Sennebogen S825M Materials Operators Manual PDF

Operation and Maintenance Manual
S 825 M
Materials Handling
825.0.315 / 09.2002
Foreword
Target group This manual serves to familiarize operators of a Sennebogen materials

handling machine with putting into service, operation, maintenance and
transport. For detailed information on the necessary previous
experience and qualifications of the users/operators refer to Chapter 1
SAFETY in this manual.
Notes on the Operation Read and understand the Operation Manual, and Chapter 1 SAFETY in
Manual particular, before using and operating the machine.
Store the Operation Manual for future use and reference.
Warning!
Do not use or operate the machine until you have read and
completely understood this Operation Manual.
Be sure to observe the load rating charts in Section 3.2.
Refrain from any unsafe operating or maintenance practices.
Setup, operation and maintenance of the machine is not permitted
unless effected by duly instructed personnel. Qualification and
training of the personnel is the responsibility of the owner/user.
This Operation Manual must be available in the operator’s cab at all
times.
In some figures, the guards and protective devices specified have been
omitted for sake of clarity in the illustrations. Machine operation with
guards or protective devices removed is prohibited!
Danger
Before operating the machine, be sure to fit the guards or protective
devices.
Currency at time of State-of-the-art technology and the high quality level of our machines
printing are being ensured by ongoing product development. This might
possibly have caused changes to your machine which are not included
in this Operation Manual. Also we cannot rule out the possibility of
inadvertent errors. We ask for your understanding of the fact that no
legal claims can be deduced from the data, illustrations and
descriptions contained in this manual.
Copyright © Straubing 2002 Sennebogen Maschinenfabrik GmbH

No part of this publication may be reproduced without the prior written
permission of Sennebogen Maschinenfabrik GmbH, Straubing,
Germany.
Printed in Germany.
Contents
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Use as Intended . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 Abuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.4.3 Commissioning . . . . . . . . . . . . . . . . . . . . . . 1-9
1.4.4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.4.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.5 Obligations of the Owner . . . . . . . . . . . . . . . . . . . 1-12
1.6 Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.7 Warning Signs and Labels on the Machine . . . . . 1-16
1.8 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.9 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
2 General View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 Overall Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Outriggers (Option) . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Upper Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5 Operator’s Station . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Base Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Load Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
4 Preparing to Operate . . . . . . . . . . . . . . . . . . . . . . . . . . 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
4.4.2 Starting the Engine . . . . . . . . . . . . . . . . . . . 4-5
4.4.3 Stopping the Engine . . . . . . . . . . . . . . . . . . 4-5
4.4.4 Jump Starting . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.5 Warming Up the Machine to
Operating Temperature . . . . . . . . . . . . . . . . 4-7
S 825 M / 09.2002 0-1

Contents
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.1 Hydraulically Adjusting Operator’s Cab . . . . 5-3
5.2.2 Emergency Lowering . . . . . . . . . . . . . . . . . . 5-6
5.3 Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.3.1 General View . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.3.2 Left-Hand Control Lever . . . . . . . . . . . . . . . 5-9
5.3.3 Right-Hand Control Lever . . . . . . . . . . . . . 5-10
5.3.4 Safety Lever . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.3.5 Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.3.6 Steering Column . . . . . . . . . . . . . . . . . . . . 5-12
5.3.7 Sennebogen Diagnostic System (SDS) . . . 5-13
5.3.8 Right-Hand Control Panel . . . . . . . . . . . . . 5-20
5.3.9 Central Lubrication System (Option) . . . . . 5-23
5.4 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5.5 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . 5-25
5.5.1 Air Conditioner (Option) . . . . . . . . . . . . . . . 5-25
5.6 Operating Technique . . . . . . . . . . . . . . . . . . . . . . 5-26
5.6.1 Safety Information . . . . . . . . . . . . . . . . . . . 5-26
5.6.2 Boom Stop (Option) . . . . . . . . . . . . . . . . . . 5-27
5.6.3 Stick Limiting Stops (Option) . . . . . . . . . . . 5-28
5.6.4 Traveling the Machine . . . . . . . . . . . . . . . . 5-31
5.6.5 Stabilizing the Machine . . . . . . . . . . . . . . . 5-32
5.6.6 Swinging the Upper Structure . . . . . . . . . . 5-34
5.6.7 Lifting/Lowering Loads . . . . . . . . . . . . . . . 5-36
5.6.8 Grab Operation . . . . . . . . . . . . . . . . . . . . . 5-37
5.6.9 Generator and Magnet System (Option) . . 5-38
5.6.10Refueling the Machine . . . . . . . . . . . . . . . . 5-41
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.2 Oils and Lubricants . . . . . . . . . . . . . . . . . . . 6-5
6.2.3 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.1 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.3.2 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.3.3 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.3.4 Belt drives . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
0-2 S 825 M / 09.2002

Contents
6.4 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6.4.1 Hydraulic hose lines . . . . . . . . . . . . . . . . . 6-14
6.4.2 Hydraulic System Pressure Relief . . . . . . . 6-15
6.4.3 Checking Oil Level . . . . . . . . . . . . . . . . . . 6-16
6.4.4 Changing Hydraulic Oil . . . . . . . . . . . . . . . 6-17
6.4.5 Return Flow Filter –
Replacing Filter Element . . . . . . . . . . . . . . 6-19
6.4.6 Pilot Control Filter –
6.4.7 Leakage Oil Filter –
6.4.8 Replacing Breather Filter . . . . . . . . . . . . . 6-22
6.4.9 Hydro Clean –
Superfine-Filter-System (Option) . . . . . . . 6-23
6.4.10Checking Precharge Pressure
of the Accumulators . . . . . . . . . . . . . . . . . 6-24
6.5 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6.5.1 Cleaning and Lubricating . . . . . . . . . . . . . 6-25
6.5.2 Tire Inflation Pressure
(Machines with Pneumatic Tires) . . . . . . . 6-25
6.5.3 Retightening Wheel Nuts . . . . . . . . . . . . . 6-26
6.5.4 Hub Gears . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6.5.5 Travel Gear . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6.5.6 Differential . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6.6 Slewing Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
6.7 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6.7.1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6.7.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
6.8 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
6.9 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
6.9.1 Maintenance Schedule . . . . . . . . . . . . . . . 6-37
6.9.2 Schedule of Lubrication Points . . . . . . . . . 6-40
6.9.3 Refill Capacities . . . . . . . . . . . . . . . . . . . . 6-41
6.9.4 Tightening Torques for Bolts . . . . . . . . . . . 6-42
7 Setting up works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
S 825 M / 09.2002 0-3

Contents
8 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Dimensions and Weights . . . . . . . . . . . . . . . . . . . . 8-2
8.2.1 Shipping Dimensions . . . . . . . . . . . . . . . . . . 8-2
8.2.2 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3 Locking the Upper Structure . . . . . . . . . . . . . . . . . 8-4
8.4 Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5 Lashing and Tying Down the Machine . . . . . . . . . . 8-6
9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.3 Sennebogen Diagnostic System . . . . . . . . . . . . . . 9-4
9.3.1 Bank of keys with LEDs . . . . . . . . . . . . . . . . 9-4
9.4 Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.5 Air Conditioner (Optional) . . . . . . . . . . . . . . . . . . . 9-7
9.6 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.7 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
10 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.1 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2 Lubrication-Table . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.3 Additional Documentation . . . . . . . . . . . . . . . . . . 10-1
10.3.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.3.2 Operator’s Seat . . . . . . . . . . . . . . . . . . . . 10-1
10.3.3 Magnet system . . . . . . . . . . . . . . . . . . . . . 10-1
10.3.4 Central Lubrication System . . . . . . . . . . . 10-1
10.3.5 Cleaning the Cooler . . . . . . . . . . . . . . . . . 10-1
0-4 S 825 M / 09.2002

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
the machine fails to be used as intended;
operation or maintenance of the machine is performed by
unqualified personnel;
the safety notices and messages are ignored.
Over and above the safety information contained in this Operation

Manual, national and international rules and regulations are applicable
as well.
Regulations applicable in the Federal Republic of Germany include:
“Winden, Hub- und Zuggeräte” (VBG 8) (Winches, lifting and pulling
equipment)
“Krane” (VBG 9) (Cranes)
“Lastaufnahmeeinrichtungen im Hebezeugbetrieb” (VBG 9a) (Load
take-up devices in hoisting service)
“Erdbaumaschinen” (VBG 40) (Earthmoving machinery)
EC Machinery Directive (89/392/EEC)
Safety of Machinery (DIN EN 292)
Note
When a conflict exists between the national rules and regulations in the
country of destination and our recommendations, follow the strictest
procedure.
S 825 M / 09.2002 1-1

Safety - General
Identification of Notices Throughout this Operation Manual, safety notices and messages are
used to alert you to hazardous operating practices. These safety
notices and messages are identified by a safety alert symbol and a
signal word.
This safety alert symbol means: Attention - your safety and that of other
persons is involved.
The associated signal word identifies the hazard’s degree of
seriousness:
Danger
Used to identify a major immediate hazard. Failure to avoid this hazard
will result in most serious bodily injury or in the death of persons.
Warning
Used to identify potentially hazardous situations. Failure to avoid this
hazard could result in most serious bodily injury or in the death of
persons.
Caution
Used to identify potentially hazardous situations. Failure to avoid this
hazard could result in bodily injury or in major property damage.
Information that will make work easier for you or promote better
understanding of handling of the machine is identified as follows:
Note
Used to identify notes that draw your attention to special features.
Note
Used to identify cross references to other documents.
1-2 S 825 M / 09.2002

Safety - Use as Intended
1.2 Use as Intended

The machine is intended to be used for the exclusive purposes of lifting,
moving and loading loads.
The working attachments allowed are:
Grabs
Magnet systems
For specifications refer to Chapter 3 SPECIFICATIONS. Due allowance
must be made for the machine performance specifications.
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.
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 Abuse
Practices considered to be improper use (abuse) include in particular:
Lifting, moving and handling of persons
Oblique pulling of loads
Dragging of loads
Breaking loose any loads that have got stuck
Operation in a potentially explosive atmosphere
Warning
Improper use will exempt the manufacturer from any and all liability!
The user will bear sole responsibility.
S 825 M / 09.2002 1-3

Safety - Safety Information
1.4 Safety Information

The safety information contained in this Operation Manual is intended
as a guide to assist qualified operators in safe operation of the
machine. Sennebogen cannot foresee every situation however that
may involve a potential hazard in the field.
The safety information and warnings on the machine and in this
Operation Manual can therefore not be all inclusive. Safety remains the
responsibility of the owner and the operators.
1.4.1 General
Danger area The danger area of the machine is the surrounding area in which
persons are within the reach of:
Work-related movements of the machine
Working equipment and attachments
Loads swinging out or dropping down
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 / 19.69 inch) 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 S 825 M / 09.2002

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, safety shoes).
Stability Position the machine on a firm, level supporting surface only.

Where necessary, stabilize the supporting surface.
Beware of edges of excavations, banks, vaults, etc.
Set outriggers on a firm, level supporting surface as well.
Do not use outriggers to raise the machine off the ground. The tires
must always maintain contact with the ground.
Pay attention to wind speeds!
Stability is lowest when the working equipment is positioned at right
angles to the direction of travel.
Stability is highest with the working equipment in a diagonal position
(see illustration below).
Danger
Refrain from any operating practice impairing stability of the machine!
Note that stability is reduced when the load swings out to the side.
S 825 M / 09.2002 1-5

Working in the vicinity Clearly mark off the power lines in the job site area with your
of power lines supervisor. Do so before starting work!
Consider all overhead lines to be energized electric power lines.
Operate the machine so that neither parts of the machine nor any
loads being handled enter into the danger zone.
Maintain a safety clearance to the overhead lines. Unless otherwise
provided in the national laws and regulations, maintain the following
minimum clearances:
Rated voltage Safety clearance (meter)

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
Use a signal person to observe the safety clearance.

