Operating and Maintenance Instructions

BS 80

10/2005 BS80.6.623
Foreword

Important notes on the Read the instruction, in particular Chapter 1 SAFETY thoroughly, before
Instruction starting work with the machine.
Keep the instruction in a safe place for future use.
WARNING!
z Only work with the machine once these instruction have been read
and completely understood.
z Observe safe working load tables in Abschnitt 3.2.
z Forbid unsafe operation or unsafe maintenance.
z Do not operate machine if a fault has been detected!
z Setting up, operation and maintenance of the machine is only
permitted by trained personnel. The employer is responsible for the
qualification and training of the personnel.
z These instruction are an integral part of the machine. Always keep
the instruction in the cab.
Recommended location to keep instructions: In the storage
compartment behind the driver’s seat.
In the event of sale, disposal or loan, the operating manual must
accompany the machine!
z Contact SENNEBOGEN immediately if there is anything in the
operating manual that you do not understand!
Your comments will help us to make the operating manual even
more user friendly.

For reasons of clarity, the specified safety devices are not shown in
some of the illustrations. Operation with safety devices removed is not
permitted!
DANGER
Safety devices must be fitted when working with the machine.

Current when going to Ongoing development ensures the advanced technology and the high
press 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).

2 Actuate control lever (2).
3 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 product and
are sufficiently aware of the relevant national occupational safety
guidelines, accident prevention guidelines, regulations and
generally recognized technical regulations (e.g. EEC-Guidelines,
VDE-Regulations, VBG) as to be able to judge the operational safety
of the machine.
z Specialists
Specialists are those who are authorized by the German technical
monitoring organization TÜV or by their professional organization to
check the machine. Authorization on the part of a professional
organization must comply with the “Principles for authorizing
specialists to check cranes” (ZH 1/518). It is linked to the issue of an
identity number. This is to be entered by the specialist in the check
report and/or check notice.
Authorizations can be limited to parts of checks or to certain types
of crane.

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 The following documents go with the machine:

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 The instruction are divided into 10 chapters:
divided up?
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 SENNEBOGEN Maschinenfabrik GmbH

us at 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: [email protected]
Fax: +49 9421 540 226

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

Copyright © Straubing 2005, SENNEBOGEN Maschinenfabrik GmbH

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

W-8 BS80
 Contents

1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Use as Intended . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Potential instances of misuse . . . . . . . . . . . . . . . . 1-2
1.4 Abuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5 Residual hazards . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6.2 Preparing to Operate . . . . . . . . . . . . . . . . . . 1-8
1.6.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.6.4 Setup work . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.6.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.6.6 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.7 Obligations of the Owner . . . . . . . . . . . . . . . . . . . 1-13
1.8 Guards and Protective Devices . . . . . . . . . . . . . . 1-16
1.9 Warning Signs and Labels on the Machine . . . . . 1-17
1.9.1 Identification plate . . . . . . . . . . . . . . . . . . . 1-17
1.9.2 CE symbol of conformity . . . . . . . . . . . . . . 1-17
1.9.3 Safety signs and warning symbols . . . . . . 1-18
1.10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.11 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

2 General View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 Overall Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5 Operator´s Station . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

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

3.1 Base Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

4 Preparing to Operate . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Initial Commissioning . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4 Starting the Machine . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.4.1 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

BS80/ 10.2005 0-1

Contents

4.4.2 Starting the Engine . . . . . . . . . . . . . . . . . . . 4-5

4.4.3 Jump Starting . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.4 Bring Machine up to Operating Temperature . .
4-7
4.5 Turning off the machine . . . . . . . . . . . . . . . . . . . . . 4-8
4.5.1 Switching off engine . . . . . . . . . . . . . . . . . . 4-8
4.6 Taking the machine out of service . . . . . . . . . . . . . 4-8

5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.1 General View . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.2 Emergency Stop . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.3 Safety Lever . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.4 Right-Hand Control Lever . . . . . . . . . . . . . . 5-7
5.3.5 Left-Hand Control Lever . . . . . . . . . . . . . . . 5-7
5.3.6 Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.3.7 Sennebogen Diagnostic System (SDS) . . . . 5-9
5.3.8 Right-Hand Control Panel . . . . . . . . . . . . . 5-17
5.4 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.5 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.5.1 Air Conditioner . . . . . . . . . . . . . . . . . . . . . . 5-22
5.6 Operating Technique . . . . . . . . . . . . . . . . . . . . . . 5-23
5.6.1 Safety Information . . . . . . . . . . . . . . . . . . . 5-23
5.6.2 Swinging the Upper Structure . . . . . . . . . . 5-24
5.6.3 Refueling the Machine . . . . . . . . . . . . . . . . 5-26

6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.2 Oils and Lubricants . . . . . . . . . . . . . . . . . . . 6-5
6.2.3 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.1 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.3.2 Water separator . . . . . . . . . . . . . . . . . . . . . 6-10
6.3.3 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.3.4 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.3.5 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

0-2 BS80/ 10.2005

 Contents

6.3.6 Belt Drives . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6.4 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.4.1 Hydraulic Hose Lines . . . . . . . . . . . . . . . . 6-18
6.4.2 Relieving Hydraulic System Pressure . . . . 6-19
6.4.3 Checking Hydraulic oil Level . . . . . . . . . . . 6-20
6.4.4 Changing Hydraulic Oil . . . . . . . . . . . . . . . 6-21
6.4.5 Return Flow Filter – Replacing Filter Element . .
6-24
6.4.6 Pilot Control Filter – Replacing Filter Element .
6-25
6.4.7 Leakage Oil Filter – Replacing Filter Element . .
6-26
6.4.8 Replacing Ventilation Filter . . . . . . . . . . . . 6-27
6.4.9 Checking and Cleaning Hydraulic Oil Cooler . .
6-28
6.4.10Checking Precharge Pressure of the Accumula-
tors 6-29
6.5 Distributor Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
6.5.1 Checking Oil Level . . . . . . . . . . . . . . . . . . 6-31
6.5.2 Changing Gear Oil . . . . . . . . . . . . . . . . . . 6-31
6.6 Slewing Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6.6.1 Lubricate the ball-type swing gear and bearing
6-32
6.6.2 Lubricating the gear teeth . . . . . . . . . . . . . 6-33
6.6.3 Retightening bolts . . . . . . . . . . . . . . . . . . . 6-34
6.7 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
6.7.1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
6.7.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
6.8 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
6.9 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
6.9.1 Maintenance Schedule . . . . . . . . . . . . . . . 6-38
6.9.2 Refill Capacities . . . . . . . . . . . . . . . . . . . . 6-41
6.9.3 Tightening Torques for Screws . . . . . . . . . 6-42

7 Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 Detaching/Attaching Counterweight . . . . . . . . . . . 7-1
7.1.1 Detaching Counterweight . . . . . . . . . . . . . . 7-2
7.1.2 Attaching Counterweight . . . . . . . . . . . . . . . 7-4

8 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

BS80/ 10.2005 0-3

Contents

8.2 Dimensions and Weights . . . . . . . . . . . . . . . . . . . . 8-3

8.2.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.2.2 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.3 Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4 Lashing and Tying Down the Machine . . . . . . . . . . 8-7

9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.3 Electronic System . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.4 Sennebogen diagnositc system SDS . . . . . . . . . . 9-6
9.4.1 Bank of keys with LEDs . . . . . . . . . . . . . . . . 9-6
9.4.2 Indicator and warning lights . . . . . . . . . . . . . 9-8
9.5 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.6 Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.7 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

10 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.1 List of abbreviations . . . . . . . . . . . . . . . . . . . . . . . 10-1

0-4 BS80/ 10.2005

 Safety - General

1 Safety
1.1 General
In the design and construction of the machine, allowance has been
made for the state of the art and the recognized safety-related
standards. Its operation may nevertheless involve potential hazards for
persons, the machine and other property if
z the machine fails to be used as intended;
z operation or maintenance of the machine is performed by
unqualified personnel;
z the safety notices and messages are ignored.

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/ 10.2005 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 operator’s work station is in the operator’s cab of the machine.
Note
Study and observe the information contained in the BAUER
documentation.

Target group The machine has been designed to perform specific exacting duties.
Persons who operate the machine or work on it must have received
adequate training or instruction.
Operation and application must be performed only by persons that
have been duly instructed. Commissioning, maintenance, transport
and assembly/disassembly must be assigned to trained qualified
personnel.

1.3 Potential instances of misuse

z Inadequate equipment for the application (e.g. protection of cab
against falling objects with guard grill).
z Operating on insufficiently firm base.
z Neglect of necessary inspection and maintenance work.
z Using non SENNEBOGEN parts.
z Use in inadmissible ambient conditions.
z Misuse by untrained and uninstructed personnel.

1-2 BS80/ 10.2005

 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 be all inclusive. The owner and machine operator still
remain responsible for safety.

BS80/ 10.2005 1-3

Safety - Safety Information

1.6 Safety Information

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

1-4 BS80/ 10.2005

 Safety - Safety Information

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

Problems Report problems or damage immediately to a responsible person!

Prevent the machine from incorrect or erroneous use.
Repairs may only be performed by trained specialist personnel.

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

z Where necessary, stabilize the supporting surface.
z Beware of edges of excavations, banks, vaults, etc.
z Set outriggers on a firm, level supporting surface as well.
z Pay attention to wind speeds!
DANGER
Refrain from any operating practice impairing stability of the machine!
Note that stability is reduced when the load swings out to the side.

BS80/ 10.2005 1-5

Safety - Safety Information

Working in the vicinity z Clearly mark off the power lines in the job site area with your
of power lines 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 operator’s station.
z Caution all outside persons against approaching or touching the
machine.
z Where possible, move the working equipment or the entire machine
out of the danger zone.
z Arrange for the power to be disconnected.
z Do not leave the machine until after de-energization of the line that
has been touched or damaged.
DANGER
If you must leave the machine in an emergency, e.g., if there is a fire,
never contact the machine and the ground at the same time. Jump
clear of the machine with your feet together.

