
of a specialist while they are working on the
machine.
– Work on the machine's electrical equipment
must only be carried out by a qualified spe-
cialist electrician.
– Work on travel gear, braking systems, and
steering systems must only be carried out by
trained specialized personnel.
– Work on hydraulic equipment must only be car-
ried out by personnel with specific knowledge
and experience in the area of hydraulic sys-
tems.
– Work on hydro-pneumatic devices must only
be carried out by personnel with specific knowl-
edge and experience in the areas of hydro-
pneumatics and hydraulic systems.
Technical condition of the machine The owner is under constant obligation to monitor the overall tech-
nical condition (apparent defects and damage, as well as changes
in the operating behavior) of the machine.
Do not operate the machine if a fault has been detected!
Observe the mandatory intervals for routine checks.
All damage and incidents are subject to mandatory logging and
data storage regulations.
It must be possible to vacate the The owner must take precautions to ensure the cab can be
cab safely in case of emergency vacated safely in case of emergency, taking into account local
conditions and how the machine is being operated.
Unauthorized modifications and For safety reasons, the machine must not be modified or altered in
spare part production any way.
This applies also for the installation and use of safety devices and
valves, as well as for welding on load bearing parts.
Genuine SENNEBOGEN spare parts and accessories ensure the
safety of personnel. Parts and equipment from other manufacturers
are not tested by SENNEBOGEN and are not approved. The use
of third-party components can alter the machine's characteristics
and pose a safety hazard.
If third-party components are used, SENNEBOGEN cannot be held
liable for any resulting consequences.
Impermissible modes of operation n The operating safety of the machine can only be assured sub-
ject to use as intended as specified in this manual.
n The specified capacity specifications must be respected.

Safety
n The capacity data listed in the instructions must not be

exceeded.
n If there is a risk of heavy items dropping, only use the machine
if the driver's area is covered by a protective roof (FOPS). The
protective roof is available from SENNEBOGEN as an optional
extra.
Specific dangers The machine owner must check whether its operation poses spe-
cific dangers, e.g., due to toxic gases, soil condition, etc., and take
appropriate measures to avoid or limit such dangers.
Use outside Germany If the machine is used outside Germany:

n Comply with the safety regulations of the country of use.
n Ensure that operating personnel have the necessary qualifica-
tions for the intended tasks.
n Ensure that the contents of this manual are read and fully
understood. If necessary, procure the manual in the appro-
priate official language from SENNEBOGEN.
Dangers of non-compliance with Non-compliance with safety instructions is dangerous and can be
safety instructions hazardous to persons, as well as to the environment and the
machine. Non-compliance will also will also lead to forfeiture of
any and all rights to claims for damages.
Fire extinguisher Fire extinguishers are only suitable as a first measure when
fighting incipient fires. If you are not absolutely certain that you
can put the fire out, it is more important to get yourself and others
to safety.
The storage location of the fire extinguisher is marked by a red
sticker.
SE 187974
Fig. 1: Fire extinguisher
1. First call the fire department.

2. Deploy the fire extinguisher in short bursts until the fire is out.
Follow the instructions on the fire extin-

guisher.
3. Have the fire extinguisher serviced and topped up after use.

Safety
Recording service work or recurring tests
First-aid kit (option) A first-aid kit is included for emergencies.

Top up the first-aid kit after use.
Note the expiry date on the first-aid kit.
Warranty The warranty terms of SENNEBOGEN Maschinenfabrik GmbH are

summarized in the warranty manual.
1.4 Recording service work or recurring tests

Records n Service and repair work must be performed and recorded in
accordance with the manufacturer's instructions.
n Recurring tests must be performed and recorded in accord-
ance with the manufacturer's instructions.
Together with your service partner, record all service and
repair work or recurring tests performed on your machine in
SENtrack.
ð A full record of all service and repair work is essential
for any warranty claims and will increase the value when
selling the machine.
Further notes Ä Chapter 1.3 “Responsibilities of the owner” on page 17

Ä Appendix A “Warranty manual” on page 230
User manual for SENtrack telemetry system

Safety
Auxiliary materials and operating materials > SENNEBOGEN CONTROL System (SENCON)
1.5 Auxiliary materials and operating materials

1.5.1 SENNEBOGEN CONTROL System (SENCON)
NOTICE!
Sensors monitor the current operating status of the
machine and transmit the measurement results to
the SENCON. The measurement results are evalu-
ated in the SENCON and displayed automatically
or at the push of a button on the unit. The indicator
lights and warning lights are activated if irregulari-
ties occur on the machine.
Correct a minor fault condition (clogged air filter,
empty fuel tank or the like) by yourself without
delay.
Contact SENNEBOGEN Customer Service to cor-
rect a more serious irregularity (one that you
cannot correct yourself).
SENNEBOGEN CONTROL System
CAUTION!
The SENNEBOGEN CONTROL system must
never be cleaned with cleaning agents containing
alcohol or solvents. Failure to comply with this
instruction will result in damage to the plastic sur-
face.

Safety
Auxiliary materials and operating materials > Diesel fuel
1.5.2 Oils and lubricants
NOTICE!
Only use oils and lubricants approved by
SENNEBOGEN. These are listed in the LUBRI-
CANTS TABLE. The ambient temperature for oper-
ating the machine can be between -20 °C and
50 °C.
If the temperature at the site is outside these
values, consult with your SENNEBOGEN Service
Partner before start-up.
WARNING!
Mixing different types of oils, lubricants, or oper-
ating fluids is not permissible!
Pouring in or mixing different types of oils, lubri-
cants, or operating fluids (such as hydraulic oil,
gear oil, engine oil, or coolant) may cause damage
to machine components due to chemical reactions.
This consequence can result in significant material
damage and personal injuries.
Only use oils, lubricants and operational fluids that
are approved by SENNEBOGEN. Only mix oils,
lubricants, and operating fluids that are of the
same type or identical (same specifications) from
one manufacturer!
Oil diagnosis Regular oil diagnosis helps to avoid unnecessary costs. A series of
tests will determine:
n the condition of the oil
n Amount of abraded metal particles in the sample
n Wear rate of components
recommended for the hydraulic system.
Further information is available from

SENNEBOGEN service partner.
1.5.3 Diesel fuel

The machine comes filled with diesel fuel by SENNEBOGEN which
conforms to EN 590 as well as ASTM D975 ULSD with a sulfur
content of < 15 mg/kg.

Safety
Auxiliary materials and operating materials > Engine oil
NOTICE!
Risk of engine damage due to use of high-
sulfur fuels
The use of fuels that contain more than 15 mg/kg
of sulfur can cause severe damage to the engine
and exhaust aftertreatment system. This can inva-
lidate the emission certification of the diesel engine
and have legal consequences for the owner.
Fig. 2: Information sign concerning the
use of sulfur-free fuel on the diesel – Only use fuels with a sulfur content of no more
tank filler neck than 15 mg/kg.
– Observe the information in the engine manu-
facturer’s operating manual.
The use of sulfur-free fuel in accordance with EN 590 or

ASTM D975 ULSD is strictly required for engines of the following
exhaust levels:
n US EPA Tier 4f / EU Stage IV
n US EPA Tier 4f / EU Stage V
The use of fuels with a sulfur content greater than

15 mg/kg is permitted under certain circumstances
for engines subject to US EPA Tier 3 / EU Stage
IIIa emissions standards. This however requires
the use of an engine oil with special properties
matched to this requirement. Engine oil filled at the
SENNEBOGEN factory is not suitable for this use
and must be replaced.
1.5.4 Engine oil

The SENNEBOGEN factory filling of engine oil is selected for use
with sulfur-free diesel fuel with a sulfur content of <15 mg/kg.

Safety
Auxiliary materials and operating materials > Coolant
NOTICE!
Damage to the exhaust aftertreatment system
caused by using the wrong engine oils
Using the wrong engine oil will damage the
exhaust aftertreatment system. This can invalidate
the emission certification of the diesel engine and
have legal consequences for the owner.
– Use engine oils meeting the prescribed specifi-
cation.
The use of low-ash API CJ-4 or API CK-4 engine oils is strictly
required for engines of the following exhaust levels:
n US EPA Tier 4f / EU Stage IV
n US EPA Tier 4f / EU Stage V
The use of engine oils with specifications other

than API CJ-4 or API CK-4 is permissible for
engines of exhaust level III a / US EPA Tier 3.
1.5.5 Coolant
General
WARNING!
Mixing coolants and adding cooling system sealing
agents or antifreeze that contains sealing agents is
not permissible.
By filling or mixing different types of cooling fluid or
cooling agent additives, gelling, for example, can
occur in the coolant, causing the cooler to clog
(deposits) and resulting in the engine overheating,
or failure of the cooling system, and the associated
engine damage.

Safety
NOTICE!
Observe the instructions on the coolant sticker in
the radiator area.
If the ambient temperature at the implementation
site is under this value -36 °C/-34 °F, comply with
the instructions in the operating manual of the
engine manufacturer or contact SENNEBOGEN
Customer Service before commissioning.
NOTICE!
If only a small amount (up to maximum 5 l/1.3 gal.)
is required to fill the water-coolant circuit and no
suitable coolant is available, you can add clean
water to top up in the meantime.
However, we recommend that you test the concen-
tration as soon as possible before temperatures
drop to freezing. In some cases, you must top up
with the appropriate coolant so that the required
concentration to prevent freezing is again ensured.
The mixture of water and anti-freeze agent not only
ensures frost protection, it is also important for
corrosion protection. This also requires checking
the correct concentration and adjusting when nec-
essary.
CAUTION!
Observe the instructions in the operating manual
provided by the engine manufacturer. These
instructions are for the operational reliability of the
machine.
Water
NOTICE!
– SENNEBOGEN recommends distilled water as
the best option. In exceptional cases, clean,
neutral, filtered, fairly soft fresh water can be
used.
– Comply with the specifications provided by the
engine manufacturer!
– Do not use ditch water, industrial drain water,
salt water, sea water or rain water.
– Always fill using a mixture of water and refrig-
erant. Observe the mixing ratio. Mix before
filling!
Ensure that the water has the following characteristics:

Safety
pH value 7-8
Chloride content maximum 40 ppm
Sulfate content maximum 100 ppm
Water hardness 3-12°dGH
Ca + Mg maximum 70 ppm
NOTICE!
Observe the recommended mixing ratio (see man-
ufacturer's specifications). If the content of anti-
freeze agent is too high, the cooling and frost pro-
tection properties will be adversely affected.
CAUTION!
Comply with the specifications of the coolant man-
ufacturer.
WARNING!
Never fill with coolant when the engine is warm.
This will damage the engine. Allow the engine to
cool first.
Observe the coolant manufacturer's use guide-
line/use instructions to avoid possible health haz-
ards or environmental hazards.
Changing coolant
WARNING!
Danger of scalding!
Be careful when draining hot coolant! Allow the
engine to cool first. Collect the coolant in a suit-
able container when draining and dispose of it in
accordance with regulations.
– The cooling system must be emptied com-
pletely before filling again.
– Rinse the cooling system several times with
clean water to get rid of any residue.
– Fill the cooling system and, after a short
waiting period, check the level.
– Start the engine and check the coolant level

Safety
Maintenance
CAUTION!
Adjustment of the correct fill level of the coolant
must be checked several times if necessary.
Check the coolant level regularly, paying special
attention to:
– lubricant in the coolant circuit,
– conspicuous opacity caused by corrosion res-
idue or other suspended substances.
If any of these conditions is identified, the coolant
must be replaced as described above.
Change intervals Information on changing the coolant and change intervals is pro-
vided in the operating manual provided by the engine manufac-
turer.
1.5.6 Fuel (not for equipment with electric motors)

Fill the tank with the specified grade of fuel. Clean fuel is essential
for trouble-free operation of the diesel engine.
Notice on quality and fuel selection:

provided by the engine manufacturer.
1.6 Maintenance

Safety
Maintenance
WARNING!
– Comply with the instructions posted on all
labels and safety stickers on the machine, as
well as those in the manual. They contain
important information about maintenance pro-
cedures.
– The listed tasks must only be executed by
trained and instructed specialists.
– Wear personal protective equipment (for
example, hard hat, hearing protection, protec-
tive gloves, safety footwear) if the work condi-
tions require it. At working heights of 2.00 m or
more, SENNEBOGEN recommends the use of
a safety harness to prevent falling. At working
heights of 3.00 m or more, using a safety har-
ness is a legal requirement.
The hook-in eyes are marked.
– Use only original SENNEBOGEN spare parts.
– Use only oils and lubricants listed in the lubri-
cant table.
– Collect lubricants and other operating fluids in
suitable containers and dispose of them prop-
erly.
– Observe statutory accident prevention and
safety regulations.
– Also comply with the instructions in the supple-
mental documentation (for example, engine, et
cetera.) during maintenance tasks.
– Keep the vehicle (for example, handles, steps,
platforms, railing, et cetera) free from dirt, snow
and ice.
– Smoking and handling of open flame are pro-
hibited.
– Use safety-compliant access ladders or work
platforms.
– Maintain a safe distance from rotating and
moving parts.
– Relieve the pressure of the hydraulic system
and other operating fluids before starting main-
tenance tasks.
– Dispose of hydraulic oil as prescribed.
– Wear protective gloves when working on steel
wire rope.
– Do not lift heavy components manually. Use
lifting equipment.
– For pneumatic tires:
When pumping up tires, maintain adequate
safety clearance and use tire cage.
– Keep the cab clean and orderly.
» Continued on the next page

Safety
Maintenance
– Actuate the battery disconnecting switch or dis-

connect battery poles to interrupt the power
supply.
– When working near batteries, they must be
covered with insulating material. Do not place
tools on top of batteries.
– When handling batteries, comply with the
safety instructions and protective measures
specified by the battery's manufacturer. Fire,
sparks, open flames and smoking are pro-
hibited when handling batteries.
– When working on air conditioning systems, be
aware that coolants and coolant vapors are
hazardous to health. Wear the appropriate pro-
tective equipment.
– Replace all protective devices after completing
any tasks on the machine. Replace damaged
safety equipment with new safety equipment.
– Execute a function check to ensure faultless
operation.
– Only the machine owner or representative may
approve the machine for operation following
maintenance tasks.
– If an accident occurs in spite of all safety and
precautionary measures, for example
– scalding by hot oil or coolant
– contact with strong acid
– penetration of fuel or hydraulic oil into the
skin
– eyes are splashed with coolant or hydraulic
oil, for example.
take the necessary immediate measures and con-
sult a doctor.
– After maintenance or repair tasks, carry out a
thorough visual inspection and function check
in accordance with the operating manual, so
that proper and safe operation is ensured.
– Further disassembly or service tasks that are
not described in the manual must only be exe-
cuted under the personal responsibility of the
owner. Use necessary special tools.
– Before recommissioning, the correct and com-
plete maintenance tasks must be checked by
an expert.

Safety
Maintenance
Parts that are tightly nested together are never to

be loosened with hard objects.
Never tighten loosely seated parts with a hard
object. Roller bearings, drive flanges, and so on
that require mounting/dismounting require the use
of suitable pull-off fixtures or special tools.
Qualifications of personnel
WARNING!
– Only qualified electricians are permitted to
work on the electrical equipment of the
machine.
– Tasks on undercarriage, braking and steerage
systems must only be executed by specialists
trained for these tasks!
– Work on hydraulic devices must only be carried
out by personnel with specific knowledge and
experience in the area of hydraulic systems!
– Only specialized personnel who have been
authorized and trained by SENNEBOGEN are
allowed to perform repair, maintenance and
measurement tasks.
– No welding whatsoever may be carried out on
the device without consultation with the manu-
facturer.
Only specialist personnel who have been author-

ized and trained by SENNEBOGEN are allowed
to perform repair, maintenance, and measurement
tasks.

Safety
Cleaning
DANGER!
Explosion hazard when working on the Green
Hybrid system or on the boom damping
The hydraulic components of the Green Hybrid
system and the boom damping are pressurized
with gas. Working on pressurized components
without the requisite expertise may lead to explo-
sions. This can cause serious injury or death.
– Components working with gas pressure:
– Piston accumulators
– Bladder accumulator
– Diaphragm accumulators
– Hydropneumatic damping elements
– Do not carry out any work on these compo-
nents.
– In the event of malfunctions, contact
SENNEBOGEN Customer Service.
1.7 Cleaning
Clean the machine monthly, particularly prior to maintenance and
repair work. Shorten the cleaning intervals depending on operating
conditions and contamination.
WARNING!
Danger of injury due to falling.
Danger of falling when performing work above
body height.
– Place the machine in park position, lower
equipment to the ground.
– Only perform work from a safe standing sur-
faces.
– Use work platforms.
– Do not use machine parts as climbing aids if
they are not intended for this purpose.

Safety
Cleaning
WARNING!
Danger of injury due to unintentional machine
movements.
Danger of crushing and falling due to unintentional
machine movements.
– Switch off the machine and safeguard it
against being switched on again.
– Attach a sign in the cab that alerts to the fact
that service tasks are being executed.

Safety
Cleaning
NOTICE!
Incorrect cleaning can lead to machine
damage!
General safety measures before cleaning
– The cleaning agents must not damage sealant.
– Only use neutral or slightly alkaline cleaning
agents.
– Only clean the acoustic insulation mats with
neutral cleaning agents.
– Only use clean sponges, brushes and lint-free
cloths.
Wet cleaning
– Remove all foreign objects with compressed
air from the coolers before washing. In a
dusty environment, e.g. with fine dust or paper
dust, wet-cleaning the radiators or coolers may
cause concrete-like clumping.
– Lubricate all bearing points to prevent water
ingress.
– Seal all openings into which water must not
penetrate:
– Exhaust pipe
– Air filter
– Climate control system external air filter
– Protect all components that must not be
cleaned with water from the direct water jet:
– Electrical components
– Exhaust aftertreatment system
– Slewing ring
– Bolt bearing points
– Do not use a hose or jet spray to clean the cab.
Compressed air cleaning
– Only use dry, filtered compressed air, to a max-
imum of 2 bar.
– Take note of the device's manufacturer's
instructions and country-specific regulations.
General safety measures after cleaning
– Remove all coverings that were attached prior
to cleaning.
– Lubricate all bearing points and the slewing
ring.
– Warm up the diesel engine so residual water
can evaporate.
– Treat all rubber seals with a commercial rubber
conditioner.
» Continued on the next page

Safety
Cleaning
– After cleaning works, always carry out a visual

and function check of the machine. In partic-
ular, check the following:
– Make sure that all warning signs and infor-
mation signs are complete and legible.
Replace missing or damaged signs.
– Check the paint for visible damage. Imme-
diately have any paint damage repaired by
a specialist firm. Pay attention to the corro-
sivity class of the coating.
– Check the corrosion protection and have
touched up or restored as needed.
– Check all lines for damage and leaks.
ENVIRONMENT!
Environmental hazard due to improper handling of
environmentally harmful substances.
– Carry out damp cleaning on a surface
equipped with an oil separator.
– Dispose of environmentally-dangerous
cleaning agents and operating fluids in accord-
ance with the regulations.
Repair paint damage as specified in the

SENNEBOGEN Repair Manual for Paint Damage.
Have anti-corrosion measure carried out in accord-
ance with the SENNEBOGEN manual for con-
servation. The manuals are available from your
SENNEBOGEN Service Partner.
During the first three months after commissioning

or after repainting, observe the following:
– Use cold water with a low dose of a neutral
cleaning agent.
– Working pressure: maximum 60 bar
– Spray distance: minimum 30 cm
– Spray angle: 30° to 60° degrees
After three months, observe the following:
– Water temperature: maximum 60 °C
– Working pressure: maximum 100 bar
– Spray distance: minimum 30 cm
– Spray angle: 30° to 60° degrees
Dry cleaning If there is minor dust contamination, execute dry cleaning with
compressed air (maximum 2 bar / 29 psi) and a soft brush.