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.
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:

Do not leave the operator’s station.
Caution all outside persons against approaching or touching the
machine.
Where possible, move the working equipment or the entire machine
out of the danger zone.
Arrange for the power to be disconnected.
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.
Qualifications of Only those persons must be assigned to operate or maintain
personnel earthmoving machines on their own who
1-6 S 825 M / 09.2002

Extract from VBG 40 have attained the age of 18 (majority);

regulations (Germany) are both physically and mentally fit;
have received training in the operation or maintenance of the
earthmoving machine and have proven their relevant qualification to
the employer; and who
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.
S 825 M / 09.2002 1-7

1.4.2 Transport
Warning
Transport of the machine and of the accessories is the responsibility of
the respective carrier as a general principle.
Observe the applicable cargo securing rules and regulations.

During loading and transport, secure the machine and its working
equipment against any accidental movement.
Remove mud, snow and ice from the undercarriage of the machine
sufficiently to allow the use of ramps without the risk of slippage.
Before loading ramps of flatbed trailers are used by crawler-type
machines, provide them with wood blocking.
Before setting off, investigate the condition of the travel route.
For transport of the machine, use only the lashing, tie-down and
lifting points provided for the purpose.
1-8 S 825 M / 09.2002

1.4.3 Commissioning
Warning
Make sure that all guards and protective devices of the machine are
in place and are properly secured.
Wear personal protective equipment (hard hat, safety glasses)
where this is required by job conditions.
Avoid wearing jewelry or loose clothing.
Secure any loose items, e.g., tools or other accessories.
Agree on hand signals with the signal person.
Obtain information about first aid and about assistance and rescue
services.
Perform the pre-start checks as specified in Section 4.3.
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.
Make sure that there are no persons in the danger area.
Check the safety features (brakes, signaling and lighting equipment)
of the machine.
While traveling at slow speed, check the controls and protective
devices for proper operation.
S 825 M / 09.2002 1-9

1.4.4 Operation
Warning
Be sure to observe Chapter 1 SAFETY.
Before the machine is put into operation, perform the checks as
specified in Section 4.3.
have been duly instructed.
Exercise extreme caution when overriding the stick limiting stops.
Maintain a safety clearance to overhead lines.
Operate the machine only while you are in the operator’s seat.
Do not use the machine for handling of personnel.
Make due allowance for ambient conditions, e.g., poor visibility,
wind speeds, etc.
Use the correct load rating chart belonging to the machine.
Observe performance specifications.
Check whether the load capacity of attachment points is adequate.
Obey the signals given by signal persons, where applicable.
For any long-distance travel, put the boom in the direction of travel.
Before leaving the operator’s cab:
– Fully lower the cab, where applicable.
– 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.
– Block the tires/undercarriage.
– Stop the engine.
– Lock the operator’s cab; use warning lamps to mark the machine,
where applicable.
1 - 10 S 825 M / 09.2002
1.4.5 Maintenance
Warning
The maintenance work described may only be carried out by trained
and instructed specialist personnel.
Wear personal protection equipment (e.g. safety helmet, ear
protection, protective gloves, safety boots) where working conditions
require.
Observe the applicable statutory accident prevention and safety
regulations.
Land any attached loads, and lower the boom to ground level.
Pull the left safety lever backwards.
Before attempting to perform any maintenance, shut down the
machine and secure it against unauthorized restarting.
Attach a warning tag to the controls.
Do not smoke and do not allow open flames.
Use personnel hoists or work platforms that satisfy safety
requirements.
Stay clear of all rotating and moving parts.
Relieve the pressure before working on the hydraulic system.
Always wear protective gloves when handling wire ropes.
Use only genuine Sennebogen spare parts.
Use only those oils and lubricants that are specified in the lubricants
chart.
Do not lift heavy components by hand. Use hoists or lifting
equipment.
Actuate battery isolator switch to interrupt the power supply.
When working near battery, cover with insulating material; do not lay
tools on the battery.
On completion of the maintenance operations, reinstall all guards
and protective devices.
Keep the operator’s cab clean and tidy.
Perform a functional check to ensure proper operation.
On completion of any maintenance operations, only the crane owner
or his agent is permitted to clear the machine for service again.
S 825 M / 09.2002 1 - 11
Safety - Obligations of the Owner
1.5 Obligations of the Owner

Warning
The owner/user is obliged to prepare relevant operating instructions
when dealing with dangerous machines or hazardous materials.
The necessary information is to be found in
EG directives on occupational health and safety
National occupational health and safety laws
Accident prevention regulations and
the present operation manuals.
Inspection by The machine must be subjected to a thorough inspection by a

competent person competent person
Prior to initial use, and prior to recommissioning after any material
changes have been made;
At least once a year;
In between, depending on the severity of service and on the
operational conditions.
For these purposes, a competent person is defined as one who
by reason of technical training and
after special instruction provided by Sennebogen
has acquired thorough knowledge of this machine and of the applicable
rules and regulations and is capable of assessing the safe operating
condition of the machine.
Personnel selection and Employ only personnel that has been duly trained or instructed.
qualifications Define responsibilities for operation and maintenance.
Observe the minimum age permitted by law.
Danger
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.
Have any work on electrical equipment of the machine performed by
a qualified electrician only.
Only qualified personnel having received relevant training is allowed
to perform work on undercarriages, braking and steering systems!
Work on hydraulic equipment must only be performed by personnel
having specific knowledge and experience of hydraulics!
1 - 12 S 825 M / 09.2002
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 79/113 EEC, 84/
532 EEC, and 86/662 EEC.
It is possible however that environmental 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.
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.
Unauthorized Any modification or alterations of the machine are not allowed.

modification and spare This is equally applicable to the installation and adjustment of safety
parts fabrication devices and valves and also to welding on bearing structures.
Genuine 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 Sennebogen from
all and any liability for any resulting consequences.
Inadmissible operating 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
operation manual.
The performance limits specified in Chapter 3 SPECIFICATIONS must
not be exceeded.
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
Sennebogen as an option.
The machine is not suited for drawing of a trailer.
Due to the higher axle load involved, trailer operation is not
permitted unless heavy-duty axles with multiple-disc brakes (option)
are used.
S 825 M / 09.2002 1 - 13
Employment in foreign When the machine is employed abroad, take the following precautions:
countries
Observe the safety regulations applicable in the respective country
of use.
Make sure that the operating personnel has the necessary
qualifications for the scheduled work.
See to it that the contents of the present operation manual are read
and fully understood. Where necessary, obtain a manual in the
respective official language from Sennebogen.
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.
Fire extinguisher and Locations for installation 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 Sennebogen, if required.
1 - 14 S 825 M / 09.2002
Safety - Protective Devices
1.6 Protective Devices

Danger
Do not remove any protective devices and covers.
Whenever the machine is started, make sure first that all protective
devices of the machine are in place and are properly secured.
On completion of fitting or maintenance operations, properly
reinstall all protective devices and covers.
Replace any damaged protective devices by new items.
Overload warning The overload warning system gives an audible and a visual warning
system signal when the allowable capacity is exceeded. Whenever lifting
equipment is used, make sure the overload warning system has been
activated (see Section 5.3.8). The tipping hazard is not averted by the
overload warning system!
Danger
Machine tipping hazard!
Land the load immediately! Reduce the load and diminish the radius.
S 825 M / 09.2002 1 - 15
Safety - Warning Signs and Labels on the Machine
1.7 Warning Signs and Labels on the Machine

There are specific safety signs and warning symbols on the machine.
Do not remove the safety signs and labels.
Keep all safety signs and labels in an undamaged and readable
condition.
Use water and soap to clean the safety signs, where necessary.
Do not use gasoline or solvents to clean the signs and labels.
Replace any damaged, scratched or illegible safety sign or label by
a new item.
Note
Warning signs and labels are available from Sennebogen (see spare
parts catalog).
Identification plate
Tie-down point
Lifting point
1 - 16 S 825 M / 09.2002
Attaching restraint belt (optional)
Read and follow the operating manual
Battery isolation switch (optional)
Read and follow maintenance instructions
Hydraulic oil Diesel fuel
S 825 M / 09.2002 1 - 17
Danger of crushing! Cab mounting
1 - 18 S 825 M / 09.2002
Safety - Disposal
1.8 Disposal
Caution
Be mindful of the environment!
Substances and materials used must be properly handled and
disposed of, in particular
when working on lubrication systems and equipment, and
when handling solvents.
1.9 Hand Signals

The operator and the signal person make use of hand signals 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.
Caution
The signal person must have been trained in the use of the hand
signals.
While spotting, he/she must not pursue any additional activity!
The signal person must stand outside the danger area, facing the
operator!
The signal person must be clearly visible, by wearing warning
clothing, for example!
Attention
Raise streched arm with open
hand.
S 825 M / 09.2002 1 - 19
Safety - Hand Signals
Stop
Stretch out both arms
horizontally.
Stop! Danger!
Stretch out and blend both arms
horizontally in quick succession.
Set off
Raise stretched arm with open
hand and wave.
Drive slowly forward

Bend both arms and beckon with
hands turned inward.
1 - 20 S 825 M / 09.2002
Reverse slowly
Bend both arms and beckon back
with hands turned outward.
Drive to the right

Use left thumb to point to the left.
Drive to the left

Use right thumb to point to the
right.
Rotate upper structure to the

right
Use left thumb to point to the left,
rotate right index finger.
S 825 M / 09.2002 1 - 21
Rotate upper structure to the

left
Use right thumb to point to the
right, rotate left index finger.
Lift attachment (load)

Point stretched right index finger
in the air, move left hand up and
down.
Lower attachment (load)

Point streched right index finger at
the ground move left hand up and
down.
Inrease radius
Point both thumbs outward.
1 - 22 S 825 M / 09.2002
Reduce radius
Point both thumbs inward.
Open grab
Hold arm horizontally to the side
with hand half opened.
Close grab
Hold arm horizontally to the side
with hand closed.
S 825 M / 09.2002 1 - 23
1 - 24 S 825 M / 09.2002
General View - Overall Machine
2 General View
2.1 Overall Machine
1 Undercarriage 5 Operator´s station, cab

elevating
2 Outriggers
6 Compact boom
3 Upper structure
7 Grab stick
4 Working attachments
S 825 M / 09.2002 2-1

General View - Undercarriage
2.2 Undercarriage
1 2 3 4 5 6
1 Front axle (oscillating axle) 4 Slewing ring

2 Wheel-mounted step 5 Access steps
3 Oscillating axle cylinder 6 Rear axle
2.3 Outriggers (Option)
1 2 3 4
1 Outrigger support
2 Outrigger pad
3 Restraining rope
4 Outrigger box
2-2 S 825 M / 09.2002

General View - Upper Structure
2.4 Upper Structure
1 2 3 4 5
Motorraum:
1 Generator set
2 Gear
3 Engine
4 Cooler (Water/Air)
5 Overload warning system
S 825 M / 09.2002 2-3

General View - Upper Structure
1 2 3 4
Storage Compartment:
1 Central lubrication system
2 Batteries
3 Hydraulic oil cooler
4 Air filter
2-4 S 825 M / 09.2002

General View - Operator’s Station
2.5 Operator’s Station
1 2 3 4 5 6 7 8
1 Pedals 5 Lever - Cab height adjustment

2 Steering column 6 Safety lever
3 Steering wheel 7 Heater/Air conditioner (option)
4 Water reservoir, window 8 Control lever
washer
S 825 M / 09.2002 2-5

General View - Operator’s Station
1 2 3 4 Pedals:
1 Float position (option)
2 Outriggers
3 Braking (with lock)
4 Travel
2-6 S 825 M / 09.2002

Specifications - Base Machine
3 Specifications
For the specifications of the base machine refer to Section 3.1. The
load ratings of the machine are specified in Section 3.2.
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
operation manual of the assembly concerned.
3.1 Base Machine
Engine Deutz BF6M 1013 ECP Diesel Engine