1-6 BS80/ 10.2005

 Safety - Safety Information

Qualifications of The machine must be operated and maintained only by qualified

personnel personnel.

Extract from VBG 40 Only those persons must be assigned to operate or maintain
regulations (Germany) 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 Operators are required to meet the following qualifications:
regulations (United
z Pass a practical operating examination for the machine they will
States)
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/ 10.2005 1-7

Safety - Safety Information

1.6.2 Preparing to Operate

WARNING
z Make sure that all guards and protective devices of the machine are
in place and are properly secured.
z Wear personal protective equipment (hard hat, safety glasses)
where this is required by job conditions.
z Avoid wearing jewelry or loose clothing.
z Secure any loose items, e.g., tools or other accessories.
z Agree on hand signals with the signal person.
z Obtain information about first aid and about assistance and rescue
services.
z Perform the pre-start checks as specified in Section 4.3.
z Get onto or off the machine only while it is parked. Use the means
of access and ladders provided for the purpose:
– Before using the means of access and the ladders, clean them as
necessary.
– While mounting or dismounting, your hands must be free of any
objects. Use a hand line or a hoist to lift any items of equipment
onto the machine.
– Do not use controls in the operator’s cab as handholds.
z Make sure that there are no persons in the danger area.
z Check the safety features (brakes, signaling and lighting equipment)
of the machine.
z While traveling at slow speed, check the controls and protective
devices for proper operation.

1-8 BS80/ 10.2005

 Safety - Safety Information

1.6.3 Operation
WARNING
z Be sure to observe Chapter 1 SAFETY.
Before the machine is put into operation, perform the checks as
specified in Section 4.3.
z Persons who operate the machine or work on it must have received
adequate training or instruction.
Operation and application must be performed only by persons that
have been duly instructed.
z Make sure that there are no persons in the danger area.
z Maintain a safety clearance to overhead lines.
z Operate the machine only while you are in the operator’s seat.
z Do not use the machine for handling of personnel.
z Make due allowance for ambient conditions, e.g., poor visibility,
wind speeds, etc.
z Observe performance specifications.
z Check whether the load capacity of attachment points is adequate.
z Obey the signals given by signal persons, where applicable.
z Before leaving the operator’s cab:
– Park the machine on a safe surface. Back off from the edge of an
excavation, where applicable.
– Lower any attached loads to the ground.
– Secure the working attachments.
– Pull the safety lever backward.
– Chock the tires/block the undercarriage.
– Stop the engine.
z Lock the operator’s cab; use warning lamps to mark the machine,
where applicable.

BS80/ 10.2005 1-9

Safety - Safety Information

1.6.4 Setup work

WARNING
z Wear personal protection equipment (e.g. safety helmet, ear protec-
tion, protective gloves, safety boots) if working conditions require it.
z When disassembling components or equipment, always use load
suspension equipment with a sufficient load carrying capacity at the
attachment points.
z Ensure that there is no one within the danger area.
z Note the relevant accident prevention directives for working with load
suspension equipment.
z Carry out all setup steps in turn. Never carry out more than one set
up task at a time.
z Do not climb or run on equipment parts (e.g. boom components,
ballast components) suspended on the crane. Do not stand on parts
suspended from the crane.

1 - 10 BS80/ 10.2005
 Safety - Safety Information

1.6.5 Maintenance
DANGER
Danger to life!
There is a risk of serious injury or even death to persons using the
machine or in its vicinity if it moves suddenly or is started
unintentionally. Observe the following:
z Place the machine on a firm base, if necessary set back from the
edge of the excavation.
z Lower suspended loads and booms to the ground.
z Apply the brake.
z Switch off machine and secure against unauthorised re-starting.
z Use a chock to stop the machine from rolling away.
WARNING
z Observe the applicable statutory accident prevention and safety
regulations.
z Land any attached loads to ground level.
z Pull the left safety lever backwards.
z Before attempting to perform any maintenance, shut down the
machine and secure it against unauthorized restarting.
z Attach a warning tag to the controls.
z Do not smoke and do not allow open flames.
z When working in the area of the battery, cover the battery with
isolating material; do not deposit any tools on the battery.
z Use personnel hoists or work platforms that satisfy safety
requirements.
z Stay clear of all rotating and moving parts.
z Relieve the pressure before working on the hydraulic system.
z Always wear protective gloves when handling wire ropes.
z Use only genuine BAUER/SENNEBOGEN spare parts.
z Use only those oils and lubricants that are specified in the lubricants
chart.
z Do not lift heavy components by hand. Use hoists or lifting
equipment.
z Operate the optional battery disconnect switch, if equipped, to
interrupt power supply.
z On completion of the maintenance operations, reinstall all guards
and protective devices.
z Keep the operator’s cab clean and tidy.

BS80/ 10.2005 1 - 11
Safety - Safety Information

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.

1.6.6 Transport
WARNING
Transport of the machine and of the accessories is the responsibility of
the respective carrier as a general principle.

z Observe the applicable cargo securing rules and regulations.

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 Before loading ramps of flatbed trailers are used by crawler-type
machines, provide them 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.

1 - 12 BS80/ 10.2005
 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 Specialist testing, required for crane or backhoe operation

inspections
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 18th 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.

BS80/ 10.2005 1 - 13
Safety - Obligations of the Owner

Risks incurred by Non-observance of the safety notices and messages is dangerous, and
ignoring safety notices 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 z Employ only personnel that has been duly trained or instructed.
qualifications of z Define responsibilities for operation and maintenance.
personnel
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 z Safety of operation of the machine is ensured only when it is used
practices as intended, consistent with the specifications in Section 1.2 of this
instruction.
z The performance limits specified in Chapter 3 TECHNICAL DATA must
not be exceeded.
z When the machine is exposed to risks of falling heavy objects, it
must not be used unless the operator’s station is protected by a
canopy (FOPS structure). The canopy is available from BAUER/
SENNEBOGEN as an option.
Specific dangers The machine operator must check whether the operation gives rise to
specific dangers, e.g. on account of toxic gases, ground quality etc.,
and adopt appropriate measures to avoid or limit those dangers.

Technical condition of It is the obligation of the owner to continuously monitor the overall
the machine 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.

1 - 14 BS80/ 10.2005
 Safety - Obligations of the Owner

Noise protection The permanent sound pressure level of the machine – measured at the
operator’s seat with the operator’s cab closed – is about 80 dB(A).
Wearing of hearing protective devices therefore is not a mandatory
requirement. Measurements are made as specified in EN ISO 11201.
It is possible however that ambient influences cause the level to exceed
85 dB(A), e.g., owing to dropping or transport of material, or in
combination with other machines on a job site.
In such cases, noise protection arrangements for the operating
personnel are a mandatory requirement.
The owner must make sure that adequate hearing protective devices
are available and are worn by the operating personnel.

Genuine BAUER/ Conversions and modifications of the machine are not permitted.
SENNEBOGEN spare This applies also to the installation and use of safety devices and
parts 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 When the machine is employed abroad, take the following precautions:
countries
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 Locations for mounting of a fire extinguisher and a first aid kit have
first aid kit (option) 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.

BS80/ 10.2005 1 - 15
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.

1 - 16 BS80/ 10.2005
 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

1 2 3
1 Machine type (forexample BS 80)
2 Year of manufacture
3 Admissible weight on the front axle (for wheeled carrier)
4 Engine performance specification (in kW)
5 Machine number (Manufacturer’s No.)
6 Admissible overall weight of machine!
7 Admissible weight on the rear axle (for wheeled carrier)

1.9.2 CE symbol of conformity

BS80/ 10.2005 1 - 17
Safety - Warning Signs and Labels on the Machine

1.9.3 Safety signs and warning symbols

1 - 18 BS80/ 10.2005
 Safety - Warning Signs and Labels on the Machine

BS80/ 10.2005 1 - 19
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 - 20 BS80/ 10.2005
 Safety - Hand Signals

1.11 Hand Signals

The operator and the signal person use the hand signals illustrated
below to communicate with each other when view of the work and travel
area is restricted or impaired.
The signal person gives the signals necessary for safe operation.
Safety information Note the safety information before you start work.
CAUTION
z Only reliable persons are qualified to act as signal persons. They
must be informed about their duties before they start working.
z A signal person must not perform any additional functions which
distract him/her from this work.
z Note the information provided in section 35 (Einweiser) of VBG 40
as well as DIN 33409 specifications (Handzeichen zum Einweisen).

Attention
Arm extended upward with hand
open.

Stop
Both arms extended horizontally.

Emergency Stop
Alternately bend and extend both
arms horizontally.

BS80/ 10.2005 1 - 21
Safety - Hand Signals

Drive off
Move upwards extended arm
back and forth with hand open.

Travel slowly forward

Both arms bent, beckon forward
with palms turned inward.

Travel slowly back

Both arms bent, beckon back with
palms turned outward.

Move to the right

Left thumb pointing outward.

1 - 22 BS80/ 10.2005
 Safety - Hand Signals

Move to the left

Right thumb pointing outward.

Swing upper structure to the

right
Left thumb pointing outward,
move right forefinger in horizontal
circle.

Swing upper structure to the

left
Right thumb pointing outward,
move left forefinger in horizontal
circle.

Raise attachment (load)

With right forefinger pointing up,
move left hand up and down.

BS80/ 10.2005 1 - 23
Safety - Hand Signals

Lower attachment (load)

With right forefinger pointing
down, move left hand up and
down.

Increase radius
Both thumbs pointing outward.

Reduce radius
Both thumbs pointing inward.

Open grab
Arm extended horizontally to the
side with hand half open.

1 - 24 BS80/ 10.2005
 Safety - Hand Signals

Close grab
Arm extended horizontally to the
side with hand clenched.