Safety
Welding
Wet cleaning
1. Apply the water with a cleaning agent to the respective
machine parts and allow to work in.
2. Remove firmly adhering contamination with a sponge or
brush.
3. Rinse off the machine with clean water.
4.
NOTICE!
Material damage due to improper cleaning
of cab windows
Improper cleaning of cab windows can cause
material damage.
– Proceed as follows to clean cab windows
made from polycarbonate (PC):
– Do not use a glass cleaner.
– Do not use an abrasive cleaner.
Use clean water to clean cab windows made from polycar-

bonate (PC).
5. Clean the cab windows and mirrors with a commercial glass
cleaner.
1.8 Welding
WARNING!
– Welding tasks must only be carried out by an
authorized and qualified welding specialist.
– Only specialist personnel who have been
allowed to perform repair, maintenance, and
measurement tasks.
– Drilling or welding are prohibited on
– boom sections.
– load-bearing frame parts.
– the engine.
– the hydraulic tank.
– the fuel tank.
– components supplying fuel and oil.
– Cover vulnerable components with fireproof
material.
– Unplug control devices.
Preliminary work Before welding, carry out the following preliminary work:

Safety
Safe entry and exit > General information
1. If necessary activate the optional battery disconnect switch to

interrupt the supply of power.
2. Switch off ignition.
3. Disconnect battery.
4. The lines should be de-energized when connecting and con-
necting.
5. Clamp the ground terminal of the welding unit directly to the
component to be welded.
6. Prior to any welding, remove the varnish from a generously
dimensioned area around the point to be welded. Hazardous
gases can form and cause irritations.
1.9 Safe entry and exit

1.9.1 General information
n If necessary, clean access ladders and ladders before use.
n Enter or exit machine only when stationary and after the cab
has been lowered completely – never when the machine is in
motion.
n Do not carry any objects when climbing up or down.
n When climbing up or down, always ensure that you have three
points of contact on the access ladders, ladders and grip han-
dles. (for example two hands and one foot or two feet and one
hand).
n Lift items of equipment, tool and spare parts onto the machine
using a rope or hoist.
n Do not use operating elements in the cab as grip handles.
n Only use the provided access ladders and/or ladders.
n When the cab is elevated, mounting via the access ladder to
the catwalk is not permitted.
n At working heights of 2.00 m or more, SENNEBOGEN rec-
ommends the use of a safety harness to prevent falling. At
working heights above 3.00 m, using a safety harness is a
legal requirement. The hook-in eyes are marked.
n Every 3 months, check the catwalk for damage (particularly for
cracks) and missing fastening screws, and repair immediately if
necessary.
CAUTION!
Danger of falling.
Catwalk access prohibited when the cab is raised!
The maximum load permitted on the catwalk is
200 kg (440 lb) per gridiron segment. Excess
weight can damage the walkway and result in
serious injury. Check the catwalk for damage every
3 months (especially cracks) and repair if neces-
sary.

Safety
Safe entry and exit > Cab without gallery access ladder
DANGER!
Wear personal protective equipment (for example,
hard hat, hearing protection, protective gloves,
safety footwear) where working conditions require.
At working heights of 2.00 m or more,
SENNEBOGEN recommends the use of a safety
harness to prevent falling. At working heights
above 3.00 m, using a safety harness is a legal
requirement. The hook-in eyes are marked.
In some cases, it may be necessary to turn the

superstructure to 90° offset to the undercarriage to
allow safe entry/exit.
1.9.2 Cab without gallery access ladder
1. Open the sliding door (1) from the ground.

2. Hold onto the grip handles (2) and place your feet on the
access ladders (3) and climb into the cab.
3. Close the sliding door.

Safety
Safe entry and exit > Cab with gallery access ladder
1.9.3 Cab with gallery access ladder
1. Hold onto the grip handles (2) and use the access ladder to
step on the operator catwalk (4).
2. Enter from the rear to the front via the operator catwalk (4).
3. Open door (1).
4. Enter the cab and then close the door.

Safety
Safe entry and exit > Rigid cab access ladder
1.9.4 Rigid cab access ladder
1. Hold onto the grip handles (2) and use the access ladders (3)
to step on the operator catwalk (4).
2. Open door (1).
3. Enter the cab and then close the door.

Safety
Safe entry and exit > Uppercarriage access ladder
1.9.5 Uppercarriage access ladder
1 Grip handles
2 Access ladders
1. Climb up the access ladders (2) from the ground.
2. Hold onto the grip handles and enter the upper structure via
the access ladder (1).

Safety
Safe entry and exit > Uppercarriage attachment machine access ladder
1.9.6 Uppercarriage crawler access ladder
1 Grip handles
2 Access ladders
2. Hold onto the grip handles and enter the upper structure via
the access ladder (1).
1.9.7 Uppercarriage attachment machine access ladder
1 Access ladder
2 Gallery
3 Railing
1. Climb onto the gallery (2) from the ground.
2. Hold onto the railing and enter the uppercarriage via the
access ladder (1).

Safety
Safe entry and exit > Uppercarriage with gallery access ladder
1.9.8 Uppercarriage with gallery access ladder
1 Undercarriage access ladder

2 Grip handles
3 Ladder
4 Catwalk
5 Cover
6 Access ladder – uppercarriage
1. Climb up the access ladders (1).
2. Hold onto the grip handles (2) and climb up.
3. Open cover (5) and step onto the gallery (4).
4. Close cover (5) securely.
5. Go backwards round uppercarriage, hold onto the grip han-
dles (2)and enter the upper carriage via the access ladder
(6).

Safety
Safe entry and exit > Access ladder to uppercarriage electric motor with gallery
1.9.9 Uppercarriage electric motor access ladder
1 Grip handles
2 Undercarriage access ladders
3 Uppercarriage access ladders
4 Gallery
5 Uppercarriage grip handles
6 Crawler track
7 Platform
2. Hold onto the grip handles (1) and step onto the platform (7)
via the crawler track (6).
3. Hold onto the grip handles (5) and enter the uppercarriage
via the access ladders (4).
1.9.10 Access ladder to uppercarriage electric motor with gallery
DANGER!
Danger of crushing due to moving machine
parts
When you turn the uppercarriage or move the cab,
persons can get caught on the uppercarriage and
be crushed. This can cause serious injury or death.
Only enter or exit the machine when stationary.
– You may only enter or exit the machine after
consulting the machine operator.

Safety
WARNING!
Risk of falling due to overloaded step grid
Step grids may give if overloaded. This can cause
serious injury or death.
– The maximum load on each step grid segment
is 200 kg (440 lbs).
– Repair cracks and damage to the step grids
immediately.
Crawler undercarriage
1 Grip handles
3 Gallery door
4 Catwalk
5 Uppercarriage access ladder
1. Hold onto the grip handles (1) and climb the undercarriage
(2) via the access ladder.
2. Open the door (3) and step onto the gallery (4).
3. Hold onto the grip handles and enter the uppercarriage via
the uppercarriage access ladder(5).

Safety
Rail undercarriage

2 Gallery door
3 Uppercarriage gallery
4 Uppercarriage access ladder
1. Hold onto the grip handles and climb up the undercarriage
access ladder (1).
2. Open the gallery door (2) and step onto the gallery (3).
3. Hold onto the grip handles and enter the uppercarriage via
the uppercarriage access ladder(4).

Safety
Safe entry and exit > Emergency exit
4-point steel subframe

2 Grip handles
4 Catwalk
5 Gallery cover
6 Access ladder – uppercarriage
1. Climb up the access ladder (1) from the ground.
2. Hold onto the grip handles (2) and climb up the undercar-
riage access ladder.
3. Open the gallery cover (5) and enter the gallery (4).
4. Close the gallery cover (5) securely.
5. Go backwards round the uppercarriage, hold onto the grip
handles (2) and enter the uppercarriage via the access
ladder (6).
1.9.11 Emergency exit

Cab The cab can be exited in an emergency through the cab door or
the rear window.
A safety hammer that can be used to knock out the rear window is
located in the cab.

Safety
Safe entry and exit > Emergency exit
In an emergency, you can exit via the window

(2). Use the emergency hammer (1) to break the
window.
Protective roof (FOPS): The emergency exit
through the front window may be blocked by the
protective grating (FOPS) that is available as an
option. In this case, emergency exit is only pos-
sible through the door.
CAUTION!
Danger of falling.
Exit the cab via the rear attachments with extreme
caution and climb down from the vehicle.

Safety
Safety equipment > Disposal of lubricants and operating fluids
1.10 Safety equipment
DANGER!
– Do not remove safety equipment or covers.
– Always check that safety equipment is com-
plete and properly secured before starting the
machine. Examples of safety equipment are
engine flaps, doors, protective gratings, clad-
ding, fire extinguishers, and first-aid kits.
– Replace all safety equipment and covers cor-
rectly on completion of installation or mainte-
nance tasks.
– Replace damaged safety equipment with new
safety equipment.
Fig. 3: Example
1.11 Disposal
1.11.1 Disposal of lubricants and operating fluids
CAUTION!
Protect the environment! Handle and dispose of
used substances and materials correctly, espe-
cially
– when working on the cooling systems
– when working on lubrication systems and
devices
– when working with solvents and
– when working on hydraulic oil systems.
Extract from the EC-Disposal Directive:

n "It is prohibited to mix spent oil with other waste."
n "Spent oils must not be mixed together."
n "Used oil filters must be collected, kept, transported and dis-
posed of separately from other waste."
ENVIRONMENT!
– Lubricants and other operating materials must
be disposed of at suitable collection points.
– National environmental regulations for disposal
specified in the country of use also apply.

Safety
Disposal > Disposal of batteries
1.11.2 Disposal of batteries

Batteries
Observe the safety instructions and protective measures when
handling batteries.
ENVIRONMENT!
– Do not dispose of batteries in domestic waste
containers! Dispose of defective batteries at a
recycling point for old batteries.
– National environmental regulations for disposal
specified in the country of use also apply.

Maintenance schedule
Safety instructions
2 Maintenance schedule
2.1 Safety instructions
NOTICE!
In extreme conditions of use – at high or low
ambient temperatures, for example – shorter inter-
vals may be necessary.
NOTICE!
The standard engine oil change interval is every
500 hours of operation or every 3 months. In
extreme conditions of use – at high ambient tem-
peratures, for example – the engine oil change
intervals can be reduced to 250 operating hours
or once a month.
For this reason, it is essential that you comply
strictly with the instructions in the operating
manual provided by the engine manufacturer.
NOTICE!
Please comply with the maintenance intervals and
the maintenance schedules cited in the supple-
mental documentation (for the engine or attach-
ments, for example).
NOTICE!
Methods of alerting user:
– F = Check fill level
– W = Change oil or filter
NOTICE!
ized and trained by SENNEBOGEN are allowed to
perform repair and measurement tasks.
WARNING!
Observe all safety instructions before starting work.

Daily/weekly maintenance > Daily/weekly maintenance
2.2 Daily/weekly maintenance

2.2.1 Daily/weekly maintenance
CAUTION!
NOTICE!
The following pages contain the checklist to be
worked through.
Visual checks Steps Chapter ☐

Are all protective coverings, If necessary, replace ☐
insulating materials, and
warning signs attached and
undamaged?
Are all access ladders, handles, If necessary, repair or replace ☐
and anti-slip coverings present
and undamaged (e.g., cracks)?
Is the machine clean enough to If necessary, clean using a ☐
ensure no danger areas exist high-pressure cleaner. CAU-
due to dirt (danger of slipping, TION when dealing with sensi-
falling, poor visibility)? tive or electrical components!
Are all windows cleaned and If necessary, de-ice or clean ☐
free of ice and snow?
Is the undercarriage (tires, If necessary, repair or replace ☐
axles, drive shafts/universal
joints) undamaged?
Are the wheel nuts tight and If necessary, retighten to the Ä 7.3.2 ☐
the intermediate rings firmly specified torque
seated?
Is the tire pressure correct? If necessary, look for leaks ☐
(For pneumatic tires) and/or pump with air (using tire
cage!)
Is the hydraulic system (lines, If necessary, tighten connec- Ä 9.2.1 ☐
hoses, et cetera) free of leaks tions or replace seals
or undamaged?
Are the hydraulic cylinders If necessary, tighten connec- ☐
(e.g., outrigger, stick, floating tions or replace seals
axle cylinders, steering cylin-
ders) free of leaks and undam-
aged? Do the piston rods show
any signs of damage (cracks,
etc.)?


Are the piston rods of the If necessary, clean and oil. ☐
hydraulic cylinders cleaned and
oiled?
Is the shut-off flap on the If necessary, open ☐
hydraulic tank open?
Are the fill levels of all If necessary, look for leaks and ☐
liquid media sufficient (coolant, top up the liquids. Observe the
grease, diesel, hydraulic oil, manufacturer’s instructions.
engine oil, fuel, windshield
washer fluid, slewing gear, DEF,
etc.)?
Is the air filter cartridge dam- If necessary, replace ☐
aged or contaminated?
Is the fan wheel undamaged? If necessary, replace ☐
Are the cooling fins on the com- If necessary, clean via fan ☐
bination cooler soiled or dam- reversal or replace.
aged?
Is the cooling system (cooler, If necessary, look for leaks and ☐
hoses, tubing et cetera) free of top up the coolant. Observe
leaks? the manufacturer’s instructions.
Replace any defective compo-
nents.
Are all hose clips and hose con- If necessary, retighten or Ä 6.3.5 ☐
nections tight and secure? replace
Has the water separator on the If necessary, drain Ä 6.4.2 ☐
fuel system been drained?
Are the V-belts undamaged and If necessary, tension again or Ä 6.9 ☐
tensioned? replace
Are the electrical lines dam- If necessary, repair or replace Ä 10.2 ☐
aged?
Have the cable connections If necessary, clean and Ä 10.2 ☐
(poles) of the battery corroded? regrease, attach the pole pro-
tection caps.
Are the batteries held in place If necessary, retighten the ☐
securely? holders
Are all service access doors If necessary, close ☐
closed?
Are all screw connections – If necessary, retighten or ☐
particularly those on the height- replace
adjustable cab – undamaged
and tightened?
Are all bolt/screw connections, If necessary, retighten or ☐
for example, on the mast and replace
the gallery undamaged and
tight (high-strength bolts, with/
without distance tubes)?


Have any existing cable con- If necessary, disconnect ☐
nections to external power sup-
plies been disconnected?
Is the correct counterweight Replace if necessary or ☐
installed and secured in place? retighten to specified torque
Are the boom sections/steel If necessary, repair or replace ☐
structures undamaged (corro-
sion, cracks)?
Do the pin retainers show any If necessary, replace ☐
signs of damage (e.g., cracks)?
Are the pipe fracture safety If necessary, replace ☐
devices tight and undamaged?
Is there sufficient grease in the If necessary, top up Ä Ä 9.4.6 ☐
central lubrication system?
Are the lubrication pipes If necessary, replace, clean, ☐
undamaged and are all lubrica- and lubricate
tion points being greased?
Are all hydraulic pipes and If necessary, tighten the fasten- ☐
hoses tight? ings
Is the seal of the rotary connec- If necessary, repair or activate Ä 8.2 ☐
tion undamaged and is a suffi- the central lubrication system
cient grease collar present?
Are the mechanical steering If necessary, replace ☐
stops worn?
Is the energy chain damaged/ If necessary, replace ☐
worn?
Is the pump distributor gearbox Repair if necessary ☐
sealed?
Does the structural steelwork Consult with Customer Service. ☐
show damage or cracks?
Are the entire exhaust system If necessary, replace the seals ☐
piping and the insulation on the and consult with Customer
exhaust aftertreatment system Service.
and on the engine sealed
against leaks? Is any soot
visible?
Have airborne, combustible If necessary, remove the parti- ☐
particles accumulated on the cles.
exhaust aftertreatment system?
Are the clips on the exhaust If necessary, replace the clips ☐
aftertreatment system and on and consult with Customer
the engine firmly seated? Service.
Do you detect cracks or leaks Consult with Customer Service. ☐
on the exhaust line?

One-time maintenance > After 250 operating hours at the latest

Are warnings displayed on the Check in chapter 5 of the oper- ☐
SENCON? ating manual and consult with
Customer Service if necessary.
Is the filter on the switch cab- If necessary, replace the filter. Ä 10.9.1 ☐
inet for the electrical system
contaminated?
Has the telescopic boom Lubricate the telescopic boom ☐
already been lubricated? manually
Have the lateral slide blocks If necessary, have a service ☐
of the telescopic boom been technician adjust the slide
checked? blocks of the telescopic boom.
2.3 One-time maintenance

2.3.1 After 50 operating hours at the latest
NOTICE!
The following maintenance work is to be performed
one time only after 50 hours of operation at the
latest.
Undercarriage
☐ Subassemblies/activities Chapter
☐ Travel drive Ä 7.3.2
Retighten wheel nuts.
2.3.2 After 250 operating hours at the latest
NOTICE!
The following maintenance work is to be performed
one time only after 250 hours of operation at the
latest.
☐ Travel drive Ä 7.4.3.1
Oil change
☐ Slewing gear box
Oil change

One-time maintenance > After 250 operating hours at the latest
☐ Play in the swing bearing
Measure wear and check drive
system/bearing play
The measurement is to be
regarded as the base position for
the delivery status.
☐ Rail undercarriage Ä 7.5.4
Cable drum
Geared motor
Travel gear
Track wheels
Uppercarriage
☐ Hydraulic system Ä 9.4.14
Charge pressure filter – replace
filter element
☐ Hydraulic system
Changing the filter element of the
return filter
Leakage oil filter – change filter
element
HydroClean- change filter element
(option)
Pre-load pressure – have
hydraulic accumulator checked by
a specialist hydraulics company
☐ Pump distributor gearbox Ä 9.5.3
Oil change
☐ Diesel engine
Air filter – check
☐ Diesel engine
Check charge air lines

Regular maintenance/Maintenance interval > Monthly or at the latest after250 operating hours
☐ Diesel engine
Check charge air cooler
☐ Diesel engine
Check radiator hoses
☐ Diesel engine
Check air intake lines
☐ Diesel engine
Cooler – check
See the operating and mainte-
nance manual provided by the
engine manufacturer for more
extensive information.
☐ Electric motor
See the operating and mainte-
nance manual provided by the
engine manufacturer for more
extensive information.
2.4 Regular maintenance/Maintenance interval

2.4.1 Monthly or at the latest after250 operating hours
NOTICE!
Observe the maintenance intervals and the mainte-
nance schedule specified in the supplemental doc-
umentation. (for the grapple, engine, and so on)
CAUTION!
Undercarriage ☑ Subassem- Chapter

blies/activities
☐ Steering axle: Ä 7.3
Hub
Check oil level.
☐ Differential Ä 7.3
Check oil level.

☑ Subassem- Chapter
blies/activities
☐ Steering
Check the steering
stops.
☐ Steering
Check steering cyl-
inder for leaks and
function.
☐ Axle distribution Ä 7.3
gearbox
Check oil level.
☐ Axle hinges
Lubricate all axle
hinges using the
lubricating nipples.
☐ Rigid axle: Ä 7.3
Hub
Check oil level.
☐ Differential Ä 7.3
Check oil level.
☐ Steel structure Ä 12
Use suitable equip-
ment to check for
structural damage
(for example, defor-
mation, damage,
corrosion, cracking).
Clean and maintain
using suitable mate-
rials.
☐ Slewing ring Ä 8
Visually check all
connecting elements
for damage and cor-
rosion.
☐ Wedge lock
Lubricate crawler
undercarriage
wedge lock.

blies/activities
☐ Crawler track
Check track tension
and adjust if neces-
sary.
☐ Travel gear Ä 7.4.3.1
Change oil of both
travel gears.
☐ Travel drive Ä 7.4.3.1
Retighten wheel
nuts.
Cable drum
Geared motor
Travel gear
Track wheels
Uppercarriage ☑ Subassem- Chapter

blies/activities
☐ Cab air condi- Ä 11
tioning and aux-
iliary heating
system
Visual inspection of
the entire system
for contamination,
secure fastening,
seal, hose connec-
tions and cable con-
nections.
☐ Cab air condi-
tioning and aux-
iliary heating
system
Switch on at least 1x
per month.
☐ Pump distributor Ä 9.5.2
gearbox
Check oil level.

blies/activities
☐ Diesel engine
Check air filter
restraint.
☐ Diesel engine
Check charge air
lines.
☐ Diesel engine
Check charge air
cooler.
☐ Diesel engine
Check cooler hoses.
☐ Diesel engine
Check air intake
lines.
☐ Diesel engine
Check cooler.
See the operating
and maintenance
manual provided by
the engine manufac-
turer for more exten-
sive information.
☐ Electric motor
See the operating
and maintenance
manual provided by
the engine manufac-
sive information.
☐ Engine: Air condi-
tioner compressor
Check the air con-
ditioning compressor
threaded union for
firm seat.
tioner compressor
Check belt condition
and tension.
Check hydraulic
hoses and hydraulic
lines for damage.