Power output 122 kW (165 hp)
(acc. to ISO 9349) at 2000 rpm
Displacement 7146 cm 3
Cylinders 6
Permissible inclinations of engine:
left right front rear

30° 30° 30° 30°
For short periods (about 5 min):
45° 45° 45° 45°
Note
At any greater inclinations, an adequate engine oil level is no longer
ensured. In case higher degrees of inclination are required, consult with
Sennebogen beforehand.
For further information on the engine, consult the engine
manufacturer’s operation manual.
Electrical system 24 volt
Travel speed Off road 5.4 km/h (3.4 mph)

On road 20 km/h (12.43 mph)
S 825 M / 09.2002 3-1

Specifications - Base Machine
Hydraulic system Max. operating pressure 350 bar (5076 psi)
Swing drive Swing speed 0 to 8 rpm, infinitely variable
Sound pressure level Operator’s seat 72 dB(A)
Weighted vibration Chassis 19

severity Kzeq
(on the basis of Operator’s seat 37
statistical measurements)
Ambient temperature -20 °C ... +50 °C (-4 °F ... + 122 °F)
Maximum tolerable Wind speed

wind
14.14 m/s (45.9 fts) 50.9 km/h (31 mph)
Note
When the wind reaches the speed specified above, stop operation of
the machine immediately (land the load; lower the boom to ground
level). For a schedule of wind forces and wind speeds refer to table in
Section 3.3.
3-2 S 825 M / 09.2002

Specifications - Load Rating
3.2 Load Rating

Notes
Load ratings
are stated in metric tons (t) and do not exceed 75% of static tipping
load or 87% of hydraulic capacity, according to ISO 10567.
are applicable with the machine on firm, level ground and apply to
360 degree operation.
The weight of the lifting accessories (hooks, slings) must be deducted
from the load ratings. The figures in parentheses apply over end of
undercarriage.
Load ratings with loading boom 7,4 m and grab stick 5,7 m
Höhe Abstütz- Ausladung in m / radius in m

height zustand
in m support
position 3,0 4,5 6,0 7,5 9,0 10,5 12,0
13,5 freistehend/free on Wheels 7,6 (8,3)
abgestützt/on outriggers 8,3 (8,3)
12,0 freistehend/free on Wheels 5,0 (7,0) 3,4 (4,8)
abgestützt/on outriggers 8,2 (8,2) 6,7 (6,7)
10,5 freistehend/free on Wheels 5,1 (7,1) 3,5 (4,9) 2,5 (3,5)
abgestützt/on outriggers 8,9 (8,9) 7,0 (7,6) 5,1 (6,5)
9,0 freistehend/free on Wheels 5,1 (7,1) 3,5 (4,9) 2,5 (3,5) 1,8 (2,7)
abgestützt/on outriggers 8,8 (8,8) 7,0 (7,5) 5,1 (6,6) 3,9 (5,0)
7,5 freistehend/free on Wheels 5,0 (7,0) 3,4 (4,8) 2,4 (3,5) 1,8 (2,6)
6,0 freistehend/free on Wheels 7,6 (10,9) 4,7 (6,7) 3,2 (4,6) 2,3 (3,4) 1,7 (2,6) 1,3 (2,0)
abgestützt/on outriggers 11,0 (11,0) 9,6 (9,6) 6,7 (7,9) 4,9 (6,4) 3,8 (4,9) 3,0 (3,9)
4,5 freistehend/free on Wheels 12,1 (12,1) 6,8 (10,0) 4,3 (6,2) 3,0 (4,3) 2,2 (3,2) 1,6 (2,5) 1,2 (1,9)
abgestützt/on outriggers 12,1 (12,1) 13,9 (13,9) 9,3 (10,4) 6,4 (8,3) 4,8 (6,2) 3,7 (4,8) 3,0 (3,9)
-1,5 freistehend/free on Wheels 2,9 (4,7) 2,1 (3,4) 1,6 (2,6) 1,3 (2,1)
S 825 M / 09.2002 3-3

Specifications - Load Rating
Adverse Load ratings must be limited or derated to make allowance for any
conditions adverse conditions. Adverse conditions include
Soft underfoot conditions or uneven ground;
Gradients;
Wind;
Side loads;
Swinging loads;
Jerking or sudden stopping of the load;
Inexperience of operating personnel;
Traveling with a load.
3-4 S 825 M / 09.2002

Specifications - Appendix
3.3 Appendix
Wind force Wind speed Description

Beaufort Name m/s km/h Onshore
number (ft/s) (mph)
0 Calm 0 - 0.2 1 Calm; smoke rises vertically
(0 - 0.66) (0.62)
1 Light air 0.3 - 1.5 1-5 Direction of wind shown by drifting of
(0.94 - 4.92) (0.62 - 3.11) smoke but not by wind vanes
2 Light 1.6 - 3.3 6 - 11 Wind felt on the face; leaves rustle;
breeze (5.25 - 10.83) (3.73 - 6.84) ordinary vane moved by wind
3 Gentle 3.4 - 5.4 12 - 19 Leaves and small twigs in constant
breeze (11.16 - 17.72) (7.46 - 11.81) motion; wind extends light flag
4 Moderate 5.5 - 7.9 20 - 28 Raises dust and loose paper; twigs and
breeze (18.05 - 25.92) (12.43 - 17.40) small branches are moved
5 Fresh 8.0 - 10.7 29 - 38 Small trees in leaf begin to sway;
breeze (26.25 - 35.11) (18.02 - 23.61) crested wavelets form on inland waters
6 Strong 10.8 - 13.8 39 - 49 Large branches in motion; telegraph
breeze (35.43 - 45.28) (24.23 - 30.45) wires whistle; umbrellas used with
difficulty
7 Moderate 13.9 - 17.1 50 - 61 Whole trees in motion
gale (45.61 - 56.11) (31.07 - 37.91)
8 Fresh 17.2 - 20.7 62 - 74 Breaks twigs off trees; generally
gale (56.43 - 67.92) (38.53 - 45.98) impedes progress outdoors
9 Strong 20.8 - 24.4 75 - 88 Slight structural damage occurs
gale (68.24 - 80.06) (46.61 - 54.68) (chimney pots and slates removed)
10 Whole 24.5 - 28.4 89 - 102 Trees uprooted; considerable structural
gale (80.38 - 93.18) (55.30 - 63.38) damage occurs
11 Storm 28.5 - 32.6 103 - 117 Widespread storm damage (very rarely
(93.51 - 106.96) (64.00 - 72.70) experienced onshore)
12 Hurricane 32.7 - 36.9 118 - 133 Devastation occurs
(107.29 - 121.07) (73.33 - 82.65)
S 825 M / 09.2002 3-5

Specifications - Appendix
3-6 S 825 M / 09.2002

Preparing to Operate - Safety Information
4 Preparing to Operate
Warning
Make sure that all guards and protective devices of the machine are
in place and are properly secured.
Wear protective clothing (hard hat, safety glasses) where this is
required by job conditions.
Avoid wearing jewelry or loose clothing.
Secure any loose items, e.g., tools or other accessories.
Agree on hand signals with the signal person.
Obtain information about first aid and about assistance and rescue
services.
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.
Check the safety features (brakes, signaling and lighting equipment)
of the machine.
While traveling at slow speed, check the controls and protective
devices for proper operation.
S 825 M / 09.2002 4-1

Preparing to Operate - Initial Commissioning
4.2 Initial Commissioning

Initial commissioning of the machine is performed by 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 Sennebogen service department before putting
it back in service.
Warning
4.3 Pre-Start Checks

Safety information Note the safety information before you start work.
Danger
Familiarize yourself with the machine and with its equipment. To that
end, study this Operation Manual, and Chapter 1 SAFETY in
particular, before putting the machine into operation.
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 traveling gear undamaged?
6 Has the correct counterweight (ballast) been fitted?
7 Are the boom components undamaged?
8 Have the stick limiting stops been properly adjusted?
9 Has the boom stop been properly adjusted?
10 Has any maintenance required been performed as specified in
the maintenance schedule?
4-2 S 825 M / 09.2002

Preparing to Operate - Pre-Start Checks
11 Are the oil reservoirs filled to the proper levels (hydraulic

system, engine)?
12 Is the fuel tank of the machine filled to the proper level?
13 Are the V-belts undamaged and of proper tension?
14 Are all bolted/screwed connections undamaged and properly
tightened?
15 Are all fasteners on the elevating cab undamaged and property
tightened?
16 Are the operating and ambient conditions known?
17 Is the weight of the load known?
18 Is an experienced signal person available if and when
required?
19 Are the loads to be attached within the ratings of the machine
and of the sling devices? Be sure to observe Chapter 3
SPECIFICATIONS!
20 Have any danger points at the job site been identified and
marked off (overhead lines, excavations, etc.)?
21 Are the doors for maintenance at the upper structure closed?
22 Is the danger area clear of personnel?
23 Are all safety devices working properly (brakes, signaling and
lighting equipment)?
24 Has the overload warning system been activated?
25 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.
S 825 M / 09.2002 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
Keep service access doors closed.
Before starting the engine, make sure that there are no persons in
the danger area.
The exhaust gases of diesel engines are harmful to health. Operate
the engine only in the open or in well ventilated areas.
Do not start the machine if there is a warning tag attached to the
controls.
Adjust the operator’s seat and the mirror(s) to the proper positions.
Fasten the seat belt correctly and securely.
4.4.1 Seat Belt

The machine has been provided with a lap belt.
Warning
Before placing the machine in service, check the belt for signs of
wear. If the belt is damaged, immediately replace the belt.
If the belt is dirty, use water to clean the belt.
The belt must not be twisted.
The belt must fit low across the operator’s hips, not over his
stomach.
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 S 825 M / 09.2002

4.4.2 Starting the Engine
1 Perform the checks as specified in Section 4.3.

2 Insert the key into the starter lock and turn it to position “1”.
– The Swing brake indicator light comes on.
3 Turn the ignition key clockwise in order to start the engine.
– The Preheating indicator light goes off.
– The indicator light of the travel speed selected comes on
(Fast travel / Slow travel).
4 Use the rotary knob to adjust engine rpm to the desired speed.
4.4.3 Stopping the Engine
1 Park the machine on a safe surface.