BS80/ 10.2005 1 - 25
Safety - Hand Signals

1 - 26 BS80/ 10.2005
 General View - Overall Machine

2 General View
2.1 Overall Machine

1 2 1.1

1 Upper structure
1.2 1.1 Engine
1.2 Hydraulic system
2 Operator’s station / cab

BS80/ 11.2004 2-1

General View - Engine

2.2 Engine

1 2 3 4 5

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/ 11.2004

 General View - Engine

1 2b 2a 2 3 4 5

1 Main fuse
2 Engine
2a Water separator
2b Fuel filter
3 Charge air cooling system
4 Batteries
5 Battery disconnect switch

6 Coolant cooler

BS80/ 11.2004 2-3

General View - Hydraulic System

2.3 Hydraulic System

1 Hydraulic tank
1 1a 1b 1a Oil level display - hydraulic tank
1b Fuel fill strainer - hydraulic tank
2 Refueling pump
3 Oil cooling

4 Shutt-of flap
5 Power receptacle,
24 volt, 20 amp
4 5 6 6 6 Main control valve
bank

2-4 BS80/ 11.2004

 General View - Hydraulic System

3 1 2 1

1 Swing gear
2 Leakage oil block
3 Brake

BS80/ 11.2004 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/ 11.2004

 General View - Operator´s Station

2.5 Operator´s Station

1 2 3 4 5 6

1 Pedals 4 Emergency switch

2 Safety lever 5 Fuses
3 Water reservoir, window washer 6 Control lever

BS80/ 11.2004 2-7

General View - Operator´s Station

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

2-8 BS80/ 11.2004

 Technical Data - Base Machine

3 Technical Data
For the specifications of the base machine refer to Section 3.1. Section
3.2 provides wind speed information.
Note
For the shipping dimensions and weights of the base machine refer to
Section 8.2. Special attachment system data can be found in the
instruction of the assembly concerned.

3.1 Base Machine

Engine Caterpillar C-15 Diesel Engine

Power output 354 kW (475 HP)
(acc. to ISO9349) at Nominal speed 1800 rpm
Cylinders 6
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
manufacturer’s instruction.

Electrical system 24 volt

Hydraulic system Max. operating pressure 300 bar

Swing drive Swing speed 0 to 3 rpm, infinitely variable

Ambient temperature On the job / Production application ca. - 20°C ... ca. + 40°C

BS80/ 10.2005 3-1

Technical Data - Appendix

3.2 Appendix

Wind Speed
Wind Force Description
Beaufort Name m/s km/h Onshore
number
0 Calm 0-0.2 1 Calm; smoke rises vertically
1 Light air 0.3-1.5 1-5 Direction of wind shown by drifting of smoke but
not by wind vanes
2 Light breeze 1.6-3.3 6-11 Wind felt on the face; leaves rustle; ordinary
vane moved by wind
3 Gentle 3.4-5.4 12-19 Leaves and small twigs in constant motion; wind
breeze extends light flag
4 Moderate 5.5-7.9 20-28 Raises dust and loose paper; twigs and small
breeze branches are moved
5 Fresh breeze 8.0-10.7 29-38 Small trees in leaf begin to sway; crested
wavelets form on inland waters
6 Strong 10.8-13.8 39-49 Large branches in motion; telegraph wires
breeze whistle; umbrellas used with difficulty
7 Moderate 13.9-17.1 50-61 Whole trees in motion
gale
8 Fresh gale 17.2-20.7 62-74 Breaks twigs off trees; generally impedes
progress outdoors
9 Strong gale 20.8-24.4 75-88 Slight structural damage occurs (chimney pots
and slates removed).
10 Whole gale 24.5-28.4 89-102 Trees uprooted; considerable structural
damage occurs.
11 Storm 28.5-32.6 103-117 Widespread storm damage (very rarely
experienced onshore).
12 Hurricane 32.7-36.9 118-133 Devastation occurs

3-2 BS80/ 10.2005

 Preparing to Operate - Safety Information

4 Preparing to Operate
4.1 Safety Information
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 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 operator’s cab as handholds.
z Make sure that there are no persons in the danger area.
z Check the safety features (brakes, signaling and lighting equipment)
of the machine.
z While traveling at slow speed, check the controls and protective
devices for proper operation.

BS80/ 11.2004 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.
Before the machine is put into operation, perform the checks as
specified in Section 4.3.

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 1 Are all guards, protective covers and safety signs and labels in
place on the machine and undamaged?
2 Has the machine been cleaned to the point where dirt fails to
constitute a potential hazard (risk of slippage or falling off; poor
visibility)?
3 Have the windows been cleaned and been cleared of ice and
snow?
4 Is stability of the machine ensured?
5 Is the undercarriage undamaged?
6 Has the correct counterweight (ballast) been fitted?
7 Are the boom components undamaged?
8 Has any maintenance required been performed as specified in
the maintenance schedule?
9 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?

4-2 BS80/ 11.2004

 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?

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/ 11.2004 4-3

Preparing to Operate - Starting the Machine

4.4 Starting the Machine

Safety information 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 operator’s 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 operator’s hips, not over his
stomach.
z Replace the belt after it has been in service for three years.

1 Slide the metal catch (1) into the belt buckle (2).
An audible clicking noise indicates that the belt is locked.
2 To release the belt, push in the red button (3) on the belt buckle
(2).

4-4 BS80/ 11.2004

 Preparing to Operate - Starting the Machine

4.4.2 Starting the Engine

1 Perform the checks as specified in Section 4.3.

2 Insert the key into the starter lock (2) and turn it to position “1“.
– The Slewing gear brake indicator light comes on.
3 Turn the ignition key clockwise in order to start the engine.
4 Use the rotary knob (1) to adjust engine rpm to the desired
speed.
5 Push the safety lever forward if you want to enable the
hydraulic functions.
6 Where applicable, release the slewing gear brake if you want
to rotate the upper structure.
– The Slewing gear brake indicator light goes off.

BS80/ 11.2004 4-5

Preparing to Operate - Starting the Machine

4.4.3 Jump Starting

The machine has a 24-volt starting system. Take care to ensure that
the external power source has the same voltage.

CAUTION
Using a power source that has a higher voltage could result in serious
damage to the electrical system of the machine.

1 Operate optional battery disconnect switch, if equipped, to

interrupt power supply.
2 Remove battery cover as required.
3 Use appropriate jump start cables to connect the positive poles
(+) (1) of the power sources.
4 Use appropriate jump start cables to connect the negative
poles (–) (2) of the power sources.
5 Operate optional battery disconnect switch, if equipped.
6 Start engine as specified in Section 4.4.2.
7 After the engine starts:
– Disconnect jump start cables of the negative poles (–) (2).
– Disconnect jump start cables of the positive poles (+) (1).
8 Refit battery cover where applicable.

1
2

WARNING
When working in the vicinity of batteries, it is prohibited
z to use open flames;
z to cause sparks; and
z to smoke.
When working on the electrical system, take care to observe the
applicable standards and the accident prevention regulations.

4-6 BS80/ 11.2004

 Preparing to Operate - Starting the Machine

4.4.4 Bring Machine up to Operating Temperature

Guidelines for Ambient tem- Warm-up max. engine speed

warm up period perature range period
up to 0 °C approx. 15 min. Nominal speed - 250 min -1
(Nominal speed see Chapter3.1)
0 °C ... -20 °C approx. 30 min.

Note
If the hydraulics are still slow to respond after the warm-up period, oper-
ate 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. 25 °C
z Water: approx. 35 °C.

BS80/ 11.2004 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. 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.

1 Place the machine on a firm surface.

2 Lower suspended loads and lower jib if necessary.
3 Lower engine speed to approx. 50 % of the rated speed to
prevent the engine and cooling system from being damaged.
4 Allow engine to run for a further approx. 5-10 minutes.
5 Turn ignition key to position "0" and remove.
6 If necessary pull back safety lever.
7 Secure the machine area (lights, warning triangle, etc.).

4.6 Taking the machine out of service

Proceed as follows if the machine will be taken out of service for an
extended period of time.

4-8 BS80/ 11.2004

 Operation - Safety Information

5 Operation
5.1 Safety Information
DANGER
z Be sure to observe Chapter 1 SAFETY.
Before the machine is put into operation, perform the checks as
specified in Section 4.3.
z Persons who operate the machine or work on it must have received
adequate training or instruction.
Operation and application must be performed only by persons that
have been duly instructed.
z Make sure that there are no persons in the DANGER area.
z Maintain a safety clearance to overhead lines.
z Operate the machine only while you are in the operator’s seat.
z Do not use the machine for handling of personnel.
z Make due allowance for ambient conditions, e.g., poor visibility,
wind speeds, etc.
z Observe performance specifications.
z Check whether the load capacity of attachment points is adequate.
z Obey the signals given by signal persons, where applicable.
z For any long-distance travel, put the boom in the direction of travel.
z Before leaving the operator’s cab:
– Park the machine on a safe surface. Back off from the edge of an
excavation, where applicable.
– Lower any attached loads to the ground.
– Secure the working attachments.
– Pull the safety lever backward.
– Chock the tires/block the undercarriage.
– Stop the engine.
z Lock the operator’s cab; use warning lamps to mark the machine,
where applicable.

BS80/ 05.2005 5-1

Operation - Operator’s Cab

5.2 Operator’s Cab

1 2 3

1 Release - Door locking device

2 Cab door
3 Door lock
4 Emergency exit - Side window
5 Emergency exit - Front window
The comfortable operator’s 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/ 05.2005

 Operation - Operator’s 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 operator’s 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 operator’s cab. Have the reservoir filled with
antifreeze at all times.
Operator’s seat Information on handling of the operator’s seat is provided in a separate
instruction. The instruction can be found in Chapter 10.

BS80/ 05.2005 5-3

Operation - Machine Controls

5.3 Machine Controls

5.3.1 General View

1 2 3 4 5 6

1 Pedals 4 Emergency switch

2 Safety lever 5 Fuses
3 Water reservoir, window washer 6 Control lever

5-4 BS80/ 05.2005

 Operation - Machine Controls

5.3.2 Emergency Stop

The Emergency Stop switch (1) puts the machine out of operation im-
mediately.