Regular maintenance/Maintenance interval > Every 6 months or at the latest after 500 operating hours
2.4.2 Every 6 months or at the latest after 500 operating hours
CAUTION!
NOTICE!
umentation. (for the grapple, engine, and so on).

blies/activities
☐ Steering
Check that aggre-
gates and steering
parts are securely
fastened and
retighten to required
torque if necessary
☐ Slewing ring lubri-
cation
Check the plastic
sliding wear pad in
the lubrication appa-
ratus for wear.
☐ Swing bearing:
Gearing/bearing
raceway
Using suitable tools,
check the swing
bearing bolts for firm
seating and tighten
to the required
torque if necessary.
☐ Swing bearing: Ä 8
Gearing/bearing
raceway
Check the seal
between the bearing
race and the gearing
for damage.


blies/activities
☐ Catwalk
check for structural
damage (such as
deformation, corro-
sion, and cracking)
☐ Cladding
Check that hinges,
quick latches, and
gas pressure springs
are functioning cor-
rectly
☐ Cab: air condi- Ä 11.2
tioning system and
auxiliary heating
system
Have an authorized
workshop perform
checks on the air
conditioning system
☐ Equipment
Load holding test
with 1 t
Aeration filter - per-
form visual check
of hydraulic tank for
contamination and
damage, replace if
necessary
☐ Hydraulic system Ä 9
Pre-load pressure –
have hydraulic accu-
mulator checked
by a specialist
hydraulics company
☐ Diesel engine
Replace fuel filter
(screw-on filter)
☐ Diesel engine
Change lubricant
☐ Diesel engine
Replace engine oil
filter

blies/activities
☐ Diesel engine
Check concentration
of coolant additive
(SCA) and anti-
freeze
☐ Diesel engine
Replace coolant
filter
☐ Diesel engine
Check batteries
☐ Diesel engine
Check battery
cables and terminals
☐ Diesel engine
Check radiator pres-
sure cap
☐ Diesel engine Ä 6.4.3
Water separator
filter/diesel prefilter –
change filter insert
☐ Diesel engine Ä 6.4.4
Fuel filter/diesel fine
filter – change filter
insert
☐ Diesel engine
Charge air cooler –
drain condensation
See the operating
and maintenance
manual provided by
the engine manufac-
sive information.

Regular maintenance/Maintenance interval > Once a year or at the latest after 1000 operating hours
blies/activities
☐ Electric motor
See the operating
and maintenance
manual provided by
the engine manufac-
sive information.
☐ ballast elements
Check that counter-
weight elements are
securely fastened
with the required
torque.
2.4.3 Once a year or at the latest after 1000 operating hours
CAUTION!
NOTICE!

blies/activities
☐ Axle distribution Ä 7
gearbox
Check that gearbox
and cardan shafts
are securely fas-
tened; retighten to
required torque if
necessary
☐ Axle distribution Ä 7
gearbox
Oil change
☐ Steering axle: Ä 7
Hub
Oil change

blies/activities
☐ Brake
Measuring the wear
of the brake
☐ Differential Ä 7
Check that cardan
shafts are securely
fastened; retighten
to required torque if
necessary
Oil change
☐ Rigid axle: Ä 7
Hub
Oil change
☐ Brake Ä 7
Measuring the wear
of the brake
☐ Oscillating axle
cylinder
Check to ensure
secure fastening;
tighten to required
torque if necessary
☐ Differential
Check that cardan
shafts are securely
fastened; retighten
to required torque if
necessary
Oil change
☐ Steel structure
damage (such as
deformation, corro-
sion, and cracking)
☐ Travel drive Ä 7
Oil change


blies/activities
☐ Swing bearing: Ä 8.4
Gearing/bearing
raceway
Check mesh/gearing
of the swing bearing
gear teeth
☐ Slewing ring
gearing
Adding grease
☐ Play in the swing
bearing
Measure wear and
check drive system/
bearing play
Check to ensure
secure fastening;
tighten to required
torque if necessary
damage (such as
deformation, corro-
sion, and cracking)
☐ Ballast
Check to ensure
secure fastening;
tighten to required
torque if necessary
☐ Fuel/hydraulic
system tank
Check to ensure
secure fastening;
tighten to required
torque if necessary
☐ Equipment
damage (such as
deformation, corro-
sion, and cracking)

blies/activities
☐ Equipment
Check pin retainers
for cracks or
damage
☐ Equipment
Check that lifting
limit settings for stick
and boom are cor-
rect
☐ Equipment
Check pipe fracture
safety devices
Aeration filter-
change hydraulic
tank
☐ Pump distributor Ä 9.5.3
gearbox
Oil change
☐ Diesel engine
Check fan drive belt
☐ Diesel engine
Check automatic
belt tensioner (water
pump)
☐ Diesel engine Ä 6.3
Safety cartridge –
change air filter
☐ Diesel engine Ä 6.3
Replacement car-
tridge – change air
filter
See the operating
and maintenance
manual provided by
the engine manufac-
sive information.

Regular maintenance/Maintenance interval > Every 2 years or at the latest after 4,000 operating hours
blies/activities
☐ Electric motor
See the operating
and maintenance
manual provided by
the engine manufac-
sive information.
☐ Electrical system Ä 10.9.2 Ä
switch cabinet –
cleaning
☐ Cab/heating
system
Change internal
heated air filter
☐ Cab/heating
system
Change outside air
heating system filter
☐ Air conditioning
system
Change V-belt
2.4.4 Every 2 years or at the latest after 4,000 operating hours
CAUTION!
NOTICE!
blies/activities
☐ Fuel tank
Changing the vent
filter

Regular maintenance/Maintenance interval > At the latest after 2000 operating hours
2.4.5 At the latest after 2000 operating hours
CAUTION!
NOTICE!

blies/activities
Charge pressure
filter – replace filter
element
Changing the filter
element of the return
filter
Leakage oil filter –
change filter element
Auxiliary control
filter* - change filter
element
HydroClean -
change filter element
(option)
Changing the
hydraulic oil
☐ Motor
Engine maintenance
intervals (see
engine manufactur-
er's instructions)
☐ Motor Ä 6.7.3
Changing coolant

Regular maintenance/Maintenance interval > At the latest after 2000 operating hours
blies/activities
☐ Motor
Change crankcase
ventilation filter
☐ Electric motor
See the operating
and maintenance
manual provided by
the engine manufac-
sive information.
☐* Slip ring assembly
Isolators, slip rings,
carbon brushes,
check feed line,
clean and replace if
necessary.
Oil change
*: There is no auxiliary control filter if the HydroClean is present!

**: More than 3000 hours of operation possible, with the prerequi-
site that:
n The machine must be equipped with a SENNEBOGEN
HydroClean system and
n after 2000 operating h, an oil diagnosis must be executed
every 500 operating h by a lab that has been authorized by
SENNEBOGEN, and the findings must be in order.

Regular maintenance/Maintenance interval > At the latest after 4,000 operating hours
2.4.6 At the latest after 3000 operating hours

Hydraulic system ☑ Subassemblies/activities Chapte
r
High-pressure filter
☐ Replacing the filter element Ä Chap
ter
9.4.13
“Boom
high-
pres-
sure
filter
(option)
–
change
filter
ele-
ment”
on page 200
2.4.7 At the latest after 4,000 operating hours
CAUTION!
NOTICE!

blies/activities
Changing the
hydraulic oil
Check hydraulic
hoses for damages
☐ Electric motor
See the operating
and maintenance
manual provided by
the engine manufac-
sive information.
CAUTION!
NOTICE!

blies/activities
☐ Engine: DEF
(AdBlue)
DEF (AdBlue) tank
filter: Replace
☐ Engine: DEF
(AdBlue)
Filter DEF (AdBlue)
supply module filter:
Replace
See the operating
and maintenance
manual provided by
the engine manufac-
sive information.
CAUTION!
NOTICE!

At the latest after 5,000 operating ☑ Subassem- Chapter

hours or 5 years blies/activities
☐ Engine: Diesel
particulate filter
service
See the operating
and maintenance
manual provided by
the engine manufac-
sive information.
☐ Swing bearing con-
nection
Have swing bearing
bolts checked by a
specialist company.
Replace if necessary
CAUTION!
NOTICE!

tioner compressor
Oil change
CAUTION!

NOTICE!

Change hydraulic
hoses
CAUTION!
NOTICE!


☐ Slip ring assembly
Replace bearing
☐ Hydraulic system Ä 9
Preload pressure
- Have the pre-
load pressure of
the hydraulic accu-
mulator checked
by a hydraulic spe-
cialist company and
have the pressure
testing done with
the internal test by
inspectors
☐ Rail undercarriage:
Travel gear
Have
SENNEBOGEN
Customer Service
perform a complete
overhaul.

Technical data
General > General information
3 Technical data
3.1 General
More information can be found in the operating

manual in chapter 3.
3.2 Drive engine


Quality is of the utmost importance at

SENNEBOGEN. The installation of the engine
and the cooling system for the engine have been
designed, tested and manufactured to meet the
high demands of handling. This means that the
machine not only has an optimal service life, but
that it is also certified as being compliant with stat-
utory exhaust emission limits.
WARNING!
Any modifications made to the delivered machine
concerning the
– Engine
– Engine cooling system including ventilation
ducts
– Air filter system
– Exhaust aftertreatment system
– Exhaust system
lead to the termination of the certification of
the diesel motor exhaust emissions, leading to
the extinction of the operating permit for the
device and to the extinction of any claims against
SENNEBOGEN.

Technical data
Drive engine > US EPA Tier 4f / EU Stage IV
3.2.2 US EPA Tier 3/EU Stage IIIa

Cummins QSB6.7-C203 CM850
Power (acc. to ISO14396) 164 kW (220 PS) at ref. speed
2000min -1
Displacement 6,700 cm3 (479 in3)
Cylinder 6
Engine oil capacity with filter approx. 19.7 l/5.20 gal (US)
Overall system coolant capacity approx. 50 l/12.68 gal (US)
Engine coolant capacity approx. 10.0 l/2.64 gal (US)
General drive engine informa- see manufacturer's manual
tion
3.2.3 US EPA Tier 4f / EU Stage IV

2200min -1
Cylinder 6
Refrigerant capacity of overall approx. 50 l/12.68 gal (US)
system
DEF (AdBlue) tank approx. 30 l/7.93 gal (US)
tion

2000min -1
Cylinder 6
Refrigerant capacity of overall approx. 50 l/12.68 gal (US)
system
tion

Technical data
Machine (fill levels)
3.2.4 US EPA Tier 4f / EU Stage V

Cummins B6.7-C225
Output (in accordance with ISO 168 kW (225 PS) at ref. speed
14396) 2000min -1
Displacement 6,700 cm3
Cylinders 6
Motor oil capacity without filter approx. 23.1 l/6.1 gal (US)
Overall system coolant capacity approx. 46.2 l/12.2 gal (US)
Engine coolant capacity approx. 10 l/2.6 gal (US)
General drive engine informa- See manufacturer's manual
tion
3.2.5 Electric motor

SENNEBOGEN 132 kW
Power (acc. to ISO14396) 132 kW at rated speed
1480 rpm-1
tion
3.3 Machine (fill levels)

Tanks in uppercarriage
Component Quantity
Fuel tank 450 l (118.9 gal.)
Hydraulic tank max. 310 l (max. 81.9 gal.)
Hydraulic tank, center of sight glass approx. 245 l (approx. 64.7 gal.)
Hydraulic system, complete (*) approx. 440 l (approx. 116.2 gal.)
(*): When operating special machines with pylon, it must be noted

that for each 0.5 m of pylon length, an additional quantity of
approximately 30 l (approx. 7.9 gal.) of hydraulic oil is required.
Lubrication of uppercarriage
Component Quantity
Slewing ring lubrication - reservoir approx. 1.2 l (approx. 0.32 gal.)
Central lubrication system reservoir approx. 4.0 kg (approx. 0.009 lb)

Technical data
Gear unit in uppercarriage
Component Quantity
Slewing gear box each approx. 3.5 l (approx. 0.92 gal.)
Crawler undercarriage R35
Component Quantity
Travel gear each approx. 9.0 l (approx. 2.4 gal.)
Crawler undercarriage R44
Component Quantity
Crawler undercarriage T41
Component Quantity
Mobile undercarriage MP30E
Component Subassembly Quantity

Axle distribution gearbox approx. 2.9 l (approx.
0.8 gal.)
Steering axle Final drive (axle housing) approx. 11 l (approx. 2.9 gal.)
Hub gear per wheel side approx. 2.5 l
(approx. 0.7 gal.)
Rigid axle Final drive (axle housing) approx. 14 l (approx. 3.7 gal.)
(approx. 0.7 gal.)

0.8 gal.)
(approx. 0.7 gal.)
Rigid axle Final drive (axle housing) approx. 15 l (approx. 4.0 gal.)
(approx. 0.7 gal.)

Technical data

0.8 gal.)
(approx. 0.3 gal.)
Rigid axle Final drive (axle housing) approx. 19.5 l (approx.
5.2 gal.)
(approx. 0.4 gal.)

(trailer)

0.8 gal.)
Steering axle Final drive (axle housing) approx. 33.8 l (approx.
8.9 gal.)
(approx. 1 gal.)
6.7 gal.)
(approx. 1 gal.)

0.8 gal.)
(approx. 0.3 gal.)
5.2 gal.)
(approx. 0.4 gal.)

Technical data
Conversion factors
3.4 Conversion factors

Pressure 1 bar 100 Kpa 14.5 psi
10 psi 68.95 Kpa 0.6895 bar
Flow rate 1 l/min 0.0353 cfm 0.2642 gal/min (US)

1 gal/min (Brit.) 0.1605 cfm
1 gal/min (US) 3.78541 l/min
Length 1 mm 0.03934 in
1m 39.34 in 3.281 ft
1 in 25.4 mm
1ft 0.3048 m 304.8 mm
1 km 39340 in 3280.8 ft
1 km 1093.6 yd 0.62137 mile
1 mile 1.609 km 1609 m
Weight 1 kg 2.205 lb 35.27 oz

1 lb (US) 0.454 kg 16 oz
Power kW = HP × 0.746
hp = kW x 1,341
Temperature °C = (°F -32) x 5/9

°F = (°C x 9/5) + 32
Volume 1 m3 1000 l 35.31 ft3 1.308 yd3

1 ft3 28.32 l 0.02832 m3 1.728 inch3
1l 0.2642 gal. 0.2201 gal -
(US) (Brit.)
1 gal. (US) 3.785 l 231 inch3 -
1 gal. (Brit.) 4.544 l 277 inch3 -
1 yd3 764.55 l 0.765 m³ 27 ft³

Technical data
Tightening torques > Standard connections
1 m/s 3.281 ft/s 2.237 mile/h

1 ft/s 0.305 m/s 1.097 km/h
3.5 Tightening torques

If screws or nuts are changed, only use new or reconditioned parts.
Screws, nuts and all threads must be clean, dry and free of grease.
There are 3 different tables for tightening torques:

n Standard connections
n Rotary connection
n Wheel nuts
3.5.2 Standard connections

Utilization To prevent a threaded connection from failing, only black phosph-
ated screws must be used in the following applications:
n Sprocket
n Slewing ring
n Track rollers
n Slewing gear, travel drives, and travel gear
n Winch installations
n All the screws for the following connections:
– Cab console - Cab
– Base frame - Cab adjustment
– Base frame - Engine
Tightening torques The tightening torques are valid for screws with metric standard
thread and a pitch according to DIN13. The tightening procedure
is carried out using a calibrated torque wrench with mechanical or
electrical torque release.
Screw Tightening torque

Dimensions Strength class Zinc flake coated Black phosphated
[Nm] [Nm]
M6 8.8 6.4 9.4
10.9 9.4 13.8
12.9 11 16.1
M8 8.8 15.4 22.8

Technical data
Tightening torques > Standard connections

[Nm] [Nm]
10.9 22.7 33.4
12.9 26.5 39.1
M10 8.8 30 45
10.9 44.2 65.8
12.9 51.7 77.5
M12 8.8 52.5 77.5
10.9 76.7 114.2
12.9 90 133.3
M14 8.8 83.3 123.3
10.9 121.7 181.7
12.9 142.5 212.5
M16 8.8 127.5 191.7
10.9 186.7 281.7
12.9 218.3 329.2
M18 8.8 183 274
10.9 262 391
12.9 306 458
M20 8.8 257 387
10.9 365 551
12.9 428 644
M22 8.8 348 528
10.9 496 753
12.9 580 881
M24 8.8 441 665
10.9 628 947
12.9 735 1108
M27 8.8 643 980
10.9 917 1395
12.9 1073 1633
M30 8.8 878 1331
10.9 1250 1895
12.9 1463 2218
M33 8.8 1179 1801
10.9 1679 2565

Technical data
Tightening torques > Rotary connection

[Nm] [Nm]
12.9 1965 3001
M36 8.8 1521 2315
10.9 2167 3298
12.9 2535 3859
M39 8.8 1957 2998
10.9 2788 4269
12.9 3262 4995
3.5.3 Rotary connection

Tightening torques The tightening torques are valid for strain-hardened screws with
metric standard thread and a pitch according to DIN13. The tight-
ening procedure is carried out using a calibrated torque wrench
with mechanical or electrical torque release.

Dimension Strength class Zinc flake coated Black phosphated
[Nm] [Nm]
M16 10.9 Not permissible 280
M33 10.9 Not permissible 2,600

General Controls
Buzzer and indicator light self-test [Quick-changer check] regeneration
4 General Controls
4.1 Buzzer and indicator light self-test [Quick-changer check] regeneration
Personnel and protective equip-
ment
Personnel: n Machine operator
Protective equipment: n Protective clothing
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves
Buzzer and indicator light self-test After the ignition has been switched on, a self-test of the buzzer
[Quick-changer check] (option) and the indicator light runs for 2 seconds [Quick-changer check] .
Requirement:
The ignition key is in position [I].
1. Check: The [Quick-changer pre-selection] symbol lights up.
2. Check: An acoustic signal will sound.
ð The self-test was successful.
If the indicator light does not light up or an acoustic signal does not
sound, contact a service technician.
Use suitable means (e.g. tape off, put up an information sign) to
disable the functions for unlocking or locking the quick-changer
system for use.
4.2 Checking the function of the hydraulic quick-changer system

Please contact a service technician to get this maintenance work
done.

Lubricating the machine
Lubricating the machine automatically > Overview of lubrication systems
5 Lubricating the machine

5.1 Lubricating the machine automatically
5.1.1 General
NOTICE!
– The reservoir for the central lubrication system
must always be adequately filled in order to
prevent damaging the bearing points.
– Insufficient lubrication can damage the compo-
nents.
– Please read the instructions in .
NOTICE!
If work conditions are harsh, the lubrication cycles
must be adjusted accordingly.
Examples of harsh work conditions:
– Multi-shift operation.
– Increased drive proportion of more than 25 %
of the deployment time.
– Use in extremely wear-promoting material.
– Frequent contact with water or corrosion-pro-
moting substances.
– Use at extreme temperatures.
After a run-in phase of approximately 100 hours

and after inspecting all lubrication points, the lubri-
cation time can be increased or decreased as
needed.
The machine comes standard with a central lubri-

cation system for the swing bearing and the equip-
ment.
5.1.2 Overview of lubrication systems

The machine is fitted with two lubrication systems as standard:

Lubricating the machine automatically > Uppercarriage central lubrication system
n One central lubrication system for the uppercarriage. This

system lubricates the following points:
– Swing bearing raceway
– Boom pivot point
– Hydraulic cylinder of the boom
– Stick pivot point
– Hydraulic cylinder of the stick
– Tool holder at stick end
n One lubrication system for the slewing ring pinion.
5.1.3 Uppercarriage central lubrication system

5.1.3.1 830E – Central lubrication points (uppercarriage, slewing ring, equipment)
Lubrication point overview 830E
1 Lubricant pump
2 Main distributor
3 Distributor between the uppercarriage and the slewing ring
4 Distributor – boom
5 Distributor – stick

5.1.3.2 Manual operation of the central lubrication system for the uppercarriage
NOTICE!
Damage to the machine due to insufficient
lubrication
In some cases, the supply from the automatic cen-
tral lubrication system is not sufficient.
Typical cases are
– Failure of the central lubrication system
– Especially demanding work conditions
In these cases, manually actuate the central lubri-
cation system.
Lubrication can be actuated manually via the SENCON ():

n Actuate the central lubrication system (uppercarriage) manually
using the symbol:
If the SENCON fails, trigger lubrication using the

button for emergency operation of the central lubri-
cation system ().

5.1.3.3 Starting central lubrication manually

Requirement:
n The drive engine has been started.
1. Press and hold the [Central lubrication] button for at least
1 minute.
ð The countdown until the next lubrication cycle is set to 0;
a new lubrication cycle starts.
2. Release the [Central lubrication] button.
ð Once lubrication is complete, the countdown until the
next automatic lubrication cycle starts.
3. Check whether an uninterrupted film of lubricant is present.
ð Repeat the lubrication cycle if the lubrication film is inter-
rupted.
5.1.3.4 Checking the fill level of the lubricant pump

ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves
1 Filling nipple
2 Filling connection
The lubricant level must be between the lower MIN marking and
the upper MAX marking.