2 Lower any attached loads and the boom, where applicable, to
the ground.
3 Reduce engine speed to avoid the turbocharger getting
damaged.
4 Turn the ignition key to position “0” and remove the key.
5 Where applicable, pull the safety lever backwards.
6 Mark the machine (lights, flares, warning triangle, etc.).
S 825 M / 09.2002 4-5

4.4.4 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 the optional battery disconnect switch, if equipped, to

interrupt power supply.
2 Remove the battery cover as required.
3 Use appropriate jump start cables to connect the positive poles
(+) of the power sources.
4 Use appropriate jump start cables to connect the negative
poles (–) of the power sources.
5 Operate the optional battery disconnect switch, if equipped.
6 Start engine as specified in Section 4.4.2.
7 After the engine starts:
– Disconnect the jump start cables of the negative poles (–).
– Disconnect the jump start cables of the positive poles (+).
8 Refit the battery cover where applicable.
Warning
When working in the vicinity of batteries, it is prohibited
to use open flames;
to cause sparks; and
to smoke.
When working on the electrical system, take care to observe the
applicable standards and the accident prevention regulations.
4-6 S 825 M / 09.2002

4.4.5 Warming Up the Machine to Operating Temperature

You can warm up the machine to operating temperature by operating
the engine at low idle.
Recommended warm- Outside temperature Warm-up period

up times
to 0 °C (32 °F) approx. 15 min
0 °C ... -20 °C (32 °F ... -4 °F) approx. 30 min
Note
Before you attempt to operate the machine, the display should show
the following temperature values:
Water: 35°C (95 °F)
Hydraulic oil: 25°C (77 °F)
If the reactions of the hydraulic system are still sluggish after the warm-
up period, warming up should be extended by another 15-minute
period.
S 825 M / 09.2002 4-7

4-8 S 825 M / 09.2002

Operation - Safety Information
5 Operation
Danger
Exercise extreme caution when overriding stick limiting stops.
wind speeds, etc.
where applicable.
S 825 M / 09.2002 5-1

Operation - Operator’s Cab
5.2 Operator’s Cab
1 2 3 1 Door lock
2 Cab door
3 Release - Door locking device
4 Emergency exit - Rear 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
5 Hammer - Emergency exit

In case of emergency, you can exit through the rear window. Damage
the window with the hammer (5).
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 (3) inside the cab
allows the door to be unlocked again.
5-2 S 825 M / 09.2002

Front window Opening 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 Section 10.3.
5.2.1 Hydraulically Adjusting Operator’s Cab

You can adjust the height of the operator’s cab in an infinitely variable
manner.
Danger
An elevated cab involves risk of accidents!
Check the cab support, bolts and screwed connections every day!
Do not travel the machine unless the cab is in the bottom position
and the slewing gear brake is applied.
Keep the cab door closed.
Do not leave the cab.
Do not step on the grate beside the cab.
S 825 M / 09.2002 5-3

1 Lever - Cab height adjustment

2 Information label
Elevating the cab 1 Close cab door.

2 Fasten seat belt as specified in Section 4.4.1.
4 Use speed adjustment rotary knob on right-hand control panel
to increase engine speed.
5 Pull lever for height adjustment of operator’s cab (1)
backwards (towards operator’s seat). The cab will rise slowly.
Danger
An elevated cab involves risk of accidents!
Do not travel the machine unless the cab is in the bottom position
and the slewing gear brake is applied.
Keep the cab door closed.
Do not leave the cab.
Do not step on the grate beside the cab.
Note
Do not raise the cab right up to its upper end position (TDC).
Stop the cab with about 10 cm to go to the upper end position.
This serves to ensure optimum damping conditions and to create
favorable working conditions in the cab.
5-4 S 825 M / 09.2002

Lowering the cab 1 Start engine as specified in Section 4.4.2.

2 Use speed adjustment rotary knob on right-hand control panel
to increase engine speed.
Danger
Shearing and crushing could result in injury or death!
Take care to ensure that the danger area is clear of personnel while the
cab is being lowered.
During lowering, the danger area is defined to be the area
at/underneath the cab;
at/underneath the mechanical cab suspension.
3 Push lever for height adjustment of operator’s cab (1) forward

(towards windshield). The cab will lower slowly.
Warning
Uncontrolled rising of the cab can cause personal injury!
Keep the lever (1) actuated for about another 5 s after the lower end
position has been reached. This serves to dissipate pressure in the
integrated accumulator.
Otherwise any uncontrolled movements of the cab during pressure re-
lief of the accumulator could cause personal injury.
Dismantling/mounting
the cab Danger
It could be result in injury or death when the cab is falling
down!
Dismantling/mounting the cab must only be performed by
qualified personnel that has received adequate training
and instruction.
Renew all bolted/screwed connections at the cab support
and cab frame-support.
S 825 M / 09.2002 5-5

5.2.2 Emergency Lowering

The machine has been fitted with the following emergency lowering
systems:
Cab emergency lowering system (cab-mounted)
Location: to the right of operator’s seat/heater.
Required in the event of the drive system failing, for example.
Cab emergency lowering system (storage compartment mounted)
Location: left storage compartment, at cab rear wall.
Required in the event of the operator getting into an emergency due
to ill health.
Boom emergency lowering system
Location: front of engine compartment.
Required in the event of the drive system failing, for example.
Danger
Shearing and crushing could result in injury or death!
Take care to ensure that the danger area is clear of personnel while the
cab is being lowered. During lowering, the danger area is defined to be
the area
at/underneath the cab;
at/underneath the mechanical cab suspension.
Cab emergency
lowering system
055785
1
Shown here = Lower cab
1 Turn lever (1) (into horizontal position). The cab will lower
slowly.
2 After the lower end position has been reached, restore lever (1)
to its initial position.
5-6 S 825 M / 09.2002

Cab emergency
lowering system
(storage compartment
mounted)
055786
Shown here = Cab raised
1 Turn lever (1) (into horizontal position). The cab will lower
slowly.
2 After the lower end position has been reached, restore lever (1)
to its initial position.
Boom emergency
lowering system
1 Shown here = Boom raised
Danger
Make sure that there are no persons in the danger area of the compact
boom.
1 Move emergency lowering lever (1) down into the vertical

position. The compact boom will move downward.
2 Restore emergency lowering lever (1) to its initial position.
S 825 M / 09.2002 5-7

Operation - Machine Controls
5.3 Machine Controls
5.3.1 General View
1 2 3 4 5 6 7 8
1 Pedals 5 Lever - Cab height adjustment

2 Steering column 3 Safety lever
3 Steering wheel 4 Heating/Air condition(Option)
4 Water reservoir - window 5 Control lever
washer
Danger
Incorrect operation involves risk of accidents!
When the boom is over the rear axle, the operational movements of the
machine are in the reverse way. Exercise extreme caution when you
choose to work or travel with the boom over the rear axle.
5-8 S 825 M / 09.2002

5.3.2 Left-Hand Control Lever
2
3 Push buttons:
4 1 Option
1
2 Option
3 Option
4 Rotate grab counterclockwise
Directions of movement:
S 825 M / 09.2002 5-9

5.3.3 Right-Hand Control Lever
2 Push buttons:
3
1 Magnet On/Off
1
4 2 Horn
3 Override - stick limiting stops
4 Rotate grab clockwise
Directions of movement:
Danger
Overriding stick limiting stops could result in injury or death!
Attachments and parts of the load can hit and penetrate the operator’s
cab. Exercise extreme caution when operating in this mode.
Keep your eyes on the attachments and the load. Engagement in this
practice is solely the personal responsibility of the operator.
Notice also the information provided in Chapter 5.6.3.
5 - 10 S 825 M / 09.2002
5.3.4 Safety Lever

The safety lever (1) serves as a protective device.
Shown here = Safety lever

released (pushed forward)
When the safety lever is released (see illustration above),

All hydraulic functions are available;
All work movements can be performed;
The slewing gear brake must be released separately.
Note
When the safety lever has been released (pushed forward), the slewing
gear brake continues to be engaged. Use the left-hand control lever to
release the slewing gear brake (see Section 5.3.2).
Shown here = Safety lever

applied (pulled backward)
When the safety lever is applied,

All hydraulic functions are disabled;
The machine can be traveled.
S 825 M / 09.2002 5 - 11
5.3.5 Pedals
1 2 3 4 1 Float position (option)

2 Outriggers/Dozer blade
3 Braking (with lock)
4 Travel
5.3.6 Steering Column
1 Steering column lever

1 2 3 2 Clamping lever - Steering
column
3 Steering column
4 Steering wheel
5 - 12 S 825 M / 09.2002
5.3.7 Sennebogen Diagnostic System (SDS)
1
2
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 will be
activated.
Self-test:
Once the 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 Sennebogen customer
service.
Display (1) The two-line display serves to indicate 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.
S 825 M / 09.2002 5 - 13
Bank of keys with LEDs The bank of keys is fitted with 8 function keys. You can use these keys
to retrieve information and have it shown on the display. Each key has
a red light-emitting diode (LED) assigned to it.
The LED will come on when the associated key is pressed. The LED
will also be illuminated when an irregularity has been detected by the
diagnostic system. This is the case, for example, when the allowable
engine temperature is exceeded. A buzzer will sound to alert you to the
fault. You can acknowledge the fault alarm by pressing the respective
key.
Any faults are logged and stored in the SDS; this allows service
personnel to track down the causes and take fast corrective action.
1 2 3 4
8 7 6 5
1 Battery charging 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 - 14 S 825 M / 09.2002
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.
S 825 M / 09.2002 5 - 15
Fault signaling
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 the – Clean cooling fins on the 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.

continuous alarm
sounds Fuel level in the tank – Refuel the machine as specified in
too low Section 5.6.10.

buzzer sounds
Engine overheated – Idle the engine.
engine oil cooler dirty
Fan drive loose or – Tighten fan drive, replace if necessary.
defective
Coolant level too low – Add coolant as specified in Section
6.3.3.
Note
If the coolant temperature continues to rise, the temperature reading on
the display flashes in addition, and a continuous alarm sounds.
5 - 16 S 825 M / 09.2002

buzzer sounds
Engine oil pressure too – Stop the engine immediately.
low (< 1.3 bar) – Check the engine oil level as specified
in Section 6.3.1.
– Add engine oil as necessary.
– If fault continues to occur, inform the
Sennebogen service department
accordingly.
Note
When the oil pressure falls below 1.0 bar, the pressure reading on the
display flashes in addition, and a continuous alarm sounds.
S 825 M / 09.2002 5 - 17
Indicator and warning Indicator and warning lights come on whenever immediate action has
lights to be taken on the machine, e.g., Clean air filter.
1 2 3 4 5
10 9 8 7 6
1 Slewing gear brake 6 Preheating

2 Air filter service indicator 7 High beam headlights
3 Parking brake accumulator charge 8 Coolant level
pressure
9 Turn signals
4 Fast travel speed - On road
10 Battery charging
5 Slow travel speed - Off road
When the “Coolant level” warning light comes on, the engine will be
shut down automatically.
Warning
In case of emergency, you can override this shutdown function.
This will allow you to start the engine and to move the machine out of
the danger area.
Remove the fuses F2 and F28 in the fuse distribution box.
The functions of the SDS system are disabled.
No warning will be given in the event of faults occurring!
Move the machine out of the danger area.
Re-install the two fuses F2 and F28.
Eliminate the cause of the fault immediately.
5 - 18 S 825 M / 09.2002
Fault signaling
comes on, Cause Remedy

warning signal
sounds Air filter foul/blocked – Clean filter as specified in Section
6.3.2.
– Where necessary, replace filter
element.
comes on Cause Remedy

during engine
operation Accumulator charge – Have hydraulic system checked by a
pressure too low hydraulics specialist.
comes on, Cause Remedy

warning signal
sounds Coolant level too low – Add coolant.
comes on during Cause Remedy

engine operation,
warning signal Battery charge – Check state of charge; where
sounds inadequate necessary, recharge or replace
batteries.
– Check battery connections; tighten
terminals as necessary.
S 825 M / 09.2002 5 - 19
5.3.8 Right-Hand Control Panel
11 12
13
10
9 14
8 15
7 16
6 17
5 18
4
3 19
2
20
1
1 Service hour meter 12 Travel speed slow/fast

2 24 volt power receptacle 13 Parking brake
3 Lighting switch 14 Oscillating axle lock-up
4 Blower fan 15 Overload warning system
5 Magnet system 16 Indicator light - Overload
warning system
6 Hazard warning light
17 Indicator light - EMR
7 Air condition
18 Automatic idling
8 Skylight wiper
19 Engine speed control
9 Intermittent operation - Front
window wiper 20 Starter lock/Start engine
10 Front window wiper
11 Working lights
5 - 20 S 825 M / 09.2002
Overload warning The overload warning system serves as an alert to inadmissible loading
system levels. It will not avert the tipping hazard however! The tipping hazard
increases when the radius is extended. In case of tipping hazard (when
warning signal has sounded)
Land the load immediately, or
Reduce the radius/the load.
Danger
For all operations involving lifting equipment, activate the overload
warning system.
1 2 1 Lever - Overload warning system

