Operating and Maintenance Instructions

Operating and Maintenance Instructions
BS 80
05.2008
BS80.6.1049
Foreword
Important notes on the

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

starting work with the machine.
Keep the instruction in a safe place for future use.
WARNING!
z Only work with the machine once these instruction have been read
and completely understood.
z Observe safe working load tables in Abschnitt 3.2.
z Forbid unsafe operation or unsafe maintenance.
z Do not operate machine if a fault has been detected!
z Setting up, operation and maintenance of the machine is only
permitted by trained personnel. The employer is responsible for the

qualification and training of the personnel.
z These instruction are an integral part of the machine. Always keep
the instruction in the cab.

Recommended location to keep instructions: In the storage
compartment behind the drivers seat.
In the event of sale, disposal or loan, the operating manual must
accompany the machine!
z Contact SENNEBOGEN immediately if there is anything in the
operating manual that you do not understand!

Your comments will help us to make the operating manual even
more user friendly.
For reasons of clarity, the specified safety devices are not shown in
some of the illustrations. Operation with safety devices removed is not
permitted!
DANGER
Safety devices must be fitted when working with the machine.
Current when going to
press
Ongoing development ensures the advanced technology and the high

level of quality in our machines. This may result in deviations between
these instruction and your machine. Errors can also not be ruled out.
Please understand that no legal claims can be derived from the
specifications, illustrations and descriptions within these instructions.
Illustration aids
These instruction contain safety instructions that highlight dangerous

working practices. These safety notes are indicated with a warning
symbol and a keyword.
This warning symbol means: Attention - this concerns your safety and
the safety of others.
The associated keyword signifies the degree of danger:
DANGER
Is used for great, directly threatening danger. If this danger is not
averted, serious physical injuries or loss of life of persons will result.
WARNING
Is used for potentially dangerous situations. If this danger is not
averted, serious physical injuries or loss of life of persons may result.
CAUTION
Is used for potentially dangerous situations. If this danger is not
averted, physical injuries or serious material damage may result.
Notes which make the work easier or contribute to better understanding
when operating the machine are displayed in the following way:
Note
Indicates notes which draw attention to peculiarities.
Note
Indicates cross references to other documents.
Handling instructions are shown in table form as follows:
1
Press switch (1).
Actuate control lever (2).
Unfasten pins (3).
z Listings are marked with bullet points.
Sub-points in listings or handling instructions are marked with

dashes.
BS80
W-3
Glossary of terms
Operator
The operator (owner of the company/company) is responsible for
operating the machine in a correct manner, or for ensuring that the
product is being used by suitable and instructed personnel.
Operating personnel
The operating personnel are the person/s authorized by the operator to
use the product.
Trained technicians
Trained technicians are those authorized by the operator to fulfil certain
obligations such as installation, fitting, repair and maintenance and
troubleshooting.
z Specialists
Specialists are those who, on the basis of specialist training,

knowledge and experience with the product and in the full
knowledge of the relevant standards, can appraise the work
allocated to them and can recognize potential dangers and avoid
them.
z Instructed personnel
Instructed personnel are those who have received instruction in the

tasks allocated to them and in the potential dangers of misuse and
misbehavior, who have been taught about the necessary safety
equipment, safety measures, relevant regulations, accident
prevention guidelines and operating conditions and who have
proved their abilities.
z Experts
Experts are those who, on the basis of specialist training and

experience have sufficient knowledge in the area of the productand
are sufficiently aware of the relevant national occupational safety
guidelines, accident prevention guidelines, regulations and
generally recognized technical regulations (e.g. EEC-Guidelines,
VDE-Regulations, VBG) as to be able to judge the operational safety
of the machine.
z Specialists
Specialists are those who are authorized by the German technical

monitoring organization TV or by their professional organization to
check the machine. Authorization on the part of a professional
organization must comply with the Principles for authorizing
specialists to check cranes (ZH 1/518). It is linked to the issue of an
identity number. This is to be entered by the specialist in the check
report and/or check notice.
Authorizations can be limited to parts of checks or to certain types
of crane.
W-4
BS80
Target group
The machine has been developed for demanding work.

Persons working on or with the machine must be trained or instructed
for that purpose.
The operation and deployment may only be carried out by
persons suitably instructed. Initial operation, maintenance,
transportation and assembly/dismantling only by trained specialists.
Detailed information on the required prior knowledge and qualifications
of the operator can be found in Chapter 1 SAFETY of these instructions.
What documents go
with the machine?
The following documents go with the machine:

z These operating and maintenance instruction
z Spare parts catalog
z Service checkbook.
Note
The complete scope of materials included with delivery is specified in
the order confirmation.
How are the instruction
divided up?
The instruction are divided into 10 chapters:

z 1: Safety
You will find generally applicable safety instructions that must be

universally observed in this section.
z 2: Overview
Chapter 2 illustrates the main components of the machine.
z 3: Technical data
You will find basic information about the machine in this section,
forexample lifting capacities.
z 4: Starting operation
This section provides information about starting operation on a daily

basis.
z 5: Operation
You will also find information on operating instruments and working

operation.
z 6: Maintenance
Chapter 6 illustrates procedures used to ensure that the machine is

suitable for use.
z 7: Setting up
Chapter 7 may contain information on setting up counterweight.
z 8: Transportation
In Chapter 8 you will find the dimensions and weights of the

machine.
BS80
W-5
z 9: What to do if ...
Here you will find information on recognizing causes of malfunctions

and introducing measures to eliminate faults.
z 10: Appendix
Here you will find an index and additional information, forexample

on the warranty.
W-6
BS80
Please contact
us at
SENNEBOGEN Maschinenfabrik GmbH

Hebbelstrasse 30
D-94315 Straubing
Telephone:
+49 9421 540-0
Internet:
http://www.sennebogen.de
Fax Customer service:
+49 9421 540279
Fax Spare parts storage:
+49 9421 40811
Technical documentation:
E-mail:
doku@sennebogen.de
Fax:
+49 9421 540 380
Note
The addresses of SENNEBOGEN sales and service partners are
available on the Internet through our homepage.
BAUER Maschinen GmbH
Wittelsbacher Str. 5
D-86529 Schrobenhausen
Telephone:
+49 8252 97-0
Internet:
http://www.bauer.de
Fax Customer service:
+49 8252 972587
Technical documentation:
E-mail:
juergen.schoderer@bauer.de
Fax:
+49 8252 2815
Note
The addresses of BAUER sales and service partners are available on
the Internet through the homepage.
instruction
BS80
W-7
CE symbol of
conformity
Copyright
W-8
The CE symbol indicates that basic safety requirements have been

met. For more information, see the separate Declaration of conformity.
Straubing 2007, SENNEBOGEN Maschinenfabrik GmbH
Reproduction, in whole or in part, only with written permission of

SENNEBOGEN Maschinenfabrik GmbH, Straubing, Germany.
Printed in Germany.
BS80
Contents
BS80/ 05.2008
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Use as Intended . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Potential instances of misuse . . . . . . . . . . . . . . . . 1-2
1.4 Abuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5 Residual hazards . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6.2 Preparing to Operate . . . . . . . . . . . . . . . . . . 1-8
1.6.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.6.4 Setup work . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.6.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.6.6 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.7 Obligations of the Owner . . . . . . . . . . . . . . . . . . . 1-14
1.8 Guards and Protective Devices . . . . . . . . . . . . . . 1-17
1.9 Warning Signs and Labels on the Machine . . . . . 1-18
1.9.1 Identification plate . . . . . . . . . . . . . . . . . . . 1-18
1.9.2 CE stamp of conformity . . . . . . . . . . . . . . . 1-19
1.9.3 Euro-test identification . . . . . . . . . . . . . . . . 1-19
1.9.4 Safety signs and warning symbols . . . . . . 1-20
1.10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.11 Hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
General View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Overall Machine . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Operators Station . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Base Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Preparing to Operate . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Initial Commissioning . . . . . . . . . . . . . . . . . . . . . .
4.3 Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Starting the Machine . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-1
2-2
2-4
2-6
2-7
4-1
4-1
4-2
4-2
4-4
0-1
Contents
4.4.1
4.4.2
4.4.3
4.4.4
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Starting the Engine . . . . . . . . . . . . . . . . . . . 4-5
Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Bring Machine up to Operating Temperature . .
4-7
4.5 Turning off the machine . . . . . . . . . . . . . . . . . . . . . 4-8
4.5.1 Switching off engine . . . . . . . . . . . . . . . . . . 4-8
4.6 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
0-2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Operators Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.1 General View . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.2 Emergency Stop . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.3 Safety Lever . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.4 Right-Hand Control Lever . . . . . . . . . . . . . . 5-7
5.3.5 Left-Hand Control Lever . . . . . . . . . . . . . . . 5-7
5.3.6 Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.3.7 Sennebogen Diagnostic System (SDS) . . . . 5-9
5.3.8 Right-Hand Control Panel . . . . . . . . . . . . . 5-17
5.4 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.5 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.5.1 Air Conditioner . . . . . . . . . . . . . . . . . . . . . . 5-22
5.5.2 Auxillary heating / Water heater . . . . . . . . 5-24
5.5.3 Hydraulicoil- , cooling water- and diesel preliminary heating, batterie preliminary heating 5-25
5.6 Operating Technique . . . . . . . . . . . . . . . . . . . . . . 5-27
5.6.1 Safety Information . . . . . . . . . . . . . . . . . . . 5-27
5.6.2 Swinging the Upper Structure . . . . . . . . . . 5-28
5.6.3 Refueling the Machine . . . . . . . . . . . . . . . . 5-30
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.2 Oils and Lubricants . . . . . . . . . . . . . . . . . . . 6-5
6.2.3 Coolant for CATERPILLAR - Drive motors . 6-6
6.2.4 Coolant - General . . . . . . . . . . . . . . . . . . . . 6-7
6.2.5 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
BS80/ 05.2008
Contents
6.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6.3.1 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.3.2 Water separator . . . . . . . . . . . . . . . . . . . . 6-14
6.3.3 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.3.4 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.3.5 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.3.6 Belt Drives . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.4 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6.4.1 Hydraulic Hose Lines . . . . . . . . . . . . . . . . 6-22
6.4.2 Relieving Hydraulic System Pressure . . . . 6-23
6.4.3 Checking Hydraulic oil Level . . . . . . . . . . . 6-24
6.4.4 Changing Hydraulic Oil . . . . . . . . . . . . . . . 6-25
6.4.5 Return Flow Filter Replacing Filter Element . .
6-28
6.4.6 Pilot Control Filter Replacing Filter Element .
6-29
6.4.7 Leakage Oil Filter Replacing Filter Element . .
6-30
6.4.8 Replacing Ventilation Filter . . . . . . . . . . . . 6-31
6.4.9 Checking and Cleaning Hydraulic Oil Cooler . .
6-32
6.4.10Checking Precharge Pressure of the Accumulators 6-33
6.5 Distributor Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6.5.1 Checking Oil Level . . . . . . . . . . . . . . . . . . 6-35
6.5.2 Changing Gear Oil . . . . . . . . . . . . . . . . . . 6-35
6.6 Slewing Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
6.6.1 Lubricate the ball-type swing gear and bearing
6-36
6.7 Swing drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
6.7.1 Lubricating the gear teeth . . . . . . . . . . . . . 6-38
6.7.2 Retightening bolts . . . . . . . . . . . . . . . . . . . 6-39
6.8 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
6.8.1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
6.8.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
6.9 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
6.10 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
6.10.1Maintenance Schedule . . . . . . . . . . . . . . . 6-43
6.10.2Refill Capacities . . . . . . . . . . . . . . . . . . . . 6-46
6.10.3Tightening Torques for Screws . . . . . . . . . 6-47
BS80/ 05.2008
0-3
Contents
0-4
Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 Detaching/Attaching Counterweight . . . . . . . . . . . 7-1
7.1.1 Detaching Counterweight . . . . . . . . . . . . . . 7-2
7.1.2 Attaching Counterweight . . . . . . . . . . . . . . . 7-4
7.2 Setting Up (Option) . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.3 Detaching/Attaching Counterweight . . . . . . . . . . . 7-8
7.3.1 Detaching Counterweight . . . . . . . . . . . . . . 7-9
7.3.2 Attaching Counterweight . . . . . . . . . . . . . . 7-11
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Dimensions and Weights . . . . . . . . . . . . . . . . . . . .
8.2.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.2 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 Disconnect electrical system from battery . . . . . . .
8.4 Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . .
8.5 Lashing and Tying Down the Machine . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.3 Electronic System . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.4 Sennebogen diagnositc system SDS . . . . . . . . . . 9-6
9.4.1 Bank of keys with LEDs . . . . . . . . . . . . . . . . 9-6
9.4.2 Indicator and warning lights . . . . . . . . . . . . . 9-8
9.5 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.6 Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.7 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
1.1 List of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . 2-1
8-1
8-2
8-3
8-3
8-4
8-5
8-6
8-8
BS80/ 05.2008
Safety - General
Safety
1.1 General
In the design and construction of the machine, allowance has been
made for the state of the art and the recognized safety-related
standards. Its operation may nevertheless involve potential hazards for
persons, the machine and other property if
z the machine fails to be used as intended;
z operation or maintenance of the machine is performed by
unqualified personnel;
z the safety notices and messages are ignored.

z the machine is found to be defective.
z the operating tools attached do not comply with the relevant safety
regulations.
z the operating tools attached are found to be defective
National and international regulations apply in addition to the safety

information in these instruction.
In the Federal Republic of Germany e.g:
z Winches, Lifting and pulling devices (VBG 8)
z Crane (BGV D6)
z Hoisting devices in lifting appliance operation (VBG 9a)
z Earth-moving machinery (VBG 40)
z EC Machinery guideline 98/37/EC
z EMC Guideline 89/336/EEC
z Electrical Machinery Equipment (EN 60204-1)
z Safety Requirements for Fluid Engineering Systems and their
Components - Hydraulic (EN 982)
z Earth-Moving Machinery Safety (EN 474-1/-5)

z Safety of Machinery (DIN EN 12100-1 und DIN EN 12100-2)
z "Outdoor" Regulation 2000/14/EG
Note
When a conflict exists between the national rules and regulations in the
country of destination and our recommendations, follow the strictest
procedure.
BS80/ 01.2006
1-1
Safety - Use as Intended
1.2
Use as Intended
The machine has been designed as a carrier machine for BAUER,

Schrobenhausen, Germany.
Any other use or any use beyond the scope set out above is considered
to be improper use.
Work station:
The operators work station is in the operators cab of the machine.
Note
Study and observe the information contained in the BAUER
documentation.
Target group
The machine has been designed to perform specific exacting duties.

Persons who operate the machine or work on it must have received
adequate training or instruction.
Operation and application must be performed only by persons that
have been duly instructed. Commissioning, maintenance, transport
and assembly/disassembly must be assigned to trained qualified
personnel.
1.3 Potential instances of misuse

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

z Neglect of necessary inspection and maintenance work.
z Use in inadmissible ambient conditions.
z Misuse by untrained and uninstructed personnel.
z Counterweight disassembly or replacement of counterweight
elements with device attached (e.g. Ram)
1-2
BS80/01.2006
Safety - Abuse
1.4
Abuse
Practices considered to be improper use (abuse) include in particular:

z Lifting, moving and handling of persons
z Oblique pulling of loads
z Dragging of loads
z Breaking loose any loads that have got stuck
z Operation in a potentially explosive atmosphere
WARNING
Improper use will exempt the manufacturer from any and all liability!
The user will bear sole responsibility.
1.5 Residual hazards

The safety information in these instruction are guidelines for the safe
use of the machine by qualified machine operators. However,
SENNEBOGEN cannot anticipate every situation in practice that may
result in danger.
Therefore, the safety notes and warnings on the machine and in the
instruction cannot beall inclusive. The owner andmachine operator still
remain responsible for safety.
BS80/ 01.2006
1-3
Safety - Safety Information
1.6
Safety Information
DANGER
Danger to life!
There is a risk of serious injury or even death to persons using the
machine or in its vicinity if it moves suddenly or is started
unintentionally. Observe the following:
z Place the machine on a firm base, if necessary set back from the
edge of the excavation.
z Lower suspended loads and booms to the ground.

z Apply the brake.
z Switch off machine and secure against unauthorised re-starting.
z Use a chock to stop the machine from rolling away.
1.6.1 General
Danger area
The danger area of the machine is the surrounding area in which

persons are within the reach of:
z Work-related movements of the machine
z Working equipment and machine attachments
z Loads swinging out or dropping down
z Working equipment dropping down
DANGER
No persons are allowed in the danger area!
In case of danger to persons, the operator must give warning signals.
If the persons fail to leave the danger area in spite of the warning,
operations must be stopped.
To avoid crushing hazards, maintain an adequate safety clearance (at
least 500 mm) to any fixed structures such as building structures,
banks of excavations, scaffolds or other machines.
Where maintenance of the safety clearance is precluded, mark off the
area between any fixed structure and the working area of the machine.
When the operators view of his work and travel area is restricted or
impaired, a signal person must be provided.
1-4
BS80/01.2006
Gallery = Catwalk for

operators
DANGER
Risk of falling!
A maximum of 100 kg (220 lbs) is permitted per segment of grid iron on
the gallery (= operator catwalk). Overloading will lead to damaging the
construction, the results of which can lead to personal injury.
Check the gallery for cracks and general damaged every 3 months and
repair immediately if necessary.
Personal protective
equipment
Problems
Stability
While performing work on the machine, the operating personnel is

obliged to wear personal protective equipment as required by the
national rules and regulations (e.g., hard hat, hearing protective, safety
shoes, protective gloves).
Report problems or damage immediately to a responsible person!
Prevent the machine from incorrect or erroneous use.
Repairs may only be performed by trained specialist personnel.
z Position the machine on a firm, level supporting surface only.
z Where necessary, stabilize the supporting surface.
z Beware of edges of excavations, banks, vaults, etc.
z Set outriggers on a firm, level supporting surface as well.
z Pay attention to wind speeds!
DANGER
Refrain from any operating practice impairing stability of the machine!
Note that stability is reduced when the load swings out to the side.
BS80/ 01.2006
1-5
Working in the vicinity

of power lines
z Clearly mark off the power lines in the job site area with your
supervisor. Do so before starting work!
z Consider all overhead lines to be energized electric power lines.

z Operate the machine so that neither parts of the machine nor any
loads being handled enter into the danger zone.
z Maintain a safety clearance to the overhead lines. Unless otherwise
provided in the national laws and regulations, maintain the following

minimum clearances:
Rated Voltage (Volts)
Safety Clearance (Meters)
to 1000 V
1.00
over 1000 V to 110 kV
3.00
over 110 kV to 220 kV
4.00
over 220 kV to 380 kV
5.00
unknown
5.00
z Use a signal person to observe the safety clearance.