Positionings:
pulled = machine on
pressed = machine off

BS80/ 05.2005 5-5

Operation - Machine Controls

5.3.3 Safety Lever

The safety lever (1) acts as a protective feature.

shown here = safety lever re-

leased (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 acti-

vated (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/ 05.2005

 Operation - Machine Controls

5.3.4 Right-Hand Control Lever

2 3 Push buttons:
1 Option
1 4
2 Option
3 Option
4 Option

Note
For control lever assignment refer to the BAUER documentation.

5.3.5 Left-Hand Control Lever

2 3 Push buttons:
1 Option
1 4
2 Option
3 Option
4 Option

Note
For control lever assignment refer to the BAUER documentation.

BS80/ 05.2005 5-7

Operation - Machine Controls

5.3.6 Pedals

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

5-8 BS80/ 05.2005

 Operation - Machine Controls

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/ 05.2005 5-9

Operation - Machine Controls

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 The bank of keys is fitted with 8 function keys. You can use these keys
(2) 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 2 3 4

n
min

8 7 6 5

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 20°C (hydraulic oil) or below 30°C (coolant)
respectively will not be shown.

5 - 10 BS80/ 05.2005
 Operation - Machine Controls

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.
2 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).
3 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.
2 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/ 05.2005 5 - 11
Operation - Machine Controls

Fault Signaling

LED flashes, Cause Remedy

continuous
alarm sounds Fuel level in tank too – Refuel machine as specified in Section
low 5.6.3.

LED flashes, Cause Remedy

buzzer sounds
Engine overheated – Idle engine.
Cooling fins on engine – Clean cooling fins on oil cooler.
oil cooler dirty
Fan drive loose or – Tighten fan drive, replace if necessary.
defective
Coolant level too low – Add coolant as specified in Section
6.3.5.
Engine switched off – After operating, allow engine to run in
without cooling phase. 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/ 05.2005
 Operation - Machine Controls

LED flashes, Cause Remedy

buzzer sounds
Engine oil pressure too – Stop engine immediately.
low (<1.3 bar) – 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
Overall performance of the machine is reduced to 65%.
When the oil pressure falls below 1.0 bar,
z the pressure 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.

LED flashes, Cause Remedy

buzzer sounds
Hydraulic oil – Operate engine at no load until the
temperature excessive hydraulic oil has cooled down.
(>84°C)
Cooling fins on – Clean cooling fins on oil cooler.
hydraulic oil cooler dirty
Hydraulic oil level too – Check oil level as specified in Section
low 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/ 05.2005 5 - 13
Operation - Machine Controls

Indicator and warning Indicator lights provide information on current operating states, e.g.,
lights (3) Slewing gear brake engaged.
Warning lights come on whenever immediate action has to be taken on
the machine, e.g., Clean air filter.

1 2 3 4 5

10 9 8 7 6

Indicator lights:
1 Slewing gear brake
5 Unassigned
6 Unassigned
8 Shut-off flap - Hydraulic tank

Warning lights:
2 Air filter service indicator
3 Return flow filter - Hydraulic oil
4 Group fault signal - Additional hydraulic filter
7 Hydraulic oil level
9 Coolant level
10 Coolant temperature

5 - 14 BS80/ 05.2005
 Operation - Machine Controls

Fault Signaling

comes on, Cause Remedy

warning signal
sounds Air filter foul/blocked – Clean filter as specified in Section
6.3.4.
– Where necessary, replace filter
element.

comes on Cause Remedy

during engine
operation (3) Hydraulic oil return flow – Replace return flow filter as specified
filter foul/blocked or in Section 6.4.5.
defective

comes on Cause Remedy

during engine
operation (4) Group fault signal - – Replace hydraulic filter (e.g. pilot
Hydraulic filter foul/ control filter as specified in Section
blocked or defective (e.g. 6.4.6.).
Pilot control filter, Hydro -
Clean Superfine-Filter)

comes on, Cause Remedy

warning signal
sounds, engine Hydraulic oil level too low – Add hydraulic oil as specified in
is stopped 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 fun-
ction however (refer to OVERRIDING SHUTDOWN FUNCTION on page 5-16).

comes on Cause Remedy

during engine
operation, Shut-off flap on hydraulic – Open shut-off flap.
warning signal tank closed

BS80/ 05.2005 5 - 15
Operation - Machine Controls

comes on, Cause Remedy

warning signal
sounds, engine Coolant level too low – Add coolant.
is stopped

WARNING
Engine starting is prevented until after the cause of the fault has been
eliminated. In case of emergency, you can override this shutdown fun-
ction however (refer to OVERRIDING SHUTDOWN FUNCTION on page 5-16).

comes on Cause Remedy

during engine
operation, Coolant temperature – Operate engine at no load until the
warning signal excessive coolant has cooled down.
sounds – Where necessary, check and clean
the radiator as specified in Section
6.3.5.

Overriding shutdown This lets you start the engine, even though a fault has been signaled,
function and move the machine out of the danger area.

2 28

2 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/ 05.2005
 Operation - Machine Controls

5.3.8 Right-Hand Control Panel

1
2

11
8
9
12
10 13

1 Intermittent operation - 7 Blower fan

Front window wiper 8 24 volt power receptacle
2 Engine speed control 9 Service hour meter
3 Automatic idling 10 Starter lock/Start engine
4 Air conditioner 11 Skylight wiper
5 Limit load control – 12 Front window wiper
Emergency operation
13 Working light
6 Indicator lights - engine
6a Diagnostic light (yellow)
6b Warning light (red)

BS80/ 05.2005 5 - 17
Operation - Machine Controls

Automatic idling 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

2 Preselect the required RPM for the work application and/or for
travel using the RPM adjustment.
3 Trigger the corresponding work function using the respective
control lever or the drive pedal. The engine switches over im-
mediately from the idling RPM to the preselected RPM.
4 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.

Limit load control – The load limit sensing control monitors the setting of the hydraulic
Emergency operation 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 operator’s 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/ 05.2005
 Operation - Machine Controls

Calibration of the load Recalibrate the load limit sensing controller after hand throttle, foot
limit sensing controller pedal or load limit sensing controller have been replaced.
Note
Calibration by means of the switching entry is possible only during a pe-
riod of no more than 5 minutes after switching on the ignition.
If the calibration was not successful, then the load limit sensing control-
ler must be switched off and then on once again (ignition off/on).

In order to start the calibration, a bridge must be placed between the

red and the blue plug socket (1) to the side of the right-hand control
console.

1 Position both set value potentials (hand throttle, gas pedal) to

minimum.
2 Place bridge between the red and the blue plug sockets. The
LED on the front panel goes out and then comes on again after
one second.
3 Now remove the bridge, the LED on the LLSC becomes dark
again and the learning stage begins (learning stage, i.e., the
engine gives gas – full gas on its own).
4 Wait until the learning stage has been completed (i.e., when
stationary gas has been achieved again) and the LED lights up
again.
5 The bridge between the red and the blue plug sockets shall not
be closed anymore during the learning stage.
6 Position both set value potentials (hand throttle, gas pedal) to
maximum.
7 Place bridge between the red and the blue plug sockets. The
LED goes out and then comes on again after one second.

BS80/ 05.2005 5 - 19
Operation - Machine Controls

8 Now remove the bridge.

The machine will then afterwards return to normal operation.
9 If the LED flashes, then an error has occurred and the proce-
dure must be repeated.

Indicator lamps - Further information is available in the instruction supplied by the engine
engine manufacturer.

WARNING
Eliminate the cause immediately.

5 - 20 BS80/ 05.2005
 Operation - Heating System

5.4 Heating System

1 2 3 3

1 Outside air/ recirculation air

4 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 To defog the cab when moisture has formed on the windows.

Recirculation air mode 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.
Mixed air mode Normal mode of operation.
(neutral position)

BS80/ 05.2005 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 1 Operate engine until it has reached operating temperature.

conditioner
2 Switch on the blower fan at the right-hand control panel.
3 Close the air vents (foot vents) under the operator’s seat.
4 Open air inlet vent at the front window and behind the
operator’s seat.
5 Press switch for air conditioner on the right-hand control panel,
the green control light goes on.
6 Use temperature variable control (2) on the heater to adjust the
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.

5 - 22 BS80/ 05.2005
 Operation - Operating Technique

5.6 Operating Technique

5.6.1 Safety Information

DANGER
z Be sure to observe Chapter 1 SAFETY.
Before the machine is put into operation, perform the checks as
specified in Section 4.3.
z Persons who operate the machine or work on it must have received
adequate training or instruction.
Operation and application must be performed only by persons that
have been duly instructed.
z Make sure that there are no persons in the danger area.
z Maintain a safety clearance to overhead lines.
z Operate the machine only while you are in the operator’s seat.
z Do not use the machine for handling of personnel.
z Make due allowance for ambient conditions, e.g., poor visibility,
wind speeds, etc.
z Observe performance specifications.
z Check whether the load capacity of attachment points is adequate.
z Obey the signals given by signal persons, where applicable.
z For any long-distance travel, put the boom in the direction of travel.
z Before leaving the cabin:
– 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 cabin; use warning lamps to mark the machine, where
applicable.

BS80/ 05.2005 5 - 23
Operation - Operating Technique

5.6.2 Swinging the Upper Structure

To swing the upper structure, use is made of the left-hand control lever.

2
3

c d

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 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 Move the control lever to the neutral (zero) position.
(deceleration) 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 - 24 BS80/ 05.2005
 Operation - Operating Technique

Slewing gear brake The slew gear brake is not an operational brake for braking the super-
structure. 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/ 05.2005 5 - 25
Operation - Operating Technique

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 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 applies, as it could otherwise result in an overflow
of the fuel.

Note
You should also observe the fuel system information provided in the
engine manufacturer’s instruction.

Manually
1 Land any attached loads to the ground.
2 Stop the engine.

3 Open the cover plate at the upper structure.

4 Open cap (1) of the filler neck.
5 Clean the strainer.
6 Install a funnel in the filler neck.

5 - 26 BS80/ 05.2005
 Operation - Operating Technique

7 Fill in fuel carefully through the funnel.

8 Re-close cap (1) and the cover plate.

Using a refueling pump 1 Land any attached loads to the ground.