2 Pressure switch
Shown here: deactivated
1 Move overload warning system lever (2) up into the vertical

position.
2 On the right-hand control panel, turn on the Overload warning
system switch.
3 Check warning system for proper operation:
– Fully raise the compact boom so that the boom cylinder
extends as far as its stop.
– The Overload warning system indicator light on the right-
hand control panel will come on.
– A horn signal will sound.
S 825 M / 09.2002 5 - 21
Automatic idling The automatic idling system 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.
Oscillating axle lock-up The machine is fitted with an oscillating front axle. After disengagement
of the lock, the oscillating axle is able to compensate for uneven
underfoot conditions.
Warning
Tipping hazard!
For traveling with a load, lock the oscillating axle.
When traveling in uneven terrain, unlock the oscillating axle.
5 - 22 S 825 M / 09.2002
5.3.9 Central Lubrication System (Option)
1 Push button - Additional

lubrication
Push button (1) can be used to initiate additional lubrication. That

means, an additional lubricating operation is performed in between the
intervals that have been preset. This is to be recommended
before and after any extended out-of-service periods;
at major exposure to dust and dirt;
in case of important temperature variations;
in high-humidity environments.
Note
Further information on operation of the central lubrication system is
provided in a separate instruction. It can be found in Section 10.3.
S 825 M / 09.2002 5 - 23
Operation - Heating System
5.4 Heating System
1 2 3 3
1 Outside air/recirculation air

selector knob
4 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 the 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)
5 - 24 S 825 M / 09.2002
Operation - Optional Equipment
5.5 Optional Equipment
5.5.1 Air Conditioner (Option)

Warning
Have any maintenance and repair work performed by adequately
trained skilled personnel only.
Do not reach into the conditioner and do not insert any objects.
Perform maintenance operations only with the engine shut down
and with the blower fan disconnected.
Burning hazard!
Allow the conditioner and the components fitted inside (heat
exchanger, resistors) to cool completely first.
Avoid contact with refrigerant.
Wear safety glasses.
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 Open air inlet vent in the operator’s seat console or at the front
window to prevent icing of the evaporator.
4 Press switch for air conditioner on the right-hand control panel.
5 Use temperature variable control (2) on the heater to adjust the
desired temperature.
Note
Operate the air conditioner at regular intervals.
Put the air conditioner into operation for at least 5 minutes every week.
This will help to keep the air conditioner in a serviceable condition.
S 825 M / 09.2002 5 - 25
Operation - Operating Technique
5.6 Operating Technique
5.6.1 Safety Information

Danger
Exercise extreme caution when overriding stick limiting stops.
wind speeds, etc.
where applicable.
5 - 26 S 825 M / 09.2002
5.6.2 Boom Stop (Option)

The boom stop feature can be used to limit upward movement of the
boom.
1 2 3 4 5
Caution
Take care to ensure that the cylinders do not move against the stroke
end stops.
1 Loosen hexagon bolt (2).

2 Adjust the location of sensor (1) with bracket in rail (3).
3 Retighten hexagon bolt (2).
4 For fine adjustment, loosen hexagon bolt (5).
5 Relocate release plate (4).
6 Retighten hexagon bolt (5).
S 825 M / 09.2002 5 - 27
5.6.3 Stick Limiting Stops (Option)

Stick out The stick-out limiting stop serves to prevent that the cylinders operate
to the end of the stroke when the stick is moved out. The limit switch of
the stick-out limiting stop is located on the right side of the stick.
Stick in The stick-in limiting stop serves to prevent that attachments and parts
of the load hit and penetrate the operator’s cab. The limit switch of the
stick-in limiting stop is located on the left side of the stick.
In exceptional cases it may be necessary to move the stick on past the
limiting stop (override the stick limiting stop).
Danger
Overriding stick limiting stops could result in injury or death!
cab. Exercise extreme caution.
Keep your eyes on the attachments and the load. Engagement in this
practice is solely the personal responsibility of the operator.
Overriding stick-in
limiting stop
1
Left-hand control 1 Push button - Right-hand control

lever lever
1 Press push button (1) on right-hand control lever and keep it

depressed.
2 Pull left-hand control lever in the direction of “b”, exercising
extreme caution in the process. Take care to avoid the cab
getting damaged.
5 - 28 S 825 M / 09.2002
Adjusting stick limiting The factory settings of the stick limiting stops are as follows:
stops
Stick in: Stick about 2.5m (8.2 ft) from the lowered cab
Stick out: Cylinder about 1m (3.28 ft) from end position
Note
When the machine is put in service, and after any change of
attachments, you must adjust the stick limiting stops to fit the new
requirements.
Adjusting stick-in limiting stop

The setting will vary
with the attachment fitted and
with the load to be moved.
Danger
Misadjustment of the stick-in limiting stop could result in injury or death!
cab. Operating the machine with the stick-in limiting stop misadjusted
or overridden is solely the personal responsibility of the operator.
1 2 3
1 Fully lower the operator’s cab.

2 Cautiously move the stick in until the required safe distance
(about 2.5m/8.2 ft) from the cab has been attained. Allowance
must also be made for the pendulum swing of attachment and
load.
3 Lower the boom.
4 Loosen screw (1) of the actuator (2).
5 Shift the actuator (2) to the point where the limit switch (3)
responds.
6 Retighten screw (1).
7 Check the setting and repeat the procedure, if necessary.
S 825 M / 09.2002 5 - 29
Adjusting stick-out limiting stop

The limit switch of the stick-out limiting stop is located on the right side
of the stick.
1 2 3
1 Fully lower the operator’s cab.

2 Move the stick out. Stop about 1m (3.28 ft) before the cylinder
end position is attained.
3 Lower the boom.
4 Loosen the screw (3) of the actuator (2).
5 Shift the actuator (2) to the point where the limit switch (1)
sponds.
6 Retighten screw (3).
7 Check the setting and repeat the procedure, if necessary.
5 - 30 S 825 M / 09.2002
5.6.4 Traveling the Machine

Danger
Incorrect operation involves risk of accidents!
When the boom is over the rear axle, the operational movements of the
machine are in the reverse way. Exercise extreme caution when you
choose to work or travel with the boom over the rear axle.
Traveling with When traveling with a suspended load, take the following precautions:
suspended load
Tipping hazard!
Carry loads as close to the ground as practicable.
Be sure to position the boom in line with the undercarriage.
Do not attach more than 50% of the allowable load.
Travel on even terrain of adequate bearing capacity only.
Lock the oscillating axle.
Move about smoothly to minimize pendulum motion of the load.
Make turns at the widest possible radius.
Traveling 1 Retract outriggers, where applicable.

2 Release parking brake.
3 Select either off-road or on-road travel.
4 Where applicable, disengage oscillating axle lock at right-hand
control panel.
5 Use travel pedal and speed adjustment control on right-hand
control panel to adjust travel speed.
6 Use the brake pedal to slow down the machine.
7 Stop the machine as specified in Section 4.4.3.
Note
Take care to avoid excessive heating of the hydraulic oil. Do not keep
the steering system in the steering lock position longer than is
necessary.
S 825 M / 09.2002 5 - 31
5.6.5 Stabilizing the Machine

The outriggers are used to stabilize the machine in uneven terrain. This
serves to provide greater stability. With outriggers on ground, the
machine is able to lift greater loads (see also Section 3.2).
1 2
Extending outriggers 1 Detach transport lock:

– Remove the four locking springs (1) at the front and at the
rear.
– Detach the two locking ropes (2).
– Securely store the ropes and springs.
3 5
5 - 32 S 825 M / 09.2002

3 Where applicable, activate the oscillating axle lock at the right-
hand control panel.
4 Push steering column lever (3) downward. A warning signal
sounds.
Warning
Put outriggers down on a firm, level supporting surface.
Do not use outriggers to raise the machine off the ground. The tires
must maintain contact with the ground.
5 Collective control:
– Depress foot pedal (5) forward until the outriggers have
been extended.
Individual control (option):
– Press and hold the corresponding keys on the left-hand
control panel (4).
– Depress foot pedal (5) forward until the outriggers have
been extended.
6 Pull steering column lever (3) up again. The warning signal
ceases.
Retracting outriggers 1 Start engine as specified in Section 4.4.2.
Danger
Make allowance for reduced lifting capacity in “free on wheels”
operation!
2 Push steering column lever (3) downward. A warning signal

sounds.
3 Depress foot pedal (5) backward until the outriggers have been
retracted.
4 Pull steering column lever (3) up again. The warning signal
ceases.
5 For transport, fit the two locking ropes (2) and lock them by
means of the four locking springs (1).
S 825 M / 09.2002 5 - 33
5.6.6 Swinging the Upper Structure

To swing the upper structure, use is made of the left-hand control lever.
c d
1
1 Switch - Slew gear brake Directions of movement:

c Swing upper structure to left
d Swing upper structure to
right
Swing speed Swing speed is dependent on:

Speed of the engine
Movement 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 will
ease off to a stop.
Note
Moving the control lever in the opposite direction will intensify deceler-
ation.
Apply the slew gear Push the switch (1) in the left-hand control panel „left“.
brake The slew gear brake is activated.
The lamp in the switch (1) and the control light in the SDS is lighting.
Release the slew gear Push the switch (1) in the left-hand control panel „right“.
brake The slew gear brake is released.
The lamp in the switch (1) and the control light in the SDS is not lighting.
5 - 34 S 825 M / 09.2002
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.
The superstructure must have completely stopped turning before the
slew gear brake is applied.
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:
Diminished braking effect due to damage to discs
Irreparable damage to slewing gear
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
safety lever is actuated (pulled backward) or
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.
S 825 M / 09.2002 5 - 35
5.6.7 Lifting/Lowering Loads

Be sure to observe the following safety precautions:
Warning
Suspended loads involve risk of accidents!
Whenever work is interrupted, be sure to lower the load to the
ground.
Never leave the operator’s cab with a load suspended.
Activate the overload warning system.
Refrain from any operating practice impairing the stability of the
machine.
Attachments (e.g., grabs) and parts of the load may swing. Exercise
extreme caution.
Mind the danger area.
To lift/lower the load, use is made of the right-hand control lever.
Directions of
movement:
a Lower the load
b b Lift the load
Lifting speed Lifting speed is dependent on:

Speed of the engine
Movement of the right-hand control lever
5 - 36 S 825 M / 09.2002
5.6.8 Grab Operation

Warning
ground.
Activate the overload warning system.
Refrain from any operating practice impairing the stability of the
machine.
Attachments (e.g., grabs) and parts of the load may swing. Exercise
extreme caution.
Mind the danger area.
To open/close the grab, use is made of the right-hand control lever.
c d Directions of
movement:
c Close the grab
d Open the grab
S 825 M / 09.2002 5 - 37
5.6.9 Generator and Magnet System (Option)

Danger
Risk of serious injury or death!
In the event of the magnet system failing, the load will drop off.
ground.
Activate the overload warning system and check for proper
operation.
Dangerous voltages may occur during operation.
Generator components may still be very hot also after operation.
Pushing in/withdrawal of plug-in connections during operation is
prohibited.
Installation/commissioning of the generator as well as maintenance
and service operations on the magnet system must only be
performed by authorized and qualified personnel.
Do not operate the magnet system until you have read the operation
manual.
Use only approved accessories. Consult the Sennebogen service
department.
Operation is permitted with magnet plates only; other applications
are inadmissible.
Observe operational data.
Cleaning by high-pressure cleaner (steam cleaner) is not allowed.
The condensate drain openings must be located at the lowest point.
Observe any further safety regulations.
Performance of modifications on the generator (e.g., place of
installation, type of drive) is not allowed.
5 - 38 S 825 M / 09.2002
Operation

2 Adjust engine speed control (1) to high idle.
3 Place the magnet on the load.
Warning
Make sure the allowable load capacities are not exceeded.
4 Turn magnet on:

– Unlock and operate switch (2).
– Press push button (3) on right-hand control lever.
The magnet system is turned on.
5 Put load down:
– Press push button (3) again. The magnet system is turned
off.
Note
The automatic idling system is deactivated for as long as the magnet
system is on.
S 825 M / 09.2002 5 - 39
Note
Information on operation of the monitoring unit (4) is provided in a
separate instruction. It can be found in Section 10.3.
5 - 40 S 825 M / 09.2002
5.6.10 Refueling the Machine

