PDF Operating Instruction Manual Sennebogen 825 830 - 1 MB
This operating instruction manual is essential for anyone working with the Sennebogen 825 or 830 material handlers.
It provides detailed guidance on the machine's controls, safety systems, and proper application techniques.
The manual also outlines critical daily maintenance and inspection points.
Following these instructions ensures safe, efficient operation and helps prolong the life of the equipment.
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OPERATING INSTRUCTIONS
Type (Model)
825 + 830
825 + 830 / 04.2008 Translation of the original operating instructions 825.0.1352
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Table of contents
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Potential instances of misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5 Other risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6 Machine Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.6.1 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.6.2 CE stamp of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.6.3 Euro-test identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.6.4 Warning and notice labels . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.7 Responsibilities of the operator . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.8 Supplementary and operational equipment . . . . . . . . . . . . . . . . . 1-19
1.8.1 SENNEBOGEN-Diagnostic-System (SDS) . . . . . . . . . . . 1-19
1.8.2 Oils and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.8.3 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.8.4 Fuel (not with electric motors) . . . . . . . . . . . . . . . . . . . . . 1-26
1.9 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.9.2 Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
1.9.3 Safe entry and exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
1.9.4 Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
1.9.5 Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
1.9.6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
1.9.7 Operation/Driving operation . . . . . . . . . . . . . . . . . . . . . . . 1-39
1.9.8 Setup work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
1.9.9 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
1.9.10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
1.9.11 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46
1.10 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47
1.11 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48
1.12 Hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49
2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Complete machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 Mobile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.2 Crawler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.1.3 Structure (4-point sub-frame) . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.1.4 Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
825 + 830 / 04.2008 Translation of the original operating instructions 0-1
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Safety - Machine Labeling
1.6 Machine Labeling
The machine is provided with special warning and notice signs.
z Do not remove the signs.
z Ensure that all signs are undamaged and legible.
z Clean labels with soap and water if necessary, not with fuel or
solvents.
z Replace damaged, scratched or illegible signs with new ones.
Note
Signs are available from SENNEBOGEN (see Spare Parts Catalogue).
1.6.1 Identification plate
1Machine type
2Manufacturer’s No. (Facility No.)
825 + 830 / 04.2008 Translation of the original operating instructions 1-5
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Safety - Responsibilities of the operator
Technical condition of The operator has an ongoing responsibility to monitor the overall
the machine technical condition (obvious external faults and damage as well as
changes to operational behavior) of the machine.
Do not operate machine if a fault has been detected!
Observe mandatory time limits for routine checks.
All damages and incidents are subject to the mandatory logging and
storage regulations.
Independent conversion For safety reasons the machine may not be modified or altered in any
and replacement part way.
production This applies also to the installation and use of safety devices and
valves as well as welding on load carrying parts.
Genuine SENNEBOGEN replacement parts and accessories ensure
the safety of personnel. Parts and fittings from other manufacturers are
not tested by SENNEBOGEN and are not therefore approved. The use
of other components can alter the machine's characteristics and
present a safety hazard.
If other components are used, SENNEBOGEN will not be considered
liable for any resulting consequences.
Impermissible operating z The operating safety of the machine is only ensured if it is used
practices correctly according to these instructions.
z The specified performance data must be observed.
z The performance data listed in the instructions must not be
exceeded.
z Trailer
The machine is not suitable for towing a trailer. Due to the greater
axle load, trailer operation is only permitted with stronger axles
(optional).
z Protective roof (FOPS)
If there is a danger of heavy items falling, the machine may only
be used if the driver's space is covered by a protective roof
(FOPS). The protective roof is optionally available from
SENNEBOGEN.
Specific dangers The machine operator must check whether the operation gives rise to
specific dangers, e. g. on account of toxic gases, ground quality etc.,
and adopt appropriate measures to avoid or limit those dangers.
825 + 830 / 04.2008 Translation of the original operating instructions 1 - 15
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Safety - Supplementary and operational equipment
Using other If you should ever use a coolant other than that specified, the following
Coolant must be considered or expresslyobserved.
SENNEBOGEN will accept no responsibility and will provide no
warranty or make any guarantees for the use of any coolants other than
those previously indicated.