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

minimum clearances specified.
z Wind can cause both the overhead lines and any working equipment
to weave or swing out and thus reduce the clearance.
High voltage contact
In case of high voltage contact, proceed as follows:

z Do not leave the operators station.
z Caution all outside persons against approaching or touching the
machine.
z Where possible, move the working equipment or the entire machine
out of the danger zone.
z Arrange for the power to be disconnected.

z Do not leave the machine until after de-energization of the line that
has been touched or damaged.
DANGER
If you must leave the machine in an emergency, e.g., if there is a fire,
never contact the machine and the ground at the same time. Jump
clear of the machine with your feet together.
1-6
BS80/01.2006
Qualifications of
personnel
Extract from VBG 40

regulations (Germany)
The machine must be operated and maintained only by qualified

personnel.
Only those persons must be assigned to operate or maintain
earthmoving machines on their own who
z have attained the age of 18 (majority);
z are both physically and mentally fit;
z have received training in the operation or maintenance of the
earthmoving machine and have proven their relevant qualification to

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

maintain the earthmoving machine.
Extract from OSHA
regulations (United
States)
Operators are required to meet the following qualifications:

z Pass a practical operating examination for the machine they will
operate.
z Have vision of at least 20/30 Snellen in one eye and 20/50 Snellen
in the other eye, with or without corrective lenses.
z Be able to distinguish colors (red, green, yellow) if color
differentiation is required for operation.
z Have adequate hearing (with or without a hearing aid).
A disabling heart condition or a history of epilepsy are sufficient reason

for disqualification as an operator.
BS80/ 01.2006
1-7
1.6.2 Preparing to Operate

WARNING
z Make sure that all guards and protective devices of the machine are
in place and are properly secured.
z Wear personal protective equipment (hard hat, safety glasses)
where this is required by job conditions.
z Avoid wearing jewelry or loose clothing.

z Secure any loose items, e.g., tools or other accessories.
z Agree on hand signals with the signal person.
z Obtain information about first aid and about assistance and rescue
services.
z Perform the pre-start checks as specified in Section 4.3.

z Get onto or off the machine only while it is parked. Use the means
of access and ladders provided for the purpose:
Before using the means of access and the ladders, clean them as
necessary.
While mounting or dismounting, your hands must be free of any
objects. Use a hand line or a hoist to lift any items of equipment
onto the machine.
Do not use controls in the operators cab as handholds.
z Make sure that there are no persons in the danger area.
z Check the safety features (brakes, signaling and lighting equipment)
of the machine.
z While traveling at slow speed, check the controls and protective
devices for proper operation.
1-8
BS80/01.2006
1.6.3 Operation
WARNING
z Be sure to observe Chapter 1 SAFETY.
Before the machine is put into operation, perform the checks as

specified in Section 4.3.
z Persons who operate the machine or work on it must have received

have been duly instructed.

z Maintain a safety clearance to overhead lines.
z Operate the machine only while you are in the operators seat.
z Do not use the machine for handling of personnel.
z Make due allowance for ambient conditions, e.g., poor visibility,
wind speeds, etc.
z Observe performance specifications.

z Check whether the load capacity of attachment points is adequate.
z Obey the signals given by signal persons, where applicable.
z Before leaving the operators cab:
Park the machine on a safe surface. Back off from the edge of an
excavation, where applicable.
Lower any attached loads to the ground.
Secure the working attachments.
Pull the safety lever backward.
Chock the tires/block the undercarriage.
Stop the engine.
z Lock the operators cab; use warning lamps to mark the machine,
where applicable.
BS80/ 01.2006
1-9
1.6.4 Setup work

WARNING
z Wear personal protection equipment (e.g. safety helmet, ear protection, protective gloves, safety boots) if working conditions require it.
z When disassembling components or equipment, always use load
suspension equipment with a sufficient load carrying capacity at the

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

z Note the relevant accident prevention directives for working with load
suspension equipment.
z Carry out all setup steps in turn. Never carry out more than one set
up task at a time.
z Do not climb or run on equipment parts (e.g. boom components,
ballast components) suspended on the crane. Do not stand on parts

suspended from the crane.
1 - 10
BS80/01.2006
1.6.5 Maintenance
DANGER
Danger to life!

z Apply the brake.
WARNING
z Observe the applicable statutory accident prevention and safety
regulations.
z Land any attached loads to ground level.

z Pull the left safety lever backwards.
z Before attempting to perform any maintenance, shut down the
machine and secure it against unauthorized restarting.
z Attach a warning tag to the controls.

z Do not smoke and do not allow open flames.
z When working in the area of the battery, cover the battery with
isolating material; do not deposit any tools on the battery.
z Use personnel hoists or work platforms that satisfy safety
requirements.
z Stay clear of all rotating and moving parts.

z Relieve the pressure before working on the hydraulic system.
z Always wear protective gloves when handling wire ropes.
z Use only genuine BAUER/SENNEBOGEN spare parts.
z Use only those oils and lubricants that are specified in the lubricants
chart.
z Do not lift heavy components by hand. Use hoists or lifting
equipment.
z Operate the optional battery disconnect switch, if equipped, to
interrupt power supply.
z On completion of the maintenance operations, reinstall all guards
and protective devices.
z Keep the operators cab clean and tidy.
BS80/ 01.2006
1 - 11
z Perform a functional check to ensure proper operation.

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

again.
z For machines with pneumatic tires:
When inflating tires, keep an adequate safe distance and use a tire
cage.
DANGER
z Work on the machine's electrical equipment may only be carried out
by a qualified electrician.
z Work on running gear, braking and steering systems may only be
carried out by specifically trained technicians!
z Work on hydraulic systems may only be carried out by personnel
with specific knowledge and experience of hydraulics!
z No welding is to be performed on the device without previous
discussion with the manufacturer.
WARNING
Mixing oils, lubrication or operational materials of different types is not
permitted!
Filling or mixing oils, lubricants or any other operational fluids (e.g.
hydraulic oil, transmission oil, motor oil, coolant, etc.) of different types
can lead to chemical reaction damage to machine components. This
damage can in turn result in severe da
mage to property and to personal
injuries.
Use oils, lubricants and operational fluids that are approved by
SENNEBOGEN only.
Only mix oils, lubricants and operational fluids that are of the same type
or identical (same specifications) from one manufacturer!
1 - 12
BS80/01.2006
1.6.6 Transport
WARNING
z In Germany:
Loading and transportation work is only to be carried out by

authorised specialist personnel in accordance with VBG 40, 48 and
Federal Motor Vehicle Safety Standards (StVo) 22.
z Comply with the relevant regulations for securing loads.
The respective transport operator is always responsible for the

transportation of machine and accessories.
z When loading and transporting, secure the machine and its working
equipment from unintended movement.
z Clean running gear of machine from mud, snow and ice so that
ramps can be accessed without danger of sliding.
z Provide low loader access ramps with wooden planks.

z Check conditions of route before starting journey.
z Only transport machine using designated tie-down and lifting points.
z Ensure that the machine does not present any hazards to other road
users.
z Wear personal protection equipment (e.g. safety helmet, protective
gloves, safety boots).
z Notify SENNEBOGEN customer service of any transport damage
immediately.
BS80/ 01.2006
1 - 13
Safety - Obligations of the Owner
1.7
Obligations of the Owner
WARNING
The owner/user is obliged to prepare relevant instruction when dealing
with dangerous machines or hazardous materials.
The necessary information is to be found in
z EC directives on occupational health and safety
z National occupational health and safety laws
z Accident prevention regulations and
z the present instruction.
Recurring
inspections
Specialist testing, required for crane or backhoe operation

The machine must be thoroughly checked by a specialist.
z before initial operation and before putting the machine back into
operation after significant modifications
z at least once yearly

z and in between according to operating conditions and conditions of
use.
A specialist in this context is a person, who

z has extensive knowledge of this machine and the corresponding
regulations and guidelines due to specialist training and
z through special instructions of Co. BAUER/Sennebogen

z has obtained extensive knowledge of this machine and the
corresponding regulations and guidelines through specialist training

and can assess the safe working condition of the machine.
Specialist testing, only required for crane operation

The following cranes must be tested by a specialist every 4 years:
Fuel driven mobile crane
Location changing fuel driven derrick crane
Vehicle attachment crane
The specialist inspection is to be performed in the 13th year of
operation and annually thereafter.
Faults that are determined in recurring inspections must be eliminated
according to the safety-relevance and within a suitable time-frame.
1 - 14
BS80/01.2006
Risks incurred by
ignoring safety notices
Non-observance of the safety notices and messages is dangerous, and

persons as well as the environment and the machine can be
endangered as a result.
Failure to observe the safety notices and messages will invalidate any
entitlement to damages.
Selection and
qualifications of
personnel
z Employ only personnel that has been duly trained or instructed.

z Define responsibilities for operation and maintenance.
z Observe the minimum age permitted by law.
DANGER
z Personnel that is being trained or instructed must not be allowed to
work on the machine except under constant supervision of an
experienced skilled person.
z Have any work on electrical equipment of the machine performed by
a qualified electrician only.
z Only qualified personnel having received relevant training is allowed
to perform work on undercarriages, braking and steering systems!
z Work on hydraulic equipment must only be performed by personnel
having specific knowledge and experience of hydraulics!
Inadmissible operating
practices
z Safety of operation of the machine is ensured only when it is used
as intended, consistent with the specifications in Section 1.2 of this

instruction.
z The performance limits specified in Chapter 3 TECHNICAL DATA must
not be exceeded.
z When the machine is exposed to risks of falling heavy objects, it
must not be used unless the operators station is protected by a

canopy (FOPS structure). The canopy is available from BAUER/
SENNEBOGEN as an option.
Specific dangers
The machine operator must check whether the operation gives rise to
specific dangers, e.g. on account of toxic gases, ground quality etc.,
and adopt appropriate measures to avoid or limit those dangers.
Technical condition of
the machine
It is the obligation of the owner to continuously monitor the overall

technical condition of the machine (for defects and damage evident on
the outside as well as changes in operational performance).
Keep the time limits specified for periodic inspections.
BS80/ 01.2006
1 - 15
Noise protection
The permanent sound pressure level of the machine measured at the

operators seat with the operators cab closed is about 80 dB(A).
Wearing of hearing protective devices therefore is not a mandatory
requirement. Measurements are made as specified in EN ISO 11201.
It is possiblehowever that ambientinfluences cause the level to exceed
85 dB(A), e.g., owing to dropping or transport of material, or in
combination with other machines on a job site.
In such cases, noise protection arrangements for the operating
personnel are a mandatory requirement.
The owner must make sure that adequate hearing protective devices
are available and are worn by the operating personnel.
Genuine BAUER/
SENNEBOGEN spare
parts
Conversions and modifications of the machine are not permitted.

This applies also to the installation and use of safety devices and
valves as well as welding on load carrying parts.
Genuine BAUER/SENNEBOGEN spare parts and accessories serve
the safety of the personnel. The use of other components may change
the properties of the machine and thus compromise safety.
The use of non-approved components will release BAUER/
SENNEBOGEN from all and any liability for any resulting
consequences.
Employment in foreign
countries
When the machine is employed abroad, take the following precautions:

z Observe the safety regulations applicable in the respective country
of use.
z Make sure that the operating personnel has the necessary
qualifications for the scheduled work.
z See to it that the contents of the present instruction are read and fully
understood. Where necessary, obtain a manual in the respective

official language from BAUER/SENNEBOGEN.
Fire extinguisher and

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

are summarised in the warranty manual.
1 - 16
BS80/01.2006
Safety - Guards and Protective Devices
1.8
Guards and Protective Devices
DANGER
z Do not remove any protective devices and covers.
z Whenever the machine is started, make sure first that all protective
devices of the machine are in place and are properly secured.
z On completion of fitting or maintenance operations, properly
reinstall all guards, protective devices and covers.
z Replace any damaged protective devices by new items.
BS80/ 01.2006
1 - 17
Safety - Warning Signs and Labels on the Machine
1.9
Warning Signs and Labels on the Machine
There are specific safety signs and warning symbols on the machine.
z Do not remove the safety signs and labels.
z Keep all safety signs and labels in an undamaged and readable
condition.
z Use water and soap to clean the safety signs, where necessary.
Do not use gasoline or solvents to clean the signs and labels.
z Replace any damaged, scratched or illegible safety sign or label by
a new item.
Note
Warning signs and labels are available from BAUER/SENNEBOGEN
(see spare parts catalog).
1.9.1 Identification plate
Machine type
Manufacturers No. (Facility No.)
Engine performance specification (in kW)
Year of manufacture
* actual - Permissible overall weight of machine
* actual - Permissible weight on the front axle
* actual - Permissible weight on the rear axle
(*) Note
The data for positions 5, 6 and 7 is not always engraved on the type
plate.
1 - 18
BS80/01.2006
1.9.2 CE stamp of conformity

affects machines that are operated within the EU/EEC.
These machines wear the CE identification. This means that these
machines meet the respective safety stipulations of the EU machine
regulations upon delivery. For changes that affect the safety of the
machine and the respective consequences, those that make the
changes are responsible and liable.
If the machine is used for purposes other than those intended or is used
with machinery other than that indicated in these instructions, safety
must be guaranteed in each case. Those performing the work are
responsible and liable. In certain cases, another CE identification and
the completion of a new EU declaration of conformity may be required.
CE Stamp
1.9.3 Euro-test identification

EuroTest is a voluntary Prototype test, which is based on the EC
machine guidelines and the respective European standards.
BS80/ 01.2006
1 - 19
1.9.4 Safety signs and warning symbols
1 - 20
BS80/01.2006
BS80/ 01.2006
1 - 21
Safety - Disposal
1.10 Disposal
Lubrication and
consumables
CAUTION
Observe environment protection!
Handle and dispose of used items and materials correctly, especially
z when working on lubrication systems and devices and
z when working with solvents.
Extract from the Disposal Guideline 75/439/EEC:

z It is prohibited to mix spent oil with other waste.
z Spent oils must not be mixed together.
z Used oil filters must be collected, kept, transported and disposed of
separately from other waste.
Notes
z Dispose of lubricants and other consumables at suitable collection
points.
z National environmental conditions valid in the country of use also
apply.
Batteries
When working with batteries, please observe safety instructions and

protective measures.
Notes
z Do not dispose of batteries in household trash!
Return defective batteries to a collection place for old batteries.
z National environmental conditions valid in the country of use also
apply.
1 - 22
BS80/01.2006
Safety - Hand signals
1.11 Hand signals

Driver and signaler communicate with each other with the aid of the
following hand signals when vision is restricted in the driving and work
area.
The guide gives the necessary signals to ensure safe operation.
Safety instructions
Observe the safety notes before starting

work.
CAUTION
z Only responsible persons may be employed as guides. They must
receive the necessary training before starting their task.
z The guide must not be diverted from this task
by other tasks.
z Observe notes of VBG 40, 35 Guides as well as the details of DIN
33409 Hand signals for guidance.
Attention
Extend arm upwards with hand
open.
Stop
Extend both arms horizontally.
Stop! Danger!
Alternately extend and fold in both
arms horizontally.
BS80/ 01.2006
1 - 23
Drive off
Move upwards extended arm
back and forth with hand open.
Drive slowly forwards

Both arms bent and beckon
forwards with palms of hands
turned inwards.
Reverse slowly
Bend both arms and wave away
with palms of hands turned
outward.
Turn right
Left thumb outwards.
1 - 24
BS80/01.2006
Turn left
Right thumb outwards.
Turn upper structure to the