There are two possible ways of refueling the machine:
Manually
Using a refueling pump
Danger
Fuel must be precluded from getting into the soil or the waters.
While refueling keep a constant watch to avoid spillage of fuel.
For refilling the machine must be stopped.
Fuel is detrimental to health and is flammable.
Smoking and handling of naked flames is strictly prohibited.
Note
You should also observe the fuel system information provided in the
engine manufacturer’s operation manual.
Manually 1 Land any attached loads and lower the boom to the ground.
2 Stop the engine.
3 Fold back 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.
7 Fill in fuel carefully through the funnel.
8 Re-close cap (1) and the cover plate.
S 825 M / 09.2002 5 - 41
Using a refueling pump 1 Land any attached loads and lower the boom to the ground.
2 Stop the engine.
3 Move keylock switch to position “P”.
4 Open the left service access door.
5 Open the filler neck lid.
This lets 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.
7 Press the green key (2) to turn the refueling pump on.
The tank will be filled automatically.
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.
5 - 42 S 825 M / 09.2002
8 Monitor the filling level at the sight gauge of the fuel tank.
The pump will cut 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 Reclose 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
(9.84 ft)?
S 825 M / 09.2002 5 - 43
5 - 44 S 825 M / 09.2002
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.
S 825 M / 09.2002 6-1

Maintenance - Safety Information

Warning
The maintenance work described may only be carried out by trained
and instructed specialist personnel.
Wear personal protection equipment (e.g. safety helmet, ear
protection, protective gloves, safety boots) where working conditions
require.
Observe the applicable statutory accident prevention and safety
regulations.
Land any attached loads, and lower the boom to ground level.
Pull the left safety lever backwards.
Before attempting to perform any maintenance, shut down the
machine and secure it against unauthorized restarting.
Attach a warning tag to the controls.
Do not smoke and do not allow open flames.
Use personnel hoists or work platforms that satisfy safety
requirements.
Stay clear of all rotating and moving parts.
Relieve the pressure before working on the hydraulic system.
Always wear protective gloves when handling wire ropes.
Use only those oils and lubricants that are specified in the lubricants
chart.
Do not lift heavy components by hand. Use hoists or lifting
equipment.
Actuate battery isolator switch to interrupt the power supply.
When working near battery, cover with insulating material; do not lay
tools on the battery.
On completion of the maintenance operations, reinstall all guards
and protective devices.
Keep the operator’s cab clean and tidy.
Perform a functional check to ensure proper operation.
On completion of any maintenance operations, only the crane owner
or his agent is permitted to clear the machine for service again.
For machines with pneumatic tires: When inflating tires, keep an
adequate safe distance and use a tire cage.
6-2 S 825 M / 09.2002

Maintenance - Safety Information
Danger
Have any work on electrical equipment of the machine performed by
a qualified electrician only.
Only qualified personnel having received relevant training is allowed
to perform work on undercarriages, braking and steering systems!
Work on hydraulic equipment must only be performed by personnel
having specific knowledge and experience of hydraulics!
S 825 M / 09.2002 6-3

Maintenance - General Information
6.2 General Information
6.2.1 Cleaning
Notes
Take care to ensure that the cleaning solvents used will not damage
the seals, gaskets and other machine components.
Do not use any aggressive cleaning solvents.
Use only lint-free cleaning rags.
Use only dry filtered compressed air of a maximum pressure of 2
bar.
On completion of cleaning, perform a visual inspection and a
functional check of the machine as specified in Section 4.3.
Warning
The electrical system is splash-proof to IP56 specifications. However,
the use of a high-pressure cleaner (steam cleaner) for washing of
electrical and electronic components is not allowed.
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 S 825 M / 09.2002

6.2.2 Oils and Lubricants

Use only oils and lubricants that have been approved by Sennebogen.
For a list refer to Section 10.2 LUBRICATION-TABLE. For proper operation
of the machine, the ambient temperature may range between - 20 °C
and + 50 °C (-4 °F ... 122 °F). When job site temperatures are outside
this range, consult the 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:
the condition of the oil
the amounts of the wear metals in the sample
the rates of component wear
Recommended for the hydraulic system.
Further information is available from the 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 Sennebogen service department has been consulted and
written approval has been obtained.
S 825 M / 09.2002 6-5

6.2.3 Welding
Warning
Fire hazard!
Do not weld on the fuel tank, on the hydraulic tank and on any lines
containing fuel or oil. Any components at risk must be covered with
non flammable material.
Have any welding operations performed by an experienced qualified
welder only.
Have any welding operations performed by a certified and
experienced qualified welder only.
Preliminary operations Before you begin welding, perform the following preliminary operations:
1 Operate the optional battery disconnect switch to interrupt

power supply.
2 Disconnect the battery.
3 Connect the ground terminal of the welding apparatus directly
to the component to be welded.
6-6 S 825 M / 09.2002

Maintenance - Engine
6.3 Engine
Caution
Perform maintenance operations or repairs only with the engine
stopped and cooled down.
Secure the machine against unauthorized restarting before starting
any maintenance procedure.
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.
Coolant must be precluded from getting into the soil or the waters.
Dispose of coolant according to the applicable statutory regulations.
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 operation manual.
S 825 M / 09.2002 6-7

6.3.1 Engine Oil

Warning
Scalding hazard!
Exercise extreme caution when draining hot oil.
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.
Note the information provided in the engine manufacturer’s
operation manual.
Checking engine oil 1 Park the machine on level ground.

level
2 Operate the engine for about 2 minutes until the system is filled
with oil.
3 Stop the engine.
4 Open the right-hand service access door.
5 Withdraw the oil dipstick 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 1 Warm up the engine.

replacing oil filter
2 Park the machine on level ground.
3 Open the right-hand service access doors.
4 Change the engine oil and replace the oil filter as specified in
the engine manufacturer’s operation manual.
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.
6-8 S 825 M / 09.2002

6.3.2 Air Filter

Caution
Never use benzine, alkaline solutions or hot liquids for cleaning of
the air filter.
On no account must the inside of the housing be cleaned by using
compressed air, otherwise dust and contaminants could get blown
into the engine.
Air filter indicator The condition of the air filter is monitored by a sensor.
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 right-hand control panel
comes on.
An audible warning signal sounds at the same time. Check and clean
the air filter immediately.
2
3
1 Protective cover
2 Wing nut
3 End cover
4 Dust ejector
5 5 Primary filter
element
6 Secondary filter
element
6
S 825 M / 09.2002 6-9

Cleaning
1 Remove protective cover (1) and empty the dust collector.
2 Re-install protective cover (1).
3 Loosen wing nut (2) and remove end cover (3).
4 Compress dust ejector (4) at the end cover to empty the
ejector.
5 Unscrew the hexagon nut and withdraw primary filter element
(5).
6 Clean the primary filter element (5):
– Use dry compressed air (max. 2 bar / 29.0 psi) to blow it out
from the inside to the outside.
– Bump or tap it in case of need only!
7 Check the primary filter element for damage to the filter paper
and to the seals or gaskets. Replace if necessary.
8 Replace the secondary filter element (6) not later than after the
filter has been serviced 5 times:
– Unscrew the hexagon nut.
– Withdraw the secondary filter element.
Do not attempt to clean secondary filter element (6)!
– Install and screw down a new secondary filter element.
9 Install and screw down new or cleaned primary filter element
(5).
10 Install end cover (3) so that dust ejector (4) is pointing
downward.
11 Use wing nut (2) to screw down the end cover.
6 - 10 S 825 M / 09.2002
6.3.3 Radiator
Warning
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.
Coolant must be precluded from getting into the soil or the waters.
Dispose of coolant according to the applicable statutory regulations.
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, a buzzer sounds.
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.
3 Check antifreeze content and coolant level; add as necessary.
The coolant must contain at least 50% antifreeze all the year
round.
4 Use dry filtered compressed air (max. 2 bar / 29.0 psi) 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 the engine
manufacturer’s operation manual (section 10.3).
S 825 M / 09.2002 6 - 11
6.3.4 Belt drives

Danger
Perform any maintenance operations only with the engine shut
down at standstill.
Secure the machine against unauthorized restarting before starting
any maintenance procedure.
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 engine.
Take care to ensure that the V-belts operate in parallel.
Note
For inspecting, adjusting and replacing the belt drives, refer to the
information provided in the engine manufacture’s operation (section
10.3.1).
6 - 12 S 825 M / 09.2002
Maintenance - Hydraulic System
6.4 Hydraulic System

Safety information Note the safety information before you attempt to perform operations
on the hydraulic system.
Danger
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!
Relieve the pressure before working on the hydraulic system
(section 6.4.2).
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.
Do not open any hydraulic lines and fittings unless all pressure has
been relieved.
Work on the hydraulic system must only be performed by trained
qualified personnel having specific knowledge and experience of
hydraulics.
Wearing personnel equipment (e.g. hard hat, hearing protective
devices, protective gloves, safety shoes).
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.
Clean hydraulic cylinders:
Use neither sharp-edged tools nor corrosive liquids or scouring
agents.
Wash the piston rods at regular intervals, using a high-pressure
cleaner.
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.
S 825 M / 09.2002 6 - 13
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):
Damage found on outer layer up to the lining (e. g. chafe marks,
cuts, cracking);
Outer layer has become brittle (formation of cracks in the hose
material);
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);
Presence of leaks;
Damaged or deformed hose fittings (sealing capability is impaired);
Hose has slipped out of hose fittings;
Corrosion of the hose fittings which affects the ability of the hose to
function and seal properly;
Hose does not fulfill installation requirements;
Permitted period of storage and/or use has been exceeded.
6 - 14 S 825 M / 09.2002
6.4.2 Hydraulic System Pressure Relief

To relieve the pressure in the hydraulic system, proceed as follows:
1 Land any attached loads and lower the boom 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 Unscrew grid (1).

5 Open screw cap (2) of the hydraulic tank.
This serves to relieve the precharge pressure in the tank.
6 Connect a pressure gauge (to a maximum of 60 bar / 870.23

psi) to the gauge fittings (P1, P2, P3, P4, PV9).
Note
The pressure gauge must read 0 bar. If the pressure has not been
relieved completely yet, repeat Steps 2 through 6.
S 825 M / 09.2002 6 - 15
6.4.3 Checking Oil Level
3 Fully retract all hydraulic cylinders.
4 Stop the engine.
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.
7 Add hydraulic oil as necessary:

– Unscrew grid (2).
– Unscrew screw cap (3) of the oil filler neck.
– Add hydraulic oil and check the oil level again.
– Replace and tighten screw cap (3).
– Screw grid (2) back on.
6 - 16 S 825 M / 09.2002
6.4.4 Changing Hydraulic Oil

Safety information Note the safety information before you attempt to perform operations
on the hydraulic system.
Danger
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!
Work on the hydraulic system must only be performed by trained
qualified personnel having specific knowledge and experience of
hydraulics.
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
3 Fully retract all hydraulic cylinders.
4 Relieve the hydraulic system pressure as specified in Section
6.4.2.
5 Remove the filter element of the return flow filter as specified
in Section 6.4.5.
6 Place a suitable container underneath the drain port of the
tank.
For refill capacity refer to Section 6.9.3.
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.
S 825 M / 09.2002 6 - 17
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.
11 Fill in new hydraulic oil through the filler neck at the top of the
tank.
12 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.
6 - 18 S 825 M / 09.2002
6.4.5 Return Flow Filter – Replacing Filter Element

2 Unscrew the four allen head screws (2).
3 Remove cover (3).
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 (3) by means of the four allen head screws
(2).
8 Tighten screw cap (1).
S 825 M / 09.2002 6 - 19
6.4.6 Pilot Control Filter – Replacing Filter Element

2 Unscrew filter housing (1).
3 Pull off filter element and dispose of as hazardous waste.
4 Clean the components; check the seals and replace if
necessary.
5 Fit new filter element into filter housing (2).
6 Screw the filter housing by hand into the filter mounting head.
7 Check the filter for leaks.
6 - 20 S 825 M / 09.2002
6.4.7 Leakage Oil Filter – Replacing Filter Element
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 with the return tube in the tank.
6 Tighten hexagon nuts (1).
S 825 M / 09.2002 6 - 21
6.4.8 Replacing Breather Filter

Note
The breather filter is integrated in the screw cap (2) of the filler neck.
The effect of the breather filter is to limit the overpressure or underpres-
sure building up in the hydraulic system during hydraulic work move-
ments.
3
2
1 Unscrew grid (1).