2 Stop the engine.
3 Move keylock switch to position “P”.
4 Open the service access door.
5 Open the filler neck lid. This tets the air escape from the fuel
tank.

6 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.

2 3

7 Press the green key (2) to turn the refueling pump on.
The tank is filled automatically.

BS80/ 05.2005 5 - 27
Operation - Operating Technique

CAUTION
Take care to avoid the pump running dry (> 30 s).
Where necessary, use the red key (3) to turn off the refueling pump to
prevent damage.

8 Monitor the filling level at the sight gauge of the fuel tank.
The pump cuts out automatically once the tank has been filled
right up.
9 Remove the refueling hose from the external fuel tank and
store it securely.
10 Re-close the filler neck lid.
11 Re-close the service access door.

Should the refueling pump fail to start after about 5 seconds, perform
the following checks:

1 Is battery charge adequate?

2 Are all fuses OK?
3 Is the suction side free of leaks?
4 Is the suction head less than the maximum lift of 3 meters?

5 - 28 BS80/ 05.2005
 Maintenance -

6 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 6.7 provide instructions for maintenance of the
individual assemblies.
Section 6.9 APPENDIX provides additional information such as
maintenance schedule, lubrication points schedule and bolt tightening
torques.

BS80/ 10.2005 6-1

Maintenance - Safety Information

6.1 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.

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/ 10.2005

 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 operator’s 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 structure’s
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.

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/ 10.2005 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 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/ 10.2005

 Maintenance - General Information

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. - 20°C and ca. + 40°C. 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 Use of these materials is mandatory in those cases where leakage of
lubricants 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
Mixing oils, lubrication or operational materials of different types is not
permitted!
Filling or mixing oils, lubricants or any other operational fluids (e.g.
hydraulic oil, transmission oil, motor oil, coolant, etc.) of different types
can lead to chemical reaction damage to machine components. This
damage can in turn result in severe damage to property and to personal
injuries.
Use oils, lubricants and operational fluids that are approved by
SENNEBOGEN only.
Only mix oils, lubricants and operational fluids that are of the same type
or identical (same specifications) from one manufacturer!

BS80/ 10.2005 6-5

Maintenance - General Information

6.2.3 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 Before you begin welding, perform the following preliminary operations:

1 Stop the engine.

2 Operate the optional battery disconnect switch to interrupt
power supply or disconnect the battery.
3 Connect the ground terminal of the welding apparatus directly
to the component to be welded.

6-6 BS80/ 10.2005

 Maintenance - Engine

6.3 Engine
Safety information Note the safety information before you start work.
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 manufacturer’s instruction (Section 10).

BS80/ 10.2005 6-7

Maintenance - Engine

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
Mixing oils, lubrication or operational materials of different types is not
permitted!
Filling or mixing oils, lubricants or any other operational fluids (e.g.
hydraulic oil, transmission oil, motor oil, coolant, etc.) of different types
can lead to chemical reaction damage to machine components. This
damage can in turn result in severe damage to property and to personal
injuries.
Use oils, lubricants and operational fluids that are approved by
SENNEBOGEN only.
Only mix oils, lubricants and operational fluids that are of the same type
or identical (same specifications) from one manufacturer!
Note
Note the information provided in the engine manufacturer’s instruction
(section 10).

Checking engine oil

level

WARNING
Mixing oils, lubrication or operational materials of different types is not
permitted!
Only mix oils, lubricants and operational fluids that are of the same type
or identical (same specifications) from one manufacturer!

6-8 BS80/ 10.2005

 Maintenance - Engine

1 Park the machine on level ground.

2 Operate the engine for about 2 minutes until the system is filled
with oil.
3 Stop the engine.
4 Open the service access door - Engine.
5 Withdraw the oil dipstick (1) and wipe it with a clean lint-free
cloth.
6 Insert the oil dipstick as far as its stop and withdraw it again.
7 Check the oil level:
The oil level must be in the area between the lower mark (MIN)
and the upper mark (MAX).
8 Add engine oil as necessary.

Changing engine oil and

replacing oil filter

WARNING
Mixing oils, lubrication or operational materials of different types is not
permitted!
Only mix oils, lubricants and operational fluids that are of the same type
or identical (same specifications) from one manufacturer!

1 Warm up the engine.

2 Park the machine on level ground.
3 Open the service access doors - Engine.
4 Change the engine oil and replace the oil filter as specified in
the engine manufacturer’s instruction.
5 Check the oil level:
The oil level must be in the area between the lower mark (MIN)
and the upper mark (MAX).
6 Add engine oil as necessary.

BS80/ 10.2005 6-9

Maintenance - Engine

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.

5 4 3 2 1

1 Shut-off valve
2 Quick clamp
3 Casing
4 Filter element
5 Fuel filter

6 - 10 BS80/ 10.2005
 Maintenance - Engine

Draining water
1 Close shut-off valve (1).
2 Open quick clamp (2).
3 Remove water and dirt from the casing (3).
4 Close quick clamp (2).
5 Open shut-off valve (1).

Changing the filter

element
1 Close shut-off valve (1).
2 Remove filter element (4).
3 Insert new filter element.
4 Check cover seal, exchange if necessary.
5 Open shut-off valve (1).

6.3.3 Fuel filter

Changing the fuel filter

5 1
1 Shut-off valve
5 Fuel filter

BS80/ 10.2005 6 - 11
Maintenance - Engine

1 Close shut-off valve (1).

2 Unscrew fuel filter.
3 Clean sealing surfaces.
4 Lightly oil the gasket of the new fuel filter and/or wet with diesel
fuel.
5 Tighten fuel filter by hand.
6 Open shut-off valve (1).

6.3.4 Air Filter

Safety information Note the safety information before you start work.
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 The condition of the air filter is monitored by a sensor.

indicator light 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

1 Loosen wing nut (1) and remove the cap (2).

2 Loosen the nut of the filter insert.

6 - 12 BS80/ 10.2005
 Maintenance - Engine

3 Remove main filter and safety element (3, 4).

4 Blow out the filter elements with dry compressed air
(max. 2 bar) from the inside outwards. Do not damage the car-
tridge in the process.
5 Replace the main filter and safety element (3, 4), if necessary.
6 Insert filter elements (3, 4).
7 Attach nut to filter insert.
8 Put cap (2) on and use wing nut (1) to screw down the cap (2).

6.3.5 Radiator
Safety information Note the safety information before you start work.
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 The filling level of the coolant is monitored by a sensor.

indicator light 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
Mixing oils, lubrication or operational materials of different types is not
permitted!
Only mix oils, lubricants and operational fluids that are of the same type
or identical (same specifications) from one manufacturer!

Checking and cleaning

1 Allow the engine and the radiator to cool.
2 Open the filler cap of the radiator slowly and carefully to relieve
the pressure.

BS80/ 10.2005 6 - 13
Maintenance - Engine

3 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.
4 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.
5 Check the radiator for leaks and for damaged cooling fins.

Note
For change of the coolant, refer to the information provided in the
engine manufacturer’s instruction (section 10).
You should also observe the information and recommendations
provided in the manual „Cleaning the Cooling System“ (Additional
Documentation).

6 - 14 BS80/ 10.2005
 Maintenance - Engine

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 in-
formation provided in the engine manufacture’s operation (Section 10).

BS80/ 10.2005 6 - 15
Maintenance - Hydraulic System

6.4 Hydraulic System

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, 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 immediate-
ly!
z Danger of injury from scalding
The hydraulic oil can reach temperatures of 70°C 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 - 16 BS80/ 10.2005
 Maintenance - Hydraulic System

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/ 10.2005 6 - 17
Maintenance - Hydraulic System

6.4.1 Hydraulic Hose Lines

Time limits for storage Even when stored and used properly, hoses and hose lines are sub-
and use ject 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 dam-
age 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 - 18 BS80/ 10.2005
 Maintenance - Hydraulic System

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.
2 Stop the engine, turn the ignition key back to position “1”
immediately.
3 Operate both control levers in the operator’s cab in all
directions several times. This serves to relieve the pressures
both in the main hydraulic system and in the pilot system
accumulator.

4 Open the cover.

5 Open screw cap (1) of the hydraulic tank.
This serves to relieve the precharge pressure in the tank.

6 Connect a pressure gauge (to a maximum of 600 bar) to the

gauge fittings (2).
7 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/ 10.2005 6 - 19
Maintenance - Hydraulic System

6.4.3 Checking Hydraulic oil Level

WARNING
Mixing oils, lubrication or operational materials of different types is not
permitted!
Only mix oils, lubricants and operational fluids that are of the same type
or identical (same specifications) from one manufacturer!

1 Lower the moving parts as far as possible and land the

attached loads to the ground.
2 Park the machine on level ground.
3 Retract all hydraulic cylinders as far as possible.
4 Stop the engine.
5 Open the service access door - Hydraulic system.

6 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 - 20 BS80/ 10.2005
 Maintenance - Hydraulic System

7 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
Mixing oils, lubrication or operational materials of different types is not
permitted!
Only mix oils, lubricants and operational fluids that are of the same type
or identical (same specifications) from one manufacturer!
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
1 Lower the moving parts as far as possible and land the
attached loads to the ground.
2 Park the machine on level ground.
3 Retract all hydraulic cylinders as far as possible.
4 Relieve hydraulic system pressure as specified in Section
6.4.2.
5 Remove filter element of return flow filter as specified in
Section 6.4.5.

BS80/ 10.2005 6 - 21
Maintenance - Hydraulic System

6 Place a suitable container underneath the drain port of the

tank.
For refill capacity refer to Section 6.9.2.

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.

7 Unscrew cover nut (1).

8 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.
9 Screw drain plug (2) back out.
10 Screw cover nut (1) back on.