5.1.3.5 Filling up the lubricating grease of the lubricant pump

Personnel and protective equip- Personnel: n Machine operator
ment
n Protective gloves
n Safety shoes
n Hard hat
Tool: n Ladder
n Standard grease gun
n Brush, lint-free cloth
n Paintbrush
Material: n Refilling
Fig. 4: Lubricant pump

1 Filling nipple
Filling via the filling nipple
Fig. 5: Standard filling via filling nipples using a grease gun

1. Connect the filling connection on the filling pump or filling

press to the filling nipple.
2. Switch on the filling pump or actuate the filling press and fill
the container up to just below the MAX marking.
3. Switch off the filling pump and detach from the filling nipple
on the pump.
Detach the filling press from the filling nipple.
Filling via filling plug or filling cou-

pling
Fig. 6: Filling via filling plugs
Fig. 7: Filling via filling coupling

1. Unscrew the protective cap from the filling connection.
2. Connect the filling connection of the filling pump to the filling
plug or filling coupling.
3. Fill the container until the fill level is just below the MAX
mark.
4. Detach the filling plug or filling coupling from the filling con-
nection.
5. Screw the protective cap back onto the filling connection.
5.1.3.6 Setting the lubrication cycle in SENCON

Personnel

Lubricating the machine automatically > Undercarriage central lubrication system (option)
The lubrication cycles of the central lubrication systems for upper-

carriage and undercarriage are set in the SENCON.
Preconditions:
n The engine is running.
n The safety lever has been released.
1 Press the quick-selection button repeatedly to set the inter-
vals.
n 70 min
n 60 min
n 50 min
5.1.3.7 Manually starting the central lubrication system

Lubrication can be actuated manually in SENCON in addition to
the pre-set lubrication cycle.
Press the quick-select button.
ð The lubrication process is started immediately.
5.1.4 Undercarriage central lubrication system (option)

ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves

Fig. 8: Lubricant pump (example representation)

1 [MAX] mark: maximum fill level
2 [MIN] mark: Minimum fill level
Read off the fill level of the lubricant pump through the sight
glass:
n The oil is at the halfway point on the sight glass: The
level is within the permissible range.
n The oil is below the halfway point on the sight glass: The
level is too low. Add lubricating grease.

ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves
Tools and equipment

Tool: n Grease gun
n Filling pump (option)
n Lint-free cloths
n Paintbrush

Overview of lubricant pump
1 Filling nipple

1. Connect the filling connection on the filling pump or grease
gun to the filling nipple on the lubricant pump.
2. Fill the lubricant pump container up to just below the MAX
marking: Switch on the filling pump or pick up the grease
gun.
3. Switch off the filling pump or put down the grease gun.
4. Disconnect the filling connection on the filling pump or grease
gun from the filling nipple on the lubricant pump.
Filling via the filling connection

1. Unscrew the protective cap from the filling connection on the
lubricant pump.
2. Connect the filling connection on the grease gun to the filling
connection on the lubricant pump.
mark. Pick up the grease gun.
4. Put down the grease gun.
5. Disconnect the filling connection on the grease gun from the
filling connection on the lubricant pump.
6. Screw the protective cap onto the filling connection on the
lubricant pump.

5.1.4.3 Setting the lubrication cycle at the lubricant pump

done.
5.1.4.4 Setting the lubrication cycle

The lubrication cycles of the central lubrication systems for upper-
carriage and undercarriage are set in the SENCON.
Preconditions:
n The engine is running.
n The safety lever has been released.
1 Press the quick-selection button repeatedly to set the inter-
vals.
n 70 min
n 60 min
n 50 min

Lubricating the machine automatically > Automatic slewing ring pinion lubrication
5.1.5 Automatic slewing ring pinion lubrication

Function
NOTICE!
Damage to the machine from insufficient lubri-
cation
When operating conditions are particularly
demanding, the preset lubrication cycles may not
be sufficient.
If lubrication cycles are not adjusted according to
machine use, no continuous lubrication film will
build up, causing lubrication to be insufficient.
Insufficient lubrication of the swing ring gearing
may cause damage to the machine.
– Check the lubrication film on the swing ring
gearing regularly.
– If in doubt, start a swing ring pinion lubrication
cycle manually.
– Adjust the lubrication cycles of the sling ring
pinion lubrication according to the machine
use.
The automatic swing ring pinion lubrication lubricates the

machine's swing ring gearing in regular intervals.
During the lubrication cycle, only the swing ring in use is being
lubricated. This requires the uppercarriage to be slewed to apply
the lubricant to the gearing.
The time settings for the lubrication cycles and for the intervals
between lubrication cycles are adjustable.
The swing ring pinion lubrication can be started manually if oper-
ating conditions are particularly demanding or if the machine has
been out of use for an extended period. Lubrication then starts
immediately: The lubrication cycle or interval in progress is inter-
rupted, and a new complete lubrication cycle is started.
5.1.5.1 Checking the fill level of the lubricant pump for slewing ring pinion lubrication
ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves

Fig. 9: Lubricant pump (example representation)

1 [MAX] mark: maximum fill level
2 [MIN] mark: Minimum fill level
Read off the fill level of the lubricant pump through the sight
glass:
n The oil is at the halfway point on the sight glass: The
n The oil is below the halfway point on the sight glass: The
level is too low. Add lubricating grease.

ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves
Tools and equipment

Tool: n Grease gun
n Filling pump (option)
n Lint-free cloths
n Paintbrush

Overview of lubricant pump
1 Container cover
3 Filling nipple
Filling via the container cover

1. Clean the area around the lubricant pump container cover.
2. Turn the lubricant pump container cover counterclockwise to
unscrew it from the container.
3. Set the lubricant pump container cover down on a clean sur-
face.
ð The inside of the container cover must not become
soiled.
4. Fill the container from above up to the MAX marking.
Make sure that air is not added along with the lubricant wher-
ever possible.
Make sure that no dirt gets into the container during the filling
process.
5. Screw the container cover back on.

Filling via the filling connection

1. Unscrew the protective cap from the filling connection on the
lubricant pump.
2. Connect the filling connection on the grease gun to the filling
connection on the lubricant pump.
mark. Pick up the grease gun.
4. Put down the grease gun.
5. Disconnect the filling connection on the grease gun from the
filling connection on the lubricant pump.
6. Screw the protective cap onto the filling connection on the
lubricant pump.

1. Connect the filling connection on the filling pump or grease
gun to the filling nipple on the lubricant pump.
2. Fill the lubricant pump container up to just below the MAX
marking: Switch on the filling pump or pick up the grease
gun.
3. Switch off the filling pump or put down the grease gun.
4. Disconnect the filling connection on the filling pump or grease
gun from the filling nipple on the lubricant pump.

5.1.5.3 Changing the lubricating cycles at the lubricant pump

The lubrication cycles must be adjusted if operating conditions are
particularly demanding.
1 Control unit cover

2 Sticker with factory specifications for lubrication times
3 Blue rotary switch
4 Red rotary switch
5 Reset button
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Intervals between lubrica- 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60
tion cycles [min]:
Blue rotary switch
Lubrication time [s]: 8 16 24 32 40 48 56 64 72 80 88 96 104 112 120
Red rotary switch
1. Remove the cover from the pump control.

2. Using a flat-bladed screw driver, set the intervals between
the lubrication cycles at the blue rotary switch.
3. Using a flat-bladed screwdriver, adjust the lubrication time at
the red rotary switch.
4. Replace the cover.
Checking the function after setting When changing the time setting, the cycle in progress will be
the times completed according to the old settings. The new settings will be
applied to the subsequent lubrication cycle.
To activate the new settings immediately, press and hold button
[Swing ring pinion lubrication] in the cab or the reset button at the
pump for at least two seconds.

1. Push button [Slewing gear parking brake] to the left.

ð The slewing gear parking brake is permanently engaged.
2. Move the left joystick into either slewing direction.
ð A slewing signal is sent to the system.
3. Press and hold button [Swing ring pinion lubrication] or the
reset button at the pump for at least 2 seconds.
ð A new lubrication cycle starts.
4. Check whether lubricant exits at the pump element or down-
stream of the T-piece.
Check whether fresh grease is present at the drive pinion
and at the swing ring.
5.1.5.4 Manual operation of the swing ring pinion lubrication system

1. Press and hold button [Swing ring pinion lubrication] for at
least 2 seconds.
ð A new lubrication cycle starts.
2. Using the control lever, slew the upper carriage slowly left
and right to distribute the lubricant evenly over the gearing.
3. Release button [Swing ring pinion lubrication].
ð Repeat the lubrication cycle if the lubrication film is inter-
rupted.
5. If the slewing procedure exceeds the lubrication time set at
the lubricant pump, temporarily extend the lubrication time of
the relubrication cycle or restart the lubrication cycle of the
lubricant pump repeatedly during the procedure.
5.1.5.5 Checking the sliding block of the slewing ring pinion lubrication system
done.
5.1.5.6 Replace the lubricating hose

done.

Lubricating the machine automatically > Central lubrication system of the grapple
5.1.6 Central lubrication system of the grapple

5.1.6.1 Grapple lubrication (option)
Function The lubricant pump for grapple lubrication lubricates the grapple
bolt at regular intervals.
Overview of lubrication system
Fig. 10: Uppercarriage – view from the left-hand side (example

representation)
1 Lubricant pump for grapple lubrication
Adjusting the lubricant pump for Revolutions of the

the grapple bolt Cycle times
lubricant pump
Switch position 1 11
Setting 0.5 h 110 revolutions

ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves

1 Filling nipple
The lubricant level must be between the lower MIN marking and
the upper MAX marking.

5.1.6.3 Topping up the lubricant in the lubricant pump

Personnel and protective equip- Personnel: n Machine operator
ment
n Protective gloves
n Safety shoes
n Hard hat
Tool: n Ladder
n Standard grease gun
n Paintbrush
Fig. 11: Lubricant pump

1 Filling nipple
Fig. 12: Standard filling via filling nipples using a grease gun

1. Connect the filling connection on the filling pump or filling

press to the filling nipple.
2. Switch on the filling pump or actuate the filling press and fill
the container up to just below the MAX marking.
3. Switch off the filling pump and detach from the filling nipple
on the pump.
Detach the filling press from the filling nipple.
Filling via filling plug or filling cou-

pling
Fig. 13: Filling via filling plugs
Fig. 14: Filling via filling coupling

1. Unscrew the protective cap from the filling connection.
2. Connect the filling connection of the filling pump to the filling
plug or filling coupling.
mark.
4. Detach the filling plug or filling coupling from the filling con-
nection.
5. Screw the protective cap back onto the filling connection.

Lubricating the machine manually > General
5.2 Lubricating the machine manually

5.2.1 General
NOTICE!
– Remove soiling from the machine before
manual lubrication.
– Take the red protective caps off the lubricating
nipples and remove any soiling.
– Remove excess grease from the lubricating
nipples.
– Do not exceed a maximum pressure of 350 bar
when using the mobile lubricator.
– The lubricating points on attachments (such
as the grapple) must be manually lubricated.
Follow the instructions in the additional docu-
mentation for the attachment.
– When relubricating using grease nipples, press
in grease until new grease escapes at the lubri-
cating point.
NOTICE!
If work conditions are harsh, the lubrication cycles
must be adjusted accordingly.
Examples of harsh work conditions:
– Multi-shift operation.
– Increased drive proportion of more than 25 %
of the deployment time.
– Use in extremely wear-promoting material.
– Frequent contact with water or corrosion-pro-
moting substances.
– Use at extreme temperatures.
If you have any questions, contact your
SENNEBOGEN service partner.
The lubricating nipples must be covered with a red

protective cap after the lubricating process.

Lubricating the machine manually > Lubricating the lubricating points on the central lubricating bar for the undercarriage
5.2.2 Manual operation of the central lubrication system for the uppercarriage
NOTICE!
Damage to the machine due to insufficient
lubrication
In some cases, the supply from the automatic cen-
tral lubrication system is not sufficient.
Typical cases are
– Failure of the central lubrication system
– Especially demanding work conditions
In these cases, manually actuate the central lubri-
cation system.
Lubrication can be actuated manually via the SENCON ():

using the symbol:
If the SENCON fails, trigger lubrication using the

button for emergency operation of the central lubri-
cation system ().
5.2.3 Lubricating the lubricating points on the central lubricating bar for the under-
carriage
The mobile undercarriage has a central lubricating bar that must
be lubricated manually. The central lubricating bar is on the front of
the undercarriage.
NOTICE!
– During lubrication, the stabilizer of the mobile
undercarriage must be completely extended to
offload the axle bearings.
– Lubricate the mobile undercarriage every 100
operating hours (or at least once a month) with
3 ccm (2 pump strokes with a standard grease
gun) per lubricating nipple.

Lubricating the machine manually > Distributed manual lubrication points on Mobile undercarriage
Lubrication points overview

MP26E-MP30E-MP31E
1 Floating axle bearing
2 Steering knuckle, bottom left
3 Steering knuckle, bottom right
4 Steering knuckle, top left
5 Steering knuckle, top right
6 Outrigger, front left
7 Outrigger, front right
8 Outrigger, rear left
9 Outrigger, rear right
Lubrication points overview MP38E

6 Steering cylinder, outer left
7 Steering cylinder, outer right
12 Steering cylinder, inner right
13 Steering cylinder, inner left
Lubrication points overview

MP41E-MP42E
6 Steering cylinder, outer left
7 Steering cylinder, outer right
12 Steering cylinder, inner right
13 Steering cylinder, inner left
5.2.4 Distributed manual lubrication points on Mobile undercarriage

The mobile undercarriage has distributed lubricating points that
must be lubricated manually:

Undercarriage support Three grease nipples (1) on each of the four outriggers must be
manually lubricated.
Lubrication specification (per grease nipple)

3.0 ccm
Tie rod The two lubricating nipples on the tie rod must be manually lubri-
cated.
Position Lubrication specification (per grease nipple)

1-2 3.0 ccm

Dozer blade (option) The six grease nipples on the dozer blade must be manually lubri-
cated.
Position Lubrication specification (per grease nipple)

1-3 3.0 ccm

Lubricating the machine manually > Distributed manual crawler undercarriage lubrication points
5.2.5 Distributed manual crawler undercarriage lubrication points

Telescoping frame top side 8 grease nipples on the top side must be manually lubricated.
Item Lubrication specification (per

grease nipple)
1-8 3.0–5.0 ccm/40 operating hours

Lubricating the machine manually > Distributed manual crawler undercarriage lubrication points
Telescoping frame underside 8 grease nipples on the underside must be manually lubricated.
Item Lubrication specification (per

grease nipple)
1-8 3.0–5.0 ccm/40 operating hours

Drive engine
Safety instructions > General information
6 Drive engine
Also observe the safety instructions in chapter 1 SAFETY before
starting to work on Drive engine.
WARNING!
– Only carry out maintenance or repair tasks with
engine switched off and cooled down.
– Safeguard the machine against unauthorized
restart before starting maintenance work.
– After maintenance work on the engine, ensure
that all protective devices have been installed
and that all tools have been removed from the
engine.
Also observe the instructions and recommenda-

tions in the operating manual of the engine manu-
facturer.
6.2 Engine oil

CAUTION!
Indicator light oil pressure The oil pressure of the diesel engine is monitored by the SENCON.
SENCON If there is insufficient oil pressure the following symbol is displayed
in the SENCON:
1. Shut down diesel engine immediately.

2. Check engine oil.

Drive engine
Engine oil > General information
WARNING!
Danger of scalding!
– Proceed with the utmost caution when draining
hot oil.
– Waste oil must not seep into the ground or
waterways. Dispose of oil and oil filters in
accordance with statutory regulations.
CAUTION!
ating fluids is not permissible! Only mix oils, lubri-
cants and operational fluids that are of the same
type or identical (same specifications) from one
manufacturer.


Drive engine
Engine oil > Detailed view of the diesel engine
6.2.2 Detailed view of the diesel engine
1 Oil dipstick
2 Oil filler neck

Drive engine
Air filter > General information
6.2.3 Check engine oil level

n Chemical-resistant protective gloves
n Safety shoes
n Safety goggles
Material: n Lint-free cloth
1. Open the service access door.
2. Grasp the handle and pull out the oil dipstick and wipe it off
with a fiber-free, clean cloth.
3. Insert oil dipstick to the stop and pull it out again.
4. Check oil level:
ð The oil level must be between the lower marking (MIN)
and the upper marking (MAX).
5. Refill engine oil to specification as needed.
6. Slide the oil dipstick back in to the stop.
7. Close the service access door.
6.2.4 Changing the engine oil and oil filter

done.
6.3 Air filter

CAUTION!
SENCON air filter indicator light The condition of the air filter is monitored by the SENCON. If
there is contamination, the following symbol is displayed on the
SENCON:

2. Check air filter.

Drive engine
Air filter > Replacing the air filter
6.3.2 Detailed view – air filter system
1 Air filter
2 Dust discharge valve
(example illustration)
6.3.3 Replacing the air filter

done.

Drive engine
Air filter > Checking the air intake system
6.3.4 Cleaning the air filter pre-separator
CAUTION!
NOTICE!
Testing the air intake system on a regular basis
can help prevent damage to the drive engine.
NOTICE!
If dust escapes when pressing the dust discharge
valve, the pre-separator of the air filter must be
cleaned.
1. Set down loads and shut down the engine.

2. Open the locking clamps of the pre-separator cover (1).
3. Carefully clean the pre-separator of the air filter with a suit-
able tool and compressed air if necessary.
4. Refasten the pre-separator cover (1) using the locking
clamps.
6.3.5 Checking the air intake system
CAUTION!

Drive engine
Air filter > Checking the air intake system
NOTICE!
Testing the air intake system on a regular basis
can help prevent damage to the drive engine.
– Check the bends (2, 6) and suction pipe (4) for
leaks.
– Check that clips (1, 3, 5, 7) are seated firmly.
CAUTION!
Maximum drive engine protection against destruc-
tion due to dust is only ensured through regular
maintenance of the air filter and air intake system!

Drive engine
Fuel system (US EPA Tier 3 / EU Stage IIIa / US EPA Tier 4f / EU Stage IV / US EPA Tier 4f / EU Stage V) > Detailed view of the fuel
system
6.4 Fuel system (US EPA Tier 3 / EU Stage IIIa / US EPA Tier 4f / EU Stage IV /
US EPA Tier 4f / EU Stage V)
6.4.1 Detailed view of the fuel system
1 Aeration pump
2 Bleed screw
3 Screw cap for filter element
4 Diesel pre-filter
5 Sensor connector
6 Feed valve for fuel system
7 Drain plug

Drive engine
Replacing the fuel tank vent filter
6.4.2 Visual inspection of the water separator to check for dirt and water
Tool: n Container
1. Open the service door.
2. Carry out a visual inspection of the water container to check
for dirt and water.
ð If dirt and water are visible, drain the water container.
3. Place a suitable collecting vessel under the drain plug.
4. Open the drain plug.
5. Drain water and contamination from the water container until
fuel flows out.
6. Close the drain plug.
7. Close the service door.
6.4.3 Changing the diesel pre-filter cartridge

done.
6.4.4 Changing the diesel fine filter filter cartridge

done.
6.5 Replacing the fuel tank vent filter

done.
6.6 Exhaust after-treatment system

Drive engine
Exhaust after-treatment system > Performing a visual check of the exhaust aftertreatment system for damage, leaks
6.6.1 Checking the DEF level

Preconditions
n The ignition key is in position I.
n SENCON is running.
Check the SENCON parameter field for the DEF level. The
37 % current fill-level is displayed in %.
ð If necessary, top up with DEF.
6.6.2 Performing a visual check of the exhaust aftertreatment system for damage,
leaks
Carry out this maintenance task 250 operating

hours after start-up.

n Service Technician
1. Park the machine.
2. Secure the machine against being restarted without authori-
zation.
3. Let diesel engine cool down.
4. Open the service flap.
5. Perform a visual check of the exhaust aftertreatment system
and check that it is not blocked, corroded, or damaged.
In particular, carry out the following visual checks:
Visual inspection Particular features

Visible soot discharge, par- Black substance
ticularly on the clips
Visible DEF deposits White substance
Visible coolant deposits Greenish substance
Soiling of exhaust aftertreat-
ment system
6. Remove any soiling and combustible deposits from the

exhaust aftertreatment system.

Drive engine
Combination cooler, coolant > Checking the coolant level
6.6.3 Cleaning the DEF tank filling filter

done.
6.6.4 Replacing the container filter for the DEF tank

done.
6.6.5 Replacing the DEF (AdBlue) supply module
Carry out this maintenance task after 4,500 OH or

every 3 years.

done.
6.6.6 Checking the diesel particulate filter
Carry out this maintenance work every 6500 OH.

done.
6.7 Combination cooler, coolant

6.7.1 Checking the coolant level
Indicator light coolant level The coolant level of the diesel engine is monitored by the
SENCON SENCON. If there is insufficient coolant the following symbol is
displayed in the SENCON:

Drive engine
Combination cooler, coolant > Checking the coolant level

2. Check coolant level.
3. Check threaded unions and lines for leaks.
The machine is equipped with a combination

cooler for coolant, hydraulic oil, as well as a charge
air cooler.
1 Charge air cooler

2 Combination cooler
3 maintenance door
WARNING!
– Risk of injury from rotating parts and scalding!
Only perform maintenance work when the drive
engine is shut down and the cooling system
has cooled down.
– The coolant must not seep into the ground or
into waterways. Dispose of coolant in accord-
ance with statutory regulations.
CAUTION!
cants and operational fluids that are of the same
manufacturer.