3 Pull off filter element (3) from the screw cap (2).
4 Dispose of filter element (3) as hazardous waste.
5 Fit new filter element (3) in the screw cap (2).
6 Screw on the screw cap (2) complete with breather filter (3).
7 Screw grid (1) back on.
6 - 22 S 825 M / 09.2002
6.4.9 Hydro Clean – Superfine-Filter-System (Option)
Note
Pressure gauge (1) measures resistance to flow. At a resistance to flow
of more than 5 bar (72.52 psi), no filtration of the hydraulic oil will take
place. Once the pressure gauge reads 5 bar (72.52 psi), replace the
filter element.
Replacing Filter
Element
2
1 Unscrew cover (2).

2 Withdraw the filter element.
3 Remove the filter element and dispose of as hazardous waste.
necessary.
5 Install a new filter element.
6 Install cover (2) with the superfine filter element and screw it
down by hand.
7 Check the filter for leaks.
S 825 M / 09.2002 6 - 23
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.
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 sh (service hours).
6 - 24 S 825 M / 09.2002
Maintenance - Undercarriage
6.5 Undercarriage
Warning
Rotating parts can cause personal injury!
Perform maintenance operations only with the engine shut down.
Oil must be precluded from getting into the soil or the waters.
Dispose of spent oil according to the applicable statutory
regulations.
6.5.1 Cleaning and Lubricating

2 Stop the engine.
3 Use a steam cleaner to clean tires and traveling gear.
4 Lightly grease the guides and pins.
5 Grease all lubrication points (see Section 6.9.2).
6.5.2 Tire Inflation Pressure (Machines with Pneumatic

Tires)
Danger
When inflating tires, keep an adequate safe distance and use a tire
cage.
Tire Size Inflation Pressure

bar psi
10.00-20 7.5 108.78
12.00-20 9 130.53
12.00-24 10 145.04
395/85 8.5 123.28
S 825 M / 09.2002 6 - 25
6.5.3 Retightening Wheel Nuts

Verify that all wheel nuts are firmly secured in place. The tightening
torque is 550 Nm. Use a torque wrench for tightening.
6.5.4 Hub Gears
1 Oil filler plug

2 Oil level mark
3 Oil drain plug
Checking oil level

2 Move the machine until mark (2) on the hub is horizontal.
3 Stop the engine.
4 Screw out oil filler plug (1). The oil level must reach as far as
mark (2); add oil as necessary.
necessary.
6 Re-install and tighten oil filler plug (1).
7 Repeat the procedure for the three remaining hubs.
6 - 26 S 825 M / 09.2002
Changing oil 1 Park the machine on level ground.

2 Move the machine until oil drain plug (3) is at the lowest point
on the hub.
3 Stop the engine.
4 Loosen oil filler plug (1) to relieve the pressure.
5 Place a suitable receiving container underneath oil drain plug
(3). For refill capacity refer to Section 6.9.3.
6 Unscrew oil drain plug (3) and collect the spent oil in the
container.
necessary.
8 Re-install and tighten oil drain plug (3).
9 Screw out oil filler plug (1).
10 Move the machine until mark (2) on the hub is horizontal.
11 Fill in new oil up to the level of mark (2).
13 Repeat the procedure for the three remaining hubs.
14 Re-check the oil level after 2 service hours.
S 825 M / 09.2002 6 - 27
6.5.5 Travel Gear
2
1
Checking oil level 1 Warm up the machine to operating temperature.

3 Stop the engine. Wait approx. 10 minutes for the oil to collect
in the travel gear.
4 Use a cloth to clean the outside of the travel gear.
5 Unscrew oil filler plug (2). The oil level must reach as far as the
bottom of the plug hole; add oil as necessary.
necessary.
Changing oil 1 Warm up the machine to operating temperature.

in the travel gear.
4 Use a cloth to clean the outside of the travel gear.
container.
necessary.
6 - 28 S 825 M / 09.2002
10 Unscrew oil filler plug (2).

11 Fill in new oil up to the bottom of the filler plug hole.
6.5.6 Differential
Checking oil level 1 Warm up the machine to operating temperature.

in the differential.
4 Use a cloth to clean the outside of the differential.
5 Unscrew oil filler plug (2). The oil level must reach as far as the
bottom of the plug hole; add oil as necessary.
necessary.
Changing oil 1 Warm up the machine to operating temperature.

S 825 M / 09.2002 6 - 29
in the differential.
4 Use a cloth to clean the outside of the differential.
container.
necessary.
10 Unscrew oil filler plug (2).
11 Fill in new oil up to the bottom of the filler plug hole.
6 - 30 S 825 M / 09.2002
Maintenance - Slewing Ring
6.6 Slewing Ring

Check the grease
1 Rotate the upper structure 360° counterclockwise starting from

travel direction.
2 Rotate the upper structure further in counterclockwise direction
until the boom is at right angles to the undercarriage (90° to
travel direction.
3 Rotate the upper structure 90° in clockwise direction (boom is
beeing set in driving direction):
4 Remove the cover (1).
5 You must see a „peak of grease“ (min. 20mm). Add more
grease if necessary.
6 Refit the cover (1).
S 825 M / 09.2002 6 - 31
Retightening bolts
Retighten fixing bolts with a torque wrench. While doing so relieve the
screw connection from any strain from external forces.
Observe the torque!
Notes
Ensure that you adhere to the number and diameter of fixing bolts.
Oil the threads and support surfaces of nuts and bolts each week
with a light coating of machine oil.
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.
Ideally tighten bolts over M30 with a hydraulic screw tension cylin-
der.
Please contact Sennebogen customer service with any further
questions.
Danger
Danger to life!
Corroded and damaged bolts can shear off and cause the upper struc-
ture to tilt.
Do not retighten corroded or damaged bolts. Replace immediately
with new bolts.
Only use genuine Sennebogen replacement parts!
6 - 32 S 825 M / 09.2002
Service interval
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:
Once a week, tighten the live ring screws with a torque wrench.
Once a year, have the live ring screws check by an expert.
Replace the live ring screws at least every 5000 operating hours /
every five years, even when they fail to exhibit any safety-related
defects.
S 825 M / 09.2002 6 - 33
Maintenance - Electrical System
6.7 Electrical System

Danger
Have any work on the electrical system performed by adequately
trained qualified electricians only.
6.7.1 Batteries
Danger
Explosion hazard!
Smoking and handling of naked flames is prohibited. Take care to
avoid sparking in the vicinity of the battery.
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.
Do not deposit any tools on the battery.
Disconnect the battery before welding.
Mind not to interchange battery posts.
Dispose of spent batteries as hazardous waste.
Check the terminals and cable connections of the batteries:
1 Open the left-hand service access door.

2 Remove battery cover (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 Re-install the battery cover.
6 - 34 S 825 M / 09.2002
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 the cover of fuse box (1).
3 Replace the defective fuse.
4 Check the contacts, clean any oxidized contacts.
5 Refit the cover of fuse box (1).
S 825 M / 09.2002 6 - 35
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.
6 - 36 S 825 M / 09.2002
Maintenance - Appendix
6.9 Appendix
Safety information Note the safety informations before you start work.
Warning
The maintenance operations set out below must only be performed
by qualified personnel that has received adequate training and
instruction.
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 50 once af- every every every Sec-

10 sh* / sh* / ter 250 500 sh* / 1000 sh* 2000 sh* tion
daily weekly sh* 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 cool- 6.3.3
ing fins, if necessary.
– Hydraulic system – check oil level. 6.4.3
– Superfine filter – check service 6.4.9
indicator.
– Slewing ring – lubricate. 6.6
– Central lubrication system –
check filling level.
– Hydraulic oil cooler – check and
clean.
S 825 M / 09.2002 6 - 37

– Tire inflation pressure – check as 6.5.2

necessary.
– Wheel nuts – retighten by means 6.5.3
of torque wrench.
– Hub gears – check oil level. 6.5.4
– Differential – check oil level. 6.5.6
– Slewing ring fixing bolts – retight- 6.6
en by means of torque wrench.
– Battery cable connections and 6.7
fuses – check.
– Heating system filter – check. 6.8
– Lubrication points – grease. 6.9.2
– Radiator – clean. 6.3.3
– Hydraulic accumulator precharge 1) 1) 1) 1) 6.4
pressure - have it checked by a
hydraulics specialist 1).
1)
After 250 sh*/6 weeks and after 500 sh*/3 months; then every 1000 sh*/1 year
– Observe engine intervals.
– All screwed/bolted connections –
verify firm seating.
– Travel gear – check oil level. 6.5.5
– Antifreeze content – check. 6.3.3
– Filter element of return flow filter – 6.4.5
replace 2).
– Leakage oil filter – replace filter 6.4.7
element.
– Pilot control filter – replace filter 6.4.6
element.
– Hub gears – change oil 2)
. 2) 2) 6.5.4
– Travel gear – change oil 2)
. 2) 2) 6.5.5
– Differential – change oil 2). 2) 2) 6.5.6
2)
Once after 250 sh*/6 weeks; then every 1000 sh*/1 year
6 - 38 S 825 M / 09.2002

– Slewing ring fixing bolts - check by

an expert.
– Coolant – change. 6.3.3
– Primary and secondary filter ele- 6.3.2
ments of air filter – replace.
– Hydraulic system – change oil. 6.4.4
– Screw cap with breather filter on 6.4.8
hydraulic tank – replace.
– Slewing ring fixing bolts - 3) 6.6
change 3)
3)
every 5000 sh* / every 5 years
S 825 M / 09.2002 6 - 39
6.9.2 Schedule of Lubrication Points
Lubrication effected via:

Central lubrication system (option)
In the standard version without the optional central lubrication
system, the lubrication points are provided with grease fittings.
Grease fittings
The grease fittings have been provided with a red protective
cover.
6 - 40 S 825 M / 09.2002
6.9.3 Refill Capacities

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 about 500 l
Hydraulic tank about 300 l
Overall hydraulic system about 360 l
Travel gear about 3.0 l
Differential
front about 23 l
rear about 17.5 l
Hub gears about 1.0 l
Slewing ring gearing as required
Central lubrication system as required
Lubrication points as required
S 825 M / 09.2002 6 - 41
6.9.4 Tightening Torques for Bolts

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

Bolt Tightening torque Bolt 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 S 825 M / 09.2002

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
S 825 M / 09.2002 6 - 43

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 S 825 M / 09.2002
Setting up works -
7 Setting up works
Note
The upcoming setting up works depend on the chosen work
tools. Please not with the operating instructions from the tools
manufacturer.
S 825 M / 09.2002 7-1

Setting up works -
7-2 S 825 M / 09.2002

Transport - Safety Information
8 Transport
Preliminary operations Transport the machine by means of a flatbed trailer. Be sure to perform
the following preliminary operations:
Select an appropriate vehicle for transport.
Observe the machine dimensions and weights as specified in
Section 8.2.1.
Clean the machine.
Fold the boom and the stick into the transport position.
Lock the upper structure and the undercarriage as specified in
Section 8.3.
Remove working attachments and tools, if any.