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

Right thumb outwards to the right,
rotate left index finger.
Hoist equipment (load)

Right extended index finger
points upwards, left hand moves
up and down.
BS80/ 01.2006
1 - 25
Lower equipment (load)

Right extended index finger
points downwards, left hand
moves up and down.
Increase reach
Both thumbs point outwards.
Decrease reach
Both thumbs point inwards.
Open grab
Hold arm horizontal with half open
hand to the side.
1 - 26
BS80/01.2006
Close grab
Hold arm horizontal with closed
hand to the side.
BS80/ 01.2006
1 - 27
1 - 28
BS80/01.2006
General View - Overall Machine
General View
2.1 Overall Machine
1.1
1 Upper structure
1.2
1.1 Engine
1.2 Hydraulic system
2 Operators station / cab
BS80/ 10.2007
2-1
General View - Engine
2.2
Engine
3 4
1 Air conditioner indicator lamp

2 Gear pumps
3 Distributor gear
4 Leakage oil block
5 Power receptacle, 24 volt, 20 amp
2-2
BS80/ 10.2007
General View - Engine
2b
2a
3 4
1 Main fuse
2 Engine
2a Water separator
2b Fuel filter
3 Charge air cooling system
4 Batteries
5 Battery disconnect switch
6
6 Coolant cooler
BS80/ 10.2007
2-3
General View - Hydraulic System
2.3
Hydraulic System
3
2
1a
1b
1 Hydraulic tank
2 Refueling pump
1a Oil level display
3 Oil cooling
1b Fuel fill strainer
4 Thermostat - Hydraulikoil preliminary

heating
5 Shutt-of flap
6 Power receptacle, 24 volt, 20 amp
7 Main control valve bank
2-4
BS80/ 10.2007
General View - Hydraulic System
1 Swing gear
2 Leakage oil block
3 Brake
BS80/ 10.2007
2-5
General View - Air Filter
2.4
Air Filter
2,3
1
1 Air filter
2 Primary filter element
3 Secondary filter element
2-6
BS80/ 10.2007
General View - Operators Station
2.5
Operators Station
BS80/ 10.2007
2 3 4
1 Pedals
4 Emergency switch
2 Safety lever
5 Fuses
3 Water reservoir, window washer
6 Control lever
2-7
General View - Operators Station
Pedals:
1 Left travel pedal, with hand lever
2 Right travel pedal, with hand lever
2-8
BS80/ 10.2007
Technical Data - Base Machine
Technical Data
For the specifications of the base machine refer to Section 3.1. Section
3.2 provides wind speed information.
Note
For the shipping dimensions and weights of the base machine refer to
Section 8.2. Special attachment system data can be found in the
instruction of the assembly concerned.
3.1 Base Machine

Engine
Caterpillar C-15 Diesel Engine

Power output
(acc. to ISO9349)
354 kW (475 HP)

at Nominal speed 1800 rpm
Cylinders
Capacity
14,6 l (14634 cm3)
Permissible inclinations of engine:

left
right
front
rear
30
30
30
30
Note
At any greater inclinations, an adequate engine oil level is no longer
ensured. In case higher degrees of inclination are required, consult with
BAUER/SENNEBOGEN beforehand.
For further information on the engine, consult the engine
manufacturers instruction.
Electrical system
24 volt
Note
Ensure that the available output power of the alternator is not exceeded
when installing additional current consumers (e.g. lights).
Hydraulic system
Swing drive
BS80/ 06.2006
Max. operating pressure 300 bar
Swing speed
0 to 3 rpm, infinitely variable
3-1
Technical Data - Base Machine
Ambient temperature
On the job / Production application
ca. - 20C ... ca. + 40C
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.
3-2
BS80/ 06.2006
Technical Data - Appendix
3.2
Appendix
Wind Speed
Wind Force
Description
Beaufort
number
Name
m/s
km/h
Onshore
Calm
0-0.2
Calm; smoke rises vertically
Light air
0.3-1.5
1-5
Direction of wind shown by drifting of smoke but

not by wind vanes
Light breeze
1.6-3.3
6-11
Wind felt on the face; leaves rustle; ordinary

vane moved by wind
Gentle
breeze
3.4-5.4
12-19
Leaves and small twigs in constant motion;wind

extends light flag
Moderate
breeze
5.5-7.9
20-28
Raises dust and loose paper; twigs and small

branches are moved
Fresh breeze
8.0-10.7
29-38
Small trees in leaf begin to sway; crested

wavelets form on inland waters
Strong
breeze
10.8-13.8
39-49
Large branches in motion; telegraph wires

whistle; umbrellas used with difficulty
Moderate
gale
13.9-17.1
50-61
Whole trees in motion
Fresh gale
17.2-20.7
62-74
Breaks twigs off trees; generally impedes

progress outdoors
Strong gale
20.8-24.4
75-88
Slight structural damage occurs (chimney pots

and slates removed).
10
Whole gale
24.5-28.4
89-102
Trees uprooted; considerable structural

damage occurs.
11
Storm
28.5-32.6
103-117
Widespread storm damage (very rarely

experienced onshore).
12
Hurricane
32.7-36.9
118-133
Devastation occurs
BS80/ 06.2006
3-3
Technical Data - Appendix
3-4
BS80/ 06.2006
Preparing to Operate - Safety Information
Preparing to Operate
4.1 Safety Information

WARNING
z Make sure that all guards and protective devices of the machine are
in place and are properly secured.
z Wear personal protective equipment (hard hat, safety glasses)
where this is required by job conditions.
z Avoid wearing jewelry or loose clothing.

z Secure any loose items, e.g., tools or other accessories.
z Agree on hand signals with the signal person.
z Obtain information about first aid and about assistance and rescue
services.
z Get onto or off the machine only while it is parked. Use the means
of access and ladders provided for the purpose:
Before using the means of access and the ladders, clean them as
necessary.
While mounting or dismounting, your hands must be free of any
objects. Use a hand line or a hoist to lift any items of equipment
onto the machine.
Do not use controls in the operators cab as handholds.
z Check the safety features (brakes, signaling and lighting equipment)
of the machine.
z While traveling at slow speed, check the controls and protective
devices for proper operation.
BS80/ 06.2006
4-1
Preparing to Operate - Initial Commissioning
4.2
Initial Commissioning
Initial commissioning of the machine is performed by BAUER/

SENNEBOGEN or by a trained and duly authorized skilled person.
Where the machine has been idle for any length of time (> 6 months),
you should contact the BAUER/SENNEBOGEN service department
before putting it back in service.
WARNING
Be sure to observe Chapter 1 SAFETY.
4.3 Pre-Start Checks

Safety information
Note the safety information before you start work.

DANGER
z Familiarize yourself with the machine and with its equipment. To that
end, study this instruction, and Chapter 1 SAFETY in particular,
before putting the machine into operation.
z Perform only operations for which you have been trained and which
are within the scope of your duties.
Checklist
4-2
Are all guards, protective covers and safety signs and labels in
place on the machine and undamaged?
Has the machine been cleaned to the point where dirt fails to
constitute a potential hazard (risk of slippage or falling off; poor
visibility)?
Have the windows been cleaned and been cleared of ice and
snow?
Is stability of the machine ensured?
Is the undercarriage undamaged?
Has the correct counterweight (ballast) been fitted?
Are the boom components undamaged?
Has any maintenance required been performed as specified in

the maintenance schedule?
Are the oil reservoirs filled to the proper levels (hydraulic

system, engine)?
10
Is the fuel tank of the machine filled to the proper level?
BS80/ 06.2006
Preparing to Operate - Pre-Start Checks
11
Are the V-belts undamaged and of proper tension?
12
Are all bolted/screwed connections undamaged and properly

tightened?
13
Are the operating and ambient conditions known?
14
Is the weight of the load known?
15
Is an experienced signal person available if and when

required?
16
Are the loads to be attached within the ratings of the machine

and of the sling devices? Be sure to observe Chapter 3
TECHNICAL DATA!
17
Have any danger points at the job site been identified and
marked off (overhead lines, excavations, etc.)?
18
Is the danger area clear of personnel?
19
Are all safety devices working properly (brakes, signaling and

lighting equipment)?
20
Has the machine been properly leveled?
21
If necessary, switch the optional battery isolation switch on or

connect the battery pole.
DANGER
Report all irregularities to the person responsible before you place the
machine in service. Do not put the machine into operation until after all
deficiencies have been corrected.
BS80/ 06.2006
4-3
Preparing to Operate - Starting the Machine
4.4
Safety information
Starting the Machine
Note the safety information before you start the machine.

DANGER
z Keep service access doors closed.
z Before starting the engine, make sure that there are no persons in
the danger area.
z The exhaust gases of diesel engines are harmful to health. Operate
the engine only in the open or in well ventilated areas.
z Do not start the machine if there is a warning tag attached to the
controls.
z Adjust the operators seat and the mirror(s) to the proper positions.
z Fasten the seat belt correctly and securely.
4.4.1 Seat Belt

The machine has been provided with a lap belt. The belt conforms to
the standards EN ISO 6683 and SAE J 386 (for the United States).
WARNING
z Before placing the machine in service, check the belt for signs of
wear. If the belt is damaged, immediately replace the belt.
z If the belt is dirty, use water to clean the belt.
z The belt must not be twisted.
z The belt must fit low across the operators hips, not over his
stomach.
1
2
3
4-4
Slide the metal catch (1) into the belt buckle (2).
An audible clicking noise indicates that the belt is locked.
To release the belt, push in the red button (3) on the belt buckle
(2).
BS80/ 06.2006
4.4.2 Starting the Engine

1
2
1
Perform the checks as specified in Section 4.3.
Insert the key into the starter lock (2) and turn it to position 1.
The Slewing gear brake indicator light comes on.
Turn the ignition key clockwise in order to start the engine.
Use the rotary knob (1) to adjust engine rpm to the desired
speed.
Push the safety lever forward if you want to enable the

hydraulic functions.
Where applicable, release the slewing gear brake if you want

to rotate the upper structure.
The Slewing gear brake indicator light goes off.
Never let the machine unattended, while the engine is running!
BS80/ 06.2006
4-5
4.4.3 Jump start

The machine is equipped with a 24-volt starting system. Ensure that the
external power source has the same voltage.
CAUTION
If a power source with a higher voltage is used, this can cause serious
damage to the machine's electrical system.
1
Actuate battery isolator switch to interrupt the power supply.
Detach battery cover.
Connect the positive terminal (+) of the power source to

appropriate
jump leads.
Using a jump lead, connect the negative terminal (-) of the

donor battery to the engine block or to a solid, unpainted metal
part of the receiving vehicle that is connected to the engine
block.
Actuate the battery isolator switch to regenerate the power

supply.
Start engine acc. to Section4.9.3
Switch on the electrical consumer (protection against

overvoltage). .
Dismantling::
Detach jump lead from negative terminal (-).
Detach jump lead from negative terminal (-).
Switch off the electrical consumer.
10
Replace battery cover.
WARNING
z Explosion hazard!
Avoid excessive heating by fire, open light or smoking.
z Battery acid is corrosive.
Avoid any contact with the skin, eyes or clothing. Rinse acid
splashes and spills with clean water immediately. A visit to the
doctor can be necessary.
z When working on electrical system, adhere to current regulations
and the accident prevention regulations.
4-6
BS80/ 06.2006
4.4.4 Bring Machine up to Operating Temperature

Guidelines for
warm up period
Warm-up
procedures
Ambient temperature range
Warm-up
period
max. engine speed
up to 0 C
approx. 15 min.
0 C ... -20 C
approx. 30 min.
Nominal speed - 250 min -1

(Nominal speed see Chapter3.1)
z Allow the engine to run at idle speed for 3 minutes after starting.
Additional warm-up time can be required at temperatures under

0C.
z Then incrase the rpm in steps up to
the nominal speed of 250 rpm (no-load)
z If approx. 20C water temperature has been achieved, put a loadon
the engine by carefully actuating hydraulic functions and continue to

warm-up the machine.
z The machine can be loaded if the temperatures indicated below
have been achieved.
Note
If the hydraulics are still slow to respond after the warm-up period, operate for a further 15 minutes at reduced speed.
The following temperatures should be displayed before operating the
machine at full speed:
z Hydraulic oil: approx. 30C
z Water: approx. 35 C.
ATTENTION
Not warming up the engine and the machine can result in damage to
the engine, hydraulic pump, hydraulic motor, hydraulic oil cooler and
hydraulic tank.
BS80/ 06.2006
4-7
Preparing to Operate - Turning off the machine
4.5
Turning off the machine
4.5.1 Switching off engine

Note
Switching off the driving engine without allowing a cooling down phase
may cause heat storage and overheating of engine parts and especially
the turbocharger. Allow the driving engine to cool down before
switching off.
z Lower engine speed to approx. 50 % of the rated speed (see
Chapter 3).
z Allow machine to run for another approx. 5-10 minutes.
Non-observance may cause increased wear to the engine and cooling

system.
4-8
Place the machine on a firm surface.
Lower suspended loads and lower jib if necessary.
Lower engine speed to approx. 50 % of the rated speed to

prevent the engine and cooling system from being damaged.
Allow engine to run for a further approx. 5-10 minutes.
Turn ignition key to position "0" and remove.
If necessary pull back safety lever.
Secure the machine area (lights, warning triangle, etc.).
BS80/ 06.2006
Preparing to Operate - Decommissioning
4.6
Decommissioning
Proceed as follows if the machine is to be decommissioned for a

prolonged period.
1
Switch off machine according to Section 4.5.1.
Clean machine according to maintenance instructions.
Replenish operating fluids and lubricants, for levels see

maintenance instructions.
Lubricate machine according to maintenance instructions.
If necessary, switch the optional battery isolation switch off or

disconnect the battery pole, see Section 8.3..
Protect bright metal parts (e.g. piston rods of hydraulic

cylinders), see maintenance instructions.
Choose as dry and dust-free storage location as possible.
Note
Admissible ambient temperatures see Section 3.1
BS80/ 06.2006
4-9
Preparing to Operate - Decommissioning
4 - 10
BS80/ 06.2006
Operation - Safety Information
Operation

DANGER

z Make sure that there are no persons in the DANGER area.

wind speeds, etc.

z For any long-distance travel, put the boom in the direction of travel.
z Before leaving the operators cab:
Stop the engine.
z Lock the operators cab; use warning lamps to mark the machine,
where applicable.
BS80/ 10.2007
5-1
Operation - Operators Cab
5.2
Operators Cab
5
4
1 Release - Door locking device

2 Cab door
3 Door lock
4 Emergency exit - Side window
5 Emergency exit - Front window
The comfortable operators cab offers you a convenient and safe work
environment. You may adjust some of the features to suit your
individual requirements.
Emergency exit
6 Hammer, emergency exit

In case of emergency, you can exit through the front window (5) or
through the side window of the cab door (4). To that end, use the
hammer to smash the window.
5-2
BS80/ 10.2007
Operation - Operators Cab
Cab door
While in the fully open position, the cab door can be locked in place at
the side wall of the cab. Pressing the release device (1) inside the cab
allows the door to be unlocked again.
Front window
To open the front window: Tilt it inwards or push it upwards. Make sure
that the window wiper is supported on the bracket. Press the two
vertical handles inwards and move the window accordingly. Take care
to ensure that the window latches home in the desired position. Press
the two vertical handles outwards again.
Interior lighting
A courtesy light is fitted in the operators cab.