Drive engine
Cleaning the cooling system > Safety instructions
Further information on changing the coolant can

be found in the operating manual provided by the
engine manufacturer.
6.7.2 Coolant - Cummins engine
CAUTION!
NOTICE!
Only use the coolant specified below:
– In the factory, SENNEBOGEN fills with:
– ES Compleat Antifreeze protection to
-36 °C (-33 °F).
– Do not use more or less than the recom-
mended concentration of 50 Vol.% coolant. If
the content of anti-freeze agent is too high, the
cooling and frost protection properties will be
adversely affected.
NOTICE!
Further information on changing the coolant can
be found in the operating manual provided by the
engine manufacturer.
6.7.3 Checking the coolant level and topping up the antifreeze

done.
6.8 Cleaning the cooling system

6.8.1 Safety instructions
The cooling system ensures that the engine runs at a constant
operating temperature. The cooling system has a crucial influence
on the function and service life of the engine.
The cooler is matched to the respective engine. The cooler must
be kept fully operational to prevent damage to the drive system, for
example due to overheating. Therefore you must check the cooler
regularly and clean it if necessary.

Drive engine
Cleaning the cooling system > Using fan reversal to clean the combination cooler
Coolers can be fouled on the outside (for example, through dust)

and on the inside (for example, through corrosion).
This section provides you with general instruc-

tions on cleaning the cooler. Also observe the
instructions in the engine manufacturer's operating
manual.
WARNING!
– If the cooler is damaged, contact
SENNEBOGEN Customer Service before
starting on the repair tasks.
– Repair tasks on the cooling system should only
be carried out by specialists.
– Do not touch the protective grating of the fan.
Rotating fan blades can cause severe injury.
Objects that fall against the fan blades can be
accelerated out of the fan with great force.
– Switch off the machine and ensure that it
cannot be switched on again before starting
any cleaning tasks.
– Always wear face protection or protective gog-
gles when working on the cooling system.
– Always relieve the pressure in the cooling
system before starting any cleaning tasks. To
do this, let the cooling system cool down, place
a cloth over the sealing cover and open the
cover slowly to allow the cooling system to cool
down.
– Do not use cleaning agents that can damage
the cooler materials or the paint on the
machine.
– Antifreeze agents are flammable. Do not
smoke in the vicinity of the cooling system and
do not ignite an open flame.
Comply with the manufacturer’s specifications when handling

coolant or cleaning agents.
6.8.2 Using fan reversal to clean the combination cooler

ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves

Drive engine
Cleaning the cooling system > Visual inspection of the combination cooler
Small amounts of dirt can be blown out by reversing the fan.

1. Allow the drive engine and combination cooler to cool down.
3. Touch the [Manual fan reversal] quick-select icon on the
SENCON in the cab.
4. Close the service door again.
6.8.3 Visual inspection of the combination cooler

Procedure Personnel: n Machine operator
Carry out a visual inspection of the combination cooler and
the grille to check for damage and foreign bodies.
ð Remove any foreign bodies identified. Contact the
service technician in the event of damage being identi-
fied.

Drive engine
Cleaning the cooling system > Check and clean combination cooler
6.8.4 Check and clean combination cooler
WARNING!
Risk of injury from rotating, sharp or hot parts.
Persons can be injured by moving, sharp or hot
parts on or near the combination cooler.
– Only perform maintenance when the drive
engine is off and the cooling system has
cooled down.
NOTICE!
Coolant that has not been properly disposed of or
poured contaminates ground water.
– Make sure coolant does not seep into the soil
or reach bodies of water.
– Observe applicable environmental standards
for disposing of coolants.
Observe the engine manufacturer's operating

manual. Only mix the same type of or identical
(same specification) oils, lubricants and operating
fluids from the same manufacturer.
Check and clean combination

cooler

Protective equipment:
1. Let the diesel engine and combination cooler cool down.

2. Carefully open the sealing cap (2) in of the expansion tank
(1) in to equalize the pressure.

Drive engine
Cleaning the cooling system > Interior cleaning of the cooling system
3. Check the antifreeze and coolant level. Add coolant as

needed. The coolant must contain at least 50% antifreeze
throughout the year.
4. Close the expansion tank with the sealing cap.

5. Blow off the cooling fins on the exhaust side with dry, filtered
compressed air (max. 2 bar). If contaminated with grease
and oil, clean the radiator fins using cold-cleaning agent and
a steam cleaner.
6. Check the combination cooler for leaks and damaged cooling
fins.
– See the engine manufacturer's operating

manual for coolant change intervals.
6.8.5 Interior cleaning of the cooling system
CAUTION!
NOTICE!
Also observe the instructions in the engine manu-
facturer's operating manual.
It is necessary to clean the interior of the cooling system in the

following situations:
n The engine is constantly overheating even though the V-belt,
thermostat, and water pump are functioning properly.
n Contamination is visible in the expansion tank. Remove and
check the sealing cover.
n Green sludge (chromium hydroxide) is present on the under-
side of the sealing cover.
n The coolant is very cloudy.
n Lubricating oil is in the coolant.
Procedure
1. Observe the safety instructions.
2. Drain the refrigerant into suitable containers and dispose of it
in accordance with regulations.

Drive engine
Visual inspection of the diesel engine V-belts
3. Add a mixture of standard cooling system cleaner and water.
CAUTION!
Observe the mixing ratio and ensure that the
cooling system cleaner is used properly.
4. Start the engine and allow it to run for approximately

1.5 hours.
5. Drain the mixture into suitable containers and dispose of it in
accordance with regulations.
6. Flush the cooling system thoroughly with clean water; repeat
this process several times.
CAUTION!
Always fill using a mixture of water and refrig-
erant. Observe the mixing ratio. Mix before
filling!
7. Fill the cooling system with a mixture of water and refrigerant.
Cleaning that extends beyond these instructions

is only possible with the cooler removed. Con-
tact SENNEBOGEN Customer Service before
removing the cooler.
6.9 Visual inspection of the diesel engine V-belts
DANGER!
– Only carry out maintenance work when the
drive engine is shut down and at a standstill.
– Shut down machine and secure it against
unauthorized restart before starting mainte-
nance tasks.
– Replace protective covering after maintenance
work, if necessary.
– Ensure sure that the V-belts run in parallel.
To check, tension, and replace the belt drives,

comply with the instructions in the operating
manual provided by the engine manufacturer.

Drive engine
Electric motor > Performing the major inspection

1. Ensure that the V-belts are not damaged and that they run in
parallel.
2. Check the tension of the V-belts.
6.10 Electric motor

6.10.1 Performing the initial inspection
done.
6.10.2 Performing the major inspection

done.

Drive engine
Electric motor > Lubricating the roller bearings
6.10.3 Lubricating the roller bearings

done.

Undercarriage
Safety instructions
7 Undercarriage

tasks.

starting to work on the undercarriage.
7.2 Notice
WARNING!
Risk of injury from rotating parts!
Only carry out maintenance work when the drive
engine is shut down.
– Maintenance and repair tasks must only be
executed by specialized personnel.
– Oil must not seep into the ground or water-
ways. Dispose of old oil in accordance with
statutory regulations.
DANGER!
Risk of injury due to improperly mounted or
damaged wheels and tires!
Accidents can occur if the wheels are not mounted
correctly.
Damaged tires or incorrect air pressure can influ-
ence the handling of the machine and lead to acci-
dents.
– Do not operate the machine with damaged
wheels or tires.
– The assembly and repair work on the wheels
and tires should only be carried out by qualified
personnel.
– Check the tire pressure regularly and correct if
necessary.
– Check the attachment of the wheel nuts regu-
larly and tighten if necessary.

Undercarriage
Mobile undercarriage > Tightening the wheel lug nuts
7.3 Mobile undercarriage

7.3.1 Cleaning the mobile undercarriage
ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves
1. Park the machine on a level surface.

2. Switch off drive engine and safeguard it against restart.
3. Clean the tires and the undercarriage using a steam cleaner.
ð Hold the steam cleaner at least 20 cm away from the
surface to be cleaned.
4. Lightly grease the guides and bolts.
5. Lubricate all lubrication points. Ä Chapter 5.2.3 “Lubricating
the lubricating points on the central lubricating bar for
the undercarriage” on page 108, Ä Chapter 5.2.4 “Distrib-
uted manual lubrication points on Mobile undercarriage”
on page 109
7.3.2 Tightening the wheel lug nuts
Carry out this maintenance task every 50 OH after

startup.

ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves
Tool: n Torque wrench, width 32 mm

Undercarriage
Mobile undercarriage > Measuring the wear of the brake

zation.
3. Set the torque wrench to the specified value.
1
10 2
9 3
1
10 3 8 4
7 5
8 6
5
6
7
4 9
2
00453
Fig. 15: Tightening wheel lug nuts

4. Tighten the wheel nuts one after the other crosswise.
ð Start with the wheel nut at the top (1).
Turn the nuts clockwise with the torque wrench.
5. Release the torque wrench so that the spring does not go
slack and the set torque values will remain accurate in the
future.
Further notes: n
7.3.3 Measuring the wear of the brake

Once a year, particularly if there is a change in brake behavior (for
example, brake noise, reduced braking power).
1. Turn the hub until the mark (2) is horizontal and the lettering
is legible.
2. Shut down drive engine and safeguard against restart.
3. Unscrew oil filler screw/drain screw (1).

Undercarriage
Mobile undercarriage > MP38E axle distribution gearbox
4. With the brake disengaged, position the dial gauge (3)

through the oil filling opening (1) as shown (zero position).
5. Activate the brake and use the dial gauge to determine the
piston stroke (X) (limit value: 6.5 mm/approximately 0.256 in).
If the maximum wear limit is reached, replace the pad linings.
6. Remove the dial gauge, clean components, check seals and
replace if necessary.
7. Re-tighten the oil filler screw/drain screw (1).
CAUTION!
The brake linings of the axle must be replaced if
the residual brake lining thickness has worn down
to these values.
7.3.4 MP38E axle distribution gearbox
WARNING!

Undercarriage
1 Oil filler plug

2 Oil drain plug
NOTICE!
Only mix oils, lubricants, and operating fluids that
are of the same type or identical (same specifica-
tions) from one manufacturer!
Checking the oil level 1. Bring machine up to operating temperature.

Wait approximately 10 minutes for the oil to collect in the axle
distribution gearbox.
4. Clean exterior of the axle distribution gearbox using a cloth.
5. Unscrew the oil filler plug (1). The oil level must reach the
lower edge of filler opening; top up if necessary.
6. Clean the components, check the seal, and replace if neces-

sary.
7. Re-tighten the oil filler screw (1) (MA = 50Nm).
Changing the oil 1. Bring machine up to operating temperature.

Wait approximately 10 minutes for the oil to collect in the axle
distribution gearbox.

Undercarriage
4. Clean exterior of the axle distribution gearbox using a cloth.

5. Loosen oil filler plug (1) to relieve the pressure.
6. Place a suitable collecting vessel under the oil drain screw

(2).
7. Unscrew the oil drain plug (2) and collect the waste oil in the
container.
8. Clean components, check seals, and replace if necessary.

9. Retighten oil drain screw (2).
10. Unscrew the oil filler plug (1).
11. Fill with new oil to the lower edge of the filler opening.
12. Retighten the oil filler plug (1).
13. Operate for 2 hours, then re-check the oil level.
Top up oil, if required.
WARNING!
The lubricating nipple (4) on the emergency acti-
vation mechanism must not be used for lubrica-
tion purposes. It is used exclusively for triggering
the emergency activation. The gearbox can be
destroyed.

Undercarriage
Mobile undercarriage > MP26E / MP30E / MP31E - Hub drives
7.3.5 MP26E / MP30E / MP31E - Hub drives
1 Oil filler/drain screw

2 Oil level marking
CAUTION!
Checking the oil level

is legible.
4. Unscrew oil filler screw/drain screw (1). The oil level must be
at the marking (2), top up if necessary.
sary.
7. Repeat procedure on the three remaining hubs.
Changing the oil

2. Turn hub until the oil filler screw/drain screw (1) is at the
bottom.
4. Place a suitable collecting vessel under the oil filler screw/
drain screw (1).

Undercarriage
Mobile undercarriage > MP38E hub gear
5. Unscrew the oil filler screw/drain screw (1) and collect the
waste oil in the container.
is legible.
8. Fill with new oil to the mark (2).
11. Operate for 2 hours, then re-check the oil level. Top up oil, if
required.
7.3.6 MP38E hub gear
1 Oil filler plug

2 Oil drain plug
NOTICE!
cants, and operating fluids that are of the same
manufacturer!
Checking the oil level 1. Place machine in a horizontal position.

2. Rotate the hub until the oil drain plug (2) is down (6- o'clock
position).
3. Shut down the drive engine.

Undercarriage
Mobile undercarriage > MP38E hub gear
4. Unscrew the oil filler plug (1). The oil level must reach up to
lower edge of oil filler screw, add oil if necessary.

sary.
Changing the oil 1. Place machine in a horizontal position.

2. Turn hub until the oil drain screw (2) is at the bottom.
5. Place a suitable collecting vessel under the oil drain plug (2).
For capacity, see Section 3.3.
container.

10. Fill with new oil up to lower edge of oil filler screw (1).

Undercarriage
Mobile undercarriage > MP26E / MP30E / MP31E - Differential
7.3.7 MP26E / MP30E / MP31E - Differential
1 Oil filler plug

2 Oil drain screw
CAUTION!
Fig. 17: Rear axle

Fig. 16: Front axle

1. Bring machine up to operating temperature.
3. Shut down drive engine and safeguard against restart. Wait
approximately 10 minutes for the oil to collect in the differen-
tial.
4. Clean exterior of differential using a cloth.

Undercarriage
Mobile undercarriage > MP26E / MP30E / MP31E - Differential
lower edge of the fill opening. Top up oil, if required.
sary.
Changing the oil

3. Shut down drive engine & safeguard against restart. Wait
approximately 10 minutes for the oil to collect in the differen-
tial.
(2).
7. Unscrew oil drain screw (2) and collect the waste oil in the
container.
9. Re-tighten oil drain screw (2).
required.

Undercarriage
Mobile undercarriage > MP38E differential
7.3.8 MP38E differential
1 Oil filler plug

2 Oil drain plug
NOTICE!
manufacturer!

Wait approximately 10 minutes for the oil to collect in the
differential.

Undercarriage
Mobile undercarriage > Oil change at differential

lower edge of the filler opening. Top up oil, if required.

sary.

differential.
container.

required.
7.3.9 Oil change at differential


Undercarriage
1 Oil filler plug

2 Oil drain plug
NOTICE!

differential.
lower edge of the filler opening. Top up oil, if required.

sary.

differential.

Undercarriage

container.

required.
CAUTION!
The parking brake does not function if the emer-
gency actuating mechanism has been activated.
No attempt to shift gears should be made if the
emergency actuating mechanism has been acti-
vated.

Undercarriage
Mobile undercarriage > MP42E - Intermediate gear and differential
7.3.10 MP42E - Intermediate gear and differential
WARNING!
Checking oil
2. Place machine in a horizontal position.
3. Shut down the drive engine. Wait approximately 10 minutes
for the oil to collect in the differential.
4. Unscrew the oil filler plug (2). The oil level must be at the
lower edge of the filler opening, top up if necessary.
sary.
NOTICE!
The oil level from the back gear and differential is
checked using the oil filler screw (2).

Undercarriage
Mobile undercarriage > Oil change at parking disc brake
Changing the oil

for the oil to collect in the differential.

(1). For capacity, see Section 3.3.1.
(3). For capacity, see Section 3.3.1.
container.
container.
13. Unscrew oil filler screw (2).
14. Unscrew oil filler screw (4).
15. Fill with new oil up to lower edge of filler opening (2).
16. Fill with new oil up to lower edge of filler opening (4).
NOTICE!
The oil level from the back gear and differential is
checked using the oil filler screw (2).
7.3.11 Oil change at parking disc brake


Undercarriage
Mobile undercarriage > Oil change at parking disc brake
1 Oil filler plug

2 Oil level control screw
3 Oil drain screw
WARNING!

for the oil to collect in the travel gear.
4. Unscrew the oil level control screw (2). Oil flows out when the
oil level has been reached.
5. If necessary, unscrew oil filler plug (1) and top up with oil.
sary.
7. Re-tighten oil level check screw (2).

Undercarriage
Mobile undercarriage > MP31E/MP38E drive shafts
Changing the oil

for the oil to collect in the travel gear.
(3). For capacity, see Section 3.3.
container.
10. Unscrew the oil level control screw (2).
11. Add new oil.
Oil flows out when the oil level has been reached.
12. Re-tighten oil level control screw (2).
7.3.12 MP31E/MP38E drive shafts
The two drive shafts/universal joints have one

lubricating nipple each.
Each joint is lubricated by one lubricating nipple.
NOTICE!
To avoid damaging the seals and prevent the
ingress of water and dirt, high-pressure cleaning
must not be used to clean the drive shafts/uni-
versal joints.

Undercarriage
Mobile undercarriage > MP31E/MP38E drive shafts
Check the following items regularly:

– Fittings and connecting flanges
– Drive shaft/universal joints for unusual noises
and vibration during operation
– Drive shaft/universal joints for play in the bear-
ings and length compensation prior to lubri-
cating
1 Grease nipple for cross joint (shown here with protective cap)
Lubricating the drive shafts/uni- 1. Lift the machine using all four supports.
versal joints
3. Turn the wheels until the lubricating nipples are in an acces-
sible position.
4. Remove the protective caps from the grease nipples.
5. Press the fill valve on the grease gun onto the grease nipple
until it snaps into place.
6. Grease the joint by pumping the grease gun with a smooth
motion. Note: Grease must exit from the seals of the cross
joints visibly. However: When lubricating the telescopic pro-
file, pump the grease gun only a few times (not until grease
appears, as otherwise excessive axial forces and damage to
the seals will result!).
7. Repeat these steps with the remaining grease nipples.
8. Wipe off excess grease with a cloth.
9. Replace all protective caps on the grease nipples.
10. Retract the supports completely.

Undercarriage
Crawler undercarriage > Cleaning and lubricating
7.4 Crawler undercarriage

7.4.1 Carrying out a visual inspection of the crawler chassis
ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves
Carrying out visual inspections of

the crawler chassis
2. Switch off drive engine and safeguard it against restart.
3. Check the bolt connections and the threaded unions for firm
seat and completeness.
4. Check the bushes for any signs of damage or deformation.
5. Check the running surfaces of the chains and the bushes for
any signs of wear.
6. Inform the service technician about the damaged or worn
components.
7.4.2 Cleaning and lubricating

2. Shut down the drive engine and secure it to prevent it being
restarted.
3. Check components and threaded unions for firm seat and
completeness.
4. Clean crawler running gear, crawler track and pulleys with
steam cleaner.
CAUTION!
Attention! Hold the steam cleaner lance at
least 20 cm away from the surface to be
cleaned.
5. Lightly grease guide mechanisms and bolts.

6. Lubricate all lubrication points.

Undercarriage
Crawler undercarriage > Crawler travel drive
7.4.3 Crawler travel drive

7.4.3.1 Travel gear
1 Fastening bolts – sprocket

2 Oil filler plug
3 Oil drain screw
1. Park the machine on a level surface. Ensure that the oil drain
screw (3) is at the lowest position.
3. Unscrew the oil filler plug (2). The oil level must be at the
lower edge of the filler opening, top up if necessary.
Changing the oil

1. Park the machine on a level surface. Ensure that the oil drain
screw (3) is at the lowest position.
3. Place a collecting vessel under the oil drain screw (3).
container.
8. Pour fresh oil in through the oil filler plug (2) up to the lower
edge of the filler opening.

Undercarriage
Crawler undercarriage > Crawler track
required.
7.4.3.2 Checking the quality of the crawler travel drive oil

done.
7.4.3.3 Change crawler transmission oil


done.
7.4.4 Crawler track

7.4.4.1 Check the crawler track tension
Adequate but not excessive track tension is essential for the track
running gear to function smoothly and with minimal wear.
Properly adjusted track tension will reduce the

wear of undercarriage parts.

ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves

Undercarriage
Crawler undercarriage > Crawler track
Check the crawler track tension
X Sag measurement
DANGER!
– Ensure no one is in the danger zone of the
machine.
– Use suspension gears with sufficient capaci-
ties!
– For lattice mast cranes – dismount ballast and
boom!
– Raise machine using suitable means and with
extreme caution (use lifting points provided).
1. Clean the running gear and crawler tracks thoroughly.

2. Park the machine on level and firm ground.
3. Lift the machine with suitable lifting gear until the crawler
track is no longer in contact with the ground.
4. Check the sag measurement “X” between the track roller and
the chain link.
ð The crawler track is properly tensioned when the sag
dimension "X" in the center of the track wheel carrier is
between min. 70 mm and max. 80 mm.
If the sag measurement "X" is not within the specified
range, the crawler track needs to be tensioned: Contact a
service technician to have this maintenance work carried
out.
5. Lower the machine back down to the ground and remove the
suspension gear.
7.4.4.2 Tension the crawler track

done.

Undercarriage
Rail undercarriage > Cleaning and lubricating
7.4.5 Retighten the sprocket screws

done.