Warning
Any loading and transport work must only be performed by duly
authorized qualified personnel observing section 48 of VBG 40
(German accident prevention regulations for earthmoving
machinery) and section 22 of StVO (German highway code).
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.
During loading and transport, secure the machine and its working
equipment against any accidental movement.
Remove mud, snow and ice from the undercarriage of the machine
sufficiently to allow the use of ramps without the risk of slippage.
With worked out pylon do not swing the upper structure.
Provide ramps of flatbed trailers with wood blocking.
Before setting off, investigate the condition of the travel route.
For transport of the machine, use only the lashing, tie-down and
lifting points provided for the purpose.
Take care to ensure that the machine does not constitute a source
of danger for other road users.
S 825 M / 09.2002 8-1

Transport - Dimensions and Weights
8.2 Dimensions and Weights
8.2.1 Shipping Dimensions
11000
Maschine
3400
2750
2750
3900
4250
8-2 S 825 M / 09.2002

Transport - Dimensions and Weights
8.2.2 Weights
Note
Machine weight may differ from the specifications below if any optional
features have been added.
Machine Weight approx. 30 tonnes
Weight includes 122 kW (165 hp) diesel engine, loading boom and
counterweight.
S 825 M / 09.2002 8-3

Transport - Locking the Upper Structure
8.3 Locking the Upper Structure
1 Position the upper structure in the direction of travel.

2 Apply the slewing gear brake.
3 Pin and lock the locking link (1) at the undercarriage and at the
upper structure.
8-4 S 825 M / 09.2002

Transport - Lifting the Machine
8.4 Lifting the Machine

Danger
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.
Take care to ensure that the sling devices are of adequate load
capacity and undamaged.
Mind the danger area!
No persons are allowed at, on or underneath the machine.
Procedure
1 Select an appropriate lifting crane and proper rated sling

devices.
Observe 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!
S 825 M / 09.2002 8-5

Transport - Lashing and Tying Down the Machine
8.5 Lashing and Tying Down the Machine

Caution
To lash the machine, use the tie-down points (1) provided for the
purpose. The tie-down points are marked with green paint and
located on the undercarriage.
Take care to ensure that the sling devices are of adequate load
capacity and undamaged.
In the event of an additional securing device being required, take
care to avoid the machine getting damaged.
Transport of the machine and of the accessories is the responsibility
of the respective carrier as a general principle.
8-6 S 825 M / 09.2002

Troubleshooting - Engine
9 Troubleshooting
Warning
The maintenance, inspection and troubleshooting personnel must
have the appropriate qualification for these operations.
In case of operations not described in detail, consult the
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 – Unlock travel pedal.
active
Fuel tank empty – Refuel the machine.
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 defective – Have the fault corrected.
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 operation manual.
S 825 M / 09.2002 9-1

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 Cause Remedy

fails to operate
Fault in pump circuit – Have the fault investigated and
corrected by a hydraulics specialist.
No functions, or Cause Remedy

malfunctioning, of the
working attachment Hydraulic oil level too – Check hydraulic oil level.
low – Add hydraulic oil as necessary.
Leaks in the – Check the working cylinders,
hydraulic 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.
9-2 S 825 M / 09.2002

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 Cause Remedy

hydraulic system
Hydraulic pump sucks – Have the fault corrected by a hydraulics
in air 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.
S 825 M / 09.2002 9-3

Troubleshooting - Sennebogen Diagnostic System
9.3 Sennebogen Diagnostic System
9.3.1 Bank of keys with LEDs

buzzer sounds
Hydraulic oil – Operate engine at no load until the
temperature excessive hydraulic oil has cooled down.
(>84°C)
hydraulic oil cooler dirty
Hydraulic oil level too – Check oil level as specified in Section
low 6.4.2.
– 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.

continuous alarm
sounds Fuel level in the tank – Refuel the machine as specified in
too low Section 5.6.10.

buzzer sounds
Engine overheated – Idle the engine.
engine oil cooler dirty
Fan drive loose or – Tighten fan drive, replace if necessary.
defective
Coolant level too low – Add coolant as specified in Section
6.3.3.
Note
If the coolant temperature continues to rise, the temperature reading on
the display flashes in addition, and a continuous alarm sounds.
9-4 S 825 M / 09.2002

Troubleshooting - Sennebogen Diagnostic System

buzzer sounds
Engine oil pressure too – Stop the engine immediately.
low (< 1.3 bar) – Check the engine oil level as specified
in Section 6.3.1.
– Add engine oil as necessary.
– If fault continues to occur, inform the
Sennebogen service department
accordingly.
Note
When the oil pressure falls below 1.0 bar, the pressure reading on the
display flashes in addition, and a continuous alarm sounds.
S 825 M / 09.2002 9-5

Troubleshooting - Heating System
9.4 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).
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.
Heating cannot be shut Cause Remedy

off
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.
9-6 S 825 M / 09.2002

Troubleshooting - Air Conditioner (Optional)
9.5 Air Conditioner (Optional)
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
slipping clutch.
Temperature controller – Replace temperature controller.
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
slipping clutch.
V-belts loose or worn – Increase V-belt tension or replace V-
belts.
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.
S 825 M / 09.2002 9-7

Troubleshooting - Undercarriage
9.6 Undercarriage
Oil leaks at differential, Cause Remedy

wheel-hub or travel
gearboxes End plugs loose – Tighten end plugs.
Seals damaged – Replace seals.
Oil leaks at Cause Remedy

swing gear drive
Connections loose – Tighten connections.
Swivel joint leaking Cause Remedy

Seals damaged – Replace seals.
Lines loose – Retighten fixing bolts.
Noises in swing Cause Remedy

mechanism
Inadequate lubrication – Lubricate ring gear as specified in the
on ring gear lubrication schedule.
9.7 Cab
Cab is swinging very Cause Remedy

strong
Cab frame or cab fra- – All bolted/screwed connections at the
me-support is damaged cab support and cab frame-support
must be checked for damages.
– Renew all damaged parts immediatly by
qualified personnel that has received
adequate training and instruction.
9-8 S 825 M / 09.2002

Appendix - Index
10 Appendix
10.1Index
10.2Lubrication-Table
10.3Additional Documentation
10.3.1 Engine
10.3.2 Operator’s Seat
10.3.3 Magnet system
10.3.4 Central Lubrication System
10.3.5 Cleaning the Cooler
S 825 M / 09.2002 10 - 1
Appendix - Additional Documentation
10 - 2 S 825 M / 09.2002
Index
A F Operator’s work station 1-3

Abuse 1-3 Fire extinguisher 1-14 Oscillating axle lock-up 5-22
Adding hydraulic oil 6-16 First aid kit 1-14 Overhead lines 1-6
Adjusting stick limiting stops Overload warning system
5-29 G 1-15, 5-21
Adjusting time of day 5-15 Gauge fittings 6-15 Overriding stick-in limiting
Ambient temperature 3-2 stop 5-28
Automatic idling 5-22 H
Automatic idling system 5-22 Hand signals 1-19 P
High voltage contact 1-6 Permanent sound pressure
B Hydraulic fittings 6-13 level 1-13
Bank of keys 5-14 Personal protective
I equipment 1-5
Belt drives 6-12
Inadmissible operating Personnel qualifications 1-12
Biological oils 6-5
practices 1-13 Personnel selection 1-12
Bolt strength grades 6-42
Boom stop 5-27 Indicator lights 5-18 Preparing to operate
Inspection by competent Checklist 4-2
C person 1-12 Pressure cylinders 6-13
Cab International rules and Protection of the environment
Elevate 5-4 regulations 1-1 1-19
Lower 5-5 Pull-ring - Emergency exit 5-2
J
Checking hydraulic oil level
Jump starting 4-6 Q
6-16
Cleaning hydraulic cylinders Qualifications of personnel
L
6-13 1-6
LEDs 5-14
Crushing hazards 1-4
Lifting points 8-5 R
D Loads Release (cab door) 5-2
Lift 5-36 Relieving hydraulic system
Danger area 1-4
Lower 5-36 pressure 6-15
Description
Lock - Oscillating axle 5-22 Replacing oil filter 6-8
Wind 3-5
Display (SDS) 5-13 Resetting daily service hour
M
Disposal 1-19 meter 5-15
Machine
Retracting outriggers 5-33
E Stabilize 5-32
Emergency exit 5-2 Travel 5-31 S
Maximum tolerable wind 3-2 Safety alert symbol 1-2
Emergency lowering 5-6
Modification of the machine Safety clearance 1-4
Emergency lowering system
1-13 Safety clearance to overhead
Cab mounted 5-6
Storage compartment Multiple disc brake 5-35 lines 1-6
mounted 5-7 Safety information 1-4
N
Employment in foreign Safety lever 2-5, 5-11
National rules and
countries 1-14 Sicherheitsabstand 1-6
regulations 1-1
Engine Signal word 1-2
Noise protection 1-13
Changing oil 6-8 Slewing gear brake 5-35
Checking oil level 6-8 O Stability 1-5
Engine speed control 5-20 Oil analysis 6-5 Stabilizing the machine 5-32
Extending outriggers 5-32 Oil filler neck 6-16 Stick-in limiting stop 5-28
Adjust 5-29
S 825 M / 09.2002 S-1

Index
Stick-out limiting stop 5-28

Adjust 5-30
Swinging upper structure
5-34
T
Target group 1-3
Tie-down point 8-6
Tightening torque 6-42
Tipping hazard 5-21
Transportmaße 8-2
Traveling the machine 5-31
Traveling with suspended
load 5-31
U
Überlast-Warneinrichtung
2-3
Upper structure swing 5-34
Use as intended 1-3
W
Warm-up period 4-7
Warning lights 5-18
Warning system - Overload
5-21
Wind force 3-5
Wind speed 3-5
S 825 M / 09.2002 S-2

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Operation and Maintenance Manual

Target group This manual serves to familiarize operators of a Sennebogen materials

Copyright © Straubing 2002 Sennebogen Maschinenfabrik GmbH

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

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

S 825 M / 09.2002 0-1

0-2 S 825 M / 09.2002

6.4 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . 6-13

7 Setting up works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

S 825 M / 09.2002 0-3

0-4 S 825 M / 09.2002

Over and above the safety information contained in this Operation

S 825 M / 09.2002 1-1

1-2 S 825 M / 09.2002

1.2 Use as Intended

S 825 M / 09.2002 1-3

1.4 Safety Information

1-4 S 825 M / 09.2002

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

S 825 M / 09.2002 1-5

Rated voltage Safety clearance (meter)

Use a signal person to observe the safety clearance.

High voltage contact In case of high voltage contact, proceed as follows:

1-6 S 825 M / 09.2002

Extract from VBG 40 have attained the age of 18 (majority);

S 825 M / 09.2002 1-7

Observe the applicable cargo securing rules and regulations.

1-8 S 825 M / 09.2002

S 825 M / 09.2002 1-9

1.5 Obligations of the Owner

Inspection by The machine must be subjected to a thorough inspection by a

Unauthorized Any modification or alterations of the machine are not allowed.

1.6 Protective Devices

1.7 Warning Signs and Labels on the Machine

Attaching restraint belt (optional)

Read and follow the operating manual

Battery isolation switch (optional)

Read and follow maintenance instructions

Hydraulic oil Diesel fuel

Danger of crushing! Cab mounting

1.9 Hand Signals

Drive slowly forward

Drive to the right

Drive to the left

Rotate upper structure to the

Rotate upper structure to the

Lift attachment (load)

Lower attachment (load)

1 Undercarriage 5 Operator´s station, cab

S 825 M / 09.2002 2-1

1 Front axle (oscillating axle) 4 Slewing ring

2.3 Outriggers (Option)

2-2 S 825 M / 09.2002

2.4 Upper Structure

S 825 M / 09.2002 2-3

2-4 S 825 M / 09.2002

2.5 Operator’s Station

1 Pedals 5 Lever - Cab height adjustment

S 825 M / 09.2002 2-5