6 - 22 BS80/ 10.2005
 Maintenance - Hydraulic System

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/ 10.2005 6 - 23
Maintenance - Hydraulic System

6.4.5 Return Flow Filter – Replacing Filter Element

1 2 3 4

1 Open screw cap (1) of the hydraulic tank.

This serves to relieve the precharge pressure in the tank.
2 Unscrew the four hexagon nuts (2) and the hexagon bolt (3).
3 Remove cover (4).
4 Withdraw the filter element and dispose of as hazardous
waste.
5 Clean the components; check the seal and replace if
necessary.
6 Install a new filter element.
7 Screw down cover (4) by means of the four hexagon nuts (2)
and the hexagon bolt (3).
8 Tighten screw cap (1).

6 - 24 BS80/ 10.2005
 Maintenance - Hydraulic System

6.4.6 Pilot Control Filter – Replacing Filter Element

1 Open the service access door - Engine.

2 Place a suitable receiving container underneath.

3 Unscrew the head screw (1) at the cover and remove the co-
ver.
4 Withdraw the filter element (2) and dispose of as hazardous
waste.
5 Clean the components; check the seal and replace if
necessary.
6 Fit new filter element (2) into filter housing (3).
7 Screw down cover by means of the head screw (1).
8 Check the filter for leaks.

BS80/ 10.2005 6 - 25
Maintenance - Hydraulic System

6.4.7 Leakage Oil Filter – Replacing Filter Element

1
2

1 Loosen hexagon nuts (1).

2 Remove cover (2).

3 Unscrew filter element (3) from the return tube.

4 Screw a new filter element to the return tube.
5 Install the cover (2) with the return tube in the tank.
6 Tighten hexagon nuts (1).

6 - 26 BS80/ 10.2005
 Maintenance - Hydraulic System

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 under-
pressure 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.

1 Open screw cap (1) of the hydraulic tank.

This serves to relieve the precharge pressure in the tank.
2 Pull of filter element (2) from the screw cap (1).
3 Dispose of filter element (2) as hazardous waste.
4 Fit new filter element (2) in the screw cap (1).
5 Screw on screw cap (1) complete with new breather filter.

BS80/ 10.2005 6 - 27
Maintenance - Hydraulic System

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.

1 Use dry filtered compressed air (max. 2 bar) to blow-clean the

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

6 - 28 BS80/ 10.2005
 Maintenance - Hydraulic System

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 Lower the moving parts as far as possible and land the

attached loads to the ground.
2 Connect a pressure gauge to the PV fitting at the test panel.
3 Stop the engine, turn the ignition key back to position “1”
immediately.
4 Operate both control levers in the operator’s cab in all
directions several times.
5 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.
6 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.
7 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/ 10.2005 6 - 29
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.

3
2

1 Vent plug
2 Oil dipstick
3 Oil filling hole
4 Oil drain plug

6 - 30 BS80/ 10.2005
 Maintenance - Distributor Gear

6.5.1 Checking Oil Level

WARNING
Mixing oils, lubrication or operational materials of different types is not
permitted!
Only mix oils, lubricants and operational fluids that are of the same type
or identical (same specifications) from one manufacturer!

1 Park the machine on level ground.

2 Stop the engine.
3 Open vent plug (1).
4 Unscrew oil dipstick (2).
The oil level should be at the Max. notch on the oil dipstick.
5 Add gear oil as necessary. (For specification refer to
Lubricants Chart)
6 Re-install and tighten vent plug (1) and oil dipstick (2).

6.5.2 Changing Gear Oil

WARNING
Mixing oils, lubrication or operational materials of different types is not
permitted!
Only mix oils, lubricants and operational fluids that are of the same type
or identical (same specifications) from one manufacturer!

1 Park the machine on level ground.

2 Stop the engine.
3 Place a suitable receiving container underneath oil drain plug
(4). For refill capacity refer to Section 6.9.2.
4 Unscrew vent plug (1) and oil dipstick (2).
5 Unscrew oil drain plug (4) and collect the spent oil in the
container.
6 Clean the components; check the seals and replace if
necessary.
7 Re-install and tighten oil drain plug (4).
8 Fill in new gear oil by way of oil filling hole (3).
9 Re-install and tighten oil dipstick (2) and vent plug (1).
10 Re-check the oil level after 2 service hours.

BS80/ 10.2005 6 - 31
Maintenance - Slewing Ring

6.6 Slewing Ring

6.6.1 Lubricate the ball-type swing gear and bearing

WARNING
Mixing oils, lubrication or operational materials of different types is not
permitted!
Only mix oils, lubricants and operational fluids that are of the same type
or identical (same specifications) from one manufacturer!
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.

1 Stop the engine.

2 Open the service access door - Engine.
3 Lubricate the nipples (1) until grease emerges at the sealing
lips.
4 Rotate the upper structure several times in either direction to
allow the grease to spread out evently.
5 The operation must be continued until the ball-type swing gear
and bearing is complete filled with grease.

6 - 32 BS80/ 10.2005
 Maintenance - Slewing Ring

6.6.2 Lubricating the gear teeth

WARNING
Mixing oils, lubrication or operational materials of different types is not
permitted!
Only mix oils, lubricants and operational fluids that are of the same type
or identical (same specifications) from one manufacturer!

1 Stop the engine.

2 Thoroughly clean the gearing.
3 Check slewing ring and swing drive pinion for wear; replace if
necessary.
4 Use BAUER/SENNEBOGEN gear spray to spray the gear
teeth from a distance of approx 30 cm.
5 Rotate the upper structure several times for the lubricating
layer to spread out evenly over the gearing.

BS80/ 10.2005 6 - 33
Maintenance - Slewing Ring

6.6.3 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 fur-
ther bolts. It is therefore necessary to go round at least twice.
z Ideally tighten bolts over M30 with a hydraulic screw tension cylin-
der.

6 - 34 BS80/ 10.2005
 Maintenance - Electrical System

6.7 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.

6.7.1 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.

Check the terminals and cable connections of the batteries:

1 Open the service access door - Engine.

2 Change over battery disconnect switch (1).
3 Clean the terminals and cable connections of the batteries (2).
Verify that they are firmly secured in place and coat them with
petroleum jelly.
4 Restore battery disconnect switch (1) to its initial position.

BS80/ 10.2005 6 - 35
Maintenance - Electrical System

6.7.2 Fuses
DANGER
Fire hazard!
Fuses must not be repaired. Always install new fuses of the same
ampere rating.

1 Stop the engine.

2 Remove cover (1).
3 Replace the defective fuse.
4 Check the contacts, clean any oxidized contacts.
5 Re-install cover (1).

6 - 36 BS80/ 10.2005
 Maintenance - Heating System

6.8 Heating System

Cleaning filter element
1

1 Unscrew knurled screws (1) at the back of the operator’s seat.

2 Remove cover (2).

3 Take out filter element (3).

4 Tap out the filter element or blow it out carefully by means of
compressed air.
5 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/ 10.2005 6 - 37
Maintenance - Appendix

6.9 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 in-
struction.
z Wearing personnel equipment (for example Helmet, protective
gloves, protective shoes).

6.9.1 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 every once after every every every Section

10 sh*/ 50 sh* / 250 sh/ 500 sh* / 1000 sh*/ 2000 sh*/
daily weekly 6weeks 3months 1 year 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. ‡ ‡ ‡ ‡ ‡ ‡ 6.3.1
Observe intervals specified in
engine manufacturer’s manual.
– Coolant level – check; clean ‡ ‡ ‡ ‡ ‡ ‡ 6.3.5
cooling fins, if necessary.
– Hydraulic system – check oil ‡ ‡ ‡ ‡ ‡ ‡ 6.4.3
level.
– Slewing ring – lubricate. ‡ ‡ ‡ ‡ ‡ ‡ 6.6
– Distributor gear – Check oil ‡ ‡ ‡ ‡ ‡ 6.5
level.
– Hydraulic oil cooler – check and ‡ ‡ ‡ ‡ ‡ 6.4.9
clean.

6 - 38 BS80/ 10.2005
 Maintenance - Appendix

Operation every every once after every every every Section

10 sh* / 50 sh* / 250 sh*/ 500 sh* / 1000 sh*/ 2000 sh*/
daily weekly 6weeks 3months 1 year 2 years

– Swivelling connection: ‡ ‡ ‡ ‡ ‡
Visually check all connecting
elements for damage and
corrosion
– Battery cable connections and ‡ ‡ ‡ ‡ ‡ 6.7
fuses – check.
– Heating system filter – check. ‡ ‡ ‡ ‡ ‡ 6.8
– Shut-off flap -hydraulic tank: ‡ ‡ ‡ ‡
visual check of leckage
– Lubrication points – grease. ‡ ‡ ‡ ‡ ‡
– Radiator – clean. ‡ ‡ ‡ ‡ ‡ 6.3.5
– Hydraulic accumulator pre- ‡1) ‡1) ‡1) ‡1) 6.4.10
charge pressure - have it
checked by a hydraulics spe-
cialist 1).
1)
After 250 sh*/6 weeks and after 500 sh*/3 month; then every 1000 sh*/1 year
– Observe engine intervals. ‡ ‡ ‡ ‡
– All screwed/bolted connections ‡ ‡ ‡ ‡
– verify firm seating.
– Antifreeze content – check. ‡ ‡ ‡ ‡ 6.3.5
– Distributor gear – change oil. ‡ ‡ ‡ 6.5
– Retighten slewing ring bolts2). ‡2) ‡2) 6.6
2) After 250 sh*/6 weeks, then every 2000 sh*/yearly
– Return flow filter - replace filter ‡ ‡ 6.4.5
element .
– Leakage oil filter – replace filter ‡ ‡ 6.4.7
element.
– Pilot control filter – replace filter ‡ ‡ 6.4.6
element.
– Slewing ring bolts –check of ‡ ‡ ‡
verify firm seating with suitable
device.