7.4.6 Checking the fastening screws on the base plates for firm seat and tightening
if necessary
done.

7.5 Rail undercarriage

7.5.1 Cleaning and lubricating
CAUTION!

2. Shut down the drive engine and secure it to prevent it being
restarted.
3. Check components and threaded unions for firm seat and
completeness.
4. Clean track wheel carrier, track wheels, and travel drive with
steam jet.
CAUTION!
Attention! Hold the steam cleaner lance at
least 20 cm away from the surface to be
cleaned.
5. Lightly grease guide mechanisms and bolts.

Undercarriage
Rail undercarriage > Travel gear
6. Lubricate all lubrication points.
7.5.2 Travel gear
WARNING!
1 Bleeder plug
2 Oil filler plug
3 Oil drain plug
lower edge of filler opening; top up if necessary.
2. Screw in oil filler plug (2).
3. Check bleeder plug (1), clean or replace if necessary.

Undercarriage
Rail undercarriage > Track wheels
Changing the oil
For capacity, see Section 3.3.
container.
5. Screw in the oil drain screw (3).
6. Fill with new oil to the lower edge of the filler opening. For
capacity, see Section 3.3
7. Screw in oil filler plug (2).
7.5.3 Track wheels

Check fastening

2. Thoroughly clean the machine.
3. Check the torque of all fastening bolts (1) with a torque
wrench.

Undercarriage
Structure > Middle bridge clamp - Stabilizer box
7.5.4 Cable drum
NOTICE!
Also comply with the descriptions and instructions
in the operating manual provided by the manufac-
turer. See Section 13.
7.5.5 Geared motor
NOTICE!
Also comply with the descriptions and instructions
in the operating manual provided by the manufac-
turer. See Section 13.
7.6 Structure
7.6.1 Middle bridge clamp - Stabilizer box
1 Strain relief
2 Stabilizer box
3 Center bridge

Undercarriage
Structure > Ballast
The following is to be checked in regular intervals:

– The correct clamping between middle bridge
and outrigger box.
7.6.2 Ballast
1 Locking bolts
2 Pin
3 Ballast

– The correct locking (locking bolts (1) including
the retaining spring) on the counterweights.
– The secure fastening/guying of the ballasts (2).

Undercarriage
Structure > Outrigger
7.6.3 Outrigger
1 Spindle
2 Clamping - spindle
3 Lubricating nipple
4 Adapter, bracket, outrigger pad
Lubricate stabilizers
NOTICE!
The lubricating nipples are fitted with a red protec-
tive cap.
1. Clean lubricating nipple (3). (see Section 1.7)

2. Apply high pressure grease gun to the lubricator nipple and
actuate.
NOTICE!
– The horizontal alignment of the entire machine.
Readjust the spindle (1), if necessary.
– The clamping of the spindle (2). Re-clamp, if
necessary.
– The correct seat of the brackets (4).
– The lubrication for the spindle.

Rotary connection
Safety instructions
8 Rotary connection

ized and trained by SENNEBOGEN are allowed to
perform repair and measurement tasks.
Please also observe the safety instructions in chapter 1 SAFETY

before starting to work on the swing bearing.
8.2 General information
NOTICE!
manufacturer!
Ensure that the rotary connection is well lubricated.

n Bearing race (1):
– Via central lubrication system.
n Gearing (2):
– with gear spray or
– via the slewing ring pinion lubrication system.
n Seal (3):
– Check the seal between the bearing race and the gearing
for damage.
Relubrication must be carried out before and after

longer periods during which the machine is decom-
missioned (longer than 3 months)!

Rotary connection
Lubricating the slewing ring bearing race > Central lubrication system
1 Bearing race
2 Gearing
3 Seal
8.3 Lubricating the slewing ring bearing race

8.3.1 Central lubrication system
WARNING!
The central lubrication system automatically lubricates the bearing

race of the rotary connection, as well as the bearings of the equip-
ment and the adjustable cab. The lubrication cycle is pre-set at the
factory.
The preset lubricating cycle can be shortened.

See the documentation for the CENTRAL LUBRI-
CATION SYSTEM in the operating manual.
Shorter lubrication intervals are required in the following cases:

n High humidity
n High levels of dust or contamination
n Severe temperature fluctuations
n Continuous rotation

Rotary connection
1 Grease reservoir - note MIN/MAX markings

2 Add grease **/***
3 Add grease */**
Manually actuating the bearing race Lubrication can be actuated manually via the SENCON:
lubrication system
using the symbol:

Rotary connection
Adding grease
Setting parameters
The lubrication cycles of the central lubrication systems for the
uppercarriage and undercarriage are set via the SENCON ().
If work conditions are harsh, the lubrication cycles must be
adjusted accordingly. Examples of harsh work conditions:
n Multi-shift operation
n Increased drive proportion of more than 25% of the deployment
time
n Use in extremely abrasive material
n Frequent contact with water or corrosion promoting substances
n Use at extreme temperatures
If you have any questions, contact your SENNEBOGEN service
partner.

Rotary connection
Lubricating the slewing ring gearing > Lubricating the slewing ring pinion
After a run-in phase of approximately 100 hours

and after inspecting all lubrication points, the lubri-
cation time can be increased or decreased as
needed.
8.4 Lubricating the slewing ring gearing

8.4.1 Gear spray (option)
CAUTION!

2. Thoroughly clean the gearing.
3. Check gearing of slewing ring and slewing ring pinion for
wear and replace if necessary.
4. Spray gearing from a distance of approximately 30 cm with
SENNEBOGEN gear spray (see Lubricant Table).
5. Swing the uppercarriage a number of times so that the lubri-
cant is distributed uniformly over the gearing.
8.4.2 Lubricating the slewing ring pinion
CAUTION!

Rotary connection
NOTICE!
Clean the lubrication point thoroughly down to
the bare metal before the first application of lubri-
cant to ensure that the lubricant creates an uninter-
rupted lubricant film across the surface!

2. Thoroughly clean the gearing.
3. Check gearing of slewing ring and slewing ring pinion for
wear and replace if necessary.
4. Start the drive engine
5. Releasing swing bearing lubrication:
n Press and hold the push button for slewing ring lubrica-
tion on the right of the control panel for at least 2 sec-
onds.
n Use the control lever to swing the uppercarriage 360° to
the left and right to distribute the lubricant evenly over the
gearing.
Repeat the lubrication process if necessary.
NOTICE!
Check the lubricant tank weekly and refill with lubri-
cant if necessary!
CAUTION!
Check the plastic sliding wear pad (2) in the lubri-
cation assembly (1) once every three months for
wear. Observe the wear limit!
Replace the plastic sliding wear block (2) when the wear limit has
been reached! Otherwise considerable damage can occur on the
machine. The owner of the machine is solely liable for this type of
damage and for consequential damage!

Rotary connection
Checking the plastic skid
WARNING!
Before checking the plastic skid (2):
– Lower attached loads and boom to the ground.
– Pull the left-hand safety lever back.
– Shut down the machine and secure it against
unauthorized restarting before starting the
maintenance tasks.
– Attach warning sign on the operating elements.
1. Remove the lubrication device (1).

2. Check plastic sliding wear pad (2) for wear (min. 28 mm).
3. Replace the plastic skid if necessary.

Rotary connection
Slewing gear box
Adding grease
1 Lubricant reservoir
1. Open cover (1) of lubricant reservoir.
2. Add lubricant (see lubricant table).
3. Close cover.
8.5 Slewing gear box
CAUTION!
WARNING!

Rotary connection
Slewing gear box
NOTICE!
Depending on the machine type, multiple slewing
gears with the respective oil expansion tank may
be installed. Maintenance must, therefore, be car-
ried out on all slewing gears.
1 Oil expansion tank per slewing gear

2 Filling level at 15 °C - 20 °C Oil temperature (marking - approx.
Quarter filling of the oil equalizing tank).
3 Slewing gear box
4 Oil drain with hose
5 Transmission vent (via compensating tank (1))

1. Lower attached loads and the boom to the ground.
4. Allow the oil in the swing gear box to cool.
5. Check oil level:
n Fill level at 15 °C to 20 °C oil temperature (marking –
approx. quarter of fill volume of oil expansion tank).
n The oil level can vary according to the oil temperature, up
to a three-quarter filling is possible.
6. If necessary top up oil of the specified grade.

Rotary connection
Slewing gear box
Changing the gear oil

1. Lower attached loads and the boom to the ground.
4. Unscrew oil expansion tank (1) cover.
5. Old oil will escape via the oil drain with hose. Collect used oil
in a suitable container.
6. Screw cover nut back on.
Adding oil
1. Add new oil via the oil expansion tank (1) until marking (2) is
reached.
2. Check oil level:
n Fill level at 15 °C to 20 °C oil temperature (marking –
approx. quarter of fill volume of oil expansion tank).
n The oil level can vary according to the oil temperature, up
to a three-quarter filling is possible.
3. Screw oil expansion tank (1) cover closed.

Rotary connection
Visual inspection of the seals on the rotary connection for the slewing ring
8.6 Visual inspection of the seals on the rotary connection for the slewing
ring
ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves
Tools and equipment

Tool: n Putty knife
n Lint-free cloths
Material: n Commercial solvent
Overview
Fig. 18: Seals on the rotary connection for the slewing ring
(example sectional view)
1 Sealing lip
2 Grease collar
3 Bearing race

Rotary connection
Visual inspection of the slewing ring screw connection
Checking the seals on the rotary

connection
1. Carry out a visual inspection of the area around the sealing
lips to check for sufficient lubrication:
n Dry areas due to insufficient lubricant quantity
n Dust deposits in the lubricant
ð Relatively little of the lubricating grease has been used all
the way around the sealing lips.
If lubrication is insufficient, check the cause:
n Lubricate the bearing race of the rotary connection
manually: Fresh lubricating grease must escape from
the sealing lips.
n On machines with central lubrication systems, adjust
the lubrication cycles according to machine usage.
2. Use a putty knife to remove any excess lubricating grease
that has escaped.
ð The grease collar should be retained all the way round
the sealing lips.
3. Use lint-free cloths to wipe clean any areas of the rotary
connection where dirt has accumulated.
Take care to stop dirt getting into the bearing races or the
lubrication.
4. Check the seals for signs of visible damage:
n Cracks
n Cuts
n malformations
ð The seals are intact if there are no signs of damage all
the way round.
Have damaged seals replaced by an expert.
8.7 Visual inspection of the slewing ring screw connection

ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves

Rotary connection
Using wear measurement to check the bearing play of the rotary connection for the slewing ring
Checking slewing ring screw con-

nection
1. Check that the visible slewing ring screw connections are
complete.
2. Check the visible slewing ring screws for deformation or
external changes:
n Deformation due to buckling
n Elongation
n Discoloration due to heat
3. Check the visible slewing ring screws for corrosion:
n Incipient oxidation on the surface can be easily wiped
away.
n Increased oxidation will make the surface rougher.
n Heavy oxidation is indicated by decomposition of the sur-
face.
In the case of heavy oxidation, have the slewing ring
screws checked and replaced by an expert.
4. Make a note of any significant change in condition and inform
the expert.
8.8 Using wear measurement to check the bearing play of the rotary connec-
tion for the slewing ring
done.
8.9 Checking the preload of the bolts of the rotary connection of the slewing
ring
done.

Hydraulic system
Safety instructions
9 Hydraulic system
starting to work on hydraulic system.
WARNING!
– Warning - high oil pressure!
The hydraulic system is subject to high
pressure. Serious injuries can be caused
by escaping hydraulic oil when loosening a
hydraulic connection or if a leak should occur.
Only perform work on the hydraulic system
when it is fully depressurized!
– Wear personal protective equipment (e.g.
hard hat, hearing protection, protective gloves,
safety footwear).
– De-pressurize the hydraulic system before
starting maintenance work (see Section 8.2.6).
– The pilot control is equipped with a pressure
accumulator, which remains under high pres-
sure even after the engine is shut down. The
pressure accumulator must therefore be dep-
ressurized.
– Danger of injury!
Hydraulic oil escapes under high pressure if
there are leaks. Hydraulic oil escaping under
high pressure penetrates the skin and causes
severe health impairments. Danger of infection.
In the event of injury contact a doctor immedi-
ately!
– Danger of injury from scalding
The hydraulic oil can reach temperatures of
70 °C (158 °F) and higher. Only carry out main-
tenance tasks after the hydraulic oil system
has cooled down.
– Risk of injury from rotating parts.
Only perform maintenance tasks when the
engine is shut-off and only if you have ensured
that the fan blade is at a standstill and auto-
matic start-up is not possible. Before recom-
missioning, ensure that:
– No items (tools, for example) are in the
vicinity of the fan wheels or could fall
into this area as a result of vibration, for
example
– The safety devices have been installed.

Hydraulic system
General information > Hydraulic hoses
9.2 General information

9.2.1 Hydraulic hoses
9.2.1.1 Checking the tightness of the fittings on the hydraulic hoses
done.
9.2.1.2 Checking the fittings on the hydraulic hoses for leaks
WARNING!
Risk of severe burns from hot parts and hot
hydraulic oil
Contact with hot hydraulic system parts or hot
hydraulic oil can cause severe burns.
– Only check the hydraulic oil level when the
hydraulic system is cooled.
– Only fill up with hydraulic oil when the hydraulic
system is cooled.
– Avoid contact with hot parts.
– Wear protective clothing and protective gloves.
– Shut down the leaking hydraulic system imme-
diately.
WARNING!
Risk of serious injury from pressurized
hydraulic oil
Opening the hydraulic system can cause pressur-
ized hydraulic oil to eject and result in serious
injury.
– Depressurize the hydraulic system before
starting work on it.

ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves

Hydraulic system
General information > Hydraulic hoses
Checking the fittings on the

hydraulic hoses for leaks
1. Set the boom down.
zation.
4. Depressurize the hydraulic system.
5. Turn off the battery disconnect switch.
6. When performing a visual inspection of all fittings on the
hydraulic hoses, check the following criteria:
ð If a fitting does not meet at least one of the stated criteria,
the fitting must be replaced.
7. Inform the service technician about the detected defects.
Test criteria Hose connection and connection components

No deformations, damage, corrosion of the fitting Hose fitting and connection, coupling sleeve, coupler
and the connection, that hinder the function, security, plug
and impermeability of the connection
9.2.1.3 Check the hydraulic hoses

done.
9.2.1.4 Change hydraulic hoses

every 6 years.

done.

Hydraulic system
General information > Hydraulic cylinder
9.2.2 Hydraulic cylinder

9.2.2.1 Visual inspection of hydraulic cylinders for damage and leaks
ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves
1. Carry out a visual inspection of the hydraulic cylinders, the

pipework and the screw connections to check for leaks.
ð Contact a service technician if leaks are detected.
2. Check that the screw connections are tight.
3. Carry out a visual inspection of the hydraulic cylinders to
check for damage.
ð Contact a service technician if damage or leaks are iden-
tified.
9.2.2.2 Cleaning and oiling the piston rods of the hydraulic cylinders
ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves
Tools and equipment

Tool: n Ladder
n Paintbrush

Hydraulic system
General information > Piston accumulators
NOTICE!
Property damage due to contamination/corro-
sion of the piston rods
Contamination of the piston rods and the wipers
(e.g., due to salt, water, dust, sand, corrosion-
causing materials) will damage the sliding surfaces
and seals.
– Check the piston rods and wipers for contami-
nation every day and clean them as needed.
– Clean piston rods and wipers according to
maintenance plan.
– At the end of daily operation, position the
machine so that the piston rods are fully
retracted and protected in the cylinder liners.
Cleaning and oiling the piston rods

of the hydraulic cylinders
1. Fully extend each piston rod.
ð The piston rod is fully accessible.
2. Clean the piston rod with the cloth only.
3. Completely wet the piston rod with the fresh mineral oil.
ð The piston rod is protected against the elements.
9.2.2.3 Replacing the seal of the hydraulic cylinder

done.
9.2.3 Piston accumulators

9.2.3.1 Checking the connections of the piston accumulator for leaks
ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves

Hydraulic system
General information > Piston accumulators
9.2.3.2 Checking fittings and safety devices on piston accumulator for correct condition
ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves
9.2.3.3 Checking the fastening elements of the piston accumulator

ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves
9.2.3.4 Checking the piston accumulator for corrosion and deformation

ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves
9.2.3.5 Checking the pilot pressure of the piston accumulator


done.

Hydraulic system
General information > Hydraulic pumps
9.2.4 Safety valves
WARNING!
Tampering with safety valves will place you and
other persons in life-threatening danger!
When performing maintenance on hydraulic
valves, especially safety valves, comply with the
following instructions:
– Lead seals that have been attached must not
be removed or damaged.
– The setting values of the safety valves must
not be changed by the user. Only authorized
testing centers are permitted to make readjust-
ments.
– Only new, tested spare parts that are identical
in design and comparable in quality to original
equipment are approved for replacement.
Installing untested components is not permitted for safety reasons.
9.2.5 Threaded unions

Check hydraulic threaded unions and couplings regularly for leaks.
Seal leaks and remove oil spots. Escaping hydraulic oil is harmful
to the environment and poses a hazard due to danger of slipping.
Always seal disconnected threaded unions with stoppers on both
sides.
9.2.6 Hydraulic pumps
Slight oil moisture or moistening due to oil in the

area around the shaft sealing ring of the pump(s)
is normal and does not necessarily mean that
the shaft sealing ring or the pump needs to be
replaced.

Hydraulic system
General information > Hydraulic pumps
Slight oil humidity in the area of the

shaft sealing ring
The shaft sealing ring or pump do not need to be replaced!
Slight leakage in the area of the

shaft sealing ring
Traces of dripping oil; the shaft sealing ring must be replaced.

During the warranty period, please contact the SENNEBOGEN
Warranty Department first.
Bleeding the hydraulic pump
Carefully loosen or unscrew the Allen plug until oil escapes without
bubbles.

Hydraulic system
Measuring the hydraulic pressure > General
9.2.7 Depressurizing the hydraulic system

done.
9.3 Measuring the hydraulic pressure

9.3.1 General
The hydraulic pressure must only be measured on

the measuring strip installed at the factory.
CAUTION!
Every 10 years/20,000 operating hours, arrange
for a pressure test and an internal inspection of the
pressure accumulator by an authorized expert.
WARNING!
– Warning – high oil pressure and danger of
scalding. The hydraulic system is subject to
high pressure. Serious injuries can be caused
by escaping hydraulic oil when a hydraulic con-
nection is loosened. Only perform work on the
hydraulic system when it is fully depressurized.
– The hydraulic oil can reach temperatures of
tenance work once the hydraulic oil system has
cooled down.
– Only specialist personnel who have been
allowed to perform repair and measurement
tasks.

Hydraulic system
Measuring the hydraulic pressure > Check hydraulic pressure on measuring block
Warranty
Removing the protective caps (1) and lead seal (2)
will invalidate any warranty claims!
9.3.2 Measurement equipment

To measure the hydraulic pressure, you require a measurement
device (manometer) with a pressure display range from 0 to
600 bar.
9.3.3 Check hydraulic pressure on measuring block
NOTICE!
The hydraulic pressure should be measured when
the hydraulic oil is warm (approx. 50 °C).

Hydraulic system
CAUTION!
WARNING!
The hydraulic pressure must be measured when
the engine is running! Proceed with extreme cau-
tion.
Overview of measuring block
A Maintenance hatch, front left
1 ML1 - Main pump

2 ML3 - Combination cooler
3 ML25 - Pilot control
4 ML34 - Turning brake air pressure
5 ML41 - Load-sensing pressure
ML1 - Check main pump (1) The working pressure of the main pump can be checked on meas-
urement connection ML1 of the measuring block (385+10 bar).

Hydraulic system
WARNING!
tion.
NOTICE!
Pressure measurement device (manometer) with
pressure display range from 0 to 400 bar is neces-
sary.
1. Prevent the machine from rolling away.

2. Pull back the safety lever.
3. Open the service access door (A).
4. Remove sealing cap from the measuring point on the meas-
uring block.
5. Connect manometer to measuring block ML1.
6. Take manometer into the cab.
7. Move safety lever forward.
8. Set the engine speed to 30%, approx. 1160 RPM.
9. Drive function: Move the boom up toward the stop, bypass by
pressing the button, and carefully drive the boom forward.
10. Read the value on the manometer.
11. Shut down the boom.
12. Set the engine speed to idle.
14. Disconnect the pressure gauge.
15. Fix the sealing cap onto the measuring point.
16. Close service access door (A).
NOTICE!
If necessary, contact SENNEBOGEN Customer
Service.
In the case of deviating values outside of the tol-
erance levels, contact SENNEBOGEN Customer
Service immediately.
ML3 - Check combination cooler (2) The working pressure of the combination cooler can be checked
on measurement connection ML3 of the measuring block
(310+/-10 bar).

Hydraulic system
WARNING!
tion.
NOTICE!
sary.