You can turn the light on and turn it off again by rotating the lamp glass.
Window washer
For control of the window wipers, use is made of the switches on the
right-hand control panel. The reservoir for the window washer fluid is
located at the floor of the operators cab. Have the reservoir filled with
antifreeze at all times.
Operators seat
Information on handling of the operators seat is provided in a separate

instruction.
BS80/ 10.2007
5-3
Operation - Machine Controls
5.3
Machine Controls
5.3.1 General View
5-4
2 3 4
1 Pedals
4 Emergency switch
2 Safety lever
5 Fuses
3 Water reservoir, window washer
6 Control lever
BS80/ 10.2007
5.3.2 Emergency Stop

The Emergency Stop switch (1) puts the machine out of operation immediately.
Positionings:
pulled = machine on
pressed = machine off
BS80/ 10.2007
5-5
5.3.3 Safety Lever

The safety lever (1) acts as a protective feature.
1
shown here = safety lever released (pushed to the front)
With the safety lever released (see illustration)
z all hydraulic functions are available for use
z all work movements can be performed
z the slewing gear brake must be released separately
Note
The slewing gear brake remains engaged after the safety lever has
been released (by pushing it forwards). Use the left-hand control lever
to release the slewing gear brake (see Section 5.6.2).
shown here = safety lever activated (pulled back to the rear)

When the safety lever is activated
z all hydraulic functions are out of operation
z the slewing gear brake is engaged.
5-6
BS80/ 10.2007
5.3.4 Right-Hand Control Lever

2
Push buttons:
1 Option
2 Option
3 Option
4 Option
Note
For control lever assignment refer to the BAUER documentation.
5.3.5 Left-Hand Control Lever

2
Push buttons:
1 Option
2 Option
3 Option
4 Option
Note
For control lever assignment refer to the BAUER documentation.
BS80/ 10.2007
5-7
5.3.6 Pedals
Pedals:
1 Left travel pedal, with hand lever
2 Right travel pedal, with hand lever
5-8
BS80/ 10.2007
5.3.7 Sennebogen Diagnostic System (SDS)
2
n
min
3
1 Display
2 Bank of keys with LEDs
3 Indicator and warning lights
The SDS offers a means of retrieving additional information, e.g.,
current hydraulic oil temperature.
Note
Do not clean the Sennebogen Diagnostic system with fluids containing
alcohol or solvents! These may cause the plastic surface to become
brittle.
Note
All temperature readings are in degrees Celsius (C).
Sensors on the machine serve to continuously monitor the operating
condition, and the measurement results are transmitted to the SDS.
The measurement results are analyzed in the SDS, and pressing a key
causes them to be shown on the display. In the event of irregularities
occurring on the machine, the indicator and warning lights are
activated.
Self-test:
Once ignition is turned on, the SDS system performs a self-test. All
segments of the display are activated; all LEDs come on. The sensors
are checked. After that the SDS system is ready for operation.
Any fault detected by the SDS will be indicated on the display and by
the LED. Have any faults corrected by the BAUER/SENNEBOGEN
customer service.
BS80/ 10.2007
5-9
Display (1)
The two-line display serves to show additional information, e.g., the

time of day. Press a function key in the bank of keys (2) to retrieve the
corresponding information and have it shown on the display.
Bank of keys with LEDs

(2)
The bank of keys is fitted with 8 function keys. You can use these keys
to retrieve information and have it shown on the display. Each key has
a red light-emitting diode (LED) assigned to it.
The LED comes on when the associated key is pressed.
When an intolerable level has been reached, e.g., excessive engine
temperature, the LED flashes. The intolerable value flashes on the
display, and a buzzer sounds. Acknowledge the fault alarm by pressing
the respective key. Eliminate the cause.
1
n
min
1 Battery charge
5 Time of day
2 Fuel level
6 Service hour meter
3 Coolant temperature
7 Speed indication - Engine
4 Oil pressure - Engine
8 Hydraulic oil temperature
Note
Temperatures below 20C (hydraulic oil) or below 30C (coolant)
respectively will not be shown.
5 - 10
BS80/ 10.2007
Adjusting time of day:

1
Press keys (6) and (7) at the bank of keys simultaneously for 5
seconds. The time of day as set will flash on the display, e.g.,
16:52.
To adjust the time of day, press the keys as follows:

(8) = Hour indication - Tens place (16:52)
(7) = Hour indication - Units place (16:52)
(6) = Minute indication - Tens place (16:52)
(5) = Minute indication - Units place (16:52).
To accept the time setting, press keys (6) and (7)

simultaneously until the display stops flashing.
Resetting daily service hour meter:

1
Press key (6). The service hour meter function is showing on

the display.
Press key (6) for about 3s. This serves to reset service hours
to zero.
Note
The service hour meter on the right-hand control panel shows the
overall service hours of the machine. This meter cannot be reset.
BS80/ 10.2007
5 - 11
Fault Signaling
LED flashes,
continuous
alarm sounds
Cause
Remedy
Fuel level in tank too

low
Refuel machine as specified in Section

5.6.3.
LED flashes,
buzzer sounds
Cause
Remedy
Engine overheated
Idle engine.
Cooling fins on engine

oil cooler dirty
Clean cooling fins on oil cooler.
Fan drive loose or

defective
Tighten fan drive, replace if necessary.
Coolant level too low
Add coolant as specified in Section

6.3.5.
Engine switched off

without cooling phase.
After operating, allow engine to run in

low neutral for approx. 5-10 minutes
before switching off.
Note
Overall performance of the machine is reduced to 65%.
When the coolant temperature continues to rise,
z the temperature reading on the display flashes in addition;
z a continuous alarm sounds;
z the engine is shut down.
Pressing the function key allows the engine to be started again.

CAUTION
There is a risk of engine and hydraulic units being destroyed.
Use the acknowledgement procedure only for the purpose of moving
the machine out of the danger area. Eliminate the cause of the fault
immediately.
5 - 12
BS80/ 10.2007
LED flashes,
buzzer sounds
Cause
Remedy
Engine oil pressure too

low (<1.3 bar)
Stop engine immediately.

Check engine oil level as specified in
Section 6.3.1.
Add engine oil as necessary.
If fault continues to occur, inform the
BAUER/SENNEBOGEN service
department accordingly.
Note
When the oil pressure falls below 1.0 bar,
z the pressure reading on the display flashes in addition;

CAUTION
immediately.
LED flashes,
buzzer sounds
Cause
Remedy
Hydraulic oil
temperature excessive
(>84C)
Operate engine at no load until the

hydraulic oil has cooled down.
Cooling fins on
hydraulic oil cooler dirty
Hydraulic oil level too

low
Check oil level as specified in Section

6.4.3.
Add hydraulic oil as necessary.
Note
When the hydraulic oil temperature rises to more than +94 C, the
temperature reading on the display flashes in addition.
BS80/ 10.2007
5 - 13
IIndicator and warning

lights (3)
Indicator lights provide information on current operating states, e.g.,

Slewing gear brake engaged.
Warning lights come on whenever immediate action has to be taken on
the machine, e.g., Clean air filter.
1
10
Indicator lights:
1 Slewing gear brake
6 Unassigned
8 Shut-off flap - Hydraulic tank
Warning lights:
2 Air filter service indicator
3 Hdyr. Main filter contamination
4 Hydr. Secondary filter contamination A / B
5 Hydr. Secondary filter contamination C
7 Hydraulic oil level
9 Coolant level
10 Coolant temperature
Note
In order to properly identify the contaminated filter, the
plug-connector must be removed from the differential pressure switch
If the display goes out, the respective contaminated filter has been
I
identified.
5 - 14
BS80/ 10.2007
Fault Signaling
comes on,
warning signal
sounds
Cause
Remedy
Air filter foul/blocked
Clean filter as specified in Section

6.3.4.
Where necessary, replace filter
element.
comes on
during engine
operation (3)
Cause
Remedy
Hydraulic oil return flow

filter foul/blocked or
defective
Replace return flow filter as specified

in Section 6.4.5.
comes on
during engine
operation (4)
Cause
Remedy
Group fault signal Hydraulic filter foul/

blocked or defective (e.g.
Pilot control filter, Hydro Clean Superfine-Filter)
Replace hydraulic filter (e.g. pilot

control filter as specified in Section
6.4.6.).
comes on,
warning signal
sounds, engine
is stopped
Cause
Remedy
Hydraulic oil level too low
Add hydraulic oil as specified in

Section 6.4.
WARNING
Engine starting is prevented until after the cause of the fault has been
eliminated. In case of emergency, you can override this shutdown function however (refer to OVERRIDING SHUTDOWN FUNCTION on page 5-16).
comes on
during engine
operation,
warning signal
BS80/ 10.2007
Cause
Remedy
Shut-off flap on hydraulic

tank closed
Open shut-off flap.
5 - 15
comes on,
warning signal
sounds, engine
is stopped
Cause
Remedy
Add coolant.
WARNING
eliminated. In case of emergency, you can override this shutdown function however (refer to OVERRIDING SHUTDOWN FUNCTION on page 5-16).
comes on
during engine
operation,
warning signal
sounds
Overriding shutdown
function
Cause
Remedy
Coolant temperature
excessive

coolant has cooled down.
Where necessary, check and clean
the radiator as specified in Section
6.3.5.
This lets you start the engine, even though a fault has been signaled,
and move the machine out of the danger area.
2
28
28
z Remove the cover.

z Remove the two fuses in positions 2 and 28 in the fuse distribution
box.
z Move the machine out of the danger area.

z Re-install the fuses 2 and 28.
z Eliminate the cause of the fault immediately.
WARNING
The functions of the SDS system are disabled. No further warning will
be given in the event of faults occurring!
5 - 16
BS80/ 10.2007
5.3.8 Right-Hand Control Panel

1
2
3
5
6
11
8
9
10
13
1 Intermittent operation Front window wiper
7 Blower fan
2 Engine speed control
9 Service hour meter
3 Automatic idling
4 Air conditioner
5 Limit load control
Emergency operation
6 Indicator lights - engine
6a Diagnostic light (yellow)
6b Warning light (red)
BS80/ 10.2007
12
8 24 volt power receptacle

10 Starter lock/Start engine
11 Skylight wiper
12 Front window wiper
13 Working light
5 - 17
Automatic idling
Limit load control

Emergency operation
The automatic idling feature reduces engine speed automatically when

no work movement has been performed for a few seconds. When a
control lever is operated, adjustment to the speed level preset at the
engine speed control is effected immediately.
1
After starting the motor's switch, switch on Automatic idling
Preselect the required RPM for the work application and/or for
travel using the RPM adjustment.
Trigger the corresponding work function using the respective

control lever or the drive pedal. The engine switches over immediately from the idling RPM to the preselected RPM.
Once the working and/or travel function has been completed

(control lever or drive pedal in zero position), the engine will be
redirected automatically to the idling RPM after a brief delay.
The load limit sensing control monitors the setting of the hydraulic
pumps in terms of the power output of the diesel motor, in accordance
with changing operating conditions.
The location of the control unit of the limit load control system is on the
wall behind the operators seat.
Function of the LED (1):

LED lights up - working operation
LED flashes - in the event of a failure
Note
The LED (1) is a reliable indicator only when the engine is running.
If further use of the limit load control system is precluded by a defect in
the electronic system, operation can be continued without any
downtime by changing over from Automatic to Manual.
5 - 18
BS80/ 10.2007
Calibrating the power

metering regulator
Calibrate the power metering regulator if the hand throttle, foot throttle
or power metering regulator have been replaced.
Note
The calibration can be made through the switch input up to 5 minutes
after switching the ignition on.
If the calibration is unsuccessful, the power metering regulator
must be switched off and then back on again (ignition off/on).
Calibration process
BS80/ 10.2007
Set both set-point potentiometers (hand throttle, foot throttle)

to minimum.
Make the bridge between the red and blue connectors (1)
on the right-hand console and remove again after one second.
The initialisation run begins (initialisation run means that the

engine accelerates automatically, until 1350 - 1450 rpm are
attained)..
Set both set-point potentiometers (hand throttle, foot throttle)

to maximum.
Make the bridge between the red and blue connectors and
remove again after one second.
The engine starts the initialisation run, slowly progressing

from full speed to idling speed.
Once the engine has reached the lower idling speed,

the initialisation run is complete.
If the LED on the power metering module box flashes,

an error has occurred. Repeat the process.
5 - 19
Indicator lamps engine
Further information is available in the instruction supplied by the engine

manufacturer.
WARNING
Eliminate the cause immediately.
5 - 20
BS80/ 10.2007
Operation - Heating System
5.4
Heating System
1 Outside air/ recirculation air

selector knob
2 Temperature variable control
3 Air vents
4 Blower fan switch, three-stage
(right-hand control panel)
The heating system can be run on outside air, on recirculation air or in

mixed air mode.
Outside air mode
Recirculation air mode
Mixed air mode

(neutral position)
BS80/ 10.2007
To defog the cab when moisture has formed on the windows.

Faster heating-up of the cab and also higher end temperature.
The air is made to circulate inside the cab, i.e., there is no supply of
fresh air from the outside. Do not leave this mode of operation on for
more than 15 minutes, otherwise air quality in the cab will deteriorate
markedly. Take care to ensure adequate supply of outside air.
Normal mode of operation.
5 - 21
Operation - Optional Equipment
5.5
Optional Equipment
5.5.1 Air Conditioner

WARNING
z Have any maintenance and repair work performed by adequately
trained skilled personnel only.
z Do not reach into the conditioner and do not insert any objects.
z Perform maintenance operations only with the engine shut down
and with the blower fan disconnected.
z Burning hazard!
Allow the conditioner and the components fitted inside (heat

exchanger, resistors) to cool completely first.
z Avoid contact with refrigerant.

z Wear safety glasses.
z Allways use PAG oil for compressor. No ester-based oils!
z No fluorescing additives (tracer agent, sticks)!
Note
Close windows and doors, to ensure an efficient air conditioning.
The air conditioner controls the temperature as a function of the outside
temperature.
Activating air
conditioner
5 - 22
Operate engine until it has reached operating temperature.
Switch on the blower fan at the right-hand control panel.
BS80/ 10.2007
Close the air vents (foot vents) under the operators seat.
Open air inlet vent at the front window and behind the
operators seat.
Press switch for air conditioner on the right-hand control panel,

the green control light (1) goes on.
Use temperature variable control (2) on the heater to adjustthe

desired temperature.
Note
Operate the air conditioner at regular intervals.
This will help to keep the air conditioner in a serviceable condition.
Put the air conditioner into operation for at least 30 minutes at
maximum fan rate every month, open windows and doors.
BS80/ 10.2007
5 - 23
5.5.2 Auxillary heating / Water heater

The machine is mounted with an engine independent water heater for
warming up the motor and the cab.
Note
The capacitiy of the batteries can be take off when the water heater is
used.
5
4
Note
Adjust temperature variable control (5) at maximum setting for activte
the water heater.
Note
For warming up the cab turn on the blower fan (4) on fan stage1
(minimum setting).
Note
Information on handling of the water heater is provided in a separate
instruction. The instruction can be found in Section 10.3.
5 - 24
BS80/ 10.2007
5.5.3 Hydraulicoil- , cooling water- and diesel preliminary

heating, batterie preliminary heating
The Hydraulic oil heating system (1) is mounted on the hydraulic tank.
Therefor the time of warming up of the hydraulic oil is shorter (Section
4.4.5).
You can choose the temperature with the regulator (2) on the thermostat (normal: 20C).
When the oil has the right temperature the thermostat switches off.
2
1
Through connect the plug socket (3) underneath the operators cab of
the machinery with the circuit (230 V) the
z hydraulic oil preliminary heating
z cooling water preliminary heating
z diesel preliminary heating
are activated.
BS80/ 10.2007
5 - 25
Through connect the plug socket (3) at the operators cab of the machinery with the circuit (230 V) the
z cooling water preliminary heating
is activated.
Only the plug (3 and 4) but not the feeder cable is availabled by Sennebogen.
DANGER
The feeder cable and the plugs must be connected by a qualified person.
WARNING
z Service and maintenance shall only be done by qualified persons.
z Protection for voltage feeding must be supplied/mounted by the
customer!
5 - 26
BS80/ 10.2007
Operation - Operating Technique
5.6
Operating Technique
5.6.1 Safety Information

DANGER


wind speeds, etc.

z For any long-distance travel, put the boom in the direction of travel.
z Before leaving the cabin:
Stop the engine.
z Lock the cabin; use warning lamps to mark the machine, where
applicable.
BS80/ 10.2007
5 - 27
5.6.2 Swinging the Upper Structure

To swing the upper structure, use is made of the left-hand control lever.
2
Swing speed
Push buttons:
Directions of movement:
2 Release slewing gear brake
c Swing upper structure to left
3 Engage slewing gear brake
d Swing upper structure to right
Swing speed is dependent on:

z Speed of the engine
z Deflection of the left-hand control lever
DANGER
The area of swing of the upper structure (danger area) must be clear of
personnel, building structures or machines.
Stopping swing motion
(deceleration)
Move the control lever to the neutral (zero) position.