BS80/ 10.2005 6 - 39
Maintenance - Appendix

Operation every every once after every every every Section

10 sh* / 50 sh* / 250 sh*/ 500 sh* / 1000 sh*/ 2000 sh*/
daily weekly 6weeks 3months 1 year 2 years

– Ventilation filter-hydraulic tank: ‡ ‡ ‡

visual check for dirt and
damage, change if necessary.
– Primary and secondary filter el- ‡ ‡ 6.3.4
ements of air filter – replace.
– Filter element of ventilation filter ‡ ‡ 6.4.8
on hydraulic tank – replace.
– Heating system/airconditioner ‡ ‡ 6.8
(option):
check for adequately trained
skilled person only.
– Coolant – change. ‡ 6.3.5
– Hydraulic system – change ‡3) 6.4.4
oil3).
3)
If necessary, have the oil checked via an oil diagnosis by SENNEBOGEN customer service
– Slewing ring fixing bolts - ‡4) 6.6
check and change 4)
4) every 5000 sh* / 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.

6 - 40 BS80/ 10.2005
 Maintenance - Appendix

6.9.2 Refill Capacities

WARNING
Mixing oils, lubrication or operational materials of different types is not
permitted!
Only mix oils, lubricants and operational fluids that are of the same type
or identical (same specifications) from one manufacturer!
The capacities shown below are approximate values. What matters is
the filling level indicated on the compartment concerned.

Assembly or Compartment Quantity

Engine refer to manufacturer’s
manual
Fuel tank approx 775 l
Hydraulic tank approx 660 l
Overall hydraulic system approx 920 l
Distributor gear approx. 8,5 l
Slewing ring gearing as required
Central lubrication system as required
Lubrication points as required

BS80/ 10.2005 6 - 41
Maintenance - Appendix

6.9.3 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 Standard Thread Fine Thread

Screw Tightening torque Screw Tightening torque
MA [Nm] 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 - 42 BS80/ 10.2005
 Maintenance - Appendix

Strength grade 10.9 Standard Thread Fine Thread

Screw Tightening torque Screw Tightening torque
MA [Nm] 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/ 10.2005 6 - 43
Maintenance - Appendix

Strength grade 12.9 Standard Thread Fine Thread

Screw Tightening torque Screw Tightening torque
MA [Nm] 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 - 44 BS80/ 10.2005
 Setting Up - Detaching/Attaching Counterweight

7 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 Detaching/Attaching Counterweight

Preconditions Second person present for instructing and bolting.

Safety notes Observe the safety notes before starting work.

DANGER
z Accident risk through tipping of machine!
The machine is not operational with counterweight removed.
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 coun-
terweight.
Keep a safe distance.
z Only attach or dismantle 10,5 t counterweight completely.
z Multiple-section counterweights should be transported upright at all
times. They could be damaged if laid on their sides.
z Installing /Removing counterweights individually.
z Secure the bolt (3,4,7) with “Loctite 270” each time you mount the
counterweight!
Follow the instructions on the “Loctite” package!

BS80/ 11.2004 7-1

Setting Up - Detaching/Attaching Counterweight

7.1.1 Detaching Counterweight

DANGER
Before releasing or dismantling safety components, secure the coun-
terweights to prevent them from tipping or falling down.

A
1

A A-A

1 Attach suitable sling devices to the lifting equipment and to the

lifting points (1) of the 10,5 t counterweight (2).
2 Lightly tension sling devices.
3 Slacken hexagon screw (3).
4 Slacken securing bolts (4) on underside of machine. Keep bolts
in a safe place.

DANGER
Do not walk under suspended loads.

7-2 BS80/ 11.2004

 Setting Up - Detaching/Attaching Counterweight

5 Lower 10,5 t counterweight (2) safely using lifting equipment

and secure against tipping.

6 Attach suitable sling devices to the lifting equipment and to the

lifting points (5) of the 5,3 t counterweight (6).
7 Lightly tension sling devices.
8 Slacken securing bolts (7) on underside of machine. Keep bolts
in a safe place.
9 Lower 5,3 t counterweight (6) safely using lifting equipment and
secure against tipping.

BS80/ 11.2004 7-3

Setting Up - Detaching/Attaching Counterweight

7.1.2 Attaching Counterweight

1 Attach suitable sling devices to the lifting equipment and to the

lifting points (5) of the 5,3 t counterweight (9).
2 Lightly tension sling devices.

DANGER
Do not walk under suspended loads.

3 Hoist counterweight (6) onto machine using lifting equipment.

4 Lightly tension sling devices.
5 Bolt ballast to rear panel of the machine using both bolts (7).

DANGER
Tighten the bolts (7) with a torque wrench.
Tighten with torque of 1500 Nm.

7-4 BS80/ 11.2004

 Setting Up - Detaching/Attaching Counterweight

A
1

A A-A

6 Attach suitable sling devices to the lifting equipment and to the

lifting points (1) of the 10,5 t counterweight (2).
7 Lightly tension sling devices.
8 Hoist counterweight (2) onto machine using lifting equipment.
9 Bolt ballast to rear panel of the machine using both bolts (4).
10 Secure counterweight to rear panel of the machine with the he-
xagon screw (3) provided.
11 Tighten bolt (3) with torque wrench to tightening torque
2350 Nm.

WARNING
Secure the bolt (3) with “Loctite 270” each time you mount the
counterweight!
Follow the instructions on the “Loctite” package!

BS80/ 11.2004 7-5

Setting Up - Detaching/Attaching Counterweight

DANGER
Tighten the bolts (3) and (4) with a torque wrench.
Tighten with torque of 1500 Nm.

7-6 BS80/ 11.2004

 Transport -

8 Transport
Preliminary operations Transport the machine by means of a flatbed trailer. 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/ 11.2004 8-1

Transport - Safety Information

8.1 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/ 11.2004

 Transport - Dimensions and Weights

8.2 Dimensions and Weights

8.2.1 Dimensions

BS80/ 11.2004 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)

5,3 t 10,5 t
Weight [kg] 5300 10500
Length [mm] 3000 3000
Width [mm] 200 563
Height [mm] 1500 1500

8-4 BS80/ 11.2004

 Transport - Lifting the Machine

8.3 Lifting the Machine

Safety information Note the safety information before you start work.
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 5,4 t

7,1 t 8,3 t

BS80/ 11.2004 8-5

Transport - Lifting the Machine

1 Select an appropriate lifting crane and proper rated sling

devices. Allow for the machine weight and center of gravity.
2 Fasten the sling devices to the lifting points.
3 Carefully lift the machine.

DANGER
People must keep clear of the area under a suspended load!

8-6 BS80/ 11.2004

 Transport - Lashing and Tying Down the Machine

8.4 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.

BS80/ 11.2004 8-7

Transport - Lashing and Tying Down the Machine

8-8 BS80/ 11.2004

 Troubleshooting - Engine

9 Troubleshooting
WARNING
z Be sure to observe Chapter 1 SAFETY.
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 Cause Remedy

Battery capacity – Check electrolyte level of batteries.
inadequate – 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 – Pull out the Emergency Stop switch.
pressed
Shut-off flap on hydraulic – Open shut-off flap.
tank closed or not correct
opened

Loss of engine power Cause Remedy

Suction resistance – Replace filter element of water
excessive separator.

Machine fails to move Cause Remedy

Parking brake applied – Release parking brake.
Transmission/gear – Have the fault corrected.
defective

BS80/ 11.2004 9-1

Troubleshooting - Engine

Oil or fuel leaks at the Cause Remedy

engine
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
manufacturer’s instruction.

9-2 BS80/ 11.2004

 Troubleshooting - Hydraulic System

9.2 Hydraulic System

Oil leaks at the Cause Remedy

hydraulic system
Loose hose – Tighten hose connections.
connections
Hoses or seals – Replace hoses or seals.
damaged

Hydraulic pump fails to Cause Remedy

operate
Fault in pump circuit – Have fault investigated and corrected
by a hydraulics specialist.

No functions, or Cause Remedy

malfunctioning, of the
working equipment Hydraulic oil level too – Check hydraulic oil level.
low – Add hydraulic oil as necessary.
Leaks in the hydraulic – Check the working cylinders,
system connections, fittings and hoses for
leaks.
– Have the fault corrected by a hydraulics
specialist.
Fault in one of the – Have the fault corrected by a hydraulics
attachment operation specialist.
circuits

Working cylinder Cause Remedy

movement produces
noises Lack of lubricant film on – Have cylinder repaired by a hydraulics
cylinder piston rod specialist.

BS80/ 11.2004 9-3

Troubleshooting - Hydraulic System

No or inadequate output Cause Remedy

of the hydraulic system
Loose hose – Tighten hose connections.
connections
Hoses or seals – Replace hoses or seals.
damaged
Relief valve opens – Have the fault corrected by a hydraulics
prematurely specialist.
Hydraulic pump worn or – Have pump replaced by a hydraulics
defective specialist.

Noises at the hydraulic Cause Remedy

system
Hydraulic pump sucks – Check hydraulic oil level.
in air – Have the fault corrected by a hydraulics
specialist.
Oil delivery of hydraulic – Check hydraulic oil level.
pump is inadequate – Add hydraulic oil as necessary.
Relief valve knocking – Have the fault corrected by a hydraulics
specialist.

9-4 BS80/ 11.2004

 Troubleshooting - Electronic System

9.3 Electronic System

Loss of power – Limit Cause Remedy

load control LED
flashing Fault in electronic – Emergency operation (refer to “LIMIT
system LOAD CONTROL – EMERGENCY
OPERATION” on page 5-18).
– Inform service department.

BS80/ 11.2004 9-5

Troubleshooting - Sennebogen diagnositc system SDS

9.4 Sennebogen diagnositc system SDS

9.4.1 Bank of keys with LEDs

LED flashes, Cause Remedy

continuous
alarm sounds Fuel level in tank too – Refuel machine as specified in
low Abschnitt 5.6.3.

LED flashes, Cause Remedy

buzzer sounds
Engine overheated – Idle engine.
Cooling fins on engine – Clean cooling fins on oil cooler.
oil cooler dirty
Fan drive loose or – Tighten fan drive, replace if necessary.
defective
Coolant level too low – Add coolant as specified in Abschnitt
6.3.5.
Engine switched off – After operating, allow engine to run in
without cooling phase. 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.