Change coolant
WARNING
Scalding hazard!
Be careful when draining hot coolant!
Allow the motor to cool first. Catch the coolant in a suitable container
when draining and dispose of according to the respective regulations.
– The cooling system is to be emptied completely before filling
again.
– Rinse the cooling system several times with clear water to rid it of
any residue.
– Fill the cooling system and check the level after a short waiting
period.
– Start the motor and check the coolant levels
CAUTION
Adjusting to the correct coolant level must sometimes be checked more
than once.
Check the following states when inspecting the coolant levels regularly,
e.g.
– lubricant incursion,
– obvious opacity caused by corrosion residue or other particulate
matter,
in which case, the coolant must be replaced as indicated above.
Coolant change Information on changing the coolant and the changing intervals is
intervals provided in the operating instructions of the motor manufacturer.
825 + 830 / 04.2008 Translation of the original operating instructions 1 - 25
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Safety - Safety instructions
Gallery/Operator
catwalk
1
DANGER
Risk of falling!
Installation of the gallery/platform (1) is mandatory, since it is part of the
safety concept.
CAUTION
Risk of falling!
Gallery - access forbidden when the cab is raised!
A maximum of 200 kg (440 lbs) is permitted per segment of grid iron on
the gallery. Overloading will lead to damaging the construction, the
results of which can lead to personal injury.
Check the gallery for damage every 3 months (especially cracks) and
repair if necessary.
825 + 830 / 04.2008 Translation of the original operating instructions 1 - 35
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Safety - Safety instructions
Qualifications of DANGER
personnel z Work on electrical equipment of the machine may only be carried out
by an electrical specialist.
z Work on running gear, braking and steering systems may only be
carried out by specially trained technicians!
z Work on hydraulic systems may only be carried out by personnel
with special knowledge and experience on hydraulics!
z No welding is to be performed on the device without previous
discussion with the manufacturer.
825 + 830 / 04.2008 Translation of the original operating instructions 1 - 45
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Overview - Complete machine
2 Overview
2.1 Complete machine
2.1.1 Mobile
1 2* 3 4* 5 6 7 8 9 10
1 Attachments (Example: 6 Driver's cab/cabin with
grabber, scrap shears) gallery/platform, raising
2* Ulm 7 Undercarriage
3 Grabbing stick 8 Superstructure
4* Vario Tool 9 Stabilizer
5 Compact stick 10 Counterweight
*: Optional model / special function
825 + 830 / 04.2008 Translation of the original operating instructions 2-1
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Overview - Superstructure
Service doors
Driver's side
1 2 3
Driver's side front:
1 Windshield washer reservoir 3 Measurement ports -
hydraulic system
2 Emergency lowering - cab
4* 5 6 7 8 9 10 11
Driver's side rear:
4* Fueling hose/pump 8 Fuel tank
5 Fuel filler neck 9 Electrical control cabinet
6 Central lubrication system 10 Batteries
7 Air filter 11 Battery isolator switch
*: Optional model / special function
825 + 830 / 04.2008 Translation of the original operating instructions 2 - 11
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Customer-specific models and functions - Lifting capacities
stabilized:7,5 m compact boom and 5,8 m stick
Remarques : Toutes les valeurs sont indiquées en tonnes (t) et comprennent 75% de la charge de basculement statique ou 87% de la force de levage hy-
draulique conformément à ISO 10567. Elles sont applicables avec stabilisateur et sur un sol plan et résistant, pivotement sur 360°. Les valeurs entre paren-
thèses [. . . ] sont valables longitudinalement par rapport au châssis.
Observaciones: Todos los valores están especificados en toneladas (t) y constituyen el 75 % de la carga estática de volqueo, o el 87 % de la fuerza de
elevación hidráulica conforme a ISO 10567. Rigen con apoyos y con posibilidad de giro en 360° sobre suelo firme y plano. Los valores entre corchetes [...]
rigenen el sentido longitudinal para el conjunto inferior
825 + 830 / 04.2008 Translation of the original operating instructions 3-3
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Technical data - General information
4 Technical data
Note
The following values are guidelines. The level specified on the
corresponding components is authoritative (upper mark on dipstick)
4.1 General information
Electrical system 24 V
Note
Ensure that the available output power of the alternator is not exceeded
when installing additional current consumers (e.g. lights).