The upper structure is decelerated hydraulically. Swing motion eases
off to a stop.
Note
Moving the control lever in the opposite direction will intensify
deceleration.
5 - 28
BS80/ 10.2007
Slewing gear brake
The slew gear brake is not an operational brake for braking the superstructure. The slew gear brake is designed as a parking and holding
break for when the superstructure is at rest.
Note
The slewing gear holding brake cannot be applied until 3 seconds after
the slewing action has completely finished.
Check on the Sennebogen SDS diagostic system whether the holding
brake is active. The slewing gear holding brake indicator light must be
on.
WARNING
Using the slew gear brake to brake the superstructure will result in
considerable damage to the brake and/or to the slewing gear.
The following damage may occur:
z Diminished braking effect due to damage to discs
z Irreparable damage to slewing gear
z Irreparable damage to brakes or other components.
This damage is not covered by the warranty issued by Sennebogen

Maschinenfabrik GmbH.
The operator of the machine is solely liable for damage of this kind and
for any consequential damage, for example, due to diminished braking
effect.
WARNING
Never rotate the superstructure when the slew gear brake is applied.
Note
The slew gear brake is applied automatically as soon as the
z safety lever is actuated (pulled backward) or
z the motor is switched off (emergency shut-down, key switch).
If circumstances are unfavorable it can take approx. 30 seconds before

the full breaking effect is achieved.
BS80/ 10.2007
5 - 29
5.6.3 Refueling the Machine

There are two possible ways of refueling the machine:
z Manually
z Using a refueling pump
WARNING
z Fuel is detrimental to health and is flammable.
Smoking and handling of naked flames are strictly prohibited.
z For refilling the machine must be stopped.
z Position the machine on a firm, even surface
z Before filling, the fluid level must be determined in the tank - the
amount of fuel that the tank can taken on.
z Fuel must be precluded from getting into the soil or the waters.
While refueling keep a constant watch to avoid spillage of fuel.
z When fuelling from the tank vehicle, the maximum tanking speed
limit of 200 l/min (52 U.S.GPM) applies, as it could otherwise result

in an overflow of the fuel.
z The fuelling procedure must be monitored, regardless of the type of
fuelling.
Note
You should also observe the fuel system information provided in the
engine manufacturers instruction.
Manually
1
Land any attached loads to the ground.
Stop the engine.
5 - 30
Open the cover plate at the upper structure.
BS80/ 10.2007
Using a refueling pump
Open cap (1) of the filler neck.
Clean the strainer.
Install a funnel in the filler neck.
Fill in fuel carefully through the funnel.
Re-close cap (1) and the cover plate.
Land any attached loads to the ground.
Stop the engine.
Move keylock switch to position P.
Open the service access door.
Open the filler neck lid (1). This tets the air escape from the fuel
tank.
DANGER
If the cap (1) is not open, excess pressure can build up in the tank while
it is being filled. The tank can become deformed or can burst and
potentially cause damage to property or injure personnel. Spilled fuel
also causes environmental damage.
Fit the refueling hose (1) into the external fuel tank.
Note
Risk of cavitation!
Take care not to exceed the maximum suction head of 3 meters.
BS80/ 10.2007
5 - 31
3 4
Press the green key (2) to turn the refueling pump on.
The tank is filled automatically.
CAUTION
Take care to avoid the pump running dry (> 30 s).
Where necessary, use the red key (4) to turn off the refueling pump to
prevent damage.
8
Monitor the filling level at the sight gauge of the fuel tank.
Switch the pump off with the red button (4) as soon as the tank
is full..
Remove the refueling hose from the external fuel tank and
store it securely.
10
Re-close the filler neck lid (1).
11
Re-close the service access door.
Should the refueling pump fail to start after about 5 seconds, perform
the following checks:
5 - 32
Is battery charge adequate?
Are all fuses OK?
Is the suction side free of leaks?
Is the suction head less than the maximum lift of 3 meters?
BS80/ 10.2007
Maintenance -
Maintenance
WARNING
The maintenance operations set out below must only be performed by
qualified personnel that has received adequate training and instruction.
Section 6.1 SAFETY INFORMATION lists basic safety precautions relating
to machine maintenance.
Section 6.2 GENERAL INFORMATION provides specifications and
information on cleaning operations, on oils and greases, and on
welding.
Section 6.3 to Section 6.8 provide instructions for maintenance of the
individual assemblies.
Section 6.10 APPENDIX provides additional information such as
maintenance schedule, lubrication points schedule and bolt tightening
torques.
BS80/ 10.2007
6-1
Maintenance - Safety Information
6.1
Safety Information
DANGER
Danger to life!
z Apply the brake.
WARNING
z The maintenance operations set out below must only be performed
by qualified personnel that has received adequate training and
instruction.
z Wear personal protective equipment (e.g. hard hat, hearing
protective devices, protective gloves, safety shoes).
z Observe the applicable statutory accident prevention and safety
regulations.
z Land any attached loads to ground level.

z Pull the left safety lever backwards.
z Before attempting to perform any maintenance, shut down the
machine and secure it against unauthorized restarting.
z Attach a warning tag to the controls.

z Do not smoke and do not allow open flames.
z Operate the optional battery disconnect switch, if equipped, to
interrupt power supply.
z When working in the area of the batteries, cover the batteries with
isolating material; do not deposit any tools on the batteries.
z Use personnel hoists or work platforms that satisfy safety
requirements.
z Stay clear of all rotating and moving parts.

z Relieve the pressure before working on the hydraulic system
(section 6.4.2).
z Dispose of hydraulic oil according to the applicable regulations.

z Always wear protective gloves when handling wire ropes.
z Use only genuine BAUER/SENNEBOGEN spare parts.
6-2
BS80/ 10.2007
Maintenance - Safety Information
z Use only those oils and lubricants that are specified in the lubricants
chart.
z Do not lift heavy components by hand. Use hoists or lifting
equipment.
z On completion of the maintenance operations, reinstall all guards
and protective devices.
z Keep the operators cab clean and tidy.

z Perform a functional check to ensure proper operation.
2
1
z Only one person (max. 100 kg) may step onto the upper structures
step grid (1) at a time.
z On completion of any maintenance operations, only the machine
owner or his agent is permitted to clear the machine for service

again.
Gallery = Catwalk for

operators
DANGER
Risk of falling!
A maximum of 100 kg (220 lbs) is permitted per segment of grid iron on
the gallery (= operator catwalk). Overloading will lead to damaging the
construction, the results of which can lead to personal injury.
Check the gallery for cracks and general damaged every 3 months and
repair immediately if necessary.
DANGER
z Have any work on electrical equipment of the machine performed by
a qualified electrician only.
z Only qualified personnel having received relevant training is allowed
to perform work on undercarriages, braking and steering systems!
z Work on hydraulic equipment must only be performed by personnel
having specific knowledge and experience of hydraulics!
BS80/ 10.2007
6-3
Maintenance - General Information
6.2
General Information
6.2.1 Cleaning
Notes
z Take care to ensure that the cleaning solvents used will not damage
the seals, gaskets and other machine components.
z Do not use any aggressive cleaning solvents.
z It is especially important to clean the noise suppression mats with
neutral cleaning agents!
z Use only lint-free cleaning rags.

z Use only dry filtered compressed air of a maximum pressure of 2
bar.
z On completion of cleaning, perform a visual inspection and a
functional check of the machine as specified in Section 4.3.
WARNING
z Electrical and electronic components such as generators, switch
cabinets etc. must not come into direct contact with the water jet!
z Wet cleaning of these components is prohibited!

z When wet cleaning the machine, always make sure that the water
does not come into contact with electrical or electronic components.
z There is a risk of damage to the electrics of the machine from
penetrating water. This can result in uncontrolled working

movements being suddenly performed.
6-4
BS80/ 10.2007
6.2.2 Oils and Lubricants

Use only oils and lubricants that have been approved by BAUER/
SENNEBOGEN. For a list refer to Lubricants chart. For proper
operation of the machine, ambient temperature may range between
ca. - 20C and ca. + 40C. When job site temperatures are outside this
range, consult the BAUER/SENNEBOGEN service department before
placing the machine in service.
Oil analysis
Sampling and analyzing the oil at regular intervals will help to avoid
unnecessary costs. A number of tests are carried out to establish:
z Condition of the oil
z Amounts of the wear metals in the sample
z Rates of component wear
Recommended for the hydraulic system.

Further information is available from the BAUER/SENNEBOGEN
service department.
Biodegradable oils and

lubricants
Use of these materials is mandatory in those cases where leakage of

oils and lubricants on a mineral-oil basis would present a hazard to the
environment. The use of environmentally friendly lubricants is a
requirement in water and nature reserve areas in particular.
Use must only be made of synthetic ester based biological oil.
WARNING
Any conversion to bio-oils and biological lubricants is not permitted until
after the BAUER/SENNEBOGEN service department has been
consulted and written approval has been obtained.
WARNING
permitted!
damage can in turn result in severe damage toproperty and topersonal
injuries.
SENNEBOGEN only.
BS80/ 10.2007
6-5
6.2.3 Coolant for CATERPILLAR - Drive motors

The Caterpillar - Drive motors can be recognised by the
17 character PIN (Product Identification Number) and the ratings plate
among other things. E.g.: *CAT 0789BG 6SL12345*
Note
The Caterpillar - drive motors are filled with coolant
z Caterpillar CAT ELCTM (Extended Life Coolant)
in the factory. Use this coolant only for the Caterpillar drive motors!
SENNEBOGEN will accept no responsibility and will provide no warranty or make any guarantees for the use of any other coolants.
Note
Observe the coolant label in the cooler area.
ATTENTION!
Observe the notes in the operating instructions of the motor manufacturer as well as the special additional documentation on the Caterpillar
CAT ELCTM- Coolant. These are for the operational safety of the machine.
Note
SENNEBOGEN recommends using the pre-mixed coolant by Caterpillar CAT ELCTM, which is available in two different concentrations.
6-6
BS80/ 10.2007
6.2.4 Coolant - General

WARNING
Mixing coolants and adding cooling system sealing agents or antifreeze that contains sealing agents is not permitted.
By filling or mixing different types of cooling fluid or cooling agent additives, gelling, etc. can occur in the coolant leading to the cooler being
plugged (build-up) and because of the engine overheating or if the cooling system fails for example, this can damage the machine.
WARNING
Mixing of nitrite-based cooling agents with amine-based agents produces health-hazardous nitrosamine.
Use the coolant indicated and described in chapter 3.3.1 and 3.3.2 depending on the motor that is installed. The antifreeze is sufficient to 37 C (-34 F).
Note
Observe the coolant label in the cooler area.
If the ambient temperature at the work-site is under this value

(-37 C (-34 F)), observe the operating instructions of the motor manufacturer or contact SENNEBOGEN - customer service before starting
operation.
Note
If only a small amount (up to max. 5 l) is required to will the water-coolant circuit and no suitable coolant is available, you can top up with
clean water in the mean time.
We recommend that you test the concentration at the next possible
time before freezing temperatures however. In some cases, you must
refill with the respective coolant so that the required mixture is achieved
again to prevent freezing.
The coolant is not only required to guarantee the protection against
freezing, it also performs the very important task of protecting against
corrosion. This also requires checking for the correct concentration and
adding when necessary.
BS80/ 10.2007
6-7
Water
Note
z Use clean, neutral, filtered, fairly soft fresh tap water. Sennebogen
recommends distilled water as the best variant.
z Please note that Caterpillar specifies using distilled water!
z Do not use ditch water, industrial drain water, salt water, sea water
or rain water.
z Always fill using a water-coolant mixture. Observe mixing ratios. Mix
before filling!
Ensure that the water has the following characteristics:

pH value
7-8
Chloride content
max. 100 ppm
Sulphate content
max. 100 ppm
Water hardness
3-12 dGH
Note
Observe the recommended mixing ratio (see manufacturer's specifications). If the coolant concentration is too high, the cooling and antifreeze behaviour will deteriorate.
ATTENTION
Observe the specifications of the coolant manufacturer.
WARNING
Never fill with coolant when the motor is overheated. This will cause
damage to the motor. Allow the motor to cool first.
WARNING
Regarding possible danger to health or environmental dangers, observe the instructions for using the coolant manufacturer as well.
Using other coolants
If you should ever use a coolant other than that specified, the following
must be considered or expresslyobserved.
SENNEBOGEN will accept no responsibility and will provide no warranty or make any guarantees for the use of any coolants other than
those previously indicated.
6-8
BS80/ 10.2007
WARNING
Scalding hazard!
Be careful when draining hot coolant!
Allow the motor to cool first. Catch the coolant in a suitable container
when draining and dispose of according to the respective regulations.
Change coolant
The cooling system is to be emptied completely before filling

again.
Rinse the cooling system several times with clear water to rid it of
any residue.
Fill the cooling system and check the level after a short waiting
period.
Start the motor and check the coolant levels
ATTENTION
Adjusting to the correct coolant level must sometimes be checked more
than once.
Check the following states when inspecting the coolant levels regularly,
e.g.
lubricant incursion,
obvious opacity caused by corrosion residue or other particulate
matter,
in which case, the coolant must be replaced as indicated above.
Coolant change intervals
BS80/ 10.2007
Information on changing the coolant and the changing intervals is provided in the operating instructions of the motor manufacturer.
6-9
6.2.5 Welding
WARNING
z Welding work must only be carried out by an authorised and
qualified welding specialist.
z It is forbidden to carry out drilling or welding on
boom sections
load-bearing frame parts
the engine
the hydraulic tank
the fuel tank
parts feeding fuel and oil
z Cover vulnerable components with fireproof material.
Preliminary operations
6 - 10
Before you begin welding, perform the following preliminary operations:

1
Stop the engine.
Operate the optional battery disconnect switch to interrupt

power supply or disconnect the battery.
Connect the ground terminal of the welding apparatus directly

to the component to be welded.
BS80/ 10.2007
Maintenance - Engine
6.3
Safety information
Engine

CAUTION
z Perform maintenance operations or repairs only with the engine
stopped and cooled down.
z Secure the machine against unauthorized restarting before starting
any maintenance procedure.
z Spent oil must be precluded from getting into the soil or the waters.
Dispose of oil and oil filters according to the applicable statutory

regulations.
z Coolant must be precluded from getting into the soil or the waters.
Dispose of coolant according to the applicable statutory regulations.
z On completion of maintenance work on the engine, make sure that
all protective guards are installed correctly and that all tools have
been removed from the engine.
Note
You should also observe the information and recommendations
provided in the engine manufacturers instruction (Section 1).
BS80/ 10.2007
6 - 11
6.3.1 Engine Oil

WARNING
z Scalding hazard!
Exercise extreme caution when draining hot oil.
z Spent oil must be precluded from getting into the soil or the waters.
Dispose of oil and oil filters according to the applicable statutory

regulations.
WARNING
permitted!
damage can in turn result in severe da
mage to property and to personal
injuries.
SENNEBOGEN only.
Note
Note the information provided in the engine manufacturers instruction
(section 1).
Checking engine oil

level
WARNING
permitted!
6 - 12
BS80/ 10.2007
Park the machine on level ground.
Operate the engine for about 2 minutes until the system is filled
with oil.
Stop the engine.
Open the service access door - Engine.
Withdraw the oil dipstick (1) and wipe it with a clean lint-free
cloth.
Insert the oil dipstick as far as its stop and withdraw it again.
Check the oil level:

The oil level must be in the area between the lower mark (MIN)
and the upper mark (MAX).
Changing engine oil and

replacing oil filter
WARNING
permitted!
BS80/ 10.2007
Warm up the engine.
Open the service access doors - Engine.
Change the engine oil and replace the oil filter as specified in
the engine manufacturers instruction.
Check the oil level:

The oil level must be in the area between the lower mark (MIN)
and the upper mark (MAX).
6 - 13
6.3.2 Water separator

Safety instructions
Observe all safety instructions before beginning work.

WARNING
z Danger of injury due to rotating parts!
Perform maintenance operations only after the engine has been
shut down and the cooling system has cooled off.
z No open fire with working on the fuel system! Do not smoke!
z You should also observe the information provided in the engine
manufacturer's operation manual.
3
1 Shut-off valve
2 Quick clamp
3 Casing
4 Filter element
5 Fuel filter
6 - 14
BS80/ 10.2007
Draining water
Changing the filter

element
Close shut-off valve (1).
Open quick clamp (2).
Remove water and dirt from the casing (3).
Close quick clamp (2).
Open shut-off valve (1).
Remove filter element (4).
Insert new filter element.
Check cover seal, exchange if necessary.
6.3.3 Fuel filter

Changing the fuel filter
1 Shut-off valve
5 Fuel filter
BS80/ 10.2007
6 - 15
Unscrew fuel filter.
Clean sealing surfaces.
Lightly oil the gasket of the new fuel filter and/or wet with diesel
fuel.
Tighten fuel filter by hand.
6.3.4 Air Filter

Safety information

CAUTION
z Never use benzine, alkaline solutions or hot liquids for cleaning of
the air filter.
z On no account must the inside of the housing be cleaned by using
compressed air, otherwise dust and contaminants could get blown

into the engine.
Air filter
indicator light
The condition of the air filter is monitored by a sensor.

To determine the degree of fouling, resistance to air flow is measured.
When the maximum permissible resistance to air flow has been
reached, the Air filter indicator light on the Sennebogen diagnostic
system SDS comes on.
An audible warning signal sounds at the same time. Check and clean
the air filter immediately.
1
2
3,4
6 - 16
Loosen wing nut (1) and remove the cap (2).
Loosen the nut of the filter insert.
BS80/ 10.2007
Remove main filter and safety element (3, 4).
Blow out the filter elements with dry compressed air

(max. 2 bar) from the inside outwards. Do not damage the cartridge in the process.
Replace the main filter and safety element (3, 4), if necessary.
Insert filter elements (3, 4).
Attach nut to filter insert.
Put cap (2) on and use wing nut (1) to screw down the cap (2).
6.3.5 Radiator
Safety information

WARNING
z Risk of injury caused by rotating parts! Scalding hazard!
Perform maintenance operations only with the engine shut down
and after the cooling system has cooled.
z Coolant must be precluded from getting into the soil or the waters.
Dispose of coolant according to the applicable statutory regulations.
z Mixing nitrite-base cooling system conditioners with amine-base
conditioners will result in formation of nitrosamines which are

injurious to health.
Coolant level
indicator light
The filling level of the coolant is monitored by a sensor.

When the filling level falls below a specific mark, the engine shuts down
automatically. The Coolant level indicator light on the Sennebogen
diagnostic system SDS comes on.
WARNING
In case of emergency, this function can be overridden.
This will allow you to start the engine and to move the machine out of
the danger area.
Refer to OVERRIDING SHUTDOWN FUNCTION on page 5-16.
WARNING
permitted!
Checking and cleaning
BS80/ 10.2007
Allow the engine and the radiator to cool.
Open the filler cap of the radiator slowly and carefully to relieve
the pressure.
6 - 17
Check antifreeze content and coolant level; add as necessary.