3. Shut down the engine.
uring block.
7. Allow drive engine and combination cooler to cool down.
8. Open right service door.
9. Disconnect the power supply to the fan control valve (1,2)

10. Close the right maintenance door.
12. Start the engine.
13. Set the engine speed to maximum speed.
14. Read the value for clockwise rotation (normal operation) on
the manometer.
16. Shut down the engine.

Hydraulic system

NOTICE!
Service.
ML25 - Check pilot control (3) The pilot control pressure of the pilot control can be checked on
measurement connection ML25 of the measuring block (maximum
speed 40+/-1 bar, idle speed 32+/-1 bar).
WARNING!
tion.
NOTICE!
sary.

uring block.
8. Read the value for maximum speed on the manometer.
10. Read the value for idle speed on the manometer.

Hydraulic system
NOTICE!
Service.
In the case of deviating values outside of the tolerance levels,

contact SENNEBOGEN Customer Service immediately.
ML34 - Check turning brake air The turning brake air pressure can be checked on measurement
pressure (4) connection ML34 of the measuring block (35+/-1 bar).
WARNING!
tion.
NOTICE!
sary.

uring block.
8. Drive function: Slightly slew uppercarriage.

Hydraulic system
NOTICE!
Service.
ML41 - Check load-sensing pres- The load-sensing pressure cut-off can be checked on measure-
sure cut-off (5) ment connection ML41 of the measuring block (330+/-10 bar).
WARNING!
tion.
NOTICE!
sary.

uring block.
8. Drive function: Move the boom up toward the stop, bypass by
pressing the button, and carefully drive the boom forward.
10. Shut down the boom.

Hydraulic system
Hydraulic oil > General information
NOTICE!
Service.
9.4 Hydraulic oil

DANGER!
– Warning – high oil pressure and danger of
scalding. The hydraulic system is subject to
high pressure. Serious injuries can be caused
by escaping hydraulic oil when a hydraulic con-
nection is loosened. Only perform work on the
hydraulic system when it is fully depressurized!
– The hydraulic oil can reach temperatures of
tenance tasks after the hydraulic oil system
has cooled down.
– Work on the hydraulic system may only be
carried out by trained personnel with special
knowledge and experience on hydraulics.
CAUTION!
Only mix/blend oils, lubricants and operating fluids
that are of the same type or identical (same specifi-
cations) from one manufacturer!

Hydraulic system
Hydraulic oil > Checking the hydraulic oil level and topping up the hydraulic oil
9.4.2 Checking the hydraulic oil level and topping up the hydraulic oil
ENVIRONMENT!
Hydraulic oil spill is harmful to the environ-
ment!
If the hydraulic oil tank is filled to the maximum
without considering the amount of hydraulic oil in
the Green Hybrid system, the hydraulic oil tank
will overflow when the hydraulic oil from the Green
Hybrid system is returned to the tank.
Hydraulic oil return occurs when the hydraulic
pressure in the Green Hybrid system is relieved.
– Be sure to consider the additional amount of
hydraulic oil in the Green Hybrid system.
– The maximum fill level for hydraulic oil listed in
the operating manual must not be exceeded.
Hydraulic oil tank filled to maximum

The hydraulic tank will reach its maximum fill level
if all cylinders are retracted and the hydraulic
pressure in the Green Hybrid system has been
relieved.
Putting the machine in the correct The machine must be placed in the correct position before
position for checking the hydraulic checking the hydraulic oil level and topping up the oil.
oil
1. Park the machine on level, solid ground.
ð The machine is in a level, horizontal position.
2. Raise the compact boom to the upper final position.
ð The cylinders for the compact boom are fully extended.
3. Retract all other cylinders.
ð The machine is in the correct position for checking the
hydraulic oil.
Fig. 19: Upper final position of com-

pact boom, using the example of a
mobile machine

Hydraulic system
Hydraulic oil > Checking the hydraulic oil level and topping up the hydraulic oil
Checking the hydraulic oil level

Prerequisites:
n The machine is in the correct position for checking the
hydraulic oil. Ä “Putting the machine in the correct position for
checking the hydraulic oil” on page 194
n The temperature of the hydraulic oil is within the permissible
range.
2. Read off the hydraulic oil level from the hydraulic oil tank
sight glass:
n The oil is level with the "MAX" marking at the top: The fill
n The oil is below the "MAX" marking at the top: The level
is too low. Top up the hydraulic oil.
1 Sight glass Meaning of the "Minimum hydraulic oil

2 Hydraulic oil level level" marking
If the hydraulic oil level is too low, warning
signals will be displayed in SENCON.
Ä “Information in SENCON: Hydraulic oil
level is too low” on page 195
Information in SENCON: Hydraulic If the hydraulic oil level in the hydraulic tank is too low, corre-
oil level is too low sponding information will be displayed in SENCON.
The "Collective fault" information icon in the "Machine information
STOP and warning icons" area in SENCON is red. An acoustic signal will
sound.
The Active Faults Machine window displays the following fault:

Hydraulic oil level too low, SPN 1011007

Hydraulic system
Hydraulic oil > Remove hydraulic oil sample for Shell LubeAnalyst
Adding hydraulic oil

n Safety shoes
n Safety goggles
n Chemical-resistant protective gloves
Material: n Hydraulic oil
Requirement:
n The machine is in the correct position for checking the
hydraulic oil. Ä “Putting the machine in the correct position for
checking the hydraulic oil” on page 194
n The temperature of the hydraulic oil is within the permissible
range.
n The hydraulic oil level is too low.
1. Clean the area around the aeration filter.
2. Unscrew the aeration filter from the hydraulic oil tank and set
it down on a clean surface.
3. Pour the hydraulic oil into the opening on the aeration filter.
Keep an eye on the fill level at all times while adding the oil.
Top up the hydraulic oil to the "Maximum hydraulic oil level"
marking.
Make sure that no dirt gets into the filter element during the
filling process.
4. Screw the aeration filter tight by hand.
9.4.3 Remove hydraulic oil sample for Shell LubeAnalyst


ment
n Safety shoes
n Hard hat
n Protective gloves
n Safety goggles

Hydraulic system
Hydraulic oil > Changing the hydraulic oil and removing oil sludge
F & Shell LubeAnalyst in the appendix.
9.4.4 Removing oil sludge

done.
Carry out this task at the same time as changing the

hydraulic oil.
9.4.5 Checking the hydraulic oil tank for cracks

done.
9.4.6 Adding hydraulic oil
Prior to topping up, check for leaks and repair any

leaks.
Adding hydraulic oil 1. Open the cover plate.

2. Clean if necessary.
3. Unscrew the threaded cap (2) on the hydraulic tank.
4. Add hydraulic oil and re-check.
5. Re-tighten screw cap
6. Close the cover plate again.
7. Close the maintenance door on the right.
9.4.7 Changing the hydraulic oil and removing oil sludge

done.

Hydraulic system
Hydraulic oil > Change the hydraulic oil return filter
9.4.8 Change hydraulic leakage oil filter


done.
9.4.9 Change the hydraulic oil return filter


done.

Hydraulic system
Hydraulic oil > Replacing the aeration filter
9.4.10 Replacing the aeration filter
CAUTION!
The aeration filter is integrated in the threaded

cap on the filler neck. The aeration filter limits the
over-pressure and under-pressure in the hydraulic
system that occurs with hydraulic work move-
ments.
CAUTION!
Clogged aeration filters allow unfiltered dust and
dirt into the hydraulic system. This can cause
damage to the hydraulic system (for example, to
the pumps) and increased wear of the hydraulic oil.
1 Screw cap
1. Unscrew screw cap (1) from the hydraulic tank.
2. Screw on new cap with integrated aeration filter.

Hydraulic system
Hydraulic oil > Boom high-pressure filter (option) – change filter element
9.4.11 Change HydroClean filter element


done.
9.4.12 Change pilot filter


done.
9.4.13 Boom high-pressure filter (option) – change filter element
CAUTION!
Replacing the filter element

Hydraulic system
Pump distributor gearbox > General
1. De-pressurize hydraulic system according to section 8.2.6.

2. Unscrew cover (2) with integrated hex nut (1). .
3. Pull out the filter element.
4. Dispose of filter element as hazardous waste.
sary.
6. Insert a new filter element.
7. Screw cover (2) on to the stop.
8. Start the drive engine
9. Switch off the drive engine and check the filter for leaks.
9.4.14 Replacing supply pressure filter elements

done.
9.4.15 Having the hydraulic oil cooler checked by an authorized workshop

Contact a qualified specialist to carry out this maintenance work.
9.5 Pump distributor gearbox

9.5.1 General
With certain options, distributor gearboxes can be mounted on the
drive unit connection.
CAUTION!
NOTICE!
Perform a daily visual inspection for leaks. An
increased oil level in the gearbox or the mounting
flange with its own oil filling means that the seals
on the hydraulic power units are defective.

Hydraulic system
Pump distributor gearbox > Checking the oil level
Procedure
1 ventilation
2 Oil filter screw with dipstick
3 Oil drain plug
4 Oil filler screw (option)
WARNING!
– Risk of injury from rotating parts and scalding!
Only perform maintenance when the drive
motor is off and the distributor gearbox is cool.
– Oil must not seep into the ground or water-
ways. Dispose of old oil in accordance with
statutory regulations.
9.5.2 Checking the oil level
WARNING!

Hydraulic system
Pump distributor gearbox > Checking seals and bolts for leaks

ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves

3. Unscrew oil filler plug with the dipstick (2).
4. Wipe off the oil from the oil dipstick.
5. Insert the oil dipstick into the opening until the thread of the
dipstick rests against the gear housing.
6. Pull the oil dipstick out.
7. The oil level must be between the lower marking (MIN) and
the upper marking (MAX) on the dipstick.
8. Top up gear oil, if necessary.
9. Screw in the oil filler plug with the oil dipstick (2).
9.5.3 Changing the gear oil


done.
9.5.4 Checking seals and bolts for leaks


Hydraulic system
Pump distributor gearbox > Refilling the roller bearings with grease

done.
9.5.5 Refilling the roller bearings with grease

every 5 years.

done.

Electrical system
Safety instructions
10 Electrical system
Please also observe the safety instructions in chapter 1 SAFETY
before starting to work on the electrical system.
WARNING!
Work on the electrical system must only be exe-
cuted by qualified electricians.
10.2 Checking the battery, the battery cable, and the battery connections
NOTICE!
The batteries are maintenance-free.
Special conditions of use (climatic conditions, high
operating hours) as well as older batteries may
require regular monitoring of the acid level in the
battery.
WARNING!
– Risk of explosion!
Smoking and working with open flame are pro-
hibited. Avoid sparks in the vicinity of the bat-
tery.
– Risk of acid burns!
Wear protective goggles and gloves.
Do not tilt the battery. Battery acid is caustic
and must not come into contact with eyes or
skin.
– Do not set tools down on the battery.
– Disconnect batteries before starting welding
work.
– Do not confuse battery connections.
– Dispose of old batteries as hazardous waste.

Electrical system
Disconnecting the electrical system from the battery (battery disconnect switch)
Checking connections and cable

connections
1. Open the rear left service access door.

2. Remove the battery terminal covers (1).
Ensure that metal parts do not get between the plus and
minus poles of the batteries (2) (danger of short circuit!)
3. Clean the battery terminals and cable connections. Check for
firm seat and grease with terminal grease.
4. Replace the battery terminal covers.
5. Close the service access door.
10.3 Disconnecting the electrical system from the battery (battery discon-
nect switch)
NOTICE!
Machine damage due to disconnection of the
electrical system from the battery when the
ignition is switched on or the engine is running
The electrical system and exhaust aftertreatment
system may be damaged if the battery disconnect
switch is pressed while the ignition is on or the
engine is running.

Electrical system
Using the maintenance lock (lockout-tagout) for the battery disconnect switch (option)
Prerequisites:
n The engine is shut down.
n The ignition is switched off.
n The battery disconnect switch lights up.
Press the battery disconnect switch.
ð n The battery disconnect switch flashes for a period of
10 minutes.
n After 10 minutes, the light on the switch goes out.
The electrical system of the machine is now discon-
nected from the battery.
Interrupting the disconnection

process
The disconnection process can be inter-
rupted.
To do this, press the battery disconnect
switch again while it is still flashing.
10.4 Using the maintenance lock (lockout-tagout) for the battery disconnect
switch (option)
Maintenance lock, lockout-tagout Lockout-tagout provides protection against unauthorized access or
unintended activation of the battery disconnect switch during main-
tenance work.
The maintenance lock is a lockout-tagout device meeting the
requirements of the Occupational Safety and Health Administration
(OSHA) in the USA.

Electrical system
Using the maintenance lock (lockout-tagout) for the battery disconnect switch (option) > Attaching the maintenance lock
Fig. 20: Maintenance lock (example representation)

1 Holder
2 Battery disconnect switch
3 Cover
4 Slot in cover
5 Slot in holder
10.4.1 Attaching the maintenance lock

Requirement:
n A padlock is required.
1. Disconnect the electrical system from the battery.
Ä Chapter 10.3 “Disconnecting the electrical system from the
battery (battery disconnect switch)” on page 206
2. Open the cover over the battery disconnect switch.
ð Line up the slot on the holder with the slot on the cover.
3. Open the padlock.
4. Guide the shackle of the padlock through the two slots.
5. Close the padlock.
ð The padlock blocks access to the battery disconnect
switch.
The maintenance lock is now attached.

Electrical system
Replacing fuses
10.4.2 Removing the maintenance lock

Requirement:
n The machine can be released for operation.
1. Open the padlock.
2. Remove the shackle of the padlock from the two slots.
ð The maintenance lock is now removed.
3. Fold the cover down.
ð The battery disconnect switch is freely accessible.
10.5 Replacing fuses
WARNING!
Risk of injury and burns from incorrect fuses.
Using incorrect fuses poses a risk of fire that can
cause serious injury.
– Do not repair fuses.
– Always use new fuses with the same
amperage.
– If a newly inserted fuse blows again after only
a short period of time, the electrical system
must be inspected by a qualified electrician.
Fig. 21: Example illustration

1. Turn off the engine.
2. Remove the fuse box cover.

Electrical system
Replacing switches or switch bulbs
3. Replace defective fuse.

4. Check the contacts.
ð Clean corroded contacts.
5. Replace the fuse box cover.
See the inside of the cover and the electric circuit

diagram for the assignments.
10.6 Replacing switches or switch bulbs
NOTICE!
Switches can only be replaced as complete units.
Exception: The symbols can be removed by care-
fully easing them out with a screwdriver, and fitted
back in again.

Electrical system
Generator (option)
10.7 Generator (option)
CAUTION!
NOTICE!
Please also refer to the information in the gener-
ator manufacturer's instructions.
Visual check The wiring, the operating element, and the generator must be
checked for visible damage, correct seat of the plug, and for con-
tamination on a monthly basis.
NOTICE!
Every 20,000 hours of operation, both ball bear-
ings of the generator must be replaced.
10.8 Additional displays (optional equipment)
Fig. 22: Hour meter, analog
Fig. 23: SENCON

Electrical system
Additional displays (optional equipment)
Fig. 24: ToolControl
Fig. 25: Generator and magnet system
Fig. 26: Auxiliary heating system
Fig. 27: Camera
Fig. 28: Load moment limitation (RCL)

Electrical system
Electrical system switch cabinet > Replacing switch cabinet filter elements
CAUTION!
The supplemental displays must not be cleaned
with alcohol or cleaning agents that contain sol-
vent, under any circumstances. Failure to comply
with this instruction will result in damage to the
plastic surface.
More information can be found in the operating

manual: See the Work application chapter and
chapter 9.
10.9 Electrical system switch cabinet

10.9.1 Replacing switch cabinet filter elements
ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves

Electrical system
Overview
1 Filter element for air outlet

2 Filter element for air inlet
1. Slide the cover (3) up from below.

Electrical system
2. Pull out the blue marking (4a) and swing the grille (4) away
3. Remove the filter elements (5).

4. Insert new filter elements.
5. Push on the grille.
6. Hook the cover correctly back into the guide (6) and slide
downward.
NOTICE!
If they are exposed to an extremely high level of
dust, the filter elements must be checked every
day and replaced as necessary. Always replace
the filter elements in both positions (1, 2).
NOTICE!
If the filter elements are not replaced in the event
of significant soiling, there is a risk of overheating
in the switch cabinet. Overheating may cause com-
ponents in the switch cabinet to fail.

Electrical system
Electrical system switch cabinet > Clean the switch cabinet
10.9.2 Clean the switch cabinet

Contact the qualified electrician to carry out this maintenance work.

Heating/air conditioning evaporator
Safety instructions > Safety instructions
11 Heating/air conditioning evaporator

starting to work on hydraulic system.
11.2 Air conditioning system

11.2.1 Safety instructions
WARNING!
When working on air conditioning systems, be
aware that coolants and their vapors are health
hazards. Wear the appropriate protective equip-
ment.
– Maintenance and repair work must be exe-
cuted by trained specialist personnel only.
– Do not reach into the interior of the device and
do not insert any objects into the device.
– Only execute maintenance tasks with the drive
engine shut down and the fan disconnected.
– Allow the device and components inside the
device (heat exchanger, resistors) to fully cool
down before starting the maintenance tasks.
– Danger of freezing, wear protective gloves!
Avoid touching the coolant with bare skin.
– Wear protective goggles! If coolant does come
into contact with your eyes, seek medical
attention.
– Danger of injury! Avoid contact with the sharp
edged clutch plates on the liquefier and the
heat exchanger.
– Welding and soldering tasks are not permitted
on components of the air conditioning system!
The pressure in the system is increased by the
extreme heating and can cause an explosion.
– Only coolant R134a may be used in accord-
ance with DIN 8960 (fill quantity approximately
1.7 kg). Do not add any fluorescent additives
(tracer agents, sticks).
– Comply with the filling guidelines of
SENNEBOGEN Maschinenfabrik GmbH.

Air conditioning system > Checking the air conditioning system
11.2.2 Visual inspection of the air conditioning system
CAUTION!
Check the wiring, the status of the cooling and heating lines, the
condensation discharge and the filter for visible damage, firm seat
of the plugs, and check for fouling at least once a month. Fouling
must be carefully removed.
1 Air conditioning system
11.2.3 Checking the air conditioning system

ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves
A dirty or damaged air conditioning system will reduce perform-

ance and may cause system failures. Visually inspect the air condi-
tioning system to check its condition.

Checking the collector drier and

liquefier
Fig. 29: Collector drier and liquefier (exemplary representation)

1 Collector dryer
2 Line
3 Condenser
1. Check the collector drier for traces of rust or condensation in
the sight glass.
2. Check the lines for cracks and leaks.
3. Check the liquefier for dirt and damage.
Checking/cleaning the air condi-

tioning system condensate drain
1 Cab door
2 Air conditioning system condensate drain
Check the condensate drain for blockages and contamina-
tion.
ð Clean the condensate drain if it is blocked or contami-
nated.

Checking the refrigerant collector

cylinder
Fig. 30: Refrigerant collector cylinder (exemplary representation)

1 Line
2 Refrigerant collector cylinder
2. Check the refrigerant collector cylinder for damage.
Checking the air conditioning com-

pressor
Fig. 31: Air conditioning compressor (exemplary representation)

1 Line
2 magnetic clutch
3 V-belt
2. Check the V-belts for damage.

Air conditioning system > Cleaning the recirculating-air filter of the air conditioner
11.2.4 Cleaning the fresh air filter

ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves
Tools and equipment

Tool: n Lint-free cloths
n Pressurized air cleaner (optional)
The fresh air filter is located in the cab behind the driver seat.
1. Open the cover closures with a screwdriver.
2. Open the cover.
3. Pull the filter element upwards out of the filter box.
4. Beat out the filter element or carefully clean it with com-
pressed air.
Replace any filter elements that are damaged or dirty.
5. Clean the filter cassette.
6. Insert the cleaned filter element or a new filter element.
ð The colored side of the filter element must point toward
the interior of the cab.
1 Filter element 7. Close the cover.
2 Filter box
8. Close the cover closures with a screwdriver.
3 Cover
11.2.5 Cleaning the recirculating-air filter of the air conditioner

ment
n Safety shoes
n Hard hat
n Safety goggles
n Protective gloves

Air conditioning system > Air conditioning compressor
Tools and equipment

Tool: n Lint-free cloths
n Pressurized air cleaner (optional)
Cleaning/replacing the recirculating

air filter
The recirculating-air filter of the air conditioner is located in the cab
behind the driver seat.
1. Use the handle to pull the filter element out of the filter car-
tridge.
2. Beat out the filter element or carefully clean it with com-
pressed air.
Replace the filter element if it has been damaged or it is too
dirty.
3. Clean the filter cassette.
4. Insert the cleaned filter element or a new filter element into
the filter cartridge.
ð The arrows on the filter element must point toward the
back of the cab.
1 Filter element
11.2.6 Air conditioning compressor
CAUTION!
NOTICE!
Also comply with the instructions in the manufac-
turer's operating manual.
WARNING!
During operation, surface temperatures of above
60 °C or under 0 °C can occur. There is danger of
severe burn injuries or freezing injuries.
WARNING!
Compressor is under pressure! Severe injuries are
possible if handled incorrectly!