Ambient temperature Operation / approx. - 20 °C (- 4 °F)... approx. + 40 °C (+
range Operation under load 104 °F)
Note
When running a machine in environmental temperatures outside the
specified temperature range, special temperature packages are
available (optional!).
Please contact SENNEBOGEN customer service if you have any other
questions.
Hydraulics Operating pressure, max. 350 bar
Slewing drive Slewing speed 0 - 8 rpm, continuously variable
Limitations during wind Wind speed
25 m/s 90 km/h 10 Beaufort
Note
Machine operation is generally possible - without any attachments - at
wind speeds of up to 25 m/second.
The decision concerning when operation is to be shut down is to be
made by the machine operator and depends on the attachment being
used.
Different attachments react differently to wind and may affect the
stability of the machine. These are to be determined by the operator
and the machine is to be shut down accordingly.
825 + 830 / 04.2008 Translation of the original operating instructions 4-1
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Technical data - Wind speed
4.6 Wind speed
Wind
Wind strength speed Effect
Beau- Designation m/s km/h Inland
fort
scale
0 Calm 0-0,2 1 Calm, smoke rises straight up
1 Light draft 0.3-1.5 1-5 Direction of wind is displayed by
direction of
smoke, but not by a weather
vane
2 Light breeze 1.6-3.3 6-11 Wind is felt on face, leaves
rustle,
weather vane moves
3 Weak breeze 3.4-5.4 12-19 Leaves and thin twigs move,
wind stretches a flag
4 Moderate 5.5-7.9 20-28 Lifts dust and loose paper,
breeze moves twigs and thin branches
5 Fresh breeze 8.0-10.7 29-38 Small deciduous trees start to
sway, breaker foam forms on
lake surface
6 Strong wind 10.8-13.8 39-49 Strong branches are moving,
whistling in power lines,
umbrellas difficult to use
7 Stiff wind 13.9-17.1 50-61 Whole trees are moving
8 Stormy wind 17.2-20.7 62-74 Branches are broken off trees,
walking outdoors is made very
difficult
9 Storm 20.8-24.4 75-88 Slight damage to houses
(chimney hoods and tiles are
blown off)
10 Heavy storm 24.5-28.4 89-102 Uproots trees, considerable
damage to houses
11 Hurricane 28.5-32.6 103-117 Extensive storm damages
type storm (rarely in inland)
12 Hurricane 32.7-36.9 118-133 Severe devastation
825 + 830 / 04.2008 Translation of the original operating instructions 4 - 11
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Commissioning - Tests before start-up
5.5.2 Check fuel level
Note
The fuel fill level can be determined with two different ways:
z with the indicator on the right next to the filler neck (rough indication)
z with the SENNEBOGEN diagnostics system in the initial mask, see
Section6.3.16
1 2
1 Filler strainer
2 Control displays
Note
Fill the tank with the specified grade of fuel. Clean fuel is essential for
trouble-free operation of the diesel engine.
Notes on quality and fuel selection
Observe the notes in the operating instructions of the engine
manufacturer.
825 + 830 / 04.2008 Translation of the original operating instructions 5-9
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Commissioning - Check water heating coolant level (Optional)
6 Close the cap on the expansion tank.
7 Close the service access door at the left, rear.
825 + 830 / 04.2008 Translation of the original operating instructions 5 - 19
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Commissioning - Switch on machine - Electric motor
5.11 Switch on machine - Electric motor
5.11.1 Safety instructions
Observe the safety notes before starting machine.
DANGER
z Danger of injury!
Keep cab door and service access doors closed.
z Before starting the engine, ensure that there is no one within the
danger area.
z Do not start engine if a warning sign is present on the operating
elements.
z Adjust driver's seat, steering column and mirror to the correct
position.
z Fit restraint belt correctly.
z Close the cab doors.
5.11.2 Restraint belt
The machine is equipped with a lap belt. The belt complies with
standards SAE J 386 (USA) and FMVSS 209 (EU).
WARNING
z Check belt for signs of wear before starting to operate the machine.