The coolant must contain at least 60% (not more than 65%)
antifreeze (diethylene glycol) all the year round.
Use dry filtered compressed air (max. 2 bar) to blow-clean the

cooling fins from the exhaust air side. If grease and oil has
accumulated on the cooling fins, clean them by means of a
cold cleaner.
Check the radiator for leaks and for damaged cooling fins.
Note
For change of the coolant, refer to the information provided in the
engine manufacturers instruction (section 1).
You should also observe the information and recommendations
provided in the manual Cleaning the Cooling System (Additional
Documentation).
6 - 18
BS80/ 10.2007
6.3.6 Belt Drives

Safety information
Note the safety informations before you start work.

DANGER
z Perform any maintenance operations only with the engine shut
down at standstill..
z Secure the machine against unauthorized restarting before starting
any maintenance procedure.
z On completion of maintenace work on the engine, make sure that all
protective guards are installed correctly.
z Take care to ensure that the V-belts operate in parallel.

z Risk of injury caused!
Never reach into an current belt.
Note
For inspecting, adjusting and replacing the belt drives, erfer to the information provided in the engine manufactures operation (Section 1).
BS80/ 10.2007
6 - 19
Maintenance - Hydraulic System
6.4
Safety information
Hydraulic System
Note the safety information before you attempt to perform operations

on the hydraulic system.
DANGER
z High oil pressure warning!
The hydraulic system is under high pressure. When a hydraulic line
or fitting is disconnected, or in case of a leakage, escaping hydraulic
oil can cause serious personal injury.
Perform any work on the hydraulic system only after all pressure has
been relieved!
z Relieve the pressure before working on the hydraulic system
(Section 6.4.2).
z The pilot system incorporates an accumulator which continues to be
under high pressure even after the engine has been shut down. The
accumulator pressure must therefore be relieved.
z Do not open any hydraulic lines and fittings unless all pressure has
been relieved.
z Work on the hydraulic system must only be performed by trained
qualified personnel having specific knowledge and experience of

hydraulics.
z The hydraulic valves may be adjusted only by trained BAUER/
SENNEBOGEN service personnel.
z Wearing personnel equipment (e.g., hard hat, hearing protective
devices, protective gloves, safety shoes).
zDanger of injury!
If leaks are present hydraulic oil will leak out under high pressure.
Hydraulic oil will leak out under high pressure, penetrate the skin
and cause severe damage to health.
Danger of infection. In the case of injury contact a doctor immediately!
z Danger of injury from scalding
The hydraulic oil can reach temperatures of 70C and above. Only
carry out maintenance work once the hydraulic oil system has
cooled down.
z Danger of injury from rotating parts.
Only carry out maintenance work when the engine is switched off,
and then only if you are sure that the fan wheel has come to a stop
and there is no risk of automatic start-up.
Before starting up again, ensure that:
No items (e.g. tools) are in the vicinity of the fan wheels or could
fall into this area as a result of vibrations, for example
The protective features have been fitted.
6 - 20
BS80/ 10.2007
Cylinders
Pressure cylinders show minor leakages. Use a rag to remove any

excessive leakage oil. Dispose of the oily rag as hazardous waste.
The sliding surfaces of the piston rods are chrome plated. Any major
leakages are indicative of damaged sliding surfaces or defective seals.
To clean hydraulic cylinders:
z Use neither sharp-edged tools nor corrosive liquids or scouring
agents.
z Wash the piston rods at regular intervals, using a high-pressure
cleaner.
z On completion of cleaning, provide the extended piston rods with a
protective coating. This serves to protect the surface against

environmental and atmospheric influences.
Fittings
Check hydraulic fittings and couplings for leaks at regular intervals.

Seal any points of leakage and remove oil stains.
Leaked or spilled hydraulic oil is harmful to the environment and is a
source of danger as it involves a risk of slippage.
Be sure to immediately seal both sides of disconnected fittings by
means of plugs.
Shut-off flap
Close the shut-off flap:

z When performing work on the pump regulators;
z When replacing pumps;
z When performing repair or maintenance work.
This prevents outflow of major amounts of hydraulic oil.

An indicator light in the SDS system monitors the shut-off flap (Refer to
SENNEBOGEN DIAGNOSTIC SYSTEM (SDS) on page 5-9.).
CAUTION
Hydraulic oil must be precluded from getting into the soil or the waters.
BS80/ 10.2007
6 - 21
6.4.1 Hydraulic Hose Lines

Time limits for storage
and use
Even when stored and used properly, hoses and hose lines are subject to natural deterioration due to aging. For this reason, their use is
limited to a specific period of time.
The operator is responsible for ensuring that hose lines are changed
in adequate time intervals, even if there are no evident signs of damage to hose line that could pose a safety hazard.
Use of a hose line, including possible storage for up to two years, is not
to exceed a period of six years.
Routine checks
Hose lines must be checked by qualified personnel at least once a year

to ensure that they are safe and in working order.
Any problems with hoses must be eliminated immediately.
Defective hoses
Hose lines must be replaced in the following instances (see also

DIN 20066):
z Damage found on outer layer up to the lining (e. g. chafe marks,
cuts, cracking);
z Outer layer has become brittle (formation of cracks in the hose
material);
z Deformation affecting the original shape of the hose or hose line and
occurring in both a pressurized and non-pressurized state or when

hose is bent (e. g. layer separation, formation of blisters);
z Presence of leaks;
z Damaged or deformed hose fittings (sealing capability is impaired);
z Hose has slipped out of hose fittings;
z Corrosion of the hose fittings which affects the ability of the hose to
function and seal properly;
z Hose does not fulfil installation requirements;

z Permitted period of storage and/or use has been exceeded.
6 - 22
BS80/ 10.2007
6.4.2 Relieving Hydraulic System Pressure

To relieve the pressure in the hydraulic system, proceed as follows:
1
Lower the moving parts as far as possible and land the

attached loads to the ground.
Stop the engine, turn the ignition key back to position 1

immediately.
Operate both control levers in the operators cab in all

directions several times. This serves to relieve the pressures
both in the main hydraulic system and in the pilot system
accumulator.
Open the cover.
Open screw cap (1) of the hydraulic tank.

This serves to relieve the precharge pressure in the tank.
Connect a pressure gauge (to a maximum of 600 bar) to the

gauge fittings (2).
Close the cover.
Note
The pressure gauge must read 0 bar. If the pressure has not been
relieved completely yet, repeat Steps 2 through 6.
BS80/ 10.2007
6 - 23
6.4.3 Checking Hydraulic oil Level

WARNING
permitted!
1

Retract all hydraulic cylinders as far as possible.
Stop the engine.
Open the service access door - Hydraulic system.
Check the oil level at oil level gauge (1):

The oil level must reach as far as the upper mark (MAX).
A thermometer is integrated in the sight gauge. Here you can take a

reading of the current temperature (C/F) of the hydraulic oil as well.
6 - 24
BS80/ 10.2007
If necessary, add hydraulic oil:

Open the cover and unscrew screw cap (2) of the oil filler
neck.
Add hydraulic oil and check the oil level again as
necessary.
Replace and tighten screw cap (2) and close the cover.
6.4.4 Changing Hydraulic Oil

Safety information
Note the safety information before you attempt to perform operations

on the hydraulic system.
DANGER
z High oil pressure warning!
The hydraulic system is under high pressure.
When a hydraulic line or fitting is disconnected, escaping hydraulic
oil can cause serious personal injury.
Perform any work on the hydraulic system only after all pressure has
been relieved!
z Work on the hydraulic system must only be performed by trained
qualified personnel having specific knowledge and experience of

hydraulics.
WARNING
permitted!
Note
It will make work easier for you if you pump off as much of the oil as
possible. Use the opening of the return flow filter for the purpose.
Procedure
BS80/ 10.2007

Retract all hydraulic cylinders as far as possible.
Relieve hydraulic system pressure as specified in Section

6.4.2.
Remove filter element of return flow filter as specified in

Section 6.4.5.
6 - 25
Place a suitable container underneath the drain port of the

tank.
For refill capacity refer to Section 6.10.2.
CAUTION
Take care to ensure that the container is of adequate capacity to hold
the amount of oil.
Hydraulic oil must be precluded from getting into the soil or the waters.
Dispose of spent oil and oil filters according to the applicable statutory
regulations.
Unscrew cover nut (1).
2
3
6 - 26
Screw in drain plug (2) until the spent oil comes out by way of
plastic hose (3). Collect the spent oil in a suitable container.
Screw drain plug (2) back out.
10
Screw cover nut (1) back on.
BS80/ 10.2007
4
5
11
Fill in new hydraulic oil through the filler neck (4 or 5) at the top
of the tank.
12
Monitor the filling level at the sight gauge of the hydraulic tank.
13
Prime the hydraulic pumps:

Clean the housing.
Release the vent screw at the pump. Do not screw it out
completely; apply light thumb pressure to keep hold of it.
Allow a few seconds for the air to be expelled.
Retighten the vent screw.
CAUTION
Whenever the hydraulic oil has been changed, prime the pumps before
returning them to service to avoid damage.
BS80/ 10.2007
6 - 27
6.4.5 Return Flow Filter Replacing Filter Element
6 - 28
2 3 4

Unscrew the four hexagon nuts (2) and the hexagon bolt (3).
Remove cover (4).
Withdraw the filter element and dispose of as hazardous

waste.
Clean the components; check the seal and replace if

necessary.
Install a new filter element.
Screw down cover (4) by means of the four hexagon nuts (2)
and the hexagon bolt (3).
Tighten screw cap (1).
BS80/ 10.2007
6.4.6 Pilot Control Filter Replacing Filter Element

1
Place a suitable receiving container underneath.
BS80/ 10.2007
Unscrew the head screw (1) at the cover and remove the cover.
Withdraw the filter element (2) and dispose of as hazardous

waste.
Clean the components; check the seal and replace if

necessary.
Fit new filter element (2) into filter housing (3).
Screw down cover by means of the head screw (1).
Check the filter for leaks.
6 - 29
6.4.7 Leakage Oil Filter Replacing Filter Element
1
2
Loosen hexagon nuts (1).
Remove cover (2).
6 - 30
Unscrew filter element (3) from the return tube.
Screw a new filter element to the return tube.
Install the cover (2) with the return tube in the tank.
Tighten hexagon nuts (1).
BS80/ 10.2007
6.4.8 Replacing Ventilation Filter

Note
The ventilation filter is integrated in the screw cap (1) of the filler
strainer. The ventilation filter limits the over-pressure and underpressure in the hydraulic system occurring during hydraulic operations.
CAUTION
Dirty ventilation filters let dust and dirt unfiltered into the hydraulic
system. This can cause damage to the hydraulic system (e.g. to the
pumps) and increased hydraulic oil wear.
BS80/ 10.2007

Pull of filter element (2) from the screw cap (1).
Dispose of filter element (2) as hazardous waste.
Fit new filter element (2) in the screw cap (1).
Screw on screw cap (1) complete with new breather filter.
6 - 31
6.4.9 Checking and Cleaning Hydraulic Oil Cooler

WARNING
Risk of injury caused by rotating parts! Scalding hazard!
Perform maintenance operations only with the engine shut down and
after the hydraulic system has cooled.
6 - 32
Use dry filtered compressed air (max. 2 bar) to blow-clean the

cooling fins. Be careful not to damage the cooling fins.
Use cold cleaner to remove any grease and oil. Collect the
cleaning fluid and dispose of as hazardous waste.
Check the cooler (1) for leaks and for bent and/or damaged
cooling fins.
BS80/ 10.2007
6.4.10 Checking Precharge Pressure of the Accumulators

Note
Checking of the precharge pressure is outlined below using the pilot
system accumulator as an example.
1

Connect a pressure gauge to the PV fitting at the test panel.
Stop the engine, turn the ignition key back to position 1

immediately.
Operate both control levers in the operators cab in all

directions several times.
Watch the pressure gauge.

Once the precharge pressure has been reached, the valve in
the accumulator closes. The pressure gauge indicator drops to
0 abruptly. The reading prior to the pressure drop
corresponds to the precharge pressure in the accumulator.
Compare the reading with the tolerance specification on the

accumulator. If the precharge pressure is outside the
tolerance, replace the accumulator or have it recharged with
nitrogen.
Disconnect the pressure gauge.
CAUTION
Have an expert subject the accumulator to a pressure test and an
internal check every 10 years/20,000 service hours.
BS80/ 10.2007
6 - 33
Maintenance - Distributor Gear
6.5
Distributor Gear
WARNING
z Risk of injury caused by rotating parts! Scalding hazard!
Perform maintenance operations only with the engine shut down
and with the pump distributor gear at standstill and cooled.
z Oil must be precluded from getting into the soil or the waters.
Dispose of spent oil according to the applicable statutory

regulations.
1
3
2
4
1 Vent plug
2 Oil dipstick
3 Oil filling hole
4 Oil drain plug
6 - 34
BS80/ 10.2007
Maintenance - Distributor Gear
6.5.1 Checking Oil Level

WARNING
permitted!
1
Stop the engine.
Open vent plug (1).
Unscrew oil dipstick (2).

The oil level should be at the Max. notch on the oil dipstick.
Add gear oil as necessary. (For specification refer to

Lubricants Chart)
Re-install and tighten vent plug (1) and oil dipstick (2).
6.5.2 Changing Gear Oil

WARNING
permitted!
1
Stop the engine.
Place a suitable receiving container underneath oil drain plug

(4). For refill capacity refer to Section 6.10.2.
Unscrew vent plug (1) and oil dipstick (2).
Unscrew oil drain plug (4) and collect the spent oil in the
container.
Clean the components; check the seals and replace if

necessary.
Re-install and tighten oil drain plug (4).
Fill in new gear oil by way of oil filling hole (3).
Re-install and tighten oil dipstick (2) and vent plug (1).
10
BS80/ 10.2007
Re-check the oil level after 2 service hours.
6 - 35
Maintenance - Slewing Ring
6.6
Slewing Ring
6.6.1 Lubricate the ball-type swing gear and bearing

WARNING
permitted!
Note
Shorter greasing intervals apply
z in tropical countries
z in high-humidity enviroments
z at major exposure to dust and dirt
z in case of important temperature changes and
z in case of continuous rotation.
6 - 36
Stop the engine.
Lubricate the nipples (1) until grease emerges at the sealing

lips.
Rotate the upper structure several times in either direction to

allow the grease to spread out evently.
The operation must be continued until the ball-type swing gear

and bearing is complete filled with grease.
BS80/ 10.2007
Maintenance - Swing drive
6.7 Swing drive

WARNUNG
z Danger of injury through rotating parts and through scalding!
Do not carry out maintenance work until the drive engine has been
switched off.
z Oil must not be allowed to seep into the ground or waterways.
Dispose of old oil in accordance with statutory regulations.
3
1
1)
Oil filler
2)
Oil drain screw
3)
Expansion tank
Level must always be between Min and Max and the transmission
must be completely ventilated.
BS80/ 10.2007
6 - 37
6.7.1 Lubricating the gear teeth

WARNING
permitted!
6 - 38
Stop the engine.
Thoroughly clean the gearing.
Check slewing ring and swing drive pinion for wear; replace if
necessary.
Use BAUER/SENNEBOGEN gear spray to spray the gear

teeth from a distance of approx 30 cm.
Rotate the upper structure several times for the lubricating

layer to spread out evenly over the gearing.
BS80/ 10.2007
6.7.2 Retightening bolts

DANGER
Danger to life!
Defective live ring screw can cause the upper structure to tip over. For
this reason, be sure to observe the following intervals:
z Once a week, tighten the live ring screws with a torque wrench.
z Check or change slewing ring bolts at least every 5000 hrs run/
every 5 years.
Note
Testing must be performed by an expert from an independent specialist
company/ independent institut.
Unrestricted use of the slewing ring bolts must be proven by means of
a certificate.
The slewing ring bolts must be changed otherwise.
Corroded and damaged bolts can shear off and cause the upper
structure to tilt.
z Do not retighten corroded or damaged bolts. Replace immediately
with new bolts.
z Ensure that you adhere to the number and diameter of fixing bolts.
z Only use genuine BAUER/SENNEBOGEN replacement parts!
z If you suspect damage to the screw fastenings, call SENNEBOGEN
customer service and arrange for a check to be carried out.
z Please contact BAUER/SENNEBOGEN customer service with any
further questions.
Notes
z Pretension bolts anticlockwise carefully to prescribed values. The
pretensioning of initially tightened bolts is affected by tensioning further bolts. It is therefore necessary to go round at least twice.
z Ideally tighten bolts over M30 with a hydraulic screw tension cylin-
der.
BS80/ 10.2007
6 - 39
Maintenance - Electrical System
6.8
Electrical System
DANGER
z Have any work on the electrical system performed by adequately
trained qualified electricians only.
z Before performing operations on the electrical system, disconnect
the main fuse and change over the battery disconnect switch.
6.8.1 Batteries
DANGER
z Explosion hazard!
Smoking and handling of naked flames is prohibited. Take care to
avoid sparking in the vicinity of the battery.
z Acid can cause burns!
Wear safety glasses and gloves.