9-6 BS80/ 11.2004

 Troubleshooting - Sennebogen diagnositc system SDS

LED flashes, Cause Remedy

buzzer sounds
Engine oil pressure too – Stop engine immediately.
low (<1.3 bar) – Check engine oil level as specified in
Abschnitt 6.3.1.
– Add engine oil as necessary.
– If fault continues to occur, inform the
BAUER/SENNEBOGEN service
department accordingly.

Note
Overall performance of the machine is reduced to 65%.
When the oil pressure falls below 1.0 bar,
z the pressure 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.

LED flashes, Cause Remedy

buzzer sounds
Hydraulic oil – Operate engine at no load until the
temperature excessive hydraulic oil has cooled down.
(>84°C)
Cooling fins on – Clean cooling fins on oil cooler.
hydraulic oil cooler dirty
Hydraulic oil level too – Check oil level as specified in Abschnitt
low 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/ 11.2004 9-7

Troubleshooting - Sennebogen diagnositc system SDS

9.4.2 Indicator and warning lights

comes on, Cause Remedy

warning signal
sounds Air filter foul/blocked – Clean filter as specified in Abschnitt
6.3.4.
– Where necessary, replace filter
element.

comes on Cause Remedy

during engine
operation (3) Hydraulic oil return flow – Replace return flow filter as specified
filter foul/blocked or in Abschnitt 6.4.5.
defective

comes on Cause Remedy

during engine
operation (4) Group fault signal - – Replace hydraulic filter (e.g. pilot
Hydraulic filter foul/ control filter as specified in Abschnitt
blocked or defective (e.g. 6.4.6.).
Pilot control filter, Hydro -
Clean Superfine-Filter)

comes on, Cause Remedy

warning signal
sounds, engine Hydraulic oil level too low – Add hydraulic oil as specified in
is stopped Abschnitt 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 fun-
ction however (refer to “SENNEBOGEN DIAGNOSTIC SYSTEM (SDS)” on
page 5-9).

comes on Cause Remedy

during engine
operation, Shut-off flap on hydraulic – Open shut-off flap.
warning signal tank closed

9-8 BS80/ 11.2004

 Troubleshooting - Sennebogen diagnositc system SDS

comes on, Cause Remedy

warning signal
sounds, engine Coolant level too low – Add coolant.
is stopped

WARNING
Engine starting is prevented until after the cause of the fault has been
eliminated. In case of emergency, you can override this shutdown fun-
ction however (refer to “SENNEBOGEN DIAGNOSTIC SYSTEM (SDS)” on
page 5-9).

comes on Cause Remedy

during engine
operation, Coolant temperature – Operate engine at no load until the
warning signal excessive coolant has cooled down.
sounds – Where necessary, check and clean
the radiator as specified in Abschnitt
6.3.5.

Switches do not work

Cause Remedy
Fuse defective – Replace fuse.
Switch faulty or fault in – Have fault inspected and rectified by an
circuit electrical engineer.

BS80/ 11.2004 9-9

Troubleshooting - Heating System

9.5 Heating System

No or inadequate heater Cause Remedy

output
Water inlet temperature – Operate engine to warm it up.
too low – Replace thermostat (with air conditioner
fitted).
Thermostat on vehicle – Replace vehicle thermostat.
defective
Water valve fails to – Check valve and valve control; replace
open as necessary. Mind the direction of flow.
Heat exchanger louvers – Clean heat exchanger.
dirty
Filter foul/blocked – Clean filter; replace if necessary.
No air flow – See below.

No air flow Cause Remedy

Fuse failed – Replace fuse.
Power supply – Check wiring for loose contacts or open
interrupted circuits.
Blower motor defective – Have blower motor replaced.
Blower switch defective – Check switch, replace if necessary.
Resistor defective – Have resistor replaced.

Heater will not turn off Cause Remedy

Bowden cable for water – Re-adjust Bowden cable.
valve maladjusted
Heater valve not – Check direction of flow at the valve;
mounted properly where necessary, exchange inlet/return
flow.
Control and/or Bowden – Replace control or Bowden cable
cable defective respectively.

9 - 10 BS80/ 11.2004
 Troubleshooting - Air Conditioner

9.6 Air Conditioner

Cooling efficiency Cause Remedy

inadequate
Fuse failed – Replace fuse.
Power supply – Check wiring for loose contacts or open
interrupted circuits.
Pressure switch – Have pressure switch replaced.
defective
Refrigerant line broken – Have line replaced.
Expansion valve – Have customer service replace the
sticking valve.
Compressor clutch – Have customer service replace the
slipping clutch.
Air filter foul/blocked – Clean air filter.

Air conditioner cooling Cause Remedy

intermittently
Compressor clutch – Have customer service replace the
slipping clutch.
Temperature variable – Replace temperature variable control.
control defective
System iced – Have air conditioner checked by the
customer service.
Blower switch defective – Check switch, replace if necessary.

Air conditioner Cause Remedy

extremely noisy
Compressor clutch – Have customer service replace the
slipping clutch.
V-belts loose or worn – Increase V-belt tension or replace V-
belt.
System overcharged – Have refrigerant extracted by the
customer service.
Lack of refrigerant in the – Have customer service check the
system system for leaks.
– Have system charged with refrigerant.

BS80/ 11.2004 9 - 11
Troubleshooting - Cab

No function of the con- Cause Remedy

tol lamp of the
selected air condi- Refrigerant too low – Have customer service check the
tioning system for leaks.
– Have system charged with refrigerant.
Power supply – Check wiring for loose contacts or open
interrupted circuits.
Pressure switch – Have pressure switch replaced.
defective
Pressure switch is out – Reduce overpressure.
Thermostat defective – Have customer service replace the ther-
mostat.
Thermostat is out – Ambient temperature </= 5°C.

9.7 Cab

Cab moves or swings Cause Remedy

drastically
Cab mounting or cab – Check all connection elements, bolts
fastening damaged and pins of cab mounting and fastening
for damage, cracks or deformation.
– Have damaged components replaced
immediately by trained and instructed
specialist personnel.

9 - 12 BS80/ 11.2004
 Appendix - List of abbreviations

10 Appendix
10.1List of abbreviations

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

BS80/ 11.2004 10 - 1
Appendix - List of abbreviations

10 - 2 BS80/ 11.2004
 Index

A E 5-18
Abuse 1-3 Emergency exit 5-2 List of abbreviations 10-1
Adding hydraulic oil 6-21 Emergency Stop 5-5
Adjusting time of day 5-11 Employment in foreign M
Automatic idling 5-18 countries 1-15 Machine number 1-17
Automatic speed control 5-18 Engine Main fuse 2-3
Changing oil 6-9 Misuse 1-2
B Engine speed control 5-17 Multiple disc brake 5-25
ballast 8-4 environmental protection
Bank of keys 5-10 1-20 N
Battery disconnect switch Environmental regulations National regulations 1-1
2-3, 6-35 1-20 National rules and
Biological oils 6-5 regulations 1-1
Bolt strength grades 6-42 F Noise protection 1-15
Fax Not-Aus 2-7, 5-4
C Customer service 1-7
Calibration of the load limit Documentation 1-7 O
sensing controller 5-19 Spare parts warehouse Oil analysis 6-5
CE certificate of conformity 1-7 Oil filler neck 6-21
1-8, 1-17 Fire extinguisher 1-15 Operator’s work station 1-2
CE symbol 1-8 First aid kit 1-15 Overhead lines 1-6
Checking hydraulic oil level Fuses 6-36 Overriding shutdown function
6-20 5-16
Cleaning hydraulic cylinders G
6-17 Gauge fittings 6-19 P
Conversion of the machine Permanent sound pressure
1-15 H level 1-15
Copyright 1-8 Hand signals 1-21 Permissible total weight 1-17
Counterweight 8-4 High voltage contact 1-6 Personal protective
Crushing hazards 1-4 Hydraulic fittings 6-17 equipment 1-5
Current when going to press Personnel qualifications 1-14
1-2 I Personnel selection 1-14
Customer service 1-7 Illustration aids 1-3 Potential instances of misuse
Inadmissible operating 1-2
D practices 1-14 Preparing to operate
Danger area 1-4 Indicator lights 5-14 Checklist 4-2
Declaration of conformity 1-8 International regulations 1-1 Pressure cylinders 6-17
Description
Effects of wind 3-2 J Q
Display (SDS) 5-10 Jump starting 4-6 Qualifications of personnel
Disposal 1-20 1-7
K
Batteries 1-20
Keyword 1-3 R
Disposal Guideline 75/439/
Release (cab door) 5-2
EEC 1-20 L Relieving hydraulic system
Disposal of consumables LEDs 5-10 pressure 6-19
1-20 Lifting points 8-5 Replacing oil filter 6-9
Disposing of batteries 1-20 Limit load control – Resetting daily service hour
Disposing of lubricants 1-20 Emergency operation meter 5-11
Disposing of the oil filter 1-20

BS80/ 10.2005 S-1

Index

Residual hazards 1-3 Wind speed 3-2

Riementriebe 6-15
Y
S Year of manufacture 1-17
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, 6-17
Slewing gear brake 5-25
Spare parts catalog 1-5
Spare parts warehouse 1-7
Specialist check 1-13
Specific dangers 1-14
Stability 1-5
Subdivision of the operating
instructions 1-5
Swinging the upper structure
5-24
Switching off engine 4-8

T
Taking the machine out of
service 4-8
Target group 1-5, 1-2
Telephone 1-7
The maintenance
instructions 1-5
Tie-down points 8-7
Tightening torque 6-42
Type plate 1-17

U
Upper structure swing 5-24
Use as intended 1-2

W
Warm-up period 4-7
Warning lights 5-14, 9-8
Warning symbol 1-3
Warranty conditions 1-15
Warranty manual 1-15
Water separator 6-11
Wind force 3-2

S-2 BS80/ 10.2005