Immediately exchange a damaged belt.
z Clean dirty belt using water.
z Do not twist belt when fastening.
z Pass belt as low as possible around the hips, not around the
stomach.
1
2
3
1 Push metal catch (1) into belt buckle (2).
An audible click indicates that the belt has engaged.
2 To release belt, press red button (3) on belt buckle (2).
825 + 830 / 04.2008 Translation of the original operating instructions 5 - 29
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Operation - Driver's cab/cab with platform, raising
Sliding door
1
2
The sliding door (1) can be latched in the open position on the side
panel of the cab. You can release the latch by pulling on the release
lever (2) on the inside of the door.
Front windshield
3
4
Opening front windshield: Tip forwards. The top window wiper pivots
ahead with the window. Press on both buttons (4) and tip the window
ahead. The two shock absorbers hold it in position. Pull the two handles
(3) on the window frame inward to close it. Ensure that the front window
latches in place again.
825 + 830 / 04.2008 Translation of the original operating instructions 6-3
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Operation - Operating elements
6.3.4 Safety lever
The safety lever (1) serves as a safety device.
Safety lever released
(pushed forward)
1
When safety lever is released (see illustration)
z all hydraulic functions are available.
z all work maneuvers can be carried out.
Note
The slewing gear holding brake remains open after releasing the safety
lever (pushed ahead), if the "right" switch has previously been actuated
in the right control panel.
Activate the slewing gear holding brake by pressing the "left" switch in
the right-hand control panel (see Section6.5.9).
Safety lever
actuated
(pulled back)
1
Note
All hydraulic functions are deactivated with the safety lever actuated.
825 + 830 / 04.2008 Translation of the original operating instructions 6 - 13
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Operation - Operating elements
Reverse fan status
indicator lamp Switch setting Indicator lamp
1 (right, single fan reversal) flashes
0 (middle, no fan reversal) not illuminated
2 (left, fan reversal every 60 min.) always illuminated
Note
The fan reversal indicator lamp (3) provides information on the status
of the fan drive controller and on faults in the fan system. A fault is
indicated with a flashing code. Contact SENNEBOGEN service in this
case.
In reversal operation, the indicator lamp flashes once per second.
Travel forwards Lamp illuminated with selected travel direction - Forward.
Travel reverse Lamp illuminated with selected travel direction - Reverse.
Magnet system Illuminated with magnet system switched on.
Switch Illuminated with activated floating axle control if the superstructure is in
steering direction 0°- or 180°-position (+/- 5°) to the undercarriage.
180° displacement Illuminated with active steering direction reversal if the boom is in the
area above the rear axle (90°-270° - position (+/- 7.5°)).
High beam Illuminated when headlight lit.
825 + 830 / 04.2008 Translation of the original operating instructions 6 - 23
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Operation - Operating elements
Rear part
15*
16*
17
18*
19*
20*
21*
22*
23*
24*
25
15*Floating boom setting 22*All-wheel steering switch
16*Grabber function Off/On 23*Boom suspension system
17*Grabber control Off/On 24*Steering direction reversal
18*Overload Off/On 25*Load limit sensing control
(GLR)
19*unlock - Magnet system Off/
On
20*unlock- Auxiliary limiting main
boom Off/On
21*Normal steering control -
0° position rear axle
*: Optional model / special function
825 + 830 / 04.2008 Translation of the original operating instructions 6 - 33
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Operation - Operating elements
Start-up mask
1
4.02 2
Automatic change
after 4 seconds
to screen 7
3 4 5
Screen 1
Coolant temperature 6
7
Fill level - Diesel fuel 8
1 SENNEBOGEN logo 5 Daily hours of operation
2 Software version (E.g.) 6 Coolant temperature
3 Time 7 Warning threshold Coolant
temperature too high
4 Date
8 Fill level - Diesel fuel
825 + 830 / 04.2008 Translation of the original operating instructions 6 - 43
--- Page 23 ---
Operation - Operating elements
Date
Start-up mask
825 + 830 / 04.2008 Translation of the original operating instructions 6 - 53
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Operation - Additional displays (special equipment)
6.4.4 Auxiliary heating / Water heater
The machine is equipped with an engine-independent water heater for
engine-heating and cab-pre-heating.
The electric water heater is set up in the factory and is controlled along