Do not tilt the battery. Battery electrolyte can cause burns and must
not get into the eyes or come into contact with the skin.
z Do not deposit any tools on the battery.

z Disconnect the battery before welding.
z Mind not to interchange battery posts.
z Dispose of spent batteries as hazardous waste.
1
2
Check the terminals and cable connections of the batteries:
6 - 40
Change over battery disconnect switch (1).
Clean the terminals and cable connections of the batteries (2).

Verify that they are firmly secured in place and coat them with
petroleum jelly.
Restore battery disconnect switch (1) to its initial position.
BS80/ 10.2007
Maintenance - Electrical System
6.8.2 Fuses
DANGER
Fire hazard!
Fuses must not be repaired. Always install new fuses of the same
ampere rating.
BS80/ 10.2007
Stop the engine.
Remove cover (1).
Replace the defective fuse.
Check the contacts, clean any oxidized contacts.
Re-install cover (1).
6 - 41
Maintenance - Heating System
6.9
Heating System
Cleaning filter element

1
2
Unscrew knurled screws (1) at the back of the operators seat.
Remove cover (2).
6 - 42
Take out filter element (3).
Tap out the filter element or blow it out carefully by means of

compressed air.
Re-install the filter element. Make sure you install it in the

correct position. Filtered air should be discharged in the
direction of travel.
BS80/ 10.2007
Maintenance - Appendix
6.10 Appendix
Safety information
Note the safety informations before you start work.

WARNING
z The maintenance operations set out below must only be performed
by qualified personnel that has received adequate training and instruction.
z Wearing personnel equipment (for example Helmet, protective
gloves, protective shoes).
6.10.1 Maintenance Schedule

Note
When working in extreme-duty conditions, e.g., at high ambient
temperatures, it may be necessary to reduce the intervals.
(* sh = service hours)
Operation
every
10 sh*/
daily
every
50 sh* /
weekly
once after
250 sh/
6weeks
every
500 sh* /
3months
every
1000 sh*/
1 year
every
2000 sh*/
2 years
Perform visual inspection and

functional check.
Cab - Check the cab support,

bolts and screwed connections.
All separable connections

(screws, bolts, cotter pins, etc.)
verify firm seating.
Engine oil level check.

Observe intervals specified in
engine manufacturers manual.
6.3.1
Coolant level check; clean

cooling fins, if necessary.
6.3.5
Hydraulic system check oil

level.
6.4.3
Slewing ring lubricate.
6.6
Distributor gear Check oil

level.
6.5
Hydraulic oil cooler check and

clean.
6.4.9
BS80/ 10.2007
Section
6 - 43
Operation
every
10 sh* /
daily
every
50 sh* /
weekly
once after
250 sh*/
6weeks
every
500 sh* /
3months
every
1000 sh*/
1 year
every
2000 sh*/
2 years
Swivelling connection:
Visually check all connecting
elements for damage and
corrosion
Battery cable connections and

fuses check.
6.8
Heating system filter check.
6.9
Shut-off flap -hydraulic tank:

visual check of leckage
Lubrication points grease.
Radiator clean.
Air conditioning compressor:

Check belt tension and status.
1)
1)
1)
1)
Hydraulic accumulator precharge pressure - have it

checked by a hydraulics specialist 1).
1)
Section
6.3.5
6.4.10
After 250 sh*/6 weeks and after 500 sh*/3 month; then every 1000 sh*/1 year
All screwed/bolted connections

verify firm seating.
Antifreeze content check.
2)
2)
2)
Air conditioning compressor:.

Check the compressor mounts
and bolts for tightness.2)
2)
Distributor gear change oil.
Retighten slewing ring bolts3).

Swing drive (.closed oil sys-
6.3.5
every 250 sh*, then every 6 weeks
6.5
3)
3)
6.6
3)
3)
tem)
3)
Return flow filter - replace filter

element .
6 - 44
After 250 sh*/6 weeks, then every 2000 sh*/yearly
6.4.5
BS80/ 10.2007
Leakage oil filter replace filter

element.
Operation
every
10 sh* /
daily
Pilot control filter replace filter

element.
every
50 sh* /
weekly
once after
250 sh*/
6weeks
every
500 sh* /
3months
every
1000 sh*/
1 year
6.4.7
every
2000 sh*/
2 years
Section
6.4.6
Slewing ring bolts check of

verify firm seating with suitable
device.
Ventilation filter-hydraulic tank:

visual check for dirt and
damage, change if necessary.
Check the gallery (= operator

catwalk) for cracks and general
damaged every 3 months and
repair immediately if
necessary.
Primary and secondary filter elements of air filter replace.
6.3.4
Filter element of ventilation filter

on hydraulic tank replace.
6.4.8
Heating system/airconditioner
(option):
check for adequately trained
skilled person only.
6.9
6.3.5
4)
6.4.4
Coolant change.
Hydraulic system change
oil4).
4)
If necessary, have the oil checked via an oil diagnosis by SENNEBOGEN customer service
5)
Slewing ring fixing bolts check and change 5)

5)
6.6
every 5000 sh* / every 5 years
Note
Testing of the slewing ring bolts must be performed by an expert from
an independent specialist company/ independent institut.
Unrestricted use of the slewing ring bolts must be proven by means of
a certificate. The slewing ring bolts must be changed otherwise.
BS80/ 10.2007
6 - 45
6.10.2 Refill Capacities

WARNING
permitted!
The capacities shown below are approximate values. What matters is
the filling level indicated on the compartment concerned.
6 - 46
Assembly or Compartment
Quantity
Engine
refer to manufacturers
manual
Fuel tank
approx 775 l
Hydraulic tank
approx 660 l
Overall hydraulic system
approx 920 l
Distributor gear
approx. 8.5 l
Swing drive
approx. 3.5 l
Slewing ring gearing
as required
Central lubrication system
as required
Lubrication points
as required
BS80/ 10.2007
6.10.3 Tightening Torques for Screws

Note
Exceptions to the specifications in the table below may apply in the
case of some mounting bolts on the undercarriage. Please note the
information provided in the relevant sections.
Strength grade 8.8
BS80/ 10.2007
Standard Thread
Fine Thread
Screw
Tightening torque
MA [Nm]
Screw
Tightening torque
MA [Nm]
M4
2.7
M8x1
24
M5
5.4
M10x1
50
M6
9.3
M10x1.25
47
M8
23
M12x1.25
84
M10
45
M12x1.5
81
M12
77
M14x1.5
135
M14
125
M16x1.5
205
M16
190
M18x1.5
305
M18
275
M20x1.5
430
M20
385
M22x1.5
580
M22
530
M24x2
720
M24
660
M27x2
1050
M27
980
M30x2
1450
M30
1350
M33
1850
M36
2350
6 - 47
Strength grade 10.9
6 - 48
Standard Thread
Fine Thread
Screw
Tightening torque
MA [Nm]
Screw
Tightening torque
MA [Nm]
M4
4.0
M8x1
36
M5
7.9
M10x1
73
M6
14
M10x1.25
69
M8
33
M12x1.25
125
M10
66
M12x1.5
120
M12
115
M14x1.5
195
M14
180
M16x1.5
300
M16
280
M18x1.5
435
M18
390
M20x1.5
610
M20
550
M22x1.5
830
M22
750
M24x2
1050
M24
950
M27x2
1500
M27
1400
M30x2
2100
M30
1900
M33
2600
M36
3300
BS80/ 10.2007
Strength grade 12.9
BS80/ 10.2007
Standard Thread
Fine Thread
Screw
Tightening torque
MA [Nm]
Screw
Tightening torque
MA [Nm]
M4
4.7
M8x1
42
M5
9.2
M10x1
86
M6
16
M10x1.25
81
M8
39
M12x1.25
145
M10
77
M12x1.5
140
M12
135
M14x1.5
230
M14
210
M16x1.5
350
M16
330
M18x1.5
510
M18
455
M20x1.5
710
M20
640
M22x1.5
960
M22
880
M24x2
1200
M24
1100
M27x2
1750
M27
1650
M30x2
2450
M30
2200
M33
3000
M36
3900
6 - 49
6 - 50
BS80/ 10.2007
Setting Up - Detaching/Attaching Counterweight
Setting Up
Note
Operations required for setting up the machine vary with the working
attachments selected. Observe the relevant information provided in the
attachment manufacturers instructions.
7.1
Preconditions
Safety notes
Detaching/Attaching Counterweight
Second person present for instructing and bolting.

Observe the safety notes before starting work.
DANGER
z Accident risk through tipping of machine!
The machine is not operational with counterweight removed.
z Accident risk through using counterweights faulty
z Switch off engine and allow detaching/attaching counterweight. Se-
cure machine against unauthorized re-starting.
z Place the machine in horizontal position on flat and firm ground.
Accident risk through tipping of parts of conuterweight!
z Carry out ballasting process with a guide.
Observe danger area!
z There must be no one in the danger area while raising and lowering
the counterweight. It is forbidden to stand on or beneath the counterweight.

Keep a safe distance.
z Only attach or dismantle 10,5 t counterweight completely.

z Installing /Removing counterweights individually.
z Accident risk through tipping of machine ! Disassembling the coun-
terweight or replacing counterweight elements with the device (e.g.

Ram) attached is not permitted !
BS80/ 03.2006
7-1
7.1.1 Detaching Counterweight

DANGER
Before releasing or dismantling safety components, secure the counterweights to prevent them from tipping or falling down.
7-2
BS80/ 03.2006
Attach suitable sling devices Minimum strand length 1,6 m to

the lifting equipment and to the lifting points (1) of the 10,5 t
counterweight (2).
Lightly tension sling devices.
Releasing the screw only, when the counterweight is secured

on a prestressed hanger.
Release hexagon screw (item 5). Remove items 5, 6, 7, 8.
Slacken hexagon screw (3).
Slacken securing bolts (4) on underside of machine. Keep bolts

in a safe place.
DANGER
Do not walk under suspended loads.
6
Lower 10,5 t counterweight (2) safely using lifting equipment

and secure against tipping.

counterweight (11).
Option
BS80/ 03.2006
7-3

in a safe place.
10

11

counterweight (10).
12
13

in a safe place.
14

7.1.2 Attaching Counterweight
7-4
Attach suitable Minimum strand length 1.6 m sling devices to

counterweight (10)..
BS80/ 03.2006
DANGER
3
Hoist counterweight (10) onto machine using lifting equipment.

Counterweight has to rest against the forepart.
Bolt ballast to rear panel of the machine using both bolts (4).
Primary torquing the screws (4), then hang out the sling devices.

counterweight (11)..
Option

4
DANGER
Tighten the bolts (4) with a torque wrench.
Tighten with torque of 500 Nm.
BS80/ 03.2006
7-5
A-A
7-6

counterweight (2).
BS80/ 03.2006
Hoist counterweight (2) onto machine using lifting equipment.(Releasing the screw only, when the counterweight is secured on a prestressed hanger)
10
11
12
Secure counterweight to rear panel of the machine with the hexagon screw (3) provided.
13
Tighten bolt (3) with torque wrench to tightening torque

1200 - 1500 Nm.
14
Move lock plate (8) over screw head (3)
15
Fasten hexagon screw (5) to the screw (3), with washers (6, 7)
(tightening torque 50 Nm)
16
Hang out the sling divices.
DANGER
Tighten the bolts (3) and (4) with a torque wrench.
Please note the individual torques.
WARNING
After each assembly of the counterweight you have to check
additionally after 50 hours of operation the individual torques of the
screws.
BS80/ 03.2006
7-7
Setting Up - Setting Up (Option)
7.2
Setting Up (Option)
Note
Operations required for setting up the machine vary with the working
attachments selected. Observe the relevant information provided in the
attachment manufacturers instructions.
7.3
Preconditions
Safety notes
Detaching/Attaching Counterweight
Second person present for instructing and bolting.

Observe the safety notes before starting work.
DANGER
z Accident risk through tipping of machine!
The machine is not operational with counterweight removed.
z Accident risk through using counterweights faulty
z Switch off engine and allow to cool down before detaching/attaching
counterweight. Secure machine against unauthorized re-starting.
z Place the machine in horizontal position on flat and firm ground.
Accident risk through tipping of parts of conuterweight!
z Carry out ballasting process with a guide.
Observe danger area!
z There must be no one in the danger area while raising and lowering
the counterweight. It is forbidden to stand on or beneath the counterweight.

Keep a safe distance.
z Only attach or dismantle 10,5 t counterweight completely.

z Installing /Removing counterweights individually.
z Accident risk through tipping of machine ! Disassembling the coun-
terweight or replacing counterweight elements with the device (e.g.

Ram) attached is not permitted !
7-8
BS80/ 03.2006
7.3.1 Detaching Counterweight

DANGER
Before releasing or dismantling safety components, secure the counterweights to prevent them from tipping or falling down.
A
A-A
BS80/ 03.2006

counterweight (2).
7-9

Slacken hexagon screw (3).

in a safe place.
DANGER
5


the lifting equipment and to the lifting points of the 5,0 t counterweight (6).
Slacken securing bolts on underside of machine. Keep bolts in

a safe place.
Releasing the screw (4) only, when the counterweight is secured on a prestressed hanger.
7 - 10
Lower 5,0 t counterweight (6) safely using lifting equipment and

secure against tipping.
BS80/ 03.2006
7.3.2 Attaching Counterweight

5

counterweight (6)..
DANGER
3

DANGER
Tighten the bolts (4) with a torque wrench.
Tighten with torque of 500 Nm.
BS80/ 03.2006
7 - 11
A-A

counterweight (2).

7 - 12
BS80/ 03.2006
Hoist counterweight (2) onto machine using lifting equipment.(Releasing the screw only, when the counterweight is secured on a prestressed hanger)
10
11
12
Secure counterweight to rear panel of the machine with the hexagon screw (3) provided.
13
Tighten bolt (3) with torque wrench to tightening torque

1200 -1500 Nm.
14
Hang out the sling divices.
DANGER
Tighten the bolts (3) and (4) with a torque wrench.
Please note the individual torques.
WARNING
After each assembly of the counterweight you have to check
additionally after 50 hours of operation the individual torques of the screws.
BS80/ 03.2006
7 - 13
7 - 14
BS80/ 03.2006
Transport -
8
Preliminary operations
Transport
Transport the machine by means of a flatbedtrailer. Be sure to perform

the following preliminary operations:
z Select an appropriate vehicle for transport.
Observe the machine dimensions and weights as specified in

Section 8.2.
z Clean the machine.

z Remove working attachments and tools, if any.
z Fold the running board on the upper carriage (1).
BS80/ 03.2006
8-1
Transport - Safety Information

Warning
z For loading and transport work in Germany:
Any loading and transport work must only be performed by duly
authorizied qualified personnel observing section 48 of VBG 40
(German accident prevention regulations for earthmoving
machinery) and section 22 of StVO (German highway code).
z Observe the applicable cargo securing rules and regulations.
Transport of the machine and of the accessories is the responsibility

of the respective carrier as a general principle.
z During loading and transport, secure the machine and its working
equipment against any accidental movement.
z Remove mud, snow and ice from the undercarriage of the machine
sufficiently to allow the use of ramps without the risk of slippage.
z Provide ramps of flatbed trailers with wood blocking.

z Before setting off, investigate the condition of the travel route.
z For transport of the machine, use only the lashing, tie-down and
lifting points provided for the purpose.
z Take care to ensure that the machine does not constitute a source
of danger for other road users.
z Wearing personnel equipment (e.g., hard hat, hearing protective
devices, protective gloves, safety shoes).
8-2
BS80/ 03.2006
Transport - Dimensions and Weights
8.2
Dimensions and Weights
8.2.1 Dimensions
BS80/ 03.2006
8-3
Transport - Dimensions and Weights
8.2.2 Weights
DANGER
Attachment of BAUER equipment will increase the weight of the
machine.
Machine
Weight: approx 15,4 metric tons
Counterweight (ballast)
8-4
5,3 t
10,5 t
Weight [kg]
5300
10500
Length [mm]
3000
3000
Width [mm]
200
563
Height [mm]
1500
1500
BS80/ 03.2006
Transport - Disconnect electrical system from battery
8.3
Disconnect electrical system from battery
If the machine is idle for an extended period or for long transport

distances, the electrical system must be isolated from the battery using
the mechanical battery isolator switch (optional).
WARNING
Do not switch off mechanical battery isolator switch if:
z the engine is still running
z or other electrical consumers are still switched on.
Doing so may damage the electrical system and its controller.
Open service access doors.
Turn the battery isolation switch (1) to the left (counterclockwise) and extract.
The electrical system is now isolated from the battery.
Close service access doors.
Note
If no mechanical battery isolation switch exists, the battery poles must
be disconnected. Properly install the battery protective caps again.
BS80/ 03.2006
Open service access doors.
IMPORTANT! Prevent short circuits!