Air conditioning system > Cleaning the recirculating air filter of the heating system
NOTICE!
An oil change must be performed every 3 years
or 10,000 hours of operation. The oil filter and
magnet plugs must be cleaned at the same time.
Checking hoses, V-belts, and mag-

netic clutch
1. Open the upper right maintenance door.
2. Check AC compressor hoses for cracks and leaks.
If there is damage have the hoses replaced by service per-
sonnel.
3. Check V-belt of the AC compressor for damage. If there is
damage have the hoses replaced by service personnel.
4. Check the magnetic clutch of the AC compressor. If there is
damage have the hoses replaced by service personnel.
11.2.7 Cleaning the recirculating air filter of the heating system
CAUTION!
Cleaning/replacing the filter ele-

ment
1 Handle
2 Filter element
NOTICE!
The filter element is located behind the driver seat.

Air conditioning system > Have heating system/air conditioning system checked by authorized workshop
1. Pull out the filter element (2) using the handle (1).
2. Knock out filter element or carefully blow it out with com-
pressed air.
3. Insert the filter element. Ensure correct position. Clean air
must exit in direction of travel.
11.2.8 Cleaning/replacing the heating system outside air filter

Cleaning/replacing the filter ele-
ment
1 Bolts
2 Filter element
The filter element is located behind the cover on the outside of the
cab.
1. Hold the cover and remove the screws.
2. Pull out the filter element.
3. Tap out the filter element or carefully clean it with com-
pressed air.
4. Reinstall the filter element. Ensure correct position.
5. Retighten the screws.
11.2.9 Topping up/replacing refrigerant

11.2.10 Have heating system/air conditioning system checked by authorized work-

shop

Auxiliary heating system (option)
11.2.11 Change climate control system collection dryer

done.
11.2.12 Change climate control system oil

done.

every 3 years.
Personnel: n Service Technician (company specialist)
11.3 Auxiliary heating system (option)

tasks.
CAUTION!
Also comply with the instructions and recommen-

dations in the manufacturer's operating manual.
WARNING!
Switch the auxiliary heating on at least once
a month for approximately 10 minutes, even if
heating is not required.
Before heating is required, test the auxiliary
heating system once (for example, danger of
smoke).

Steel structure and static load-bearing parts
Safety instructions
12 Steel structure and static load-bearing parts

Observe the safety instructions in Chapter 1 before starting work!
Components of the construction and structural steelwork are
checked as part of regular inspections. Due to the extremely high
load, these parts are subject to natural wear and tear and have a
limited service life in accordance with the finite element method.
Static load-bearing parts such as the undercarriage, mast, upper-
carriage frame, boom and stick, must therefore undergo a thorough
and detailed inspection at least every six months to check for
damage and crack formation.
SENNEBOGEN recommends that this inspection be carried out by
an expert once a year as a precautionary measure to ensure that
any serious damage is detected.
12.2 Checking static load-bearing parts and steel components for damage

1. Thoroughly clean the components as far as is possible.
2. Conduct a visual inspection of the components:
n Traces of rust indicate cracking.
ð If there is any visible damage, have a dye-penetrant test
or magnetic particle test carried out by a specialist to
check the components for structural damage.
3. Only trained and qualified specialists are authorized to exe-
cute a repair.

Checking the safe mounting of the counterweight elements
13 Checking the safe mounting of the counterweight ele-

ments
done.

List of abbreviations
14 List of abbreviations
BGV Berufsgenossenschaftliche Vorschrift (German
employers' liability insurance association regulation)
Oh Operating hours
EMC Electromagnetic compatibility
LED Light emitting diode
SDS SENNEBOGEN Diagnostic System
FMVSS Federal Motor Vehicle Safety Standards
UCTU Insurance Association of Civil Engineers
ACTU Association of Commercial Trade Unions

Appendix
Appendix

Warranty manual
A Warranty manual

Warranty manual
Warranty Manual for Machines built by

SENNEBOGEN Maschinenfabrik GmbH (VALID FROM 01.04.2020)
INFORMATION FOR CUSTOMERS
Content Page
1. Care and Maintenance .............................................................................................................. 2

2. Original Spare Parts .................................................................................................................. 2
3. Service Agreements .................................................................................................................. 3
4. Oil Analysis ................................................................................................................................. 3
5. Pre-requisites ........................................................................................................................... 3
5.1 Submission of the Commissioning Certificate .......................................................................... 3
5.2 Commissioning certificate for extended warranty .................................................................... 3
5.3 Dealer Receiving Inspection Form when delivery to the customer is at a later date ............. 3
5.4 Maintenance and service by an authorised partner ................................................................. 3
5.5 Observance of maintenance intervals ...................................................................................... 4
5.6 Use of genuine spare parts ....................................................................................................... 4
5.7 Hour meter in working condition ............................................................................................... 4
5.8 Use of machine as intended ...................................................................................................... 4
5.9 Use of approved lubricants ....................................................................................................... 4
6. Warranty Exclusions .................................................................................................................. 4
6.1 Customised solutions ................................................................................................................ 4
6.2 Damage during transportation .................................................................................................. 4
6.3 Incorrect commissioning and start-up ....................................................................................... 4
6.4 Third party negligence ................................................................................................................ 4
6.5 Normal wear and tear ................................................................................................................ 4
6.6 Warranty expiration .................................................................................................................... 4
6.7 Defects not originated from delivered item ............................................................................... 5
6.8 Disassembling of components .................................................................................................. 5
6.9 Loss of warranty parts ............................................................................................................... 5
7. Preservation of Stock Machines ............................................................................................... 5
8. Warranty Claim Processing ....................................................................................................... 6
9. Customer’s contribution to fault correction ................................................................................ 6
Page 1 of 6
Warranty Manual Version 2020-1

Warranty manual
1. Care and Maintenance
It is the proverbial equipment dependability, reliability and long life of SENNEBOGEN Maschinenfabrik GmbH
products that make customers prefer these machines. Nonetheless regular care and maintenance are necessary
for these fine qualities to be maintained, so that the sophisticated SENNEBOGEN machines match the high
standards of performance the industry demands from them.
The operation and maintenance manuals contain maintenance instructions dependant on operating conditions
and service periods. These maintenance procedures form part of the proper operation of the machine. Failure to
follow them can give rise to problems with the machine operation and to a loss in reliability and service life of the
machine.
Careful treatment, in addition to the specified maintenance procedures, will spare the owner or user problems and
failures. The deciding factors are the training and conduct of the person entrusted with operating the machine.
SENNEBOGEN Maschinenfabrik GmbH recommends training these employees with the correct qualification to
fulfil their responsibility: SENNEBOGEN therefore offers special training programmes at a shared cost. Warranty
is ruled out for any loss or damage due to neglect or inadequate care.
Maintenance parts, wearing parts and consumables do not fall within the terms of the machine’s warranty,
where the damage is caused by normal wear and tear or due to lack of maintenance.
Maintenance work specified in the service book, which has not been performed at all, has not been carried out in
due time, has been inadequately completed or has not been performed by an authorised SENNEBOGEN
Maschinenfabrik GmbH service partner can result in the warranty being forfeited. Warranty is ruled out for any loss
or damage due to lack of maintenance.
The execution of the specified maintenance serves as a basis for warranty claims. The
specified maintenance intervals must be observed and proof of all inspections must be
furnished by sending the completed service documentation form to the SENNEBOGEN
service department. Failure to meet this requirement causes warranty requests to
become void.
2. Original Spare Parts
Only genuine SENNEBOGEN parts are of proper mechanical construction and design for SENNEBOGEN
Maschinenfabrik GmbH machines and have been released after thorough testing and intensive experiments. Only
genuine SENNEBOGEN parts conform exactly to the specifications of SENNEBOGEN Maschinenfabrik GmbH for
construction, dimensional stability and material.
The use of outside parts is a risk, which can easily be avoided. SENNEBOGEN Maschinenfabrik GmbH
strongly recommends the exclusive use of original SENNEBOGEN parts. Where outside parts are used,
SENNEBOGEN does not accept any warranty whatsoever with regard to proper operation, safety and reliability of
the machines and will not be held liable for any loss or damage resulting there from. Original SENNEBOGEN parts
are available from SENNEBOGEN Maschinenfabrik GmbH authorised service partners or from the SENNEBOGEN
Spare Parts Centre in Straubing (spareparts@sennebogen.de )
Only Original SENNEBOGEN parts must be used.
Page 2 of 6

Warranty manual
3. Service Agreements
Service agreements with the authorised service partners are the safest way for owners or users to meet the
requirements and have all maintenance operations performed professionally. The SENNEBOGEN Maschinenfabrik
GmbH service partners know the SENNEBOGEN machines well. Their personnel are adequately trained and have
the required original SENNEBOGEN parts, the necessary documentation and the correct tools.
SENNEBOGEN Maschinenfabrik GmbH recommends the conclusion of a service agreement

with an authorised Service Partner.
Warranty programs as well as extended warranty periods are only valid in conjunction with a
service and maintenance agreement with an authorised SENNEBOGEN Maschinenfabrik
GmbH Service Partner.
4. Oil Analysis
Scheduled oil sampling and analysis provides the customer and owner or user with regular information about the
condition of the machine. This preventative measure helps to detect potential failures or defective components.
Maintenance intervals are listed in the operating and maintenance manual.
SENNEBOGEN Maschinenfabrik GmbH strongly recommends oil sampling

and analysis at regular intervals.
5. Pre-requisites
When claiming from warranty, the following points must be complied with:
5.1 Submission of the Commissioning Certificate

The warranty period starts from the date of commissioning on condition that the commissioning certificate is
returned to SENNEBOGEN within 10 working days after commissioning the machine. Otherwise the warranty
period begins in accordance with the lawful regulations with the ex works delivery date of the machine.
5.2. Commissioning certificate for extended warranty

The return of the commissioning certificate is imperative requirement for the extended warranty program to take
effect.
5.3 Dealer Receiving Inspection Form when delivery to the customer is at a later date
The Dealer Receiving Inspection Form is imperative when the machine is not delivered to the customer
immediately after delivery from SENNEBOGEN Maschinenfabrik GmbH. The result of the dealer’s receiving
inspection must be submitted using the “Dealer Receiving Inspection form” to the SENNEBOGEN After Sales
Service Department within 10 working days after receiving the machine. Should the Dealer Receiving Inspection
Form not be submitted within the specified time limit, the warranty begins with the date of delivery ex works.
Page 3 of 6

Warranty manual
5.4. Maintenance and servicing by duly authorized partners

Only the SENNEBOGEN Maschinenfabrik GmbH service partners are authorised to perform the maintenance
and service as specified by the warranty. Service performed by a third party will cause any warranty to become
void.
5.5. Observance of maintenance intervals specified

The maintenance intervals as specified in the operating and maintenance manuals must be observed, and the
customer must furnish proof thereof (see Service Documentation Appendix VIII).
5.6. Use of genuine spare parts

Only genuine SENNEBOGEN spare parts may be used. Upon request, the customer has to produce the relevant
evidence.
5.7. Hour meter in working condition

Proper operation of the service hour meter must be ensured at all times. Any defective service hour meters must
be reported to the SENNEBOGEN service partner for immediate replacement. The respective service hour meter
reading and the date warranty work was carried out must be noted in the warranty claim and proof thereof
furnished upon request. Failure to meet this requirement will cause any warranty to become void!
5.8. Use of the machine as intended.

Improper use of the machine will cause all warranty to be invalid.
5.9. Use of approved lubricants.

A warranty claim can be rejected when damage is caused by the use of explicitly not approved lubricants. It is
not possible to test all lubricants. The lubricants approved by SENNEBOGEN Maschinenfabrik GmbH are
summarised in the appropriate valid issue of the lubricant table.
6. Warranty Exclusions
6.1. Customised solutions

Any special solutions provided by SENNEBOGEN Maschinenfabrik GmbH for individual customers are excluded
from the extended warranty options. The parts warranty remains valid.
6.2. Damage during transportation

Any claim for damage in transit must be put forward to the forwarder immediately upon receipt, or must be reported
to the insurance company covering the transportation. Damage in transit does not fall within the scope of the
warranty.
6.3. Incorrect commissioning and start-up

The service partners are the best contact to provide technically correct and faultless commissioning and start-up of
the machien. Proper commissioning is the responsibility of the agency that has been entrusted with commissioning.
SENNEBOGEN Maschinenfabrik GmbH is not responsible for any faulty installation or faulty commissioning
performed by the ordering party (buyer) or by any third party.
6.4. Third party negligence

Defects which SENNEBOGEN Maschinenfabrik GmbH is not responsible for, are faults caused by:
� Improper operation
� Installation of spare parts of foreign origin (not genuine SENNEBOGEN parts)
� Improper or careless treatment and maintenance
� Outside influences such as chemical, electrochemical or electrical influences which can not be attributed to a
SENNEBOGEN Maschinenfabrik GmbH fault.
6.5. Normal wear and tear

Wear and tear are natural processes and not “defects”.
Page 4 of 6

Warranty manual
6.6. Warranty Expiration

Warranty is limited to a set time period from date of delivery or commissioning, in months or hours of operation
whichever is attained first. Once this has been attained, the warranty has expired and is no longer applicable.
6.7. Defects which have not originated from the delivered item
SENNEBOGEN Maschinenfabrik GmbH warranty only covers the products delivered by SENNEBOGEN
Maschinenfabrik GmbH and any defects that may occur on said products. The restrictions stated in the
SENNEBOGEN terms of delivery and payment apply. Further damage is expressly excluded.
6.8. Disassembling of components

Open or disassembled parts and components are excluded from the warranty. Once the parts have been
disassembled a damage analysis is no longer possible. The suppliers of the important and expensive parts
generally reject these warranty claims.
6.9. Loss of Warranty Parts

Warranty parts that disappear during the return delivery are considered the responsibility of the sender. A warranty
claim can only be determined when the parts, or in exceptional cases after consulting with SENNEBOGEN
Maschinenfabrik GmbH on presentation of informative photos
Generally excluded are any and all subsequent expenses incurred for machine transports,
machine downtimes as well as for any temporary equipment.
The restrictions stated in SENNEBOGEN’S terms of delivery and payments apply.
7. Preservation of Stock Machines
If machines are not put into operation immediately after delivery, it is necessary that dependent on the storage
period the respective preventive measures are taken.
1. When the machine is not in use for a longer period of time, various cylinders when possible must be
retracted. The chrome layer on cylinders that are extended must be protected against corrosion
(greased).
2. The diesel tank must be filled to capacity to prevent corrosion.
3. The batteries must be disconnected and the voltage checked regularly (min. once a month). Should the
voltage drop to below 12.4 V, the batteries must be charged.
4. The engine and the hydraulic system must be run until the normal operating temperature is reached
(approx. 1 hour). Move the machine so that the wheels turn (once a month).
5. All operating fluid levels must be checked regularly
6. Cylinders must be retracted and extended.
7. If the machine is being stored for a longer period further preservation measures for the engine must be
carried out together with the engine manufacturer’s local representative.
8. Ropes / cables must be covered or greased well.
9. Protect the exhaust, so that water or foreign particles can not enter the system
10. Place tyre machines on the outriggers, tyres must not have contact with the ground.
11. Protect the cab windshield against erosive influences, for example sand.
12. Cover and protect the air filter, so that foreign particles cannot enter.
13. Protect and preserve the diesel tank inlet on the inside against rust
14. Check the anti-freeze (-40 ° C)
15. In winter pay particular attention to the storage temperature, if necessary fill with winter / arctic diesel.
16. Close all machine inlets
Page 5 of 6

Warranty manual
The above mentioned preservation measures serve only as a recommended basis or check list without intending to
be complete. Damages caused due to incorrect storage or preservation measures not carried out, are exclude from
all warranty.
When commissioning the machine, ensure that all protective measures are removed and that a maintenance
service based on the machine and engine manufacturer’s specifications is carried out. Oil and other fluid filling
levels must be checked.
8. Warranty Processing
Correction of the fault is the responsibility . . . .

. . . of the SENNEBOGEN Maschinenfabrik GmbH service network.
SENNEBOGEN Maschinenfabrik GmbH authorised service partners, the SENNEBOGEN After Sales Service
Department and SENNEBOGEN’s subsidiaries – are the first port of call world-wide for maintenance, care, repairs,
and supply of genuine SENNEBOGEN parts, both during and after the warranty period.
In the case of a breakdown, customers can contact their nearest SENNEBOGEN Maschinenfabrik GmbH service
partner and commission him to correct the problem. When damage to parts occurs within the warranty period, the
fault correction is carried out in accordance with the warranty option selected. The service partner will process any
warranty claim directly with SENNEBOGEN Maschinenfabrik GmbH. All services rendered beyond the claim will
be charged to the customer.
The service partner addresses can be found in the SENNEBOGEN Maschinenfabrik GmbH service information, as
well as on our internet site www.sennebogen.de .
9. Customer’s contribution to fault correction
Correction of faults is not possible without the owner or user of the machine’s assistance. The owner or user is
obliged to afford the SENNEBOGEN Maschinenfabrik GmbH’s service partner the time and opportunity to correct
any faults. The customer failing to allow the service partner the time and opportunity to correct the fault during an
adequate timeframe after noticing the defect (max. 3-4 weeks), immediately for safety relevant defects, constitutes
in a waiver of the warranty.
When the operational safety is endangered, or excessively large damage needs to be repaired, the customer may
upon receipt of written authorisation from SENNEBOGEN Maschinenfabrik GmbH repair the damage himself or
have a third party complete the repair. The repair costs are then covered by SENNEBOGEN Maschinenfabrik
GmbH. Any modifications or repairs performed without prior permission from the manufacturer will cause the
warranty to become void.
Page 6 of 6

830.0.3433 WA Book en 1.0

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

830.0.3433 WA Book en 1.0

Uploaded by

Copyright:

Available Formats

Maintenance instructions

Read this manual prior to performing any task!

© SENNEBOGEN Maschinenfabrik GmbH

2 830.0.3433 Material handling machine 07.07.2022

Warranty The warranty can be invalidated, for example, if:

07.07.2022 830.0.3433 Material handling machine 3

4 830.0.3433 Material handling machine 07.07.2022

Information that makes the work easier or contributes to better

Indicates notes that draw your attention to special

Indicates instructions or notes that alert to particularities of a

Indicates instructions or notes that alert to particularities of a

Tightening torque for screws or nuts. (In this case: 50 Nm)

Flat-blade screw driver

07.07.2022 830.0.3433 Material handling machine 5

Phillips screw driver

Allen key. The size specification refers to the perpendicular dis-

Square box key. The size specification refers to the perpendicular

Connect dial gauge or manometer.

Instructions are described as follows:

n Lists are marked with squares.

Definition of terms Owner

6 830.0.3433 Material handling machine 07.07.2022

The order confirmation states all items included in

07.07.2022 830.0.3433 Material handling machine 7

8 830.0.3433 Material handling machine 07.07.2022

07.07.2022 830.0.3433 Material handling machine 9

2.4.3 Once a year or at the latest after 1000 operating

10 830.0.3433 Material handling machine 07.07.2022

5.2.4 Distributed manual lubrication points on Mobile

07.07.2022 830.0.3433 Material handling machine 11

6.10 Electric motor.......................................................... 132

12 830.0.3433 Material handling machine 07.07.2022

8.4.1 Gear spray (option)................................................ 168

07.07.2022 830.0.3433 Material handling machine 13

9.5.1 General.................................................................. 201

14 830.0.3433 Material handling machine 07.07.2022

13 Checking the safe mounting of the counterweight ele-

07.07.2022 830.0.3433 Material handling machine 15

If national regulations in the country of operation

1.2 Residual risks

16 830.0.3433 Material handling machine 07.07.2022

1.3 Responsibilities of the owner

07.07.2022 830.0.3433 Material handling machine 17

Routine checks Expert inspection, required for crane or excavating operation

18 830.0.3433 Material handling machine 07.07.2022

07.07.2022 830.0.3433 Material handling machine 19

n The capacity data listed in the instructions must not be

Use outside Germany If the machine is used outside Germany:

Fig. 1: Fire extinguisher

1. First call the fire department.

Follow the instructions on the fire extin-

3. Have the fire extinguisher serviced and topped up after use.

20 830.0.3433 Material handling machine 07.07.2022

First-aid kit (option) A first-aid kit is included for emergencies.

Note the expiry date on the first-aid kit.

Warranty The warranty terms of SENNEBOGEN Maschinenfabrik GmbH are

1.4 Recording service work or recurring tests

Further notes Ä Chapter 1.3 “Responsibilities of the owner” on page 17

07.07.2022 830.0.3433 Material handling machine 21

1.5 Auxiliary materials and operating materials

SENNEBOGEN CONTROL System

22 830.0.3433 Material handling machine 07.07.2022

1.5.2 Oils and lubricants