Disconnecting: 1. Disconnect the negative pole
2. Disconnect the positive pole
Connecting: 1. Connect the positive pole
2. Connect the negative pole
Close service access doors.
8-5
Transport - Lifting the Machine
8.4
Safety information
Lifting the Machine

DANGER
z To sling the machine, use only the lifting points provided for the
purpose. The lifting points are marked with green paint and identified
by a green load hook symbol.
z Take care to ensure that the sling devices are of adequate load
capacity and undamaged.
z Mind the danger area!
No persons are allowed at, on or underneath the machine.
Procedure
10 t
7,1 t
8-6
5,4 t
8,3 t
BS80/ 03.2006
Transport - Lifting the Machine
Select an appropriate lifting crane and proper rated sling

devices. Allow for the machine weight and center of gravity.
Fasten the sling devices to the lifting points.
Carefully lift the machine.
DANGER
People must keep clear of the area under a suspended load!
BS80/ 03.2006
8-7
Transport - Lashing and Tying Down the Machine
8.5
Lashing and Tying Down the Machine
CAUTION
z To lash the machine, use the tie-down points provided for the
purpose. Tie-down points are marked with green paint and are
located on the upper structure. They are identified by the following
symbol.
z Take care to ensure that the sling devices are of adequate load
capacity and undamaged.
z In the event of an additional securing device being required, take
care to avoid the machine getting damaged.
z Transport of the machine and of the accessories is the responsibility
of the respective carrier as a general principle.
8-8
BS80/ 03.2006
Troubleshooting - Engine
Troubleshooting
WARNING
z The maintenance, inspection and troubleshooting personnel must
have the appropriate qualification for these operations.
z In case of operations not described in detail, consult the BAUER/
SENNEBOGEN service department.
9.1 Engine
Engine fails to start
Loss of engine power
Machine fails to move
BS80/ 03.2006
Cause
Remedy
Battery capacity
inadequate
Check electrolyte level of batteries.

Recharge or replace batteries.
Use auxiliary battery to start the
machine.
Starter interlock not active
Unlock travel pedal.
Fuel tank empty
Refuel the machine.
Emergency Stop switch is

pressed
Pull out the Emergency Stop switch.

tank closed or not correct
opened
Open shut-off flap.
Cause
Remedy
Suction resistance
excessive
Replace filter element of water

separator.
Cause
Remedy
Parking brake applied
Release parking brake.
Transmission/gear
defective
Have the fault corrected.
9-1
Troubleshooting - Engine
Oil or fuel leaks at the

engine
Cause
Remedy
Loose hose connections
Tighten hose connections.
Hoses or seals damaged
Replace hoses or seals.
Note
You should also observe the information provided in the engine
manufacturers instruction.
9-2
BS80/ 03.2006
Troubleshooting - Hydraulic System
9.2
Oil leaks at the
hydraulic system
Hydraulic System
Cause
Remedy
Loose hose
connections
Hoses or seals
damaged
Hydraulic pump fails to

operate
Cause
Remedy
Fault in pump circuit
Have fault investigated and corrected

by a hydraulics specialist.
No functions, or
malfunctioning, of the
working equipment
Cause
Remedy

low
Check hydraulic oil level.

Leaks in the hydraulic

system
Check the working cylinders,

connections, fittings and hoses for
leaks.
Have the fault corrected by a hydraulics
specialist.
Fault in one of the

attachment operation
circuits

specialist.
Cause
Remedy
Lack of lubricant film on

cylinder piston rod
Have cylinder repaired by a hydraulics

specialist.
Working cylinder
movement produces
noises
BS80/ 03.2006
9-3
Troubleshooting - Hydraulic System
No or inadequate output
of the hydraulic system
Noises at the hydraulic

system
9-4
Cause
Remedy
Loose hose
connections
Hoses or seals
damaged
Relief valve opens

prematurely

specialist.
Hydraulic pump worn or

defective
Have pump replaced by a hydraulics

specialist.
Cause
Remedy
Hydraulic pump sucks

in air

specialist.
Oil delivery of hydraulic

pump is inadequate

Relief valve knocking

specialist.
BS80/ 03.2006
Troubleshooting - Electronic System
9.3 Electronic System

Loss of power Limit
load control LED
flashing
BS80/ 03.2006
Cause
Remedy
Fault in electronic
system
Emergency operation (refer to LIMIT

LOAD CONTROL EMERGENCY
OPERATION on page 5-18).
Inform service department.
9-5
Troubleshooting - Sennebogen diagnositc system SDS
9.4
Sennebogen diagnositc system SDS
9.4.1 Bank of keys with LEDs
LED flashes,
continuous
alarm sounds
Cause
Remedy
Fuel level in tank too

low
Refuel machine as specified in

Abschnitt 5.6.3.
LED flashes,
buzzer sounds
Cause
Remedy
Engine overheated
Idle engine.
Cooling fins on engine

oil cooler dirty
Fan drive loose or

defective
Tighten fan drive, replace if necessary.
Add coolant as specified in Abschnitt

6.3.5.
Engine switched off

without cooling phase.
After operating, allow engine to run in

low neutral for approx. 5-10 minutes
before switching off.
Note
When the coolant temperature continues to rise,
z the temperature reading on the display flashes in addition;

CAUTION
immediately.
9-6
BS80/ 03.2006
LED flashes,
buzzer sounds
Cause
Remedy
Engine oil pressure too

low (<1.3 bar)
Stop engine immediately.

Check engine oil level as specified in
Abschnitt 6.3.1.
If fault continues to occur, inform the
BAUER/SENNEBOGEN service
department accordingly.
Note
When the oil pressure falls below 1.0 bar,
z the pressure reading on the display flashes in addition;

CAUTION
immediately.
LED flashes,
buzzer sounds
Cause
Remedy
Hydraulic oil
temperature excessive
(>84C)

hydraulic oil has cooled down.
Cooling fins on
hydraulic oil cooler dirty

low
Check oil level as specified in Abschnitt

6.4.3.
Note
When the hydraulic oil temperature rises to more than +94 C, the
temperature reading on the display flashes in addition.
BS80/ 03.2006
9-7
9.4.2 Indicator and warning lights

comes on,
warning signal
sounds
Cause
Remedy
Clean filter as specified in Abschnitt

6.3.4.
Where necessary, replace filter
element.
comes on
during engine
operation (3)
Cause
Remedy
Hydraulic oil return flow

filter foul/blocked or
defective
Replace return flow filter as specified

in Abschnitt 6.4.5.
comes on
during engine
operation (4)
Cause
Remedy
Group fault signal Hydraulic filter foul/

blocked or defective (e.g.
Pilot control filter, Hydro Clean Superfine-Filter)
Replace hydraulic filter (e.g. pilot

control filter as specified in Abschnitt
6.4.6.).
comes on,
warning signal
sounds, engine
is stopped
Cause
Remedy
Hydraulic oil level too low
Add hydraulic oil as specified in

Abschnitt 6.4.
WARNING
eliminated. In case of emergency, you can override this shutdown function however (refer to SENNEBOGEN DIAGNOSTIC SYSTEM (SDS) on
page 5-9).
comes on
during engine
operation,
warning signal
9-8
Cause
Remedy

tank closed
Open shut-off flap.
BS80/ 03.2006
comes on,
warning signal
sounds, engine
is stopped
Cause
Remedy
Add coolant.
WARNING
eliminated. In case of emergency, you can override this shutdown function however (refer to SENNEBOGEN DIAGNOSTIC SYSTEM (SDS) on
page 5-9).
comes on
during engine
operation,
warning signal
sounds
Cause
Remedy
Coolant temperature
excessive

coolant has cooled down.
Where necessary, check and clean
the radiator as specified in Abschnitt
6.3.5.
Switches do not work
BS80/ 03.2006
Cause
Remedy
Fuse defective
Replace fuse.
Switch faulty or fault in

circuit
Have fault inspected and rectified by an

electrical engineer.
9-9
Troubleshooting - Heating System
9.5
No or inadequate heater
output
No air flow
Heater will not turn off
9 - 10
Heating System
Cause
Remedy
Water inlet temperature

too low
Operate engine to warm it up.

Replace thermostat (with air conditioner
fitted).
Thermostat on vehicle
defective
Replace vehicle thermostat.
Water valve fails to

open
Check valve and valve control; replace

as necessary. Mind the direction of flow.
Heat exchanger louvers

dirty
Clean heat exchanger.
Filter foul/blocked
Clean filter; replace if necessary.
No air flow
See below.
Cause
Remedy
Fuse failed
Replace fuse.
Power supply
interrupted
Check wiring for loose contacts or open

circuits.
Blower motor defective
Have blower motor replaced.
Blower switch defective
Check switch, replace if necessary.
Resistor defective
Have resistor replaced.
Cause
Remedy
Bowden cable for water

valve maladjusted
Re-adjust Bowden cable.
Heater valve not

mounted properly
Check direction of flow at the valve;

where necessary, exchange inlet/return
flow.
Control and/or Bowden

cable defective
Replace control or Bowden cable

respectively.
BS80/ 03.2006
Troubleshooting - Air Conditioner
9.6
Cooling efficiency
inadequate
Air conditioner cooling

intermittently
Air conditioner
extremely noisy
BS80/ 03.2006
Air Conditioner
Cause
Remedy
Fuse failed
Replace fuse.
Power supply
interrupted

circuits.
Pressure switch
defective
Have pressure switch replaced.
Refrigerant line broken
Have line replaced.
Expansion valve
sticking
Have customer service replace the

valve.
Compressor clutch
slipping

clutch.
Clean air filter.
Cause
Remedy
Compressor clutch
slipping

clutch.
Temperature variable
control defective
Replace temperature variable control.
System iced
Have air conditioner checked by the

customer service.
Blower switch defective
Check switch, replace if necessary.
Cause
Remedy
Compressor clutch
slipping

clutch.
V-belts loose or worn
Increase V-belt tension or replace Vbelt.
System overcharged
Have refrigerant extracted by the

customer service.
Lack of refrigerant in the

system
Have customer service check the

system for leaks.
Have system charged with refrigerant.
9 - 11
Troubleshooting - Cab
No function of the contol lamp of the

selected air conditioning
Cause
Remedy
Refrigerant too low
Have customer service check the

system for leaks.
Have system charged with refrigerant.
Power supply
interrupted

circuits.
Pressure switch
defective
Have pressure switch replaced.
Pressure switch is out
Reduce overpressure.
Thermostat defective
Have customer service replace the thermostat.
Thermostat is out
Ambient temperature </= 5C.
9.7 Cab
Cab moves or swings
drastically
9 - 12
Cause
Remedy
Cab mounting or cab

fastening damaged
Check all connection elements, bolts

and pins of cab mounting and fastening
for damage, cracks or deformation.
Have damaged components replaced
immediately by trained and instructed
specialist personnel.
BS80/ 03.2006
Index
A
Abuse 1-3
Adding hydraulic oil 6-25
Adjusting time of day 5-11
Automatic idling 5-18
Automatic speed control 5-18
B
ballast 8-4
Bank of keys 5-10
Battery Acid 4-6
Battery disconnect switch
2-3, 6-40
Biological oils 6-5
Bolt strength grades 6-47
C
Calibration of the load limit
sensing controller 5-19
CE certificate of conformity
1-8, 1-19
CE symbol 1-8
Checking hydraulic oil level
6-24
Chloride 6-8
Cleaning hydraulic cylinders
6-21
Conversion of the machine
1-16
Copyright 1-8
Counterweight 8-4
Crushing hazards 1-4
Current when going to press
1-2
Customer service 1-7
D
Danger area 1-4
Declaration of conformity 1-8
Decommissioning 4-9
Decommissioning machine
4-9
Description
Effects of wind 3-3
Display (SDS) 5-10
Disposal 1-22
Batteries 1-22
Disposal Guideline 75/439/
EEC 1-22
BS80/ 05.2008
Disposal of consumables
1-22
Disposing of batteries 1-22
Disposing of lubricants 1-22
Disposing of the oil filter 1-22
E
Emergency exit 5-2
Emergency Stop 5-5
Employment in foreign
countries 1-16
Engine
Changing oil 6-13
Engine speed control 5-17
environmental protection
1-22
Environmental regulations
1-22
F
Fax
Customer service 1-7
Documentation 1-7
Spare parts warehouse
1-7
Fire extinguisher 1-16
First aid kit 1-16
Fuses 6-41
G
Gauge fittings 6-23
H
Hand signals for directing
1-23
High voltage contact 1-6
Hydraulic fittings 6-21
I
Illustration aids 1-3
Inadmissible operating
practices 1-15
Indicator lights 5-14
International regulations 1-1
J
Jump starting 4-6
K
Keyword 1-3
L
LEDs 5-10
Lifting points 8-6
Limit load control
Emergency operation
5-18
List of abbreviations 2-1
M
Main fuse 2-3
Misuse 1-2
Multiple disc brake 5-29
N
National regulations 1-1
National rules and
regulations 1-1
Noise protection 1-16
Not-Aus 2-7, 5-4
O
Oil analysis 6-5
Oil filler neck 6-25
Operators work station 1-2
Overhead lines 1-6
Overriding shutdown function
5-16
P
Permanent sound pressure
level 1-16
Personal protective
equipment 1-5
Personnel qualifications 1-15
Personnel selection 1-15
pH value, water 6-8
Potential instances of misuse
1-2
Preparing to operate
Checklist 4-2
Pressure cylinders 6-21
Prototype Testing 1-19
Q
Qualifications of personnel
1-7
S-1
Index
R
Release (cab door) 5-2
Relieving hydraulic system
pressure 6-23
Replacing oil filter 6-13
Resetting daily service hour
meter 5-11
Residual hazards 1-3
Riementriebe 6-19
W
Warm-up period 4-7
Warning lights 5-14, 9-8
Warning symbol 1-3
Warranty conditions 1-16
Warranty manual 1-16
Water separator 6-15
Wind force 3-3
Wind speed 3-3
S
Safety clearance 1-4, 1-6
Safety clearance to overhead
lines 1-6
Safety instructions 1-3
Safety lever 2-7, 5-4, 5-6
Sales and service partners
1-7
Service checkbook 1-5
Service partners 1-7
Shut-off flap 2-4, 6-21
Signaling individual 1-23
Slewing gear brake 5-29
Spare parts catalog 1-5
Spare parts warehouse 1-7
Specialist check 1-14
Specific dangers 1-15
Stability 1-5
Storage location 4-9
Subdivision of the operating
instructions 1-5
Swinging the upper structure
5-28
Switching off engine 4-8
T
Target group 1-5, 1-2
Telephone 1-7
The maintenance
instructions 1-5
Tie-down points 8-8
Tightening torque 6-47
Type plate 1-18
U
Upper structure swing 5-28
Use as intended 1-2
S-2
BS80/ 05.2008
Appendix - List of abbreviations
Appendix
1.1 List of abbreviations
BS80/ 03.2006
TUR
Trade Union Regulations
Oh
Hours of operation
LED
LEDs
SDS
SENNEBOGEN Diagnosis System
FMVSS
Federal Motor Vehicle Safety Standards
UCTU
Underground Construction Trade Union
ACTU
Association of Commercial Trade Unions
1-1
Appendix - List of abbreviations
1-2
BS80/ 03.2006

Operating and Maintenance Instructions

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Operating and Maintenance Instructions

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Operating and Maintenance Instructions

Important notes on the

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

permitted by trained personnel. The employer is responsible for the

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

the instruction in the cab.

z Contact SENNEBOGEN immediately if there is anything in the

operating manual that you do not understand!

Ongoing development ensures the advanced technology and the high

These instruction contain safety instructions that highlight dangerous

Press switch (1).

Actuate control lever (2).

Unfasten pins (3).

z Listings are marked with bullet points.

Sub-points in listings or handling instructions are marked with

Specialists are those who, on the basis of specialist training,

Instructed personnel are those who have received instruction in the

Experts are those who, on the basis of specialist training and

Specialists are those who are authorized by the German technical

The machine has been developed for demanding work.

The following documents go with the machine:

The instruction are divided into 10 chapters:

You will find generally applicable safety instructions that must be

Chapter 2 illustrates the main components of the machine.

This section provides information about starting operation on a daily

You will also find information on operating instruments and working

Chapter 6 illustrates procedures used to ensure that the machine is

Chapter 7 may contain information on setting up counterweight.

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

Here you will find information on recognizing causes of malfunctions

Here you will find an index and additional information, forexample

SENNEBOGEN Maschinenfabrik GmbH

+49 9421 540-0

Fax Customer service:

+49 9421 540279

Fax Spare parts storage:

+49 9421 40811

+49 9421 540 380

+49 8252 97-0

Fax Customer service:

+49 8252 972587

+49 8252 2815

The CE symbol indicates that basic safety requirements have been

Straubing 2007, SENNEBOGEN Maschinenfabrik GmbH

Reproduction, in whole or in part, only with written permission of

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

6.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

z the safety notices and messages are ignored.

z the operating tools attached are found to be defective

National and international regulations apply in addition to the safety

Components - Hydraulic (EN 982)

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

Safety - Use as Intended

The machine has been designed as a carrier machine for BAUER,

The machine has been designed to perform specific exacting duties.

1.3 Potential instances of misuse

against falling objects with guard grill).

z Operating on insufficiently firm base.

elements with device attached (e.g. Ram)

Practices considered to be improper use (abuse) include in particular:

1.5 Residual hazards

Safety - Safety Information